Plasma reactor for the pyrolysis of waste materials

For a research institute specialising in process and environmental technology, PlasmaAir AG supplied a water vapour plasma torch for a reactor used to pyrolyse waste materials. The high-temperature reactor continuously processes up to 50 kg/h of flowable material, operating 24/7, and is heated by a 100 kW water vapour plasma source.

INITIAL SITUATION

Pilot plant: 

The customer was seeking a plant system for investigating the plasma pyrolysis of solid, shredded waste materials of organic and inorganic origin on a technical scale. The system was required to provide a continuous throughput of up to 50 kg/h, with a reactor volume of approximately 400–500 l and a plasma source power range of 50–100 kW.

OUR SOLUTION

Based on the customer requirements, PlasmaAir AG is planning a complete plasma reactor system with the following configuration:

An arc-heated water vapour plasma source (power range: 50–100 kW) heats the vertically arranged, cylindrical reactor, made of heat-resistant stainless steel with a ceramic lining.
A screw feeder with a variable feed rate and airlock principle ensures continuous, airtight and gas-tight material feed of up to 50 kg/h.
A condensation and residue unit separates liquid fractions and enables the periodic discharge of slag.
Safety-related features, such as an emergency stop system, temperature monitoring, pressure relief and a gas-tight welded process chamber, are fully integrated into the system design.
The reactor is mounted on a purpose-designed steel structure with access platforms, guardrails and an access staircase, providing designated service areas for burner access, slag removal and process monitoring.
A control cabinet handles complete process control and monitoring, including setpoint specification, alarm management and optional remote access.
The system is designed to allow expansion to operation with two plasma sources if required.