Bersys in partnership with our International partners Scogen and Ambient Energy, offer the state-of-the-art in advanced gasification technology and systems development.  The M3RP systems are certified, manufactured and installed to meet the most rigorous design specification for quality, optimized performance and efficiency.  The systems offer the latest features in safety, process control technology and modular skid mounted design.  The system is able to utilize a wide range of carbon bearing feed stocks to produce high quality biogas and liquids.

As the Gasification system can be used and run by local communities Bersys has the following suggestions.

The community can obtain canvas bags and award a monetary reward for each canvas bag

   that the plant receives.  The individuals in the community will receive a reward for all the

   carbonaceous feed stocks that they bring to the “plant”.

By rewarding the community the community will clean up the area that would lead to a

   cleaner community, cleaner rivers and dams.  Most of the refuse ends up in our rivers and

   dams.

The limiting factors are moisture content and calorific value. To lower the moisture, the

   better. In regards to post-consumer plastics, we want to stay away from chlorinated

   compounds such as PVC.

The community can sell the “GAS” and the ash from the M3RP unit. This will lead to job

   creation.

This would also lead to a cleaner and healthier environment.

The community would be setting a example for the rest of South Africa, by showing that a

   cleaner life is possible and more healthy.

Advantages of  Ambient/Scogen’s M3RP Gasification system

·      Proven State of the Art Technology

·      Production of value added products including carbon and fuel

·      Cost Effective

·      Environmentally Safe

·      Modular and Scalable

·      Carbon Neutral

·      Operator Friendly

·      System Longevity and Reliability

The Features of Gasification System

  All Ambient/Scogen manufactured equipment are designed to meet international standards

     for safety and sound engineering practices (SEP).

  All systems are custom designed to the individual customers needs and application for

     pyrolysis, biomass, biosolids, MSW, and tires.

  Demonstrations Units are available from 3-6 tons/ day in Mysore India.

  Standard commercial units are available at 24, 33.3 and 48 tons/day.

  Each unit is a “stand-alone” system mounted on one or two portable skids.

  Can integrate multiple units for easy expansion of existing facility as feedstock availability

     increases.

  State-of-the-art PLC system to ensure quality operating control and safety features.This

     also can allow off-site monitoring when incorporated in the design phase.

  Easy operator “Start-up/Shut-down” system controls and procedures.

  1 year or 8,000 hours “Limited Warranty” on all systems

  Can produce gas or liquid fuels. (depends on feedstock)

  Can be integrated with Genset or Micro Turbine technologies for power generation.

  Equipment designated as CE norms with zone 2 only

General Specification for M3RP Gasification System

·      Custom designed process vessel as defined in mutually agreed upon PI&D drawings

·      Pressure and temperature monitored by smart transmitters

·      Condensing system comes complete with high quality pumps and heat exchangers.

·      Positive Displacement Compressor Blower to deliver gas to storage tanks. (for system

       only)

·      MCC mother board for controlling all flow valves.

·      State-of-the-art PLC system for total process control.

·      Electrical panels (based upon electrical standards for each particular country)

·      Commissioning of every system.

·      Supervision/operator training for “start-up/shutdown” and operating procedures.

·      Availability of highly trained technicians for routine repairs and maintenance of

       emergency repairs.

·      Testing facilities for locally obtainable feed-stocks.

System is ATEX Certified

System complies with ATEX Directive 94/9/EC under article 100A of the Treaty of Rome.

     all manufactures must design and test each component for “risk of explosion” from

        production gases, or liquids by all possibilities of ignition.

     testing considers any other hazardous environments equipment operates in, including

        technical abilities of equipment operator.

     Compliance with Other Directives:

          - Machinery Directive 98/37/EC – EC Declaration of Conformity as per annexure IIA

          - Pressure Equipment Directive 97/23/EC under Sound

     Engineering Practices (SEP)

System M3RP is HAZOP Certified

•    Development team identifies all hazards at completion of process design or for planned

      modifications

•    Detailed examination of process and engineering design of a new, existing facility or

      equipment, to assess hazard potentials of operating outside initial design specifications.

•    Examines potential malfunctions of individual components and the consequential effects

      on operating system as a whole.

HAZOP Certification insures that:

– Potential deviations from design specifications are identified and corrected

– Process and equipment hazards are revealed

– Actions for necessary process or instrumentation improvements are designed and

   implemented

– Action responses are auditable to the operator

Analysis of Typical Air Emissions

• CO – < 100 mg/KWh

• CO2 – < 190kg/hr calculated

• NOx – = 80 Mg/KWh in natural gas

• = 140Mg/KWh for LPG

• SO2 – If 10 ppm of sulfur is present in gas then SO2 will be 2.5 ppm

• Particulate = 5 mg/m^3.

• All measurement carried out at 3.5% oxygen in the flue gas.

M3RP (Material Recycling Recovery Process) GASIFICATION

250 Kg per Hour M3RP System with a daily capacity of 6 tons (250 kg per hour)

General and technical information:

This M3RP system is designed for an average throughput of 250 Kg per hour of Salsnes primary solids cake at 40% dry matter, yielding 7 to 12 Mega Joules (Mj) of gas, per each kilogram of Salsnes feedstock. No pre-drying is necessary.  The system can operate 24 hours per day, 7 days per week. General maintenance is required but no scheduled maintenance shutdown. The complete skid mounted process vessel, including all parts to complete the gasification process, is part of the system scope, it will but excluding primary gas storage, pre-hopper feeding facilities, electricity generation processes and start-up fuel storage, unless so specified. Offsite process monitoring is included in the scope.  The M3RP meets Euro ATEX Standards for gas and pressure vessels and a Hazop protocol is allowed on the design, engineering and manufacturing of very system.  The M3RP meets Euro ATEX Standards for gas and pressure vessels and a Hazop protocol is allowed on the design, engineering and manufacturing of very system. 

The following items are included in the mentioned scope:

    agreed upon.

The following are excluded from the mentioned scope:

Process:

Depending on the feed stock (fuel item) the fuel feed hopper can be supplied with feed stock by means of a conveyor, bucket elevator or screw feed. The fuel feed hopper to be manufactured from 316/304 stainless steel. The M3RP vessel shell and all support structure to be fabricated from heavy mild steel plate, structurally reinforced and supported with heavy steel members as dictated by RSA industrial engineering practices. All mild steel items to be pre-painted by an oxide undercoat and blue final coat. All fixtures and components exposed to high temperatures or corrosive atmospheres are to be manufactured of stainless steel. All electrical motors and wiring to be protected by mild steel boxing  and / or galvanized / painted steel conduit and / or metal wire ways. Gas train assemblies must also be protected from general environmental conditions.  All electrical utilities to confirm to South African supply requirements of either, single phase: 210v to 220v / 50 Hz or three phase: 380v to 400v (average) / 50 Hz. The air compressor (excluded from scope of supply) to supply 125 PSI at 35 scfm. Chamber insulation to be fitted.

The M3RPis a continuous feed process by means of two screw conveyors inside the M3RP chamber (furnace) running in opposite directions.  This system is designed for an average fuel input of 250Kg per hour with a 10% fluctuation allowance. Daily peak flow allowances outside this scope need to be catered for by means of a day hopper or feed silo. Such a feed silo will also cater for planned or unexpected shutdowns of the M3RP.  The allowable feed stock size is 2 inches (5cm) for screenings. Shredders are not included in the supply scope.  Within these parameters, screenings can also be gasified. The top feed valve (airlock-flap valve) opens between the material bin chute and the inlet screw feeder, feeding the fuel stock into the gasification chamber.

The top screw conveyor feeds the fuel into the gasification chamber (furnace) and the bottom screw conveyor feeds the carbon residue to the outlet airlock-flap valve.

Initial startup requires an external gas supply (ave. 5.5kg of LPG gas) and takes average 40 minutes. Once enough gas is produced after startup, the complete process becomes self sufficient, supplying enough electricity to shut down external electricity supply.  12% of produced gas required for self sustaining and 80% of produced gas available for additional electricity supply.

The M3RP itself is a thermal distillation process whereby the feed stock is converted by extreme heat, in the absence of air or oxygen, into gas (the volatile portion converts to syngas) and clean carbon residue (in-organics converts to carbon ash). A percentage of the produced gas is used to run the burner for sustaining the process and the rest is available for electricity generation. The process use indirect heating technology through a gas burner, preventing oxidation / corrosion inside the vessel. It was indicated that no cracking inside the vessel or building-up of feedstock onto the screw conveyor itself is foreseen. The main constituents of the syngas are Methane, Hydrogen and carbon dioxide.

The screw conveyors are driven by two standard electric screw feed motors.

Blower motor and gas train for heating supply to the gasification process.

The burner is a 600 000 BTU/hr unit.

The produced carbon residue exits the process via the discharge flap valves. Part of the supply scope should be a transferring auger and holding bin or bagging unit.

Gasses extracted from the gasification chamber is cleaned-up  by pulling it through a cyclone for spinning out dust and small particulates.

Then through a heat exchanger for gas cooling, a venturi oil scrubber and clarifier, a second heat exchanger and clarifier and then to an intermediate gas tank. 

A cooling tower with circulating water is used for cooling down oil for the oil scrubber

The venturi oil scrubber and clarifier (condenser) for cooling down gas, removing condensable and gas cleaning

The second heat exchanger and clarifier for cleaning condensable

Vacuum pump and motor for extracting gas from furnace and maintaining negative pressure.

The clean gas is pumped into an intermediate gas holding tank from where it is pumped to a pressurized gas tank to be used as fuel for electricity generation in a gas turbine, sterling engine, etc.

Plant built for Czech Republic