Find out more about Tetronics International and what we do.
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Added: Aug 09, 2016
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Tetronics International DC Arc Plasma Technology
Our Company Our Vision To enable a thriving planet for future generations, while making it financially beneficial for companies, shareholders and governments to make responsible choices for the environment and for generations to come. Our Mission Offering economically stable and viable methods of recovering resources from waste. Using our industry-leading technology and experience to deliver maximum resource recovery and the highest levels of hazardous material destruction . UK environmental c ompany with 50 years’ global experience delivering clean plasma technology for maximum resource recovery and the highest levels of hazardous material destruction. Our Technology Developed, enhanced and continually refined over 50 years with 109 patents, granted or pending across 12 families Widely recognised as World Leaders in Plasma Tailored solutions for Resource Recovery and Hazardous Material Treatment Technically and Economically proven with an impressive track record Global S ervice P rovision Tailored Support World Class Plasma Materials Testing Facility in UK
Tetronics Background Market leader in the application of DC Plasma Arc technology on a global basis Established 1964 in Oxfordshire, UK with a R&D focus Acquisition by InvestSelect in 2004 triggered significant investment, move to new bespoke facilities at Marston Gate and strategic repositioning of the company into new areas of application Comprehensive and sophisticated R&D trial facilities Advanced Plasma Power (APP) formed 2005/2006 Mature technology platform with a securely protected IP that continues to be developed 109 patents granted or pending across 12 families Experienced process design, engineering and manufacturing staff complemented by project management, commercial and environmental regulatory expertise 9 0+ installations globally
Partners/Customers Strategic Partnerships Harsco Corporation Mitsubishi Corporation Customer and Plasma Operations BASF Solar Applied Materials Technology Corporation Furuya Metal Harsco Metals and Minerals Mitsubishi Heavy Industries Hitachi Zosen Corporation Outokumpu Steel Company POSCO Steel Company
Plasma: an ionised gas often referred to as the 4 th state of matter Examples of plasma: lightening, auroras, stars & sun - plasmas constitute more than 99% of the universe Thermal plasma emits intense heat and Ultra Violet light Formed when a gas (e.g. nitrogen) is heated to >7,000K by an electric current Plasma cracks/reforms all organic matter and melts or vitrifies inorganic matter into an inert rock (Plasmarok ® ) with properties superior to granite Plasma treatment is a recovery process – not disposal What is Plasma?
Why Choose Plasma? Proximal solution-offering quicker turnaround Flexible operational profile Robust, reliable and easy to maintain technology Small physical foot-print and no unusual building requirements - readily retrofitable to existing plants Low environment impacts – sustainable recovery Lowest capital and operation cost at ‘small’ operational scales Tolerance of feed compositional variations
Plasmarok ® – From Waste to Product Plasmarok ® an Environment Agency approved product Use - Can be used for a range of applications (e.g. aggregate) Suitability - Mechanically stronger than natural alternatives such as basalt and granite Safety - Non hazardous and extremely resistant to leaching Leachability – leaching test results (BS EN 12457-3) for Plasmarok ® from autocat and a chemical catalyst are well below waste acceptance criteria (WAC) for inert landfill in EU mg/kg As Cd Mo Ni Sb WAC Limit for Inert Landfill 0.500 0.0400 0.50 0.40 0.060 Chemical Catalyst Slag 0.005 0.0005 0.12 0.03 0.006 Autocatalyst Slag <0.014 <0.0030 <0.05 <0.05 0.031
Overview of tetronics ’ global references
Global Customer Reference Map
European Customer Reference Map
Asia Customer Reference Map North Asia Customer Reference Map
North America Customer Reference Map
South America Customer reference Map
PLASMA RECOVERY OF PRECIOUS METALS
Platinum Group Metal Recovery Process
THE TECHNOLOGY - The PM Recovery Furnace Plasmarok ® Anode Refractory Slag Overflow Spout Carbon Hearth Precessing, Adjustable Arc Length Plasma Plasmarok ® Robotic Manipulator Feed Port Anode Cathode Torch Collector metal Layer Metal Tap Hole A single facility of its type processes circa 2,000 tonnes of autocat per year. The PGM recovery system delivers excellent technical and commercial yields.
Example Waste Stream: Autocatalyst Average PGM content is typically £50 on current market prices, but can be in excess of £200 on the high value autocats . The value is in the washcoat , impregnated into the ceramic honeycomb.
Carbon Impact - Energy Use & CO 2 Emission for PGM Smelting Plasma smelting leads to significantly reduced energy use and greenhouse gas (GHG) emission compared with conventional PGM smelting used in primary extraction.
Tetronics PM Track Record Client ID Location Date Commissioned Capacity tpy autocat * MultiMetco No 1 USA 1982 6000 MultiMetco No 2 USA >1982 3723 Heesung / BASF No 1 South Korea 2005 930 Heesung / BASF No 2 South Korea 2007 1850 PPUK UK 2007 1850 Solar Taiwan 2012 1850 Furuya Metals Japan 2013 800 Chinese Client China 2013 1850 South Korean Client South Korea 2014 2790 German Client Germany 2014 1850 * Figures based on quoted specification at 85% annual availability processing autocat
Next Generation – Metal Recovery from E-Waste Segregation (manual picking, disassembly) Separation (crushing, sensing, sorting) Incineration (optional) Smelting (submerged arc, plasma) Refining (hydrometallurgical, electrolysis) Plastics, bulk metals Heating value Precious metals Aggregate
Plasma Smelting - Process Description Formulation & Blending Feeding Plasma Furnace Off Gas Cleaning Plasmarok ® Plasma Power Metal Bullion Catalyst, WEEE, etc. Collector metal, flux Stack emissions
PLASMA RECOVERY OF BASE METALS & EAF Dust processing
Process Schematic for Steel Dust Processing
Plant Layout Note: building is circa 25 x 40 m and height to apex is circa 20 m
Operational Plant Reference 1 - Harsco Ownership = JV between Harsco and the Steel Mill Operator Operator = Harsco Year of start up = 1991 Location = Terni, Italy (within the ThyssenKrupp Steel Mill) Specified Working Capacity = 20,000 tpa mixed waste Waste = EAF/AOD dust and mill scale / cuttings Operational Status = active Power rating = 7 MW at 20,000 Amps Technical recovery rates, and associate operating parameter, are altered based on changes in commodity and utility prices/costs It is estimated that since 1991 almost $190 million of value has been realised from stainless steel dusts, scales and other material
Harsco Terni, Italy
Air pollution control residues ( apcr )
APCR Treatment Process
Air Pollution Control Residue (APCR) Treatment Provides close to a near zero waste solution in the treatment of a hazardous waste stream Technology demonstrated and proven Vitrification of the inorganic fraction to recover a dense environmentally stable slag Plasmarok ® Commercial plants operational in Japan for mixed IBA/Fly ash HCl recovered as a product
Benefits of Using Tetronics Plasma Technology Proximal solution, offering quicker turnaround Small physical foot-print and no unusual building requirements Flexible operational profile-short start-up times from cold Robust, proven technology and easy to maintain Low environment impacts-helping meet corporate CSR targets Lowest capital and operation cost at ‘small’ operational scales Wide feedstock flexibility/turndown Versatile with multiple industrial applications Readily retrofitable to existing plants Provides a future proof solution for managing risk
Why Choose Tetronics Credibility of our reference plant and experience Superior technical performance of our technology Simple and robust process Breath and scope of our Intellectual Property (IP) – global patents combined with an in-depth technical competence Low environmental impact Near zero waste solution Sustainable resource recovery solution