the Ember Eco Solutions System
Our Ember Eco Solutions technology goes beyond the usual benefits of a traditional waste carbonisation plant.
Our plants use innovative technology in completely preventing pollutant emissions and residues during processing and in their simple deployment and operation. They can be built within a short time frame (up to 6 months) and installed in relatively small spaces (from 20,000 sqm), being designated to serve small, medium and large-sized cities (a minimum 60,000 habitants ensure financial viability).
Our technology runs a system that renders the plant 100% self-sustainable: it utilizes only 10% of its own produced bio-coal to heat the carbonisation oven. That is all that is required to run the plant continuously, nothing else. No fuel and no gas. All gases from the carbonisation are retrieved and recuperated into a distiller (Railtec Distiller) releasing NO pollution into the air and no residues (no secondary pollution).
Our plants are, therefore, 100% self-sustainable, with no emissions and are non-pollutant besides affording extra significant profitability to landfill owners by producing highly marketable bio-products out of the carbonised waste such as tar, lignin, bio oil, and bio coal. The latter being used to generate bio energy.
Operating privately or through a consortium, our process also differs from many others due to its simplicity and innovative non-pollutant technology.
After its collection, the waste is deposited by the truck in a container unit, the hopper. The hopper has a large storage capacity which enables the plant to run continuously with the waste gradually released according to the oven’s capacity.
The hopper is enclosed with strong metal gates and an exhaust system that isolates the garbage smells even inside the processing unit, this way, in the absence of smells, the presence of animals such as seagulls, rats, flies and other insects and creatures reduces to nil.
The waste is dumped in the hopper in the same condition it has been collected. No kind of separation is required, no human hands touch the waste even after its collection. The waste is taken into the carbonisation oven via a conveyor belt and it is heated to 900 degrees Celsius, beginning the carbonisation process.
Carbonisation means that there is no oxygen inside the oven, therefore, there are no burning flames and the usual toxic fumes from combustion, even at 900 degrees Celsius. The waste is heated and dehydrated turning into char, not burnt or melted.
Furthermore, alongside the waste, all leachate is collected through a gutter mounted on the underside of the hopper, and that is also conveyed into the oven.
A collector is located on the top side of the oven where all gases generated by the process are channelled through a tube to the Raitec Distiller.
The Raitec Distiller is another innovation exclusive to Ember Eco Solutions.
[add link to explain the distiller – collector and separator of volatile gases]
Inside the Raitec, all gases are retrieved, distilled, liquified and turned into a powerful highly marketable bio-liquid called pyro ligneous extract.
The pyro ligneous extract is a liquid substance widely used in various industrial processes as well as in farming.
The tube returning from the distiller goes to a filter where the gas temperature is reduced to minus 93 degrees Celsius.
During this step, all solid particles are retrieved and separated and only water is released to the atmosphere in vapor form. This is another incredible benefit exclusive to our Ember Eco Solutions technology. Only water in the form of vapor is released into the atmosphere.”
Bio-products, recycling and sustainability
With the carbonisation process almost complete, part of the solid waste is now transformed into charcoal (char ashes) and other solid products.
These solid products come out of the oven separated, clean and ready for the recycling industry.
They are then sorted through a rotation metal tube according to the different types of materials contained in the carbonised waste: aluminium, glass, iron, copper, bronze, sand and rocks.
Only 10% of the bio coal produced from the processing will return to the oven’s furnace, which operates continuously. This means that the plant is self-sustaining producing its own bio fuel.
The remaining 90% of the bio coal produced can have several destinations, the major is clean energy and power generation.
The bio-liquid named pyro ligneous extract resulting from gases is also separated and sold to many industries (cosmetic, construction and oil).