This is recent material from a company called EcoKat that has opened a test facility and is now operational. They are using catalytic depolymerization to produce lightweight oil whose makeup is not described. The temperature is sufficient to produce pyrolysis fluids which though like a diesel oil is still not much use so we are clearly relying on the catalyst to reform the fluids into a fuel grade product.
It also obviously must be tuned to the feedstock and that means selectivity.
Another company was doing something similar has suspended its operations and is expected out with a new information soon. The main difference was that they brought the temperature up to 600 degrees and applied high pressure in a pressure chamber. The promise was again fuel grade diesel. Thus if the same result can be achieved at half the temperature with the use of a catalyst it will surely be much cheaper.
We will keep a watch of this project to see how it turns out. This stuff was plucked out of its web site and is disorganized but still gets the message across.
Our ongoing interest is derived from the promise of converting any organic feedstock into a shippable fluid feedstock while leaving no organic residual behind. This allows difficult feedstocks like municipal waste to be processed cleanly.
KDV 500 Catalytic Pressure-Free Fuel Conversion Plant
A new recycling formulation was necessary that would convert existing hydrocarbons (CH2), not into methane (CH4), and coke crystals (C), but into hydrocarbons (CH2) and only then in molecular lengths that reduce and bind in a manner which separates out unusable pollutants. In essence, the new formulation returns to the natural processes used for hundreds of millions of years where fossilized by-products from the seas settled into suspended clay minerals and ultimately formed fossil fuels, such as oil hydrocarbons.
We have patented a process that is modeled on this fuel creation, Mother Nature's behavior without the hundreds of millions of years it took to create fossil fuels through natural processes. KDV, our patented process, also avoids the creation of unusable, environmentally unfriendly materials, such as PCBs and Teflon , which when mixed together at high temperatures, can easily form Dioxins and Furan.
• A temperature from 270°C to 350°C in place of 40° C.• Ion exchange catalysts. • Up to 100% conversion of the extremely active crystallized y-catalysts.
These elements result in a final product of high-quality synthetic lightweight combustible fuel oil very similar to Diesel or Jet Fuel.
Our patented process uses catalyzing reduction to produce a lightweight oil, similar to Diesel Fuel. The production costs are at a fraction of those associated with existing recycling processes.
In order to produce a low cost, high quality fuel product, development of a reliable, low maintenance engineering plant was necessary. The KDV Plant is a self-sustaining energy production platform. It uses up to 10% of its own energy formation to run itself through a 230kW diesel-powered generator, or can run from a municipal power grid or similar supply, using its generator as a back-up system.
• Molecular depolymenzation at low temperatures (279°C - 350°C) • System pressure-free (indeed, a negative atmoshpheric pressure of .5 bar, via a viscous friction turbine, which also creates the flameless trigger heat source and chemical / material mixing process). • Previously unachievable Hydrocarbon conversion rates of more than 80% with liquid feedstocks and plastics, without the possibility of the formation of dangerous residuals• Decontamination of dangerous residual by-products (halogens, etc.) in a liquefied process that yields salt. • High-quality Diesel Fuel or Jet-Fuel suitable for use in today's engines.• Better yield performance with lowering quality crude inputs over standard refinery methods by roughly 20%• Better yield over traditional biodiesel feedstock and methodology. This is not biodiesel in the traditional sense. It is made as a straight, high cetane clean fuel, with operating temperature envelope equal or better to standard fuel. It is intended to meet or exceed ASTM 975 standards for highway use in California
As we hurtle into the next century with the ever growing demand for limited fossil / mineral oil reserves and rapidly growing competition in the global economy, it becomes vitally important for any viable company to be vigilant about its economical success, while implementing effective methods of environmental protection and resource conservation. A clean, unencumbered environment, while powering commerce and society, free of foreign dependencies, are of no small concern.
To combine these requirements becomes essential in present day economic planning and progress. As economies such as China and India surge forward with huge growth, so this issue is further exacerbated. It also becomes apparent that carbon dioxide emissions, a by-product of combusted resources, is rapidly changing our climate, the ramifications of which we have still to fully comprehend and realize.
Therefore, we have developed and are working on a variety of technologies which will help us by reducing carbon dioxide emissions and various other toxins produced or emitted by plants, factories and other combustion sources as well as creating high quality fuel oil from organic waste and other materials at a high degree of efficiency and low cost.
• KDV. We are also able to produce a light weight synthetic fuel oil, similar to diesel, kerosene, or jet fuel, with low or no sulfur content, from nearly any organic material, with emphasis on waste products as feedstock. This process is carbon neutral, highly efficient, and pollution less. It is a decentralized (modular) concept and economically viable. The fuel produced is a straight fuel, not a mere additive, with equal or better operating temperature ranges and power produced than ASTM 975 requirements (US highway diesel fuel). However, KDV derived fuels can be mixed with conventional or existing fuel supplies. The cost to produce this fuel is well under current pump prices. This small plant (30’x30’x30’) can produce nearly a million gallons of fuel per year from 1.2 million gallons of fats, oils, greases, shredded plastics. All manner of solid agricultural, municipal and industrial organic waste has been successfully tested in the lab, with production scale techniques presently being developed.
ECOKAT Applied Technologies is proud to offer these technologies while continually striving to improve upon them. Responsible, intelligent waste management, the economical creation of clean, high efficiency fuels from low value materials or waste, as well as creating methods in which to conserve that fuel, all in a decentralized method, is what we are all about.
The standard KDV 500 plant is designed to produce 500 litres or 132 gallons of fuel per hour and is economically optimized for the most diverse biological and mineral materials to be used as plant inputs.
Presently the scope of feedstock that can be guaranteed to work smoothly in the system is limited to all organic liquids, including fats of any kind, oils of any kind, greases of any kind, and because plastics can be melted into a liquid at relatively low temperatures, plastics are on the list of good, high yield feedstock.
Brown Grease collected from septic and commercial diverters is excellent feedstock.
Tallow and rendering plant product as well as prepared input is excellent feedstock.
Any plastic is an excellent feedstock. Shopping bags are a problem to recyclers, but they melt readily in a KDV heat exchanger and become excellent input.
Waste oils of all kinds, contaminated fuels, bitumen, and standard refinery waste, are high in hydrocarbons and flow easily through the system.
Successful testing of solid organics has been accomplished in the lab. Getting solids to flow through the system reliably over extended periods has proved a challenge which we happily engage, given the potential applications and rewards in municipal, agricultural and certain industrial waste management / fuel production.
KDV Production Scale Input Materials include:
• Plastics of all kinds (including PVCs and hospital waste materials)• Fats, Waste oils, and greases, waxes and fats (FOGs) of all types (including hydraulic oils and Trafooele)• All refinery by-products (bitumen, tars, etc.)
• Agricultural wastes (including animal waste products, spoiled food, etc.)• Biologically regenerating raw materials (wood, vegetables, meat wastes, etc.)• Municipal Solid Waste
The small size of the plant makes decentralized, on-site processing possible. This eliminates considerable transportation related costs, both on the input and product distribution end.