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164 Evaluation of Opportunities for Converting Indigenous UK Wastes to Wastes and Energy AEA/ED45551/Issue 1 Figure 22 A schematic of the Toyohashi R21 system Coke-Oven A process developed by Nippon Steel converts waste plastic into energy, the “Coke-Oven from Waste Plastics to Chemical Raw Materials Method”. This method uses a chemical recycling process to recover coke, tar, light oil and gas from general wastes plastics mixed in coal by carbonisation of coke ovens without deteriorating the quality of coke. The yield from this process is approximately 20% of coke, 40% tar and light oil, and 40% gases. The recovered coke is used to reduce the iron ore in a blast furnace, the tar and light oil as raw material for making plastic and the gas in a power plant. A number of such facilities exist in Japan, and shown in Table 84. Nippon Steel have recently filed a patent for a process which would give a product with greater utility value. 300 Table 84 List of Coke-Oven from Waste Plastics to Chemical Raw Materials Method facilities Year Capacity City tonnes p.a. Nagoya 2000 40,000 Kimitsu 2000 40,000 Muroran 2002 20,000 Yawata 2002 20,000 300 Method and Apparatus for Thermal Decomposition of Waste Plastics, JP2008266452 (A), Nippon Steel Corporation, 06.11.2008.
Evaluation of Opportunities for Converting Indigenous UK Wastes to Wastes and Energy AEA/ED45551/Issue 1 As is demonstrated by the above examples, in terms of thermal treatment of waste Japan, has a wellestablished system in place. Now the agenda has begun to shift towards the generation of energy as well as waste minimisation, Japan is one of the leading countries in terms of technology development and has the largest number of plants in operation that use thermal conversion techniques to treat waste and recover energy. 10.3 Conclusions From this review the following conclusions can be drawn; • Combustion, gasification and pyrolysis all use heat to break down the structure of the feedstock so that the chemical energy can be released either as heat or a fuel product. The conditions in the reactor determine the products. • Gasification technologies are being developed but often encounter severe technical difficulties when attempting the step of using the gas for power generation in an engine or gas turbine. • The robust approach of firing the gas in a boiler is proving reliable and a worthwhile innovation. These units can be produced in smaller sizes than conventional incineration and can be matched to heat loads in CHP and process heating applications to give potentially the best GHG abatement potential. • Gasification as a pre-treatment is likely to become more popular in cofiring as generators seek to increase the proportion of biomass in coal fired utility boilers. • There are few commercial pyrolysis plant operating on waste. • The technologies available for conversion of waste to heat and power are more widespread than those for conversion to transport fuels, although work is ongoing on advanced conversion for liquid biofuels. • The use of gasification at very large scale for the production of transport fuels or pipeline methane is attracting increasing attention and is potentially an efficient use of resources. 165
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