AeroThermal offers a solution to waste disposal that delivers significant environmental benefits by diverting waste from landfill and enhancing the biogas energy recovery potential from waste. Mixed raw waste is processed in a steam filled autoclave at high pressure, breaking down the cell structure of the organics by hydrolysis which increases the proportion of waste available for anaerobic digestion, from which a methane-rich biogas is produced which is then harnessed to generate green electricity. Waste heat is utilised within the system and the remaining recyclable material is sterilised and cleaned, enhancing its appeal to the recycling market.

The UK’s anaerobic digestion market is growing with Defra suggesting that more than 100 million tonnes of waste feedstock is available each year for biogas production which could provide between 10 and 20 TWh of heat and power (enough power to supply over 1 million homes). AeroThermal is well-placed to deploy its AAD system either on a turnkey basis or through the development of merchant site joint ventures, where venture partners provide a waste stream and operating expertise and AeroThermal and its backers provide the processing equipment and funding.  Bridges Ventures and Carbon Trust Investments are keen to support AeroThermal in its pursuit and development of an existing pipeline of opportunities.

This investment builds on Bridges Ventures’ successful record of backing businesses that can achieve intrinsic social or environmental impacts as well as attractive financial returns within the UK’s most deprived areas. The environmental sector is one of Bridges Ventures’ core target sectors.

The management team of AeroThermal has a strong track record of designing and building industrial-scale autoclave pressure vessels for high-specification applications in the aerospace, motor-sport and other industrial sectors. From the Airbus ‘SuperJumbo’ A380 wing forming autoclave at 40m long, to autoclaves that cure 80% of the Formula 1 cars’ carbon fibre parts, the AeroThermal team has been behind some of the most technically advanced and largest autoclaves in the world. The team has applied the same level of innovation and technical expertise to the waste market in the development of the AeroThermal Advanced Anaerobic Digestion Process.

Ian Toll, Chief Executive of AeroThermal Group Ltd, said:
“This funding round is a major milestone enabling AeroThermal to prove its innovative technology at full commercial scale. I am especially pleased to welcome support from such prestigious investors as Bridges Ventures and Carbon Trust Investments as well as to receive support from our existing shareholders, particularly in such a challenging funding environment.”

Philip Newborough, Chief Executive of Bridges Ventures, added:
“Bridges Ventures is excited to back a capable management team to take advantage of the opportunities in the emerging waste-to-energy sector with attractive potential financial and environmental gains. AeroThermal is now well-poised to build upon its technical pedigree to commercialise its autoclave know-how in the waste sector. We are committed to invest further to support the deployment of AeroThermal’s technology, and we look forward to working with the AeroThermal management team to fully realise its potential.”

Peter Linthwaite, Managing Partner of CT Investment Partners, added:
“Carbon Trust Investments is delighted to be backing the AeroThermal team in the development of their business which will help to divert waste from landfill and contribute to the UK’s move to a low carbon economy. By making it possible to generate renewable energy from more types of waste, and by further increasing the efficiency of existing waste to energy processes, we believe that this investment could provide significant environmental and financial returns.”

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“To conclude, we can state that:

• installations are entirely realized under the CE mark regime, being totally safe for operators and respectful towards the environment, and that they will be manufactured according to the ISO 9000 standards, in order to allow for the quality control of the machineries,
• the Autoclave installation is equipped with chimneys dedicated for the only evacuation of barely significant refluents (steam) or, in the case of P2P, for the emission of pretreated refluents coming from power generators (motors),
• in addition to the foregoing, there is absolutely NO combustion plant for raw or semi-finished materials, nor for process residuals.”

Doctor of Engineering SANASI Lucio
Sefit s.r.l.

Technical-operational report

Sefit presentation

New Delhi (PTI): A new process that converts algae and other biomass into liquid fuels with the help of a catalyst can brighten the prospect of substitute fuel production in the country.

“The technology is a process for converting algae and other biomass into liquid fuels similar to petroleum diesel which is better than the bio-diesels in quality and characteristics. The technology is a pyro-catalysis process”, said T Raghavendra Rao, director of Sustainable Technologies and Environmental Projects (STEPS).

“Originally the hydrocarbon oils have been formed over a few million years from algae under the layers of the earth. Now, we are attempting to replicate the natural process using a catalytic process in a much quicker way”, Mr. Rao told PTI.

The innovation was recently conferred the gold medal at the Innovators’ Award established by aerospace giant Lockheed Martin Corporation under its India innovation growth programme.

The new process, according to Mr. Rao, is not cumbersome as the conventional one besides it yields more fuel that before.

In this method the algae is vapourized in a particular temperature, which is then passed through a catalyst conversion chamber, putting them into a molecular structure that is similar to hydrocarbon fuels.

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A new technology that would help the hospitals in the country to manage bio medical and other wastes effectively by themselves will be introduced in the market soon. Christened as Polycrack, this new technology has the capability to convert all types of inorganic wastes, especially biomedical waste into oil and gas.

Hospitals have been complaining for long about the excessive charges imposed by municipal corporations of several regions in disposing and treatment of infectious or hazardous wastes.

Developed by T. Raghavendra Rao, director, Sustainable Technologies and Environmental Projects (STEPS), Polycrack Technology would help the hospital authorities to dispose hazardous wastes at low cost and in an effective manner.

“Hospitals can adopt the system on their own as it is easy to operate and does not require expensive technicians. It operates at a lower temperature range and in a closed loop system so that the emission parameters are met easily. Besides, low capital and operating costs and added benefit of inhouse fuel production are expected to attract the hospitals to try this technology for good”, said Raghavendra Rao.

Most of the waste generated in the hospitals consist of plastics (mostly PVC), body fluids, blood, organ parts etc. As per the procedures, the waste has to be segregated and packed in distinctly marked plastic bags for disposal. However, the new technology is expected to do away with this intricate process.

Referring to the modus operandi of Polycrack, Rao, said, “The mixed waste from hospitals can be fed into the system, which then converts plastics to liquid fuels and organic matter to gaseous fuels”. The gaseous fuels thus produced can be utilised to generate electricity to run some of the hospital utilities as well as the plant itself. The liquid fuels can be used to run the stand-by generators, the hospitals normally have.

“Using the incinerators at the hospital premises is expensive, hazardous and requires consistent monitoring by trained technicians. The incinerators consume high volume of liquid fuels and considering all expenses of maintenance, employee costs and fuel, the incinerators become a liability rather than an asset to the hospitals. So, many hospitals in the country reportedly prefer a cheaper way of disposal”, Rao noted.

The technology can be used on a commercial scale now. “We are currently working on 25 TPD (ton per day) plants for general use. For hospitals we have to develop smaller units. Hospital use also requires clearances from pollution control boards. We are already working on this angle. The smaller units for hospital use may be launched after extensive testing and after obtaining approvals from statuary bodies. We estimate that such units will be available for hospitals in about 4 to 5 months time”, he said.

Asked whether Maharashtra Pollution Control Board would welcome Polycrack for waste management in hospitals, Sanjay Khandare, member secretary, MPCB, said, “First of all we have to check out whether the new system works efficiently and would not produce any toxic or hazardous substances while converting waste
materials into gas or fuels. We should also find out whether the system is environment friendly or not. If it is found efficient, we will take necessary steps to
implement the technology”.

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Picture this. Donating a dustbin full of garbage everyday could get you free gas in your kitchen or free electricity, forever.

Sounds far-fetched? It’s possible if your housing society buys one of the waste management technologies available in the market, which transforms your garbage into fuel (liquid and gas) or electricity.

Says Alka Zadgaonkar, founder of Nagpur-based Unique Waste Plastic Management and Research Company (UWPMRC), “Yes this could be a reality today if the government’s permission is taken by the residents. The technology of converting waste to fuel or electricity has huge potential as it solves two problems simultaneously—of waste management and the fuel crisis”. Industry experts estimate that India produces waste equivalent to fuel or energy that could fetch $100 billion annually.

UWPMRC currently produces 5,000 litre of fuel from plastic waste collected by ragpickers in Nagpur and sells it to industrial units in Butibori, outside the city. A year ago, Suresh Shah of Asian Electronics in Navi Mumbai bought 75% in this company for Rs 80 crore.

Meanwhile, Sustainable Technologies & Environmental Projects (STEPS), a Mumbai-based company, has also developed a technology that can thermally convert various materials like vegetable oil, animal fat, and petroleum by-products into liquid, gas and solid fuel.

“With this technology, any hydrocarbon, such as plastic, bio-medical waste, slaughterhouse waste, petroleum sludge or wax can be thermally converted into liquid or gas fuel and a powder carbon residue. The liquid fuel can then be refined into different fractions or used ‘as is’ in engines and generators”, says Raghavendra Rao T, director, STEPS.

The petroleum gas can be fed back into the system to power the process and the carbon residue or coke powder can be recovered and sold. The process is based on adding a catalyst to the feedstock and then raising the temperature through several stages to approximately 420 degrees Celsius. As the temperature rises, the materials are vaporised, drawn off and condensed into fuel. Finally at 420 degrees Celsius, any remaining material is converted into carbon powder. Says Rao, “Negotiations for twelve of our machines are in final stages, and two of the buyers are in India. Presently only industrial units are going for the technology but in the future housing societies could pool in money and adopt it”. Each machine costs around Rs 10 crore, but the company is developing a method where the machines will cost less and be more affordable for homes.

There have already been proposals made to the finance ministry for excise duty exemption on waste management technologies. Harshad Gandhi, secretary, Developmental & Eco-Friendly Enterprises (DECENT) a not-for-profit company, recently in his letter to the finance minister, says, “Waste handling agencies have not been able to keep pace with the growing urban municipal solid waste, which is currently estimated at 1,15,000 tonnes per day in India”.

He also asks that a concession be given on equipment required for waste management and excise be reduced from the present 16% to nil. According to government figures Mumbai alone generates 8,000 tonnes of waste every day, of which 5% is plastic waste. “About 52% of the waste generated is organic waste and can also be converted into compost with the help of machines like the Organic Waste Converter (OWC). This could not only solve the problem of availability of dumping grounds in cities like Mumbai and New Delhi but also reduce transportation costs if every housing society invests in this technology”, adds Gandhi.

According to an estimate, around Rs 3,000 crore is spent every year by municipal bodies in the metros on collection and disposal of garbage. “The Brihanmumbai Municipal Corporation (BMC) spends about Rs 800 crore every year in transportation of waste from homes to dumping grounds. Only if the government fixes one organic waste converter in every society this cost could be reduced at one go”, says Mohan Jawdekar, vice president of the environment and biotech division at Excel Industries, a Rs 800 crore company which manufactures organic waste converters.

The OWC is presently used by hotels and hospitals and priced at Rs 4 lakh. And it can convert organic waste into manure, which if sold even at one or two rupees per kg, can not only help governments save millions spent on transportation of garbage but also earn revenue from the sale of manure.

Notably, two companies—Sai Renewable Power and GK Bio-Energy—are using the technology to generate electricity from waste. Sai Renewable Power, based in Hyderabad, generates power after combustion of empty bunches from palm trees and residue of palm fruits. These are rich in volatile substances and are used as a fuel for the boiler in the plant.

The Rs 1,376 lakh project, funded partly by IREDA, generates 3MW of power from 100 tonnes of palm oil industry waste every day. GK Bio-Energy, a Namakkal (Tamil Nadu) based company, generates power from poultry droppings. It collects the droppings of about a million birds from nearby poultry farms to generate power. The technology is based on the Biogas Induced Mixing Arrangement (BIMA) technology developed and commercialised by Entec, an Austrian company.

Explains Anurag Garg, assistant professor at IIT Mumbai, “According to our research about 20% of the total municipal solid waste consists of plastic, which is a hydrocarbon and can be converted into fuel or energy. Presently not many companies have come into the market with their products but this field has great potential”. Many small companies are now tying with large oil companies for promotion of their products. Recently Asian Electronics entered into a joint venture with a major Indian petroleum company.

“We have signed an MOU with the oil company and would be marketing our products with them and could also use some of their residue (heavy oil) as raw material for our process. But otherwise also we can market our products through them”, says Shah refusing to divulge the name of the petroleum company. Asian Electronics plans to come out with a fuel, which could be used as a substitute for diesel and will be cheaper too.

“In the near future you could see many petroleum mammoths tying up with small companies either for the technology or the products. And we expect that it would be a business worth billions”, says Rao.

Industry experts also point out that technologies developed in India hold huge potential abroad. Says Zadgaonkar, “We are in talks with an Oman-based company and a USA-based company have also showed keen interest. Companies in the West are attracted to our technology as it gives them carbon credits”.

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Translation: “Waste is still not transformed into something else, but things could change very quickly. An engineer has just created a new technology, a machine to transform plastic waste into petroleum.
Raghavendra Rao is the alchemist of the New Age: he has found a way to transform plastic waste into black gold within a few hours.
Thanks to this machine, the plastic melts and becomes vapor before going through the catalyst. All the genius is there: a simple 50cm wide cyclinder transforms the vapor into fuel.
“Catalyst only takes into consideration the atoms of carbon and hydrogen. There is no need to know whether it’s wood or plastic or any other thing. Whatever you introduce into it, you will either get petrol, gas or both.”
The fuel just needs to be collected and filtered.
It’s a process that is very economic and simple and has the attention of two people from the Netherlands. Their company, after several tests, decided to sign a contract with the engineer in order to commercialize this technology in the entire world.
“It’s a process that seems so simple in how it transforms plastic into gas or petrol. We visited many companies and plants of the competition with huge devices, but none of them could function or provide the same result.”
Four companies have already purchased this technology and, rather than throwing away their waste, they will convert it to produce electricity.
Right now the competition is rare and the market that would be provided with this innovation could be $3 billion in three years.
“The fabrication of this technology is a big secret and well kept for many years to come.”
In countries like India, which is the first consumer of plastic in the world, to transform plastic into fuel could bring them a lot of money and reduce pollution.”

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