CA2347106A1 - Garbage processing plant - Google Patents

Abstract

Garbage material from household and other city sources is processed in a co-current gas solid processing set-up. The temperature of the material being processed is increased gradually with simultaneously increase in chemical potentials upto a temperature where all carbon is reacted, and metals not required in steel composition are melted. These melted metals are filtered out. Slag forming ingredients are melted to form liquid and separated from steel forming metals, which remain as solids. The reaction gas used is industrial grade O2 or air that may be enriched with oxygen.
Energy and blown out material is recovered from gases coming out of a high temperature reactor. The exit gases from particles recovery set up are used as heat sources in gas cleaning system from chemical impurities where purified gases CO, H2 are obtained.
These purified gases may contain variable percentage of N2. These gases may be used as alternative to the natural gases.
CO, H2 may be changed to H2 and CO2. The H2 obtained may be used as high quality household fuel or used in the synthesis of ammonia. H2 may be further purified to produce cryogenic hydrogen for space industry. CO2 and N2 gases along with steam may be used in new type of green houses.
H2, N2 and CO2 gases may be used to produce urea. Remaining CO2 and N2 may be supplied as hot gases to the greenhouses. Excess steam available from plant will be used to produce electricity.
Cu, Pb, Sn and other metallic will be recovered. The non-recovered metallic and metallic from various ashes will go with the slag material forming micronutrients fertilizer. The non-melted material will be high quality scrap.
There is no direct use of water and there fore no water pollution, no gases discharge except some small portion of CO2 and N2. There is no sold residue therefore no environmental pollution.
The introduction of all weather, composition control, temperature controlled greenhouses will be highly beneficial for the cold and hot climate regions. CO2 is used as insulating gas between double glass walls.
A new process for sizing of steel articles, tires and automobile batteries is invented.

Description

Theory and design of a GARBAGE PROCESSING PLANT
I have invented a garbage processing plant for the production of high purity CO, H2 gases, fertilizer gases (C02, N2, H20), dry ice, industrial or cryogenic grade hydrogen, urea, high quality steel scrap, micro-nutrient fertilizer. The process and plant can produce all these products or only selected products out of these depending on the quality and quantity of the garbage material available and sale potentials of these products.
1o The raw materials used for this process and plant is the household and city garbage, which may consist of various carbohydrates, hydrocarbons, plastics and rubbers, metal and non- metal, ceramics and glass, lathers and protein materials and all sorts of human and animal wastes.
The oxidizing gases used may be oxygen or air or any mixture of these two.
Garbage disposal has become a great problem as environmental conscious public would not allow any disposal site in their neighbor hood or even allow the garbage transportation through their localities. Garbage is a disposal problem but also a costly 2o problem from transport and disposal view point.
INGREDIENTS OF GARBAGE.
Metro garbage consists of the following type of materials:
Category 1. Household garbage, which consists of leftover foods, a mixture of starch and proteins.
Wood based products namely paper and board. Cotton and polyester type mixed clothing, wool and other plastic mixes. Glass and plastic bottles.
Category 2. Thrown away electronics, which consist of plastic and metals. The metals may be copper wiring and large numbers of other metals.
3o Category 3.Rubber and plastic materials, which also include tires and variety of, mixed natural rubber and plastics.
Category 4. Leather and wool articles which consist of mainly proteins.
Category S. Metal articles, which may contain iron and steel and variety of other metals.
Category 6. Paints and fillers in the paints. Paints are plastics, which contain calcium carbonate type of fillers and inorganic or organic colors.
Category 7. Human, animal excretions and decayed organic products.
It can be realized that most of the material is cellulose and starch type which falls into CX
4o Hy OZ type of compounds. Other materials like lignin in wood and constituents in plastics and rubber are hydrocarbons, which are mainly -(CH")- type of structural blocks.
Proteins contain carbohydrates with small amount of phosphorus, sulfur and many other elements.
Ash from wood will provide large number of metal ingredients.
Eventually all these will boil down to C, H, O iron and steel, non iron metals which melt before steel forming temperature, glass and ceramic which will melt before steel forming temperature forming slag.
5o In actual practice a batch of garbage will be analyzed in plant laboratory and process parameters will be adjusted accordingly.
Here for the sake of calculations we adopt a mix as given in the following.
Our result will not very to any appreciable extent because Gases mixtures CO-COZ and H2- H20 will adjust itself according water gas sift equilibrium. Thermocouples reading the temperature of gases will adjust the amount of oxygen over the oxygen already present in the garbage material.
The estimated percentage mixture of various ingredient is given as in the following.
C6H~oOs type of compounds (building blocks in starch and cellulose) = 60 (CH32)- the building blocks in polyphone plastics and rubbers =30 Steel material = 6 Non steel metals =1.5%
Metals from ashes =0.5 1o Others like CaO, MgO, Na,K oxides, silica, P, S, Cl etc. =2.0 = 100 Based on this categorization it is estimated that metal component are in the following proportion.
C =51 H2 = 8 "
20 02 =24 "
Ca Mg, S = 3. "
Fe, Cu, Zn, etc = 4.25 "
p = 1.5 "
N =2. "
K,Na =1. "
Slag =5. "
Table 1.
METALS NOT REQUIRED IN STEEL THEIR RECOVERY AND SEPARATION.
3o Metals not required in steel their melting and boiling point is given in the following.
Metal melting point C boiling point C
Hg -38 356 Se 217 685 As 817 613 Te 447 989 Cd 320 765 Sn 321 2620 4o Cra 298 2245 Sb 630 1585 In 156 2067 Bi 276 1585 Pb 323 1754 For more details see supplement A.
Thus heating and reducing the charge upto 1000 C separates these metals.
These may be separated as soon as a metal is melted and then filtering it out.
The 5o situation is bit more diW cult because these metals are mutually soluble in all compositions and at all temperatures. Some metal may become volatile and melted simultaneously. The metal may be recovered in suitable groups and then separated into individual metal as shown in figures 5 andl0. The volatile metals are fractionally condensed and separated. The liquid metals are separated by phase inversion method. The metal mixture is heated to the highest point and then gradually cooled with simultaneously blowing oxygen through the melt. Oxide of the highest melting metal will be formed first which will be floating on the surface and is skimmed off. The next metal is then skimmed in a similar way.
The next group of metals is Cu and noble metals and platinum group metals.
These all are soluble in copper and are separated jointly. Copper is cast into anode and then these metals are separated in conventional manner. After this all metals will go with steel forming scrap or slag.
The melting and volatizing sequence is different for metal oxides than for metals. Some to oxides are more volatile then metals. The melting and separating operation should be performed under appropriate chemical potentials for the metal or metals, which are separated. Copper will be melted and separated where the chemical potential is reducing or oxidizing because at 1200 C the oxide of copper is not stable.
RAW MATERIAL PREPARATION.
The process starts with the delivery of garbage material by railway wagons and trucks.
When railways deliver material, wagon tipplers discharge the wagons. There being two such wagon tipplers discharging the wagons. The material discharged by a wagon or 2o tick falls into under ground hoppers from where two 14 inches conveyors takes these either directly to the process line or temporary storage for 4-5 days. The processing line consists of first removing the large steel pieces manually. Cans and magnetically separable steel material are separated and sent on a different line.
These materials are sized to small pieces not larger than 2.5x2.5 inches by automated means using nitrogen plasma cutting torches as shown in figure 2. The sized material along with sized tires and sized automobile batteries is recharge on the main conveyor.
Making it pass through heavy crushing rolls then crushes the material. After crushing rolls the size of the material is not larger than 2.5 x2.5 inches. Conveyors takes this 3o material to stocking reclaiming facilities for temporary storage or directly to the storage bins (day bins).
Trucks in this area deliver tires, automobile batteries and coal used in this process. The sizing process for tires and other materials is similar to cutting of steel pieces or cans; the power of the cutting torches may be matched to the requirements of the materials.
Cans are separated and sheared on a continuous line to make their inside open so that tin coating can be melted and filtered out. A closed steel can when crushed, internal coating will not be separated.
4o Material is discharges from day bins through weighing conveyors on a carrying conveyor, that discharge the material on an elevating conveyor. This high inclination conveyor discharges the material to the receiving hopper of an inclined reactor.
PROCESSING OF PREPARED MATERIALS.
Garbage material is changed small size so that it can be charged by conveyor means under double lock devices to an inclined cylindrical reactor. The inclination of this reactor is near about 10-12 degree, at this inclination the sized garbage material will not 50 move by itself but it will move by a small pushing force exerted by a pushing screw mechanism. The lower surface of this reactor is lined with porous refractory through which liquid metal can filter down ward and heating reducing gases can pass up ward.
The hot gases raising counter current to liquid metal will keep the channels open. Group of metals will be collected separately and then separated out side the system by phase inversion method. The volatile metals will be volatilized and then collected in particles collection portions. All metals with melting point upto 1300 C will be melted out at separated temperature regions in this reactor whose temperature is increased gradually along the length of the reactor and metal with higher and higher melting temperature and volatizing temperature will be eliminated.
The material falling in the vertical reactor will be slag forming ingredients and steel scrap. Slag forming material will be melted and metals in the ashes of wood and metal not separated in the inclined reactor will be mixed with slag and will be discharged at the bottom of the reactor. The metal melting at higher temperature than 1300 C, whose lower 1o melting ingredient have melted will be retained in the reactor and discharged through separate double lock mechanism. The mixed slag phase will be changed into micro particles by rapid quenching. Non melted material is high quality scrap which will be with drawn through a separate arrangement.
Material is reacted in an inclined reactor and its connected high temperature reactor. The purpose is to attain two major aims. To gradually heat the material in reducing atmosphere so that melting temperature and vaporizing temperature of some metal is achieved ( Table -1 ). These metals are filtered out and received in collecting arrangement. The material is reacted so that maximum amount of reducing gases (CO, 20 H2~ is produced.
These Energy carrying gases CO, HZ can be used for heating purposes.
This CO, HZ gases mixture is obtained when combustion gas used is 02 or CO, H2, NZ
gas mixture is obtained when air or enriched air is used for combustion..
These can be changed by shift reaction to HZ and C02 or H2, NZ and COa. H2 gas can be used as combustion gases.
COZ so obtained and N2 obtained from air fractionation plant, can be used as fertilizer gases. These gases can be mixed with required quantity of steam and heated by the excess 3o energy sources of the plant.
H2, N2 are combined to form ammonia and then combined withC02 to form urea by some modification of conventional technology.
High purity H2 and N2 are passed over iron based catalyst under high pressure 15-60 MPa and temperature 400-600 C. The ammonia which forms is condensed by cooling with cold nitrogen. For the production of urea, ammonia and COZ are fed to a high-pressure reactor upto 30 Mpa and temperature about 200 C. Ammonium carbamate CH6N202, urea and water are formed.
40 2NH3+ C02 = NHZCOONH4 + heat NHZCOONH4+ heat = NHzCONH2 + H20 Excess ammonia is fed to the reactor; NH3 and COz exit the reactor along with urea.
Efficiencies differ with various technologies. Urea production step is followed with granulation and conditioning. Because it is a continuation process from ammonia to urea Hot ammonia stream and hot C02 streams are used, a modification of conventional technology.
The production quantity of the plant depends upon the hydrogen produced in the so above steps. Usually a plant based upon garbage specified in the above as raw material will have excess COZ and fractionation plant will have excess N2 than required by the urea plant. These excess gases will be used as fertilizer gases, and other needs of the plant. The ingredients in the garbage, which will be producing, sulfur, phosphorus, nitrogen and chlorine gases will be separated before C02 separation and these gases will be mixed with NZ gas as sub soil micronutrients or with COZ as micronutrients in the gases phase.
Gases leaving the high temperature reactor are made to exit from a side arrangement.
These gases are lowered in temperature from 1300 C to 1100 C by introducing endothermically reacting gases, which will absorb heat from the high temperature gases.
(see supplement A). The heat is then recovered from 1100 or even 1300 C to 300 C by a boiler, where blown out particles are settled. Gases being passed through bag filters to further recover the blown out particles.
1o The heat recovery particles recovery system is a gradually cooling system separated into various temperature regions where volatile metal may condense according to their solidification temperature. The is no fuel particle left and metal obtained may be relatively pure.
There being two-bag houses in parallel, one on repair and other on stand by.
These gases are then freed of water-soluble impure gases and further purified by passing through NaOH solution. The gases are then freed of COZ contents and pure CO, H2 gases are obtained. The heat required in the desorption of adsorbed COZ is used from the gases stream itself which is coming at 500-300 C. The energy spend in the compression of C02 2o is recovered by expansion of gases after the removal of COZ. Similarly energy spend in compression of absorption solution is regained by expansion of these solution before C02 removal.
When CO, HZ ( CO, HZ, N2) mixture is changed to CO2, HZ by shift reaction about 2.7 times steam is used then the stichometric requirement of CO. The reaction is performed at 200-250 C and the reaction is exothermic, the product gases are cooled and energy is recovered. The COZ containing solutions are cooled by adiabatic expansion before going to desorption process for the removal of CO2. Two flow lines are shown one 3o when the end product is CO, H2 and the second when the end product gas is H2.
With HZ gas COZ is also recovered. It is this COZ which will be used in urea production and as fertilizer gas in the green houses. Because the COZ is free of impurities it can be used to prepare food grade gas after deodorizing over activated charcoal.
Absolute pure hydrogen can be produced by cryogenic separation of CO, HZ
mixture using low temperature nitrogen from the air fractionation plant. The hydrogen so produced will be about 98.5 % pure; CO still remaining will be separated by absorption through ammonical cupric chloride solution. This hydrogen can be liquefied for space 4o industry.
MATERIAL AND ENERGY BALANCE OF THE PLANT.
The elemental contents per 100 kg of the charge are given previously. In the following the calculation basis is taken per m.ton of the garbage charge. Various formalism and theoretical basis of the calculation are given in supplement A.
The final temperature of the heated materials is 1300 C.
T1 =1275 T2 =1192 5o T3 = 282 510/12 * C* (1175* 4.003 + 1192* 1.14 + 282* 2.04) = 300,517 80/2*H * ( 1175 * 6.5 + 1192* .78 + 282*.12) = 37,000 240/32* 02 * ( 1175 * 7.16 + 1192* 1.0 + 282 * 0.4) = 78,353 Ca,Mg,S 30/40*(1175* 5.25 + 1192* 3.44) - 8.094 Fe,Cu,Pb 42.5/56* (1175* 3.04+ 1192*7.58 + 282* -0.6) - 9,670 P* 15/31 * ( 1275 * 4.74 + 1192* 3.9) - 5,007 N* 20/28 * (1275* 6.83 + 1192 * 0.9 = 282* .12) - 7,010 K,Na 10/39 * (1275*6.83 + 1192* 1.08) - 2,563 Slag 50/60 * ( 1275* .3 + 100 kcal/kg ) - 376 Slag is assumed as silica. --------------------448,590 Heats taken out by melted out metals. - 74000 Io Heats taken out by slag forming ingredients - 16,565 Heat taken out by steel forming scrap - 12,000 Zinc oxide will not be reduced and will remain with steel forming metals. It will be separated in high temperature melting operation above 1650 C, where it will be volatilized forming dust material.
HEATS GENERATED BY COMBUSTION REACTIONS.
These calculations are done with the assumptions that C and H will react with Oxygen in the ratio in which they are present in the reacting material. The amount of C
reacting to CO and COZ is found by hit and trial at which the energy balance is obtained.
42.5 * .925 (C+'/2 02) = 26,400 * 39.3 CO = 39.3 Kg.mole = 1,037,836 42.5 * .725 (C + OZ) - 94,050 * 3.08 - C02= 3.08 Kg.mole 289,792 40* .925 HZ H2 = 37 kg.mole 40* .0725 (H2 + 1/202) = 57,800 * 2.9 = H20 = 2.9 Kg.mole 167,620 Ca,Mg, S * 1. S * (Ca +'/z 02)=1 S 1,500* Ca,Mg O, SOZ = 1.5 1.5 = 227,250 kg mole 2P +3/2 02* 15/30.9 (P+3/20)= 356600* .242P2 03= .24 Kg. mole = 43148 K * 10/39 ( 2K +'/z 02) =107,700 *.128 K20 = .128 Kg mole = 13785 __ ______________________________ Total heats = 1,703,681Kca1 Heats brought from lower chamber CH4 +'/z = 104,525 Kcal.
OZ

Gases composition going out CO = 39.3 kg mole COZ = 3.08 "

HZ = 37 "

H20 = 2.9 "

P2O3 .12 "

Other gases = .6 "

Total = 83. kg.mole Heat taken out by exit gases at 1300 C
83 * 8.5 Kcal/kg.mole-C * 1300 C = 917,150 Kcal Heat absorbed by external oxygen input = 24.68 -7.2 =17.48 kg.mole 17.48* 7.5 * 1300 =160,466 Kcal 5o Heat taken by dissociation of hydrocarbons and polythenes = 45000 *0 .85=38,240 Kcal ENERGY BALANCE

Inputs Kcal Outputs Kcal Heat taken up by the charge = 448,590 Heat taken out by gases = 917,150 Taken by oxygen - 160,466 Heat taken out by steel scrap=12,000 Heat taken up for dissociation=38,240 Heat taken out by slag = 16562 Heat of reactions - -1,703,680 Heat taken out by melted metal=74,000 Heat from lower chamber - - 104,525 Conduction and other losses to @6% of input heats =69,654 Net inputs = 1,091,255 Net out puts = 1,019,712 GASES COMPOSITION GOING OUT FROM HIGH TEMPERATURE REACTOR.:
CO = 39.3 kg mole C02 =3.08 H2 =37 2o H2 O =2.9 Others ( SO2, HZS, N02,N2 O, PZOs, PH3, OC12, HCl ) = 1.5 83.45 kg mole Gases after purification CO = 39.3 kg. mole HZ = 3 7 "
76.3 kg.mole 30 CO = 51.5% Hz =48.5 Calorific value of product gas 0.515*(CO +1/2 OZ = COZ OH = - 67650 Kcal) =34840 Kcal 0.485*( HZ +'/z OZ = H20 " -57800 " ) = 28033 "
one cu meter = 62873 /22 =2859 kcal one cu meter of natural gas =7800 kcal Caloric value of CO, H2 = .365 of natural gas.
Total annual production of CO, H2 =76.3 * 500,000 = 38.15 x 106 kg. mole 40 = 839.3x 106 cu meters PRODUCTION OF HZ:
Shift conversion takes place according to the following reaction CO+HZ+H20=HZ+COZ
In a two step process approximately 95 % CO changes to C02. We assume that 100 conversion takes place, so the volume of hydrogen produced is equal to the volume of CO,HZ gases.
HZ = 38.x 106 K~.mole 839x 106 cu.meters.
5o COZ = 19.65 x 10 kg. mole 431x106 cu. meters.
Because of economic reasons some 20 % of CO, Hz of the volume of these gases will be used for green house heating, which it is assumed it is an associated concern of the garbage processing plant.

The rest of the hydrogen is either marketed as heating gas as a clean heating fuel for the households, because when it burns it will produce water vapors only. If properly promoted this can bring better revenue than the natural gas heating. For the present it can be marketed as a combustible fuel bring revenue according its calorific value.
Both CO,H2 and HZ when marketed will be treated as combustible fuel brings revenue 0.36 % of the natural gas.
UREA PRODUCTION FROM HYDROGEN.
A more economical proposition is to produce urea from the hydrogen, which is a more to accepted market commodity.
It goes through the following steps.
3H2+N2=2NH3 2NH3 + COZ = CO ( NH2)2 + Hz0 3-kg mole of hydrogen will produce 60-kg urea.
Total urea produced = 60 x 38x106/3 * 1000 = 760,000 m.ton per annum C02 excess after using in urea formation = 7 x 10'° kg mole per annum.
Nitrogen consumed in urea formation 12.6 x 106 20 Remaining nitrogen = 37.5 x 106 kg. mole per annum.
These gases heated to a desired temperature, having required moisture and fertilizer potential may be used as green house gases in cold and hot surroundings.
C02 has lowest coefficient of thermal conductivity as compared to other gases and construction material. It will be employed as insulation material between the double glass wall of Green house enclosures.
PLANT CAPACITY.
The plant is designed to process 500,000 ton of garbage per annum. This includes about 50,000 tons of tires. Any deficiency in the availability of garbage will be met by 3o inclusion of steam coal of the same tonnage.
This plant will use about 700-kg industrial oxygen (98.5%) per ton of the charge. In stead of using oxygen the plant can be design on oxygen enriched air, particularly when a mixture of H2, NZ is used for production of ammonia. For the present design industrial oxygen will be used.
It will produce about 42.5 * 106 kg. mole of CO, HZ per annum.
Alternatively it wil l produce about 41. 5 * 106 kg. mole of HZ per annum and about 19, 5 106 kg.mole C02 gas per annum and 50x 106 kg.mole of NZ per annum. Nitrogen is used 4o for cooling, for ammonia production, for plasma cutting, as form gas and some miscellaneous uses.
As a third alternate the plant will produce 750000 m.ton of urea per annum, quite a large amount of COZ and NZ for 4-5 industrial forms and other miscellaneous uses.
FERTILIZERS.
A fertilizer may be any substance which when applied to the soil will contribute to the cultivation of the plant by supplying nutrients to it. The optimum input level of fertilization is reached when a marginal monetary yield (marginal return) and marginal 5o cost are equal. Along with fertilizers other beneficial chemical such as pesticides, insecticides, herbicides and stem shortening chemicals are also applied.
Consumption of fertilizers are usually in the ratio N: Pz05: K20 :1: 0.5: 0.4.
Western Europe applies highest fertilizer per acre in the world, about 130 kg/hectare.
In North America this figure is about 44 kg/hectare.
s Table 1 Nutrients application kg/ha N P205 K20 Total North America 22.5 10.3 11.3 44.1 W. Europe 62.5 32.7 32.4 128.7 Eastern Europe 22.7 14.4 14.0 51.0 World average 14.5 7.1 5.5 27.0 Crrain crops use about 60% NZ
Vegetable crops use about 30 % N2 1o Division of nitrogen fertilizers.
Among the nitrogen compounds urea is applied in the highest about 33 %, ammonia 14 %, nitrates and mixed ammonia compound 29%, multi-nutrients 19%, all-others 15%.
Plants dried material consist of 44 % C which enters the plant via leaves and through C02 in the air.
Although air contain 79 % nitrogen by volume, but this is of little use for the plants. Plant is considered to consume nitrogen through its roots and via the formation of water-soluble nitrates. Ammonia is supplied to the soil via submerged soil injection techniques, 2o it decomposes and then forms nitrates by reaction with soil moisture, which is then taken up by the plant. It is considered that only a fraction of ammonia is consumed by the plants, rest of the ammonia being volatile leaves the soils and goes to air.
Urea when supplied to the soil in water decomposes to ammonia and carbon dioxide. Urea is often washed away with water. Plant take up nitrogen from urea is similar to ammonia by the roots and similar to COZ from the air.
Before the large scale production of nitrogen fertilizer by modern industry the plant intake of nitrogen was promoted by crop rotation means, i.e. certain plant varieties particularly legumes of guawara and sun crop and peas were grown and then ploughed 3o into ground when the crop is tender and easily decomposed. This bacterial soil so produced has the ability to use atmospheric nitrogen. The regular crop, which is grown over this decayed soil, has the ability to use the atmospheric nitrogen. About a month and half is taken by this rotation process, effectively delaying the period of regular crop sowing. Instead of sowing and decaying of crop already decayed soil or material may be used. This consists of animal and human excretions, decayed vegetation, guano, ground fish meal and slaughterhouse waste. Nitrogen gas containing micro nutrient gases is blown under the layer of this material. A mechanical method of this system is shown in 4o figure(13). Nitrogen blown is not pure nitrogen; it is air enriched with nitrogen. The nitrogen contents and humidity level will differ for particular crop. Other two fertilizers namely phosphates and potash has to be applied along with decayed soils. Human and animal excretion has many micronutrients contained in these. Solid micronutrients should be added with soil analysis a8er suitable periods of time.
Plants obtain C,O,H through atmosphere. N, P,K and micro constituents from soil. A
regular supply of all these have to be maintained.
5o Methods and approach of directly supply of nitrogen from air fractionation system has not been developed because nitrogen production is not economical by this route.
However by the development of large tonnage oxygen plant for metal industry this approach has become viable. Nitrogen available from fractionation plant has large amount of cold value. This cold can be used in certain operation as replacement of conventional refrigeration and cooling system.

This nitrogen may be used for temperature control in green houses of those regions where temperature is high, and plant growth is not possible.
USING CARBON DIOXIDE AND WATER VAPOR TO SUPPLY C, H,O to the plant.
C02 is also a necessary ingredient in life cycle of animal and plant. In animal metabolism oxygen from atmosphere reacts with sugars to produce energy.
C6 HI2 06 + 6 02 = 6 C02 + 6 H2 0 + energy In plant metabolism C02 is taken by the leaves using energy from light and enzymes as catalyst producing sugar to C02 + H2 O = C6 Hi2 06 (sugar) Sugar ~ Cellulose Thus for plant growth N, P, K in the roots and carbon dioxide and water vapors in the leaves are essential ingredients.
When the plant is small during initial growth both N2 and C02 can be given in the pipes) under the plant roots, where flow rate can be controlled.
When S02 is also available it can be with N2; C02 in small percentage or alone where soil is deficient in sulfur.
2o The end products of any combustion process is a mixture of gases containing C02, H2 O, N2 and some minor amount of S02,C0, H2, 02 and others. These at appropriate temperature and saturated with water vapors can be supplied as plant nutrient (fertilizer) All combustion products saturated with water vapors can be used as fertilizers. In case the soil is already wet non-saturated combustion products can be used.
Plant need for their healthy growth the following structural and nutrients.
Structural elements 3o H 6 Primary nutrients P 0.5 K 1.0 Secondary nutrients Ca .6 Mg .3 40 S .4 Micro-nutrients B .005 Cl .015 Cu .001 Fe .02 Mn .OS

Mo .0001 50 Zn .O1 99.90 BACK GROUND INFORMATION ABOUT GREEN HOUSE INDUSTRY.

Green house industry is a new growing industry where crops, vegetables, fruit and flower can be produced in any climate cold or hot though out the year.
C02 along with H20 is required for growth atmosphere. An appropriate quantity of C02 for a particular crop may increase to growth rate to double as compared to normal atmosphere.
In normal atmosphere the concentration of C02 is 300 PPM. For flowers crop ( roses) it may be 2000 PPM. For vegetables it is higher than flowers and for grain crops higher than vegetables. The human toxicity level is round about 50,000 PPM. ( 5%) FACTORS EFFECTING COZ UPTAKE.
The following are the factors influencing the up take of CO2.
Plant species and variety.
Radiation intensity.
Wind velocity Water stress.
C02 concentration in the air.
Temperature of the atmosphere.
When out side temperature is low, no COZ injection and no ventilation, inside 2o concentration of COz decreases plant growth decreases.
Light and water level has also large effect and depends upon plant to plant.
Due to boundary layer effect increase in flow rate will increase the rate of photosynthesis.
ESTIMATED COz PER 1000 FT2.
The following figures are reported for Carnation.
Month cu.ft. 1b C02 Sept. S00 58 Oct. 520 61 3o Nov. 800 90 Dec. 720 85 Jan. 660: 78 Feb. 560 66 For the estimation given below the consumption for cucumber is taken as 1000 cu.feet per month.
After urea production the amount of COZ available = 7 x 106 kg.mole per annum Assuming the average consumption of 1000 cu m. per month for 1000 sq.ft this C02 is sufficient for = 280 forms of 150,000 sq.m.
At this stage only 4-5 such form are established each consuming about 25,000 kg.mole per annum. Thus about 900 m.ton per day high purity C02 is available for dry ice or food grade COz.
AVAILABILTY OF NITROGEN.
Assuming nitrogen consumption is equal to C02 consumption ,the remaing nitrogen is so = 37.5x106 kg.mole This nitrogen will be used for cooling purpose in the plant.
The hot water produced in the plant is used to provide moisture in the fertilizer gases.
SOME SALIENT FEATURE .
A design of 1 s0,000 square meter floor area form is provided in figure 4-8 attached with this document. This design is specifically suitable for very cold and very hot areas.

The enclosure is double layer glass, the heating and cooling passage is between the glass sheets. This way the internal atmosphere of the form is not disturbed. COZ
with moisture is blown from the ceiling down and nitrogen from the under ground embedded pipes, the exit is few inches above the ground level.
The heating and cooling gases may be supplied from the plant, with great saving for the form. In USA where heating and atmosphere control gases are to be supplied from natural gas the heating cost for 1000 sq.meter may be about $250 per month.
Natural gas produces more water than require d for the form so the atmosphere for the crop has to be 1o changed more often.
When fertilizer and heating gases are provided from the main plant the estimated cost for a double wall glass house may be US $ 150 per Sq. m.
Financial analysis of a green house set up is provided in the financial section of this report. In a normal green house the highest cost is manpower, after that the second highest cost is gaseous atmosphere and heating expenditure, and third large cost is fertilizer and herbicides. In the present situation the cost of gases and heat is drastically reduced, so is the cost of fertilizers. The form size is reasonable which can be 2o mechanized and labor cost is reduced. These combined factors will make the production cost much cheaper than a similar operation on international level.
SUPPLEMENT A
(Theoretical basis used in calculation of energy balance of the plant. Melting and separation of metals under controlled chemical potentials, porous refractories, endothermic cooling by gaseous reactions) The enthalpy of a substance is described between the temperature limits To (=0 K°) and T
3o by the following:
~T = ~~ ~o + ~To 0 Cp dT ~ LT + J TtOCpdT ( 1 where Tt is transformation temperature and LT is the latent heat of transformation.
For most substances the heat capacity may be expressed as a function of temperature by a power series:
CP a+bT+cT2+dT'Z+eT-vz Where a,b,c etc; are constants derived from experimental heat capacity data.
In the calculations performed in this document the following relationship will be assumed 4o CP = a + bT - cT'2 for most of the gases used.
The entropy change of a substance is a measure of the amount of energy, which can not be converted into useful work. It is a measure of unavailable energy.
The entropy change of a process is given by the following equation OS = ST2- STl= ~To C~/T dT ~ LT/ TT + ,~zTr C~ T dT where T~ = T= temperature for transformation (3) FREE ENERGY CHANGE:
so The free energy change of the system is net change in the energy contents of the system when contribution from enthalpy and entropy are jointly considered.
OG=~H-TOS
For a reaction at constant temperature and pressure for a spontaneous process DG<-0 At equilibrium the free energy change must be minimum. A negative free energy change does not mean that the reaction will proceed at a measurable rate under a given set of conditions, but indicate only that a reaction is possible. It will proceed depending upon the kinetics of the system. That why most of the cases external energy has to be supplied for start of the process. The process may be stopped or it may continue depending upon evolution or absorption of energy.
VARIATION OF FREE ENERGY WITH TEMPERATURE may be eXpreSSed by the following equation OGT = OH298 + ! 298 ~CpdT ~ )_.t + J Tt OCp dT - T ~ OS298 + 298 Cp dT~T ~
L,T~T +
~TtCp/T dT ]
(5) The temperature dependent terms in equation 5 are of opposite sign and to cancel in the summation process. The temperature dependence of free energy on temperature may be defined by the following equation.
OGT= OH + bT log T - TdS (6) 2o At high temperature were the accuracy of experimental determination has certain degree of limitation this relationship is generally described as OGT = OH- T OS
where ~H and OS are average values in a particular temperature range.
OGT values are determined on both sides of transformation where OGT becomes zero.
Thus there is slope change in the OG and Temperature plot at allotropic transformations, fusion and evaporation.
DETERMINATION OF AN EQUILIBRIUM RATIO FOR TTY REDUCTION OF AN METAL OXmE:
3o Reduction Potentials.
At a particular temperature metal gets oxidized or its oxide get changed to metallic form if there are more oxidizing gases then an equilibrium value or conversely more reducing gases.
This equilibrium value is a ratio between reducing and oxidizing gases where neither reduction nor oxidation of the metal takes place. The equilibrium ratio can be determined from free energy Considerations.
4o Consider the following type of reaction 2 M (s) + 02 (g) = 2 MO (g) (7) 2 CO (g) + O2 (g) = 2C02 (g) (8) A reaction between metal and oxygen and a reaction between gas in which oxygen is one of the participants Subtracting equation (8) from (7) M (s) + C02 (g) = MO (s) + CO (g) Ke =p~° a Mo ~ p cot aM
5o Ke = pcdpco2 where Ke is related to the free energy change by the following relationship.
0G° + -RT In Ke or Ke = a -~c'°/RT
a 4Go/RT
= pco/ pco2 in place of CO/COz it may be Hz/HzO
In industrial systems usually there are mixers of CO, Hz and COz and H20, the potentials values are some approximations of the values of CO/COz and Hz /H20 potentials.
The values of OG° adopted can lead to somewhat different numerical figures in above equation, but do not effect the industrial results.
The fee energy value OG°= -RT In [ azMO/ azMpoz ]
When metals, metal oxides, and gases in equilibrium with them are not at standard state.
1o Lighter metallic ores suspended in liquid metal through which reducing gases are passed.
In this situation hydrogen water vapor mixer may reduce the oxide, which otherwise in standard conditions these gases are not able to reduce these metal oxides even at their highest reduction potentials. We will use these specific situations to prepare some metal by new routes.
Some useful gaseous equilibrium is given in the following~'~.
Reaction Kp Ln KP Range of validity C°
Fe~l_y~ O + CO Pcoz~co 2075/T -2.5 500- 1370 20 =~l-Y) Fe+ COz Fe~l_y~ O + Hz PH20~H2 -1953/T -1.02 25 - 13?0 _ ~1-Y) + Ha0 COz + C = 2 CO Pzco/ Pcoz -20045/T + 20. S 500 - 2000 CO + H20 PcozPHZ 4028/T -353 500-- 2000 = COz + Hz / PCO PH2 O
1-y=0.947 T=K°
3o Table 2.1 Equilibrium chemical potentials for some metal oxides.

Fe O+CO =Fe Fe0+Hz=Fe +H20 +COz Temperature PCOz lPCO Temperature PH20/ PHz 1070 K .56 1070 K .45 1250 K .41 1250 K .59 1500 K .34 1500 K .78 Pb0 +C0 =Pb +COz CuzO +C0 =2Cu +COz Temperature PCOz/ PCO Temperature PCOz/ PCO

4o 8.4/ 10g 500 K 3.8/101o 1000 K 1.9/ 104 1000 K 5.8/104 1500 K 1.8/103 1500 K 5.8/10z Zn + COz = Zn0 +C0 Temperature PCO/PCOz 500 K 3x106 1000 K 1.5x103 50 1500 K 5.9 2000 K .2 Zinc Oxide sublimates at 1800 C°.
It can be seen that iron is reducible at chemical potentials easily achievable in practice.
While copper oxide will change to metallic copper at very low chemical potentials not easily achievable. It will change to copper when heated in air at high temperature.

Zinc is reducible at very high temperature, at achievable chemical potentials but it will change back to oxide form as soon as temperature is lowered because corresponding reduction potential are not practically achievable.
Table 2.2 Sequence of reduction Potentials of various metal oxides.
Cu20 Fe203_______ > Fe304 Ni0 1o Sn02 Fe304-----~ Fe0 Zn0 Cr2 03 Mn O

Table 2.3 2o Densities of some important metals and their oxides.
Metal density of metal density of metal oxide Pb 11.3 9.5 Ni 8.9 6.67 Fe 7.86 5.7 Cu 8.92 6.
Sn 7.28 6.95 These values of oxide densities are theoretical densities, the actual valued of industrial products will be some what lower because material formed will be porous.( density 30 =Specific gravity) Table 2. 4 Melting points , boiling points , specific gravity of some easily meltable and volatilizable metals and their oxides up to temperature of 1000 C° Metal Specific gravity m.pt b.pt metal oxide m.pt b.pt.
Hg 13.5 -38 356 Hg0 unstable Se 4.79 217 685 Se02 340 315 4o As 5.73 817 613 As203 313 465 Te 6.24 447 989 Te02 773 790 Cd 8.65 320 765 Cd0 1540 decomposes WOZ will vaporize at 800 C

Non volatile 00C but up to easily meltable metals.

Sn 5.74 321 2620 Sn0 1630 1900 sublimates Ga 5.9 29.8 2245 Ga OZ 580 sublimates Sb 6.69 630 1585 Sb2 03 655 1482 5o In 7.31 156 2067 In OZ 562 sublimates Bi 9.74 271 1582 Bi203 825 1890 Pb 11.35 323 1754 Pb O 886 1472 TI 11.85 303 1485 Tl 2 03 717 ----Ge 5.3 937 Ge02 1082 density 6.23 EXPLOSIVENESS OF CO, H2 COMBUSTION WITH OXYGEN
The combustion of CO, HZ with 02 is generally considered as hazardous The explosive situations described in literature do not apply in the present set up. In this situations , the number of moles of the product gases are less than the reacting gases and materials are present to absorb the shock waves. As the CO, HZ gaseous mixture is preheated volume increase of the product gases due to temperature effect is small. It is less than double when temperature of the product gases is doubled. The systems are capable to absorb the to expansion effects.
There are proper precautions as relief valves and rapture disks at appropriate locations.
Also pressure in CO, H2 and O z lines should be positive so that these do not diffuse in to each other's lines~2~.
A COMPARISON OF COOLING BY PERFORMING AN ENDOTHERMIC
REACTION AND COOLING BY WATER.
A reaction between a hydrocarbon and an oxidant producing elementary gases is given as following.
20 1 ~ C" Hm + n C02 = 2nC0 + m/2 HZ
2. C" H", + n H20 = n CO +(2n +m)/2 HZ
Representative example is given in the following:
CH4 + COZ = 2C0 +2HZ ~H =+ 60,000 Kcal Added to this is heat absorbed by the reacting gases to reach the reaction temperature (assumed here as 1000 C° ) =approx. 18000 Kcal Total heat absorbed is 88,000 K. cal /kg. mole of CH4 If water is used to cool steel from 1000 C° to room temperature it will absorb about 15,000 Kcal/ Kg. mole of water. Add to this exothermic heat of the reaction 3o Fe + HZO = Fe O+ HZ AH= -5,000 K.cal/kg. mole of wustite The net cooling effect is 10,000 /Kg. mole of H20. The thermal resistance of the oxide scale has been neglected.
It can be seen that heat removed by water-cooling is about one eight of that removed by above given endothermic reaction.
The mixtures of gases, which absorb heat during chemical reaction, are termed as Endo gases.
ENERGY RECOVERED BY ENDOTHERMIC REACTION COZ + CH4 4o When energy is recovered by performing endothermic reaction of the type C02 + CH4, The following two step reaction as given below may take place.
(i) CH4+ COZ =2C0+ 2H2 endothermic (ii) 2 CO + 2 H2 + 02= 2C02 + 2 H20 exothermic This is the energy absorbed in step (i), which is saved.
This saving is approximately 45 % of natural gas saving if same energy generation was required by straight combustion of CH4.
so In this write up mainly CH4+C02 mixture is mentioned for endothermic reactions, but it may be CH4+H20 as well.
THE REFORMING REACTION:
The reforming reaction CH4 + C02 will adequately take place if temperature is about 1000 C° or higher. If the temperature is lower than 1000 C catalyst is required. The catalyst has to be contained in a closed vessel and heat transfer will take place through the walls of the container. At limiting temperatures of about 700 C°, and pressure is also required. The term reforming gases is used to describe endothermic gases or Endo gases.
OTHER ENDOTHERMIC REACTIONS. Decomposition of CH30H and NH3 are also endothermic reaction and can be employed when lower quantity of heat is to be absorbed at relatively lower temperatures.
Nitrogen starts forming stable compounds with iron at about 700C with exothermic heats.
Purified natural gas is used for calcination of lime. The clean gases from this system will to have more H2 than CO. This gas can be used in annealing of cold rolled steel after performing shift reaction CO + HZ + H20= COZ + 2 HZ over a catalyst. C Oz is removed by absorption.
used where metal becomes volatile under certain chemical potentials.
HEATING AND COOLING BY SHIFT REACTIONS.
Heating and cooling is achieved by performing exothermic or endothermic reaction in direct contact with the processed material.
When it is not appropriate to perform these reaction in direct contact with the materials 2o these reaction are performed in close vessels with or without catalyst. The energy transfer then takes place through the walls of the container.
The product gases from such system are energy carriers to a recovery system, HZ or CO can be produced by carrying the following reaction by excess COZ or by excess H20 over the catalyst surface.
CO + HZ+ COZ = ZCO + H20 OH endothermic CO+ H2 + H20 = 2 HZ + COZ 0H exothermic COZ and H20 can be removed to get CO or H2, These steps can be repeated to get the gases of required purity.
3o The direct contact energy transfer reaction is performed when this has no effect on the material in contact with the reaction is performed. When temperature of the system is low and energy transfer by reaction system is not appropriate energy is transferred through water heat exchanger.
No direct cooling water is used. This eliminates the transfer of harmful pollutant from gases to water system from which it more diffcult to remove. Mud recycling and recycling of scales is eliminated.
SULFUR RECOVERY FROM HIGH CONTENTS SOZ CONTA1NG GASES. Sulfur 4o recovery as elemental sulfur can be done in a more direct way as given in the following than the conventional Claus process:
2CH4 + 3 S02 = 2 COZ +2 H20+ HZS +S
2H2S+ SOZ = 2 H20+ 3S
2CH4 + 4 SOZ = 4 H20 + 2 COZ+ 4 S OH = - 58,000 K. cal. / Kg. mole of CH4 The S is cooled and condensed and product gases are send for further purification from 5o particles and chemical impurities alone or joined with other gaseous streams.
USE OF OXYGEN FOR EXOHERMIC REACTIONS.
All energy generation reaction during steel making and calcining of flux are performed with the combustion of O z..
By using 02 in close systems all CO, H2 gases are recycled for energy generation. The energy ei~iciency of the fuels is 100 % as compared to present systems where energy recovery is hardly more than 55. %. This recycling compensate expenditure on oxygen generation. As the fuel expenditure is decreased so the emission of COz is decreased.
Some of the C02 is recycled within the plant for energy recovery purpose, thus emission of COZ is further decreased.
The flux calcination system is in parallel configuration with direct steel making from oxide ores with inclined rotary reactors connected to vertical steel making reactor. In calcining system instead of steel making reactor there are two discharge receiving vessels where one is receiving the hot calcined material which is being cooled with heat 1o recovery from it, the other is discharging the cooled material to a receiving bin.
Recycle of blown out calcined material is done directly to receiving hopper of the calcined material.
Porous filters.
Porous refractory filters are used for the separation of liquid metal from non-melted materials. These are made from aluminum oxide and stabilized with zirconium oxide. An 2o example is the use of this type of filters in the separation of inclusions from liquid steel during continuous casting~3~. These may be further standardized for specific requirements of liquid filtration and counter current gas liquid filtration.
SENSIBLE HEATS.
If the specific heat of a material is defined as CP = a + b * T + c/ TZ K cal/ K°/ kg mole then the heat capacity of the material at temperature T K° with respect line temperature of 298 K° is J 298 Cp*dT = a * (T-298) + b* ( TZ - 2982) / 2 - c* ( 1/T- 1/298 ) Kcals/kg mole If Tl = T- 298; T2 = ( TZ - 2982)* 0.5/1000; T3 = -(1/T -1/298)* 100000 The sensible heats of multicomponent gas is 0.001*4.184* volume* ( %CH4*(8.147 * T1 + 8.9* T2 + 1.965* T3) + % CO* ( 6.79*T1 + 0.98*T2+0.11 *T3) + % COz*( 10.55*T1+2.16*T2+2.04*T3) +%H2 * ( 6.52* T1+0.78*T2 -0.12*T3) +% Na *( 6.66 * Tl +1.022*T2))/100*22.414) KJ/ton product.
Where volume is volume of gas stream in question in Nm3/ton product SENSIBLE HEAT OF MULTI COMPONENT SOLIDS IS
0.001* 4.184* WEIGHT* ( % Fe203* (23.49*T1+18.2* T2+ 3.55* T3)/159.7 + % Fe304*(21.88*T1+48.2*T2)/231.55 +%Fe0 (12.38 Tl+1.62*T2+ o,38*T3)/71.85 +% Fe",~~~;°* ( 4.18* T1+5.92*T2+H)/55.85 +%C (4.1 *T1+1.02*T2+2.1 * T3)/12 + % gangue * (11.22*T1+6.2*T2+2.7*T3)/60)/100 . MJ/ton product.
Where weight of the solid stream is kg/ton product.
H is the heat of transformation of solid iron at 760, 910,1392 C and heat of fusion at1537 C°.
CALCULATION OF HEAT OF CHEMICAL REACTION.

Heat of reaction depends upon the temperature at which the reaction occurs. It is difference between the enthalpies of the reactant and the products, which depend upon temperature.
The enthalpies may be related to the temperature by the equation H = N Cp ~T.
Therefore it is possible the heats of reaction involved at any temperature from the heat capacity data of reactants and products. 4HR is known from tabulated data at standard pressure and temperature, it can be calculated at any other temperature from heat capacity data without additional experiments. Since enthalpy changes are independent of the path of the Io process, the following three-step process can accomplish the same changes as the reaction at T.
1. Cool the reactant from T K° to 25 C°.
OH = -(~ N Cp~a~erage) )R (T 298) Where the summation terms represents the sum of the products of the number of moles of each reactant times its average molar heat capacity.
2. The change in reaction enthalpy is calculated at 298 K°
20 ~H ~HR298 Ko 3. Heat the product from 298 to T° K
The sum of these three OH values is the desired heat of reaction at T° K
~RT = ~HR 298 + ~ (~ N CpV)p - (~ N Cp)R ~ ( T-298) SOME IMPOTANT CHEMICAL REACTIONS AND THEIR ENTHALPIES.

Reactions with molecular oxygen (combustion) C +'/2 02 = CO OH =-110.62 Kj /mol (1) 3o CO +'/2 02 = C02 DII =- 283.15 Kj/mol (2) H2 +'/2 02 = H2 O 0H = -242.00 Kj/mol (3) C" Hm + (ri+m/4)02 = riC02 +m/2H20 (4) CH4 + 202 = C02 + 2H20 DH = - 802.26 Kj/mol (4a) PARTIAL COMBUSTION

C" H",+ (n/2 + m/4) 02= riC0 + m/2 H20 (5) REACTIONS WITH STEAM

C + H20 = CO + H2 ~H = + 131.31 Kj/mol (6) CO + H20 = C02 + H2 OH = -41.16 Kj/mol (7) 4o C~ + H20 =CO + 3H2 DH = + 206.78 Kj/mol (8) C"H", + 2n H20 = nC02 + (m/2+2n ) H2 (9) C+C02 = 2C0 DH = + 172.54 Kj/mol ( 10) (Boudourd reaction) C"H",+ nC02 = 2nC0 +2m H2 (11) Examples.

5o CH4+ C02 = 2C0 + 2H2 0H =+ 247.45 Kj/mol (12) C2 I-I~ + 2C02 = 4C0 + 3H2 OH =+ 429.82 Kj/mol (13) C3Hg + 3C02 = 6C0 + 4H2 OH = + 621. 53 Kj/mol ( 14) Equations 4 (to generate heat), 7 (CO shift reaction), 10 protective cooling in CO/C02 atmosphere) and 12,14 (endothermic cooling) are of special significance to us as considerable use will be made of these in industrial processing Temperature dependence of these reaction is particular important. In carbon monoxide shift reaction is performed at low temperature to obtain high contents of hydrogen and eventually to obtain pure hydrogen. At high temperature the hydrogen is eliminated and more and more CO is obtained. Reactions 12-14 increase with temperature, as more heat is available for absorption.
to MATERIALS SEPARATION BY PHASE SEPARATION.
We have described the chemical potential or potentials in which a metal o a group of metals can be oxidized or reduced or partially oxidized or partially reduced.
A metal can be made to volatile, or melt at much lower temperature than when it is in oxidized form.
Similarly certain metals can be made to volatile or melt at lower temperature in their oxidized form. Certain metals are very higher melting and are not volatile when present as completely reduced or completely oxidized form, but their partially oxidized or partially reduced form is volatile and in these chemical potentials these can be separated.
2o Mo (iv) oxide is volatile at 1151 C° at one atmosphere; Mo metal is volatile at 4606 C°
and one atmosphere.
Cd is volatile at 767 C°; Cd0 is volatile at 1558 C°.
We will use these concept in separation of mixture of metals as in preparation of steel from scrap, and separation of mixture of oxides.
In this supplement certain guiding principals are described which could be foundation for efficient, pollution free, energy saving method for upto now not process-able materials:
1. Controlled chemical potential techniques for separation of metal by melting and volatizing.
3o 2. Changing from standard activity to nonstandard activities for reduction of metal oxides, which are not reducible in standard states.
3.Use of endothermic reactions for energy recovery and cooling of metals, slag phases, and high temperature gaseous streams. Using of endothermic reactions in gaseous insulation of electric system, and cooling of high temperature refractory.

4 Use of shift reaction for elimination of gaseous content not required in a particular mixture or material.
4o Supplement B
Meanings of some words and certain words used synonymously.
-Micronutrients fertilizer is a solid or gas fertilizer where solid micronutrients is a mixture formed by slag, metal from certain ashes, metals which were not separated during melt separation.
-Gaseous micronutrients are certain impurity gases { S02 , P203, N02, Cl, etc.) small in volume but are ingredient of plant growth system. The impurity gases are mixed with so either nitrogen feed or COZ
feed of the plants.
-Reducing gases and reduction gases are used synonymously.
-Greenhouse and controlled temperature, controlled potential form represents the same thing.
-Volatile and volatilizing (when some thing is made volatile by other means) -Industrial hydrogen is hydrogen obtained after shift conversion and methanation process, may contain methane and other small impurities.
-Cryogenic hydrogen is high purity hydrogen obtained through fractionation and absorption process.
-Sizing is a term used to cut the large size material to a small size which can be handled by automated charging system, In brief I have invented a new method and plant for changing garbage to valuable energy containing gases for combustion and form uses. The solid materials in garbage are changed to micronutrient fertilizer and quality steel scrap. Metals not required in steel are separated and recovered. When reason quantity of garbage is available urea can be produced with better economic returns. The attached green house can get green house gases and micronutrients gas at cheaper rate and can work around the year in hot and cold regions.
Information Some technical inventions of this project have been covered by U.S.A
2o Patent application, Serial no 09/546,014 Cnfrm No 2942, filing date 10-april-00.
Title. Making shaping and treating of steels in a continuous process steel mill.
Inventor Ghulam Nabi.

Claims (12)

1.A process and plant where by using household and city garbage high purity combustible gases, gaseous and solid fertilizers, metal not-required in steel and high quality scrap can be produced.
-Where combustible gases may be CO, H2 gases, and industrial and cryogenic grade hydrogen.
-Where gaseous fertilizer may be (CO2, N2, H2O), dry ice, and micronutrients gases such as sulfur dioxide, phosphorus trioxide, Nitrogen dioxide, and ammonia. Where solid fertilizer may contain micronutrients and urea.
-Where metal not required in steel may be Sn, Sb, Bi, Pb, Cu, Al, noble metals, platinum group metal and variety of other metals.
-Where steel scrap may contain metal melting above 1300 C.

2.A garbage processing plant where the raw materials used for this process is the household and city garbage, which may consist of various carbohydrates, hydrocarbons, plastics and rubbers, metal and non- metal, ceramics and glass, lathers and protein materials and all sorts of human and animal wastes.
-Where the oxidizing gases used may be oxygen or air or any mixture of these two.

3.A garbage processing plant as in claim 1 where garbage material is sized and crushed to convenient size that can be handled by automated discharging, weighing, conveyor transportation, and its smooth movement in the processing equipment.
-Where the size reduction is done by high-energy cutting means, which are stationary when cutting in one direction, but moving along a travelling belt with the speed of the belt and cutting perpendicular to this moving direction. This set of cutting means then moves quickly back to the starting and starts the next cutting process.
-Where the moving belt has a layer of coal to protect the belt and facilitates the cutting process.
-Where the oversize is separated and recycled to under go an-other cutting cycle.
-Where gases produced or available in the plant may be used in the cutting process,

4.A garbage processing plant where the sized material is introduced at the higher inclination end of an inclined reactor.
-Where the sized material flows co-current with gases down the inclination of the reactor.
-Where the combustible gases are introduced along the length of the inclined reactor.
-Where the bottom of this inclined reactor has holes through which liquid metal can filter down into a refractory lined enclosure partitioned into various compartments.
-Where this refractory lined compartment is heated by reducing gases, which may rise counter-current to the liquid metal into the inclined reactor.
-Where liquid metal or group of metals may be drained out for further treatment in a separate system.
-Where the solid charge introduced into the reactor is pushed down the inclination of the reactor by mechanical means.
-Where the temperature and chemical potential is gradually increased along the length of the reactor.
-Where the high temperature near the ending of this reactor is sufficient to melt all the metals not required in the steel composition.
-Where the metals, which vaporize, go along with the gases flowing out the system.

5. A garbage processing plant as in claim 1 where the lower end of the inclined reactor is connected to a high temperature reactor.
-Where the is a refractory lined vessel having inlet to receive charge and out lets for slag and its allies constituents, steel scrap, and product gases.
-Where this vessel has arrangements to discharge slag material and steel scrap under closed atmosphere.
- Where at the out let of high temperature reactor endothermically reacting gases are introduced to lower the temperature of the exit gases.

6. A heat and particles recovery process from the exit gases of claim 5 after which heat is recovered from the gases by water heat exchanger means.
- Where systematically cooling of the gases let the volatile metal to separate fractionally.
- Where after the fist heat and particles recovery unit there are additional particles recover means working in the temperature range of 500-300 C.

7. A heat and particle process of claim 6 after which gases are lead to gases purification from chemical impurities and recovery of CO2.
Where the purified gases may be CO, H2 or CO, H2,N2.
-where the water-soluble gases are separated by lowering the water temperature where at the solubility of these gases is high.
-Where these gases are driven out of water by raising the temperature of water.
-Where the remaining impurity gases are removed by passing through NaOH
solution with the precaution that only small percentage of CO2 is removed.
-where CO2 is removed by high-pressure adsorption in conventional alkaline solutions.
-Where in the desorption process the heat required is obtained from the incoming gases themselves.
-Where the energy spent in the compression steps in this process is recovered by the expansion steps.

8.A garbage processing plant as claimed in claim 1 where when H2 or H2 + N2 gases are required the clean gases obtained in claim 7 are made to under go shift reaction and then methanation reaction.
-Where CO2 obtained in the shift reaction is joined with CO2 obtained in the chemical impurities removal step.

9.A garbage-processing plant where H2 and N2 obtained within the plant is used for the production of ammonia.
-Where CO2 obtained in plant and ammonia produced is used to produce urea.

10.An ammonia production step of claim 9 where in the conventional process of ammonia condensing by ammonia refrigeration techniques is replaced by nitrogen cooling.
-Where the heated nitrogen is used in the ammonia production.

11.A garbage-processing plant of claim 1 where after fulfilling the needs of urea production, out of the remaining gases some percentage of CO2 and N2 gases is used as fertilizer gases in the greenhouse.
-Where part of the CO2 is used as insulating gas.
-Where some cold nitrogen is used to control the temperature of greenhouse when the atmospheric temperature is high.

-Where a part of nitrogen is used in plasma torch cutting of that material which can catch fire.

12.A garbage processing plant of claim 1 which has affiliated greenhouses.
-Where these green houses can use gases, steam, and fertilizer gases and micronutrients fertilizers from the plant.