• Synthetic natural gas
  • Chemicals

The primary thrust of the Waste-To-Energy (WTE) system will be to produce clean renewable energy in the format of natural gas.

Current coal power plants do not efficiently process coal. The fly ash created during the process is a toxic by-product of standard combustion. And the plant uses the heat from the hot coals to boil water, thus inefficiently producing steam to drive a turbine. Even with the new practices of converting existing coal power plant to operate as co-generation models the performance still lags.

CLAYTON INDUSTRIES INC. will configure existing coal plants to utilize plasma technology instead of gas burners. This approach is a hybrid design similar to gasification. The Clayton plasma processes all the carbon products instead of just a portion and employs a closed loop process to support the thermal plants efficiently.

Coal is abundant globally and has the highest calorific value which equates to improved WTE system operation compared to other feedstocks used to generate energy.

The WTE system is optimized by the Elimination of the coal plant boiler vessel, and retrofitting or replacing it with a reactor platform that directly converts the coal into gas by chemically breaking down the carbon products.

Existing coal to gas plants undergoing process improvements focus on creating a coal slurry; however, injection of the slurry into the reactor has caused problematic issues and system constraints. Several other poor engineering designs have included reducing the moisture content and blending regular natural gas to compensate for the internal conversation problems. Despite these improvements, the newer plants cannot achieve the standard 82% system operating capacity milestone; heat build up rate is poor thus requiring more fuel and power to sustain the process.

This is a direct correlation to the maintenance downtime due to parasitic loading. Parasitic loading refers to the continuous shutting down and restarting of the reactor. This action causes the reactor to incur repeated damage to refractory and the pressure vessel steel liner, resulting in material conformity issues.

The reactor is not engineered to be continuously ramped up and down in temperature. This lack of reactor runtime prohibits particulate matter from being processed, resulting in a dirty gas byproduct. 

The Clayton Industries design will address these problematic issues and provide an efficient reactor that does not require the preprocessing stages. The Clayton design is able to further crack the natural gas produced from processing coal into other fuels. And the gas constituent does not have to be utilized as a fuel; the gas can be converted into a vast array of chemicals, plastics, etc.