Introduction to Green Power,
Inc is a privately held Corporation founded in the State of Washington in May of 2000.
In March of
2008, Green Power, Inc. (GPI) completed their first full scale plant that is capable of processing 100 tons of
municipal and other waste per day in a low heat and low pressure, proprietary catalytic system, converting the
feedstock into high grade fossil free fuel TM , including diesel, kerosene, and fuel oil; as well
as electricity and an asphalt component.
The preparation of incoming waste stream includes chopping, extraction of metals, glass, and sand, so that
approximately 2/3 of the feedstock is able to be run through the unit to produce fuel and electricity. The key
to the system is the catalyst (trade secret) which is made from environmentally benign components.
A 100 ton/day facility will employ approximately 85 000 man hours per year, in three shifts per day, and will
produce around 120 gallons of usable fuel per ton of feedstock processed. Methane generated in the process is
used to run a generator to power the facility, with 1 Megawatt excess available for distribution.
The lead time for installing one such a plant is six months. The plant will be built at a manufacturing
facility, then shipped and assembled at the destination site. GPI will finance up to 1/3 of the
capitalization and will receive the same percentage of the revenues generated, this only applies to the
GPI portion of the project and not the land, and certain infrastructure which is Buyers responibility. The
involvement is decided on a case by case basis.
Basic Facts and Design
Municipal Solid Waste (MSW) consists of 80-90% of polymerized
long chain hydrocarbon molecules. By de-polymerization, or “cracking”, the long molecules can be reduced to
shorter length molecules with approx. 10-20 Carbon (C) atoms - equivalent to liquid diesel which is a fraction of
crude oil. Accordingly this so-called synthetic diesel (or “second generation bio-diesel”) is identical, in
its chemical and physical properties, to mineral or fossil diesel. In certain aspects, it is a superior product
with a higher Cetane number with about 5% more power and the absence of impurities such as stearin or free carbon
which is “black diesel smoke” without requiring a particle filter. The Cetane number is the performance rating
of a diesel fuel, corresponding to the percentage of Cetane in a Cetane -methyl naphthalene mixture with the same
ignition performance. A higher Cetane number indicates greater fuel efficiency. It can also be called
Cetane rating. The creation of Fossil Free Fuel™ has become reality. The process has a by-product
to Diesel “Kerosene; Gasoline and Fuel Oil” more fuel sources to drive vehicles and
What is known, so far, as “bio-diesel” is a process of
producing diesel by simple etherification from expensive vegetable oils. This raw material base however is
directly competing with the food industry and increasing demand for bio-fuels; therefore, making a huge impact on
the rising oil and food prices.
On the contrary, with a new method of technology, waste can
actually be used as the input material. Waste is, obviously, abundantly available and not only comes for free
but often uses a “tipping or gate fee” as additional income.
Other researchers and/or companies have tried to come up with
new solutions and continue to try to develop new methods; however, this revolutionary technology has been tested
and is up and running at a fully operational facility.
For the first time in history, an alternative fuel source apart
from fossil fuel is plentiful. In addition to the constant production availability and cheaper operating
costs, there are many positive results in respect to CO2 emissions and the understandable
enrichment of our environment in general.
Apart from MSW Fossil Free Fuel
TM may be produced from a large variety of input materials such as:
input materials (straw, grass, press cake from fruits and oil plants)
all kinds including PVC
(residues from car recycling)
This technology can also be used to dig up old landfill's and
recycle the remaining material.
Accordingly, no source-segregation of the MSW waste is
required. Only hard materials (stones, glass, ceramics, metals and the like) have to be removed prior to
Utilizing a form of pre-treatment eliminates all forms of odor
and other known issues when dealing with MSW and other waste. The entire waste is processed immediately when
received and the “hard materials” are separated. The remaining “soft materials” are de-watered and
technology is split into the preparation and the actual fossil free fuel conversion.
Preparation of Waste Input
All “hard” materials such as stones, glass, metals, ceramics
and the like, have to be removed. The incoming waste which arrives at the plant with moisture of 60-65% has to
be dried to residual moisture of less than 17%.
The waste is dumped into the receiving area and then picked up
by a Payloader equipped with a crusher shovel. A coarse grinding mechanism built into the shovel opens plastic
bags and reduces the particles to <50 mm. Oversize parts such as bicycle frames, refrigerators, etc. remain
in the shovel and can be simply tilted out.
The pre-shredded material passes a magnetic separator as well
as an Eddy-current separator and is subsequently sent through our proprietary autoclave system where it is broken
down to fluff. The dried material passes a fine shredder (Power Master) which reduces the particle size to
<5 mm. This is the material suitable for the Fossil Free Fuel TM conversion
De-polymerization of waste
into high quality
The shredded and dried input material is filled together with a catalyst and a
neutralizing agent into the reactor vessel. Heating to about 350° and heavy agitation starts the
cracking process resulting in a mixture of oily hydrocarbons which, after reaching the required molecular size,
turn into vapor which is conveyed into the distillation or rather condensation column. By fractional
distillation, the various hydrocarbon fractions are separated into naphtha (a light gasoline-like fraction of crude
oil), kerosene or jet-fuel, diesel and heavy oil.
Non condensable gases (methane) are used to feed a turbine
which generates the electricity and thermal energy required for the process.
The hot oil from the reactor vessel passes a filter press which
eliminates any residues such as ash, remaining catalyst, sand, silicone's, etc. This filter cake body, about
5-10% of original input volume, can be disposed of by adding it into an asphalt mixing process.
Hence, the entire process is a true no-residue zero waste and zero emission technology.
Pictures of the plant currently being utilized for