The Captured WTE Micro Material Recovery Facility
The MMRF is the smallest scale MRF that we can provide for small communities or waste generators who don’t have a large volume output. This system produces compost, electricity, hot water, and synthetic diesel and methanol with our add on fuel producer module. The basic MMRF exports aggregates, glass, and plastics.
Flexibility and Scalability:
The Micro Material Recovery Facility is designed for flexibility and scalability. If an operator wants to add on manufacturing processes, its just a matter of plugging them in. For example, an alkali activated cement production system or a 3d printer for recovered glass cement and plastic printing is available to enhance a basic system installation. Additionally, if the operator needs larger waste processing capability, additional gasifer kilns can be added on to double or triple capacity.
How It Works:
Waste haulers such as refuse, construction and demolition, and single stream recycling trucks tip their loads into the MMRF intake hopper. The materials are hammer milled for size reduction. Materials enter the auger inside of an electric kiln surrounding a horizontal steel tube. This design has four stages of temperature differential and extraction screens which remove liquefied materials.
The solid waste is mixed with steam to liquefy the biomass fraction. The auger advances this liquid to a screen where a vacuum extracts the biomass and sends it to a decanter centrifuge to recover the water. Recovered water is re-boiled and re-injected into the first stage again, The solid biomass material is sent to an in-vessel composter where it is mixed with carbon materials to make an ideal compost blend. Finished compost is sold or donated to the community.
Plastics, alloys, and aggregates, advance within the screw auger to the next stage. Here, plastics melt and are vacuumed out, pelletized, and shipped to recycled products manufacturers or used to make new products in the case where an add on system is involved.
Alloys are melted and vacuumed out in the third stage and turned into ingots. These are sold to recycled products manufacturers when operating the basic system. An additional similar extraction system may be able to separate those alloys into individual elements which is critical if you want to get full value for your recovered metals.
Lastly, glass is melted and extracted similarly. The glass is then ball milled to produce our alkali activated cement mixes or in the basic plant configuration, glass is bagged and exported to the recycling industry. The aggregates are left to be sent to the gravel hopper where they can be sold as a landscaping material or as a gravel ingredient for local Portland cement production.
Developing this core component (the material extraction gasifier) of the MMRF is essential to meet our challenge to offer a material recovery facility to the world that will come in at a far lower cost than the massive standard MRF’s that are available today. This will also vastly increase landfill diversion making our system highly desirable.
A System of Symbiotic Components:
There are many other components involved in the MMRF system that support the gasifier. Some of these include steam electric gensets for power production, fuel cells for energy conversion, fractional distillation columns for fuel production, and a series of filtration systems for cleaning up syn gas, and water.
The Renewable Fuel Dispensing Add On:
Another add on component of this system is the methanol and diesel fuel dispensing system. Renewable diesel and methanol is derived from the recovered syngas that residual plastics and biomass produce in the third stage of the gasification process. Having the ability to provide this clean renewable fuel to the public and to waste haulers is another way to draw the community in and encourage them to recycle their waste at their local Captured MMRF. Note: A methanol conversion kit has to be installed on gasoline engine cars and trucks in order to power those vehicles safely. Once converted, gasoline engines run cooler and cleaner on methanol which translates into better fuel economy. Methanol is used by the auto racing industry because it is a safer fuel to handle and operate with and provides a higher octane than gasoline.
Off Grid Operation:
The MMRF is designed to operate free of the grid and can potentially export surplus energy to the grid. As long as you are importing the minimum amount of solid waste material (the system’s fuel) into the MMRF, the facility will generate enough electricity to power itself free from the grid. If you are imputing upward of the maximum material input allowed, the system will generate either a surplus of electricity that you can sell to the grid, store the energy in flow batteries, or be converted into methanol which will be stored in above ground tanks.
Captured WTE aims to provide the MMRF to the small town or city material recovery operator as a turn key plug and play facility. All components come in shipping containers and therefore the balance of plant can be easily be unplugged and moved if the operator wants to relocate or reconfigure. We aim to fit the balance of plant into a footprint of approximately 100×100 square feet. This should reduce the operator’s barrier to entry because real estate isn’t cheap as you well know.
We also aim to provide financing options on rent to own agreements and well as leasing agreements. Our goal is to develop a plant that can repay its investment to its operator in several years time. After that period, the operator will enjoy a handsome income over and above their initial investment. Our back of the napkin estimate in these early stages of development would be that the total investment cost in dollars, not including the land, would come in at around $5 million for the basic system. This number could be a good ways off in either direction, so don’t quote me.
Thank you for researching and discovering the many benefits that could be available to your community and your material recovery business by installing a Micro Material Recovery Facility. Please check back often with us and inquire about details and questions that you may have. We are here to find out from recycling operators and waste generators about what are the biggest challenges are that they face. We ask ourselves, how can Captured Waste to Energy improve the state of material recovery and renewable resource generation within the waste management industry. Thanks again for your feedback and we looking forward to talking you about your waste to energy inquiries. Lets Innovate for solutions sake!
Captured Waste To Energy
Micro Material Recovery Facility Concept
Seeking Development Assistance
Introduction to the Concept and Core Business Model Points:
Hello, my name is Richard Haskell and I’m prototyping a machine that has a system involved with some complexity. It is called the Micro Material Recovery Facility (MMRF)
My goal is to provide communities an affordable waste recovery solution which doesn’t currently exist. To do this, I’m seeking machine and system design developers that can help me prototype the MMRF. This concept is aimed at competing with large scale material recovery facilities with its scalable design.
At the heart of the MMRF is a machine that I call a Material Recovery Gasifier (MRG). I’m in need of a design engineering team to help me build a very crude concept into professional blue prints and system diagrams.
Once I’ve achieved this, it will be possible to get cost quotes from fabrication companies from which it will be possible to build a business plan around producing the first MMRF prototype. I aim to provide this facility at commercial scale for sale or for lease to any sized community in the USA and beyond. By designing the system modularly, we can double up components to handle larger or smaller waste material process requirements. This is a crude drawing of what the basic MMRF looks like:
MMRF Component Identification Reference Key:
1. Glass Export
2. Alloy Export
3. Plastics Export
4. Carbon Material supplied to in vessel composter
5. Compost Export
6. Aggregate Export
7. Plastic Pellet Production
8. Decanter Centrifuge
9. Biomass solids
10. In-Vessel Composter
11. Tesla Turbine
14. Water Pump
15. Methanol Storage
16. Synthetic Diesel Storage
17. Fuel Distillation
18. Glass Extraction
19. Aggregate Out
20. Alloy Extraction
21. Plastic Extraction
22. Biomass Liquid Extraction
23. Hammer Mill
24. MSW Hauler Tipping
25. Construction and Demolition Hauler Tipping
26. Screw Conveyor
27. Methanol Dispensing
28. Diesel Dispensing
The Affordable MMRF; Fulfilling an unserved niche, small to mid-sized cities waste recovery and logistics.
Relative to the average modern MRF, The Captured MMRF footprint, machine portfolio, and capital investment cost for installation and operation should theoretically be 1/10 of the cost. If the average full scale MRF costs around $50 million to install (such as the MRF installed for NYC), we aim to provide our turn key plant for the installed price of approx. $5 million.
Under this premise, we believe that small to mid-sized towns and cities will be able to afford a MRF, which at this point, most can not. This is the reason that only ¼ of the 250 million tons of municipal solid waste that is landfilled or incinerated in the USA each year is recycled.
By diverting this massive amount of wasted materials into waste recovery for renewable products, communities stand to benefit in many ways. These include:
– The creation of local green jobs.
– A boost to the local economy from revenue earned from managing the regions waste and through the sale of renewable products.
– The preservation of land resources. This model circumvents the need for a landfill. The MMRF enables communities to mine their landfills so that they can repurpose their land for more valuable use such as a park or a eco village.
– The reduction of pollution. Replacing the landfill with a MMRF means that methane gas doesn’t pollutes our air. Animals such as birds feeding on trash and hazardous liquids, called leachate that eventually leak though landfill liners, are common and severe issues that no longer threaten our community’s precious natural resources when choosing the MMRF over the landfill.
– Offsetting the consumption of fossil fuels by choosing renewable resources. Our MMRF produces low to no carbon footprint synthetic diesel and methanol that the community can purchase to power their gasoline and diesel vehicles. These fuels burn clearer and do not involve environmentally disruptive extraction processes like their petroleum counterparts.
Features of the MMRF:
– 100 x 100 footprint.
– Excepts municipal solid waste from refuse trucks and public refuse drop-off.
– Excepts construction and demolition materials.
– Excepts single stream recyclables.
– Recovers biomass and produces finished compost.
– Recovers plastic and exports plastic pellets.
– Recovers alloys and exports ingots.
– Recovers glass and exports beads.
– Recovers aggregates and exports gravel.
– Produces electricity and is self-powered.
– Produces methanol and synthetic diesel and provides fuel dispensing for public and waste hauler mobility applications.
Locations and Operations that Benefit from a MMRF:
– Material transfer stations.
– Large waste generation sites such as factories, universities, and hotels.
– Dedicated MRF locations. The dedicated MRF’s “All Materials Recycling Center” would be conveniently located near a city or town center where waste haulers and the public can easily drop off materials.
Strategy to and Path to Marketability:
My goal is to partner with manufacturing companies who can build these plants for my organization, CWTE, and share in the profits generated from the sale of the plant installations and from the output of products sold to markets. The other route is to raise funds from venture capital and or angel investors/partners that will enable us to afford the purchase of MMRF plants as we secure contracts with potential MRF operators.
Potential Customers Include:
– Waste generator operators such as universities, hotels, amusement parks, large housing developments, and military installations.
– Landfill operators.
– Transfer stations.
– Cruise ships.
– Off-grid communities.
This is a more elaborate rendering of the system scaled up to a travel center concept we call the CWTE Recycling Center. Here trains and trucks deliver municipal solid waste, construction and demolition debris, and single stream recycling to the CWTE Recycling Facility from points throughout the country. These modes of transport receive the waste streams from an established network of material transfer stations who take in waste from community haulers. These transfer stations are located along interstate and main line railroad corridors running parallel to Interstate 95 on the east coast and I 5 on the west coast as well as I 40 and I 10 east-west corridors crossing the country. The public can utilize this facility in several ways. It features a drop-off for recyclables and landfill waste and provides an educational component where visitors can tour of the facilities and learn about the inner workings of waste to energy and resource production. The shipping container modules that house the components of our system will feature glass sides so that people can see the waste materials enter and move through the system from start to finish. Visitors will also learn about how the various types of materials entering and exiting the extraction process and see them move to the manufacturing systems resulting in finished products.
Please visit and discover our website Capturedwastetoenergy.com. Check out the landfill system concept where I began this journey of waste to energy conceptualization. This concept involves the excavation of buried landfill materials in order to install a large scale MRF encompassing 11 floors of production bays. This scale of facility is designed to handle an entire regions waste stream for renewable resource products and utility production.
Create a profile on our developing social network to join the online community developing resources to convert landfills into waste to energy manufacturing facilities.
Thank you for considering working with us. We are very excited to build our concept of a Material Recovery Gasifier and Micro Material Recovery Facility into a reality to begin providing zero waste solutions for communities small and large.