ARC plasma-melter electro conversion system for waste treatment and resource recovery

A system for converting waste material, comprising:

• an arc plasma furnace, the arc plasma furnace comprising:
• at least one arc plasma electrode in a predetermined position therein;
• a first discharge port positioned to discharge metal from the furnace;
• and
• a second discharge port positioned to discharge gases and slag from the furnace;
• a joule heated melter attached to the arc plasma furnace, the melter including a gas discharge port positioned to discharge gases therefrom, and a slag discharge port in a predetermined position therein;
• means for feeding the waste material into the arc plasma furnace such that a metal layer, a slag layer and a gaseous phase is formed in the arc furnace;
• a gas clean-up unit attached to the melter, the gas clean-up unit capable of separating the gaseous phase from the melter into fuel gas and particulate matter;
• a combustor attached to the gas clean-up unit;
• means for providing air to the system at a predetermined rate;
• a turbine attached to the combustor;
• a generator attached to the turbine;
• and
• a heat recovery steam system attached to the turbine.

A process for converting waste material, comprising:

• (a) introducing the waste material into an arc plasma positioned within an arc plasma furnace having first and second discharge ports at predetermined positions therein;
• (b) contacting the waste material with the arc plasma whereby the waste material is separated into a metal layer, a slag layer and a gaseous phase;
• (c) feeding the gaseous phase and the slag layer through the second discharge port from the arc plasma furnace to a joule heated melter connected to the arc plasma furnace, the joule heated melter having gas and slag discharge ports positioned therein;
• and
• (d) mixing the slag layer in the joule heated melter for a predetermined time period, thereby forming a slag product.

A process for converting waste material, comprising:

• (a) introducing the waste material into an arc plasma furnace having first and second discharge ports at predetermined positions therein and at least one arc plasma electrode positioned therein;
• (b) contacting the waste material with the arc plasma electrode such that the waste material is separated into a metal layer, a slag layer and a gaseous phase;
• (c) feeding the gaseous phase and the slag layer through the second discharge port in the furnace to a joule heated melter connected to the arc plasma furnace, the joule heated melter having gas and slag discharge ports at predetermined positions therein;
• (d) mixing the slag layer in the joule heated melter for a predetermined time period, thereby producing a slag product;
• (e) removing the gaseous phase from the melter through the gas discharge port therein;
• (f) treating the gaseous phase in a gas clean-up system such that particulates in the gaseous phase are separated therefrom and a fuel gas is provided thereby;
• (g) feeding the fuel gas to a combustor;
• (h) introducing air into the combustor substantially simultaneously with step (g), whereby combustion products are formed from the fuel gas and the air;
• and
• (i) feeding the combustion products to a turbine generator, whereby the combustion products drive the turbine generator to generate electricity.

A waste conversion unit, comprising:

• a transfer arc plasma furnace having at least one electrode in a predetermine position therein, the arc plasma furnace characterized in that at least a portion of waste material received therein forms a slag;
• and
• a joule heated melter coupled to the arc plasma furnace, the joule heated melter configured to receive at least a portion of the slag from the arc plasma furnace,
• wherein the transfer are plasma furnace portion of the waste conversion unit is configured to provide a predominant source of heat for the waste material to be treated in the unit relative to heat provided by the joule heated melter.