FORM 2
THE PATENT ACT, 1970,
(39 OF 1970)
&
THE PATENTS RULE, 2003
COMPLETE SPECIFICATION
(SEE SECTION 10; RULE 13)
"IMPROVED SYSTEM OF GENERATING ENERGY FROM WASTES AND
PROCESS THEREOF"
TRANSPARENT ENERGY SYSTEMS PRIVATE LIMITED A COMPANY REGISTERED UNDER THE PROVISIONS OF COMPANIES ACT, 1956 HAVING ADDRESS AT "PUSHPA HEIGHTS", 1ST FLOOR, BIBWEWADI CORNER, PUNE-SATARA ROAD, pUNE-411 037, MAHARASHTRA, INDIA.
THE FOLLOWING SPECIFICATION DESCRIBES THE NATURE OF THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED

FIELD OF THE INVENTION:-
Present invention relates to improved system of generating usable forms of energy from combustion of wastes such as municipal solid waste (MSW), industrial waste, Refuse Derived Fuel (RDF) etc. and process thereof. More particularly the present invention relates to the improvisation in waste preparation and handling system particularly suitable for handling wet / high moisture containing wastes. Also, the present invention relates to integration of external solid fuel fired superheater to enhance the power output of the above said system. The present invention also aims at solid fuel fired post combustion chamber / after burner as an integral part of the above said system and process thereof.
PRIOR ART:-
Wastes generation, collection, segregation and handling in developed countries and developing countries are quite different from each other. Currently, ail the waste disposal or utilization technologies available in market are developed to sui characteristics and needs of wastes in developed countries.
Technology of generating usable forms of energy from municipal and industrials wastes available in developed countries is as said further. In developed countries, wastes are collected in well segregated form. Combustible and dry wastes such as wood, paper, cloth, plastic etc. are separately collected and have very good calorific value as high as up to 3500 kcal/kg to 4500 kcal/kg. Such wastes have very good combustion characteristics and therefore, can combust readily. In case, the calorific value is lower, supplementary fuel such as natural gas / HSD is co-fired to ensure sustained combustion. Wet wastes, i.e. organic wastes such as vegetable or food wastes are collected separately and treated to generate biogas. Other wastes such as, glass, aluminum cans, metallic wastes etc are also collected separately and are sent for recycling.
In developed countries, segregated dry & combustible wastes are incinerated / combusted to generate high temperature flue gas. The waste is shredded and fed to

incinerator / combustor with widely used pusher type combustion grate. Pusher type combustion grate is made out of finely machined components sensitive to the physical form of the waste material. Alternatively, water cooled oscillating grate is also used on some parts of USA. As per 2000776/EC of European parliament, the combustion flue gas is required to be held at 1000 deg C for 1 second or at 850 deg C for 2 seconds in a post combustion chamber / after burner to ensure complete destruction of harmful gaseous products named dioxins and furans. In order to maintain this temperature after burners or post combustion chambers installed in developed countries are gas or HSD fired. The flue gas is then passed through heat recovery unit to generate high pressure steam at 40 bar(g) pressure and 400 deg C temperature. The high pressure steam drives steam turbine to generate electricity. In some cases, the heat from flue gases is also used to generate hot water or hot thermal oil to fulfill requirements such as room heating, refrigeration or chilling etc. Post heat recovery, flue gases are passed through flue gas cleaning system, to remove acid gases (HCL, HF and SO2), particulates, heavy metals and NOx. The lime based, wet scrubber or spray dryer type dry scrubbers or semi dry type system is used for removal of acid gases purpose. Activated carbon dosing is done for removal of heavy metals. Bag Filter or multiclone is used for removal of particulate matter. Selective Catalytic Reduction based DeNOx system is used for removal of NOx. Post flue gas cleaning, flue gas is exhausted to atmosphere.
LIMITATIONS OF PRIOR ART AND NEED OF THE PRESENT INVENTION:-
1. In developing countries like India, China, South East Asian countries, waste collection and segregation is not very thorough. This waste has high moisture and ash content. Therefore, the calorific value of the waste is inconsistent in range of 800 kcal/kg to 2500 kcal/kg. High moisture containing waste cannot burn self-sustainably but require firing supplementary fuel. The combustion systems available in developed countries fire natural gas or HSD as supplementary fuel.
2. In order to meet guidelines of directive 2000/76/EC of European parliament, combustion flue gas has to be held at 1000 deg C for 1 second or at 850 deg C for 2 seconds in a post combustion chamber / after burner to ensure

complete destruction of harmful gaseous products named dioxins and furans. The post combustion chamber / after burner of incinerators installed in developed countries are natural gas or HSD fired. These fuels are extremely expensive in developing countries like India, China etc. Therefore, there is need to develop a combustion system and post combustion chamber / after burner which can burn, commonly available solid fuels like, coal or biomass as supplementary fuels. 3. The composition of flue gas is such that it has to pass over the superheater of HRSG at temperature not more than 900 deg C to avoid hot end corrosion on superheater tubes due to deposit forming substances present in the gas. This limits the steam pressure and temperature to 40 bar and 400 deg C respectively there by limiting the power generation potential. Therefore, there is a need for developing a system to enable working of superheater at higher pressure and temperature to improve power generation.
OBJECT OF THE INVENTION:-
The present invention aims at the improved system for generating usable forms of energy from combustion of wastes such as municipal solid waste (MSW), industrial waste, Refuse Derived Fuel (RDF) etc. and process thereof.
More particularly the present invention aims at incorporation of external coal solid fuel fired superheater, MSW / wet waste preparation & handling system and solid fuel fired post combustion chamber/after burner to improve suitability, reliability and energy output of the claimed system and process thereof.
It is also object of present invention to eliminate limitations or drawbacks of the prior art.
STATEMENT OF THE INVENTION:-
Accordingly the invention provides An improved system of generating energy from wastes and process thereof, comprises collecting the waste in Completely enclosed

fully mechanized warehouse (1) equipped with grab crane (46) and shredder (2) connected to conveyor (47) a feeding means of shredded waste to the inlet of a hot air dryer(4) having an outlet to drop the dried waste to a first conveyor(7); a first hopper(8) to receive the said dried waste from the said conveyor(7); a second hopper (9) containing supplementary fuel; the said first and second hoppers having an controlled discharge outlet to feed fuel to a combustion grate(17) located at the bottom of Refractory lined furnace (49) connected to a post combustion chamber (18) in which the temperature required for destruction of dioxins is maintained by hot combustion gases generated by combusting coal in a separate coal combustion furnace (33); an enclosed heat recovery unit (19) having flue gas passage path provided with an evaporator (34) having an inlet connected to a steam drum (45) and an economizer (35) inlet connected to the outlet of a economizer (58) having inlet connected to de-aerator tank (22) through a boiler feed pump(36); the outlets of the said evaporator (34) and economizer (35) connected to individual inlet provided on the said steam drum(45); a steam super heater tube coil(38), heated by the flue gases generated by the supplementary fuel combusted in a separate combustion furnace (57), having inlet connected to the said drum(45) ; a generator turbine(21) having steam inlet connected to super heater tube coil(38) outlet; an air cooled condenser(20) inlet connected to the said turbine(21) exhaust steam outlet; a chimney (32)having exhaust flue gases inlet connected through a ID fan(31) to the exhaust flue gases out let of the said heat recovery unit through a flue gas cleaning system.
BRIEF DESCRIPTION OF THE SCHEMATIC DRAWING:-
The invention is described with reference to the accompanying drawing wherein, Figure. 1 describes simplified flow diagram of the improved system of generating usable forms of energy from combustion of wastes such as municipal solid waste (MSW), industrial waste, Refuse Derived Fuel (RDF) etc and process thereof.

DETAILED DESCRIPTION OF THE PRESENT INVENTION:-
Present invention aims at improved system of generating usable forms of energy from combustion of wastes such as municipal solid waste (MSW), industrial waste, Refuse Derived Fuel (RDF) etc. and process thereof. More particularly the present invention aims at the improvisation in waste preparation and handling system particularly suitable for handling wet / high moisture containing wastes. Also, the present invention aims to integration of external solid fuel fired superheater to enhance the power output of the above said system. The present invention also aims at solid fuel fired post combustion chamber / after burner as an integral part of the above said system and process thereof.
As shown in fig 1. (plan view / top view), the system aimed in the present invention comprises of,
1. Waste Preparation System comprising of enclosed warehouse under negative pressure (1) connected to ID fan (10) to suck air from the warehouse and from which waste is picked up by grab crane (46) and is dumped in to hopper (3) connected to shredder (2) to shred the waste pieces to achieve uniform particle size. The shredded waste is conveyed by belt conveyor (47) to waste dryer (4). The waste dryer is connected to a mixing type hot air generator (6) which supplies hot air for drying. The hot air generator (6) is connected to a coal/solid fuel hopper (5) which feeds solid fuel to generate hot air. ID/FD fan (11) supplies secondary combustion air to hot air generator (6) by opening the damper (12) and (13). FD Fan (48) supplies primary combustion air to hot air generator. Damper (14) is opened to allow dryer outlet air to flow in to inlet of ID fan (10). Conveyor (7) feeds the driedwaste to dry waste hopper (8) of fuel feeding system. Completely enclosed fully mechanized warehouse maintained under negative pressure avoids malodor in vicinity of plant. Warehouse air is used as combustion air for combustion system with HRU and for Hot Air Generator (6).
2. Fuel feeding system comprising of dry waste hopper (8), and supplementary fuel hopper (9) connected at bottom to screw, pusher, or rotary type feeding mechanism (15) and (16) respectively which supplies fuel to MSW furnace

(49). The Coal storage silos (50) supply supplementary fuel to hopper (9). Also, the coal storage silos (50) supply supplementary fuel to hoppers (41) and (51) connected at bottom to rotary type feeding mechanism (42) and (52) respectively to feed fuel to furnaces (40) and (33) respectively.
3. Combustion system with Heat Recovery Unit (HRU) comprising of combustion grate (17) located at the bottom of Refractory lined furnace (49) ensuring sustained combustion of MSW, a post combustion chamber (18) providing residence time of 2 sec at 850 deg or 1 sec at 1000 deg C to ensure destruction of dioxins and furans is connected to a coal combustion furnace (33) which supplies hot air to post combustion chamber comprising of a combustion grate (56) for maintaining the above said temperatures and a Heat recovery unit (19) comprising of, evaporator (34) connected to steam drum (45), economizer (35). The boiler water feed pump (36) supplies water from Deaerator tank (22) to economizer (58) connected to exhaust gas outlet of superheater (38) wherein the heat from exhaust gases is used to preheat the water in economizer (58) and the water at outlet of the said economizer (58) is connected to inlet of economizer (35). Dry and saturated steam at outlet of steam drum (45) is supplied to external fuel fired superheater system.
4. External superheater system comprises of an external solid fuel fired mixing type hot air generator (40) having combustion grate (57) at its bottom supplying hot combustion flue gas to superheater (38), supplementary solid fuel feeding system with fuel hopper (41) and feeder (42) supplying fuel to hot air generator (40) and FD fan (43) supplying combustion air to hot air generator, superheater tube coil carrying dry and saturated steam from steam drum (45), economizer (58) carrying boiler feed water supplied by feed pump (36). Superheater steam is supplied to Power generation system through Pressure Reducing and Desuperheating Station (59). The exhaust gases from superheater (38) are further cooled in economizer (58) before going to gas cleaning system.
5. The combustion grates (17), (56) and (57) comprise of arrangement for proper distribution of primary and secondary air supply to reduce possibility of unburnt carbon in ash as explained in their respective patent applications. FD fans (10), (53), (43) supply primary combustion air and FD fan (55), (54), (44)

supply secondary combustion air to respective grates. The combustion grates could be pusher type, cyclone burner or any of following grates applied for patent by the applicant of the present invention
a. Oscillating Grate (1113/MUM/2005)
b. Fully Automatic Water Cooled Agitated Rotary Positive Displacement
Grate (1752/MUM/2006)
c. Fully automatic water cooled step grate for firing wide range of solid
fuels like coal wood etc (1013/MUM/2011)
d. An Improved Water Cooled Oscillating Step Grate (3480/MUM/2012)
6. Power generation system comprises of steam turbine generator package (21) to which is superheated steam is supplied through Pressure Reducing and Desuperheating Station (59)and air cooled condenser (20) condensing exhaust steam from steam turbine. The power generated is evacuated by power evacuation system. Condensate from air cooled condenser is extracted by condensate pump (61) and pumped to Low Pressure Water Heater (62). Extraction steam from steam turbine (21) is mixed with condensate in Low Pressure Water Heater (62), also make-up water is supplied by Feed Water Treatment System (63) to the Low Pressure Water Heater (62). Preheated water from Low Pressure Water Heater (63) is pumped by pump (64) to the DeaeratorTank(22).
7. Steam is extracted from steam turbine (21) and is supplied to Air preheater (65) to preheat the combustion air supplied to furnace (49). The said combustion air is sucked from the warehouse (1) by fan (10) and it is passed through the steam heated Air Preheater (54). The steam condensed as a result of heat transfer to air, is collected in condensate pot (66).
8. Hot water circulation pump (68) circulates the water through water cooled oscillating grates (17), (56), (57) through expansion tank (67).
9. The flue gas of temperature of about 260 deg C at outlet of HRU (19) is supplied to flue gas cleaning system by opening damper (37) and by operating Fan (24). The flue gas cleaning system comprises of activated carbon dosing system (25) feeding activated carbon directly in to the flue gas duct to for removal of heavy metals by adsorption on activated carbon particle surface, a lime or adsorbent slurry or solution preparation unit (30), slurry or

solution feeder (29) to feed adsorbent to a reactor (26) for removal of acid gases (HCI, HF, S02) by reaction with adsorbent, a bag filter (27) for removal of particulates of reacted adsorbent and activated carbon from the flue gas, an ID fan (60) to convey the exhaust gases from flue gas cleaning system to common stack (32). Disposal silo (28) collects the exhausted adsorbent which is sent for land fill. Exhaust gases from external superheater system coming from economizer (58) are filtered in a separate bag filter (59) before they are conveyed by ID fan (60) to the common stack (32)
In the present invention, waste preparation system ensures consistency of moisture in the feed waste independent of the waste segregation at source of collection.
In the present invention, supplementary fuel firing ensures sustained combustion of mixed fuel as it maintains the calorific value of mixed fuel consistent.
In the present invention, solid fuel fired post combustion chamber / after burner ensures guidelines of directive 2000/76/EC of European parliament are followed by holding combustion flue gas at 1000 deg C for 1 second or at 850 deg C for 2 seconds for complete destruction of harmful gaseous products named dioxins and furans.
The system in present invention is controlled by SCADA with online real time public display of performance parameters.
Therefore, the present invention has improved reliability over prior art. In the present invention, the HRU generates dry and saturated steam of 110 bar (g) pressure and 318 deg C temperature. This dry and saturated steam is superheated in external fuel fired super heater up to 520 deg C. This enables higher power generation as compared to the prior art. The table below gives the comparison of prior art v/s present invention.

Parameter
Unit Prior Art Present Invention
Moisture in MSW 40% 50% 60% 40% 50% 60%
MSW NCV kcal/kg 2,062 1,494 926 2,062 1,494 926
MSW Processed TPD 250 250 250 250 250 250
Coal Firing TPD 0 0 0 1,925 1,351 1,104
Heat input through coal 0% 0% 0% 28% 27% 46%
Gross power output kWe 5,434 3,815 2,203 9,031 6,328 5,204
Overall Gross Efficiency 21.8% 21.1% 19.7% 26.0% 25.4% 24.8%
ADVANTAGES AND FEATURES OF THE PRESENT INVENTION:-
1. The present invention relates to improved system of generating usable forms of energy from combustion of wastes and process thereof resulting in to eco-friendly disposal of domestic and/or industrial wastes there by reducing greenhouse gas emissions.
2. The present invention relates to improved system of generating usable forms of energy from combustion of wastes and process thereof resulting in to partial substitution of power from petroleum fuels.
3. The present invention relates to improved system of generating usable forms of energy from combustion of wastes and process thereof preventing soil, air and water pollution.
4. The present invention relates to improved system of generating usable forms of energy from combustion of wastes and process thereof making it a reliable system capable of processing inconsistent quality of domestic and/or industrial waste.
VARIATIONS POSSIBLE TO BE COVERED AND PROVIDED WITHIN THE PRESENT INVENTION:-
1. The system and process thereof in the present invention can work on variety of solid fuels, such as municipal solid waste (MSW), refuse derived fuel (RDF), industrial waste or any other combustible waste.

2. The MSW / wet waste preparation unit comprises of waste drier which could work on hot gases supplied by fuel fired hot air generator or steam.
3. The usable forms of energy from the said system could be electricity, low pressure steam, hot water, hot thermal oil, chilling and refrigeration.
4. The external fuel fired superheater could work on fuels, petcoke, coal, biomass, wood chips using water cooled oscillating grate.
5. The after burner / post combustion chamber of the said system can work on fuels petcoke, coal, biomass, wood chips using water cooled oscillating grate.
TYPICAL APPLICATION AREAS:-
1. The outputs from the system in present invention are
a. Power generation from municipal / industrial wastes
b. Steam / Hot water / hot air generation from municipal / industrial
wastes.
c. Refrigeration / chilling from municipal / industrial wastes.
2. The one or more of above outputs could be obtained from the system and process thereof claimed in the present invention.
3. The system and process thereof in the present invention becomes more suitable in developing countries where cost of petroleum based liquid / gaseous fuels are high.

WE CLAIM:-
1. An improved system of generating energy from wastes and process thereof, comprises collecting the waste in Completely enclosed fully mechanized warehouse (1) equipped with grab crane (46) and shredder (2) connected to conveyor (47) a feeding means of shredded waste to the inlet of a hot air dryer(4) having an outlet to drop the dried waste to a first conveyor(7); a first hopper(8) to receive the said dried waste from the said conveyor(7); a second hopper (9) containing supplementary fuel; the said first and second hoppers having an controlled discharge outlet to feed fuel to a combustion grate(17) located at the bottom of Refractory lined furnace (49) connected to a post combustion chamber (18) in which the temperature required for destruction of dioxins is maintained by hot combustion gases generated by combusting coal in a separate coal combustion furnace (33); an enclosed heat recovery unit (19) having flue gas passage path provided with an evaporator (34) having an inlet connected to a steam drum (45) and an economizer (35) inlet connected to the outlet of a economizer (58) having inlet connected to de-aerator tank (22) through a boiler feed pump(36); the outlets of the said evaporator (34) and economizer (35) connected to individual inlet provided on the said steam drum(45); a steam super heater tube coil(38), heated by the flue gases generated by the supplementary fuel combusted in a separate combustion furnace (57), having inlet connected to the said drum(45) ; a generator turbine(21) having steam inlet connected to super heater tube coil(38) outlet; an air cooled condenser(20) inlet connected to the said turbine(21) exhaust steam outlet; a chimney (32)having exhaust flue gases inlet connected through a ID fan(31) to the exhaust flue gases out let of the said heat recovery unit through a flue gas cleaning system.
2. The system for generating energy as claimed in claims 1 and 2 wherein the said dryer air inlet connected to hot air generator to supply heated air, sucked from the said ware house through a first ID fan, by firing supplementary fuel; a second ID fan having an inlet connected to the air out

let of the said dryer through air dampers and having an out let connected to the inlet of the combustion grate.
3. The system as claimed in claims 1 to 3 wherein inlet of said first and second
ID fans is connected by pipe line, fitted with with dampers, to the said ware house to supply air to combustion furnaces and dryer.
4. The system as claimed in claims 1 to 4 wherein an air cooled condenser
provided to cool the exhaust steam the said turbine.
5. The system as claimed in claims 1 to5 wherein the waste is of solid fuels,
such as municipal solid waste (MSW), refuse derived fuel (RDF), industrial waste or any other combustible waste.
6. The system as claimed in claims 1 to 6 wherein the said flue gas cleaning
system (F) comprises of activated carbon dosing system (25) feeding
activated carbon directly in to the flue gas duct to for removal of heavy
metals by adsorption on activated carbon particle surface, a lime or
adsorbent slurry or solution preparation unit( 30), slurry or solution feeder
(29) to feed adsorbent to a reactor (26) for removal of acid gases (HCI, HF,
S02) by reaction with adsorbent, a bag filter for removal of particulates of
reacted adsorbent and activated carbon from the flue gas, an ID fan to
convey the exhaust gases from flue gas cleaning system (F) to stack (32).
Disposal silo (28) collects the exhausted adsorbent which is sent for land fill.
Stand by multiclone (24) is installed with the outlet of the said multiclone
(24) connected to the inlet of ID fan (31) operated by operating three way
diverter damper in case of abrupt stoppage of flue gas cleaning system.
7. The system as claimed in claims 1 to 7 wherein the said combustion grates
is pusher type/ cyclone burner/ Oscillating Grate (1113/MUM/2005)/Fully Automatic Water Cooled Agitated Rotary Positive Displacement Grate (1752/MUM/2006)/Fully automatic water cooled step grate for firing wide

range of solid fuels like coal wood etc (1013/MUM/2011)/ Water Cooled Oscillating Step Grate (3480/MUM/2012).
8. The system as claimed in claims 1 to 8 wherein the external superheater
supplied with hot exhaust flue gases generated by burning petcoke, coal, biomass, wood chips etc in a separate combustion furnace.
9. The system as claimed in claims 1 to 8 wherein the post combustion
chamber is supplied with hot exhaust flue gases generated by burning petcoke, coal, biomass, wood chips etc in a separate combustion furnace which maintain the required temperatures of 850 or 1000 dec C for dioxin destruction in post combustion chamber.