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Operating Experience - Commercial & Pilot Projects
Page 1
Westinghouse Plasma Corporation...Your Partner for Plasma Technology Solutions
Operating Experience - Commercial & Pilot
Projects

Page 2
Westinghouse Plasma Corporation...Your Partner for Plasma Technology Solutions
Operating Experience ­ Commercial Project
Plasma Gasification of Municipal Solid Waste (MSW) in Japan
I
Commissioned in 1999 at
Yoshii, Japan by Hitachi
Metals, Ltd.
I
Gasification of MSW for
Production of Steam
I
MARC-3A Torch
­
2 active, 1 spares
I
Nominal Power:
­
Total System:  600 kW
­
Individual Torch: 70 ­ 300 kW
I
Process Gas:  Air
I
Electrode Life:
­
Anode:
900 Hours
­
Cathode: 600 
Hours
The Plasma Direct Melting Reactor (PDMR) at
Yoshii, Japan converts unprocessed MSW to
fuel gas and glassy slag.  The dioxin and furan
emissions are less than 0.01 ng-TEQ/Nm3

Page 3
Westinghouse Plasma Corporation...Your Partner for Plasma Technology Solutions
Operating Experience ­ Commercial Project
Plasma Cupola for Geneva Steel in Provo, Utah
I
Commissioned in 1996
I
Supplemental Hot Metal
Production
I
MARC-11H Torch
­
9 active, 2 spares
I
Nominal Power:
­
Total System:  18MW
­
Individual Torch: 800 ­ 2400 kW
I
Process Gas:  Air
I
Electrode Life:
­
Anode:
1500 Hours
­
Cathode: 
  750 Hours
Plasma-Fired Cupola at Geneva Steel in Provo,
Utah is largest in the world and is designed to
produce up to 1 million tons of molten metal per
year.

Page 4
Westinghouse Plasma Corporation...Your Partner for Plasma Technology Solutions
Operating Experience ­ Commercial Projects
Plasma Torch used in Kinuura, Japan for Ash Vitrification
I
Waste-to Energy Ash Vitrification
Commissioned in 1995
I
MARC-3A Torches
­
4 active, 1 spare
I
Nominal Power:
­
Total System:  640 kW
­
Individual Torch:  60 ­ 160 kW
I
Process Gas:  Air
I
Electrode Life:
­
Anode:     900 Hours
­
Cathode:  300 Hours

Page 5
Westinghouse Plasma Corporation...Your Partner for Plasma Technology Solutions
Operating Experience ­ Commercial Project
Plasma Torch used in Recovery Project in Jonquiere, Canada
I
ALCAN Project Started in 1992
I
Aluminum Dross Recovery
I
MARC-11H Torch
­
2 active, 1 spare
I
Nominal Power:
­
Total System:  3.4 MW
­
Individual Torch:  800 ­ 1700 kW
I
Process Gas:  Air
I
Electrode Life:
­
Anode:     3500 Hours
­
Cathode:  1500 Hours
ALCAN Pilot Plant Project

Page 6
Westinghouse Plasma Corporation...Your Partner for Plasma Technology Solutions
Operating Experience ­ Commercial Project
Plasma Melter used at General Motors Plant in Defiance, Ohio
I
Commissioned in 1987
I
Gray Iron Foundry Process
I
MARC-11H Torch
­
6 active, 4 spares
I
Nominal Power:
­
Total System:  10.2 MW
­
Individual Torch:  800 ­ 1700 kW
I
Process Gas:  Air
I
Electrode Life:
­
Anode:    1000 Hours
­
Cathode:  500 Hours

Page 7
Westinghouse Plasma Corporation...Your Partner for Plasma Technology Solutions
O
perating Experience ­ Commercial Project
Toxic Waste Destruction Project at Plasma Center, Madison, PA
I
Project using Pyroplasma Trailer
Commenced in 1986
I
Destruction of Liquid Toxic Waste
I
MARC-11H Torch
­
1 active, 1 spare
I
Nominal Power:
­
Total System:  800 kW
­
Individual Torch:  600 ­ 800 kW
I
Process gas:  Oxygen
I
Electrode Life:
­
Anode:     900 Hours
­
Cathode:  200 Hours

Page 8
Westinghouse Plasma Corporation...Your Partner for Plasma Technology Solutions
Operating Experience ­ Pilot Plant Project
DOE-ATS Thermal Barrier Coatings Test Program
I
Subcontract with Siemens-
Westinghouse Power Corp.
1996 ­ Ongoing
I
Life Cycle Tests at Turbine
Conditions
I
Ultra Low Contamination of Test
Samples
I
MARC-3HC Torch with Hot
Cathode
I
Power:  5 ­ 80 kW
I
Process Gas:
Air/Hydrogen/Argon
The test facility is fully automated
for unattended, 24-hours/day
operation

Page 9
Westinghouse Plasma Corporation...Your Partner for Plasma Technology Solutions
Operating Experience ­ Pilot Plant Project
Diamond Deposition at Plasma Center, Madison, PA
I
Diamond Deposition Project for
NIST ­ 1992 ­ 1995
I
Low Cost Diamond Film
Production Process
I
MARC-3HC Torch
I
Hot Cathode
I
Power:  5 ­ 100 kW
I
Process Gas:  Hydrogen/Argon
This process yielded >1000 %
reduction in carat cost and
increased operating efficiencies.
Highlights:
*
 CVD diamond process scaled up from 15 KW to 100 KW
*
 Cost per carat reduced from $300 to $22
*
 Diamond deposition area increased from 80 cm
2
 to 750 cm
2

Page 10
Westinghouse Plasma Corporation...Your Partner for Plasma Technology Solutions
Operating Experience ­ Pilot Plant Project
Plasma Cupola Vitrifies LLW at Plasma Center, Madison, PA
I
Hanford Low Level Waste Tank
Project 1994 ­ 1995
I
Vitrification of Simulated
Radioactive Waste Process
I
MARC-11H Torch
I
Operates DC Current with Non-
Transferred Arc
I
Power :  750 ­ 1550 kW
I
Process Gas :  Air
Created 14 tons of glass product using
plasma vitrification on low level rad waste.
Highlights:
*
 Processed 5700 liters of simulated LLW slurry
*
 7370 Kg of glass produced with 2 orders of magnitude better PCT
*
 Steady state operation maintained for 24 hours

Page 11
Westinghouse Plasma Corporation...Your Partner for Plasma Technology Solutions
Operating Experience ­ Pilot Plant Project
Plasma Cupola used for Landfill Reclamation at Plasma Center/Madison
I
Treatment of Contaminated
Landfill Project ­ 1987 to 1990
I
MARC-11H
I
Power :  
750 ­ 1550 kW
I
Process Gas :  Air
Plasma Cupola Test Facility­state-of-the-art high
temperature process development pilot plant.
Highlights:
*
 Non-hazardous slag produced containing heavy metals
*
 Metals recovered by byproduct (Iron, Copper)
*
 Steady state operation maintained for 72 hours

Page 12
Westinghouse Plasma Corporation...Your Partner for Plasma Technology Solutions
Operating Experience ­ Pilot Plant Project
Plasma Cupola Iron & Steel Project at Plasma Center in Madison, PA
I
Scrap Iron & DRI Melting
Waste Oxide Smelting
Project ­ 1983 to 1992
I
MARC-11H Torch
I
Power:  750 ­ 1750 kW
I
Process Gas:  Air
Plasma Cupola process
offers flexibility in feedstocks
never before available.
 
Highlights:
*
 Process developed to melt finer iron feed material, i.e., borings
*
 100% DRI feed melted and residual iron oxide smelted
*
 Process developed to treat steel industry waste oxides