Waste to energy with carbon capture
Brief Summary of Carnot’s Field of Business and Goals:
Carnot’s mission is to build and operate green “waste-to-energy” and, to a lesser extent, green “waste-elimination” plants. The plants will provide an alternative to (and hopefully replace altogether) landfills, which emit harmful gases (including CO2 and methane) into the atmosphere and that pollute waterways with hazardous runoff. Carnot has the knowhow and expertise to recover the energy inherently stored in municipal solid waste material, including PFAS (and can even handle hazardous waste), to generate electrical power, all while preventing harmful atmospheric emissions and without producing any byproducts that themselves must be disposed of as waste.
Carnot intends to build modular gasification facilitates housed in a single structure each operating at 500 tons/day (tpd), with each facility consisting of ten (10) identical 50 tpd “trains” (operating 24/7). Each train comprises: 1) a novel gasifier, which is capable of partially combusting shredded solid waste including PFAS and even commercial liquid waste to extract and generate Syngas from said material; 2) a combustor, which combusts the Syngas gas; 3) a 5 MW organic Rankine cycle turbine generator; and 4) a proprietary electrostatic emission recovery device that extracts nearly all remaining carbon and regulated air pollutants from the exhaust stream prior to venting remaining gases into the atmosphere. Each compact waste-to-energy power plant is expected to generate electricity with an efficiency rating of more than 35%, an efficiency level on par or higher than that of any other waste-to-energy plant currently offered in the market, yet with extremely less emissions.
The waste-to-energy plants will receive waste either directly or in containerized form and all solid byproducts created will themselves be commodities, which too will be shipped containerized from each given site and sold. Each plant is capable of receiving tipping fees, (i.e., waste disposal fees) and fees from selling the solid char produced from the gasifiers (which is an ideal aggregate for concrete), carbon black (which is needed for the production of products such as steel and tires), and carbon credits (which are internationally tradable for currency). World-wide and even in the U.S., different customers/countries desire different needs. For example, some countries need primarily waste disposal (as does FEMA, which has expressed interest), others need carbon credits (e.g., Switzerland), some others need stable power (the U.S. Military has a need for portable power generation from waste or fuel). Single trains or more could even be mounted on ships to clean oceanic piles of waste, all while creating valuable resources without harmful emissions. Regardless, power generation or not, meeting all these needs with virtually no environmental impact is Carnot’s mission.
Still Further, Carnot expects that the EPA will verify that Carnot’s waste-to-energy system is “Best Available Technology” (an EPA designation requiring those in the field to achieve specific emissions criteria in order to be permitted) which would then require all emissions installations to meet or exceed Carnot emissions standards or they could not operate. Carnot expects that its method of handling waste will be the only one that meets this new “Best Available Technology” level and also qualify for De-minimis emissions for a 500 ton/day plant (emissions low enough that no permit would be required, even for hazardous waste streams).
Technology Of Carnot’s Unique Gasification and Electrostatic Carbon Capture Emission Device Compared to Traditional Gasification Systems:
Traditional types of gasifiers include:
The common updraft gasifier, which is a counter-current type where the fuel flow direction is the opposite that of the oxidant. The advantage of the updraft is that it is the most efficient and converts the maximum amount of solid fuel into Syngas while minimizing oxygen requirements. An updraft gasifier is able to process high moisture fuels with the moisture exiting with the Syngas. It also has a longer residence time for the fuel to be processed at higher temperatures, resulting in the ability to process a wide range of fuel particle sizes. The disadvantage of the updraft is the high amount of tars that are in the Syngas;
Common downdraft gasifiers (most common) were mainly developed as a solution to reducing the tars present in the Syngas. They are believed to have the lowest tar output, but come with several constraints. In a downdraft gasifier, the oxidant and fuel are flowing concurrently. This results in a simpler fuel feed, since both oxidant and fuel start at ambient temperature. However, the oxidant flow can force fine fuel particles to pack together and cause irregular flow with higher pressure drops that can limit or reduce mass flow. They also have shorter residence time at temperature which makes them highly susceptible to both particle size and moisture content. The result is that a larger gasifier is needed to avoid flow and clogging problems and a significantly more expensive fuel processing spec (narrow particle size range, low moisture, wasted fines that cannot be processed etc.);
Fluidized bed gasifiers utilize a higher oxygen/steam flow rate which lifts the fuel particles and mixes the small particles (usually under 6 mm). These gasifiers are similar to updraft and can have higher or lower tars depending on a variety of factors. Lower tars are obtained by operating the gasifier at high superficial velocities, which surround the fuel particles with hot gases that crack the volatilized fuel particle as the Syngas exits the fuel particle. Due to the higher air needs, the efficiency is low; and
Entrained flow gasifiers introduce air and fuel concurrently. These are a good choice when the fuel is of low density, such as straw. They need a higher percentage of air as compared to the other types of gasifiers and need the fuel to be consistent, small in size and uniform in water content (which must be low).
All of these methods produce only Syngas that must be filtered before being able to power a turbine (turbines are highly finicky, require clean fuel, and are highly susceptible to tars).
Carnot’s unique gasifier technology:
Carnot’s unique gasifier combines the benefits of the other gasification systems and adds additional intellectual property to overcome prior disadvantages of prior art gasification systems. Rather than taking conventional wisdom of focusing on the downdraft gasifier, Carnot solved the original issues of an updraft gasifiers to be able to exploit its advantages as the highest efficiency device without the side-effects.
First, the gasifier is designed to be pressurized (significantly important), which increases the boiling temperature of the water in the system, allowing steam conversion of carbon and tars into carbon monoxide fuel.
Additionally, the gasifier includes a blower that recirculates and mixes the carbon-ash particles with available steam, resulting in a marked decrease in tars and an increase in CO and H2 within the gasifier.
Carnot’s gasifier also includes plasma torches that create high temperature areas which quickly annihilate tars and carbon-ash particles to rapidly create even more CO and H2 while decreasing tars and ash further.
The gasifier also includes a refractory internal liner of proprietary formulation that can tolerate heat to 3,000°F which serves as an insulator to minimize heat needed for the gasification reaction.
Finally, the counter-flow shell-within-a-shell design of the gasifier serves as a counter flow heat exchanger that allows for pre-heating of the inlet air/oxygen. This improves thermodynamic efficiency and starts the gasification reaction sooner, allowing the entire fuel pile to begin gasification sooner and ensures uniform operation in all weather and temperature of feed material.
Finally, Carnot’s gasifier includes an integral reformer for separating ash particles from the syngas.
Carnot’s unique electrostatic carbon capture device:
Regardless of whether or not Carnot’s gasifier powers a turbine or is merely used to dispose of waste, the most significant aspect of Carnot’s technology lies in in its proprietary electrostatic carbon capture technology (which Carnot owns an exclusive license to, for use in connection with gasification). While electrostatic carbon capture technology is known in general, it’s practical use has been subject to much debate. Carnot has solved known clogging and maintenance issues due to its effectiveness and has resolved its issues with large scale operation. Carnot’s capture device involves diffusing the exhaust gases prior to passing the exhaust gases through parallel electrostatic separators. This lowers exhaust velocity, increases dwell time, and deceases power needed for electrostatic field generation. Furthermore, what most don’t understand is that the net reactions output is endothermic. Hence, the chemical reactions provide much of the power to make to make it highly efficient. The device is capable of removing emissions (nearly eliminating CO2 and CO emissions) with low maintenance. How exactly Carnot does this with very low maintenance or clogging is highly proprietary, but has been proven independently by Carnot.
Carnot’s Funding Request And Need Therefore:
Carnot is seeking $5M (USD) of upfront investment loans (3-year ballon at 18% annual interest). On top of the interest rate, Carnot is offering to transfer Federal Tax Incentives (i.e., transferable tax credits), which Carnot will qualify for under federal law (
https://programs.dsireusa.org/system/program/detail/658/business-energy-investment-tax-credit-itc), to the investors of the first $5 million for free at a dollar-per-dollar match. The transfer of those tax credits would be on top of the loan (i.e., investors would be paid back 100% in tax credits as soon as Carnot makes use of 5% of the investment funds, and would still be paid back 100% on their loan at the 18% rate).
The investment funds will be used solely toward the purpose of obtaining third party verification and letters from the EPA that Carnot’s gasifier and its electrostatic carbon capture technology perform each meet particular EPA emission guidelines standards for handling various waste (such letters are critical to Carnot’s future ability to sell and/or operate plants and equipment commercially). To this end, Carnot intends to use the investment funds to build and operate two gasifiers (to speed the testing time for demonstrating the requirements are met) attached to combustors for combusting the syngas generated by the gasifiers. Only a portion of the proprietary electrostatic separator will be built and tested using bleed air off of the exhaust combustion of one of the gasifier/combustor assemblies. A test site is available and another (leased farm land near the construction plant is preferred and in works). Turbine generators will not be included due to their extreme cost and non-necessity for purpose of the EPA verification tests. The improved gasifier design has been modeled three-dimensionally in CAD, yet needs additional tweaking and final specifications prior to commencing construction. Once all design work is complete, the control system (which has also been substantially developed, will need tweaking). We anticipate that all this work and the testing and revisions can be achieved within a year or at most two. Washinton University has agreed to conduct the third-party independent testing needed for EPA submission.
Upon receiving the EPA’s letters of the standards meet by our systems, we believe our customers that urgently seek our technology will have no more hesitations purchasing units from us. The roadblock Carnot faced has always been not having the EPA letters despite having our own rigorous test data.
So, regarding the investment loan, Carnot that within 3 years it will be able to receive standard institutional loans to cover manufacturing expenses..
Meet Our Team of Board of Directors of Carnot LLC and Key Subcontractors of Carnot Enterprises, Inc.:
Andrew (Andy) D. Schlote, PE (Chief Technology Director), Mr. Schlote has over 25 years of experience designing and operating gasifiers, combustors, turbine powered generators, and emission control devices. He is the premiere expert in designing gasification systems and has consulted for numerous companies to design/re-fine gasification systems. Andy has been awarded 26 U.S. and international patents and has developed numerous new inventions and patentable technology associated with the Sustainable Power System Carnot LLC intended for use in the US and abroad. Andy was previously the CEO of Innovative Energy, Inc., where he raised 30 million dollars and managed the development of high-speed turbine generators and gasification systems. Prior to that, Andy worked at Hussmann Corp, ultimately serving as a superintendent of a team of 140 people involved in the production of refrigerated display case parts and was awarded the prestigious Corporate Mozart Award. Mr. Schlote has a BS in Mechanical Engineering from the University of Missouri-Rolla, an MBA from Webster University and is a licensed Professional Engineer. He is also a certified Novell Netware Systems Manager and a certified Time Study Analyst.
R. Michael (Mike) Judd, (Control System Consultant), Mr. Judd has a BA in Biology and Chemistry from Washington University (“Wash U”) plus graduate studies in the Wash U Chemical Engineering Department. During his tenure at Wash U, Mr. Judd held a faculty position as part of a research team funded by NASA for the development of advanced separation technologies of bioactive substances. Following his work at Wash U, Mr. Judd took a position as Manager of the Quality Assurance Laboratory and Separations Division of Pathfinder Labs. In the late 1980’s, Mr. Judd became a partner in a full‑service systems integration company, gaining extensive experience in chemical process design, supervisory control system design, and general process engineering practices as applied to the manufacturing industries and utilities. Mr. Judd eventually sold his ownership in the systems integration company and established Bach Systems, Inc (“Bach”) in 1992. Working as an independent contractor through Bach, Mr. Judd served a wide range of manufacturing industries including food & beverage, pharmaceutical, chemical/petrochemical, and steel. In 2005, Mr. Judd became involved in renewable energy through a partnership with Neste Oil for the commercialization of the Forestera technology, an advanced biomass-to-liquid process. Following his work with Neste Oil, Mr. Judd has worked in a broad range of applied engineering applications and R&D projects in the energy sector, including anaerobic digestion, biomass gasification, fast pyrolysis, and on innovative methods for utilization of synthesis gas. Since 2014 Mr. Judd is serving as Chief Technical Officer for SynSel Energy in support of an initiative to construct renewable fuel plants in the US based on advanced GTL technologies developed by Gas Technology Institute. Mr. Judd brings great value to the operation and control systems necessary to operate Carnot LLC’s Sustainable Power System.
Michael (Mike) J. Baudrexl, (Engineering, CAD, and Mechanical Fabrication Consultant) Mr. Baudrexl earned his Bachler of Science degree in Mechanical Engineering (1987) from the University of Missouri – Rolla (Missouri S&T). Mike is the currently the owner of BEC Machining, LLC and is approaching 40 years of experience in all types of machining equipment and processes. He has been instrumental in the design of Carnot LLC’s Sustainable Power System utilizing his manufacturing knowledge and SolidWorks CAD expertise. Michael utilizes Lean Manufacturing, state of the art CNC milling, turning, CAD/CAM technology to serve the medical, aerospace, pharmaceutical, agricultural, steel and energy markets. Before starting BEC Machining, LLC, Mike obtained extensive manufacturing engineering and engineering supervision experience working for: Sunnen Products Company, Alliance Tool/Delta Gear Company, Von Weise Gear, Champion Spark Plug and Aeroquip Corporation.
Stephen (Steve) D. Fuller, (Civil Construction Consultant and Contractor) Mr. Fuller has over 27 years of experience in construction of commercial and residential buildings. Steve has served under others as a foreman and has vast knowledge of plumbing electrical and HVAC installation oversite. Steve is fully capable of following architectural and engineering plans accurately and has a vast array of subcontractors to call upon to achieve desired and dictated plans and goals. Steve is perfectionist, and doesn’t stray from professional plans. Steve now operates his own company, “Finishing Touch”, operating as GC. Steve’s greatest attribute to Carnot is his non-stop drive for doing a perfect project according to plans the first time, striving for excellence and inspiring those around him. Additionally, his skill in and at construction and assembly contractors will be of great help to Carnot, given that sites will need to be prepared and large cranes utilized carefully to assemble large operating equipment in place for assembly.
Clyde L. Smith, Esq., (Chief Legal Officer and Treasurer), Mr. Smith has a BS in Aerospace Engineering from Parks College of Saint Louis University, a JD from Saint Louis University, and is a licensed member of the Missouri Bar and a licensed U.S. Patent Attorney. Prior to working directly for the Company, Mr. Smith worked in private practice as a law partner in the firm of Thompson Coburn, LLP, handling foreign and domestic patent portfolios of numerous Fortune 500 companies and drafting hundreds of patents and opinions regarding infringement and patentability. Clyde has been Mr. Scholte’s patent attorney for more than 20 years. Prior to becoming a lawyer, Mr. Smith worked as a Strength Engineer for McDonell Douglas (now Boeing) analyzing pneumatic, hydraulic, and fuel components for strength, vibration, fatigue. Thereafter Clyde served as Chief Engineer for an orthopedic implant manufacturer designing hip and knee implants. After resigning as a partner from Thompson Coburn, Mr. Smith was employed full time as Chief Legal Counsel for Martin Engineering (a bulk material handling company with worldwide divisions) where he restructured the legal organization of Martin Engineering’s worldwide legal management. Mr. Smith has since moved on to being a sole practitioner and has primarily worked pro bono for Mr. Schlote in an effort to bring Mr. Schlote’s/Carnot LLC’s Sustainable Power System to fruition. Clyde is also proficient in the use of SolidWorks (CAD) and, in addition handling legal contacts and matters for Carnot LLC, can assist Mr. Baudrexl with modeling and design work for Carnot LLC’s Sustainable Power System.
Mark D. Steele, PE, (Primary Manufacturer and Business Consultant), Mr. Steele has a BS in Engineering from the University of Pittsburgh and a Master of Science in Industrial Administration/MBA from Carnegie Mellon University Tepper School of Business. Mark is currently the President, CEO (Chief Executive Officer) and majority owner of Craftsmen Industries, Inc. He has served as President, CEO and General Manager in eight different companies. These were all manufacturing and specialty distribution companies primarily in B2B contexts and mostly with highly engineered technical products from tens of millions to over $500MM annual revenue. He has deep experience in distressed, pre-, and post-bankruptcy as well as restructuring situations. As an officer in a $2B public company earlier in his career, Mr. Steele deployed world class compliance, environmental and health and safety compliance performance and monitoring systems. He has helped lead successful resolutions of a variety of complex legal matters including the successful exit of Superfund obligations, as well as a variety of state and local environmental clean-up matters both domestically and internationally. His leadership has earned recognition for safety excellence in several con texts. Much of the work Mr. Steele did at Kennametal led to his employer’s successful Ethisphere “most Ethical Companies” designation for seven years in a row. Mr. Steele has also led favorable settlements of labor class actions and broad product defect litigation matters. He has helped companies deploy best practice ESG (Environmental, Social, and Governance) in a variety of public and private contacts. Mr. Steele has served on the boards of ten different privately held companies owned by private equity firms with up to $3 Billion AUM with a wide range from very unsophisticated to very sophisticated governance and board disciplines. Mr. Steele has been a certified board member since 2005 starting with his first certification from UCLA Anderson to his most recent National Association of Corporate Directors certification. He has been recognized as a Board Leadership Fellow by NACD (National Association of Corporate Directors) and actively maintains his credentials and continuous learning on all governance topics. Mr. Steele has a strong background in helping advance company capabilities and talent by adding controls, strategy deployment, governance and best practices to companies that need greater sophistication in order to improve, grow and scale.