Two full-capacity trains.
The industrial concept specifies 2 × 100% WGS–Sabatier and IM-26 drying trains. One operates while the other regenerates or remains available. Gas buffers support changeover; 8,000 hours/year is the planning assumption.
01 / TECHNOLOGY
From waste.
Through plasma.
To methane.
A connected process architecture: feedstock preparation, plasma gasification, gas conditioning, catalytic conversion and final gas treatment.
IM-1 / IM-2 / IM-8
Shred, dry and meter
Municipal solid waste is shredded, thermovacuum-dried and milled before controlled feeding. The reference design starts at approximately 40% moisture and prepares the feed to approximately 13%.
REFERENCE DESIGN
1,000 kg/h dry-feed industrial reference module
IM-3 / IM-20-600
Plasma conversion
Steam-plasma gasification converts the organic fraction to raw gas while the mineral fraction is vitrified. The design includes six reaction-zone torches and one at the slag outlet.
REFERENCE DESIGN
≈1,370°C gas temperature at reactor outlet
IM-9 / IM-4 / IM-7
Cool and clean the gas
Water cooling is followed by 10% KOH cooling and acid-gas neutralisation. Condensation and gas–liquid separation prepare the syngas for the conversion circuit.
REFERENCE DESIGN
≈1,370 → 300 → 100 → 30°C
IM-5 / IM-6 / IM-7
WGS–Sabatier conversion
Water-gas shift and methanation take place in a recirculating catalytic circuit. Gas passes through the reactor repeatedly to reach the required conversion, followed by reaction-water separation.
REFERENCE DESIGN
10 bar(g) design operating pressure
IM-22 / IM-23 / IM-26
Remove CO₂. Dry the gas.
KOH absorption removes CO₂ and produces a potassium carbonate solution. Silica-gel adsorption then removes water from the produced methane.
REFERENCE DESIGN
351 kg/h modelled methane output
THE REACTOR
Two fractions.
Two pathways.
The organic fraction enters the gas conversion pathway. The mineral fraction is melted and vitrified. Prepared feed and plasma-forming steam enter the reactor through separate systems.
The reference design integrates the feed doser and gasifier on a common rack and provides access to the torches, gas outlet and slag discharge.
Basic Design, sections 4.2.3 and 4.4.2.
THE FEED CYCLE
Load. Pause. Press. Repeat.
Waste enters only after the piston has fully returned to its upper position and stopped. The piston descends slowly under its own weight and stops at the end of the cylindrical chamber, above the cone. Feeding remains off throughout the downward stroke and empty return, then resumes for the next charge. Plasma conversion continues below; methane synthesis takes place downstream.
INDUSTRIAL PROCESS ARCHITECTURE
Designed around
continuous operation.
Fresh KOH to carbonate.
The methane case uses KOH without regeneration: 1,390.2 kg/h for CO₂ absorption plus 30.0 kg/h for neutralisation. The model produces 1,712.9 kg/h of dry-equivalent K₂CO₃.
Final gas preparation.
Silica-gel drying is followed by the proposed O₂/N₂ separation and methane-recovery stage, then product buffering. After final treatment, the produced methane meets the requirements for injection into the natural gas grid.
Industrial methane concept, pp. 5–10. Redundancy is a design approach; annual availability is assessed during integrated operation.
BEYOND THE REACTOR
The process works
as a system.
Conversion takes a circuit.
The WGS–Sabatier reactor operates with gas buffering, compression and repeated circulation. Condensation removes reaction water after the catalytic stage.
A chemical input.
A separate output.
KOH absorption removes CO₂ from the produced methane. The material balance includes KOH supply and a 50% potassium carbonate solution output.
Recover and recirculate.
Condensates are collected for reverse osmosis. Recovered process water returns to the process, alongside fresh makeup water.
INDUSTRIAL SCALING
Capacity follows your waste stream.
Plant capacity is selected from the actual annual volume and composition of available waste. The required capacity is achieved by installing the corresponding number of parallel PGMCC processing lines.
Explore pilot-scale validation and supporting engineeringLET’S DEFINE YOUR PROJECT
Your waste stream.
Your next energy project.
Discuss your projectStart with feedstock, throughput and the methane use case.