OREX Process

Process description

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OREX (ORganic EXtrusion) – Single Step Automatic Segregation of Mixed Garbage

OREX automatically segregates mixed municipal waste into organic/ wet and the inorganic/dry waste fractions in a single step automatic process.

The organic fraction is also termed as “wet” fraction, and is very high in organic or biodegradable matter and moisture content. It is extracted in a pulp form which enhances the bio-methanation fermentation process.

The in-organic fraction is also termed as “dry” fraction, contains inorganic material like plastics, paper, cellulosic fiber, inert, grit etc. This fraction is also termed as refused derived fuel (RDF) and after simple removal of metals, inert and heavy fractions like sand, silt, stones can be refined into very high quality of RDF having calorific value in the range of 4000 to 5500 Kcal/kg.

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Wet or Organic fraction extracted in RDF of dry fraction extracted from OREX Pulp form from the OREX

The products obtained on average (depending on the characteristics of the incoming mixed waste) are approximately,
- Dry fraction: about 40-45 %
- Wet fraction: about 50-55 %

Principal of operation

Mixed waste is subjected to high pressure (~ 250 to 300 bar) in a perforated extrusion chamber, due to which, the organic parts (food waste and fermentable material) become a pulp and is extracted from the rest of the material, which are mechanically more resistant (paper, cardboard, plastics, rubber, metals, inert, etc.)

Extrusion chamber

Process Steps

The main hydraulic cylinder feeds the incoming mixed waste from the feeding hopper into the extrusion chamber presses it at high pressure. While the organic fraction is extracted from the extrusion chamber in a pulp form, the residual material / dry inorganic material is pushed out from the extrusion chamber.

The complete process has three distinct phases:
1. The feeding phase,
2. The compression phase
3. The expulsion phase.

1. Feed phase:

The main cylinder feeds the incoming mixed waste from the feeding hopper into the extrusion chamber. The output gate is kept closed at this stage.

2. Compression phase:

The main cylinder presses the waste at 280 bar against the closed gate, as the pressure inside the extrusion chamber is much higher than the outside pressure, the organics (90 to 95%) fraction is totally pulped and extracted. The cellular matrix is ruptured and mixed with the cellular moisture contained within the cell mass. This wet fraction is collected and can be conveyed using a screw auger or a conveyor. into a bio-methanation fermenter to generate biogas and electricity. The dry, inorganic, residual fraction along with cellulosic material remains inside the extrusion chamber and is expulsed in the next step.

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Wet fraction being conveyed using screw conveyor into the fermenter

3. Expulsion phase:

After the compression phase is finished a front door/gate opens and the main cylinder evacuates the dry, inorganic fraction from the extrusion chamber, on a conveyor belt. The dry fraction is an excellent source of RDF, which can be used for Co-Processing in cement plants after minimum cleaning in a RDF line or can also be used in a waste to energy incineration plant.

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RDF being transported on the Conveyor belt to the RDF line.     RDF line comprising Flip flow screen and wind sifter.

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