The ConVerTec Process

 The basic premise of ETA’s ConVerTec system is that MSW (Municipal Solid Waste), green waste, and tires are a resource, not a problem. By creatively transforming “waste” into valuable products, we can effectively reduce the planet’s consumption of non-renewable resources. ConVerTec is PAID to take its raw materials as well as generating income from the sale of it’s end products. 

The ConVerTec process creates no pollution – nothing to be burned or buried. All of the material that goes in is incorporated in the process. The ConVerTec process does not currently address toxic waste (we have identified and are preparing for introduction of systems that will process toxic waste) It does convert what was waste to a variety of valuable resources in an environmentally sound and economically profitable manner. The first patent on the “recycling” of MSW has been awarded with numerous additional patents following. Foreign patent protection has also been filed.  

There are two primary machines that accomplish this task. The first is called TYCON, which consumes rubber tires at a rate of 10-800+ per hour (depending on the size of the unit). In a patented process that includes “devulcanization,” the tires are reduced to their original elements. These elements, Bunker Grade Oil #6, fuel gas (which is converted into electricity), conductive carbon black and high grade stainless steel are then available for sale and use. As an integrated system, TYCON produces enough power for the Tycon unit and Dura-Build and the balance is then available for sale to local utilities as a fully recycled source of energy. The following projections for a 300 TPH (tire per hour) plant would produce   

273,825,640 cu. ft. of 1200 btu Fuel Gas per year AFTER plant use;  

36,752 barrels of Bunker Grade Fuel Oil #6;  

19,584,000 pounds of N700 Carbon Black 

2,448 tons of Stainless Steel.

The second machine, called Dura-Build, is a combination of modular components that consume almost all waste that would otherwise be landfilled or burned. The process sorts out the unwanted recyclable material, which is forwarded and sold to the appropriate recycler. The rest is chopped to < 1/8” particles, and sterilized at which time it is used as a filler with an industrial polymer. This mixture is then fed through a screw, press, and extrusion processes. The end result is a product that can be designed to the specification of the end user.

Anything from 2x4’s and plywood to fencing materials and a huge variety of other useful products. The shape, size and configuration of the extrusion die or injection mold can be designed to fit the end user’s greatest market needs. Using the following projections for a

100 TPD (ton per day) plant, Dura-Build produces 

3,777,781 cubic feet of building material in various profiles 

2,720 tons of Compost; 

680 tons of Recycled Glass; 

816 tons of Scrap Steel

680 tons of Recycled Aluminum in a given year.

These figures will vary to a certain extent, of course, depending on the composition of the waste stream.

The end products from this ConVerTec system are designed to serve three major industries:

1)          Energy

2)          Agriculture and

3)          Construction and Building Products.

The versatility of the ConVerTec system (both Dura-Build and TYCON together) is summarized on the following chart. Depending upon the type of waste (listed in column A), one or more processing options are employed (as shown in column B. The end result is the manufacturing of various types of products, each with the characteristics required by the end-user (as seen in column C).    

   
  The determination of which end products to manufacture will be made by a combination of an analysis of the local waste stream and a knowledge of the market driven demand for products. A sophisticated computer system is pre-programmed with recipes to match the specifications of the desired end product. If the end product is to be 2x4’s, then that would be programmed in and the polymer (correct color, strength, UV resistance and other properties) is added as specified. The die through which the material is extruded is designed for whatever size and shape are desired. Waste stream lumber can be produced at almost half of the cost of traditional lumber, which also benefits the Earth by reducing the use of virgin materials. ETA is not a manufacturer of machine parts. Well-established and specialized corporations manufacture all of the component parts that make up both Dura-Build and TYCON. ETA specifies the equipment that is then ordered and drop-shipped directly to the facility site for assembly. Most of these component parts have been used for years in industry and are proven to perform their required tasks. It is the innovative and unique configurations of these component parts that produce the magic of ConVerTec. It is also relatively easy to change the size of the facility by adjusting only those parts that are affected by volume. While ConVerTec plants are designed to produce standard products they can also easily be custom designed for the specific waste stream content and product requirements of the particular customer or market.