PRODUCT/PROCESS DEVELOPMENT

With broad ranging capabilities in project planning, Integrated Materials Analysis, Computerized Process Modeling, and plant design, construction, and operation, PMET offers a complete range of product and process support services that assist clients to develop ideas from concept through commercialization. Services offered include:
  • conceptual analysis

  • bench-scale experimentation

  • process modeling

  • feasibility studies

  • economic analysis

  • pilot plant design, construction
    and operation

  • process/product optimization

  • production plant design

  • start-up & operational support
Pilot-scale projects may be performed on-site or at PMET's facility in New Brighton, Pennsylvania. Recent projects for which PMET has provided pilot equipment design, construction, operation, and demonstration services have included the production of high purity, ultra-fine tungsten carbide high purity magnesium sulfate from flue gas desulfurization sludge metallic magnesium from industrial wastes low-cost hydrogen from petroleum coke and other low-cost carbonaceous materials, as well as utilization of PMET's Ash Utilization Pilot Facilities to evaluate ashes and generate commercially viable ash-based and carbon-based products.



LOW-COST HYDROGEN

PMET's Hydrogen Pilot Plant was designed and constructed to prove the technical and economic feasibility of Alchemix Corporation's process (patent pending) for the production of low-cost pure hydrogen and methane from coal, petroleum coke, and other carbonaceous feedstocks. This technology, which produces hydrogen from only coal and steam, has been successfully demonstrated on a pilot scale and is currently undergoing beta testing. The process utilizes off-the-shelf technology and equipment to:

  • produce pure hydrogen and products based upon hydrogen

  • produce methane via chemical reductions of hydrocarbons in a hydrogen atmosphere

  • produce electricity from methane produced by hyrogenation

  • produce feedstock for the production of ammonia and methanol

  • eliminate landfill disposal of coal combustion wastes


PMET's Hydrogen Demonstration Plant




PMET'S PILOT PLANTS

PMET's in-house pilot operations offer clients the opportunity to evaluate alternative methods of recovering value from industrial by-products and industrial wastes, optimize processing conditions, determine product properties and characteristics, and finalize equipment specifications for full-scale operation, whle eliminating the need to perform experimentation on a full production scale.




MERCURY REMOVAL/RECOVERY

The mercury pilot unit is a scaled-down version of PMET's 2-ton capacity mobile and fixed-site modular production units operated by PMET licensees in England, and Germany to remove and recovery mercury from contaminated soils, debris, industrial wastes, and mercury-containing products. The unit consists of a nominal 250-pound capacity furnace controlled for two stage heating, an air handling and purification circuit for removing water emitted during the low temperature heating stage, a condenser for recovering mercury released during the high temperature heating stage, and a multistage carbon filtration system for removing traces of mercury from the process effluent. The unit is totally enclosed in a secondary containment chamber for added worker and environmental safety.




BRIXX� PILOT PLANT

PMET's pilot facility for the manufacture of structural building products (Brixx) for coal combustion fly ash and bottom ash is designed to produce full-size brick, block, and paver products. The flexibility of the plant makes it especially useful in comparing ash compositions, optimizing product chemistry and process parameters, and producing product for acceptance testing and field trials. The plant is capable of:

  • compacting single or multiple Brixx in sizes up to 8" x 8" x 4"

  • producing hollow, shaped, and interlocking Brixx

  • hydrothermally forming up to 3 tons per day of Brixx under a wide range of conditions.


Brixx Compacting Press




FLY ASH/CARBON SEPARATION

PMET's fly ash/carbon separation pilot facility is used to assist power plant operators, ash distributors, and other companies interested in converting coal combustion fly ash from a landfilled waste to a salable product. The facility include alternative means of grinding the ash in order to liberate adhered and entrapped carbon and separating the liberated ash and carbon particles into a low-carbon fly ash product for use as a substitute for Portland Cement and carbon-rich products for use in pigments, sorbents, fillers, and fuel additives.

  • Grinding

    • Jet Mill Autogenous Grinding

    • Mechanical Grinding

      • Ball Mill

      • Rod Mill

      • Atrritor Mill

  • Separation

    • Air Classification

    • Screening

    • Electrostatic Separation


PMET's Hosokawa AFG-100 Jet Mill


COMPUTERIZED PROCESS MODELING

PMET's state-of-the-art process modeling capability dramatically reduces the time, cost, and experimentation required for process optimization. By efficiently modeling the whole process, individual unit operations in the process flow diagram can be examined, altered, and optimized, and mass and heat balances can be determined in a matter of hours rather than days. Using these process models, PMET is able to (a) quickly evaluate the effect of variations in a wide range of processing conditions, such as reaction rates and equilibria, process temperature, feed rates, environmental heat loss, etc., and (b) determine the interactions among variables and the importance and overall effect on the process of each variable and combinations thereof. This is especially important in determining the extent to which each variable affects unit operation requirements, feed requirements, and product and by-product yields.

Computerized Process Modeling has been used effectively in supporting PMET's in-house development programs and assisting clients in optimizing both existing and planned production operations.






ON-SITE PROCESS DEVELOPMENT & TROUBLESHOOTING

PMET offers a wide range of on-site process development, engineering, optimization, and trouble shooting services in the fields of materials processing, waste minimization, by-product utilization, environmentally-sound operation, and raw material and operational cost reduction. With back-up from our experienced engineering and laboratory staffs, our on-site consulting and project management personnel offer services in the areas of :

  • Acidic Reactors

  • Alkaline Reactors

  • Calcination

  • Crystallization

  • Dewatering

  • Drying
  • Excavation

  • Filtration

  • Grinding

  • Ion Exchange

  • Leaching

  • Precipitation
  • Heat Exchange & Recovery

  • Materials Sampling

  • Metal Fabrication

  • Solvent Extraction/Recovery

  • Waste Water Treatment