© VICA Business & Financial Services Inc. 2010. All rights reserved.
The products from our power plants are a
result of the following processes and include:
  • Electricity
  • Steam
  • Recycled metals
  • Compost
  • Glass building materials or
    aggregates for road construction
Combined cycle power generation

The traditional approach to the thermal production of electric energy has been to
combust the fuel in a boiler to produce steam which is then passed to a

The Combined Cycle approach involves the combustion of the fuel in an internal
combustion machine such as an Otto cycle piston device or a gas turbine.  The hot
exhaust gas exiting from the internal combustion stage then is passed through a Heat
Recovery Steam Generator (HRSG) to produce steam which is sent to a steam turbine
to produce additional electric energy.   

As a result of the two stage approach, greater efficiency of conversion of the heat value
of the fuel into electric energy than is possible with the simple use of the steam cycle.  
Ash Vitrification   

This is the process of melting the resulting ash so as to achieve physical properties similar to obsidian or other natural glass.
Occasionally it is necessary to add certain low cost materials to optimize the chemical composition.   

Most of the glass that is produced is of the soda-lime-silica type that is normally made from a mixture of sand, soda ash and
carbonates of calcium and/or magnesium. The combination of bottom and fly ash along with the Air Pollution Control (APC)
gatherings usually have an average composition which can make a good glass. If required, the composition can be benefited by the
addition of low cost materials such as sand or limestone. As a result, the material produced is useful for the making of building
materials. The means to take a good molten glass and produce specific shapes is well worked out and available off the shelf.

The gasification process creates a Synthesis Gas (Syngas) in the gasifiers which then passes to the cleaning stage where sulfur,
chlorine, heavy metals and other harmful species will be removed.  The clean syngas then passes to the first stage of the combined
cycle power generation where it is combusted to drive a gas turbo-alternator.  The gas emerging from the gas turbine then enter a Heat
Recovery Steam Generator where steam is made.  The steam then goes to a steam turbo-alternator to produce additional power.   

The gas exiting the HRSG then passes to a cleaning stage where any remaining pollutants are removed prior to its release to the
environment.   The melted inorganic fraction (slag) exiting the gasifier is quenched in water and conveyed to a bunker it is removed and
transported to the concrete block manufacturing area to be used as aggregate.   

The sludge from the cleaning of the syngas and the gathering from the final stage of gas cleaning after the HRSG are sent to the
blending area where they become part of the infeed to the gasifiers ultimately becoming part of the slag.

Edit Text  
The slag and cleaned and sized inorganics are sent to the concrete block manufacturing area where they are mixed with Portland
cement to form high quality standard 190x190/390 mm construction blocks.
VICA ENERGY COMPLEX Overall Process Flow
A very important aspect, which must be taken into account in the design of thermal waste processing facilities, is that the data
regarding the quantity and composition of the wastes, taken as the initial design data, may change significantly and may fluctuate
during the operating period.  These circumstances raise the requirement at the design stage for provision of sufficient flexibility of
the technological processing system and its equipment makeup to compensate for the possible variations in the quantity and
composition of the wastes to be processed.  At the same time all regulatory requirements for protection of the surrounding
environment must be fully satisfied.  The above considerations were included in the basis of the design of the ENERGY COMPLEX.

The Complex has no liquid discharge, no sludge and no solid waste to dispose of in a landfill.  All waste entering the facility is
converted to useful commercial product. The technology converts 100% of the waste into useful product leaving no residue to be
buried in landfills.  Waste is converted to steam, electricity, vitrified building products and other commercial commodities,
depending on local market needs and on the composition of the waste  

The stack gas emissions  complies with European regulations namely “EC Directive 76/2000” and US EPA standards.  The
Process is enclosed in a building so as to prevent the escape of odors or dust.  Combustion air for the gas turbines is drawn from
the waste storage area so as to maintain sub-ambient (negative) pressure thereby destroying any odor or fumes from originating
from the waste. The noise level is 75 decibels or less at the property line.
Rendering (left) and Photograph of IGCC Plants Using Siemens Gas Turbines
Send us email
4155 Lancaster Avenue   Philadelphia   PA 19104   Tel: 1-215-386-8140    Fax: 1-215-386-8190
VICA ENERGY COMPLEX Overall Process Flow