The Alphakat Technology ( Technology) is a new technology in the Energy

sector, which ensures:

✓ Breakthrough in energy conversion

✓ Economical Energy Production

✓ Environmentally friendly methods

✓ Safety during operation

✓ Easy handling and treatment

✓ Use of waste with biomass content and renewable resources as feedstock

✓ A satisfactory financial return

The facts:

➢ Crude oil reserves are continuously reduced

(production in 2025 will be only 33% of demand)

➢ Notwithstanding cyclical fluctuations, the price

of crude oil is moving upwards. If price collapse
emerges the market coverage will be about 25%.
As a result the following trends on use of fuels are under consideration:

➢ Efforts are made worldwide to produce fuels that can substitute natural
crude oil, petrol or diesel oil production. Alternative fuels such as biomass
are presently in use.

➢ The emphasis is on Low Cost Technologies that can produce petrol or

diesel without toxic airborne or solid residue emissions.

➢ Emphasis is also on Technologies that can produce fuels in a short period

of time (minutes rather than hours).

THE BEST APPROACH TO THE ABOVE IS KDV_ALPHAKAT

(based on the catalytic de-polymerization developed by Dr. Koch)
 The Alphakat Technology is based on the de-polymerization process,
which through the passage of thousands and thousands of years resulted
in the production of crude oil:

Pressure
Polymers of organic matter Petroleum HCs (short chain c-18)
Heat

In order to achieve this result in a matter of minutes,, rather than thousands

of years, Alphakat invented the catalytic de-polymerization technology, based
on the effectiveness of the process whereby :

✓ The de-polymerization reaction is effected at a much lower temperature and

pressure levels within and very close to the atmospheric range.

✓ The ion exchange catalyst is such that it cracks down the HC molecule.

✓ The temperature required is between 270 to 350 degrees Celsius and, as a

result, the production of CO2, dioxins and furans is avoided.

✓ Perfect de-polymerization is achieved through proper mixing of the catalyst

and the feedstock.
MAIN CHARACTERISTICS OF THE CATALYST AND THE PROCESS:

➢ Ion exchange type Catalyst

➢ Process holds halogens (chlorine and fluorine), phosphates, Nitrogen and

Heavy Metals, transforming them into inorganic salts within the raw
material.

➢ The process leads to the conversion of 85% of the HCs of the input
materials into valuable fuel.

➢ The process is very low in maintenance cost, reliable and very safe.

➢ The energy demand for the process in Heat and Power is supplied by the
operation of a CHP (combined Heat and Power) plant which consumes only
10% of the diesel fuel produced by the KDV process unit.
Operating conditions (parameters & products);

Parameters Products

Operating temperature 270-350 oC High output >85% of input HCs

Ion exchange catalyst Fixation of hazardous matter into salts

100% crystalline y-catalyst High grade standard diesel fuel

Why is the hydrogenation process very effective:

✓ Hydrogenation is effected under pressureless conditions and without the

use of gaseous Hydrogen at high pressures (90 bar)

✓ No Nickel catalyst is used because the catalyst effect is achieved from the
minerals existing in the biomass of the raw materials (Ca-Al-Si).

✓ The required temperature of 300 oC is achieved NOT by external heating

media but through a FRICTION turbine (turbine mixing the raw materials in
the mixing chamber).
What happens during the process:
❖ The catalyst is already present in the biomass content of the raw materials.

❖ The quantity of catalyst ranges from 5 to 20%, depending on the type of

raw material.

❖ The biomass destruction during the process produces CELLULOSE and

SUGAR (formulae C6H11O5 and C6H12O6 respectively). These have the
following ingredients:

Cellulose ======== 2.5 CO2 + 3.5(CH2)n + 4H

Sugar =========== 3.0 CO2 + 3.0(CH2)n + 6H

❖ The 4H and the 6H are the basic elements that facilitate the hydrogenation
of the raw materials at slight sub-ambient pressure at the temperature of
300 degrees Celsius. Hydrocarbon materials like olefins, plastics, oil,
rubber, bitumen are hydrogenated. This is a chemical reaction and not
thermal splitting pyrolysis or thermal destruction.

❖ A fuel, free of ammonium, dioxin, furans and light components is

produced.
What happens during the process:

❖ What takes place in the process is exactly what nature has been exerting to
the minerals under the earth for years, resulting in the production of crude
oil.

❖ The catalyst’s life time can be unlimited when some lime is added to the
system’s mixing chamber to keep the ph > 8.5.

❖ The catalyst, therefore, can be supplied as a Ca-AL-Si matter in silicate or

sodium Aluminate synthetic form (a patented product supplied by Alphakat
and Partners, when no biomass is present in the raw mix) OR through the
biomass present in the raw mix with some lime addition to the system.

❖ The ash produced is a good catalyst for industrial and municipal waste
plants and can be used to reduce or remove completely the CO2 and SO2.

❖ The product diesel is unique and of very high grade EN590 with saturated
hydrocarbons produced at slight sub-ambient pressure conditions (0.9
bar), thereby achieving inherent safety.

❖ No emissions are attributed to the Plant and the whole operation is

odorless.
Plant diagram and
modules

1 - Sludge plant for the feedstock preparation

2 - KDV main core for the sludge conversion
3- Ash plant for the inorganics extraction
4 - Genset module-optional (Generators and heat
: exchangers
5 - Desulphurization module for sulphur extraction
Summary of the main plant features:

❖ Plant is self supporting in Heat and Power (electrical needs).

❖ Plant is emission free. Only the CHP unit emits from its diesel engines.

❖ There is a permanent slight negative pressure inside the Plant, with the
necessary safety disconnection valve.

❖ No possible spills reach the soil.

❖ The process reaction is effected in a friction turbine and takes place in

emulsion (oil + catalyst) in a processing loop (recirculation) with topping
up control.

❖ The Plant can utilize all types of burnable waste as well as crude oil and
brown coal.

❖ The Plant is secured in emergency by cutting off the process followed by

very quick cooling and rinsing the circuits with oil to prevent any blockage
due to plastic cooling solidification.

❖ Start-up procedure to reach the temperature of 300 0C takes only 45mins

TECHNOLOGY PARTS:

➢ Sludge plant

➢ Ash handling plant

➢ Turbine plant

➢ Refinery-Condensing plant

➢ Power generation plant

A DEMO PLANT OPERATES IN EPPENDORF GERMANY

A major breakthrough in the design is that, nowadays following extensive

design review, piping is hidden and as a result the plant’s view is very
attractive and does not scare the viewer looking at complicated systems
(public-visitors mainly).
FINANCIAL ISSUES:
Input material and cost:

In addition to crude oil and coal, the Plant can also utilize all types of
burnable waste, preferably with 10-20% biomass content, to produce high
grade diesel. Such waste is normally a source of income from the gate fee
which can be collected. In any case the cost of raw material is very low or
even negative ( in other words an earning).

Business model:

The business model is flexible. The investor can choose between the
production of power (electricity) production from the diesel produced or its
use as a fuel for automotive transportation. This can sometimes depend on
the local (each country’s) conditions and legislation (eg. taxes etc).

Feasibility study:

The feasibility study differs from plant to plant due to local conditions and
characteristics (eg. Cost of land, need for CSR etc.). It is though certain that
the production cost of diesel will be in the range of 23 to 25 euro cents per
litre and the pay back period will be around 4 years and will not exceed 5
years.
FAQ (Frequently asked questions):

What raw materials can be converted by KDV system into diesel?

✓ All organic matter (biomass C3 and C4), wood, biogenous residues

(leaves, straw etc.).
✓ Waste oils, refinery residues, bitumen etc.
✓ All kinds of plastic and synthetic materials (PVC, PP, PET, PE etc)
✓ Municipal solid waste and industrial waste.
✓ Crude oil.
✓ Brown coal.

What are the advantages of KDV Vs ethanol & biodiesel production?

✓ KDV maximizes land utilization ( to produce ethanol or biodiesel the

energy yield per acre is 5 times and 4 times respectively lower to the yield
of KDV process).
✓ No food or fuel grade off – Can convert into KDV-Diesel a wide variety of
feed stocks including MSW, agricultural waste, (straw husk, bagasse) and
grown energy sources like jatropha and other vegetations.
✓ KDV is economical – Can achieve and enjoy a 42% per unit enrgy cost
advantage over ethanol and 51% over bio-diesel.
FAQ (Frequently asked questions):

What are the advantages of KDV Vs ethanol & biodiesel production?

✓ Can achieve immediate market acceptance - Cost effective and universally

usable, requiring no new infra-structure investment. It is compatible with
existing engines, pipelines and fuel pumps.
✓ The catalyst cannot fail – It is much more effective to produce fuels and
petrochemicals utilizing cellulosic biomass than fermentation methods.
✓ KDV is carbon neutral – the process
also produces a net gain in energy
recaptured. It helps reducing the
greenhouse phenomenon.

ambient air CO2 concentration chart

What is the quality of the KDV produced diesel?
Cetane approx. 59
Density (150C) 830 kgs/[Link]
Kinematic visc.(400C) 3.2 cst
Flash point 570C
Sulphur content from zero to higher depending on RM
Lubricity around 255
FAQ (Frequently asked questions):
What are the benefits of high cetane index fuels?

➢ Fuels have faster burning

➢ Fuels are spontaneously ignited in the combustion chamber
➢ No unburned fuel is left (like the case of turbo charging systems)

What are the benefits of Low Sulphur fuels?

➢ Lower sulphur results in Lower PM10 and PM2.5 (particulate matter)

➢ Lower sulphur results in lower emission of sulphur oxides which together
with water form sulphuric acid, which is responsible for acid rain,
ecological damages and corrosive wear of engine piston rings.

How does normal desulphurization process works?

➢ Sulphur comes from benzo and di-benzothiophene substances. These are

broken down by reacting the gas oil with hydrogen at the presence of
Nickel catalyst under high temperature and pressure. In such a
desulphurization, the aromatics are removed and the N and O substances
that give good lubricity of the diesel are reduced, resulting in the injection
pump moving parts being affected or blocked. KDV has no such problem.
FAQ (Frequently asked questions):

How about patents?

➢ KDV is protected by many patents

➢ Patents exist both for the technology as well as the catalyst
➢ The following patents are the major ones out of a large list

Patent DE 102005 from 29.11.2005

Patent DE 102006 from 17.11.2006
Patent EP 1798274A1 (European registry)
Patent WO 2007062811A3 (Worldwide registry)

What are air emissions produced by the KDV process?

➢ All burnable gas (synthesis gas) is sucked by the vacuum pumps, that
create light under pressure in the system, and sent to the air supply duct
of the electricity generating set’s engine. So no chimney exists for the KDV
plant.
Development of the invention:

1998/1999 Pilot plant in Puchan, Korea

2000 Pilot Plant at Neuensalz, Germany
2004 KDV 500 first industrial plant in Monterrey, Mexico
2005 KDV development of the turbine reactor
2007 KDV500 plant in Bulgaria
2007 KDV500 plant in Ontario,Canada
2008 Industrial KDV 500 demo plant for diverse material testing in Hoyerswerda,
Germany.

2009 Industrial plant in Tarragona, Spain KDV1000

2009 Design of the first KDV large system KDV 5000
2010 Full installation of the KDV500 industrial plant in Massachusetts
2010 Development of the MDS (Multiple Dynamic Sealing) turbine reactor
2010 Design of the first KDV small system KDV150
2010 Startup of the first KDV150 in Eppendorf, Germany
2012 Construction of the first KDV150 in Bari, Italy
2012 Construction of the first KDV150 in Ethiopia, Africa
2012 Construction of the first KDV1000 "Compact" in Poland
Problems with Municipal Solid waste
Massive amounts of urban and industrial waste
Necessity to recycle and minimize environmental
impact and hazards
High cost of managing Recycling programs
Inefficiency of Recycling programs

Current solutions
Incineration
• Obsolete
Landfill
• Obsolete
Recycling – Separation at source
• Inefficient – High Cost
Recycling – Separation at the factory
• More efficient – High Cost
Recycling – Automated separation at the factory
• Higher Efficiency – Higher Cost
Process
PRODUCTION
INPUT • 1.2 tns mass = 500Kg
• MSW (municipal solid Synthetic Fuel
waste) • No Chimneys
• All Plastics • No Pollution
• Animal waste • No Furans
• Mineral oils • No Dioxins
• Sewage Sludge • No Heat
• Agricultural waste
• Biomass Cultivated
OUTPUT
WASTE TREATMENT • SYNTHETIC FUEL
(shredding,separation) • FUEL DIESEL QUALITY
• Separate Glass/Metal • Cetane number : 65
• Create Feedstock • Freezing point : -20 oC
• Particle Size : 25mm • ASH
• Humidity: 20% • Fertilizer
• Inorganics: 5% • Construction Raw Material
Synopsis
-- Zero Environmental Impact

-- 100% Recycling

-- Revenue Generating

-- Positive Income for Municipalities and Operators

-- Waste to Fuel conversion

 THANK YOU

FOR

YOUR ATTENTION

Ready to answer any queries