Powerhouse’s Thermal Conversion Chamber (TCC) is a proprietary gasification device for converting waste streams (e.g. non-recyclable plastics, tyres) into syngas. The aim of this project was to model in detail the internal processes of the TCC, optimise components, and develop a new outlet duct (deflector) at the point of syngas / char separation to improve performance and longevity.
Our work included combustion modelling, multiphase flow (gas, syngas, char) heat transfer, and specifically the inclusion of rotating fins inside the chamber to aid mixing, heat transfer, and movement of char. Using CFD simulations, we examined temperature fields, flow paths, char deposition zones, and syngas trajectories. We then designed and optimised the outlet duct (deflector) to reduce blockages, improve separation, and maintain syngas quality and throughput.
Powerhouse have since incorporated our recommended deflector duct as part of their patented TCC device. We worked with the client through all stages from initial modelling, design iteration, through to support for fabrication and ensuring that the simulation findings translated into an operational improvement.