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How Today's Waste
Becomes Tomorrow's Resources

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The Gate 5 Energy System (G5ES)

The Energy System

The G5ES is an innovative integration of sustainable management of residuals with on-site energy production that runs without using any fossil or other fuels, on (self-sustaining) energy recovered solely from these combusted residuals. The patented Gate 5 technology will efficiently transform 100% of these residuals into valuable by-products: renewable electrical and thermal energy, clean water, and ash. The process employs a circular drier with no internal moving parts that dries and pulverizes the residuals into a powdered biofuel; followed by a conventional combustion system, adapted from the coal industry for steam generation; and a turbine for electric power production.

The G5ES is simpler to operate and maintain and more efficient than competitive practices (incineration, anaerobic digestion, thermal hydrolysis, gasification, or pyrolysis). The entire process is designed for optimal energy recovery: in certain areas solar water heating can be economically employed to increase steam and energy production and, in some cases, the addition of FOG (fats, oil, and grease) or brine waste to the feedstock will be beneficial.

Self-sustaining and energy positive, the G5ES can be scaled to process the residuals generated by a community’s WWTP, food processing plant, food waste disposal facility, feedlot, or dairy operation thereby enabling these facilities to avoid the rising costs, environmental risks, and increasing regulation attributable to processing, managing, transporting, and disposal of their residuals. Excess sustainable power generated by the G5ES can be used on site by Gate 5's customers.

How the Gate 5 Energy System Works at a Wastewater Treatment Plant

The system diagram and text below illustrates and describes the four key G5ES operational stages of the Gate 5 process. The G5ES is an innovative yet straightforward process for transforming sewage sludge, manure, and food wastes (residuals) into energy and keeping these residuals out of the environment. While innovative, the G5ES employs only well-proven subsystems for drying and combusting these residuals with more efficient energy recovery and without the technology risk associated with many other innovative energy recovery and waste reduction systems that have yet to succeed in the marketplace. The diagram illustrates a G5ES treating biosolids at a WWTP employing anaerobic digestion. However, the preferred feedstock for the G5ES would be primary sludge/WAS, which would produce significantly more sustainable energy than biosolids because of its higher latent energy content (~ 2x). The G5ES can easily be configured to operate on primary and waste activated sludge (WAS) alone, or in combination with other residuals.

The G5ES can also be configured to run on primary sludge/WAS and without digester gas.


  • A live-bottom silo, sized to provide adequate volume of material so the G5ES can produce renewable energy and operate on a 24/7 basis holds the feedstock
  • Screening of feedstock as it enters the silo keep oversized and “trash-like” material from the G5ES (not used with biosolids)
  • A screw-drive delivery system will prevent the feedstock from being compacted into a cake-like material that would be difficult to dry


  • The flash/ring dryer utilized in the G5ES has no moving parts and is capable of continuously producing biofuel from dewatered sewage sludge, biosolids, food waste or manure [1]
  • Moist high-temperature (<600 F) drying gas absorbs the moisture in the feedstock and particles collide to pulverize the feedstock into a finely powdered and dried biofuel that is delivered to the energy recovery cycle
  • A gas-solids separator and cyclone equipment processes the post-dryer vapor into usable distilled water (<200 gallons per ton) from the prepared feedstock.
  • The drying gas is reheated in the boiler; mixed with combusted waste heat from the boiler (see below); and then circulated back to the dryer (Waste heat from the drying cycle may also be used to heat a WWTP digester, thereby saving a WWTP the need for a separate digester heating system)

Energy Recovery

  • 100-percent of biofuel produced from the drying cycle is combusted at a temperature >2,000o F in a biomass boiler (assuring complete destruction of all organics in the residuals)
  • Steam heated by the combusted biofuel is utilized in a turbine to produce the power to run the G5ES and, in cases where there is not sufficient waste heat for the drying process, to heat the drying gas
  • Combusted air is cleaned by separating the remaining inert ash and water from the air and scrubbing the air with pollution control equipment to meet applicable air quality standards before it is discharged [2]
  • Ash is the inert solid that remains after the combustion of the biofuel and also includes the non-volatile inorganics material that was in the system’s feedstock [3]

Sustainable Power Production

  • A steam turbine, and in some cases an organic Rankine cycle (ORC) turbine, will run on heat produced in the G5ES boiler
  • Solar heat collectors installed on the G5ES canopy can increase renewable power production by between 200 kW and 300 kW where project size and the particular location and microclimate will justify the additional expense
  • The waste heat from the turbine(s) can be used to heat the digesters as well as satisfy other heated water needs of the customer or community
  • G5ESs configured to run with anaerobic digested sludge (biosolids) and digester gas are estimated to produce gross and surplus renewable energy production as follows:

Renewable Energy Production

[1] The Company has exclusive industry rights to this highly efficient and proven equipment that has been utilized for more than 50 years to effectively dry and mill a wide range of organic and synthetic materials and products. Gate 5 has successfully dried hundreds of pounds of biosolids and manure to confirm its applicability for the G5ES.

[2] By way of an example, in a design for a system running on biosolids that was approved by South Coast Air Quality Management District, the boiler will be equipped with a wet scrubber, a baghouse, selective catalytic reduction (SCR), and an oxidation catalyst. The wet scrubber and baghouse will control metal and some organic toxic air contaminants (TAC) emissions and the oxidation catalyst will control (dioxin/furan and other) TAC emissions. Ammonia emissions are expected from incomplete reactions of NOx and the reactant in the SCR.

[3] This inert ash, which is no more than six percent of the volume of the G5ES’s feedstock, is marketable as an asphalt or concrete additive or can be further processed for some of its component compounds (N and P, for example), or alternately, can be safely buried.