BAT Incineration

8/14/2019 BAT Incineration

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Environmentally SoundEnvironmentally Sound

Destruction of POPs Destruction of POPs

Incinerationncineration

Kre Helge KarstensenKre Helge Karstensen


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Technology descriptionTechnology descriptionHigh temperature hazardous waste incineratorsHigh temperature hazardous waste incineratorsare available in a number of configurations andare available in a number of configurations and

principles.principles.

Typically a process for treatment involvesTypically a process for treatment involvesheating to a temperature greater than 850C or,heating to a temperature greater than 850C or,

if the chlorine content is above 1 %, greaterif the chlorine content is above 1 %, greater

than 1,100 C, with a residence time greaterthan 1,100 C, with a residence time greaterthan 2 seconds, under conditions that assurethan 2 seconds, under conditions that assure

appropriate mixing and subsequent destruction.appropriate mixing and subsequent destruction.


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Dedicated hazardous waste incinerator


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Temperature & residence timeTemperature & residence time

Combustion temperature and residence time needed for mixedCombustion temperature and residence time needed for mixed

hazardous wastes cannot be readily calculated and are oftenhazardous wastes cannot be readily calculated and are often

determined empirically. Some common solvents such asdetermined empirically. Some common solvents such as

alcohols and toluene can easily be combusted atalcohols and toluene can easily be combusted at

temperatures less than 1,000oC and less than one secondtemperatures less than 1,000oC and less than one secondresidence time, while other more complex organic halogensresidence time, while other more complex organic halogens

require more stringent conditions.require more stringent conditions.


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...more complex organicmore complex organic

halogens such as PCBhalogens such as PCB

requiresrequires 12001200ooC and 2C and 2

secondsseconds residence time residence time

US EPA Toxic Substances ControlUS EPA Toxic Substances Control

Act (TSCA) PCB Incineration CriteriaAct (TSCA) PCB Incineration Criteria

A DRE of 99.9999% is required by TSCA for the incineration of PCBsA DRE of 99.9999% is required by TSCA for the incineration of PCBs


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...if more than 1 % of halogenated...if more than 1 % of halogenated

organic substances, expressed asorganic substances, expressed as

chlorine, are incinerated, thechlorine, are incinerated, thetemperature has to be raised totemperature has to be raised to

minimumminimum 1100C during at1100C during atleast two secondsleast two seconds..

EU Directive 2000/76/EC on Incineration of Waste regulatesEU Directive 2000/76/EC on Incineration of Waste regulates

Co-incineration of Hazardous Waste in Cement KilnsCo-incineration of Hazardous Waste in Cement Kilns


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Technology descriptionTechnology description

Hazardous waste is normally incinerated in two types of facilities:Hazardous waste is normally incinerated in two types of facilities:

merchant plants who accept different types of waste for disposal; andmerchant plants who accept different types of waste for disposal; and

dedicated incinerators that handle a particular waste stream. Andedicated incinerators that handle a particular waste stream. An

example of the latter might be a chemical manufacturing plantexample of the latter might be a chemical manufacturing plant

treating chlorinated wastes to recover HCl.treating chlorinated wastes to recover HCl.The most common combustion technology in hazardous wasteThe most common combustion technology in hazardous waste

incineration is the rotary kiln. Facilities in the merchant sector rangeincineration is the rotary kiln. Facilities in the merchant sector range

in size from 30,000 to 100,000 tons/year throughput. Dedicatedin size from 30,000 to 100,000 tons/year throughput. Dedicated

hazardous waste incinerators use a variety of incineration, pyrolysis,hazardous waste incinerators use a variety of incineration, pyrolysis,and plasma treatment techniques.and plasma treatment techniques.

Similar to the incineration of municipal solid waste, hazardous wasteSimilar to the incineration of municipal solid waste, hazardous waste

incineration offers the benefits of volume reduction and energyincineration offers the benefits of volume reduction and energy

recovery.recovery.


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Dedicated hazardous waste incinerator for treating liquid and

gaseous chlorinated wastes at a chlorinated chemical

manufacturing facility


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Technology descriptionTechnology description In Rotary kilns solid, sludge, containerized orIn Rotary kilns solid, sludge, containerized or

pumpable waste is introduced at the upper end of thepumpable waste is introduced at the upper end of the

inclined drum. Temperatures in the kiln usually rangeinclined drum. Temperatures in the kiln usually range

between 850 and 1300C. The slow rotation of the drumbetween 850 and 1300C. The slow rotation of the drum

allows a residence time of 30-90 minutes.allows a residence time of 30-90 minutes. The secondary combustion chamber following theThe secondary combustion chamber following the

kiln completes the oxidation of the combustion gases.kiln completes the oxidation of the combustion gases.

Liquid wastes and/or auxiliary fuels may be injected hereLiquid wastes and/or auxiliary fuels may be injected here

along with secondary air to maintain a minimum residencealong with secondary air to maintain a minimum residencetime of two seconds and temperatures in the range of 900-time of two seconds and temperatures in the range of 900-

1300C, effectively destroying any remaining organic1300C, effectively destroying any remaining organic

compounds.compounds.


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Rotary kiln incineratorRotary kiln incinerator


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Formation and Releaseormation and Releaseof Unintentional POPsf Unintentional POPsEmission testing has confirmed that composition of theEmission testing has confirmed that composition of the

waste, furnace design, temperatures in the post-waste, furnace design, temperatures in the post-

combustion zone, and the types of air pollution controlcombustion zone, and the types of air pollution control

devices (APCD) used to remove pollutants from thedevices (APCD) used to remove pollutants from theflue gases are important factors in determining theflue gases are important factors in determining the

extent of POPs formation and release. Depending onextent of POPs formation and release. Depending on

the combination of these factors, POPs releases canthe combination of these factors, POPs releases can

vary over several orders of magnitude per ton of wastevary over several orders of magnitude per ton of wasteincinerated.incinerated.


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Average 6 - 7 Nm3 of flue

gas per kg waste

Specific collection/treatment for:

Dust - staged filters

Chlorine - neutralised by scrubbing with lime

Sulphur - washing stage

Dioxins - combustion control, activated carbon


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Example of flue gas cleaning technologyExample of flue gas cleaning technology


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Examples of APCDs relevant to theExamples of APCDs relevant to the

prevention or reduction of unintentionalprevention or reduction of unintentional

POPs releasesPOPs releases

Cyclones and multi-cyclonesCyclones and multi-cyclones

Electrostatic precipitators wet, dry, orElectrostatic precipitators wet, dry, orcondensationcondensation

Fabric filters including catalytic bag filtersFabric filters including catalytic bag filters

Static Bed FiltersStatic Bed Filters

Scrubbing systems - wet, spray dry, or ionizationScrubbing systems - wet, spray dry, or ionization

Selective catalytic reduction (SCR)Selective catalytic reduction (SCR)

Rapid Quenching SystemsRapid Quenching Systems

Carbon Adsor tionCarbon Adsorption


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Unintentional POPs

formation can occurwithin the ESP at

temperatures in therange of 200C to

about 450C.Operating the ESP

within thistemperature range

can lead to theformation of

unintentional POPs inthe combustion gases

released from thestack.


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Fabric filters are alsoreferred to as baghouses or

dust filters. These

particulate matter control

devices can effectivelyremove unintentional POPs

that may be associated with

particles and any vapors

that adsorb to the particles

in the exhaust gas stream.

Filters are usually 16 to 20

cm diameter bags, 10 m

long, made from woven

fiberglass material, and

arranged in series. Fabric

filters are sensitive to acids;therefore, they are usually

operated in combination with

spray dryer adsorption

systems for upstream

removal of acid gases.


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Fabric filters (bag filters) are widely applied in waste incineration and have the

added advantage, when coupled with semi-dry sorbent injection (spray

drying), of providing additional filtration and reactive surface on the filter

cake.

Pressure drop across fabric filters should be monitored to ensure filter cake is

in place and bags are not leaking.

Fabric filters are subject to water damage and corrosion and are best suited for

dry gas streams with upstream removal of acid gases. Some filter materialsare more resistant to these effects.


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CarbonarbonAdsorptiondsorption Activated carbon is injected into the flue gas prior toActivated carbon is injected into the flue gas prior to

the gas reaching the spray dryer-fabric filter/ESPthe gas reaching the spray dryer-fabric filter/ESP

combination. PCDD/PCDF (and mercury) arecombination. PCDD/PCDF (and mercury) are

absorbed onto the activated carbon, which is thenabsorbed onto the activated carbon, which is thencaptured by the fabric filter or ESP. The carboncaptured by the fabric filter or ESP. The carbon

injection technology improves capture of theinjection technology improves capture of the

unintentional POPs in the combustion gases by anunintentional POPs in the combustion gases by an

additional 75% and is commonly referred to as flueadditional 75% and is commonly referred to as flue

gas polishing. Many APCDs have been retrofittedgas polishing. Many APCDs have been retrofitted

to include carbon injection.to include carbon injection.


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Spray dry scrubbing, also called spray

dryer adsorption, removes both acid gas

and particulate matter from the post-

combustion gases.

The spray drying technology is often usedin combination with ESPs and fabric filters.

Spray drying reduces ESP inlet

temperatures to create a cold-side ESP.


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Selective Catalytic Reduction (SCR) is a secondary control measureprimarily designed to reduce NOx emissions. The process also destroys

unintentional POPs via catalytic oxidation. SCR is a catalytic process in which

an air-ammonia mix is injected into the flue gas stream and passed over a

mesh catalyst. The ammonia and NOx react to form water and N2.

SCR units are usually placed in the clean gas area after acid gas and

particulate matter removal. Efficient operation of the SCR process requires

maintenance of the catalyst between 130 and 400C. For this reason, SCR

units are often placed after ESPs to avoid the need for reheating of the flue

gases. Caution must be exercised in such placement to avoid additional

unintentional POPs formation in the ESP.


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Wastewater from incinerationWastewater from incineration

Controls vary from country to countryQuantity:

influenced by gas scrubbing technology

chosen i.e. wet, semi-dry, dry

Treatment:

in aerated lagoons / widely used / lowcost / may not meet required standard

physico-chemical treatment may also be

needed


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Best Environmentalest EnvironmentalPractices for Wasteractices for WasteIncinerationncineration Well-maintained facilities, well-trained operators, aWell-maintained facilities, well-trained operators, a

well-informed public, and constant attention to thewell-informed public, and constant attention to theprocess are all important factors in minimizing theprocess are all important factors in minimizing the

formation and release of the unintentional POPsformation and release of the unintentional POPs

from the incineration of waste. In addition, effectivefrom the incineration of waste. In addition, effective

waste management strategies (waste management strategies (e.g.,e.g., wastewasteminimization, source separation, and recycling), byminimization, source separation, and recycling), by

altering the volume and character of the incomingaltering the volume and character of the incoming

waste, can also significantly impact releases.waste, can also significantly impact releases.

W t I ti d Ch t i ti


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Waste Inspection and Characterization


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Proper Handling,roper Handling,Storage, and Pre-torage, and Pre-TreatmentreatmentStorage areas must be properly sealed with

controlled drainage and weatherproofing. Fire

detection and control systems for these areas

should also be considered. Storage andhandling areas should be designed to prevent

contamination of environmental media and to

facilitate clean up in the event of spills orleakage.

Odors can be minimized by using bunker air

for the combustion process.


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Proper Handling, Storage, and Pre-TreatmentProper Handling, Storage, and Pre-Treatment


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Minimizing Storageinimizing StorageTimesimes Minimizing the storage period will help prevent

putrefaction and unwanted reactions, as well

as the deterioration of containers and labeling.

Managing deliveries and communicating with

suppliers will help ensure that reasonable

storage times are not exceeded.


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Establishing Qualitystablishing QualityRequirements for Wasteequirements for WasteFeded

Facilities must be able to accurately

predict the heating value and otherattributes of the waste being combusted

in order to ensure that the design

parameters of the incinerator are beingmet.


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Incinerator Operating and Management PracticesIncinerator Operating and Management Practices

Ensuring Good CombustionEnsuring Good Combustion

Optimal burn conditions involve:

mixing of fuel and air to minimize the existence of

long-lived, fuel rich pockets of combustion products,

attainment of sufficiently high temperatures in the

presence of oxygen for the destruction of

hydrocarbon species, and

prevention of quench zones or low temperature

pathways that will allow partially reacted fuel to exit

the combustion chamber.


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CirculatingCirculating

fluidised bedfluidised bed


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Proper management of time, temperature, andturbulence as well as oxygen (air flow), by means of

incinerator design and operation will help to ensure the

above conditions. The recommended residence time of

waste in the primary furnace is 2 seconds.

Temperatures at or above 850C are required for

complete combustion in most technologies. Turbulence,

through the mixing of fuel and air, helps prevent coldspots in the burn chamber and the buildup of carbon

which can reduce combustion efficiency. Oxygen levels

in the final combustion zone must be maintained above

those necessary for complete oxidation.

Incinerator Operating and Management PracticesIncinerator Operating and Management Practices

Ensuring Good CombustionEnsuring Good Combustion cont.cont.

BubblingBubbling


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BubblingBubbling

fluidised bedfluidised bed


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MonitoringMonitoringIn addition to carbon monoxide, oxygen in theflue gas, air flows and temperatures, pressure

drops, and pH in the flue gas can be routinely

monitored at reasonable cost. While thesemeasurements represent reasonably good

surrogates for the potential for unintentional

POPs formation and release, periodicmeasurement of PCDD/Fs in the flue gas will aid

in ensuring that releases are minimized and the

incinerator is operating properly.


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OperatorperatorTrainingrainingRegular training ofpersonnel is essential for

proper operation of

waste incinerators


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Maintaining Publicaintaining PublicAwareness andwareness andCommunicationommunication

Successful incineration projects have been

characterized by: holding regular meetings

with concerned citizens; providing days forpublic visitation; posting release and

operational data to the Internet; and

displaying real time data on operations andreleases at the facility site.


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BAT - General CombustionAT - General CombustionTechniquesechniquesEnsure design of furnace is appropriately matched to characteristics of theEnsure design of furnace is appropriately matched to characteristics of thewaste to be processed.waste to be processed.

Maintain temperatures in the gas phase combustion zones in the optimalMaintain temperatures in the gas phase combustion zones in the optimalrange for completing oxidation of the waste.range for completing oxidation of the waste.

Provide for sufficient residence time (e.g., 2 seconds) and turbulent mixing inProvide for sufficient residence time (e.g., 2 seconds) and turbulent mixing in

the combustion chamber(s) to complete incineration.the combustion chamber(s) to complete incineration.Pre-heat primary and secondary air to assist combustion.Pre-heat primary and secondary air to assist combustion.

Use continuous rather than batch processing wherever possible to minimizeUse continuous rather than batch processing wherever possible to minimizestart-up and shut-down releases.start-up and shut-down releases.

Establish systems to monitor critical combustion parameters including grateEstablish systems to monitor critical combustion parameters including gratespeed and temperature, pressure drop, and levels of CO, CO2, O2.speed and temperature, pressure drop, and levels of CO, CO2, O2.

Provide for control interventions to adjust waste feed, grate speed, andProvide for control interventions to adjust waste feed, grate speed, andtemperature, volume, and distribution of primary and secondary air.temperature, volume, and distribution of primary and secondary air.

Install automatic auxiliary burners to maintain optimal temperatures in theInstall automatic auxiliary burners to maintain optimal temperatures in the

combustion chamber(s).combustion chamber(s).


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BAT - Hazardous WasteAT - Hazardous WasteIncineration Techniquesncineration Techniques Rotary kilns are well demonstrated for the incineration ofRotary kilns are well demonstrated for the incineration of

hazardous waste and can accept liquids and pastes as wellhazardous waste and can accept liquids and pastes as wellas solids.as solids.

Water-cooled kilns can be operated at higher temperaturesWater-cooled kilns can be operated at higher temperaturesand allow acceptance of wastes with higher energy values.and allow acceptance of wastes with higher energy values.

Waste consistency (and combustion) can be improved byWaste consistency (and combustion) can be improved by

shredding drums and other packaged hazardous wastes.shredding drums and other packaged hazardous wastes.

A feed equalization system e.g., screw conveyors that canA feed equalization system e.g., screw conveyors that cancrush and provide a constant amount of solid hazardouscrush and provide a constant amount of solid hazardouswaste to the furnace, will ensure smooth feeding.waste to the furnace, will ensure smooth feeding.

C d ti


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Condensation

electrostatic

precipitator


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BAT Flue GasAT Flue GasTreatmentreatmentThe type and order of treatment processesThe type and order of treatment processes

applied to the flue gases once they leave theapplied to the flue gases once they leave theincineration chamber is important, both forincineration chamber is important, both for

optimal operation of the devices as well as foroptimal operation of the devices as well as for

the overall cost effectiveness of the installation.the overall cost effectiveness of the installation.Waste incineration parameters that affect theWaste incineration parameters that affect theselection of techniques include: waste type,selection of techniques include: waste type,

composition, and variability; type of combustioncomposition, and variability; type of combustionprocess; flue gas flow and temperature; andprocess; flue gas flow and temperature; andthe need for, and availability of, wastewaterthe need for, and availability of, wastewater

treatment.treatment.


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Destruction efficiencyDestruction efficiency

DREs of greater thanDREs of greater than99.9999 percent have been99.9999 percent have been

reported for treatment ofreported for treatment ofwastes consisting of,wastes consisting of,

containing or contaminatedcontaining or contaminatedwith POPs.with POPs.


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BAT - Residue Management TechniquesBAT - Residue Management Techniques Unlike bottom ash, APCD residuals including fly ash and scrubber sludges mayUnlike bottom ash, APCD residuals including fly ash and scrubber sludges may

contain relatively high concentrations of heavy metals, organic pollutants (includingcontain relatively high concentrations of heavy metals, organic pollutants (includingPCDD/F), chlorides and sulfides.PCDD/F), chlorides and sulfides.

Mixing fly ash and FGT residues with bottom ash should be avoided since this willMixing fly ash and FGT residues with bottom ash should be avoided since this willlimit the subsequent use and disposal options for the bottom ash.limit the subsequent use and disposal options for the bottom ash.

Treatment techniques for these residues include:Treatment techniques for these residues include: Cement solidification. Residues are mixed with mineral and hydraulic binders andCement solidification. Residues are mixed with mineral and hydraulic binders andadditives to reduce leaching potential. Product is landfilled.additives to reduce leaching potential. Product is landfilled.

Vitrification . Residues are heated in electrical melting or blast furnaces to immobilizeVitrification . Residues are heated in electrical melting or blast furnaces to immobilizepollutants of concern. Organics, including PCDD/F are typically destroyed in thepollutants of concern. Organics, including PCDD/F are typically destroyed in theprocess.process.

Catalytic treatment of fabric filter dusts under conditions of low temperatures and lack ofCatalytic treatment of fabric filter dusts under conditions of low temperatures and lack ofoxygen;oxygen;

The application of plasma or similar high temperature technologies.The application of plasma or similar high temperature technologies.

Fly ash and scrubber sludges are normally disposed of in landfills set aside for thisFly ash and scrubber sludges are normally disposed of in landfills set aside for thispurpose. Some countries include ash content limits for PCDD/F in their incineratorpurpose. Some countries include ash content limits for PCDD/F in their incineratorstandards. If the content exceeds the limit, the ash must be re-incinerated.standards. If the content exceeds the limit, the ash must be re-incinerated.


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Costs and Economic ConsiderationsCosts and Economic Considerations

The construction of large state-of -the-art incineratorsThe construction of large state-of -the-art incineratorsrequires major capital investment, often approachingrequires major capital investment, often approachinghundreds of millions USD. Installations recover capital andhundreds of millions USD. Installations recover capital andoperating costs through treatment fees and, in the case ofoperating costs through treatment fees and, in the case of

waste-to-energy facilities, through the sale of steam orwaste-to-energy facilities, through the sale of steam or

electricity to other industries and utilities.electricity to other industries and utilities.

The ability to fully recover the costs of construction andThe ability to fully recover the costs of construction andoperation is dependent on a number of factors including:operation is dependent on a number of factors including:

the relative cost of alternative disposal methods; thethe relative cost of alternative disposal methods; theavailability of sufficient waste within the local area;availability of sufficient waste within the local area;provisions for disposal of residues; and proper staffing,provisions for disposal of residues; and proper staffing,operation, and maintenance to maintain peak efficiencyoperation, and maintenance to maintain peak efficiency

and minimize downtime.and minimize downtime.


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CostsostsRelated to site-specific andcountry-specific factors

High level of sophistication &control = high constructioncosts

Air pollution control costs = 30-40% of total

Capital and operating costs for anCapital and operating costs for an


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Capital and operating costs for anCapital and operating costs for an

average 70,000 tpy HWI facilityaverage 70,000 tpy HWI facility

Cost Structure EUR

Planning/approval 3,000,000

Machine parts 16,000,000

Other components 14,000,000

Electrical works 10,000,000

Infrastructure works 6,000,000

Construction time 3,000,000

Total investment costs 54,000,000

Capital financing costs 5,000,000

Personnel 3,000,000

Maintenance 4,000,000

Administration 300,000

Operating resources/energy 1,300,000

Waste disposal 800,000

Other 300,000

Total operational costs 14,700,000

Per ton incineration costs (without revenues) 200-300


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Costs and Economic ConsiderationsCosts and Economic Considerations

Country Gate Fees in EUR/tonMSW Hazardous Waste

Belgium 56-130 100-1500

Denmark 40-70 100-1500

France 50-120 100-1500

Germany 100-350 50-1500

Italy 40-80 100-1000 Netherlands 90-180 50-5000

Sweden 20-50 Not available

United Kingdom 20-40 Not available


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ThroughputhroughputHazardous wasteHazardous waste

incinerators have aincinerators have a

capacity from a fewcapacity from a fewhundred tons to >100,000hundred tons to >100,000

tons per yeartons per year


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AvailabilityAvailability

Dedicated incinerators areDedicated incinerators are

available in many countriesavailable in many countries


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Hazardous wasteazardous wasteincinerationncineration are in principle capable to treat POPs and

POPs waste in an environmentally soundway and can meet stringent ELVs

are highly regulated need skilled personnel require high operating and safety

standards require high capital investment have medium to high operating costs

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BAT Incineration