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Integrated Waste Treatment including Residue Utilization
Integrated Waste Treatment including Residue Utilization
Andreas Richter
Waste Treatment, Principles
Based on the existing guideline 89/369/EWG the main purpose of waste incineration plants was defined as listed below:
Waste incineration plants are industrial premises which shall be designed for the main purpose of treatment of municipal waste incl. recovery systems for generated thermal energy.
History Waste Incineration Plants:
• Firstdiscontinuousstoker-firedfurnaceforwasteincineration1876inManchester(GB)and1894inHamburg(D).Developmentofcontinuousstoker-firedsystemsstartingin1920.Currently,worldwidemorethan1.000wasteincinerationplantswithcombustiongrate,fluidizedbedaswellasrotarykilntechnologieshavebeenrealized.
• Today,variouscompaniesingratecombustion,fluidizedbed,rotarykiln,boilerdesignandfabricationtechnologyaswellasoperatorsofcomplexenvironmentalfacilitiesbuildon100yearsoftraditioninconstructionandoperationofwasteincinerationplants.
• Duetodevelopmentofenvironmentalmovementthetermwaste incineration plant was afflictedwithovertones.HencethetermWaste to EnergywasdevelopedinthepasttosubstitutetheolddefinitionandtorebrandWtEprojectswithpositivegreen public image.
Duringthelast5decadesanintensivedevelopmentinwastemanagementwasrealizedworldwideandimplementedinEuropeanaswellaslocallawsandguidelineslikeexem-plary listed below:
• EC–IncinerationDirectiveNo.2000/76/EC
• D–OrdinanceonEnvironmentallycompatiblestorageofwastefromhumansettlementandonbiologicalwastetreatmentfacilities,(Abfallablagerungsverordnung–AbfAbIV)
• D–Technicalguideline(TA)municipalwaste(TASi)
• D–Federalcontrolofpollutionact(BImSchG)
• A–Federalimmissioncontrolact(IG-L)
TypicalWtEconcepts:
• Purewaste incinerationplants=>forunsortedwastecollectionbasicallywithgratecombustion technology
• Wasteincinerationplantswithupstreammechanicaltreatmentfacilities=>forunsor-tedwastecollectionandlocalrecyclingmarketaswellascementkilnwithcombustiontechnologiesforincinerationofrefuse-derivedfuel(RDF)–highcalorificvaluefraction
• Wasteincinerationplantswithupstreammechanicalandbiologicaltreatmentfacilities=>basicallyforunsortedwastecollectionandlocalrecyclingmarketaswellasexistinglocal law for application of renewable energy
• Wasteincinerationplantswithfuelpre-treatmentfacilities=>forselectivewastecollec-tionandadditionalfueltypes(e.g.sewagesludge)basicallywithfluidizedbedtechnology
Andreas Richter
270
Figure1: Waste to Energy concepts
Flue Gas Cleaning Systems, Basics
Typicalfluegassystemsforwasteincinerationplantscanbelistedandsplitintothefol-lowing systems:
• Conditioneddryabsorption(CDA)andSNCRfluegascleaningsystem,SNCRstageinstalled in the boiler section at the combustion chamber
• Conditioneddryabsorption(CDA)andSCRfluegascleaningsystem
• Conditioneddryabsorption(CDA)andwetscrubbingandSCRfluegascleaningsystem
Basedonstatistics,thedesignandrealizationforfluegascleaningsystemsinWtEplantsduringthelastyearshasbeenheavilyinfluencedbysemidryfluegascleaningsystems.Duetothisreasontheauthorwillfocusonthissystem.
TheconditioneddryabsorptionfluegassystemincombinationwithSNCRsystemwillhavethefollowingadvantagescomparedtoothers:
• EmissionsessentiallybelowFederalcontrolofpollutionact(BImSchG)
• Lesscapitalexpenditures(CAPEX)
• Lessoperationalexpenditures(OPEX)
• Systemwithoutsewage&wastewater
• Lowrequirementstothestructuralbuildingandcivilconstruction
• Lowrequirementstofireprotectionsystemduetostandardmaterial,mostlysteelstructure
RoadSubstructure
PrecastConcrete
PrecastConcrete Railroad
Sleepers
RemainingFly ash disposal in salt mine
RDFRefuse-Derived Fuel
Sewage Sludge
Municipal Waste
Bulky Waste
Waste to Energy PlantGrate or Fluidized bed combustion Boiler
and combined heat and power cyle
Ferrous fraction after incineration
Digestion and Biogas
GenerationSTABILAT
Biogas Engine for
Energy Production
Compost PET Cardboard NonFerrous
Glass
Reuse Energythermal and
electric Energy
Reuse of treated boiler slag and ash and fly ash
Sorting FacilitiesHandsorting and
optical sorting devices
MBT-Mechanical-biological
Treatment
Pre-SortingOrganic fraction
Recyclablefractions
from MBT
Boiler and fly ashstabilisation plant
271
Integrated Waste Treatment including Residue Utilization
• Low-pressuredualfluidnozzles,principleofultra-sonicatomization,withnomovingparts
• Lowconsumptionofatomizingagent(steamorcompressedair)
Flue Gas Cleaning Systems, Line Up
• Conditioneddryabsorption(CDA)andSNCRfluegascleaningsystem
• Conditioneddryabsorption(CDA)andwetscrubbingandSCRfluegascleaningsystem
Dust SO2/HCl/HF Heavy Metals NOx PCDD/F +++ ++ + ++ +
• Conditioneddryabsorption(CDA)andSCRfluegascleaningsystem
Dust SO2/HCl/HF Heavy Metals NOx PCDD/F +++ ++ + +++ +++
Flue Gas Cleaning Systems, Typical design
Dust SO2/HCl/HF Heavy Metals NOx PCDD/F +++ +++ +++ +++ +++
Figure2: Conditioneddryabsorption(CDA)andSNCR*fluegascleaningsystem
* SNCRstageinstalledintheboilersectionatthecombustionchamberandnotshowninfigureabove
Recirculation sytem
CDA
ActivatedCarbon
Fabric Filter
CleanFlue Gas
ResiduesFly ash
Absorbente.g. lime milk
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272
Flue Gas Cleaning Systems, layout and construction
Figure3: Conditioneddryabsorption(CDA)andSNCRfluegascleaningsystem–Typicalar-rangement(left),Designelementsandpictures(right)
Flue Gas Cleaning Systems, Statistics
Figure4: Statistic:Emissionvaluesforconditioneddryabsorption(CDA)systemsinWtEfacilities
70
60
50
40
30
20
10
%
Carbon
Monoxide (CO)
Emission limit according EU 76/2000Acutal Emissions of German WTE plants operating with semi-/conditioned dry flue gas treatment
80
90
100
Total Organic
Carbon (C)
Hydrogen Chloride (H
CI)
Hydrogen Fluoride (H
F)
Sulfur D
ioxide (SO 2)
Nitrogen Oxide (N
O x)
Dust
Mercury (H
g)
Cadmium + Thallium (C
d + Tl)
Heavy Metals (
Sb + As + Pb + Cr +
Co + Cu + Mn + Ni + V + Sn)
Dioxins/Furans (P
CDD/F)
50mg/N3
10mg/Nm3
10mg/Nm3
1mg/Nm3
50mg/Nm3
200mg/Nm3
10mg/Nm3
0.05mg/Nm3
0.05mg/Nm3
0.5mg/Nm3
0.1ng/Nm3
0
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Integrated Waste Treatment including Residue Utilization
InseratERC GmbH
275
Integrated Waste Treatment including Residue Utilization
Residue Utilization
Duetoenvironmentalmovement,residueutilizationsgethighlyimportantevenfordeve-lopmentandfinancingofpublic-private-partnershipWtEproject.
Multilateralinstitutessuchas
• EuropeanBankforReconstructionandDevelopment–EBRD
• InternationalFinanceCorporation–IFC(MemberofWorldBankGroup)
shall evaluate technologies,materialbalanceand furtherutilizationof residues inWtEprojectsindetailandasbasicfortheirinternaldue-diligenceprogress.
Henceintegratedwastetreatmentincl.Conceptsforresidueutilizationsgetmoreandmoreimportantforprojectdevelopment,constructionandoperation.
Residueutilizationssecuresustainabilityforwastetreatmentprocessaswellasforlongtermoperationperiodincludingresidueapplicationbasedoneconomizinghandlingwithresourcesfrommothernature.
ResiduesfromWtEfacilitiescanbestructuredinthefollowingcategories:
• Boilerslag => fromthecombustionchamber
• Boilerash => fromdownstreamsectionse.g.evaporator,superheater,economizer in the boiler
• Flyash => fromfluegascleaningsystems
Residue Utilization, Quantities
Boiler residues (slag and ash)approx. 160 – 240 kg
Residues from FGC (fly ash)approx. 20 – 50 kg
Scraps (Fe and Non-Fe)approx. 10 – 30 kg
1 Mg Wastethermal treated
Figure5: Incinerationresidues,expectedoutputbalance*
* basedongratecombustiontechnologyandwastemorphologyforcentralEurope
Table1: Incinerationresidues,outputbalancestatisticalrecords1
Country/City therm. waste treatment Boiler slag and ash Fly ash
Mg/a
Vienna2 approx. 1,070,000 approx. 185,000 approx. 30,000
Austria approx. 2,400,0003 approx. 528,0004 approx. 96,0004
Germany approx. 26,800,0003 approx. 5,900,0004 approx. 1,070,0004
1 partly based on internet research2 incl.quantitiesforhazardouswasteincineration(rotarykiln)andsewagesludgeincineration(FBC)3 researchVZ&A–07/20114 Estimatedvaluesbasedon22%ratioforBoilerslagandashand4%ratioforflyash
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276
Based on Europeanaswellasonlocallaws(e.g.OrdinanceonEnvironmentallycompa-tiblestorageofwastefromhumansettlementandonbiologicalwastetreatmentfacilities,AbfAbIVforGerman),residuesfromthermalwastetreatmentmustbestoredbasedonmorphologyindifferentlandfillcategories.
• BoilerslagandashshallbedisposedinmostofthecasesonlandfillclassificationIII.Afterutilization,thematerialmightbeusedas intermediateandcover layerforre-cultivation.InmostoftheregionsinCentralEuropeadequatecapacitiesforthisland-fillclassificationareavailable.Duetothisfact,longtermpermittingprocessfornewlandfillsaswellasrisingcapacitiesinwasteincineration,aviewapplicationinresidueutilizationhavebeeninstalledinthelastyears.Theactualexpendituresfordisposalboilerslagandashareinarangebetweenapprox.15–50EUR/Mg.
• Dependingonnational&locallegislation,wastemorphology,incinerationtechnologyaswellaslocalrestrictionsandpermits,residuestabilizationcanberealizedforfurtherutilizationandre-useofpartialfractions.
• Flyashfromfluegastreatmentsystemsisclassifiedashazardousmaterialandmustbestoredincloseddownsaltmines.InCentralEuropetheavailablelocationswithofficialapprovalsandpermitsarelimited.Duetofewerpossibilitiestheexpendituresforfinaldisposalarequithighandinarangeofapprox.120–180EUR/Mg.Hencethatfactandmoreorlessexpiringcapacitiesadditionalsolutionsforfurthertreatmentofflyashareunderdevelopment.
Referenceplants:
• Forboilerslagandash,STRABAGisoperatingthegrateslagandashtreatmentplantinVillenearCologne/Dsince2009.
• InViennathemunicipaldepartmentforwastecollectingMA48isoperatingsince1991themixingplantforresiduesfromseveralwasteandsewagesludgeincinerationplantsinVienna.
Figure6: ResidueUtilization,ReferencePlantVille/D
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Integrated Waste Treatment including Residue Utilization
InseratSTRABAG
GmbH
279
Integrated Waste Treatment including Residue Utilization
Materialquantities:
ThegrateashofthewasteincinerationplantinCologneistransportedfromtheincinerationplanttothetreatmentplantinVillebytrucks.Thestockpilingisoutsidewithoutcovering.
PlantCapacity: 100,000Mg/a
Grateashsize: 0–1,000mm
Fraction0/6mm: approx.40–60M.-%
Fraction6/16mm: approx.20–30M.-%
Fraction16/45mm: approx.20–30M.-%
Fractionofnotincinerated: <5M.-%
Averageamountofrecyclables:
• Ferrousmetalscrap:
* ca.5M.-%,
– with3–4M.-%finescrap
– 1–2M.-%mediumscrap,
– 0,1M.-%scrap
• NonFerrousscrap
* 1,5–2M.-%
Maintreatmentfacilities
• Bunkerincl.feedinghopper,steelplatedosingconveyor,vibrationconveyor
• Polygonscreeningdrum
• FerrousandNonFerrousseparationbymagneticseparatorandmagneticdrumseparator
• Mechanicalseparationbyflopscreenmachine
• Windsifterforremovallightfraction
• Recirculationsystemforwasteair,incl.ventilationsystemandchimney
Figure7:
Function ofmagnetic drumseparator
Fe scrap Inerts
Screen overflow > 45 mm
Andreas Richter
280
Figure8: GrateAshTreatmentPlantCologne–Ville
Figure9: Finalproductsslagandash,severalfractions
Grate ash 0 - 1,000 mm
Bunker
drumscreen
screened< 45 mm
Fe Sep. Flip-flopscreen
overflow8 - 45 mm
EddySep.
Fe Sep.Fe Sep.
Fe Sep.
EddySep.
Airclassifier
fraction 8 - 45 mm
fraction< 8 mm
fraction45 - 1,000 mm
overflow 45 - 1,000 mm
screened< 8 mm
Overflow Inert45 - 1,000 mm
Fine fraction0 - 8 mm
Fe metal scrap Light fractionMedium fraction8 - 45 (0 - 45) mm
Non Fe metalscrap
Fe Sep.
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Integrated Waste Treatment including Residue Utilization
Residue Utilization, Ref. Plant MA48 Vienna/Austria
Plant history:
• ProfessorWruss andProfessorLukasdevelop a typeof slurry containing slag, ash,bondingagentsandwater,socalledash and slag concrete.MA48startstousetheslurryforreinforcingsidewallsoftheexistinglandfillRautenweginVienna.
• In1991MA48realized theconstructionofa single linemixingplantbasedon theadaptedtechnologyofastandardconcretemixingplant.
• In1994/1995MA48realizedthedesignandconstructionofasecondlineforslagandash processing and mixing
• Since2008ahighlyefficientferrousandnonferrousseparationsystemwasimplemented
From1991to2007approx.2.7MillionMgofslag&ashconcretehavebeentreatedanforwarded to the existing landfill Rautenweg as basic construction material for surrounding barrier.
Mainbenefitsfromslag&ashconcrete:
• Significantreductionofeluateclassificationcomparedtoun-compactedlandfillmate-rial as pollutants are embedded in the cement matrix
• reductionofdustandodoremissions
• Duetohighcompactiondensity(1.80Mg/m³)steeperslopeforconstructingsurroun-dingbarrier,thereforeincreasingoflandfillcapacity.
Residue Utilization, Basics
Basicallythereexist2possibilitiestoimpactresidueconditions
• Primarymeasure=>optimizationofmaintreatmentprocess,whichmeansincinerationprocess,e.g.optimizationofincinerationconditionssuchase.g.combustiontempera-ture,airsupply,etc.
• Secondarymeasure=>optimizationofdownstreamtreatmentprocess,whichcanbedevelopmentofresidueutilizationprocess
Primary measures
Optimizationofprimarymeasuresisfluentlyexecutedbyallofwellknownboilersuppliersworldwideandcanbedemonstratedinhighercombustionrate,higherboilerefficiency,risingplantavailabilityandlessresidueoutcome.
Secondary measures
Optimizationofsecondarymeasureswasfocusedinthepastmainlyontreatmentofboi-lerslag&ashandrecyclingofferrousandnonferrousfractions.Duetoenvironmentalmovement, lessdisposal capacities andhighdisposal costs,developmentofutilizationtechnologiesandprocessesforflyashfromfluegascleaningsystemsaregettingmoreandmoreimportantinthelastfewyears.
Andreas Richter
282
Residue Utilization, Categories
Duetolowdevelopmentandexperienceoffurtherflyashtreatmentsystemstheauthorwillconcentrateonlyonevaluation,visions&potentialsinflyashtreatmentforresiduesfrom waste to energy facilities
In professional literature there were listed two different categories of residue treatment processes:
• Low-temperaturetreatmentprocess
• High-temperaturetreatmentprocess
High-temperatureprocesses aredefinedwith aminimum temperature runningabove 650°C.
Low-Temperatureprocesses are from theoretical point ofdefinitionbelow650 °C, inpracticelessthan100°C.
Residue Utilization, Categories
Low-temperature treatment process
Thiscategorycanbesplitintofurther3subgroups.
Figure10: Low-temperaturetreatmentprocesswiththreesubgroups
FortreatmentofflyashfromwasteincinerationplantsthesubgroupStabilization(utili-zation)willbethetechnologywithhighestpotentialindevelopmentandoptimization.
This subgroup contains two main treatment processes:
• Stabilization(utilization)withcement
• Stabilization(utilization)withclay
Wettreatmentofresiduesisexecutedwithintheprocessoffluegascleaningsystemifexe-cutedasconditioneddryabsorption(CDA)andwetscrubbingandSCRfluegascleaningsystem.The2maintreatmentprocessescanbelistedwith
• Acidtreatment
• Alkalinetreatment
Stabilization (Utilization) Chemical treatment Wet (fluidized) treatment
Low-temperaturetreatment process
283
Integrated Waste Treatment including Residue Utilization
Chemicaltreatmentisseldomandbasicallyusedforindustrialapplicationsandintegrationofheavymetalsinformofcarbonizingandimmobilizationofheavymetals.
High-temperature treatment process
Thiscategorycanalsobesplitinfurther3subgroups.
Figure11: High-temperaturetreatmentprocesswiththreesubgroups
Sintering Glazing by melt down Generating stock minerals
High-temperaturetreatment process
High temperature treatmentprocesseshave to implementhighenergyquantity in thetreatmentprocesstorealizesinteringormeltdownprocess.Allhigh-temperatureprocesseswilldestroyorganicpollutants.
Iftheprocessrunsunderreducedatmosphericconditionstherecoveryprocessformetalswillbethemaintopic.
Duringtreatmentunderoxidationatmosphericconditionsthegenerationofoptical,che-micalandelectricalspecialglassesorglassfiberswillbethemaintopic.
Therealizationofenergyinputcanberealizedvia
• Plasmamethod
• Electricalenergy
• Fossilenergysources
Summary
Integrated waste treatment including residue utilizationisnotonlyacatchphrase,itshallbethemaximforfurtherdevelopmentinwastemanagementforallkindsofwastetypesandlocalconditionsandrequirements.
ModernWtE – Waste to Energyprojects,shallbeunderstoodasinnovativeturnkeysolutionstoconvertwasteproductsinrecyclableswhichsubstitutethelimitednaturalresourcessuchasfossilenergysourcesandsecuressustainablepreservationofMotherNature.