>> TRENDS IN INDUSTRIAL WASTE MANAGEMENT:

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1 >> TRENDS IN INDUSTRIAL WASTE MANAGEMENT: CURRENT CHALLENGES AND STATE OF THE ART CONCEPTS THORSTEN APPEL, VICE PRESIDENT WASTE MANAGEMENT, INFRASERV HÖCHST

2 RDF waste incinerator External partner and network facilities Hazardous waste incinerator Sewage sludge incinerator Biogas plant Wastewater treatment plant Biomethane upgrading plant Turnover: Ranking in D: Capacity: # loads accepted: 100 mn #1CFA/EVA >1mn t/a >100/d INFRASERV HÖCHST

3 TRENDS AND CHALLENGES 1. Waste management is evolving into resource management 2. Waste-to-energy offers attractive synergies for infrastructure service providers and energy-intensive companies 3. Approach There are challenges in expanding infrastructure and managing the market situation and real-life example from Infraserv Höchst 3

4 RELEVANCE OF THE WASTETOENERGY APPROACH FOR INDUSTRIEPARK HÖCHST Demand for electrical energy in 2013 Industriepark Höchst: 1,959 GWh Heat required in 2013 Industriepark Höchst: 3,363 GWh 6 % RDF-fired WTE plant: 116 GWh 1 % waste heat power from customer plants: 13 GWh 1 % renewable energy sources: 20 GWh 13 % waste heat from disposal plants: 427 GWh 11 % waste heat of customer plants: 381 GWh 37 % bought in externally: 721 GWh 56 % CHP plant: 1,089 GWh 76 % CHP plant: 2,555 GWh GOAL: Keep Industriepark Höchst international competitive Source: Infraserv Höchst's carbon footprint report for 2013 THE SUPPLY OF ELECTRICITY AND STEAM ARE KEY PRODUCTION FACTORS AT INDUSTRIEPARK HÖCHST 4

5 SELECTED WASTE DISPOSAL INFRASTRUCTURE: RDFFIRED WASTETOENERGY PLANT TECHNICAL DATA TECHNICAL DATA TECHNICAL DATA Fuel Fuel Refuse-derived Fuel fuel 675,000 t/a Refuse-derived fuel 675,000 t/a Comb. Refuse-derived temperature fuel 850 C 675,000 t/a Comb. temperature > 850 C Comb. temperature > 850 C Process Process Process Fluidized bed combustion Fluidized bed combustion Co-generation Fluidized bed or combustion condensation Co-generation Number Co-generation of combustion or condensation lines: Number of combustion lines: 3 Number of combustion lines: 3 Energy generation Energy generation Steam Energy generation generation 250 t/h Steam generation 250 t/h Electricity Steam generation generation MW t/h Electricity generation 70 MW Electricity generation 70 MW FOCUS ON SUSTAINABILITY FOCUS ON SUSTAINABILITY Conserve resources: Replace fossil fuels with refuse-derived fuels Conserve resources: replace fossil fuels with refuse-derived fuels Protect the environment: By reducing CO 2 emissions Protect the environment by reducing CO 2 emissions Guaranteed availability: With three parallel combustion lines Guaranteed availability with three parallel combustion lines 5

6 SELECTED WASTE DISPOSAL INFRASTRUCTURE: INDUSTRIAL BIOGAS PLANT TECHNICAL DATA Digester volume Capacity Biogas production 2 x 10,800 m3 300,000 t/a WTP sewage sludge ~ 170,000 t/a cosubstrate ~ 60,000 m³/d ~ 5.0 MW el Output ~ 5.0 MW therm ~ 10 MW biomethane FOCUS ON SUSTAINABILITY Conserve resources: Use wastewater and co-substrates to produce energy Protect the environment: Recover energy from waste in the form of methane Availability: Redundant design with two digesters 6

7 SELECTED WASTE DISPOSAL INFRASTRUCTURE: BIOMETHANE UPGRADING ENVIRONMENTAL PROTECTION Approach: Biogas generated at the site is upgraded to pipeline-quality methane and fed into the public grid. Conserve resources: Replace conventional natural gas and reduce CO 2 emissions by up to 16,000 t/a. 80,000 MWh of biomethane is equal to the consumption of roughly 4,000 households. 7

8 WASTETOENERGY USE HAS EXCEEDED CONVENTIONAL WASTE DISPOSAL SINCE 2011 INFRASTRUCTURE Examples of disposal assets: Industrial biogas plant RDF-fired WTE plant Residue incineration Sewage sludge incineration x Tons of waste disposed of in Infraserv plants 2/3 10 1/ Conventional Waste-to-energy WASTE STREAM MANAGEMENT WASTE-TO-ENERGY REQUIRES ACTIVE PARTICIPATION IN THE WASTE MARKET (WASTE STREAM MANAGEMENT) 8

9 LEVERAGE FOR CUTTING SECONDARY COSTS IN UTILITIES AND WASTE MANAGEMENT INFRASTRUCTURE Examples of disposal assets: Industrial biogas plant RDF-fired WTE plant Residue incineration Sewage sludge incineration Third-party plants WASTE STREAM MANAGEMENT Participation in waste market: Cont. plant utilization Optimization of waste menu Reliable waste disposal at any time, even during production peaks and test runs Quality assurance, audits, documentation Reliable supply Reliable disposal Compliance ACTIVE WASTE STREAM MANAGEMENT IS A KEY SUCCESS FACTOR FOR RELIABLE SUPPLY AND WASTE DISPOSAL 9

10 THE CHALLENGE: BALANCING PLANT UTILIZATION AND RELIABLE DISPOSAL Successful acquisition of utilization volumes: Challenge: Capacity vs. Material Flow Typical situation: Reliable disposal of dependent production: Challenge: Acquisition resources Knowledge of waste streams 100% 80% 60% Contract management Management of cooperation partners Suitability of waste streams Knowledge of market 40% 20% 0% t1 t2 Audit readiness Regulatory compliance Installed capacity Production volume WASTE STREAM MANAGEMENT REQUIRES BROAD MARKET KNOWLEDGE AND BENEFITS HEAVILY FROM ECONOMIES OF SCALE 10

11 LEVERAGE FOR CAPITALIZING ON THE POTENTIAL OF WASTETOENERGY INFRASTRUCTURE Examples of disposal assets: Industrial biogas plant RDF-fired WTE plant Residue incineration Sewage sludge incineration Third-party plants WASTE STREAM MANAGEMENT Participation in waste market: Cont. plant utilization Optimization of waste menu Reliable waste disposal at any time, even during production peaks and test runs Quality assurance, audits, documentation ENERGY EFFICIENCY Sustainable projects: Consistent use of cogeneration even in disposal plants Power plant efficiency >90% Energy management and marketing Cross-plant steam/electricity management 15:30 WASTE-TO-ENERGY IS A COMPLEX DISCIPLINE THAT MUST BE MANAGED SEPARATELY IN ORDER TO EXTRACT MAXIMUM BENEFITS 11

12 INTEGRATION AND UNIFIED CONTROL OF SUPPLY AND DISPOSAL FACILITIES External purchase Sewage sludge incineration Biogas plant Biomethane upgrading CHP plant with gas, coal, waste Electrode boilers 3 gas turbines Exothermic production processes RDF-fired WTE plant Wastewater treatment Residue incineration FLEXIBLE PORTFOLIO ENSURES DIVERSITY AND SUSTAINABILITY IN ENERGY GENERATION 12

13 THANK YOU FOR LISTENING! WHAT PARALLELS DO YOU SEE? INFRASTRUCTURE Examples of disposal assets: Industrial biogas plant RDF-fired WTE plant Residue incineration Sewage sludge incineration Third-party plants WASTE STREAM MANAGEMENT Participation in waste market: Cont. plant utilization Optimization of waste menu Reliable waste disposal at any time, even during production peaks and test runs Quality assurance, audits, documentation ENERGY EFFICIENCY Sustainable projects: Consistent use of cogeneration even in disposal plants Power plant efficiency >90% Energy management and marketing Cross-plant steam/electricity management Development and operation of infrastructure Outcome-oriented utilization of supply and disposal infrastructure Optimization of the interface between supply and disposal 13

14 THANK YOU FOR YOUR ATTENTION SITE OPERATION. SITE SERVICES. UTILITIES. WASTE MANAGEMENT. LOGISTICS.