EU-project RECOMBIO: Part 3: Project introduction Production of BIOBS in Erftstadt. Part 4: Part 5: Messages Closing remarks Back-up

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1 EU-project RECOMBIO: Part 1: Part 2: Part 3: Part 4: Part 5: Project introduction Production of BIOBS in Erftstadt Use of BIOBS Messages Closing remarks Back-up Dr.-Ing. Th. Glorius, Final Conference RECOMBIO, Helsinki

2 Part 2: Production of BIOBS by in Erftstadt Dr.-Ing. Th. Glorius, Final Conference RECOMBIO, Helsinki

3 Three quality groups of SRF since 1995/1998/2009 BPG SBS BIOBS Brennstoff aus Produktionsspezifischen Gewerbeabfällen SubstitutBrennStoff BIOBrennStoff Source seperated wastes / production residues High calorific fractions (HCF) sorted out from poste-use waste High calorific fractions with a high biogenic content and different biowastes 3

4 Input materials for BIOBS mechanical-biological treatment plant (MSW) high calorific fraction (HCF MSW ) bulky waste different other wastes composting used wood high calorific fraction (HCF BW ) sreening overflow BIOBS-production BIOBS QA of BIOBS different biowastes Quality Assurance of Input 4

5 QMS for the production of SRF in Erftstadt Process-chain Acceptance area Positive sorting of HCF QA-chain Input control Process control ISO 9: a EFB: a RAL-GZ 724: a CEN/TC 343: a SRF-production Process control SRF-storage Product control: Internal and external QMS is the fundament for reliable SRF-qualities 5

6 Waste treatment center VZEK, Erftstadt Flow-sheet for BIOBS-production (04/2012) Bulky waste feeding screening Fe-/ NFseparation surplus water to WWTP MSW feeding biol. drying residues to MSWI screening Fe-/ NFseparation Fe-/ NFmetals Fe-/ NFseparation Sorting plant (ABA) NIRseparation SRF-plant (AKEA) HCF`s windshifting storage/ loading BIOBS Production specific wastes, biowastes feeding NF-separation Fe-separation Fe-/ NFmetals NIRquality control Secondary size reduction Prior size reductionwindshifting disturbent materials/residues 6

7 Online-analysis with NIR-device new position since 04/2012: product stream - 100% New position after promising results of TAMARA-trials (SRF-layer ca. 15 cm) 7

8 Online-analysis with NIR-device analytical results of total Cl for BIOBS in comparision Produkt BIOBS Parameter Chlor gesamt [% TS] Jahr (Alle) 0,50 Ergebnisse 0,40 0,30 0,20 0,10 NIR/UCL Median Mittelwert 80. Perzentil 90. Perzentil 95. Perzentil UCL Analyse Delta MW- UCL 0,00-0, Analysenummer Produktionszeitraum Baseline for inorganic Cl is not constant during the year (0,10 0,21%), Cl-average NIR (0,30% ds) and laboratory (0,27% ds) are well comparable 8

9 Online-analysis with NIR-device information for the control personnel (examplary lot) BIOBS, ,20 1,10 1,00 0,90 0,80 0,70 0,60 0,50 0,40 0,30 0,20 0,10 0,00 Production period: Measured NIR-value Average Limit value according contract Estimated value of inorganic Cl Prevention of longer periods with higher Cl-values possible : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :39 Cl [% ds]

10 Windshifting 2 t/h test device and heavy fraction Intentions: 1.) Reduced energy consumption (fine crushing not necessary) 2.) Improved SRF-quality (Cr, Cu, Pb,..., disturbing materials) 3.) Increased recycling rate 10

11 New windshifting-system 2 x 10 t/h since 02/2012: 100% of product stream Positive influence on SRF-quality and recycling rate 11

12 Quality development of BIOBS for parameters with slagging-/corrosion-potential (incl. 05/2013) mg/kg ds Mean 2010 Mean 2011 Mean 2012 Mean 2013 Al K Na Cl Chlorides Consequence of adapted recipe, improved QA,... 12

13 Development of Hg-values for BIOBS (incl. 05/2013, n = 102) 0,040 0,030 Median Linear (Median) 80th Perc. Linear (80th Perc.) mg/mj 0,020 0,010 0, classification according EN 15359: class 1 for Hg, values comparable to coal 13

14 Quality of SBS 1 Erftstadt and BIOBS compared to Rhenish lignite (05/2013) Unit Lignite from the Rhine, SBS 1, Mean Mean (Berrenrath/Wachtberg) Classification code according EN of SBS 1 and BIOBS: NCV: 4; Cl: 2; Hg: 1 SBS 1, Mean 2012 BIOBS, Mean BIOBS, Mean 2012 Short analysis Net. Calorific Value MJ/kg o.s. 10,1 13,3 13,4 11,5 11,7 H 2 O % o.s ,9 23,2 25,2 25,6 Ash % o.s. 2,5 9,7 8,9 11,9 10,5 Chlorine % o.s. 0,02 0,38 0,33 0,23 0,21 Volatile % o.s. 23,5 53,5 55,9 49,5 54,1 Elementary analysis C org % o.s. 30,5 34, ,1 31,2 H % o.s. 2,2 4,6 4,6 4,9 4,2 O % o.s. 10,3 23, ,1 26,9 N % o.s. 0,4 1,5 1,5 1,2 1,1 S % o.s. 0,2 0,19 0,18 0,14 0,12 Addtional parameters Biogenic C % of TC 0 69,8 77,8 84,3 85,7 Chlorides mg/kg d.s Al mg/kg d.s K mg/kg d.s Na mg/kg d.s Pb mg/kg d.s Zn mg/kg d.s. 3,

15 Energy specific CO 2 -emissions of different fuels t CO 2 /TJ Lignite Hard coal Heavy fuel oil Light fuel oil BPG 2 CO 2 -reduction: >= 1 (BC) t CO 2 /SBS1 or BIOBS Emission factors of SRF certified according to RAL-GZ 724 Natural gas realistic fossil share SBS 1 BIOBS 15 15

16 Output as a result of sorting and treatment in Erftstadt 948 t Output ABA/AKEA 2009: ca t/a t t 832 t 191 t t t SBS, BIOBS To MSWI Plastic (PVC) NF-metals / Aluminium Fe-Metals Inert Excess water Drying losses t Residues to MSWI`s are more homogeneous than without sorting/treatment 16 16

17 CO 2 -effect as a result of sorting and treatment in Erftstadt Contribution of output-streams to CO 2 -reduction ABA/AKEA 2009: t t 191 t ca t/a or 0,55t CO2/t Input t SBS, BIOBS To MSWI Plastic (PVC) NF-metals / Aluminium Fe-Metals t Decisive way to increase CO 2 -reduction: increase SRF- and recycling-rates 17 17

18 Part 3: Use of BIOBS Dr.-Ing. Th. Glorius, Final Conference RECOMBIO, Helsinki

19 CHP-Plant Wachtberg SRF-delivery (BIOBS) with walking floor-trucks CFB combustion system 2 x 166 MW th Used amount of BIOBS: Mg ( ) Source: RWE Power 19

20 Use of BIOBS in CHP-plant Berrenrath CFB combustion system 2 x 235 MW th BIOBS used : ca Mg (ongoing, planned Mg) Source: RWE Power 20

21 Used amounts of BIOBS in CHP-plants of Wachtberg and Berrenrath Annual amount in t/a Berrenrath Wachtberg till week planned Used total amount of BIOBS a.) in Wachtberg ca t b.) in Berrenrath: ca t (planned sum ca t) 21

22 Results Life Cycle Assessment of the JRC-EU with respect to Erftstadt-Berrenrath/Wachtberg Observation of the effects of sorting/ treatment in Erftstadt and of the output on Combined energetic use of certified SRF in co-incineration plants (brown coal power plants) and residuals from sorting in MSWI`s substantial recycling of plastics, Fe-/Non-iron metals, Regarding all 15 LCA-categories according to ISO and ILCD handbook for compared to using primary resources (brown coal, primary plastics, primary metals, ) production and use of SRF in Erftstadt is a successful combination of recycling and resource strategies (advantages in 14 of 15 categories) Treatment technology in Erftstadt (MBS-plant) is a sustainable contribution to reach the environmental aims of modern resource and energy management 22

23 Summary Demonstration case Germany (06/2013) NIR-technology is the key to produce high-quality fuels based on high calorific waste fractions can be used/developed as an online-analysis-system for NCV, Cl and H 2 O RAL- quality certified SRF`s (RAL-GZ 724) guarantee a high quality reliabilty and ensure an environmently friendly use in cement industries and power plants Fuel-quality is the decisive tool for high efficiency About 1t CO 2 reduction/t SBS or BIOBS in brown-coal substitution Results of external LCA by the JRC Ispra on behalf of the EU-Commission taking into account 15 life cycle impact categories shows environmental sustainability; this means that co-incineration of quality assured SRF is ecologically useful No food or fuel -problematic Production and use of SRF is recommended for other (EU-) countries (i.e. GB, PL) European potential SRF co-incineration cement and power plants: Mio t /a MSW-Incinerators as the last step of modern waste management (ultima ratio) 23

24 Back-up Dr.-Ing. Th. Glorius, Final Conference RECOMBIO, Helsinki

25 Development of Cl-values of SBS Erftstadt Internal / external supervision (n = 1.601) Cl [% of ds] 1,50 1,00 0,50 Median Average 80th-Percentile 0, First trials with NIRsorting Effect of German landfill-directive Effect of increasing input competition NIR-online analysis 25