PURATEK PURATEK SOLIDIFICATION. International SOLIDIFICATION. innovative solutions - 1 -

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1 SOLIDIFICATION SOLIDIFICATION innovative solutions

2 General Content 1. General 3 2. Process Description SOLIDIFICATION 4 3. Applications SOLIDIFICATION 5 4. Equipment SOLIDIFICATION Input Material Feed Hopper Conveyors for the Input Material Silo Plant(s) for Additives Conveyors for Additives Dosing Units for Input Material and Additives Process Water Tank, Process Water System and 12 Feeding and Dosing Units for Additive Chemicals 4.7. Mixing Equipment Conveyor and Loading / Dispatch Equipment for the 14 Final Product 4.9. Equipment for Casting, Compaction and Transport 15 of Molds Process Control System References SOLIDIFICATION Handling of the Final Product of SOLIDIFICATION Scope of Work and Scope of Delivery PURATEK 19 The SOLIDIFICATION, also known under the terms STABILIZATION, IMMOBILIZATION or CONDITIO- NING, encapsulates contaminants non-leachably and permanently and minimizes the risk of environmental hazards. The SOLIDIFICATION is specifically qualified to treat inorganic waste and skid-mounted unit contaminants, specifically heavy metals, but also organic waste and radioactive waste. Typical types of waste, which are qualified to be treated by SOLIDIFI- CATION are: > Inorganic waste / solids, e.g. spent catalysts from petrochemical and chemical industry, fly ash and fine slag from incineration plants, specifically municipal waste and hazardous waste incineration plants > Inorganic sludge, e.g. heavy metal containing sludge from galvanizing and leather industry > Radioactive sludge > Municipal and industrial sewage sludge > Contaminated soil The SOLIDIFICATION process is based on the physical encapsulation of the contaminants and the chemical fixation of the contaminants in the solid matrix of the new generated product. Normally cement, limestone or fly ash is used as additives in combination with water. The chemical fixation is caused by additives like sulfides, iron salts, sodium silicate, clay, zeolite etc. Depending on the specification of the waste to be treated and the specification of the final product, the final product of the SOLIDIFICATION will be reintegrated at site, disposed and integrated at approved landfills or used for construction e.g. base layer of roads or core of dykes and banks. Furthermore the final product of SOLI- DIFICATION can be casted to molds. The hardened molds can be reused or integrated into a landfill. Mixer (solidification reactor), inside hardened block after removing the form

3 Process Description SOLIDIFICATION Applications SOLIDIFICATION The SOLIDIFICATION process is the input material will be encapsula- ly precipitation processes are used Typical input material / type of waste for Typical clients for the SOLIDIFICATION: based on the physical encapsulation of the contaminants and the chemical fixation of the contaminants in the solid matrix of the new generated product. Normally cement, limestone or fly ash is used as additives in combination ted by the binding material and the additives. Thereby it shall be differentiated between micro encapsulation (encapsulation of single particles) and macro encapsulation (encapsulation of agglomerates of particles or the whole waste matter). In case of the physical encapsulation the porosity to transfer the heavy metals to a non leachable form and to fix the heavy metals in the final solidified product. The alkalinity of cement causes in presence of certain heavy metals the generation of non leachable hydroxides and carbonates. To some extent special precipitation chemicals like sulfides or organic sulfur components (e.g. TMT 15) are used to immobilize heavy metals. SOLIDIFICATION: > Inorganic waste / solids, e.g. spent catalysts from petrochemical and chemical industry, fly ash and fine slag from incineration plants, specifically municipal waste and hazardous waste incineration plants > Inorganic sludge, e.g. heavy metal containing sludge from galvanizing and leather industry > Radioactive sludge > Municipal and industrial sewage sludge > Contaminated soil > Waste treatment facilities > Landfill facilities, specifically hazardous waste landfill facilities > Hazardous waste incineration facilities > Incineration facilities: Municipal waste and hazardous waste incineration plants, power plants > Waste treatment operation companies, also soil treatment companies > Chemical industry > Petrochemical industry Furthermore chemical sorption and physical sorption processes are used > Metal processing industry, like galvanizing industry for the fixation and immobilization of contaminants. In case of the sorpti- > Nuclear power industry and disposal facilities for radioactive waste on processes heavy metals and also organic molecules are bonded to electrically charged surfaces of special substances like clay materials. For sorption of heavy metals clays like bentonite or vermiculite or ion exchange resins are used. user-friendly operation and adjustment of the recipe through touch-panel with water. The chemical fixation is will be reduced substantially and the caused by additives like sulfides, iron connecting paths to the surface will salts, sodium silicate, clay, zeolite be blocked and a water infiltration is etc. not possible. The leaching process is limited to the surface or fracture surface of the final solidified product. The input material / waste is mixed in continuous or batch wise operated mixers with additives like cement, lime- In case of the chemical fixation of the stone, gypsum, fly ash or blast furnace contaminants, the contaminants will slag (scoria) and water intensively. In be integrated into the crystal lattice or this process the waste and the contaminants of the waste are encapsula- product. the solid matrix of the final solidified ted and fixed. In case of the treatment of heavy metal containing input material In case of the physical encapsulation, frequent- Depending on the specification of the waste to be treated and the specification of the final product, the final product of the SOLIDIFICATION will be reintegrated at site, disposed and integrated at approved landfills or used for construction e.g. base layer of roads or core of dykes and banks. Furthermore the final product of SOLI- DIFICATION can be casted to molds. The hardened molds can be reused or integrated into a landfill

4 Equipment SOLIDIFICATION Feed Hopper for the Input Material PURATEK SOLIDIFICATION Units consist of the following parts: > Feed hopper for the waste (including grid for the protection of the downstream equipment) > Conveyor for the waste, e.g. drag chain conveyor, screw conveyor, sludge and slurry pumps etc. > Silo plant(s) for the additives > Conveyors for the additives, e.g. screw conveyors, pneumatic conveyors etc. > Dosing units for the waste and the additives (gravimetric or volumetric) > Process water tank and process water system > Feeding and dosing units for the additive chemicals > Mixer (continuous or batch operated) > Conveyors and loading facilities for the final solidified product > Alternative: Casting facilities for the production, compaction and transport of molds PURATEK feed hoppers are designed for the filling via wheel loader. Special design for the filling via truck and skip truck are available also. The design of the feed hopper avoids bridging, even during handling of very difficult input material, like inorganic sludge or sewage sludge. For the protection of the downstream equipment and the retention of bigger par- feed hopper with integrated screen ticles like stones the feed hopper can be equipped with a grid. The discharge of the material from the feed hopper is carried out via a double screw conveyor. The throughput will be adjusted via a manual adjustable gear box or a frequency inverter in accordance with the required throughput and the specification of the input material. PURATEK SOLIDIFICATION Units are PLC controlled and work fully automatically. The units are operated via touch panel (HMI human machine interface) and the recipes can be adjusted easily. According to the applications the SOLIDIFICATION Units are equipped with required accessories like air extraction and filter units. Robust designed feeding screws for various input material Feed hopper for truck feeding

5 Conveyors for the Input Material / Waste Silo Plant(s) for the Additives Preferably drag chain conveyors are LIDIFICATION plant. PURATEK Drag ground chain consists of C45 steel or PURATEK Silo Plants are designed used for the transportation of the in- Chain Conveyors transport reliably 42CrMo4 steel. The ground chain is as round silos with conical bottom put material / waste. In accordance to either solids / bulk materials or also routed via gears made from low abra- segment. the specification of the waste and the sludge with a dry substance content sion manganese steel. The design of layout of the SOLIDIFICATION unit, more than 15 %. Drag chain convey- the conveying paddles is adjusted to The silo plants for the additives are specifically the distance between feed ors cause only a low mechanical load the specification of the input material filled pneumatically. A pneumatic hopper and mixer, also screw convey- on the transported material and there- / waste. pinch valve which is controlled via a ors, belt conveyors or sludge or slurry fore drag chain conveyors work with level switch protects the silo against pumps are used. low abrasion. over filling. PURATEK Drag Chain Conveyors The drag chain conveyor consists of PURATEK Silo Plants are equipped ensure the highest flexibility and ro- a robust steel frame construction with with automatic pneumatic silo top fil- bustness for the conveying of various renewable abrasion protection panels ters which are activated during the fil- input materials considering discre- at the bottom. The flanged convey- ling process of the silo. The automatic pancies in the specification of the in- ing elements are connected via flexi- cleaning process is controlled either put material and the layout of the SO- ble fasteners. The one or two string by time or by differential pressure. The silo plants are in accordance to the application either equipped with level switches or continuous level monitoring systems. small cement silo integrated in a solidification plant with low capacity To avoid bridging in the silo the coni- spiral conveyor / screw conveyor, inside cal bottom segment is equipped with pneumatic bulking systems, mechani- Cement silo plant, capacity 100 m³ cal knocking systems or special vib- spiral conveyor / screw conveyor ration bottoms to avoid bridging in the conical bottom segment of the silo. Discharge via powered vibration-bottom The transition to the conveyor is designed as sliding valve and/or star feeder system depending on the speci- chain belt conveyor fication of the additives. Star feeders are variable speed controlled. drag chain conveyor, inside production of a drag chain conveyor Loading of a spiral conveyor / screw conveyor in our factory Discharge via pressurized air system Silo plant, capacity 40 m³

6 Conveyors for the Additives Dosing Units for the Input Material and the Additives In general the additives are transpor- Input material / waste and additives In general the gravimetric dosing ted via screw conveyors to the SO- are dosed via volumetric dosing units takes place batch wise via weighing LIDIFICATION unit. According to the or gravimetric weighing drums into drums, which are located on weighing application and the specification of the mixer. The selection whether vo- cells. Continuous weighing systems the additives screw conveyors with lumetric or gravimetric dosing units are used in special applications only, shaft or spiral conveyors without shaft are used is based specifically on the if the specification of the dosing ma- are used. required quality of the final solidified terial enables the use of a continuous product and the selection of the mixer weighing system. Specifically for the The screw conveyors are designed type (continuous or batch wise ope- input material / waste the use of con- either as trough screw conveyors or rated). tinuous weighing systems is limited tube screw conveyors and throughput because of the specification of the controlled via manual gear boxes or Volumetric dosing units consist of a waste and the variation of the specifi- frequency inverters. feed hopper and a dosing screw. The type of the dosing screw is adjusted cation of the waste materials. volumetric dosing device Based on the material selection and to the specification of the dosing ma- the special design, specifically the terial. The throughput is controlled eit- low rotation speed, PURATEK screw screw conveyor for additives her via manual gear boxes or variable conveyors work with very low abrasi- speed control via frequency inverter. on. For highly abrasive additives the According to the specification of the screw conveyors are equipped with dosing material bulking agitators and abrasion protection panels. feeding improvers are installed in the feed hopper to ensure a continuous and homogeneous filling of the do- load cells at dosing system gravimetric dosing system sing screw and an exact dosing of the material. Screw conveyor with shaft special design to operate 2 plants with 1 silo screw conveyor for cement shaftless screw conveyor volumetric dosing device

7 Process Water Tank, Process Water System and Feeding and Dosing Units for additive Chemicals Mixer In accordance to the application and ensure the required specification of size of the mixer or the filling level of The process water system consist of a process water tank (break tank), which ensures the independence from the local water supply, the pressure generation and maintenance system, the flow control system and the required dosing valves. the required specifications of the final solidified product various mixing devices are used: > Continuous operated double shaft mixers with paddles > Continuous operated plough share mixers > Batch plough share mixers the final solidified product. The mixing devices are equipped with manual adjustable gear boxes or variable speed drive via frequency inverter and changeable, adjustable mixing tools. The qualified material selection for the shell of the mixer and the mi- the mixer, the rotation speed of the mixer shaft(s) and the adjustment of the mixing tools. PURATEK Mixers are multiple in operation and proven for various applications and ensure a proper mixing, a high flexibility, low maintenance effort The chemical additives are dosed via qualified dosing pumps to the process water. Static mixers ensure the required mixing and homogenization with the process water. The mixers are the core equipment of the SOLIDIFICATION unit and ensure a proper mixing of the input material / waste with the additives, the process water and the chemical additives and xing tools ensures low abrasion. For abrasive applications renewable abrasion protection panels are applied to the mixer shell. The required mixing and the required retention time is controlled via the and a long lifespan. double shaft paddle mixer (continuous mixer) mixer shafts in operation mixer shafts before first operation plough share mixer designed as a batch mixer plough share mixer designed for continuous operation continuous mixer, capacity 600 l plough share mixer, interior view with weir mixing tool with wear-protection

8 Conveyors and Loading Facilities for the Final Solidified Product The transport and the loading of the final solidified product are executed via belt conveyors in general. For the homogeneous and complete filling of skips various types of PURATEK belt conveyors are available: > Belt conveyors and cascades of belt conveyors > Slidable belt conveyors (also available with reverse transport) > Swivel-mounted belt conveyors > Telescopic belt conveyors (also available swivel-mounted) The skip handling is designed as a skip shifting system or skip carrousel systems. For the skip shifting systems skip trolleys for single or multiple skips, which are moved on rails, are used. Via special turn tables the filled skips are provided for the loading to special skip trucks. Equipment for Casting, Compaction and Transport of Molds The final product of SOLIDIFICATION can also be casted into forms, compacted and get hardened to molds. The molds can be removed from the form / shattering after short period already, but the final strength will be achieved after approximately 30 days only. The hardened molds have a very low porosity. A water infiltration is not possible further on. Leaching is limited to the surface of the concrete block. For the production of molds batch mixers are used. The content of the mixer is adjusted to the size of the molds to be produced. The content of the mixer is emptied after the mixing process into the form / shattering completely. Therefore an empty form / shattering is transported via a roller conveyor system under the mixer. A vibration and compaction unit, which ensures the required compaction of the final solidified product and the final strength of the molds, is located under the mixer. The filled forms / shattering are transported via a roller conveyor system out of the SOLIDIFICATION unit. At the end of the roller conveyor system the filled forms are picked up by a fork lift and transported to the hardening area. fully automatic operated roller conveyor for casting molds PURATEK Skip Carrousels provide a comfortable skip handling, specifically a smooth dropping of the empty skips and smooth pick-up of the filled skips and provide also a possibility for intermediate storage for several skips. block after removing of the form casting mold and completed blocks, approx. 1 m³ mold feeding process

9 Process Control References SOLIDIFICATION PURATEK SOLIDIFICATION Units are controlled via PLC and operated via Touch Panel (HMI Human Machine Interface). Semi Mobile Plant Place of Installation: Landfill Hochhalde Schkopau Date of Installation: 2008 / 2009 The process flow is automatic. The operation software is comfortable for the operators and the operators can adjust the recipes easily. Beside the program NORMAL OPE- Client: SUC Sächsische Umweltschutz Consulting GmbH Application: Waste Treatment Plant for the production of alternative building materials to use in landfills. For the EU-LIFE-Demonstration-Project ENV/D/ CONWASTE RATION also special programs for START and STOP of the plant and for CLEANING of the plant, specifically of the mixer, are available. In emergency case and for maintenance purposes also MANUAL OPERATION is BeAAT Anlage Client: TAKREER (Abu Dhabi Oil Refining Company) Place of Installation: Ruwais, Abu Dhabi, United Arab Emirates Used Materialt: Inorganic waste form Oil and Gas Refining Company, particularly used catalyzer Aggregate: Cement, Sand foreseen. Date of Installation: 2007 / 2008 Capacity: 10 t/h end-product Alarms and warnings are provided optically and acoustically to the operators. For smooth trouble shooting PURA- TEK SOLIDIFICATION Plants are Dörentrup Place of Installation: Waste Water Treatment Plant Dörentrup, Germany equipped with modems, which enable PURATEK Engineers an online-debugging and online-trouble shooting. Date of Installation: 2008 Used Material: Municipal stabilized dewatered sewage sludge Client: City of Dörentrup Aggregate: Quicklime Capacity: Input 15m³/h Brewery Nikolaev Place of Installation: Brewery Nikolaev, Ukraine Date of Installation: 2013 Used Material: Dewatered sewage sludge for brewery Client: CUSS Chriwa Umwelt- Systemtechnik und Service GmbH Aggregat: Quicklime

10 Handling of the Fianl product of SOLIDIFICATION Depending on the specification of the waste to be treated and the specification of the final product, the final product of the SOLIDIFICATION will be re-integrated at site, disposed and integrated at approved landfills or used for construction e.g. base layer of roads or core of dykes and banks. The re-integration or the integration of the final solidified product in landfills takes place in layers with qualified compaction. The result is a monolithic block of final solidified product. Furthermore the final product of SO- LIDIFICATION can be casted to molds. The hardened molds can be reused or integrated into a landfill. PURATEK EXPERIENCE AND COMPETENCE FROM THE CONSTRUCTION OF SOLIDIFICATION-PLANTS WORLD WIDE PURATEK Scope of Services: > Concept Studies > Laboratory Testing > Basic-Engineering, including Layout > Detail-Engineering > Manufacturing of the Equipment of the SOLIDIFIKATION Units > Delivery at Site and Construction / Erection > Commissioning > Optimization of Operation and Troubleshooting > After Sales-Service Solidified waste / concrete blocks before dumping to landfill

11 Thölauer Straße 16 D Marktredwitz / Germany Phone +49 (0) / Fax +49 (0) / info@puratek.eu