Thermo-Chemical Recycling with Energy from Waste

Transcription

1 Thermo-Chemical Recycling with Energy from Waste Dr. Marc R. Stammbach / MD HZI Australia 27 th WasteMINZ Conference Oct 2015 Rotorura NZ

2 Thermo-Chemical Recycling with Energy from Waste (EfW) Basics of EfW Thermal-Chemical Recycling And beyond for NZ Summary 2

3 Basics of EfW 3

4 Office block, warehouse, EfW or tourism? 4

5 EfW closes the energy cycle - Material and energy recycling are complementary CO 2 Material Recycling AUS & NZ 43% EU 40% CH 50% Reduction EfW saves up to 2t CO 2 per treated t of waste. Methane emissions EfW offsets CO 2 from power production. Reduction Thermal Recycling AUS & NZ 0% EU 24% CH 49% AUS & NZ 57% EU 36% CH 1% Groundwater leakage EfW eliminates Methane emissions from Landfill. 5

6 We need at least three bins to achieve zero waste to landfill Energy & Compost from biowaste with anaerobic digestion Energy & Material from non recyclable waste with thermal treatment Recycling Compost & fertiliser Direct Recycling Glass, paper, metals Recycling Metals & minerals 6

7 Electric Power and R1 status for classification of EfW as recycling Main Features Only electricity production without heat utilization Efficiency Up to 27% R1 around 0.7 to 0.8 Grate R1 = [Ep - (Ef + Ei)] / [0,97 * (Ew + Ef)] Energy efficient if R1 > 0.65 for new plants Reference for R1: EC Guidelines on the Energy Efficiency Formula ste/framework/pdf/guidance.pdf (downloaded 26 June 2014) 7

8 Issy-les-Moulineaux Paris, France 8

9 Combustion is safe As is your car De-novo synthesis of dioxins during cool-down after combustion is countered by flue gas treatment (coke injection and catalyst) 460,000 tpy Thermal Waste Treatment Plant Isséane, Greater Paris, France Serving 1.1 Mio people, mostly underground, district heating, no plume at stack 9

10 Waste to Energy - A potential danger? - Say farewell to dioxin spouting! Industry Dioxin Emissions per Year in g TU (toxicity units) Metal extraction & processing Waste incineration Power stations Industrial incineration plants <10 Domestic firing installations <10 Traffic 10 4 <1 Crematoria 4 2 <2 Total air emissions <<70 Reference: German Federal Ministry for the Environment, Sep

11 Dioxins in formula milk come from other sources than EfW Use of EfW: low zero high high high zero medium Reference: Hsu JF et al, A comparison of PCDD/PCDFs exposure in infants via formula milk or breast milk feeding, Vol 56, Issue 3, January 2007, Pages

12 Lucerne, Switzerland l New plant with 2 lines supplying steam to neighbouring paper mill l Hitachi Zosen Inova supplies incineration and flue gas treatment Client Renergia Zentralschweiz AG Start-up 2015 Technology Incineration Grate furnace Energy recovery 4-pass-boiler, turbine, steam export, district heating Flue gas treatment ESP, dry sorption with Bicar, SCR, dry sorption with Lime/AC, heat recovery by two heat exchangers Technical Data Fuel Municipal waste Waste capacity 250,000 t/a (2 x 15.6 t/h) Net calorific value MJ/kg Thermal capacity 2 x 47 MW Steam 2 x 58 t/h (41 bar, 410 C) Flue Gas flow 2 x 82,000 Nm 3 /h l Process aims for high energy efficiency and low emissions using a two-stage dry sorption process with two heat exchangers l Advanced technology with Inova grate, staged secondary air injection and advanced combustion control system 12

13 Xiamen, China Client Xiamen Environment & Sanitation Comprehensive Process Plan Start-up 2006 Technology Furnace Energy recovery Flue gas treatment Residue treatment Technical Data Fuel Waste capacity Net calorific value Thermal capacity Steam Grate furnace 4-pass boiler, turbine Semi dry process Metal separation of slag Municipal waste 144,000 t/a (2 x 9 t/h) 1400 Kcal/kg 29.4 MW 31.8 t/h (40 bar, 400 C) l Waste incineration plant with two incineration lines for the city of Xiamen known as Garden on the Sea l State-of-the-art furnace, flue gas cleaning, metal separation l Hitachi Zosen Inova responsible for overall process design, grate, boiler, semi dry reactor and bag filter, detail design, supply of key components, erection and commissioning supervision 13

14 Jabalpur, India Client Essel Infraprojects Limited Start-up 2015 Technology Concept Furnace Energy recovery Flue gas treatment Standard Local Plus / FGT Type II Grate furnace (air-cooled) 4-pass vertical boiler, turbine Evaporation Cooler / Bag Filter l First reference plant in India, located in Jabalpur (Central India) l Standardized plant design to meet extremely low target price expectations l HZIND is consortium leader with overall responsibility for EPC coordination l HZIND supplies chute to stack technology, as well as materials handling l HZI provides support in engineering and project execution Technical Data Fuel Waste capacity Net calorific value Thermal capacity Steam Gross Power Municipal Solid Waste 600 t/d (1 line) 6.9 MJ/kg 1 x 48 MW 1 x 57 t/h (46 bar, 410 C) 11.5 MW l Consortium partner is Isgec Heavy Engineering (scope is WSC, BOP, E&IC, Civil Engineering) l Based on HZ s engineering, the client supplies waste crane, stack and emission measurement system 14

15 Ferrybridge, UK Client Ferrybridge Multifuel Energy Ltd. (Owned by SSE & WTI) Start-up 2015 Technology Furnace Energy recovery Flue gas treatment Technical Data Fuel Waste capacity Net calorific value Thermal capacity Steam Grate furnace (water/air-cooled) 5-pass boiler, turbine generator set SNCR, semi-dry system SRF/RDF, waste wood, MSW 675,000t/a MJ/kg 2 x 117 MW 2 x 145 t/h (71.5 bar, 430 C) l Multi-fuel facility for RDF and waste wood l Fuel delivery by road and train l High efficient process with direct driven turbine l Built on power station site l Integrated site management to ensure continuous operation of power station l HZI with maintenance contract 15

16 Eastern Creek TNG Project, AUS (in process of permitting) Client Start-up Technology Furnace Energy recovery Flue gas treatment Technical Data Fuel Waste capacity Net calorific value Thermal capacity Steam DADI Dial A Dump Industries 2019 (subject to permit approval) Grate furnace (water/air-cooled) 5-pass boiler, turbine generator set SNCR, semi-dry system Residual waste from C&I and C&D 1,350,000t/a MJ/kg 4x 117 MW 4 x 145 t/h (71.5 bar, 430 C) l Multi-fuel facility for residual waste l Fuel delivery from adjacent recycling centre and by road l High efficient process with direct driven turbine l Built on existing recycling and landfill site 16

17 Thermo-Chemical Recycling 17

18 Urban mining from fly ash Swiss style 99,995% zinc Reference: 18

19 Re-use of hazardous flue gas residuals Norwegian style Langøya is located in Holmestrand fjord (Norway): Consists of limestone with an age of 300 to 400 million years Approximately 3 km long and 500 m wide Limestone extraction for cement production up to 1985 left two craters totaling 9.3 mio cbm below sea level Waste treatment since 1985: Treatment and final disposal of hazardous waste, inorganic industrial wastes, unearthed soil and sediments. Fill large craters as rehabilitation work supported by Norwegian authorities Accepts waste from Scandinavia & Northern Europe Reference : Picture and information from (downloaded 15 Sep 2015) 19

20 Bottom ash treatment to metal and road aggregate Bottom ash treatment wet and dry 20

21 Metal content in bottom ash Analysis of wet bottom ash from a Swiss EfW-plant Content of particular metal [kg/t bottom ash] % of Al in fraction 10-32mm 50% of precious metals in fraction 1-5mm mm 5-10 mm mm mm LNF HNF 2.8±0.2 weight % LNF (Light non-ferrous metals, e.g.. aluminum) 1.3±0.1 weight % HNF (Heavy non-ferrous metals, e.g. Cu, Zn, Pb, Ag, Au, etc.) 21

22 Efficiency of metal recovery from wet and dry bottom ash Content η Wet η Dry (dry basis) FE <8mm 3 % 95% 95% FE >8mm 7 % 95% 95% NF <8mm 2% 50% 95% NF >8mm 1% 95% 95% Stainless > 8mm 0.50% as option as option Depending on local laws, the metal reduced, non-hazardous bottom ash can be used in road construction, industrial construction, sealing/covering layer in landfill, cement and/or concrete industry 22

23 De-tox of bottom ash with thermo-chemical recycling Environmental benefits: 15 20% less weight, less water required Significant reduction in residual organic carbon content thanks to afterburning Lower values for critical heavy metals Recycles multi-composite articles, e.g. coffee capsules, toys, clothes with zippers, foils with metals, cables etc Comparison of non-ferrous metals from dry (top) and wet discharge (bottom) Status: Pilot successful in KEZO Hinwil, Switzerland tpy dry bottom ash recycling plant in construction serving 6 EfW plants (end of 2015) Reference : Picture and information from (downloaded 10 June 2014) 23

24 tpy bottom ash plant fed by 6 EfW Plants In commissioning right now, e.g. late

25 And beyond for NZ 25

26 New Zealand s annual GHG emissions broken down by sector Year Energy Industrial processes Solvents Waste Agriculture Forestry Net Removals Deforestation Gross removals Total Source: (downloaded 15 Sep 2015) 26

27 New Zealand waste statistics and high level GHG impact with EfW MSW Statistics (1): Daily MSW Generation in urban areas: Urban Population: Yearly MSW Generation in urban areas: Greenhouse Gas abatement (2): Impact with 40% recycling and 60% to EfW: NZ with 40% recycling and 60% EfW: Resulting Greenhouse Gas impact: Baseline 2012 (3): Net impact: 3.68 kg/capita/day 3,612,147 people 4,852,000 t/y 0.86 t CO2e/t MSW -4.2 mio t CO2e/y +3.6 mio t CO2e/y -0.6 mio t CO2e/y References: (1) The World Bank 2012: What a waste A global review of waste management, (downloaded 15 Sep 2015) (2) Seghers: GHG abatement: landfill vs. incineration of MSW, (downloaded 15 Sep 2015) (3) Source: (downloaded 15 Sep 2015) 27

28 «Waste hierarchy» beyond Energy from Waste PREVENTION Not only Energy-from-Waste PREPARE FOR RE-USE but also Material-from-Waste! PfW SfW Energy Recovery Power Steam Heating Cooling RECYCLING OTHER RECOVERY DISPOSAL MetalRecovery Precious metal Ferrous Aluminium MfW HfW CfW 28

29 Summary 29

30 EfW closes and extends the material and energy cycle Energy from Waste is environmentally sound and empowers the circular economy Recovers steam, heat and electricity (50% renewable) and is recycling with R1 > 0.65 Chemically recycles recovery of metals from flue gas treatment residues Thermally recycles urban mining of metals and aggregate from bottom ash Turns NZ s CO2 emission from waste below zero and will achieve zero waste to landfill 30

31 Waste is our Energy. Engineering is our Business. Sustainable Solutions are our Mission. Check our References. 31