Produc'on of ammonia and urea from industrial, non- recyclable waste: fantasy or opportunity Albert Van Rillaer, Energy Recovery Systems
ERS Energy Recovery Systems Company, Ltd ( 2012, Saudi Arabia) Founded and managed by Al Issa family, Saudi Arabia Management: William Edgar Smith, Technical Director (USA) Albert Van Rillaer, CEO (B) ERS management has solid, experienced leadership in North- America: first use of waste hydrocarbons as cement kiln fuel, exported interna'onally Numerous waste sources as addi'ves and feedstock in cement manufacturing Crea'on new waste management equipment and technology
Waste to Chemicals in Antwerp Energy Recovery Systems Company plans to build a Waste to Chemicals (WtC) plant in the Antwerp port, changing on a yearly basis 3.485.000 tons of industrial, non- recyclable waste into 645.500 tons of green ammonia and 1.231.500 tons of green urea. Ammonia is used as base chemical in the Antwerp chemical cluster and urea is a sustainable fer'lizer. ERS and the port authori'es are currently nego'a'ng the concession of 150 ha at the Delwaidedock.
Waste to Chemicals ammonia waste Thermoselect gasifica'on urea
WtC plant in Antwerp An investment of 3.7 billion Euro Feedstock arrival 9.500 ton waste/day Daily capacity of 4.500 ton Ammonia and 3.850 ton Urea Trade Balance effect: 500 million euro/year Mari'me Cargo: up to 5 million ton/year import: 1400 ships/year - - export: 35 ships/year Employment 900 FTE + contractors during construc'on phase
Technology Waste to Chemicals installa'on uses Thermoselect technology: Developed in coopera'on with Sinerga SA (CH) Oxygen fed, high temperature, closed gasifica'on system Full Recovery: 100% of waste vola'les as gas Waste inert material as reusable byproduct (metals, minerals)
Material balance
Production process
Why Antwerp? Integra'on with exis'ng chemical cluster ERS ammonia produc'on capacity designed to cover the Antwerp chemical cluster net short Large volumes of excellent quality waste available and delivery by ship Gas and liquid pipeline distribu'on infrastructure Sea, road and rail distribu'on Well trained workforce Presence of contractors and local support Development of synergies with local industrial partners & stakeholders
Technical process & impact by VITO
Produc'on of ammonia and urea from industrial, non- recyclable waste: fantasy or opportunity Ive Vanderreydt, VITO
VITO in a nutshell 200 scien9fic ar9cles 400 patents worldwide 1000 Research projects +500 Research partners 750 Highly- qualified researchers 26 Na9onali9es 7 loca9ons in Belgium HQ in Mol, Belgium Data 31/12/2013
ERS Concept Waste + Air GasificaFon Oxygen Air SeparaFon Nitrogen THERMOSELECT Water SYNTHESIS GAS CO CO 2 H 2 Compression Conversion CO + H 2 O à CO 2 + H 2 Ammonia Synthesis Hydrogen H 2 Reformed syngas SeparaFon NH 3 CO 2 = SYNTHETIC FERTILIZER Urea CO(NH 2 ) 2
Approach 1 Technical feasibility Prof. A. Buekens Does the project have a sound technical design? Is it an innova9ve concept? 2 Environmental impact evaluafon Prof. K. Vrancken + team What will be the overall impact on the environment? How does this impact compare to tradi9onal waste management tradi9onal produc9on 7/09/15 14 2014, VITO NV
Assessment of environmental impacts METHODOLOGY taking into account the total life cycle all relevant inputs and outputs of the system, including all upstream and downstream impacts
Assessment of environmental impacts METHODOLOGY energy resources ERS concept emissions water energy byproducts Environmental impacts
Assessment of environmental impacts METHODOLOGY Inputs and outputs
Assessment of environmental impacts ERS System Waste collec'on Transport industrial waste to ERS ERS treatment of industrial waste FuncFonal unit: produc'on of 650 kton of ammonia and 1,240 kton of urea from 3,500 kton of industrial post- recycling waste AMMONIA UREA
Assessment of environmental impacts Benchmark from ammonia and urea produc'on perspec've Waste collec'on System boundaries of system urea and ammonia from waste Transport IW to ERS ERS treatment of IW ANALYZED PROCESS AMMONIA UREA FuncFonal unit: produc'on of 650 kton of ammonia and 1,2400 ton of urea Primary producfon AMMONIA Primary ProducFon UREA System boundaries of system virgin urea and ammonia AVOIDED PROCESS
Assessment of environmental impacts Benchmark from waste management perspec've FuncFonal unit: treatment of 3,500 ton of industrial post- recycling waste ERS concept Waste collec'on FuncFonal unit: treatment of 3,500 ton of industrial post- recycling waste Transport to incinerator System boundaries of system waste treatment at MSWI with energy recovery IncineraFon (IW) ELECTRICITY System boundaries of system Belgian electricity produc>on Belgian Electricity ProducFon
Result Ammonia and urea produc'on perspec've ERS concept Fossil based producfon
Result Ammonia and urea produc'on perspec've 300 300 200 100 Net result Environmental Benefit 200 100
Result Waste management perspec've 300 Urea and ammonia 200 producfon 100 Environmental Benefit IncineraFon
Conclusions Innovative concept, based on proven technologies Better overall environmental performance compared to traditional techniques Recommenda'ons Focus on high calorific input Effects on input and output markets Use exis'ng experience for opera'on Op'malisa'on poten'al