remondis gmbh dr.-ing. th. glorius, quovadis-workshop, rome, 23.-25.10.2007 the eu-project recofuel...

REMONDIS GmbH

Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007

The EU-Project RECOFUEL

Part 1: Production of SBS®

Part 2: Use of SBS® in PC and CFB-plants

REMONDIS GmbH


Part 1:

Production of SBS®

REMONDIS GmbH

3Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007

Brennstoff ausproduktionsspezifischen

Gewerbeabfällen

BPG®

Source seperatedwastes /

production residues

High calorific fractions(HCF)

sorted out from poste-use waste

SBS®

Substitutbrennstoff

Two quality groups, two trade marks since 1995/1998

REMONDIS GmbH


paper wastesas BPG 1,plastics- resins- polyacrylic- polyester- polyolefine- PUR- etc.fibre fabricscarpets etc.

BPG 2cement kilns

BPG 1power plants

residues frompaper productionrejects,punchings,photography paper,blocks,wet-strengthpaper,cellulose cloths etc.

BPG 3lime kilns

low ash plastics- resins- polyacrylic- polyester- polyolefine- PUR- etc.

SBS 1 power plants

lignite

different high-calorific fractionsfrom-MSW-demolition wastes

SBS 2cement kilns

hard coal

see SBS 1

5 different qualitiesfor different customers

REMONDIS GmbH


Input materialsfor SBS®

SB

S

®-pro

du

ctio

n

SBS®construction and demolition wastes

LFP-sorting

mechanical-biological treatment plant

bulky wastes

commercial wastes

composting

high calorific fraction (HCF2)



high calorific fraction

(HCF1)



Quality Assurance of HCF`s

QA of SBS®

REMONDIS GmbH


Specifications for BPG® and SBS®

Parameter UnitBPG 1 power plants

BPG 2 cement kilns

BPG 3 lime kilns

SBS 1 power

plants (BC)

SBS 2 cement kilns/ power

plants (HC)NCV MJ /kg 16 - 20 20 - 24 23 - 27 13 - 18 18 - 23Cl % < 1,0 < 1,0 < 1,0 < 0,7 < 1,0F % < 0,05 < 0,05 < 0,05 < 0,05 < 0,05

H2O % < 35 < 20 < 12,5 < 35 < 20

S % < 0,2 < 0,3 < 0,3 < 0,5 < 0,8

Ash % < 20 < 15 < 9 < 20 < 15

As mg/kg ds < 10 < 10 < 10 < 10 < 10Be mg/kg ds < 1 < 1 < 1 < 1 < 1Cd mg/kg ds < 9 < 9 < 9 < 9 < 9Co mg/kg ds < 12 < 12 < 12 < 12 < 12Cr mg/kg ds < 120 < 120 < 120 < 250 < 250Cu mg/kg ds < 400 < 400 < 400 < 1.000 < 1.000Hg mg/kg ds < 0,5 < 0,5 < 0,5 < 1,0 < 1,0Mn mg/kg ds < 100 < 100 < 100 < 400 < 400Ni mg/kg ds < 50 < 50 < 50 < 160 < 160Pb mg/kg ds < 100 < 100 < 100 < 400 < 400Sb mg/kg ds < 120 < 120 < 120 < 120 < 120Se mg/kg ds < 4 < 4 < 4 < 5 < 5Sn mg/kg ds < 70 < 70 < 70 < 70 < 70Te mg/kg ds < 4 < 4 < 4 < 5 < 5Tl mg/kg ds < 1 < 1 < 1 < 1 < 1V mg/kg ds < 15 < 15 < 15 < 25 < 25

(*): values for digestion with aqua regia in a closed microwave system

REMONDIS GmbH ThermWert Dr. Glorius Spezifikation.xls, Stand: 01.01.2007

REMONDIS GmbH


Waste treatment center VZEK, Erftstadt Flow-sheet (12/2005)

MSW

Bulky/Commer-cial waste

New plant (ABA)

feeding

screeningFe-/ NF-

seperation

Fe-/ NF-seperation

Fe-/ NF-metals

biol. drying residues/ MSWI

NIR-seperation

water

feeding biomass

SRF-plant (AKEA)

Production wastes

feeding

size reduction

Prior size reduction-

windshiftingdisturbent materials

Fe-seperation

NF-seperation

fine grindingSRF`s:

BPG® and SBS®

storage/ loading

Fe-/ NF-metals

HCF

LFP-residues, production w.

feeding NIR-seperation residues

REMONDIS GmbH


FeedingFeeding

Acceleration conveyorAcceleration conveyor

Sorting residuesSorting residues

Positive Positive fractionfraction

ComputerComputerNear Infrared-SystemNear Infrared-System

(NIR)(NIR)

NozzlesNozzles

Nozzle Pipes Nozzle Pipes Control SystemControl System

Positive fractionPositive fraction SBSSBS®®

Sorting residues Sorting residues MSWIMSWI

CameraCamera

HCF-Sorting with NIR-systems positive separation

REMONDIS GmbH


Development of input materials for SBS®1E [weight %]

Input Material 2004 Weisweiler

2005 Weisweiler

20062007

Berrenrath (projected)

Production specific waste (high Al-content) 30 0 0 0

Production specific waste (low Al-content) 0 25 10 10

High Calorific Fraction from MSW 70 75 38 40

High Calorific Fraction from bulky waste 0 0 50 46

High Calorific Fraction from mixed commercial waste 0 0 2 4

REMONDIS GmbH


Extended QMS for the production of SBS®

Acceptance area

Positive sorting of HCF

SBS®-Production

Process-chain

SBS®-Storage

QA-chain

Input control

Process control

Process control

Product control:

Internal and external

ISO 9001 EFB RAL-GZ 724 CEN TC 343

REMONDIS GmbH


Quality/product control

Regular samplingduring production

Analysis of H2O in the plant

Single samples are combined to 500-Mg-mixed-samples,....

Delivery to the customer

Sampling behind last step of size reduction

Every 1.500 Mg additional parameters are analysed:

Analysis report – Number ...1.500-Mg-analysisfor BPG and SBS

Parameter:ds, H2O, Cl, Ash, NCV, F, ...HM Group I-III:As, Be, Cd, Co, Cu, Hg, Mn, Mo, Ni, Pb, Sb, Se, Sn, Te, Tl, V, ZnAsh:Al2O3, CaO, Fe2O3, K2O, MgO,Na2O, P2O5, SiO2, SO3, TiO2, ZnO

... and are analysed by an external laboratory :

Analysis report – Number ...500-Mg-analysisfor BPG and SBS

Parameter:ds, H2O, Cl, Ash, NCV+ 2 HM (changing monthly)

REMONDIS GmbH


Development of SBS1Erftstadt-quality

Short analysis and elementary analysis

Unit Lignite from the Rhine (Inden),

Mean

SBS 1 Mean

2004 - 2005

SBS 1 Mean 2006

SBS 1 Mean 2007

Short analysisNet. Calorific Value MJ /kg o.s. 8,15 14,1 13,6 14,2H2O % o.s. 58,8 29 22,7 21,5Ash % o.s. 3,0 10,3 9,6 9,4Chlorine % o.s. 0,02 0,34 0,42 0,35Volatile % o.s. n.a. 55 57 49,2Elementary analysisCorg % o.s. 24,8 33,5 32,8 37,2H % o.s. 2,2 5,5 4,7 5,3O % o.s. 10,6 20,3 28,4 24,6N % o.s. 0,4 0,5 1,5 1,4S % o.s. 0,2 0,1 0,2 0,2

REMONDIS GmbH


Development of Cl-values of SBS® since 1997 (n = 919, 10/2007)

First trials with NIR Effect of German landfill-directive

0,00

0,50

1,00

1,50

2,00

2,50

3,00

1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007

% o

f ds

MedianAverage80%-Perc.

REMONDIS GmbH


Development of parameterswith slagging, fouling- or corrosion-potential for SBS®1 (08/2007)

0

2.000

4.000

6.000

8.000

10.000

12.000

14.000

16.000

18.000

20.000

Al K Na Cl Chlorides

mg

/kg

ds

Mean 2004Mean 2005Mean 2006Mean 2007

REMONDIS GmbH


Biogenic share of SBS®1Erftstadt

Results Dissolution method (prCEN/TS 15440)

28,263,463,8050100[% v. TS bzw. J% (waf)] , n = 1728,2 32,7

75,0

63,874,5

63,4

0,0010,0020,0030,0040,0050,0060,0070,0080,00

Biogenic C2005 [% of

ds]

Biogenic C2006 [% of

ds]

Biomasscontent

2005 [% ofds]

Biomasscontent

2006 [% ofds]

Sharebiomass ofNCV 2005[J% (waf)]

Sharebiomass ofNCV 2006[J% (waf)]

[%]

REMONDIS GmbH


Energy specific CO2-emissionsof different fuels

t CO2/TJ

BP

G2

Lig

nit

e

Ha

rd c

oa

l

Hea

vy f

uel

oil

Lig

ht

fuel

oil

Nat

ura

l g

as

SB

S1

CO2-reduction:0,75(HC) - 1(BC) t CO2 /SBS

(with 50% biomass content)

40 50 60 70 80 90 100 110 120

30

realisticfossilshare

realisticfossilshare

REMONDIS GmbH


Part 2:

Use of SBS®

in Pulverized Coal- and Circulating Fluidized Bed-plants

within the RECOFUEL-project

REMONDIS GmbH


term

duration

36/48 month start

June 2004

partner consortium

12 partner of 6 EU-states coordinator

REMONDIS

issues1. sustainable production of SRF`s suitable for power plants2. environmental acceptability and technological feasibility3. accompanying research4. european technology transfer

EU-Project RECOFUELProduction of SRF (SBS®) and use in lignite boilers

REMONDIS GmbH


Project RECOFUELmain issues of the partners

• REMONDIS SRF-production + coordination

• RWE Power large-scale demonstration co-combustion

• University Stuttgart lab tests + simulation

• INFA balances of SRF-production

• KEMA ash properties + corrosion

• TAUW quality control in the power plant

• CESI corrosion

• Åbo Akademi Process SFR properties + ash

• University of Athens combustion model

• VINCA mill measurements

• ESSENT technology transfer

• PPC technology transfer

REMONDIS GmbH


PC-plant of RWE Powerin Weisweiler

Source:

RWE Power

REMONDIS GmbH


PC-plant of RWE Power in WeisweilerFeeding device for paper sludge (incl. 3 hoppers)

Source:

RWE Power

REMONDIS GmbH


Co-combustion of SBS® with lignite in Weisweiler

SRFdelivery

hopper

lignite supply 1200 Mg/h

8 coal mills electrostatic filter

boilers with primary DENOX:

2 x 600 MWel

cooling towerSBS-delivery:

average 20-25 Mg/h maximum 50 Mg/h

REAdesulphorisation

FluffFluff

Source:

RWE Power

REMONDIS GmbH


Trials at WeisweilerPP in 2005

SBS®1: 4200 Mg, 12,5 Mg/h (up to 4% thermal share) Paper sludge during SBS®1: ca. 13000 Mg Lignite during SBS®1: ca. 345 000 Mg Steam data: 530°Cel., 169 bar

Test and measurement plan:• Input and output analysis of SBS®1 production • Fuel input analysis at the power plant• Analysis of the biogenic content • Investigation of fuel preparation and mill behaviour• Emission measurement in flue gas

- Flue gas composition - HCl-measurement in the raw gas

• Furnace measurements

• O2- and temperature meas. before/after mill

• Analysis combustion residues• First investigations of the corrosion potential

Source: IVD, University Stuttgart

REMONDIS GmbH


Direct co-combustionof SBS®1 in Weisweiler

Source:

RWE Power

REMONDIS GmbH


quality of SRF (SBS®)

delivery and transfer

feeding and dosing

combustion behaviour (ignition and burnout)

fixing of heavy metals etc. in ash and gypsum

flue gas cleaning system

emissions according 17. BImSchV (WID)

landfilling characteristics of combustion residues

Co-incineration of SBS® in lignite power plants is technically and environmentally feasible

Evaluation of SBS®-co-incinerationin Weisweiler

Source:

RWE Power

REMONDIS GmbH


Extension of the projectto a new power plant and a duration of 48 months

Motivation:

Missing longterm permission in PC-plant of Weisweiler

Existing feeding technology in CFB/CHP-plant Berrenrath

Existing longterm permission for SBS®-use in Berrenrath

Consequences:

Additional administrative work (Consortium and EC)

Increased knowledge about corrosion risk with respect to two technologies

Use of the potential of lignite burning PC-power plants in West-Germany postphoned

Use of the potential of CFB-plants stabilized

REMONDIS GmbH


Berrenrath Power Plant

Source:

RWE Power

REMONDIS GmbH


Co-combustion installations of the Berrenrath Power Plant

sewage sludge

SBS®1

run-of-mine-lignite

pulverized lignite coke (activated carbon)

Source:

RWE Power

REMONDIS GmbH


BERRENRATH CFB (ca. 300 MWtherm)

Steam data :• 77.8 kg/s• 510 ºC• 90 bar

Fuels :• Lignite• Sewage sludge• Lignite sludge• Demolition wood• SRF (up to 25%

thermal share)

SUPERHEATER 4

SUPERHEATER 3

SUPERHEATER 2

ECONOMIZER

AIR PREHEATER

CFB boiler (CHP)in Berrenrath

Source:

RWE Power

REMONDIS GmbH


Summarypart 1-2

NIR-technology is the key to select suitable high calorific fractions from MSW, bulky waste and mixed commercial wastes

NIR-technology in development (improvements of selectivity)

Modern treatment-technology is the basis for good chemical und physical fuels properties

QMS according RAL-GZ 724/CEN TC 343 can improve the reliability of fuel properties

Improved SBS®1-qualities even after effectiveness of landfill directive

Very low Cl-values (mean of 3 assays < 0,5% of d.s., max < 0,7% of d.s.) requested by RWE Power

New location for longterm-tests: CHP-plant in Berrenrath (CFB-techn.)

Interesting CO2-reduction potential: 1t CO2/t SBS®1

REMONDIS GmbH


Acknowledgment

The RECOFUEL-project is funded by the European Commission under the Sixth Framework Programme

European Commission Directorate-General for Energy and Transport

and

Intelligent Energy Europe

Thank you!

remondis gmbh dr.-ing. th. glorius, quovadis-workshop, rome, 23.-25.10.2007 the eu-project recofuel...

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