dr. marc r. stammbach waste expo australia 3 & 4 october 2018 … · 2020. 11. 13. ·...

WtE from an overseas and local context

Dr. Marc R. Stammbach

Waste Expo Australia3 & 4 October 2018 Melbourne VIC

1

Construction of sustainable waste management in Australia

Setting the Scene

Make it happen

Summary

2

Setting the Scene

3WtE from an overseas and local context

Waste frame work of EU countries is around 20 years advanced (except USA)

Country revenue High revenue countries (USA, EU 15) Australia

GDP in $/capita/year > $20,000 > $20,000

Municipal waste by kg/capita/ year 350 – 750 350 – 750

Formal collection rate > 95% > 95%

Statutory waste management National environmental strategy, Ministry of the Environment, statutory framework set up and applied, statistics

No national Environmental strategy, State Departments of the Environment, statutory framework but insufficient application, little statistics, NSW EfW policy which favour landfilling

Waste treatment Selective collection with at least 3 binsCollection schemes and treatment for hazardous wasteRecycling & composting > 50%Waste to Energy accepted àincreasing (except USA)Landfilling decreasing (compulsory treatment or high levy in UK)

Selective collection with 2 to 3 binsLimited schemes for hazardous wasteRecycling & composting <50%Waste to Energy – first projectsLandfilling continues and levy goes to general taxDelta State landfill levies lead to unnecessary waste transports

4

Waste composition by of EU countries and USA and validity for Australia

Municipal waste composition (%) High revenue countries (USA, EU 15) Australia

Organic / fermentable 20 – 40 20 – 30

Paper and cardboard 15 – 50 15 - 25

Plastics 10 – 15 15 – 30

Metals 5 – 8 2 – 4

Glass 5 – 8 5 – 8

Humidity 20% – 30% 20% – 30%

Energy content 1,500 – 2,700 kcal/kg 1,500 – 3,000 kcal/kg

5

EfW closes the energy cycle -Material and energy recycling are complementary

6

EfW saves up to 2t CO2 per

treated t of waste.

CO2

Reduction

Reduction

EfW offsets CO2from power production.

MaterialRecyclingMaterial

Recycling

ThermalRecyclingThermal

Recycling

EfW eliminates Methane emissions

from Landfill.

AUS & NZ 43%EU 40%CH 50%

AUS & NZ 0%EU 24%CH 49%

AUS & NZ 57%EU 36%CH 1%

Methaneemissions

Groundwaterleakage

Australia is behind the curve ball with 57% going to landfill

Source: Eurostat 2016

7

Waste Treatment Transition in Japan

Source: 3R Forum

8

Improvement of Waste Management in Japan

Waste Management Act(1970)

Act on Special Measures against

Dioxins(2000)

Public Cleansing Act(1954)

1950 1960 1970 1980 1990 2000 2010

1st Waste to Energy Plant (1965)

Waste to Energy

Grate

Batch-type Furnace

Fluidized BedGasification

Small Mechanical Incinerator

1st Continuous Stoker Furnace

(1963)

Osaka City (closed in 1999)Throughput : 200t/d, 2linesLHV : 1,200kcal/kg(5MJ/kg)

n Major Furnace Type

Guidelines for the Prevention of Dioxin

Emissions(1990)

n Major Laws Enacted

n History

amendment

9

Major WtE types in Japan

Moving grateFluidized Bed System Gasification and Melting SystemDirect Melting System

MSW Exhaust gas+ Ash

Fluidized Bed System

Coke

Exhaust gas

Slag

Direct Melting System

MSW

Bottom Ash

MSW

Exhaust gas

Moving Grate System

MSW

Slag

Exhaust gas

Gasification and Melting System

10

Trend of EfW plant in Japan after a high in gasification around 2000,now going moving grate again

Number of operating plants as of 2015

Total1,141

11

Comparison of Various WtE Technologies working in Japan

Furnace Type

ItemsGrate

Grate +

Melting

Gasification+

MeltingRemarks

Gross Electricity Generation 450 – 700 kWh/t 450 – 700 kWh/t 450 kWh/t

Internal Electricity Consumption 110 kWh/t 200 kWh/t 210 kWh/t

Net Electricity Generation (supplied to grid) 340 – 590 kWh/t 250 – 500 kWh/t 240 kWh/t

Maximum Throughputper line 1,100tpd G 1,100tpd

M 250tpdF 200tpdD 265tpd

Volume Reduction Ratio 90% 94% 94% as of ash content10%

Gate fee ratio 100% 200% 300%

Notes G : Grate, M : Ash melting furnace, F : Gasification using fluidized bed and melting furnace,D : Direct melting furnace

12

Gasification - a billion dollar debacle in Europe

Thermoselect 110 tpd demonstration plant in Fondotoce, Italy (picture above): Never properly worked, but ended in a large scale plant in Karlsruhe, Germany – never worked….Siemens Schwelbrennverfahren – serious accident in Fuerth, Germany – withdrawal from EU marketRCP by Von Roll Inova (today HZI) – worked, but not economical leading to major rebuilt from pyrolysis grate to normal grate, no high temperature smelt redox, CFB removed

Gexit before Brexit: Latest gasification disaster (next to a few minor ones)

2 x 350,000 gasification lines for Refuse Derived Fuel in Tees Valley, UK Front-end Dirty Material Recycling Facility produces also residuals to landfill next to some metals); RDF now exported to mainland Europe and Scandinavia to grate-based EfW plantsPlasma burners from Westinghouse (never used long-term with similar waste and anywhere near scale)Air Products to record USD $900 million to USD 1 billion pre-tax charge

Reference: Press release “Air Products Will Exit Energy-from-Waste Business”, 4 April 2016, www.airproducts.com

14

http://www.airproducts.com

Incineration happened in many placesIt is also the number one embedded memory in Australia

“Many rural residents may think that burning their own garbage is a good thing because it helps keep garbage out of the landfill. Or, they may think it’s okay if they just burn paper and food scraps, and leave the plastics out.But, new research shows that the burning by rural residents of ALL types of garbage is the fourth largest source of dioxins and furans in Ontario. (Hospital incineration and industrial processes lead the way.)Whether garbage is burned in woodstoves, burn barrels, outdoor furnaces or open pits, it releases toxic pollutants into the air. These include dioxins and furans, and also arsenic, styrenes, PCBs, lead and mercury.These pollutants are produced when oxygen is combined with the chlorine (that exists in most products) in a low-temperature burn.”Picture and citation reference:

http://www.realaction.ca/waste/backyard-burning/ (downloaded 1 Oct 2018)

15

http://www.realaction.ca/waste/backyard-burning/

What else happened in Australia - No WtE technology made it into this millennium

Several incinerators in Australia in last century:Waterloo Incinerator closed in 1997 due to public protest over lack of flue gas treatmentRefurbishment killed of in cross-fire of local elections

SWERF Wollongong:autoclave / pyrolysis / gasificationEDL wrote-down of $136.7 million in 2003

Picture and citation reference: Source SWERF: EDL Annual Report 2003

16

“Waste to Energy - A potential danger? - Say farewell to dioxin spouting!”

Industry Dioxin Emissions per Year in g TU (toxicity units)

1990 1994 2000

Metal extraction & processing 740 220 40

Waste incineration 400 32 0.5Power stations 5 3 3Industrial incineration plants 20 15 <10Domestic firing installations 20 15 <10

Traffic 10 4 <1Crematoria 4 2 <2

Total air emissions 1’200 330 <<70

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Reference: German Federal Ministry for the Environment, Sep 2005.

Concept evaluation Flue Gas Treatment7 Key Questions

Question Yes No

Emission NOx > 80 mg/m3 ? SNCR down to 120 mg/m3DynorTM down to 80 mg/m3

Low temperature SCR system.

Emission levels WID compliant? One step process Lower emissions: Combined processes

Plume at the stack acceptable? Dry or semi-dry scrubbing

Solidification of APC residues required? No use of Bicarbonate. Evaluate Xerosorp system with Bicarbonate.

High discharge fees of APC-residues?

Wet scrubbing & residue treatment Semi-dry scrubbing

Draining of treated waste water possible? Wet scrubbing in favour.

Connection to District Heating Network? Wet scrubbing with flue gas condensation.

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Concept evaluation FGTFour main concepts

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WID compliance*No water discharge

No plumeFlue gas condensation

HZI Xerosorp+ HZI Semi Dry

HZI Scrubber

Residue solidification WID compliance*No water discharge


Residue solidification

WID compliance

No water discharge


Residue solidification WID complianceNo water discharge



HZI Semi Dry & Scrubber


Quantity of APC residues

A P C re s id u e q u a n tity o f d if fe re n t A P C te c h n iq u e sb a s e d o n 6 0 0 H C l / 2 0 0 S O 2 ( in m g /m 3 N ) a s ra w g a s c o n c e n tra t io n

1 0

1 5

2 0

2 5

3 0

3 5

4 0

d ry (b ic a r b o n a te ) s e m i-d r y ( l im e ) w e t s c ru b b e r

kg/t

trea

ted

MSW

h u m id ity

e x c e s sn e u tra lis a t io na g e n t &im p u r it ie sre a c t io np ro d u c ts

P A C

d u s t ( in c lu d in gb o ile r a s h )

WtE from an overseas and local context 20

Energy vision: Maximized energy recovery with tailor-made solutions

21

30.6 18.9 22.3

65.586

16

55.3

0

20

40

60

80

100

Effic

ienc

y [%

]

< Power only Heat only >

Power Heat Heat from Flue Gas Condensation Process Steam

Riverside, UK Lucerne, CH Vaasa, FIN Uppsala, SWE

Influencing factors: l steam parametersl turbine size and designl condenser type and design (ACC, cooling tower, district heating condenser)

l …


Make it happen


Energy & Compostfrom biowaste withanaerobic digestion

Energy & Material from non recyclable waste with thermal treatment

We need at least three bins to achieve “zero waste to landfill”

23

RecyclingCompost & fertiliser

Direct RecyclingGlass, paper, metals

RecyclingMetals & minerals




Plus add some regulatory changes…

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Implement Paris climate agreement with

incentives

Copy & paste EU WID/IED

Rethink some local EfW Policies

Ban untreated waste going to landfill

$100/t + 3x$20/t increases; uniform landfill levies across

States, Territories, and regions & repurpose levy

legislate uniform bin systems

Copy & paste bottom ash reuse regulations

Set landfilling of stabilised flue gas residues at zero or 15% of levy like in UK as already BAT technology


300,000 tpy East Rockingham ProjectEPC Technical Concept – Layout / 3D view


Bottom ash treatment process

Waste reception area

Administration and visitor centre

Weigh bridges

Turbine hall and ACC

Bottom ash storage/maturation areaCombustion line & boiler

Flue gas treatment

25

Strategy for Bottom Ash AggregatesReplicate European experience in the local context

Comply with UK and European Standard

A safely useable product in building materials and aggregates in parallel with recycling of metals

Strategy for Bottom Ash aggregates replicates European experience in the local context

Products manufactured to a robust Quality Protocol

Low embodied energy demand during production

Supporting a sustainable future


Will WtE jeopardize waste reduction, composting and recycling efforts?

-20

0

20

40

60

80

100

was

te[%

]

reduction food &green residual waste

27

Collectionsystem

Fraction of Initial

Unit Cost Waste Arising

Put orPay

Initial 2-binresidual

100% $200/t

3-bin & reduction

-10% nil nil nil

FOGO in third bin

40% $100/t $40 $40

Residualwith 3-bin

50% $200/t $100 $200

Total na $140 $240

• ”Waste Arising” contracts protect waste reduction, composting, and recycling and leads to lower cost

• “Put or Pay” contracts lead to costly & not sustainable outcomes

What if waste avoidance, education and a third bin can lead to less residual waste?

Summary


Summary of “WtE from an overseas and local context”

WtE is proven overseas, powerful, environmentally sound, reliable, bankable and innovating:WtE is the compliment to recycling and composting for all waste which cannot be economically recoveredMoving grate is workhorse of industry, decontaminates, and recycles metals and aggregatesGasification & melting costly and proven in Japan, but on the way out due to missing benefits

Transformation of Australian waste industry to 1% residuals going to landfill possible with:Regulatory waste management framework should be unified and benefit from some copy & paste from EuropeWtE will then become the logical choice for residual wasteWtE with a “service provider” model that allows for improvements in recycling and third bin (biowaste)

Potential for an industry worth $12.5B investment based on 500 kg residual waste per year and capita


Thank you very much!

Waste is our Energy.Engineering is our Business.Sustainable Solutions are our Mission.

Check our References.

Lucerne, Switzerland

l New plant with 2 lines supplying steam to neighbouring paper milll Hitachi Zosen Inova supplies incineration and flue gas treatmentl Process aims for high energy efficiency and low emissions using a two-stage dry sorption process with two heat

exchangersl Advanced technology with Inova Grate, staged secondary air injection and advanced combustion control system

Client Renergia Zentralschweiz AG

Start-up 2015

TechnologyIncineration Grate furnaceEnergy recovery 4-pass-boiler, turbine, steam export, district heatingFlue gas treatment ESP, dry sorption with Bicar, SCR, dry sorption with Lime/AC, heat recovery by two heat exchangersTechnical DataFuel Municipal wasteWaste capacity 250‘000 t/a (2 x 15.6 t/h)Net calorific value 10.85 MJ/kgThermal capacity 2 x 47 MWSteam 2 x 58 t/h (41 bar, 410°C)Flue Gas flow 2 x 82’000 Nm3/h


Buckinghamshire, UK

l Big single line plantl Enabled for combined heat and power productionl Hitachi Zosen Inova acting as Turnkey contractor including civilsl Bottom ash transported to adjacent IBA treatment areal Developed in exclusive partnership with FCC UK

Client FCC UK

Start-up 2016

TechnologyFurnace Grate furnace (air-cooled)Energy recovery 5-pass-boilerFlue gas treatment Turbosorp ® with SNCR

Technical DataFuel Municipal and industrial waste

Waste capacity 300‘000 t/a (1 x 37,5 t/h)Net calorific value 9,8 MJ/kgThermal capacity 102 MW

Steam rate 127,4 t/h (51 bar, 402°C )


Severnside, UK

l EPC turnkey contract for complete plant incl. civil worksl Located in South Gloucestershire with rail link for waste transport from West London by containersl Electrical power production: 38 MW grossl Use of LEAP (O2, wet = 5 vol.%) and DyNOR (NOx < 150 mg/Nm3)l Bottom ash treatment on site (by others)l Developed by SITA UK as Public Private Partnership with West London Waste Authority

Client SITA West London Ltd.

Start-up 2016

TechnologyFurnace Grate furnace (air-cooled)Energy recovery 5-pass horizontal boiler, turbineFlue gas treatment Semi-dry with SNCR

Technical DataFuel Municipal and commercial wasteWaste capacity 388,000 t/a (2 x 24.2 t/h)Net calorific value 9.3 MJ/kgThermal capacity 2 x 62.6 MWSteam 2 x 77 t/h (60 bar, 420°C)


Herefordshire and Worcestershire, UK

l EPC turnkey contract for complete plant incl. civil worksl Located west of Birmingham to recover energy from municipal wastel Electrical power export: 18MW, enough to power 43’000 homesl Development by Mercia as a Waste Management Service PFI contract for the councils of Herefordshire and

Worcestershirel First fire: 5 October 2016

Client Mercia Waste Management Ltd.

Start-up 2017


Technical DataFuel Municipal and commercial wasteWaste capacity 200,000 t/a (1 x 26 t/h)Net calorific value 9.4 MJ/kgThermal capacity 1 x 68MWSteam 1 x 86 t/h (60 bar, 415°C)


Poznan, Poland

l Hitachi Zosen Inova is lead partner in a consortium with HOCHTIEF Polska in a turnkey construction contract l New EfW plant including bottom ash treatment and FGT residue solidification plant on sitel Building Permit engineeringl Combined heat and power:

l max. electrical power ca. 17 MWl max. district heat export ca. 34 MW

l Developed by SITA Polska as Public Private Partnership with city of Poznan as public partner

Client SITA Zielona Energia Sp. z.o.o.

Start-up 2016

TechnologyFurnace Grate furnace (air-cooled)Energy recovery 4-pass vertical boiler, turbineFlue gas treatment SemiDry with SNCR

Technical DataFuel Municipal and industrial wasteWaste capacity 240,000 t/a (2 x 15 t/h)Net calorific value 7.6 MJ/kgThermal capacity 2 x 31.5 MW


Dublin, Irland

l EPC turnkey contract for complete plant excluding civil worksl Located on Poolbeg Peninsula in Dublin to recover energy from municipal wastel Electrical power export: 58 MW, enough to power 80,000 homesl Very low emissions and high efficiency by applying advanced combustion technology and a condenser with

seawater cooling

Client Covanta

Start-up 2017

TechnologyFurnace Grate furnace (air-cooled)Energy recovery 4-pass horizontal boiler, turbineFlue gas treatment SemiDry and wet scrubber,

with SNCR

Technical DataFuel Municipal wasteWaste capacity 600,000 t/a (2 x 32 t/h)Net calorific value 11.5 MJ/kgThermal capacity 1 x 102.5 MWSteam 1 x 125 t/h (62 bar, 443°C)


37

l Consortium IP13 (Suez consortium leader) awarded design, building and operations contractl Combined EfW and MBT plant for total waste treatment capacity of around 490’000 t/a of municipal solid waste,

replacing a thermal EfW plant from 1960 on the same sitel HZI responsible for grate and boilerl Combined heat and power export:

l max. electrical power: ca. 15 MWl max. district heat export: ca. 118 MW

Client SYCTOM

Start-up 2022

TechnologyFurnace Grate furnace (water-cooled)Energy recovery 4-pass horizontal boiler, external eco, turbineFlue gas treatment Dry (2 filter, bicarbonate) SCR

Technical DataFuel Mix of untreated and treated municipal solid wasteWaste capacity 350’000 t/a (max. 2 x 24.64 t/h)Net calorific value 11.04 MJ/kgThermal capacity 2 x 75.55 MW

Ivry-sur-Seine, France


38

Hartlebury, UK


Worcestershire


Start-up 2016




39

Severnside, United Kingdom

l EPC turnkey contract for complete plant incl. civil worksl Located in South Gloucestershire with raillink for waste transport from West London by containersl Electrical power production: 38 MW grossl Use of LEAP (O2, wet = 5 vol.%) and DyNOR (NOx < 150 mg/Nm3)l Bottom ash treatment on site (by others)l Developed by SITA UK as Public Private Partnership with West London Waste Authority


Start-up 2015





Buckinghamshire, UK

l Single line plantl Enabled for combined heat and power productionl Hitachi Zosen Inova acting as Turnkey contractor including civilsl Bottom ash transported to adjacent IBA treatment areal Developed in exclusive partnership with FCC UK

Client FCC UK

Start-up 2015





40

41

Vantaa, Finland

l Utilization of municipal waste of the Helsinki metropolitan areal Hitachi Zosen Inova supplier of furnace / boilerl Combined cycle power plant with superheating of 91 bar steam to 520ºC by exhaust gas of 80 MW gas turbine l Combined heat and power production - 107 MW heat and 78 MW electrical powerl Advanced SNCR system - DyNORTM

l Designed for maximum energy recovery

Client Vantaan Energia Oy

Start-up 2014

TechnologyFurnace Grate furnace (water-cooled)Energy recovery 4-pass boiler with additional

external vertical economizer(downstream of ESP)

Flue gas treatment SNCR



42

Cleveland 4+5, United Kingdom

l EPC turnkey contract for complete plant incl. civil worksl Independent new plant adjacent to existing plant incl. line 3 built by Hitachi Zosen Inoval Electrical power production 21 MW, turbine enabled for combined heat and power productionl Developed by SITA UK as Public Private Partnership under the Project Finance Initiative

Client SITA South Tyne & Wear Ltd.

Start-up 2013

TechnologyFurnace Grate furnace (air-cooled)Energy recovery 4-pass vertical boiler, turbineFlue gas treatment Semi-dry with SNCR

Technical DataFuel Municipal and industrial wasteWaste capacity 304,000 t/a (2 x 19 t/h)Net calorific value 8.7 MJ/kgThermal capacity 2 x 45.9 MWSteam 2 x 55 t/h (50 bar, 410°C)


43

Poznan, Poland

l Hitachi Zosen Inova is lead partner in a consortium with HOCHTIEF Polska in a turnkey construction contract

l New EfW plant including bottom ash treatment and FGT residue solidification plant on sitel Building Permit engineeringl Combined heat and power:




Start-up 2016




44

Barcelona - Sant Adrià de Besòs, Spain

l Existing waste treatment plant for Barcelona supplying electricity and district heating / cooling to local inhabitantsl Replacement / modernisation of existing grate furnace (built by Hitachi Zosen Inova in 1975) while plant remains in

operationl Hitachi Zosen Inova supplier of grate furnaces to Ros Roca S.A. (general contractor)

Client Ros Roca S.A. for TERSA

Start-up 2012 - 2013

TechnologyFurnace Grate furnaceEnergy recovery 3-pass boiler, turbineFlue gas treatment SNCR, semi-wet process

Technical DataFuel Pre-treated municipal and

commercial wasteWaste capacity 3 x 15 t/hNet calorific value 9.2 MJ/kgThermal capacity 3 x 38 MWSteam 3 x 41 t/h (39 bar, 400°C)


45

Vaasa, Finland

l EfW plant for 400,000 inhabitants in more than 50 communities in Western Finland

l First plant in Finland with heat supply to district heating networkl Combined heat and power production - 40 MW heat and 13 MW electrical powerl Container system for slag storagel Advanced SNCR system – DyNORTM

l Supplier of furnace, boiler, water steam cycle, district heating system, crane facilities, electrical installation and control system for complete plant, BOP

Client Westenergy OY

Start-up 2013

TechnologyFurnace Grate furnace (water-cooled)Energy recovery 4-pass boilerFlue gas treatment SNCR

Technical DataFuel Municipal and industrial wasteWaste capacity 160,000 t/a (1 x 20 Mg/a)Net calorific value 11.0 MJ/kgThermal capacity 61.1 MWSteam 73.1 t/h (40 bar, 400°C)


46

Oslo Klemetsrud Line 3, Norway

l Independent third line to adjacent existing plantl Hitachi Zosen Inova general contractor for incinerator / boiler and flue gas treatmentl Optimized for maximum energy recovery - with district heat economizers and condensation of flue gas (absorption

heat pumps) - 50 MW heat and 10 MW electrical powerl Combined heat and power productionl Designed for minimum emissions

Client Oslo EGE

Start-up 2011

TechnologyFurnace Grate furnace (water-cooled)Energy recovery 4-pass boiler, absorption heat pumpFlue gas treatment ESP, wet scrubber with integrated

condensation stage, heat exchangers, SCR

Residue treatment Waste water treatment,

Technical DataFuel Municipal and industrial wasteWaste capacity 160,000 t/a (1 x 20.0 t/h)Net calorific value 12.0 MJ/kgThermal capacity 66.7 MWSteam 77.8 t/h (41 bar, 400°C)


47

Newhaven, United Kingdom, UK

l Hitachi Zosen Inova is lead partner in a consortium with HOCHTIEF in a turnkey construction contract

l Additional land secured adjacent to site for lay down and pre-assemblyl As a result of difficult ground conditions, first EfW facility using floating caisson as construction

method for bunker construction (now grouted andfixed in position)

Client Veolia

Start-up 2011

TechnologyFurnace Grate furnace (air-cooled)Energy recovery 4-pass boiler, turbineFlue gas treatment SNCR, semi-dry process

Technical DataFuel Municipal wasteWaste capacity 226,000 t/a (2 x 14.5 t/h)Net calorific value 8.9 MJ/kgThermal capacity 2 x 35.85 MWSteam 2 x 43.5 t/h (50 bar, 400°C)



Dr. Marc R. Stammbach

Waste Expo Australia3 & 4 October 2018 Melbourne VIC

1

Construction of sustainable waste management in Australia

Setting the Scene

Make it happen

Summary

2

Setting the Scene
