Mechanical-Biological waste Treatment (MBT) Actual state of affairs and perspective in Germany - Ennigerloh, 19 th May 2011
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Mechanical-Biological waste Treatment (MBT) Actual state of affairs and perspective in Germany Ennigerloh, 19 th May 2011
Agenda ASA e. V. Registered Society (RS) of MBT plant operators The implementation of MBT technology in Germany State of MBT technology in Germany MBT as a raw material and fuel supplier Influence available overcapacity Potential developments by legal rules Perspective
ASA e.V. – RS of MBT plant operators Emphases of RS work Promotion of the knowledge transfer between the members e. g. from planning, construction and operation of MBT plants Support with the plant optimisations and operating optimisations Use of other plants capacities in the group in case of breakdown (short fall association) Organisation and performance of the international ASA waste days (ASA-Abfalltage) Execution of research projects and appraisal Statements on bills and regulation drafts in the federal law and in the European law ASA is active member in the European Compost Network (ECN) e. V., in the Gütegemeinschaft Sekundärbrennstoffe und Recyclingholz (BGS) e. V. (quality assurance of Solid Recovered Fuels – SRF) Member support, public relations Foreign affairs, co-operation/information exchange
ASA e.V. – RS of MBT plant operators Realised projects for standardisation / QA Laboratory comparison to the determination of the biomass content in SRF (in cooperation with German Gütegemeinschaft Sekundärbrennstoffe und Recyclingholz e. V. (BGS) Installation attempts of mechanical-biological pre-treated wastes on the landfill of the GFA, Lüneburg (ASA e. V., IGB Hamburg, Bomag) Standardisation of the waste-mechanical parameters to the marking of output from MBT plants Standardisation of the sampling, sample preparation and analytics of the material for landfilling, produced by MBT plants Evaluation of the Renewable Thermal Oxidation (RTO) from ecological view (Ifeu-Institut Heidelberg, gewitra Bonn) Comparison of laboratories with the aim of QA and validation ASA’s analysis standard for landfill parameters according to German AbfAblV (iba Hannover) Energy efficiency of MBT and saved CO2 emissions (iba Hannover)
ASA e.V. – RS of MBT plant operators Members of the ASA e. V. (49 Members) Office Board Advisory Council M. Balhar Chairman Head of advisory Council C. Ebeling Th. Grundmann Dr. K. Ketelsen Vice-chairman Members of advisory council Organisation A. Nieweler Prof. Dr. B. Gallenkemper Support of members Prof. Dr. K. Gellenbeck Public relations Members of board Dr. G. Hälsig Dr. N. Bruhn-Lobin Prof. Dr. M. Nelles D.-U. Michaelis Dr. A. Radde H. Ringe B. Schulte Working group Working group Working group Short fall technical ASA GmbH organisation plant operation association development Leader of WG Leader of WG Leader of WG Services for ASA 20 Members Ch. Niehaves M. Rakete J. Düsterloh Members Stand: 07/11
Agenda ASA e. V. Registered Society (RS) of MBT plant operators The implementation of MBT technology in Germany State of MBT technology in Germany MBT as a raw material and fuel supplier Influence available overcapacity Perspective
The implementation of MBT technology
The implementation of MBT technology
The implementation of MBT technology Strong increase of waste rates since the 1980’s Environmental damage by leachate and outgasing of methangas Waste experts recognised problems caused by waste disposal and landfilling 1993 fixed the Upper House of the German Parliament the pre-treatment of biodegradable waste by means of incineration in the Technical Instructions on Waste (TASi) German federal state Lower Saxony promoted 1989/1990 first basic studies to the MBT technology Center of the 1990’s encouragement and realisation of three industrial MBT plants with different technical concepts, technical and scientific steering of these research projects Examination of the equivalence of waste incineration and MBT with further research projects: 1995 -1999 collaborative project founded by German Ministry of Education and Research 1998 North Rhine-Westfalian manual for the MBT technology
The implementation of MBT technology Result of the Federal Ministry of environment to August 20, 1999: Waste incineration and MBT technology are alike to evaluate 1999 - 2001 scientifically/technically and politically motivated controversy over the justifiable standard of MBA plants Controversy phase ended then with the deposit regulation and the 30th Federal Immission Control Regulation (“30. BImschV”). MBT technology had achieved a legal requirement equilibrium in the comparison to waste incineration. But was it also practicable? High legal demands are made against the MBT technology, which were not determined by practical experiences and/or by industrial MBT plants
The implementation of MBT technology Challenges to the MBT operators Investment security starting from 2001 = four years for a new technology Road Map March 2001 2002 2003 2004 June 2005 Political decisions with the publicly legal carriers had to be caused Bidding of the planning services, process engineering and equipment technology according to that assignment-legally regulations Licensing procedure (at least: 6 to 7 month) Execution phase/building phase: (1.5 to 2 years) Further problems by insolvencies
The implementation of MBT technology Reasons for the decision for the MBT technology Existing TASi landfills could further be used in connection with the MBT plants as well as further use of infrastructure Waste incineration was not often achievable against the resistance of the population Allegedly more favourable solution/smaller invest than with waste incineration Creation and/or protection of jobs by an own design capacity Creation of value remains in the region (orders to medium-size-companies) Good combination in connection with mono stream power plants or cement works or coal-fired power stations Saving of fossil fuels by the employment of Solid Recovered Fuels (SRF) in (mono stream) power stations and thus CO2 saving Energy and fuel supplier for producing trade
Agenda ASA e. V. Registered Society (RS) of MBT plant operators The implementation of MBT technology in Germany State of MBT technology in Germany MBT as a raw material and fuel supplier Influence available overcapacity Perspective
State of MBT technology in Germany MBT, MBS and MPS plants in Germany Schleswig- Number Holstein Capacity Federal state of tons/a Mecklenburg- plants Western Pomerania Hamburg Brandenburg 8 1,040,500 Bremen Bathe-Württemb. 1 110,000 Lower Saxony Berlin Bavaria 1 40,000 Hesse 2 204,500 Saxonia- Brandenburg North Rhine- Anhalt Mecklenburg-W. P. 4 455,000 Westphalia Lower Saxony 11 1,012,100 Hesse Thuringia Saxonia North Rine-W. 5 891,500 Rhineland- Rhineland-P. 5 620,000 Palatinate Saxonia-Anhalt 1 50,000 Schleswig-Holst. 2 406,000 Saarland Saxonia 4 655,000 Bathe Bavaria Thuringia 3 275,000 Württemberg Total 46 5,759,600
State of MBT technology in Germany MPS, 3 MBS, 13 MBT, 30 MPS, 0,5 MBS, 1,8 Point of time: 2009 MBT, Source: ASA 3,4
State of MBT technology in Germany MBT = Mechanical-Biological Treatment (30 plants) Is a combination out the mechanical processing with separation of high calorific fractions (to be used as RDF) as well as the valuable material for material recycling and the biological treatment (decomposition, digestion) of the fine fraction for the reaching of the deposit criteria . MBS = Mechanical-Biological Stabilisation (13 plants) the entire waste stream is dried before the mechanical processing biologically (under use of the self heating) and reduced by the organic components MPS = Mechanical-Physical Stabilisation (3 plants) mechanical processing with following drying process (e. g. by means of drum dryer), here fossil fuels for the drying process are used
State of MBT technology in Germany MBT – Mechanical-Biological Treatment Mechanical processing Acceptance and control, separation contraries, crushing, metal separation Selection of valuable materials (e. g. wood, paper, metal) Metal deposition (non-ferrous metals)
State of MBT technology in Germany MBT – Mechanical-Biological Treatment Mechanical processing Separation of the material flow over sieving into biological and high calorific components Shaking screen Drum sieve
State of MBT technology in Germany MBT – Mechanical-Biological Treatment Mechanical processing Division of the high calorific components into High Calorific Fractions (HCF) and Solid Recovered Fuels (SRF) Air separator Shaking screen
State of MBT technology in Germany MBT – Mechanical-Biological Treatment Mechanical processing NIR-Technology (Near-InfraRed spectroscopy) to the separation of valuable material or for the removal from extraneous material (e. g. chlorine (polyvinyl chloride, PVC)) Cement works or coal-fired power stations: limit values for chlorine < 0.5%
State of MBT technology in Germany Box, channel, windrow 10% Percolation Wet 3% digestion 15% Tunnel Dry 64% digestion 8% Point of time: 2009 In total: 30 plants Source: ASA
State of MBT technology in Germany MBT – Mechanical-Biological Treatment Biological Treatment The decomposition process (aerobic treatment in tunnels, windrows (table windrows) or channels) is separated in two phases: the intensive decomposition (4 to 6 weeks) and the past decomposition (8 to 10 weeks). The total treatment takes 10 to 15 weeks Table windrow Channels point of time 09/08
State of MBT technology in Germany MBT – Mechanical-Biological Treatment Biological Treatment Decomposition in tunnels with automatic tunnel discharge equipment Reduction of the necessary amount of air by tunnels
State of MBT technology in Germany MBT – Mechanical-Biological Treatment Biological treatment Digestion (anaerobic treatment), dry digestion Dry digestion can be designed as a partial or full stream process with inoculation and turning. Full stream digestion requires a post dewatering. Afterwards the material is treated in post decom-position for the storage or in a landfill. The treatment period in a dry digestion needs three weeks Gas production rate 90 - 120 m3/ton waste Use of the fermentation gas over block heating station or processing of the gas
State of MBT technology in Germany MBT – Mechanical-Biological Treatment Biological treatment Digestion (anaerobic treatment), wet digestion At first the material is wet-mechanically prepared then transferred in the two-step full-stream digestion which is followed by the wet-aerobic stabilisation through dewatering and thermal drying. The treatment period in the wet digestion needs 3 weeks, the aerobic stabilisation additional 5 days.
State of MBT technology in Germany MBT with Decomposition and Digestion Box, channel, windrow 6% Wet digestion 15% Tunnel 55% Percolation 3% Dry digestion 21% Point of time: 2009 In total: 30 plants Source: ASA
State of MBT technology in Germany MBT – Mechanical-Biological Treatment Deposit Stabilised waste is deposited on landfills of the German class II Avoidance of setting and landfill gas formation Compression of the MBA output to approx. 1.3 ton/cbm Avoidance as well as reduction of landfill leachate Thus future generations no longstanding pollution is left!
State of MBT technology in Germany MBT – Mechanical-Biological Treatment For the deposit the criteria of the German Waste Storage Ordinance („AbfAblV“) are valid Measured values of the MBT Ennigerloh TOC in the solid matter DOC in the eluate Breathability 4 Limit values: ≤ 18 Mass-% ≤ 300 mg/l ≤ 5 mg/g
State of MBT technology in Germany MBT = Mechanical-Biological Treatment (30 plants) Is a combination out the mechanical processing with separation of high calorific fractions (to be used as RDF) as well as the valuable material for material recycling and the biological treatment (decomposition, digestion) of the fine fraction for the reaching of the deposit criteria . MBS = Mechanical-Biological Stabilisation (13 plants) the entire waste stream is dried before the mechanical processing biologically (under use of the self heating) and reduced by the organic components MPS = Mechanical-Physical Stabilisation (3 plants) mechanical processing with following drying process (e. g. by means of drum dryer), here fossil fuels for the drying process are used
State of MBT technology in Germany MBS – Mechanical-Biological Stabilisation Biological drying process of the entire waste input before the mechanical treatment over tunnels, channels or containers Reduction of the moisture content in the wastes of approx. 40 % on approx. 20 % Freed warmth is used for the evaporation of the moisture content Container in Nehlsen procedures Good mechanical processing after biological drying process Channels in Biodegma procedure Rotting boxes in Herhof procedure
State of MBT technology in Germany MBS – Mechanical-Biological Stabilisation Separation of metals, inert components, contraries Production of (high) calorific fractions of different qualities
State of MBT technology in Germany MBT = Mechanical-Biological Treatment (30 plants) Is a combination out the mechanical processing with separation of high calorific fractions (to be used as RDF) as well as the valuable material for material recycling and the biological treatment (decomposition, digestion) of the fine fraction for the reaching of the deposit criteria . MBS = Mechanical-Biological Stabilisation (13 plants) the entire waste stream is dried before the mechanical processing biologically (under use of the self heating) and reduced by the organic components MPS = Mechanical-Physical Stabilisation (3 plants) mechanical processing with following drying process (e. g. by means of drum dryer), here fossil fuels for the drying are used
State of MBT technology in Germany MPS – Mechanical-Physical Stabilisation Separation of the material flow (only over mechanical and physical procedures) Multi-level treatment process (e. g. separation of Fe- and non-ferrous metals) Separation of contaminated components Physical drying process of the high calorific components (HCF and/or SRF) Rotary drier (Vandenbroek)
State of MBT technology in Germany MPS – Mechanical-Physical Stabilisation
State of MBT technology in Germany Exhaust air treatment On-line monitoring of the limit values by the responsible authority Air washer with bio filter in container building method Dust filter Sour scrubber with RTO and chimney
State of MBT technology in Germany For the exhaust air treatment the limit values of the German 30th Immission Ordinance are valid Parameter Unit Limit value Operating values Reference value Organic 40 8 to 30 Half hour average value mg/m3 (daily maxima) Components as Ctotal mg/m3 20 10.4 Daily average (mean) 55 29.3 Monthly average value as g/Mg mass ratio Entirely total dust 30 < 1.5 Half hour average value mg/m3 (daily maxima) mg/m3 10 1.7 Daily average (mean) Dinitrogen oxide N2O 100 19.9 Monthly average value as g/Mg mass ratio Dioxins/Furane1) ng/m3 0.1 < 0.002 Individual measurements Smell1) GE/m 3 500 400 Individual measurements 1) The individual measurements were accomplished in the period March until May 2006. Result: Emission values of the 30th Immission Ordinance are kept and/or fallen below clearly!
State of MBT technology in Germany offen/Ausschreibung MA 3,2 % MBS 2,9 % 8,7 % MBA 15,5 % MVA 69,7 % MBT = approx. 25 % of the pre-treatment technology
Agenda ASA e. V. Registered Society (RS) of MBT plant operators The implementation of MBT technology in Germany State of MBT technology in Germany MBT as a raw material and fuel supplier Influence available overcapacity Perspective
MBT as a raw material and fuel supplier
Stand der MBA in Deutschland Material recycling of Fe/non-ferrous metals from MBT plants (approx.200,000 tons/p.a.)
MBT as a raw material and fuel supplier Material recycling of paper/pasteboard from MBT plants Material or energetic recycling of separated wood from the MBT plants
MBT as a raw material and fuel supplier Aspects of energy with MBT Supply and use of Refuse Derived Fuels (RDF) Component for the protection of disposal security Increasing meaning against the background rising markets for secondary raw materials Larger independence from the rising energy costs Contribution for the reduction of the CO2 emissions and thus to climate protection
MBT as a raw material and fuel supplier Supply and use of RDF Range of the treatment depends on - The whereabouts and use of the removed fractions - The respective quality requirements of the customers - Quality assurance necessary Two groups from RDF to differentiate: - High Calorific Fractions (HCF) - Solid Recovered Fuels (SRF)
MBT as a raw material and fuel supplier High Calorific Fraction (HCF) - From wastes separated components and/or fractions, which exhibit clearly higher net calorific values due to their composition and characteristics than the original waste mixture (approx. 11 to 15 MJ/kg ) - E. g. HCF from MBT or commercial/industrial waste sorting plants - Smaller treatment depth, e. g. rougher grain size - Use in mono stream power plants from MSW > 100 mm from commercial/industrial from bulky waste > 60 mm waste > 150 mm
MBT as a raw material and fuel supplier Disposal ways of the High Calorific Fraction 2007 of all MBT, MBS and MPS plants (approx. 2.5 Mio. tons/a) Entsorgungswege der heizwertreichen Fraktion aus MBA, 2007 Zwischenlager 6% Braunkohlekraftwerk (n=5) 8% (n=5) Zementwerk 7% (n=4) Weitere Aufbereitung 12% (n=11) Industrie- / Monokraftwerk 35% (n=8) Sonstiges 8% (n=4) MVA 17% (n=8) Makler / Handel 8% (n=2) Source: ASA study
MBT as a raw material and fuel supplier Solid Recovered Fuel - Final ready made fuel after large treatment - to be co-incinerated in cement works/lime works/power plants (quality e. g. belonging to German quality assurance RAL-GZ 724) - from production specific waste and/or high calorific fractions from MSW (NCV from 20 to 25 MJ/kg) Source: ASA study
MBT as a raw material and fuel supplier Quality control by German ”Gütegemeinschaft Sekundärbrennstoffe und Recyclingholz e. V. (BGS)” (www.bgs-ev.de) Manual „quality control of High Calorific Fractions“ - also for the utilization ways of the High Calorific Fractions are quality criteria in advertisements and/or contracts demanded, e. g. • net calorific value (NCV) • chlorine content • contents of contraries and if necessary heavy metals Quality assurance RAL quality label 724 – Solid Recovered Fuels - Heavy metal guideline values are accepted and considered in the manual to the co-incineration (North Rhine-Westphalia) - Quality assured quantity in 2010: approx. 300,000 tons
MBT as a raw material and fuel supplier SRF: Heavy metal contents after German RAL-GZ 724 by Gütegemeinschaft Sekundärbrennstoffe und Recyclingholz e. V. (BGS) H eavy m etalcontents (SRF) Param eter Unit M edian 80th percentile Cadm ium m g/kg dm 4 9 M ercury m g/kg dm 0,6 1,2 Thallium m g/kg dm 1 2 Ardenic m g/kg dm 5 13 Cobalt m g/kg dm 6 12 Nickel m g/kg dm 251) 80 2) 50 1) 160 2) Antim ony m g/kg dm 50 120 Lead m g/kg dm 70 1) 190 2) 200 1) 400 2) Chrom ium m g/kg dm 40 1) 1252) 120 1) 250 2) Copper m g/kg dm 200 1) 400 2) 500 1)3) 1.000 2)3) M anganese m g/kg dm 50 1) 250 2) 100 1) 500 2) Vanadium m g/kg dm 10 25 Tin m g/kg dm 30 70 1) For Solid Recovered Fuels from production specific waste 2) For Solid Recovered Fuels from the high calorific fractions from municipal solid waste 3) exceeding of critical levels in particular cases possible
MBT as a raw material and fuel supplier Use of SRF in cement works and coal-fired power plants Physical characteristics The Net Calorific Value (NCV) of the fuels amounts to 21 - 23 MJ/kg The moisture content is less than 10 % Burning in the flight phase Chemical characteristics Chemical characteristics of the SRF in the context of the guidelines values of BGS e. V.
MBT as a raw material and fuel supplier Use of SRF in the cement works of Cemex, Rüdersdorf (close to Berlin) Clean delivery and acceptance (e. g. walking floor) Homogenisation and packaging (important for equal lasting NCV)
MBT as a raw material and fuel supplier Use of SRF over fivefold burner lance in the cement works of Cemex, Rüdersdorf Solid Recovered Fuel, animal meal Primary fuels (brown coal/coal, gas, oil) Combustion in the flight phase with 1.500 C°
MBT as a raw material and fuel supplier Development of the SRF use in the German cement industry (source: VDZ (German cement works association)) 70 61 58,4 60 55 52 49 50 50 42 38,3 40 34,9 30,3 30 25,7 23 20 15,8 7,4 10,8 10 4,1 0 1987 1990 1995 1997 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
MBT as a raw material and fuel supplier Design values for the use of SRF in the brown coal power station of Vattenfall, Jänschwalde General information Average operation hours of the SFR co-incineration 8,000 h/a Annually used SRF quantity approx. 400,000 tons Middle SRF use for each boiler approx. 6 tons/h Maximum SRF use for each boiler approx. 10 tons/h Delivery of SRF everyday 00:00 - 24:00 o’clock
MBT as a raw material and fuel supplier Burn-specific parameters of the SRF, brown coal power station, Jänschwalde Net calorific value (NCV min) 9 MJ/kg Net calorific value (NCV max) 25 MJ/kg Ash content < 35 mass % Moisture content approx. 2 - 30 mass % particle size < 25 mm Delivery e. g. over walking floor Addition of SRF on the conveyor for brown coal for combustion in the airborne current boiler
MBT as a raw material and fuel supplier High Calorific Fractions (HCF) to be used in mono stream power plants NCV 10 - 15 MJ/kg Lumpiness < 250 mm 25 Moisture content approx. 25 % 20 Mass % (dry matter) 15 10 5 0 Air classifier fraction Hard plastics, thick parts from leather or rubber, paper, wood, etc. (analysis INFA, 2005)
MBT as a raw material and fuel supplier Use of HCF in mono stream power plants by the example “Energos Minden” Plant data MBT Plant data Mono stream power plant (HCF) Capacity 100,000 tons/a Capacity 40,000 tons/a HCF MSW and commercial waste 60,000 and 40,000 tons/a Boiler output 15 MWthermal, ca. 22 t/h steam Sewage sludge 15,000 tons/a Form of energy supply Process steam, 13 bar (250 °C) Amount of produced HCF ca. 40,000 tons/a Yearly heat supply 115 GWh Input mono st. power plant ca. 36,000 – 38,000 tons/a Production of steam for BASF, Minden Supplier of HCF MBT Pohlsche Heide, Minden-Lübbecke
MBT as a raw material and fuel supplier Use of HCF in mono stream power plants by the example „HKW Blumenthal Bremen“ Plant data MBT Plant data Mono stream power plant (HCF) Capacity 100,000 tons/a Capacity 60,000 tons/a MSW 70,000 tons/a Boiler output 31 MWelectric Commercial/industrial waste 30,000 tons/a Form of energy supply Steam: 35 t/h (40 bar/400 °C) Amount of produced HCF approx. 46,000 tons/a Electricity: 30.000.000 kWh/a Input mono st. power plant approx. 46,000 tons/a Production of steam for the neighbouring „Woll- kämmerei“ (industrial plant), generation of electricity over turbine possible Supplier of HCF RABA Bassum MBT Oldenburg
MBT as a raw material and fuel supplier Use of HCF in mono stream power plants by the example “TEV Neumünster” Plant data Mono stream power plant (HCF) Plant data MBT Capacity 190,000 tons/a (by NCV = 12 MJ/kg) Capacity/MBT approx. 200,000 tons/a Boiler output 75 MW thermal Capacity/“BAA“ ca. 170,000 tons/a Form of energy supply Steam: 97,6 t/h (65 bar/470 °C) (thereof 100,000 Mg from MBT) Yearly heat supply Steam: approx. 800,000 tons/a Amount of produced HCF approx. 160,000 tons/a Electricity approx. 150 million kWh Input in mono st. power plant approx. 160,000 tons/a Generating of electricity and steam for „SWN“ Supplier of HCF MBT Neumünster MBT Lüneburg
MBT as a raw material and fuel supplier Use of HCF in mono stream power plants by the example “Vattenfall Rüdersdorf” (close to Berlin) Plant data Mono stream power plant (HCF) Capacity 220,000 tons/a HCF Boiler output 115 MWthermal Current delivery/rating 29 MWelectric Generating of electricity for the neighbouring cement works of Cemex
MBT as a raw material and fuel supplier Mono stream power plants for the use of HCF Capacity working/in building approx. 5,802,000 tons/a Capacity permission approved/requested approx. 1,420,000 tons/a Capacity projects approx. 370,000 tons/a Total capacity approx. 7,592,000 tons/a Point of time February 2010
MBT as a raw material and fuel supplier Gas utilisation and gas preparation Generation of electricity of the gas depending upon procedure 90 - 120 m3/tons waste processing of the gas and feed into the gas net Block-unit heating power plant Digestion container and gas tank
MBT as a raw material and fuel supplier Result energy balance/energy efficiency The energy efficiency of the MBT, MBS and MPS plants is considerably determined of the energy efficiency of the plants for the energy recycling and of the amount of high calorific components in the waste During optimised energetic recycling higher energy efficiency can be achieved with MBT concepts opposite waste incineration plants The digestion of the fine fraction can make a significant contribution with higher gas yields for the improvement of the energy efficiency Development and perspectives of the MBT technology MBT/MBS/MPS actually permit a flexible adjustment in case of changing basic conditions (market, proceeds, raw material costs, laws) Optimisation of the plant concepts depends on the material, raw material and energetic recycling Increased selection of metals (Fe/non-ferrous) Sorting of plastics Separation of wood/biomass Separation of contraries/pollutants (chlorine-lower, e. g. by NIR technology)
MBT as a raw material and fuel supplier Future perspective Production of diesel fuel from RDF by means of catalytic depolymerisation First attempts ran Pilot projects
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