Research in the Waste Area. Research needs on WASTE: the CEFIC Perspective

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1 Who is involved? Forschungszentrum Karlsruhe Research in the Waste Area Research needs on WASTE: the CEFIC Perspective CEFIC = European Chemical Industry Council IT (Issue Team) Waste Head: Dr. Korn (BASF AG) Members: - European Chemical Associations like German VCI - European Chemical Companies - Product orientated associations like Plastics Europe EURITS = European Union for Responsible Incineration and Treatment of Special Waste Members: - 18 HWI-operating companies (most public, but also industrial) from 7 European Countries - Operators Association like German BDSAV

2 Which type of WASTE should be considered? NON-HAZARDOUS WASTE (compare MSW)

3 (Source: Cefig

4 Which type of WASTE should be considered? HAZARDOUS WASTE

5 (Source: Cefig -

6 Which type of Treatment Plants are available? Hazardous Waste Incineration Plants (HWI) - Mostly: Rotary Kilns

7 THERESA Post Combustion Boiler Spray Drier Bag Filter Scrubber1 Scrubber 2 Stack Fuels Air Steam 40 bar, 250 C H 2 O gaseous H 2 O Adsorbens liquid pasty SCR solid Rotary Kiln NaOH NH 3 Air Slag Fly ash Salts, Fly ash Adsorbens

8 HWI Capacity Mg/a total number of HW-Incinerators Total Number : 70 Total Capacity : Mg/a Austria Belgium Denmark Finland France Germany Italy Spain Sweden Netherlands UK number capacity Number and Capacity of Hazardous Waste Incinerators (HWI) (Source : Draft Reference Document on the Best Available Techniques for Waste Incineration, EC 2004)

9 HWI Capacity Mg/a Total Capacity : Mg/a Belgium Denmark Germany Finland France Italy Netherlands Austria Sweden Spain Capacity of the Hazardous Waste Incineration Plants (Rotary Kilns) in Europe (Source : BDSAV)

10 HWI Capacity Mg/a rotary kiln (public) rotary kiln (chemical industry) other plants (gasifier, combustion chamber) Capacity of the Thermal Treatment Plants for Hazardous Wastes in Germany (Source : BDSAV)

11 SWOT-Analysis (Strengths-Weaknesses-Opportunities-Threats) Strengths reduction of hazardous waste by waste management system, i. e. 4-steps model (German chemical industry)

12 4-steps Model Steps Hierarchy of objectives Used materials Production Process Processes in the production network Energy utilization Products Objectives 1. Avoiding/reduction of wastes e.g. by increasing the yield, by recycling of auxiliary materials 2. Materials recovery from wastes e.g. by reprocessing / conversion to valuable materials Criteria (examples) Theoretical/technically feasible residue volume Influence of process conditions on selectivity and yield Costs of yield increase Expenditure (raw materials, energies, investments) for additional process steps Additional emissions Credits for valuable products Residues Treatment of waste gas, solid waste, waste water Energy Waste gas Waste Waste water 3. Energy recovery from wastes for the reduction of primary energy 4. Observation of limits by central/decentralized waste management Costs of central/decentralized combustion facilities Credits for energy generated Proportion of combustable materials Costs of central/decentralized waste management Ecological Aspects - Production-integrated Environmental Protection Source: DECHEMA, Germany

13 SWOT-Analysis (Strengths-Weaknesses-Opportunities-Threats) Strengths reduction of hazardous waste by waste management system, i. e. 4-steps model (German chemical industry) high developed thermal treatment technique: rotary kiln technology - with low emissions

14 Rotary kilns Rotary kilns are very robust and almost any waste, regardless of type and composition, can be incinerated. Rotary kilns are, in particular, very widely applied for the incineration of hazardous wastes. The technology is also commonly used for clinical wastes (...) but less so for municipal wastes. source: Draft Reference Document on the Best Available Techniques for Waste Incineration, EC 2004

15 Emission limit values (EC-directive 2000/76/EC effective 04/12/ /12/ on the incineration of wastes daily average values - Total dust Gaseous and vaporous organic substances, expressed as total organic carbon Hydrogen chloride (HCl) Hydrogen fluoride (HF) Sulfur dioxide (SO 2 ) 10 mg/m³ 10 mg/m³ 10 mg/m³ 1 mg/m³ 50 mg/m³ Nitrogen monoxide (NO) and nitrogen dioxide (NO 2 ), expressed as nitrogen dioxide for existing incineration plants with a nominal capacity exceeding 6 t/h or new incineration plants Nitrogen monoxide (NO) and nitrogen dioxide (NO 2 ), expressed as nitrogen dioxide for existing incineration plants with a nominal capacity of 6 t/h or less 200 mg/m³ (*) 400 mg/m³ (*) (*) Until 1 January 2007 and without prejudice to relevant Community legislation the emission limit value for No x does not apply to plants only incinerating hazardous waste. EU-Directive 2000/76/EC (1)

16 Emission limit values (EC-directive 2000/76/EC effective 04/12/ /12/ on the incineration of wastes Half-hourly average values - (100 %) A (97 %) B Total dust 30 mg/m³ 10 mg/m³ Gaseous and vaporous organic substances, expressed as total organic carbon 20 mg/m³ 10 mg/m³ Hydrogen chloride (HCl) 60 mg/m³ 10 mg/m³ Hydrogen fluoride (HF) 4 mg/m³ 2 mg/m³ Sulfur dioxide (SO 2 ) 200 mg/m³ 50 mg/m³ Nitrogen monoxide (NO) and nitrogen dioxide (NO 2 ), expressed as nitrogen dioxide for existing incineration plants with a nominal capacity exceeding 6 t/h or new incineration plants 400 mg/m³ (*) 200 mg/m³ (*) Until 1 January 2007 and without prejudice to relevant Community legislation the emission limit value for No x does not apply to plants only incinerating hazardous waste. EU-Directive 2000/76/EC (2)

17 SWOT-Analysis (Strengths-Weaknesses-Opportunities-Threats) Weaknesses Research Needs High incineration costs because of 1) limited throughput developments for increased throughput, i. e. for solid waste (drums) combustion control system

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21 CO Concentration at the Stack with/without Adjustment of Burner without adjustment drum: 1 litre fuel oil frequency: 1 drum/2 minutes thermal load of RK: 1,7 MW flue gas flow rate: 4800 Nm 3 /h CO concentration [mg/nm³] averaged CO concentration at the stack: 138 mg/nm 3 CO concentration [mg/nm³] averaged CO concentration at the stack: 12 mg/nm time [min] time [min] with adjustment drum: 1 litre fuel oil frequency: 1 drum/2 minutes thermal load of RK: 1,7 MW flue gas flow rate: 4800 Nm 3 /h

22 SWOT-Analysis (Strengths-Weaknesses-Opportunities-Threats) Weaknesses Research Needs High incineration costs because of 1) limited throughput developments for increased throughput, i. e. for solid waste (drums) combustion control system 2) short life time of refractory material investigation of causes, i. e. influence of fluorine residues (counter measures!)

23 Slag Deposit Rotary Kiln THERESA K

24 SWOT-Analysis (Strengths-Weaknesses-Opportunities-Threats) Weaknesses Research Needs High incineration costs because of 1) limited throughput developments for increased throughput, i. e. for solid waste (drums) combustion control system 2) short life time of refractory material investigation of causes, i. e. influence of fluorine residues (counter measures!) 3) boiler deposits causing reduced investigation of causes and deboiler efficiency velopment of counter measures, (i. e. adaption of operation conditions)

25 Boiler Deposits at the 15,5 m Level: Sidewall Backside 3. thin white layer 1. Deposit mm bis 1 cm corrosive layer 2. reddish layer

26 SWOT-Analysis (Strengths-Weaknesses-Opportunities-Threats) Weaknesses Research Needs High incineration costs because of 1) limited throughput developments for increased throughput, i. e. for solid waste (drums) combustion control system 2) short life time of refractory material investigation of causes, i. e. influence of fluorine residues (counter measures!) 3) boiler deposits, causing reduced boiler investigation of causes and deefficiency velopment of counter measure, (i. e. adaption of operation conditions) 4) too many stages for APC integration of flue gas cleaning steps in one stage

27 ADIOX (Tower packings in wet scrubbers) cost effective reduction police filter SCR- pre-filter primary dioxin removal system

28 Simultaneous Removal of Mercury, Dioxins and Submicron Particles by Multifunctional Scrubber Raw Gas Water for Cleaning Water Clean Gas Collector (Tube Bundle) CAROLA Ionization Stage H 2 O 2 Additive Fresh Water ADIOX Tower Packing Material MercOx Scrubbing Liquid Quencher Absorber To Waste Water Treatment

29 Weaknesses Research needs - Special emissions 1) Mercury new processes for control of Hg-peaks 2) Aerosols, fine particles new precipitators with improved separation of fine particles

30 Absorber CAROLA* mit elektrostatischem Corona-induced Aerosolabscheider Aerosol Collector Aerosolabscheider Surface Collector ca. 10 KV 3kV Tropfenabscheider Droplet Eliminator Inlet Removal Efficiencies: % for nm Particles Pressure drop 2 hpa / 350 m 3 /h Coronaentladung Power consumption : 50 W Anzahlkonzentration dn/dlog(dp) [1/cm³]_ 5,E+06 4,E+06 3,E+06 2,E+06 1,E+06 0,E+00 Inlet Rohgas vor Agglomerator Reingas CAROLA Outlet Xm [nm] 1000

31 Weaknesses Research needs - Quality control of waste 1) for liquid waste combustion behavior of low calorific wastes 2) for co-combustion ingredients orientated selection / evaluation of wastes, related to the specific requirements of the co-combustion process - Need of alternative techniques - gasification - plasma processes - mobile small devices

32 Opportunities - technology transfer to other branches - high potential for export esp. emerging countries (i. e. China)

33 country G F GB Japan India China world inhabitants in GDP in 10 9 US$ industrial part of GDP in % demand of incineration capacity in 10 6 t/a evaluated out of GDPindustry Base Germany demand for plants related on GDP with 40 kt/a /plant 1 0,6 0,6 1,6 1,2 4,8 23, CIA, World Fact Book 2004 Estimated Need of Rotary Kiln Incinerators for Hazardous Waste (Source : Prof. Dr.-Ing. T. Kolb ITC-TAB/FZK)

34 Threats - cost situation (accession EU-countries, developing countries) - energy recovery not acknowledged waste framework directive

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36 MSWI Capacity Mg/a total number of MSW-Incinerators Total Number : 421 Total Capacity : Mg/a Austria Belgium Denmark Finland France Germany Italy Spain Sweden Netherlands UK number capacity Number and capacity of municipal solid waste incinerators (MSWI) (Source : Draft Reference Document on the Best Available Techniques for Waste Incineration, EC 2004)

37 SSI Capacity Mg/a total number of SSI Total Number : 43 Total Capacity : Mg/a Austria Belgium Denmark Finland France Germany Italy Spain Sweden Netherlands UK number capacity Number and capacity of dedicated sewage sludge incinerators (SSI) (Source : Draft Reference Document on the Best Available Techniques for Waste Incineration, EC 2004)

38 Market Used materials Production Process (internal) Products Hierarchy of aims Processes in the production network Energy utilization Residues Treatment of waste gas, solid waste, waste water Energy Waste gas Waste Waste water Atmosphere Landfill Preclarifier 4-steps Model