the development of waste-to-energy technologies around the world waste to energy workshop - qcat...
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The Development of Waste-to-Energy Technologies around the WorldWaste to Energy Workshop - QCAT
ENERGY TECHNOLOGY
San Shwe Hla| Senior Research Scientist
23rd June 2014
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About today presentation
The Development of Waste-to-Energy Technologies around the World| San Shwe Hla | Page 2
Current Status for MSW Generation/Management around the World
Development of Waste-to-Energy Technologies
Brief History of Waste-to-Energy Process and Environmental impacts
Conventional and Advanced Incineration Technologies
Novel Gasification-based WtE Technologies
Comparison between Conventional and Novel WtE Technologies
Main Drivers for Practices of WtE
Summary and Conclusions
(Notes: Economic of WtE is not included)
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What a Waste!
The Development of Waste-to-Energy Technologies around the World | San Shwe Hla | Page 3
Waste is an unavoidable by-product of our modern days living.
Waste generation increases as GDP increases.
MSW generated continues to increase.
Current global MSW generation levels are approximately 1.3 billion tonnes per year.
Reference: Tanaka, M. 2009; Hoornweg & Bhada-Taka, 2012; US EPA, 2013:
1995 2000 2005 2010 20150
10
20
30
40
50
60
0
0.5
1
1.5
2
2.5
Total solid waste generation Per capita generation
Tota
l sol
id w
aste
(mill
ion
tonn
es)
Per c
apit
a so
lid w
aste
gen
erati
on
(ton
/per
son/
year
)
Australia
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MSW generation per capita, selected countries
Reference: National Waste Report, 2010:
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What is Municipal Solid Waste (MSW)?• This is domestic waste that is generated by household kerbside-
collected material and local government street sweeping, maintaining
litter bins and public parks and gardens. It includes- food wastes- containers (product packaging)- yard wastes - other miscellaneous inorganic wastes. Such as
o applianceso newspaperso clothingo boxeso office and classroom papero furnitureo wood palletso rubber tires o cafeteria wastes
Food and garden
Paper
Plastics
Glass
Metals
Concrete
Timber
Other
Typical MSW composition (Australia)
Reference: Australian Bureau of Statistics: Australia’s Environment: Issues & Trends, 2006
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The functional elements of MSW
Recycling/ Reused/
Composting
Landfilling/ Dumping
Thermo-chemical Treatment
Incineration Some Novel Technologies
Landfill gas capture – Some of methane released in Landfill sites are captured in the modern sanitary landfills that are provided with a gas collection network
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The Management of MSW in Europe
Belg
ium
, th
e N
e...
Aus
tia &
Sw
izer
...
Ger
man
y
Scan
dina
via
Fran
ce
Ital
y
UK
& Ir
elan
d
Spai
n &
Por
tuga
l
Pola
nd
Cent
ral a
nd E
ast.
..
0
10
20
30
40
50
60
70
80
90
100
LanfilledCompostingRecycling WTE
Func
tiona
l Ele
men
ts o
f MSW
(%)
Reference: European Waste to Energy Plant Market, 2013
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The Management of MSW in Selected countries
Reference: MSW Management in Asia & the Pacific Islands, 2014 TEPA, http://www.epa.gov.tw/en/statistics/c4010.pdf. McCrea et al, 2008 US EPA 2013 National Waste Report 2010 (Environment Protection and Heritage Council (EPHC), 2010) Victorian Local Government Annual Survey (2010-2011)- Published by Sustainable Victoria NSW Local Government Waste and Resource Recovery Data Report 2011-12 State of Waste and Recycling in Queensland 2012 (Department of environment and Heritage Protection)
Japa
n
Tiaw
an
Sing
apor
e
Kore
a
Chin
a
US
Aus
tral
ia
Vict
oria
New
Sou
th W
ales
Que
ensl
and
0
10
20
30
40
50
60
70
80
90
100
LanfilledCompostingRecycling WTE
Func
tiona
l Ele
men
ts o
f MSW
(%)
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Incineration of MSW
1. Reducing the amount waste (about
70% - 80% in mass) and (80% -90% in
volume), if compress (90-95%).
2. Significant reduction of landfill space-
30 times less (incineration does not
completely replace landfilling).
Major Benefits
1. High investment and operating
cost
2. Emission in flue gas & fly ash
3. Amount of mass residues and
impurities in bottom ash
4. Public’s view on WTE
Major Drawbacks
• The first incinerators for MSW were built in England in 1874, in New York in 1885.
• Large scale MSW incinerator was mounted in Hamburg in 1895.
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A very brief history of WTECombustion chamber
with fix grate
Development of moving
grate/ Stoker grate
Fluidized bed
technology Introduced
Slagging operating started
1900
1920
1930
1950
2000
1960
1970
1980
1990
2000
1950Public still satisfied as long
as the flue gas is invisible
TA-LuftAwareness of toxic
effects of dioxins &
furansEU- 89/369
BImSchV
1980
1990
Advanced WTEs (moving grate)
with complex cleaning systems
EC 2000/76
Melting in WTE is mandatory in Japan
CAA
USEPA- MACT
First rotary kiln in US
Incinerators’ smoke & odors were
accepted as a necessary evil
1900
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Fixed grate incinerators• Simple technology with a fixed metal grate over an ash pit below.
• Brick-lined cell ovens, opening in the top or sides for loading, another opening in
the side for removing the solid residues.
• Low efficiency , high emissions.
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Moving grate incinerators (Stokers)• Traveling grates support the fuel, while conveying it from the front feeding to the
ash-discharging side.
• Primary airs under the grate for primary reactions distributed differently
• Secondary airs above the grate for post-combustion.
• The most common, the most proven technology
• 84% of Japanese WTE (33 mtons/year)
• 91% of European WTE , almost all of US WTE
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Fluidized bed Incinerators• Waste mixed with inert materials are fluidized by
air.
• High thermal efficiency up to 90%, suitable for
wide range of fuel and mixtures of fuel (sludge &
solid waste)
• Pre-treatment of waste always required
• Suitable for RDF.
• 6% of European WTE
• 80 plants in Japan
(Ebara)
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Rotary Kiln Incinerators• A slight inclined shaft-furnace operating (generally) in a co-
current mode.
• The waste are transported through the furnace by rotations.
• Long retention, good thermal isolation, and high excess air.
• Applicable for hazardous waste, chemical waste and dry
sewage sludge incinerations.
• The capacity 2.4 t/day 480 t/ day.
Hitachi Zosen- Kiln Incinerator
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Advanced Moving Grate MSWI system
Reference: http://www.khi.co.jp/english/kplant/business/environment/g_waste/heat.html
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Mass balance of MSW Incineration
Moving Grate Incineration System
1 ton of MSW
6.2 – 7.8 ton of Air
7 – 8.6 ton of flue gas (Need cleaning before stack)
20 – 40 kg of fly ash (highly toxic)
250 – 350 kg of bottom ash (contains heavy metals, salts,
chloride & organic pollutants)
5 – 15 kg boiler slag
5 – 15 kg neutralization salts
Reference: Incineration Technologies, 2012
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About Dioxin/Furan• Polychlorinated dibenzo-p-dioxins (PCDDS) DIOXINS
• Polychlorinated dibenzofurans (PCDFs) FURANS
• Small amounts of PCDD/Fs are formed whenever carbon, oxygen and
chlorine are available at certain operating temperatures
• Dioxins are highly toxic and can cause reproductive and developmental
problems, damage the immune system, interfere with hormones and
also cause cancer.
• Sources of Dioxin Industrial processes
• Waste incineration
• Smelting
• Chlorine bleaching of paper pulp
• The manufacturing of some herbicides and pesticides
2,3,7,8-Tetrachlorodibenzo-p-dioxin
Other sources
• Volcanic eruptions
• Forest fires
• Backyard trash burning
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Flue gas cleaning• Because of the very heavy (public and political) pressures, MSW incineration
(at present) is the most regulated and best controlled form of combustion.
Reference: Incineration Technologies, 2012
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Dioxin/Furan in MSW incinerations• Dioxins were discovered on MSW incinerator fly ashes and flue gases in 1977. (Olie
et al. 1977).
• MSW incinerators were major sources of dioxins emissions in 80s. The dioxins
became an extremely large problem in Japan, US, Europe form around the mid
1990s. Emissions amount reduced 99% since then.
Reference: Deriziotis 2004; Kawamoto, Yokohama National University The Development of Waste-to-Energy Technologies around the World | San Shwe Hla | Page 19
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Required reduction of emission levels
Reference: Achternbosch & Richers (2002); Quina, et al. 2011
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Pollutant Concentration in raw gas
from boiler(mg/Nm³, dry)
Maximum admissible
at exhaust
(mg/Nm³, dry)
Removal
efficiency
required (%)
Dust 2,000 – 10,000 (Stokers)
10,000 – 50,000 (FB)
10 99.9
Fly Ash 1,500 – 2,000 10 99.9
HCl 300 – 2,000 10 >99
SO2 200 – 1,000 5 99.5
NOx 200 – 500 70 86
HF 2 – 25 1 96
Hg 0.2 – 0.8 0.01 99
Cd , Tl + other metals 2 – 15 0.05 >99.5
Dioxins and furnas (ng
I-TEQ/Nm³)
0.5 – 5 0.1 98
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Modern MSWI with advanced cleaning system
B – Quick cooling of gas prevents the dioxin reformation
C – Fine particulates, dust, Fly ash, SOx, HCI (absorbed) are eliminated
D – HCl, SOx, Hg are removed
E– Discharge heavy metal and the dioxin in the flue gas absorbed in activated carbon.
F – NOx revmoved and, dioxin decomposed and removed.
Reference: http://www.khi.co.jp/english/kplant/business/environment/g_waste/heat.html
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Main Drivers for Adapting Novel/ Gasification Technologies for WTE
• 1995 UN Environmental Program published that 4 kg out of 10kg TEQ of dioxin
came from Japan.
• New regulations and policies between 1995 -2005 in Japan were main drivers
for the development and installation of new gasification and melting systems.
• E.g. new dioxin regulation in 2003 limited 1 ng TEQ/Nm³ (for existing plants)
and 0.1 ng TEQ/Nm³ (for new plants) [up until the end of 2002, 80 ng TEQ/Nm³
was still acceptable] & melting process in WTE becomes mandatory in Japan.
• There are currently over 120 gasification based (ash melting) WTE plants
operating in Japan with a total capacity of 6.9 million tonnes / year.
• Main purposes are to reduce dioxin emissions (and other harmful substances)
and to produce glassy slag (to improve ash quality).
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Routes for Ash Melting System
Incineration
100%
(a) Incineration + Melting
Reference: http://www.kobelco-eco.co.jp/english/product/haikibutushori/ryudo_q2.html#a1
Waste Bottom ash, fly ash
Power generation, Heat utilization
With ash melting
Without ash melting Landfill (>20%)
SlagMelting
Fly ash
Recycled in construction work
Landfill (~2%)
Gasification & Melting
100%
Waste Slag
Fly ash Landfill (~2%)
Recycled in construction work
Power generation, Heat utilization(b) Gasification & Melting
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Installation of ash melting process in MSW-to-Energy plants in Japan
Reference: Professor Yoshikawa, Tokyo Institute of Technology
Incineration Gasification & melting
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Type of gasification based WtE Plants
Fixed beds(Direct Melting System) Fluidised Bed
Gasification and Ash Melting
• There are over 120 WtE plants using novel/gasification technologies in Japan & 13 plants in Europe.
Pyrolysis/ Gasification &
Melting Moving Grate
GasificationPlasma
Gasification
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Nippon Steel• The Largest supplier of gasification based WTE plants in Japan
• 33 in Japan 2 in South Korea.
• Fixed bed, updraft gasifier, Co gasification.
• 23% overall efficiency
Oxygen enriched air
Reference: Nippon Steel & Sumikin Engineering Co., Ltd, 2013
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Process Flow – Nippon Steel
Reference: Nippon Steel & Sumikin Engineering Co., Ltd, 2013
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Shin Moji Plant – NS largest gasification plant
Reference: Nippon Steel & Sumikin Engineering Co., Ltd, 2013
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JFE- Fixed Beds WTE• Merger of Kawasaki steel and NKK.
• Fixed bed types under JFE is similar to
Nippon Steel
• Currently 10 operational plants using
MSW, RDF as feed stocks
Reference: Professor Yoshikawa, Tokyo Institute of Technology
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EBARA- Fluidized bed gasification and Ash-melting Process• Shredded MSW is first gasified
inside fluidized bed gasifier operated under a low air ratio.
• Combustion of syngas in second reactor for ash melting.
• No oxygen enrichment. Fuel preparation required.
• Currently 11 plants in Japan & 4 in Korea (mostly for MSW and some for industrial wastes)
• Similar WTE process has also being supplied be Kobelco (15 plants) & Hitachi Zosen (8 Plants)
Reference: Professor Yoshikawa, Tokyo Institute of Technology
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Reference: http://www.eep.ebara.com/en/products/melting.html
EBARA Fluidized bed gasification (TIFG) & Ash melting system
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Reference: http://www.eep.ebara.com/en/products/gas.html
EBARA Pressurized twin internally circulating Fluidized bed gasification system (PTIFG)
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• Two gasifiers, with O2 and Steam as gasifying medium under high pressure.• Relatively H2 riched syngas for NH3 systhesis
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JFE- ThermoSelect
Reference: Frank Campbell, IWT, 2008
30.7% H2, 32.5% CO, 33.8% CO2, 2.3%N2
8.5 MJ/Nm³
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JFE- ThermoSelect.. Cont.
• Develop in Switzerland between (1985-1992).
• Demonstration facility in Fondotoche, northern Italy (100t/d) (1992-1999).
• Commercial scale in Germany (1999-2002, test phase), (2002-2004) full
operational. Shut down due to litigation between the supplier Thermoselect
S. A. & The owner EnBW (or) due to emissions issue.
• Currently, 7 ThermoSelect facilities are being operated in Japan by JFE
treating MSW and IW. (5 plants powered by gas engine, 2 plants by steam
turbines)
• JFE have stated that they no longer offer the technology as it is too
expensive.
Reference: Frank Campbell, IWT, 2008
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Takuma-Waste pyrolysis gasification and melting system• Wastes are first pyrolysed using a pyrolysis drum and using a verticaldownflow-type rotary melting furnace, conversion of ash to molten slag.
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ENERGOS• A leading European WTE system.
• Norway (6 plants), Germany (1), UK (1)
• Waste are pre-treated prior to use
• Gasification took place on moving grate
• High temperature oxidation in a
secondary chamber
• End used: Thermal (mostly)
Reference: http://www.energ-group.com/energy-from-waste/energos-technology/
7
8
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Plasma gasification• The use of plasma torches is not new.
• The use of Plasma torch in gasification of solid waste is new.
• Plasma is simply a high-temperature ionized gas created within a plasma torch that is both thermally and electrically conductive.
• AlterNRG/WPC design the temperature of the plasma plume would be between 5,000 °C and 7,000°C.
• In plasma gasification process, ash melting occurs in the absence or near absence of O2, prohibiting combustion.
• Two types of plasma gasification:
• Plasma assisted gasification
• Plasma assisted gas cleaning & melting
• MSW ash (from incineration plants)
melting using Plasma torch are not
considered as plasma gasification.- Westinghouse Plasma Corp Plasma Torch (Willis et al 2010)
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Plasma assisted gasification• Gasification and melting occur inside a single rector.
• Operating temperature are hot enough to drive the gasification reactions and brake down tars and higher MW compounds into CO and H2.
• Updraft type fixed bed gasification
• Torch temperature ≈ 5,000°C – 7,000°C
• Bulk bed temperature at base ≈ 2,000°C
• Molten slag temperature ≈ 1,650°C
• The syngas temperature ≈ 890°C – 1,100°C
• Utashinai Plant MSW (50%) + ASR (50%)
165 tpd 2003
• Mihama-Mikata Dried sewage sludge (20%) +
MSW (80%) 22 tpd, 2003
Reference: Willis et al 2010; Wood et al 2013
- ALTER NRG Plasma Gasification Reactor (Ref: Alter NRG)
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Plasco Plant• Plasma assisted gas cleaning and ash melting to treat MSW in Ottawa (100
tpd) by Plasco Energy Group.
• Gasification and plasma ash melting occur separately
Reference: http://www.plascoenergygroup.com/our-technology/the-plasco-process/ The Development of Waste-to-Energy Technologies around the World | San Shwe Hla | Page 39
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CHO Power WtE Plant• CHO-Power (& Europlasma) process consists of a primary gasifier (a moving
grate system) with plasma assisted syngas cracking reactor and ash melting unit.
• First commercial plant in Morcenx, near Lyon, France.
• 37,000 tpa (IW) +
15,000 tpa (WC)
Reference: http://www.cho-power.com/en/cho-power-in-morcenx-france-a-first-in-europe.html
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Utilisation of Slag and metal
Reference: Professor Yoshikawa, Tokyo Institute of Technology
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Slag recycling
Reference: Nippon Steel & Sumikin Engineering Co., Ltd, 2013
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List of proven gasification based WTE plantsCompany Type of WTE No of
plantsEnd Uses
Remarks
Nippon Steel Fixed bed-Direct Melting 33 (2) ST Enriched O2, 5% Coke
JFE (NKK) Fixed bed-Direct Melting 10 (1) ST Enriched O2, Coke
Kawasaki Giken Fixed bed-Direct Melting 5 ST High Concentration O2
JFE (ThermoSelect) Kiln Pyrolysis-Gasification-Melting 7 GT-E, ST 95% O2, Waste Compression
Mitsui Kiln Pyrolysis-Gasification-Melting 7 (2) ST Waste are shredded first.
Takuma Co. Ltd Kiln Pyrolysis-Gasification-Melting 2 ST Waste are shredded first.
Ebara Co. C-Fluidised gasification- Melting 11 (4) ST Waste are shredded first.
Kobelco Co. Ltd B-Fluidised gasification- Melting 13 (2) ST Waste are shredded first.
Hitachi Zosen B-Fluidised gasification- Melting 8 ST Waste are shredded first.
Ebara & Show Denko PTIFG & Ash melting 1 NH3 Pressurized, O2+H2O
AlterNRG-Hitachi-M Plasma Assisted Gasification 2 ST Plasma, MSW-ASR-SS
Plasco Energy Plasma assisted cleaning/melting 1 GT-Eng Plasma, MSW
CHO-Power-Europlasma Plasma assisted cleaning/melting 1 GT-Eng Plasma, MSW
ENERGOS Stoker-gasification - Combustion 8 Steam Waste pretreated. No melting.
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World’s first waste-to-biofuels facility• Enerkem waste to biofuels and
chemical facility at Edmonton
• Opened on 4th June, 2014
• 60% of waste into biofuels and
chemicals
• 100,000 tonnes/year to MSW
into 38 million liter of biofuels
• 70$/ton landfill, 75$/ton WtF
Waste Gasification SyngasManual &
mechanicalSeparating
Shredded Organic waste
Inert
Clean syngas
Reference: Edmonton Journal , 5 June, 2014; http://www.edmonton.ca/for_residents/garbage_recycling/biofuels-facility.aspx
Biofuel facilityMethanol
Ethanol
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Chemical intermediates
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What are the main drivers of WTEs?• Government regulations
• Public Health
• Environmental issues
• Emission controls
• Reducing land fill areas
• Cost of WTE Vs tipping fees
• Electricity generation from MSW is not a main driver.
• It is one of the products while reducing amount of wastes.
• Let’s see an outermost case.
• Japan with 800 Plants (310 WtE Electricity) plants utilising 40 million
tons MSW annually (80% of total MSW generation).
• Total install capacity ≈ 1673 MWe (in 2009) ≈ 0.6% of country’s
electricity generation
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Tipping fees Vs WTE plants in US
$0.00
$10.00
$20.00
$30.00
$40.00
$50.00
$60.00
$70.00
$80.00
$90.00
$100.00
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
18,000
20,000
Avg tipping fees
MSW-TPD
Ave
rage
Tip
ping
Fee
s (U
S$/t
on)
MSW
to E
nerg
y (T
ons/
day)
Reference: http://www.cleanenergyprojects.com/Landfill-Tipping-Fees-in-USA-2013.htmlThe 2010 ERC Directory of Waste-to-Energy Plants
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WTE Reduces GHG Emissions• Nearly one ton of CO2 equivalent emissions are avoided for every ton of MSW
handled by WTE (US EPA) due to
• Avoided CH4 emissions from land fills.
• Avoided CO2 emissions from fossil fuel combustion.
• Avoided CO2 emission from metals production.
Reference: Thorneloe et al, 2006
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Feasibility Study: Requirements for a Successful WTE Project• Research on Technical Feasibility
• Survey of waste characteristics, LCV and amount of waste
• Selecting suitable WTE system
• Estimation of electricity output
• Plant Location
• Evaluation of Environmental and Social Impacts
• GHG Emission/Reduction Effect
• Plant Emissions
• Research of legal system and procedure related to environmental
assessment
• Financial and Economic Feasibility
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Road Map to commercial scale WtE plant Fuel (MSW)
characterization
Lab scale reactor
Pilot/Commercial scale WtE plant
- Composition - Energy content - Reaction rates
Fuel (MSW) preparation
methods
Cost Analysis
- Steam Turbine - Gas Turbine - Combined Cycle - Chemicals - Liquid fuels
Process Modelling
Fuel (MSW), Availability
Selection of type of WtE
plant
- Data collection from local councils
- Choice of plant size & End use
Emissions Vs regulations
Meet the budget, regulations & WTE performance setno
yes
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Summary of WTE technologies
• Moving grate technology is the most commonly used for WTE (84%
Japan, 91% European, almost all of US WTE.
• Fluidised bed incineration provide higher efficiency with lower emission
level.
• Gasification technology has smaller capacity than incineration but its
integration with melting systems significantly amount of reduces WTE
wastes (bottom ash).
Source: Frost & Sullivan analysis
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Current status of gasification of MSW
• Technical reliability
o Limited number of gasification based (melting) plants (~120) are able to
offer a proven gasification process for different kinds of solid wastes.
• Environmental sustainability
o Gasification is considered as a sound response to the increasingly
restrictive emission regulations and towards zero wastes.
• Economic convenience
o Usually more expensive in operating and capital costs higher than
conventional combustion-based WtE.
o Recent evidences indicate a convenience of gasification plants for size
smaller than about 120 kt/y.
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Conclusions & some thoughts• Driving force for WTE options over landfill
o Tipping fees (Landfill tax, landfill levy)
o Government regulation regarding with landfilling
• Driving force for gasification based WTE over incineration WTE
o Government regulations on specific design of WTE plant (e.g. melting)
o Tipping fees for WTE bottom ash
o Emission control and regulations
• Important factors for establishing WTE plants in Australia
o Government regulations and policies
o Tipping fees (Landfill tax, landfill levy)
o Public acceptance
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Thank you
CSIRO Energy TechnologySan Shwe HlaThe Development of Waste-to-Energy Technologies around the Worldt +61 7 3327 4125e [email protected] www.csiro.au/Energy