Gasification of Municipal Solid Waste and Tire Pyrolysis ...

Karlsruhe, 5.12.2017Dr. Ingo Zorbach

Gasification of Municipal Solid Waste and Tire Pyrolysis as alternative solutions for commercial scale treatment of waste

Dr.-Ing. Ingo Zorbach

• Study of „Allgemeiner Maschinenbau“ at TU Darmstadt with a focus on thermal processdesign and power production

• Doctoral thesis about online measurement of waterwall corrosion in boilers

• Since January 2013 at Steinmüller• Head of R&D since 2015

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Persönliches

► International company for plant construction in the field of environmental and energy technology

► More than 150 years of tradition and know-how

► Worldwide more than 1,600 reference plants

► EPC-Contractor for turnkey plants

► Member of the Nippon Steel & Sumitomo Metal Corporation

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SBENG in brief

1898

1874

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History

1999 2002 20142000

Noell KRCEnergie- und

Umwelttechnik GmbH

Pyrolysisplant in Burgau „Noell Konversionsverfahren“

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Milestones

1985: First industrial large-scale SCR-plant in Europe (Altbach/Germany)

1993: First application of Inconel cladding at waste incineration plant in Europe(Burgkirchen/Germany)

1994: World’s first water-cooled grate surface for municipal waste(Horgen/Switzerland)

2004: First entire cladded combustion chamber at EfW plant in Europe(Aarhus/Denmark)

2009: First turbine in EfW plant with an electrical output > 120 MW (Naples/Italy)

2012: Largest EfW unit in Germany with 1,000 t/d waste output in one line(Berlin-Ruhleben/Germany)

Turnover: 38.8 billion €Employees: 92,309

Turnover: 2.2 billion €Employees: 4,923

Turnover: 179.3 million €Employees: 259

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100

%

100

%

* all information for the fiscal year 2016

Ownership structure

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NSSMC

Chemicals Steelmaking Engineering(NSENGI)

New Materials

SystemSolutions

Steel Plant andMachinery

Marine Engineering /Construction

Energy /Pipeline

Building Construction/Steel Struct.

Technical /Business Develop.

Environmental Solutions

Group structure NSSMC and NSENGI

Gasification + PyrolysisTechnologies

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Headquarter

Branch

Cooperation partner

Licensees

Representatives

Global network

Project Management

Overall Planning, Quality Assurance, Expediting, HSE, Procurement, Logistics, Planning & Supervision of Site Activities

Infrastructure

Civil Works

Incineration Technology

Boiler Technology

Flue Gas Treatment

Water-Steam Cycle

Electrical Systems

I & C System

Balance of Plant

Own basic & detailengineering Own basic engineering Procured

► Complete turnkeysolutions

► Chute-to-stack ► Full technology ---package

Your partner for turnkey solutions

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A solution for every kind of waste

Incineration and co-incineration of:

► Municipal solid waste► Refuse derived fuels► Industrial waste► Bulky waste► Biomass► Sewage sludge► Shredder light fraction► Tyres► Animal waste► Hospital waste► Hazardous waste – solid► Hazardous waste – pasty► Hazardous waste – liquid

Grate incineration

Gasification (DMS)

Rotary kiln incineration

• Tire Pyrolysis• Pyrolysis plant in Hirohata, Japan

• Gasification• Direct Melting System

Content

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Pyrolysis ofEndo of Life Tires

Plant in Hirohata

• Treatment process without air addition• Typical treatment temperature 400°C to 550°C

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Tire pyrolysis

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Tire pyrolysisOperating temperature and gas yield

Source of tables and figure:

Hirohata Tire Pyrolysis Facility, Hirohata Steelworks, Japan

Bilder: google Earth

Aufbau der Anlage

Pyrolyse und Öl-Kondensation

Lagerflächen

Reifenaufbereitung

Bilder: google Earth

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Anlagendetails2 Drehrohre mit je 30.000 t/a Kapazität

Öl-Kondensation

Gasreinigung

Ölspeicherung

Ölbrenner

Abwärmenutzung Feststoffaustrag

Bilder: google Earth

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Typical pyrolysis gas composition

0,3%

9,7%

12,0%

35,7%

16,1%

9,0%

6,3%

6,4%

4,5%

0,0% 5,0% 10,0% 15,0% 20,0% 25,0% 30,0% 35,0% 40,0%

Oxygen

Nitrogen

Hydrogen

C1

C2

C3

C4

>C4

Rest

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Verfahrensübersicht

Coo

ler 1

Coo

ler 2

Heavy Oil Light Oil

steelCarbon black

BoilerFGT

Ca. 20 °C

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Material balance in HirohataR

ubbe

r (~5

0%)

Car

bon

(~30

%)

Steel (~13%)

Zink (4%)Pyrolysis

Oil

(~37

%)

Gas

(~

19%

)C

arbo

n(~

29%

)

Steel (~13%)

Light Oil: 6.000 t/aHeavy Oil: 16.000 t/a

Ca. 11.400 t/a Gas

Ca. 17.400 t/a Carbon

Ca. 7.800 t/a Steel

Ca. 1.400 t/a Residuals

Oil

(~13 %)

Util

izat

ion

in s

teel

mill

(~85

%)

Own consumption

Gas: Utilization in Utility boiler

Oil:Heating of steel converter

Carbon:Reduction agent in steel process

SteelRecyclingsteel for steel converter

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Stoffströme in einer geplanten Anlage

Die

sel (

~30%

)C

arbo

n (~

29%

)

Steel (~13%)

Ca. 10%

Gas

(~

19%

)

Dieseloil acc. EN 590

Own consumption andpower production(ca. 1.650 kWel)

Upgrade to Carbon Black

Recycling

Residues for disposalIncluding oil not meeting spec.

Rub

ber (

~50%

)C

arbo

n(~

30%

)

Steel (~13%)

Zink (4%)Pyrolysis

Oil

(~37

%)

Gas

(~

19%

)C

arbo

n(~

29%

)

Steel (~13%)

Light Oil: 6.000 t/aHeavy Oil: 16.000 t/a

Ca. 11.400 t/a Gas

Ca. 17.400 t/a Carbon

Ca. 7.800 t/a Steel

Ca. 1.400 t/a Residuals

• Post treatment required• Flash point of Light Oil too low• Density of Oil either too low or too high• Further distillation and blending required

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Oil composition and technical issues

Light Oil Heavy Oil Gasoline Diesel FuelTemperature [°C] 15 40

Flash-point [°C] -20 55 < -20 > 55Pour-Point [°C] -20 -20

Density [kg/l] 0,86 1,056 0,75 0,84Kin. Visco [cSt] 0,6 19 < 0,5 2-4Acid/Alkali [-] Alkali Acid

Heating Value [MJ/kg] ~41 ~38 ~41 43

Pyrolysis Oils

Zusammenfassung:

• Tire pyrolysis is an option for recycling• Plant in Hirohata in operation since 2004 with a 60.000 t/a capacity

• IED: Co-Incineration plant• Flue gas has to be treated accordingly (i.e. 17. BImSchV in Germany)

• Economics of plants strongly dependet from Crude Oil price level• Currently not economical

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Gasification of Waste

Direct Melting System

• Gasification process for untreated MSW• Developed in Japan; plants in Japan and Korea• More than 40 years of experience; first plant in operation in 1974

• Treatment of:• MSW without pre treatment• Clinical waste• Sewage sludge• Hazardous waste• Material from landfill site reclaiming activities

• Very high slag quality

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Direct Melting System

Baghouse

Gasifier

Waste Pit

Recyclables

MetalSlag

Boiler

Steam Turbine

SCR

Stack

Landfilling

Fly Ash

Cyclone

Combustion AirDraft Fan (CDF)

Forced Draft Fan (FDF)

O2-PSA

Gas

Coo

ler

CombustionChamber

WaterGranulator

ID Fan

Magnetic Separator

Re-Heater

Coke and Limestone

Wet

Scr

ubbe

r

DMS Prozess Übersicht

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Tipping hall

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View inside of waste bunkerLandfill site residue treatment

Raw material fromlandfill site

Mixing with MSW

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Waste chute feeding hopper

2.2. Gasifier - Co-gasification -

Syngas

Flexibility of Processed Waste No Pretreatment (Max. 800 mm)Co-gasification

High Syngas NCV Continuous syngas measuring Approx. 5.9 MJ/m3

N based on 9.1 MJ/kg-wasterefer to N.Tanigaki et. al. Waste Management

High Temperature & Reducing AtmosphereProduced by coke burning heatToxic heavy metals are volatilized and distributed to fly ash.Few toxic heavy metals remain in slag and metal.

Material and Energy Recycling from Waste

1,800℃

400-500 ℃

600-800 ℃

Sewage sludge Bottom ash Landfill Waste Clinical Waste

Reliability - Measures for Scaling-up of Gasifier -

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Scale-up of gasification technology is one of the technical issues.- Gasification reaction in the gasifier.- optimization of waste charging and combustion conditions.

Our gasification (Direct Melting System) gradually expanded its capacity, during 38 years and reach now a capacity of 14 t/h per line (330 t/d).

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Bottom ash sample

2.3. References in Japan and South Korea

Kamaishi City, Iwate Pref.

Ibaraki City, Osaka Pref.

Kazusa Clean System Co., Ltd. Chiba Pref.

Narumi Clean System Co., Ltd. Nagoya City, Aichi Pref.

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3 4

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1

2

Kita-kyushu City 〔Shin-Moji Plant〕, Fukuoka Pref.

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1

11

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Akita City, Akita Pref.

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2 3 4

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3739

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38

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41 43 references 38 years operation 10,000 - 240,000 t/a

2.3. References - Shin-Moji Plant-

Location / PurchaserKitakyushu City, Japan

FuelMunicipal solid wasteIncombustiblesSewage sludge

Capacity3 x 10 t/h9 100 - 12 000 kJ/kgLargest gasificationPlant in operation

Year of Start Up2007

NSENGI Scope of SupplyFull Turn key +Operation & Maintenance

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