WASTE REFINERY & GENCOAL®The sustainable way to valorise waste
concept & references
2
Table of Contents
Summary 3
1. The concept 5
2. WASTEREFINERYprocessflow 6
3. ACompilationofproventechnologies 7
4. ComponentsfromtheportfolioofIPAS 8
CoalWashing 9
CoalSludgeRecovery 10
BottomAshTreatment 11
SoilWashing/Remediation/Sanitation 12
GlassRecycling 13
WaterPurification&Treatmentoforganicsinthefoodindustry 14
Sludge&WaterTreatmentintheconcreteindustry&brickworks 15
5. Advantagesofthetechnology 16
6. Equipment 17
Annex1 Exampleofabusinesscase 19
Annex2 Detailedresultsofwasteseparationatlaboratory,2013 20
Annex3 LaboratorytestresultsonGENCOAL 22
Annex3.1.Summaryofseparationresults 22
Annex3.2.Resultsfromthe‘ashtest’atTechnicalUniversityOstrava 24
Annex3.3.CertificationtestasalternativefuelatVVUÚOstrava 26
Annex 4 Impressionsofsemi-industrialtestin2018 28
Annex5 ProjectteamforWASTEREFINERY&GENCOAL 30
3
SUMMARY
WASTE REFINERY & GENCOAL is a new and straightforward approach of the solid waste challenge that meets both the need for high ecological standards and economic realism. Moreover this new concept for valorising waste streams leans on vast industrial experience with proven technologies. There certainly is a worldwide market potential. WASTE REFINERY & GENCOAL is the result of a thorough analysis of existing practices and of fresh industrial thinking, based on many years of hands on experience in the sector of separation technologies.
WASTEREFINERY&GENCOALisanewpracticalconceptforturningwaste1into‘instantrecoverablematerials’forenergygenerationandin‘instantrecyclablematerials’formaterialsrecycling.Thesolutionisbasedonanewcombinationofexistingtechnologies,allowingto:
• buildandoperatea‘WASTE REFINERY’,using‘wettechnology’;• producea‘coalequivalent’combustible:Bio Generated Coal,inshortGENCOAL.
WASTEREFINERY&GENCOAListhebestandmostrealisticalternativeforwasteincineration,asitismuchcheaperininvestmentandoperationalcost.Moreover, itreachesthemaximumpossiblerecyclingofmaterials2 and it produces a biomass combustible that can be valorized in existing installations. ’WASTE REFINERY & GENCOAL’ is the mostcontemporarysolutionasitmeetssocietalchallenges,bothinthefieldofenergyandofmaterials.
WASTEREFINERY&GENCOALisaconceptdevelopedandpromotedbytransit_LAB,togetherwiththeBelgiancompanyIPAS,aninternationallyrenownedspecialistinseparationtechnology.
Transit_LAB, isaBelgiumbasedcooperative innovationanddevelopmentcompany, founded in2012,specialising intransitiontechnologiesandregionaldevelopmentprograms.Transit_LABpromotescreativesolutionsforsocietyandindustryandoperatesasa‘platform for co-creation’.
Knowledge and technology partner IPAS, Industrial Processes – Active Services, designs and builds ‘tailor made’installationsasanindependentandhighlyexperiencedpartnerforallrefiningandseparationchallenges.IPAShasover 30 years of international experience inoptimizing industrialprocesses,refiningrawmaterialsandwaste,separatingcoal,rawmaterialsandwaste,applyingwetanddrytechnologies.
1 Wastehereis:MSW:municipalsolidwasteandlikewiseclassifiedcompanywaste.ButWASTEREFINERYcanalsobeappliedinLandfill
Mining,recoveringexisting/historicalwastedumpsites.MoreoverWASTEREFINERYcandealwithaverywiderangeincompositionofwaste
streams.
2 Maximumpossiblerecyclingofmaterials:tobeseeninthelightofanequilibrium-basedonpermanentprogressiveinsight–between
economicviability,industrialdoabilityandthehighestpossibleenvironmentalgain.
4
‘‘I am convinced that the classical waste incineration as it still is promoted throughout Europe has had its days of glory. It was a wonderful technological breakthrough towards a better care for environment and public health. But it is high time now that we start taking seriously initiatives like WASTE REFINERY & GENCOAL. The reason: this combines the best possible practice towards recycling at large scale of materials with the best possible use of the calorific fraction in waste streams. Building classical incinerators is no longer a socially responsible answer to the contemporary challenges. That is why I joined the WASTE REFINERY & GENCOAL team with com-plete conviction and commitment.’’Wilfried De Nijs
WilfriedDeNijs,honorary Inspector General at OVAM, the public WasteAgency of Flanders was responsible in Belgium for theintroduction of contemporary waste legislation. In thatposition he closed dozens of badly managed public andprivatelandfillsandintroducedinthe1980’sthefirstWASTEINCINERATORSinthecountry.
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1. The conceptIngeneral,MSWiscomposedof1/3water,1/3inertmaterialsand1/3organicsandplastics.The‘WASTEREFINERY’,theinstallationfortreatmentofwaste,usesthe1/3ofinherentwaterintheprocessingplantandtherestisseparatedand‘washed’untiltheinertmaterialsarerecyclableandtheorganicandplasticsareupgradedintoaperformantfuelforexistingelectricityorheatingplants.IfcarefullymanagedthisBio Generated Coal or new fuel is a biomass combustible.
Instant recyclable materials for RAW MATERIALS:Out of our own laboratory findings, confirmed by international literature on the composition of municipal wastestreams,weseethat,evenincountrieswherewasteisalreadysortedinthehouseholds,aportionofupto1/3ofthetotalmassor½ofthetotaldrymassofMSWiscomposedofinertmaterialsthatarerecyclable.TheWASTEREFINERYistheaccurateanswertotheworldwideneedformaterialsrecycling.Thematerialschallengeisrealasnaturalresourcesaredecliningandgettingmoreandmorecostly.Thecleanrecycledmaterialscanbesoldontheopenmarket:ferrousmetals,non-ferrousmetals,stainlesssteel,sandandgravel/stones.
Instant recoverable materials for ENERGY:BioGeneratedCoal,orGENCOAL,isacombustiblethathasthesamecalorificvalueascoalandthatcanbeprocessedintopellets,soitalsohasthephysicalcharacteristicsofcoal(fortransportandstorageandharshweatherconditions).GENCOALcanbeusedforco-firingincoalfiredpowerandheatingstationsorinbiomassinstallations.Ifneeded,thecalorificvalueoftheGENCOALcanbeadjustedbymixingwithadditives,sothatGENCOALcanbemadesuitableforallexistingcombustioninstallations.ThetestsconductedattheTechnicalUniversityofOstrava(CZ)inDecember2013confirmedthatthecalorificvalueofGENCOALisadequateforuseatindustrialscale.Thecalorificfractioncanalsobefurtherprocessedintosyngasorotherenergeticsolutions.
GENCOALorBioGeneratedCoalisaflexiblefuel,meetingtheclimatechallenge:TheuseonabigscaleofGENCOAL,giventhefactthatmanyoftheworldspowersupplyisbasedondifferentkindsofcombustioninstallations,canbringaneconomicandanecologicalbenefittosociety.BioGeneratedCoalisaflexiblebiomass.GENCOALcanbecontrolledandsteeredbyusingadditives:
• Thecalorificandthereforeeconomicvaluecanbeadjustedtothetypeofincinerationprocess.• TheenvironmentalimpactoftheuseofGENCOALasfuelcanbesteered.Theemissionsofsulphurand
chlorideswillbeinfluencedinapositiveway,probablyevenneutralised.Ofcourse,thecombustionofGENCOALwillhavetomeettheenvironmentalcriteria,alsobyuseinovensequippedwithgaswashinginstallations.
Wet technology as innovative approach:TheheartofthetechnologicalprocessconsistsmainlyofaWETseparationline.Wettechnologyhasthefollowingmainadvantages:• theendproductsarecleanandthereforehaveahighermarketvalueandgivelessleaching;• theenergyneedislow:noenergyiswastedbyevaporationofunnecessarywaterorheatingofinertmaterials;• amaximumamountofmetalscanberecycledaslittleoxidationoccurs;• theproblemofdustandfineparticleswillbetackledinherentlybythewetprocess;• thecapacityoftheinstallationcanbescaledasdesired.Unlikedryseparationprocessesforwaste,wetseparation
lineshavethepotentialtohandlebigvolumesatconstanthighqualityoutputs.IPASisspecialistatinternationallevelforwetseparationandupgradingprocesses.
WASTEREFINERY&GENCOAL is a sustainableway of treatingMSWand is aTRANSITION TECHNOLOGY, especially designedforthetimewelivein,atimeofchanginginsightsanddevelopmentsinthematerialsandenergymarket,worldwide.
The main advantage of WASTE REFINERY & GENCOAL is that investments in classic (and expensive) waste incinerators are no longer needed and that a viable and sustainable alternative for landfill is available. In addition GENCOAL can combine the treatment of actual MSW with ‘landfill mining3’ whereby historical waste is recycled or (energy) recovered. For this reason WASTE REFINERY & GENCOAL can also offer a solution in land reclamation policies.
3 Landfillminingisaprocesswherebymaterialsandenergyisrecuperatedwhilediggingupexistinglandfillsites.Theunderlyingideais
thatalandfillsitemightcontainmoreusefulmaterialsthanactualminesorquarriesfornewrawmaterials.
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2. WASTE REFINERY process flow
DexF
RDF
Clean water
F FeedDEX Screening for explosivesFe IronRDF Refused Derived FuelR RejectEp End productT TemperatureSa SandN.Fre Non-ferroO OrganicGr GravelAd AdditiveA SandB Gravel
Legende
Clean water
Fe
FeRDF
RDF
Ad
x2
A
N.Fe N.Fe
INOX
Sa Fe Fe Gr
B
R
Ep
T
O
GreenCoal Pellets
© transit_Lab / IPAS
simplifiedschematicdiagramoftheWASTEREFINERY
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3. A compilation of proven technologies
IPAS,thetechnicalpartnerinWASTEREFINERY&GENCOAL,hasover30yearsofhandsonexperienceinseparationandupgradingtechnologies.
Theinstallation‘WASTEREFINERY’isinfacta balanced compilation / synthesis of existing technologies,thatallofthemhavebeendesignedandbuiltbyIPASitselfindifferentpartsoftheworld.
It is in a laboratory test project in 2013, performedon actualwaste streams from the Karvina region in the CzechRepublicthatthisnewconceptwascreated.Inannex2and3thewasteseparationprojectforKarvinaispresented.AlsothetestresultsofGENCOALatlaboratories.
In2018anindustrialtestwasdoneinKarvina:30tonsoffreshwastewasprocessed.Thetestconfirmedthelaboratoryresultsandapositivebusinesscaseisdrafted.
MATERIALS ENERGY GENCOAL
WASTE REFINERY
COALWASHING
COALSLUDGE
RECOVERY
BOTTOMASH
TREATMENTSOIL
WASHINGGLASS
RECYCLING
WATERTREATMENT
IN FOODINDUSTRY
SLUDGE WATERTREATMENT
IN CONCRETEINDUSTRY
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4. Components from the portfolio of IPAS.
AlltheessentialcomponentsarenotonlyproventechnologyandevenBestAvailableTechnique,buttheyhavealsoallbeenbuiltseveraltimesinrecenthistorybyIPAS,theknowhowandtechnologypartneroftransit_LAB.
In this paragraph is described, the international portfolio of relevant IPAS projects. WASTE REFINERY & GENCOALis the combinationof technologies fromCoalwashing,Coal sludge recovery,bottomash treatment, soilwashing&remediation,glassrecycling,watertreatmentinthefoodindustry,sludgeandwatertreatmentintheconcreteindustryandbrickworks.
w COAL WASHING
w COAL SLUDGE RECOVERY
w BOTTOM ASH TREATMENT
w SOIL WASHING / REMEDIATION / SANITATION
w GLASS RECYCLING
w WATER PURIFICATION & TREATMENT OF ORGANICS IN THE FOOD INDUSTRY
w SLUDGE & WATER TREATMENT IN THE CONCRETE INDUSTRY & BRICKWORKS
“Waste Refinery & Gencoal
is the smart compilation
synthesis of all these
technologies and installations.
That is the only secret behind it all.”
Etienne Schouterden - IPAS
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COAL WASHING
IPAShasbuiltseveral‘totalseparationconcepts’forthecoalminingindustry.• ‘RunofMine’COAL:designandbuildofinstallationsofallpossiblecapacities.• ‘TIPwashing’:designandbuildofprofitableinstallationsfromacoalcontentof10%.
References:SSMTerneuzen(1990/Netherlands/TSC-totalseparationconcept4);Anscoalnv(1991,Belgium/TSC);Terval(1991/Belgium/PWT-processwater treatment 5);StadtwerkeSaarbrücken (1993/Germany/TSC– research);Knurow(1995/Poland/machinery);Slask(1995/Poland/machinery);Czechcoalmines(1996/CzechRepublik/chemicals);TechnoAgrar(1996/Germany/chemicals);Jankowice(1997/Poland/machinery);TrInternationalLtd(1998/USA/TSC–research);Donbasscoalmines(1998/Ukraine/chemicals);APM(2000/Indonesia/TSCresearch);Mekol(2000/Belgium/processwatertreatment);ChinaCoalmines(2000/China/chemicals);Dzerdzhinsko–Energosurs(2001/Ukraine/TSC);Gorenenrgo(2002/Ukraine/TSC);ROA/Adcoal(2003/Belgium/TSC);SEEcotekh(2003/Ukraine/TSC);ABT(2005/Belgium/processwatertreatment);CoalminesMarcel,Jankowice,Anna,Jasmos,Knurow(1991–2007/Poland/chemicals);Techexpertise(2010/Ukraine/separationplantinpartnership);
4 TSCor‘TotalSeparationConcepts’means:completeanalysis,designandbuildofindustrialsolutiontoseparateandupgrade
materials.
5 PWTor‘ProcessWaterTreatment’means:analysis,designandbuildofindustrialtreatmentinstallationforwater/processwater.
flowsheetofcoalwashingplantatKrasnoarmeyskaya-Zapadnaya
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COAL SLUDGE RECOVERY
IntheenvironmentofworkingandclosedcoalminesmostoftenexistPONDS,thatcanbeverybig.TheyareusedtostoreinatemporaryorpermanentwaytheSLUDGEfromthecoalwashingprocess.Veryoftenthesepondsarestillrichinfinecoaltoveryfinefractionsofusablecoal.IPASisatopspecialistinrecoveryofcoalfromtheseponds,asIPASmastersthewetprocesstechnology.IPAShasdesignedandbuildseveralPONDWASHINGINSTALLATIONStorecovercoalfromsludgemass.IPASinstallationsrunprofitableforcoalpondsfrom40%coalcontent.Therecoveryandsanitationofcoalpondsis,ofcoursealsoanecessitywhentheminingactivitystops.
References:IPAS references in coalmine sludge recovery. The projects are situated in run ofmine environment or in sanitationcontextsorpitrecoveryoperations.Fechner(1988/Germany/TotalSeparationConcept-TSC-);Sewater(1989/Belgium/TSC);Solichar(1989/Belgium/TSC);Haisy(1990/USA/TSC);HansenCoalGmbh(1990/Germany/TSC); Issabel(1990/USA/TSC);KempenseSteenkoolmijnen(1990/Belgium/TSC);IPASPolska(2010–2013/Poland/contaminatedCoalTipsandSludgePonds–studies).
• Coalcrushing• ScreeningWET/DRYtill350mm• Separating:
o Dens mediumo Jiggingo Cycloningo Spiralso Flotation
• Thickening:o Deepconeo Normalthickener
• Dewatering:o Centrifuges
-Decanter -Shubcentrifuges -Pushercentrifuge
o Vacuumfiltration -Drum -Disc -Belt
o Multirollfiltero Chamberfilterpress
• Drying:mechanicalandthermaldrying
Available techniques @ IPAS
DzerzinskCoalSludgeRecovery
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BOTTOM ASH TREATMENT
IPASdesignedandbuilda world premier installationintheyear2000tocleanandseparatethebottomashfromtheINDAVERwasteincineratorsinAntwerp,Belgium.ThisinstallationrunseversincewithoutanytechnicaldefectsandstillisareferenceinthesectorofWasteManagement.
Intheashtreatmentunit,ashesfromthehousehold incinerationfacilitiesarewashed,sievedandpurified.Theendproductisavaluablesecondarymaterialthatcanbeusedforseveralapplications.Ferrousandnon-ferrousmetalsarecarefullyremovedinvariouscut,sieveandwashunits.Someofthoserecuperatedmetalswillbere-usedinindustry.Inertashesremainingafterincinerationareconvertedintogranulates.Thesecanbeusedassecondarymaterialsintheconstructionindustry,inaccordancewiththerelevantenvironmentalregulations.
Top reference:ReferenceofaworldpremierinstallationINDAVER(2000/Belgium):totalrealisationforseparatingandupgradingofrestmaterialsafterwasteincinerator.Afterburningofwasteremains25to30%ofthetotalmass.This30%isreducedto3%ofrestmaterial.27%oftheashmassisrevalorisedthroughtheIPASprocess.Seealso:http://www.indaver.be/en/installations-processes/material-recovery/ash-treatment/
Other references:AZN(2005/theNetherlands/TSC);Machiels(2005/Belgium/TSC)
Ash treatment
> 50 mm
incineratorashes
rotary sieve coarse material> 50 mm
extraction of ferrous metals
ferrous metals(> 50 mm)
to land�ll
< 50 mm washer barrel
light organic materialto grate
incinerators
screening &washing
installation6 -50 mm
extraction offerrous metals
extraction ofnon - ferrous metals
6 - 50 mmgranulates
2 - 6 mmgranulates
ferrous metals non-ferrous metals
< 2 mmtot water puri�cation plant
2 - 6 mm
extraction offerrous metals
extraction ofnon-ferrous metals
sand �lter cakes
flowsheetofbottomashtreatmentatINDAVER,builtin2000
INDAVERBottomAshTreatment INDAVERBottomAshTreatment
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SOIL WASHING / REMEDIATION / SANITATION
InIPASdevelopedinstallationsforSOILWASHING,highlycontaminatedsoilsarecleanedinhighvolumesanduntila100% recyclabilityofthematerials.
www.carmans.be
Top reference:GrondreinigingscentrumLimburg/CarmansNV(2007to2015,Belgium/TSC).Thisinstallationruns90t/hourofhighlycontaminatedsoil.IPASiscurrentlypreparingansimilarinstallationtoprocess250t/hour.Moreoverthewholeplantrunsonrenewableenergy.Asfinalstep,IPASisdevelopinganaddedoninstallationtovalorisethelast20%fractionofthecontaminatedsludge:17%offinematerialswillbeturnedintoanewproduct,capturingandstabilizingthecontaminantsand3%organicswillgotoenergeticvalorisation.Sothisplantwillsoonreacha100%recyclingofcontaminatedsoils.
Other references:NMB(1991/theNetherlands/TSCforroadconstruction);Gyprocnv(1991/Poland/combustionplant inGypsumindustry);BasseSambre(1991/Belgium/TSCsandrecovery);SETnv(1991/Belgium/TSC);HogeschoolDelft(1996/theNetherlands/TSC);WatcoRSWnv(1999/Belgium/TSC);Rens(2000/Belgium/TSC);
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GLASS RECYCLING
Thecollectionofusedglass (bottles, jars,…) fromhouseholds isa commonpractise inEurope.Glass representsanimportantinertfractionintheMunicipalWastestream.IPAShasdevelopedafullyautomaticrecyclinglinethatprocessesup to 25 tons per hour.
Differentstepsintheglassrecyclingprocess:
• Separationofthecoursefractiontopreparecolourseparationoncompletebottles• Separationofgranulates• Separationofnon-ferrousfraction• Separationofstonesandporcelain.
References:GRV(1992/Belgium/TSC);VLAR(1994/Belgium/Engineering);GRL(1997:Belgium/TSC);GRL(2009/Belgium/CHPinstallation)
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WATER PURIFICATION & TREATMENT OF ORGANICS IN THE FOOD INDUSTRY
References:Clareboutnv(1991/Belgium/PWT);OrganicWasteSystem(1992/Belgium/TSC);NolikoVegetables(1992/Belgium/PWT);VanReuselSnacks(1993/Belgium/BAKreactor);VanlommelSlachthuisnv(1994/Belgium/PWTresearchmeatindustry);Krikro(1994/Belgium/PWT–potatoindustry);Decosterbvba(1996/Belgium/PWTpotatoindustry);VanReuselSnacks(1996/Belgium/consultancyonprocess);VanReuselSnacks(1998/Belgium/processoptimisation);VanReuselSnacks(2000/Belgium/PWT);Equinox(2000/Belgium/consulting);Bravinv(2002/Belgium:PWTpotatoindustry);
DAF-unit
InthefoodindustryIPAShasbuiltseveralprojectsbasedonDAFtechnologies(Dissolved air flotation). This is a water treatment process that clarifieswastewaters by the removal of suspendedmatter such as oil or solids. Theremoval is achieved by dissolving air in thewastewater under pressure andthenreleasingtheairatatmosphericpressureinaflotationtankorbasin.Thereleasedairformstinybubbleswhichadheretothesuspendedmattercausingthe suspendedmatter to float to the surface of the water where it then isremovedbyskimming.
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SLUDGE & WATER TREATMENT IN THE CONCRETE INDUSTRY & BRICKWORKS
IPASdevelopedandimplementedintheconcretesectoraveryperformantsystemforrecuperationofprocesswater.Thepaybacktimefortheseinvestmentswaseverywherelessthan6months,becauseofthereuseofwaterstreamsandthefactthatnolongercontaminatedwaterneedstobedischargedintotheenvironmentorinthepublicwastewatersystemsorthatnolongersludgeneedstobeputinthelandfills.
References:DeNieuwe Zandegroeven (1992 L/ Belgium / TSC); ECHO (1994 / Belgium / PWT– development of new concept);Varenbergnv (1994/Belgium/PWT– researchgravel recovery);Winters (1994/Belgium/PWT– researchgravelrecovery);Goudezeune(1996&1997&1998&1999/Belgium/PWT4 installations);Ropabvba (1996/Belgium/PWTmeatindustry);VosVleeswaren(1996/Belgium/PWTmeatindustry);Heylen(1997/Belgium/PWT–ceramics);Betonson (Kampen) (1997 / Belgium / PWT); Trilco (1997 / Belgium / PWT); Vasco (1997 / Belgium / PWTprocessoptimizationinheatingsystem);Ergon(1998/Belgium/PWT);Kerkstoel(1998/Belgium/PWT);CarrièresduHainaut(1998/Belgium/PWTstonequarry);Dammannv(1999/Belgium/TSC–brickworks);MartensBetonnv(1999/Belgium/PWT);CarrièresduBoulonnais(1999/France/PWTresearch–stonequarry);Agref(2000/Belgium/PWT);Ebema(2000/Belgium/PWT);Marlux(2000/Belgium/PWT);Sander-Pebüso(2000/Belgium/PWT);Tripan(2000/Belgium/PWT);CarrièresduHainaut(1998/Belgium/PWTstonequarry);Boskalis(2001/theNetherlands/TSCresearchsievesand);DeVijfhoek(2001/theNetherlands/TSCresearchsievesand);SVK(2001/Belgium/PWT);DeMeteoor(2001/theNetherlands/PWTresearch);Heembeton(2001/theNetherlands/PWT);KlapsBeton(2001/Belgium/PWT);Sevetonnv(2001/Belgium/PWTresearch);EWInv(2001/Belgium/PWT);Mostone(2001/Poland/PWTresearchstonequarry);Marlux(2001/Belgium/chemicals);Seveton(2002/Belgium/PWT–adjustment);BDIAmbés(2002/France/PWT);BDIGrigny(2002/France/PWT);DenBoerBeton(2002/Belgium/PWTadjustment);MBI(2002/Belgium/PWT);Heembeton(2002/theNetherlands/chemicals);BMI(2003/France/PWT);Lithobeton(2003/Belgium/PWT);C&G(2003/UK/PWT);C&G(2004/UK/PWT);BDIPujaut(2004/France/PWT);DenBoerBeton(2005/theNetherlands/PWT)
IPAShasmorerelevantreferencesinsectors,usefullforthenewconceptWASTEREFINERY&GENCOAL.
Other relevant references of IPAS:BooyCleanBelgium(1994/Belgium/TSCschredderinwastemanagement);Mathysnv(1994/Belgium/PWT/research–paintindustry);Mireille(1996/Belgium/PWTdrycleaningindustry);DSM(1996/Belgium/PWTplasticsindustry);Watco(1998/Belgium/TSCwastemanagement);SK-Eng&Const(2001/Korea/TSCresearchwastemanagement);Londonwaste(2002/UK/TSCresearchwastemanagement);Galloometal(2007/Belgium/Metal–NonFerroseparationstudy).
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5. Advantages of the technology
Thekeyof thetechnology inWASTEREFINERY&GENCOAL isawettechnologyallowingtoseparatenon-selectivelycollected municipal waste, as well as the rest-fraction from selective collection into combustible materials (RDF)6,stainlesssteel,ferrousmetals,non-ferrousmetals,inertsof<0.25–1mm,of1–12.5mmandof>12mm,andsludge.TheRDFcanbeusedasfuel(ifneededafteradjustingthecalorificvalue)e.g.incoalcombustioninstallationsinordertorecoverenergy.Themetalfractionscanberecycledassuch.Theinertfractionshaveapplicationsinconstruction.ThistechnologyisfullyinlinewiththewastetreatmenthierarchyoftheEU,whichplaces(material)recyclinghigherthan(energy)recovery,whichisplacedhigherthandisposal(landfill).
Themainadvantagesofwettechnologyare:• amaximumamountofmetalscanberecycledaslittleoxidationoccurs(comparedtolandfillandincineration);• thecapacityoftheinstallationcanbeadjustedasdesired;• thepossibleproblematicparticlesoftheMSW,suchasfinedust,canbelocalisedinthewastewaterstreamsand
arethereforecontrollableandtreatable.
Advantagesofthepresenttechnologycomparedtocombustionare:• intheincineratorsthewastehasfirsttodrybyevaporationofthewater,whichnecessitatesalotofenergybefore
thewasteignites,whereasinthepresenttechnologynounnecessarywaterevaporationisneeded.Thereforemoreenergycanberecovered;
• theGENCOALisacleanfuelthatcaninprinciplebe(co)incineratedinacoalfuelledpowerplant.Theseusuallyhaveahigherenergyconversionyieldthanwasteincinerators;
• sincenocombustionofthematerialtakesplace,onlylittleoxidationofe.g.metalpartsandmetalfoilsoccurs.Thishas2consequences:(1)ahigherfractionofthemetalsintheMSWcanberecycledasmetal(withmuchhighervaluethanmetaloxides);(2)somemetalsdissolvelessthantheiroxidesorsalts,sothatlowermetalleachingoftheresultingproductsoccursthanforcombustionashes.
Asaconclusionbetterenergyrecoveryandbetterrecyclingofmetals(themostvaluablefractionintheMSW)andnon-metalsisexpectedthanwithwasteincineration.
Compared to dry technology (egMBT) to separate and recycle/recoverMSW, the presentwet technology has thefollowingadvantages:• theendproductsarecleaner,aswetcleaningdissolvesallsortsof impuritiesthatsticktothematerialwithdry
technology. Therefore, themarket valueof theproducts is higher (metals) and thematerials (inerts)will showreducedleachingandwillthereforemoreeasilycomplywiththeregulationsforrecyclingasconstructionmaterials;
• wettechnologyusesthewater(=30%)oftheMSWintheprocess,ratherthanhavingtoevaporateit,whichisaccompaniedbylossofenergy;
• thecapacityofawetinstallationcaneasilybeadjustedincapacity,comparedtoadryinstallation;• inawettechnologytherearemuchlessproblemswithdust.
Of courseawet technology requiresanexcellentwater treatmentplant (biological andphysicochemical treatment)allowingrecyclingofthewater.TheWASTEREFINERYwillhaveaclosedwatercircuit.
6 RDF:RefusedDerivedFuel
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6. Equipment
Dependingon localcircumstances, localenvironmental regulationsandothervariable factorsanddependingonthenecessarycapacity(amountoftonsofMSWtobeprocessed),themachinerywillbebiggerorsmaller.Butasanindicationofinvestmentcostwecansay:
• AWASTEREFINERYprocessing10tons/hour,costsbetween4and7millioneuro.• AWASTEREFINERYprocessing20ton/hourintwoshiftsperworkingdayor80.000tons/year,costsbetween
7and14millioneuro.
ThelayoutfortheWASTEREFINERYhastoconsistofthefollowingcomponents:
• Feederwitho bunker,o bag–opener,o dosingline,o weighingunit
• Screen• Magnets:4• Non-Ferrous:2• Conveyors:10• Screens:5• Blowers:2• Shredders:3• Stainlesssteelseparators:2• Sandwashingfine:1• Sandwashingheavy:1• Gravelwasher:1• Mechanicaldryer:1• ThermaldryerwithCHP(combinedheatandpower):1• Blender:2• Thickener:1• Clarifier:1• Flocculantsstation:1• Dewateringfilter:1• Press(pellets):1• Watercyclewith10pumps• Measurementandcontrol• Electricalequipment• Steelworks• Wastewatertreatment
Thefootprintforthiswashinstallation(asmallinstallationof10t/h)canbelimitedto1.000m²,i.e.50X20mwithaheightof20m.
ANNEX
Annex 1 Example of a business case
Annex 2 Detailed results of waste separation at laboratory, 2013
Annex 3 Laboratory test results on GENCOAL
Annex 3.1. Summary of separation results
Annex 3.2. Results from the ‘ash test’ at Technical University Ostrava
Annex 3.3. Certification test as alternative fuel at VVUÚ Ostrava
Annex 4 Impressions of semi-industrial test in 2018
Annex 5 Project team for WASTE REFINERY & GENCOAL
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Annex 1– Example of a business case
Althoughbeingsubjecttoallpossiblereservations,wepresentahypotheticalbusinesscasetaking intoaccount(asexampleonly):
• Acapacityof20tons/hourintwoworkingshifts/dayor80.000tonsyearoftobeprocessedMSW.• AcompleteinstallationtakingItoaccountthehigheststandardsinenvironmentalcriteria,withamongother
things,acompletewaterpurificationsystem(biologicalandfysicochemicaltreatment)
Cost / ton
ASSUMPTIONS
Capacity 20 t/h2shifts/day 4,000 h/a
total capacity 100,000 t/a
INVESTMENT
Plant 15,600,000.00
Building 1,000,000.00 dependsoflocality
Varia(study&unforeseen)
700,000.00
TOTAL: €17,300,000.00
CAPITALCOST
depreciation 10% 1,730,000.00intrest 4% 692,000.00TOTAL: 2,422,000.00 €/a
WORKINGCOSTBased upon European standards(seebelow)8
2,500,000.00 €/a
TOTALCOST/ANNUM: 4,500,000.00 €/a
cost/ton@80000t= 56.25 €/t
Totalcost/ton=€56.25 9
This is the pre calculated cost per ton without the sale of the recuperated materials and the sale / use of the GENCOAL. If sold on the open marker, the revenue of the sale of materials and GENCOAL will probably cut the cost by half: between € 25 and 30. To compare: Total cost in waste - incinerator = 110 €/ton (accepted average cost in Europe)
Thesecalculationsdonottakeintoaccountthepossiblepositiveeffectofcombinationswithlocalopportunities,likebiogasstationsorcombustioninstallationsthatcanprovideelectricalenergyandheatfortheWASTEREFINERY.
8Workingcostinthishypotheticalbusinessprojectionisbasedupon:energycostofabout€730.000/annum,manpoweratabout€200.000/
annum;maintenanceat7%ofinvestment;overhead,chemicalproductsandinsuranceat€600.000/annum.Theseareverycautiousandnon-
optimisedestimates.Mostprobablythenumberswilldecreaseinarealtimeproject,certainlyinnon-European/Americancontext.
9Thisnumberof€56,25/tonascostoftheseparationprocesshastobeinterpretedwithcare.Thisisapre-calculationfortheEmirates(sept
2015).IncomparablequantitiesofMSW,thenumberfortheCzechRepublicIn2014was€35,30.Thecalculationcanonlybeseenasguiding
principle.Everyprojectorlocationshallhaveitsowncalculation,baseduponconcretelocaldata.Thiscalculationsarewithoutlocaltaxes.
20
Annex 2 – Detailed results of waste separation at laboratory, 2013
Thefollowingpages,showpicturesofthedifferentfractionsfroma20kgsamplefromtheDEPOSlandfillsiteinHornySucha,CzechRepublic,takenonJuly3,2013andtreatedinthelaboratoryattransit_LABandIPASinBelgium.
InBelgiumthefollowingstepsweretaken:• screening;• handpicking;• densityseparationinwaterofdifferentfractions;• dryingfirstinopenair(summerconditions),theninacoveredspace;• millingindifferentsteps:cuttingbyhand,millinginthelaboratoryusingablender,millinginanindustrialtest
installation
SEPARATION RESULTS:
RDF to be processed to pellets Possibly enriched
21
To be sold on market:Ferrous, Non-Ferrous & Stainless steel
> 12,5 mm
< 12,5 mm
22
Annex 3: laboratory test results on GENCOAL
InthisannexispresentedtheresultsoftheWASTEREFINERYseparationtestatlaboratoryscale1) theresultsofthelaboratorytestattransit_LAB&IPASonMSWfromtheKarvinaRegion2) TheresultsoflaboratorytestingatTechnicalUniversityofOstrava,LaboratoryoftheGeologicalInstitute,Prof.
HelenaRaclavska.3) ThetestresultsatVVUU,Vitkovice,testingcenterinOstrava.
Thelasttestwasaprestudytogetaclassificationas‘alternativefuel’tohavetheGANCOALallowedinexistingcombustioninstallationsintheCzechRepublic,moreconcreteintheCentralHeatingStationsofthecityofOstrava
Annex 3.1. summary of sepatarion results
DRY + MOISTDate July 31, 2013
Weight, g % of totalMoist 6,370.50 31.65%RDF 6,155.00 30.58%SS 105.00 0.52%Fe 714.20 3.55%Non Fe 85.70 0.43%Inert>12.50mm/stone 2,310.00 11.48%Inert1.00mm–12.50mm/gravel 3,348.00 16.63%Inert0.25mm–1.00mm/sand 577.00 2.87%<0,25mm 464.00 2.31%
TOTAL 20,129.40 100.00%
Conclusion:theresultiscomparabletoanalysesobtainedinotherregionsinternationally:• 1/3ofMSW=moistorwater.• 1/3ofMSW=organic&RDF• 1/3ofMSW=inertmaterial
DRY + MOIST
<0,25mm
Inert 1 - 0,25 mm
Inert 12,50mm - 1,00 mm
Moist31,65%
RDF30,58%
Inox0,52%
Non Fe0,43%
Inert > 12,50 mm
Fe3,55%
23
Afterlaboratorytreatmentthestatusofthematerialsisassummarizedinthenextfigure.
Preliminary conclusion
Thematerial(MSW)takenfromtheDEPOSlandfillsiteinHornySucha,Karvinacanbeprocessedinto:
• RDFas‘pellets’withca10%moist• SS/Ferrous/Non–ferrouswith1–3%moist• Sandwith12–15%moist• Gravelwith6–10%moist• Sludgewith50%moist.Thismaterialcanbereusedinceramics,butinanticipationitisputinatemporarylandfill
Thisscenarioallows100%recycling/recovery.
WeexpectthatthiswillleadtoMSWprocessingatacostofabout.€35/t,completelyoratleastpartlyrecoverablebythesalesofthematerialstoberecycledandoftheGENCOALproducttobeusedasfuel.
24
Annex 3.2. results from the ‘ash test’ at Technical University Ostrava
Mainconclusion:calorificvalueofGENCOALiscomparabletocoal.
VŠB–TechnickáuniverzitaOstravaLaboratořeInstitutugeologickéhoinženýrství [email protected],tel:596995460
ANALYSIS OF THE GENCOAL (RDF)
Protocol No.1/01/2013 dated on 11.12.2013
RDF – Depos Mr.Ceslav ValosekUsed method
Mixed sample
Waterdryup(Wex) % ČSN441377Tuhápaliva–Stanoveníobsahuvody
Waterrest(Wh) % ČSN441377Tuhápaliva–Stanoveníobsahuvody
Warerintotal(Wt) % ČSN441377Tuhápaliva–Stanoveníobsahuvody
Water at the sample % 3,24 ČSNISO11722Tuhápaliva–Černáuhlí–StanovenívodyvanalytickémvzorkusušenímvN2
Humidity % ČSNISO562Černáuhlíakoks–Stanoveníprchavéhořlaviny
Ashindrymatter % 20,87 ČSNISO602Stanoveníobsahupopelovin
Volatileflammableindrymatter % 74,27 ČSNISO562Černáuhlíakoks–StanoveníprchavéhořlavinyČSNISO5071-1Hnědáuhlíalignity-StanoveníprchavéhořlavinyvanalytickémvzorkuFixedCarbon % 4,86
Heatofcombustionindrymatter J/g 23013
ČSN ISO 1928 Stanovení spalného tepla kalorimetrickoumetodouvtlakovénádoběavýpočetvýhřevnosti
Caloricvalueindrymatter J/g 19835
Caloricvalueinthesample J/g 18985
Cindrymatter % 47,526
ČSNPISOTS/12902Tuhápaliva–Stanoveníveškeréhouhlíku,vodíkuadusíku–Instrumentálnímetody
Hindrymatter % 15,426
Nindrymatter % 0,769
0indrymatter(calculation) % 15,409
Sindrymatter % <0,010
Valuescalculatedasaveragefrom6samplesRightnessdueby
Mrs.Prof.Ing.H.Raclavská,CSc.
25
ASH MEASUREMENT
Temperature for ash melting ČSN ISO 540 DT(deformationtemperature):1093-1132ST(spheretemperature):1198-1211HT(hemispheretemperature):1209-1230FT(flowtemperature):1222-1257
X-RAY FLUORESCENCE ANALYSIS
IndicativeresultsfrommobileX-rayunit(X-rayfluorescenceanalysis).Ag,Ba,Cd,Co,Hg,Se,Snwereunderdetectionlimit
Element mg/kg dry matter
Ca 38457
V 31
Cr 101
Mn 221
Ti 2690
Fe 5421
Ni 51
Cu 16
Zn 677
As 11
Rb 10
Sr 119
Zr 43
Mo 31
Sb 112
Pb 38
Bi 7
26
Annex 3.3. Laboratory test at VVUÚ in Ostrava, CZ to get certificate as alternative fuel
27
ASSESSMENTREPORTN°VUÙ-017216/2014
28
Annex 4: Impressions of semi-industrial test in 2018
30 TONS OF FRESH MSW
ROUGH SHREDDING
WASHING & SEPARATING
29
FINE SHREDDING
DELIVERY OF GENCOAL AT CITY HEATING PLANT
GENCOAL
30
Annex 5: project team for WASTE REFINERY & GENCOAL
ETIENNE SCHOUTERDEN
Etienne Schouterden (1947) has 45 years of experience in business and process organisation. After his training inindustrialchemistry,hespent13yearsasheadofthelaboratorydepartmentandthepersoninchargeofnewseparationtechniquesinthecoalpreparationplantofKSWaterschei.HeleftKSin1984andhassinceworkedworldwideonprojectsfor thedesignand realisationof installations for theprocessingof rawmaterialsandcoal.Since2007,hehasbeensupervisingtheindustrialprocessofseveralSMEs(smallandmedium-sizedbusinesses) inLimburg,andinparticularprojectsonsoilremediationandrenewableenergywiththegroupCarmansNV.HehasalsobeeninvolvedinprojectswithGRL,Galloo,etc.
EtienneSchouterden’sspecialityistheintegrationofinnovativeprocessesintoexistingproductionenvironments,prac-ticalsupportfortheplacementandexploitationofcomplexinstallationsforrenewableenergy(solar,wind,CHP).HealsodoesconcreteresearchintonewpossibilitiesforPPOandotherbiomasssources.Furthermore,heholdsarecentcertificatefromtheInnovationSchool,SustainabilityinChemistryandtheNanoschoolinMaastricht.
Achievements:• Designingandbuildingwaterpurificationinstallationsinthefollowingsectors:Precastconcreteindustry,Foodin-
dustry,Coalindustry,Brickworks,Municipalwasteincineration,Soilremediation,Spoiltiptreatment,Sludgebasintreatment,Metalrecycling
• Designingandbuildingturn-keyprocessinginstallationsinthefollowingsectors:Waste-to-energy,Glassrecycling,Coal sludgetreatment,Spoiltipwashing,Coalpreparationplants,Rubbleanddemolitionwaste,Screenedsandpurification,Soilremediation,Municipalwasteincinerationslags.
• Designingandbuildingturn-keyrenewableenergyinstallations:largesolarprojects,windproject,CHPproject.
Relevantassignmentsfromhiscareer:
• R&DGevaertAgfaMortsel(1966–1971)• HeadoflaboratoryandnewseparationtechniquesKSWaterschei(1971–1984)• WorldwideflotationresponsibleforHoechstAGFrankfurt(D)(1984–1986)• Designerworldpremierecoal–sludgeprocessinginstallationfromwasteforFechnerGmbhBottrop(D)(1986–
1988)• Founderandmanagerof IPASnv,processingof rawmaterialsandwastematerialswithworldwide realisations.
(1988–2007),managingdirectorIPAS2008–now.• FreelanceprojectdesignandprocesssupervisionforLimburgSMEsCarmans,GRL,Galloo,…• Inspirerandco-founderofSCRLtransit_LAB.
EtienneSchouterden,WilfriedDeNijs&PaulBoutsen
31
PAUL BOUTSEN
PaulBoutsen(1962)has30yearsofexperienceinparticipatoryprocesssupervision,policypreparationandregionaleconomicdevelopment.Hehasahistoryinthesupervisionofrestructuringandproductadviceinthepublicandprivatesector.Hehasworkedaroundurban regeneration inMechelen,neighbourhood communitywork and regional eco-nomicplanningintheLimburgminingregion,conversionofindustrialpremisesonbehalfoftheFlemishgovernment,restructuringofaproducerofgreenenergyandvariouslarge-scaleculturalproductions.Boutsenisalsoactiveinaninternationalnetworkofminingregions.Between2009and2012,hesupervisedthetrajectorytotheCleantechCampusinHouthalen-Helchteren,aswellastheconversionofitsformerminingsite.Since2013,hehasbeenactiveintheSCRLtransit_LAB,acooperativecompanyininnovationanddevelopment;
Relevantassignmentsfromhiscareerare:• Urbanregeneration,welfareplanningandhousingprojectsinMechelenbetween1984and1990.• Neighbourhoodcommunitywork intheMiningregionascommunityworker inZwartberg(1991–1992)andas
directorofthenon-profitSTEBO(1993–1995)• RegionalPlatformMiningRegionandMiddleLimburgasmemberofstaffwithsubstantivefocusonlocaleconomic
andspatialdevelopment,conversionofminingsites,touristandsocialdevelopmentoftheminingmunicipalities(1995–2000)
• InthecompanyEcowatt(hydropowerplants),hewasinchargeofacorporaterestructuringandwithaself-assem-bledtechnicalteam,hebuilt4hydropowerplants(2000–2001)
• IndependentconsultantinregionaldevelopmentforFlemishGovernment(2001–2003)ascommissionerminingpatrimony.
• IndependentconsultantinregionaldevelopmentforTourismLimburg(2003–2004)ascommissionertouristdeve-lopmentplanMiningRegion.
• IndependentconsultantforthecityofGenkregardingtouristdevelopmentminingpatrimony(2004–2005):deve-lopmentofpartsofC-Mine.
• IndependentconsultantforthetownofHouthalen-Helchteren(2009–2012):supervisionofthepreparatoryproc-ess to theCleantechCampus, the foundingof theFlemishCleantech–management structure (vzw I-CleantechVlaanderen)andCleantechacquisitionsforLimburg.
• BelgianRepresentativeinEURACOM,Europeannetworkofminingregions.• FounderandmanagerofADACTPLC,consultingandmanagementassignmentsinregionaldevelopment.• Founder(1990)andManagingDirectorofnon-profitHetVervolg,projectcentreoftheMiningRegionandofCOAL-
FACE,internationalprojectonconceptualisationofminingregions(2006–now)• FounderandManagingDirectoroftheSCRLtransit_LAB,acooperativecompanyintransitionandregionaldevelop-
ment,promoterofWASTEREFINERY&GENCOAL.
WILFRIED DE NIJS
IR.LIC.JUR.WilfriedDeNijs(1945)isHonoraryInspectorGeneralofOVAM,thePublicWasteAgencyofFlanders,andhasbuiltacareerasmanager,directorandexecutorinvariousBelgianandFlemishgovernmentalbodies,projectsandcompanies.HeisaCivilEngineer(IR)ChemistryandAgriculturalIndustry(KULeuven),IREnvironmentalRemediation(RUGhent),Lic.Law(UIAntwerp)andAppliedEconomicSciences(KULeuven).Ascabinetadvisorundervariousmini-sters,hewasthefounderoftheFlemishenvironmentallegislation.HeistheauthoroftheWasteDecree1981andtheSoilDecontaminationDecree1995,andthefounderofOVAMandcreator-founderofINDAVER.Hehasfilledalonglistofmandates,amongwhichintheFlandersParticipationSociety(PMV),theWorldBank,andnumerousinnovativeprojectsandcompaniesintheenvironmentalsector.HisforeignexperienceisbuiltonvariousmissionstoCentralandEasternEuroperegardingwasteprocessingandenvironmentalandsoilremediation.
Relevantassignmentsandachievementsfromhiscareer:• CabinetadvisorfortheministersServaisandDeSaeger(1971–1978)• HeadEngineer–DirectorfortheMinistryofHealth,SanitaryEngineering(1974–1981)• InspectorGeneralforOVAM,ManagementRealisationandRemediation(1981–2010)• SpecialCommissionerbrownfieldsforFlandersParticipationSociety(PMV)(2004–2010)• Authorof29publicationsintheenvironmentalandwastesectors.
Asexecutiveanddirectiveofficer:• Theclosingandremediationofdozensofpublic,semi-publicandprivateandnon-controlledlandfills• thefoundingofOVAM,thePublicWasteAgencyofFlanders• theintroductionoftheinnovativeprocessesforwasteincinerationinFlandersinthe1980s• therealizationofanenvironmentallyresponsiblewastetreatmentpracticeforthechemicalindustriesinAntwerp• thefoundingofINDAVERaspublic–privatecompanyforwasteprocessingintheportofAntwerp.
The concept WASTE REFINERY & GENCOAL was reviewedby Professor Carlo Vandecasteele of the Department ofChemicalEngineeringoftheUniversityofLeuven,Belgium.
TheconceptofWASTEREFINERY&GENCOALwassignedandlaiddownattheBENELUXofficeforintellectualpropertyin2014and2015asheldbycvbatransit_LAB.
transit_LAB
CONTACT
PaulBoutsenmail:[email protected]:0032477632920CEOtransit_LABcvbathroughADACTbvba
Adress:Transit_LABscrl/cvbaRondPunt73550Heusden-ZolderBelgium
CompanyID:BE0844324325www.transit-lab.be
industrial processes & active serviceswww.ipas.world