Fluidized Bed versus Grate - ProcessEngFluidized Bed versus Grate – Two competitive Technologies...

Fluidized Bed versus Grate –Two competitive Technologies in a Waste System

IAE – FBC Workshop 24.05.04 Sei1e 1

• Introduction

• Waste System Vienna

• Path of uncategorized waste

• Plant Spittelau

• Path of sewage sludge

• Plant Simmeringer Haide

• Fluidized Bed versus Grate

• Requirements for mechanical separation

• Construction and installation of „Wirbelschichtofen 4“

Topic:


IAE – FBC Workshop 24.05.04 page 2

One Company:

Two Business Area

Waste Disposal Services Energy Supply Services

Introduction



Flötzersteig:200.000 t/a uncategorized waste50 MWth

Spittelau:270.000 t/a uncategorized waste60 MWth

Simmeringer Haide:110.000 t/a hazardous waste 180.000 t/a sewage sludge40 MWth

Introduction


IAE – FBC Workshop 24.05.04 page

paperUncategorized waste

prod

uct

whe

reho

ww

hat

glass metalplastic

Waste System Vienna (Separation)



wood2%

paper25%

metal4%

others18%

organics30%

glass7%

plastic11%

textiles3%

Fuel NCV Total Carbon Fossil Cin % to totalCarbon

biogenic C

[MJ/kg] [kg C/t FS]

55Uncategorized waste(Household waste)

8.810 184 45

in % to totalCarbon

C 195 ± 21 198 ± 10 184 ± 10Cl 4,8 ± 0,7 4,9 ± 1 4,6 ± 0,2Fe 28 ± 2 28 ± 2 27 ± 2Al 10,0 ± 1,2 11.2 ± 1,8 7.5 ± 0.6Pb 0,24 ± 0,05 0,33 ± 0,06 0,27 ± 0,03Zn 0,57 ± 0,07 0,61 ± 0,06 0,60 ± 0,05Cu 0,24 ± 0,05 0,31 ± 0,07 0,27 ± 0,02

Cd 0,0071 ± 0,0008 0,0068 ± 0,001 0,0057 ± 0,0005

Hg 0,0011 ± 0,00020,00084 ± 0,00011

0,00091 ± 0,0001

in mg/kg

2000 2001 2002

Waste System Vienna (Waste Composition)



Path of uncategorized Waste (Thermal Treatment)



38%

12%

49%

39%

14%

47%

39%

12%

49%

38%

12%

50%

44%

11%

45%

1998 1999 2000 2001 2002

873.842 938.604 935.849 964.754 988.184

seperation landfill incineration

Waste Treatment



Waste treatment in Vienna 1969 bis 2002

0100200300400500600700800900

1.000

1969

1971

1973

1975

1977

1979

1981

1983

1985

1987

1989

1991

1993

1995

1997

1999

2001

landfill sitewaste incinerationcompostingrecycling

in 1

.000

t

Waste Treatment



1

2

3

4

Waste bunker

Furnace feed chute

Firing grate

Furnace

5 Waste heat boiler

9

6

7

8

Slag discharger

Electrostatic precipitator

2-stage f lue gas scrubber

Fine dust separator

10 SCR-DeNOx facility

13

14

11

12

Stack

Feedw ater tank

Turbine generator

Heat exchanger bank

15 Electromagnet

16

17

18

19

Slag bunker

Scrap skip

Filter ash silo

Multi-stage recycling plant

20 Waste water treatment plant

21

Chamber f ilter press

22

23

24

Cleaned w ater tank

Sludge tank

Filter cake box

25 Receiving w ater

FreshwaterBasic process waterAcidic process waterSaturated steamFilter ash and slagHy droxide sludgeGy psum sludgeDistrict heating energy

Sodalye

Limeslurry

Fresh-water

Ammonia

3

1315

241716 25

1

Naturalgas

Lime slurryPrecipit. agents

11

G

7

18

21

10

9



23

2

12

14

22

88

6

19 2020

4

5

1

2

3

4

Waste bunker

Furnace feed chute

Firing grate

Furnace

5 Waste heat boiler

11

22

33

44

Waste bunker

Furnace feed chute

Firing grate

Furnace

55 Waste heat boiler

9

6

7

8

Slag discharger



Fine dust separator


99

66

77

88

Slag discharger



Fine dust separator


13

14

11

12

Stack

Feedw ater tank

Turbine generator

Heat exchanger bank

15 Electromagnet

1313

1414

1111

1212

Stack

Feedw ater tank

Turbine generator

Heat exchanger bank

1515 Electromagnet

16

17

18

19

Slag bunker

Scrap skip

Filter ash silo



1616

1717

1818

1919

Slag bunker

Scrap skip

Filter ash silo



21


22

23

24

Cleaned w ater tank

Sludge tank

Filter cake box

25 Receiving w ater

2121


2222

2323

2424

Cleaned w ater tank

Sludge tank

Filter cake box

2525 Receiving w ater



Sodalye

Limeslurry

Fresh-water

Ammonia

33

13131515

242417171616 2525

11

Naturalgas


1111

GG

77

1818

2121

1010

99



2323

22

1212

1414

2222

8888

66

1919 20202020

44

55

Waste Incineration Plant Spittelau



Hazardous waste

Rotary kiln

District heat

Electrical power

AshSlag

Flue gas

Filter cake

sewage

Biological Treatment

Clean water

Hospital waste

Fluidized bed furnace

Flue gas treatment

Plant Simmeringer Haide



dm calorific value sulphurin % in kJ/kg dm in % dm

2002 33,74 17.029,60 0,57

min maxSb mg/kg dm 0,83 3,92 10,20 As mg/kg dm 0,88 2,39 6,51 Ba mg/kg dm 200,00 366,00 993,00 Be mg/kg dm < 1,7 < 2,5 < 3,1Fe mg/kg dm 36.960,00 56.711,00 87.280,00 Pb mg/kg dm 38,00 85,00 472,00 Cd mg/kg dm < 1,1 < 2,5 < 3,8Cr mg/kg dm 18,00 36,00 96,00 Co mg/kg dm 2,00 8,00 55,00 Cu mg/kg dm 154 191 270Mn mg/kg dm 76 127 260Ni mg/kg dm 12 38 151Hg mg/kg dm 0,3 1,27 4,5Ag mg/kg dm 5,7 15,3 38,3V mg/kg dm 6,8 14,4 33,6Zn mg/kg dm 392 766 2200Sn mg/kg dm 8,3 20,1 50,3

Sewage sludge composition



Fluidized bed Dust firingSolid state firing

FT = FA + FWFC carrying ForceFL lifting forceFW resisting powerFG gravity

Firing systems



Waste Flue gas

primary air slag

Waste Flue gas

Waste Flue gasWaste Flue gas

primary air slag

slagprimary air slagprimary air

Reverse FeedGrate

ForwardFeed Grate

Rollergrate

Counter directionFeed grate

Co Current furnace

Counter flow current f.

Medium current f.

low energy transfer with fire bed (for SRF)

Increase of drying zone

For waste with high moistness; high energy transfer with fire bed

Short drying und degasification zone (unburned gas streams)

For hardly burnable waste

Grate furnace



Stationary fluidized bed Circulating fluidized bed Rotating fluidized bed

Particle size independent •Precise Particle size required•Long residence time (burnout optimized)

•Ideal distribution•Long residence time (burnout optimized)•Steady temperature distribution

Flue gas

Waste

Secondary Air

Nozzle floorPrimary Air

Bottom Ash

Ash Hopper

Flue gas

Waste

Secondary Air

Secondary Air

Primary Air Bottom Ash

Cyclone

Deflector platesDeflector plates

Waste

Waste Waste

Nozzle floorGas Chamber

Fluidizing Air

Ash Air/ Sand Ash Air/ Sand

Fluidized bed furnace



•Steady temperature distribution as a result of vertical bed disposition

•Ideal exchange surface between reaction gas and small solid particles

•Perfect heat transfer between solid particles and reaction gas

•High heat transfer by use of heat exchange in the combustion chamber

•High flexibility performance according to input particle (low demand on separation)

•Ideal adaptability to waste composition

•Approved State of the art technology

•Quick start up and shut down phases

Grate Furnace Fluidized Bed Furnace

Advantages



•Solid particles are eroded in the Fluidized bed •Small particles are moved out of the combustion chamber by the flue gas which lead to an complicated dust recovery system•Danger of erosion in the combustion chamber of all components•Danger of dust contamination in the range of the heating surfaces •Bubbling in the fluidized bed might cause inefficient combustion

•Hardly controllable gas reactions in „drying and combustion“ zone•Small particles (dust) are transported by the flue gas •Combustion of fractions with high NCV should be avoided

Disadvantages



Grate firingStationary Fluidized Bed Circulating Fluidized

Bed

Fluidized Bed

Solid state

pneumaticdischarger

Heat transfercoefficient

Pressure loss

Bed height H

Fluidizing Initial point

Reactor velocity in m/s

Lost of pressure and heat transfer coefficient



Preperation and

splitting

Input: 1 Mg ar Household waste (Vienna)

Flue gas (dust)

Ferro metalls

Non ferro metalls

Over size fraction (> 250 mm) Solid recovered fuel (50 – 250 mm)

Reject (low NCV) fraction (< 50 mm) –

Preparation and splitting



waste bunker with 3 sectionsHousehold-, bulky-, sieving reject-

waste

crane

Walking FloorB200

Slat conveyorB210

ShredderB220

crane

Walking FloorB100

B110

ShredderB120

Pre crashedContainer loading

Sieving drumB250

Sieving drumB150

fraction < 50mm, Container loading

Sieving drumB280

Sieving drumB180

Over band magnetic separator B640

< 50 mm

< 50 mm

> 50 mm

> 250mm

mm, fraction > 50Container loading

line 1

fraction > 50mm, Container loading

line 2

< 250 mm < 250mm

> 50 mm

fraction > 250mm, Container loading


Eddy current separator B660

Ferro metals

Baling press B370

wrapping machine B380

fraction 50 -250mm, Container loading

fraction 50 -250mm, Container loading

fraction < 50 mm, Container loading

> 250mm

< 250 mm < 250mm

Slat conveyor

Magnetic drum separator B635

Magnetic drum separator B635


Non Ferro metals



Mechanical Treatment Plant Vienna



capacity standardized C S N W O H inert material NCVobservation periode kg/h in % in % in % in % in % in % in % in kJ/t

25.06.2003; 13:15 - 14:45 19.183 12.789 31,86% 0,001% 0,07% 30,07% 16,30% 5,00% 16,70% 13,3125.06.2003; 14:54 - 16:25 20.301 13.385 31,03% 0,001% 0,10% 22,26% 17,80% 5,00% 23,80% 13,0725.06.2003; 16:30 - 17:56 17.106 11.934 33,34% 0,001% 0,12% 35,12% 15,71% 5,00% 10,70% 13,7925.06.2003; 17:59 - 19:26 18.023 12.430 30,59% 0,001% 0,11% 39,86% 14,79% 5,00% 9,65% 12,8126.06.2003; 11:53 - 13:23 17.890 11.927 24,94% 0,001% 0,10% 21,29% 17,81% 5,00% 30,86% 10,9826.06.2003; 13:27 - 14:57 16.366 10.911 30,91% 0,001% 0,11% 33,94% 15,26% 5,00% 14,77% 13,02

12,83mean value

Pb Al Cd Hg

SRF (Input) 197,36 6183,44 5,51 0,31

slag 88,1 5454 1,2 0,1

ash 108,9 729,4 4,3 0,1

waste (Input 250 9000 6,25 0,88

slag 172 7946 0,52 0,22

ash 72,1 1054 5,6 0,36

SRF test

2002

online m

onitoring 2002

in g/t ar

SRF Composition



1. Waste bunker2. Feed chute3. Fluidized bed incinerator4. Boiler5. Economizer6. Electrostatic precipitator7. Heat exchanger bank 18. 2-stage flue gas scrubber9. Activated carbon filter10. SCR-DENOx facility11. Heat exchanging bank 212. Stack13. Primary air fan14. Secondary air fan15. Make up water pump16. Recycling air fan17. Scrubber pumps18. Flue gas fan19. Activated carbon transceiver20. Vibrating screen21. Solid residues22. Filter ash silo23. Demister unit24. Heat exchanger25. Waste water treatment

WSO 4 (Fluidized bed incineration)



Flue gas

Secondary Air „2“

Waste feeder

Secondary Air „1“

recirculation

Primary air

Discharger/cooler

Discharging systemVertical conveyorScreening system

Burner

Sandhopper

Sand valve

Rowitech process



Household waste

570.000

Splitting177.000 WSO476.00050-250 /42,8%

WIP 1+2

393.000

Bulky waste 50.000 1)(according to NCV)

20.000 x 1,5Flötzersteig

15.000 x 1,5Spittelau 450.000

7.000 over size> 250 / 4,0%

5.000Fe + nFe / 3,3%

Low NCV fraction 89.000



Construction of WSO4



•For a complete thermal treatment of the total household and bulky waste in Vienna the capacity of Spittelau and Flötzersteig is not sufficient•By splitting the waste the target of no land filling of household waste might be achieved•Perfect treatment of sewage sludge and solid recovered fuel from the Splittingplant by the operation of the fluidized bed incinerator 4

Summary

IntroductionIntroductionWaste System Vienna (Separation)Waste System Vienna (Waste Composition)Path of uncategorized Waste (Thermal Treatment)Waste TreatmentWaste TreatmentWaste Incineration Plant SpittelauPlant Simmeringer HaideSewage sludge compositionFiring systemsGrate furnaceFluidized bed furnaceAdvantagesDisadvantagesLost of pressure and heat transfer coefficientPreparation and splittingMechanical Treatment Plant ViennaSRF CompositionWSO 4 (Fluidized bed incineration)Rowitech processTwo competetive Technologies in a Waste SystemConstruction of WSO4Summary

Fluidized Bed versus Grate - ProcessEngFluidized Bed versus Grate – Two competitive Technologies...

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