REMONDIS RECOMBIO Juni 2013 Part Production and use final · REMONDIS RheinlandGmbH Dr.-Ing. Th....

REMONDIS Rheinland GmbH

Dr.-Ing. Th. Glorius, Final Conference RECOMBIO,

Helsinki 13.06.2013

EU-project RECOMBIO:

Part 1: Project introduction

Part 2: Production of BIOBS in Erftstadt

Part 3: Use of BIOBS

Part 4: Messages – Closing remarks

Part 5: Back-up



Helsinki 13.06.2013

Part 2:

Production of BIOBS

by REMONDIS Rheinland GmbH

in Erftstadt


3Dr.-Ing. Th. Glorius, Final Conference RECOMBIO, Helsinki, 13.06.2013

Brennstoff ausProduktionsspezifischen

Gewerbeabfällen

BPG®

Source seperatedwastes /

production residues

High calorific fractions(HCF)

sorted out fromposte-use waste

SBS®

SubstitutBrennStoff

Three quality groups of SRFsince 1995/1998/2009

High calorific fractions with a high biogenic content and different biowastes

BIOBS

BIOBrennStoff



Input materialsfor BIOBS

BIO

BS

-pro

du

ctio

n

BIOBS

high calorific fraction

(HCFBW)

high calorific fraction

(HCFMSW)

sreening overflow

Quality Assurance of Input

QA of

BIOBS

bulky waste

mechanical-biologicaltreatment plant (MSW)

composting

used wood

different biowastes

different other wastes



QMSfor the production of SRF in Erftstadt

Acceptance area

Positive sorting of HCF

SRF-production

Process-chain

SRF-storage

QA-chain

Input control

Process control

Process control

Product control:

Internal and external

ISO 9001: a

EFB: a

RAL-GZ 724: a

CEN/TC 343: a

QMS is the fundament for reliable SRF-qualities



Waste treatment center VZEK, ErftstadtFlow-sheet for BIOBS-production (04/2012)

MSW

Bulky waste

Sorting plant (ABA)

feeding

screeningFe-/ NF-

separation

Fe-/ NF-separation

Fe-/ NF-

metals

biol. drying residues to MSWI

NIR-separation

surplus water

to WWTPfeeding

SRF-plant (AKEA)

Production specific

wastes,

biowastes

feeding

Secondary sizereduction

Prior sizereduction-

windshiftingdisturbent

materials/residues

Fe-separation

NF-separation

windshifting BIOBSstorage/ loading

Fe-/ NF-metals

HCF`s

NIR-quality control

screeningFe-/ NF-

separation



Online-analysis with NIR-devicenew position since 04/2012: product stream - 100%

New position after promising results of TAMARA-trials

(SRF-layer ca. 15 cm)



-0,10

0,00

0,10

0,20

0,30

0,40

0,50

15

.03

.-

05

.04

.20

12

12

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.-

27

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14

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23

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25

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25

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13

12-12931-

001

12-15697-

001

12-17747-

001

12-28065-

001

12-24995-

001

12-49587-

001

13-01081-

001

13-04196-

001

13-06310-

001

13-07211-

001

13-09028-

001

13-13456-

001

13-18951-

001

Median

Mittelwert

80. Perzentil

90. Perzentil

95. Perzentil

UCL Analyse

Delta MW- UCL

Produkt BIOBS Parameter Chlor gesamt [% TS] Jahr (Alle)

Ergebnisse

Analysenummer Produktionszeitraum

NIR/UCL

Online-analysis with NIR-deviceanalytical results of total Cl for BIOBS in comparision

„Baseline“ for inorganic Cl is not constant during the year (0,10 – 0,21%),

Cl-average NIR (0,30% ds) and laboratory (0,27% ds) are well comparable



Online-analysis with NIR-deviceinformation for the control personnel (examplary lot)

Prevention of longer periods with higher Cl-values possible

BIOBS, 13-04196-001

0,00

0,10

0,20

0,30

0,40

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0,60

0,70

0,80

0,90

1,00

1,10

1,2020.1

2.1

2 1

8:0

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20.1

2.1

2 1

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0

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2.1

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20.1

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9:5

7

20.1

2.1

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0:2

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20.1

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0:5

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20.1

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1:2

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2.1

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1:5

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20.1

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2 2

3:2

6

20.1

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3:5

6

21.1

2.1

2 1

:27

21.1

2.1

2 1

:57

21.1

2.1

2 2

:27

21.1

2.1

2 3

:26

21.1

2.1

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:57

21.1

2.1

2 4

:27

21.1

2.1

2 5

:08

21.1

2.1

2 5

:38

21.1

2.1

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:38

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2.1

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:11

8.1

.13 2

1:0

0

8.1

.13 2

1:2

8

8.1

.13 2

1:4

3

8.1

.13 2

1:5

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9.1

.13 1

4:3

1

9.1

.13 1

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1.2

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:38

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1.2

.13 1

:39

1.2

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:09

1.2

.13 2

:39

1.2

.13 3

:09

1.2

.13 3

:39

Production period: 20.12.2012 - 31.01.2013

Cl [%

ds

]

Measured NIR-value

Average

Limit value according contract

Estimated value of inorganic Cl



Windshifting 2 t/h test device and heavy fraction

Intentions:

1.) Reduced energy consumption (fine crushing not necessary)

2.) Improved SRF-quality (Cr, Cu, Pb, ..., disturbing materials)

3.) Increased recycling rate



New windshifting-system 2 x 10 t/h since 02/2012: 100% of product stream

Positive influence on SRF-quality and recycling rate



Quality development of BIOBS for parameterswith slagging-/corrosion-potential (incl. 05/2013)

Consequence of adapted recipe, improved QA, .....

0

1.000

2.000

3.000

4.000

5.000

6.000

Al K Na Cl Chlorides

mg/kg ds

Mean 2010 Mean 2011

Mean 2012 Mean 2013



Development of Hg-valuesfor BIOBS (incl. 05/2013, n = 102)

classification according EN 15359:

class 1 for Hg, values comparable to coal

0,000

0,010

0,020

0,030

0,040

2009 2010 2011 2012 2013

mg/MJ

Median 80th Perc.

Linear (Median) Linear (80th Perc.)



Quality of SBS1Erftstadt and BIOBScompared to Rhenish lignite (05/2013)

Classification code according EN 15359 of SBS®1 and BIOBS: NCV: 4; Cl: 2; Hg: 1

Unit Lignite from the Rhine,

Mean

(Berrenrath/Wachtberg)

SBS 1,

Mean

2009 - 2011

SBS 1,

Mean

2012

BIOBS,

Mean

2009 - 2011

BIOBS,

Mean

2012

Short analysisNet. Calorific Value MJ/kg o.s. 10,1 13,3 13,4 11,5 11,7

H2O % o.s. 54 24,9 23,2 25,2 25,6

Ash % o.s. 2,5 9,7 8,9 11,9 10,5

Chlorine % o.s. 0,02 0,38 0,33 0,23 0,21

Volatile % o.s. 23,5 53,5 55,9 49,5 54,1

Elementary analysis

Corg % o.s. 30,5 34,7 36 31,1 31,2

H % o.s. 2,2 4,6 4,6 4,9 4,2

O % o.s. 10,3 23,6 25 25,1 26,9

N % o.s. 0,4 1,5 1,5 1,2 1,1

S % o.s. 0,2 0,19 0,18 0,14 0,12

Addtional parameters

Biogenic C % of TC 0 69,8 77,8 84,3 85,7

Chlorides mg/kg d.s. 300 1.995 1.965 1.600 1.440

Al mg/kg d.s. 750 5.700 4.880 6.250 4.660

K mg/kg d.s. 215 2.280 1.875 3.860 2.780

Na mg/kg d.s. 1.400 2.685 2.500 1.440 1.235

Pb mg/kg d.s. 1 245 120 60 50

Zn mg/kg d.s. 3,5 405 270 250 180



15

Energy specific CO2-emissionsof different fuels

t CO2/TJ

CO2-reduction: >= 1(BC) t CO2 /SBS1 or BIOBS

Emission factors of SRF certified according to RAL-GZ 724

20

40

60

80

100

120

0

BP

G 2

Lig

nit

e

Ha

rd c

oa

l

Hea

vy

fuel

oil

Lig

ht

fuel o

il

Natu

ral

gas

SB

S 1

BIO

BS

realistic fossil share



16

Outputas a result of sorting and treatment in Erftstadt

Residues to MSWI`s are more homogeneous than without sorting/treatment

Output ABA/AKEA 2009:

ca. 146.000t/a

64.541 t

54.413 t

191 t

832 t

4.158 t

1.330 t

948 t

19.606 t

SBS, BIOBS

To MSWI

Plastic (PVC)

NF-metals / Aluminium

Fe-Metals

Inert

Excess water

Drying losses



17

CO2-effectas a result of sorting and treatment in Erftstadt

Decisive way to increase CO2-reduction:

increase SRF- and recycling-rates

Contribution of output-streams to CO2-reduction ABA/AKEA 2009:

ca. 80.000 t/a or 0,55t CO2/t Input

64.751 t

8.064 t

191 t

2.495 t 4.158 t

SBS, BIOBS

To MSWI

Plastic (PVC)

NF-metals / Aluminium

Fe-Metals



Helsinki 13.06.2013

Part 3:

Use of BIOBS



CFB combustion

system

2 x 166 MWth

CHP-Plant Wachtberg SRF-delivery (BIOBS) with walking floor-trucks

Source:

RWE PowerUsed amount of BIOBS: 20.740 Mg (2011 – 2012)



CFB combustion

system

2 x 235 MWth

Source:

RWE Power

Use of BIOBS in CHP-plant Berrenrath

BIOBS used : ca. 12.000 Mg (ongoing, planned 14.450 Mg)



Used amounts of BIOBSin CHP-plants of Wachtberg and Berrenrath

Used total amount of BIOBS

a.) in Wachtberg ca. 20.700 t

b.) in Berrenrath: ca. 12.000 t

(planned sum ca. 35.000 t)

0

5.000

10.000

15.000

2010 2011 2012 2013 till week 15 2013 planned

An

nu

al

am

ou

nt

in t

/a

Berrenrath

Wachtberg



� Observation of the effects of sorting/ treatment in Erftstadt and of the output on

� Combined energetic use of certified SRF in co-incineration plants (brown

coal power plants) and residuals from sorting in MSWI`s

� substantial recycling of plastics, Fe-/Non-iron metals, …

� Regarding all 15 LCA-categories according to ISO 14400 and ILCD handbook for

compared to using primary resources (brown coal, primary plastics, primary metals,

…) production and use of SRF in Erftstadt is a successful combination of

recycling and resource strategies (advantages in 14 of 15 categories)

� Treatment technology in Erftstadt (MBS-plant) is a sustainable contribution to

reach the environmental aims of modern resource and energy management

Results Life Cycle Assessment of the JRC-EUwith respect to Erftstadt-Berrenrath/Wachtberg



Summary

Demonstration case Germany (06/2013)

� NIR-technology

� is the key to produce high-quality fuels based on high calorific waste fractions

� can be used/developed as an online-analysis-system for NCV, Cl and H2O

� RAL- quality certified SRF`s (RAL-GZ 724) guarantee a high quality reliabilty andensure an environmently friendly use in cement industries and power plants

� Fuel-quality is the decisive tool for high efficiency

� About 1t CO2 reduction/t SBS or BIOBS in brown-coal substitution

� Results of external LCA by the JRC Ispra on behalf of the EU-Commission taking into account 15 life cycle impact categories shows environmental sustainability; this means that co-incineration of quality assured SRF is ecologically useful

� No “food or fuel“-problematic

� Production and use of SRF is recommended for other (EU-) countries (i.e. GB, PL)

� European potential SRF co-incineration cement and power plants: 15 - 30 Mio t /a

� MSW-Incinerators as the last step of modern waste management (ultima ratio)



Helsinki 13.06.2013

Back-up



Development of Cl-values of SBS®ErftstadtInternal / external supervision (n = 1.601)

Effect of Germanlandfill-directive

First trials with NIR-sorting

Effect of increasing input competition

NIR-online analysis

0,00

0,50

1,00

1,50

2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

Cl

[% o

f d

s]

MedianAverage80th-Percentile

REMONDIS RECOMBIO Juni 2013 Part Production and use final · REMONDIS RheinlandGmbH Dr.-Ing. Th....

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