1
Status and Control Technologies of Dioxin (DXN) Emission
in Municipal Solid Waste (MSW) Incineration in Japan
Yoshihiro IDE, Dr. Eng.
1
Environmental Control Plant Division Plant & Infrastructure Engineering CompanyKAWASAKI HEAVY INDUSTRIES, LTD.
2
CONTENTS
1. Status of Dioxin (DXN) Emission fromMunicipal/Industrial Waste IncinerationFacilities in Japan
2. Control Technologies in Municipal Solid Waste (MSW) Thermal Treatment
3. Examples of Retrofitting of MSWIncineration Facilities in Japan
2
3
1. Status of Dioxin (DXN) Emissionfrom Municipal/Industrial WasteIncineration Facilities in Japan (2003)
3
4
Table. Percentage of MSW Combusted and Number of MSW Incineration Facilities in Different Countries, 2000
1,71577 %JapanAsia
< 5 %World Average
5 %Other Countries
approx. 206 %Canada
approx. 15015 %USNorth America
00 %Ireland
30 %Portugal
96 %Spain
176 %UK
3217 %Italy
1125 %Norway (not in the EU)
5925 %Germany
1140 %The Netherlands
21040 %France
1760 %Belgium
3060 %Sweden
3265 %Denmark
180 %Luxembourg
80 %Switzerland (not in the EU)Europe
NumberPercentageCountryRegion
(G.Bertolini, 2003; the European IPPC Bureau, 2004)4
5
020406080
100120140160
1965 1970 1975 1980 1985 1990 1995 2000
Operation Starting Year (―)
Num
ber o
f MSW
Inci
nera
tion
Furn
aces
(―)
Fig. Histogram of Operation Starting Year of MSW Incineration Facilities in Japan (The National Survey in 2003)
*
(*Not Facilities)
5
Total 2,366 Furnaces (1,680 Facilities (2001))
6
0
2000
4000
6000
8000
10000
12000
14000
1965 1970 1975 1980 1985 1990 1995 2000
Operation Starting Year (―)
Cap
acity
of M
SW In
cine
ratio
nFa
cilit
ies
(t/d)
Fig. Histogram of Operation Starting Year of MSW Incineration Facilities in Japan (The National Survey in 2003)
6
Total 182,717 t/d
7
Emission Standard for Existing Facilities
80 ng-TEQ/m3 [N]
Up to Nov.30, 2002
10 ng-TEQ/m3 [N]5 ng-TEQ/m3 [N]Less than 2 t/h
5 ng-TEQ/m3 [N]1 ng-TEQ/m3 [N]2 to 4 t/h
1 ng-TEQ/m3 [N]0.1 ng-TEQ/m3[N]4 t/h or more
From Dec.1, 2002
onward
Emission Standard for
Facilities to be newly
Constructed
Treatment Capacity of
Combustion Furnace
Table. Emission Standards forWaste Incineration FacilitiesAccording to the Law for Special Measures Against Dioxins in Japan
Effluent Standard
Concentration Standard for Incineration Residues
Emission Factor
: 10 pg-TEQ/L
: 3,000 pg-TEQ/g
: 5μg-TEQ/t-waste
7
*
*This value was set in the DXN Guidelines.
8
5,000
1,550 1,3501,018 812
370 310
1,500
1,100
690
555533
265 200
71
74
2,650
2,040
1,5731,345
635
145
510
6,500
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
1997 1998 1999 2000 2001 2002 2003 ReductionTarget
Industrial Waste Incineration FacilitiesMunicipal Waste Incineration Facilities
Annu
al E
mis
sion
of D
XN (g
-TEQ
/y)
Fig. Trend of the Annual Emission of DXN from Waste Incineration Facilities in Japan
8
The Issue of the DXN Guidelines (Jan. 23, 1997)
The Completion of the Moratorium in the Guidelines (Nov. 30, 2002)
9
497
151
461
333
260
226
01 0101
0092
1220
200
400
600
800
1000
1200
1400
≦0.1 0.1< ≦1 1< ≦5 5< ≦10 10<
DXN (ng-TEQ/m3[N] )
Num
ber o
f Fur
nace
s (―
)
9
Fig. Histogram of DXN Concentration in MSW Incineration Facilities (2003)
2 <
4 <
≦ 2
≦ 4
Capacity (t/h)
*
(*Not Facilities)
10
2,239
4 112 110
500
1,000
1,500
2,000
2,500
Incineration Gasificationand SyngasProduction
Gasificationand Melting
The Others
Num
ber o
f Fur
nace
s (―
)
Fig. Type of MSW Thermal Treatment Processes (2003)
10
*1
(*1 Not Facilities)
(*2 A Combustible Synthesis Gas)
*2
11
1,221
535 589
210200
400600
8001,000
1,2001,400
Continuous Semi-Continuous
Mechanical-Grate Batch
Fixed- Grate Batch
Num
ber o
f Fur
nace
s (―
)
Fig. Operation Type of MSW Incinerators (2003)11
*
(*Not Facilities)
12
1,970
37113 2100
500
1,000
1,500
2,000
Fabric orBag Filters
(FF/BF)
ElectrostaticPrecipitators
(ESP/EP)
Multi-Cyclones
(MC)
The Others Not Installed
Num
ber o
f Fur
nace
s (―
)
Fig. Type of Dust and Particle Collector EquipmentMSW Incinerators (2003)
12
*
(*Not Facilities)
13
Fig. Scatter Plot of DXN vs. Treatment Capacityof MSW Incinerators
13(Data of ND are plotted at 0.000001ng-TEQ/m3[N] expediently.)
0.000001
0.00001
0.0001
0.001
0.01
0.1
1
10
100
0 5 10 15 20 25Capacity (t/h)
DXN
(ng-
TEQ
/m3 [N
])
0 100 200 300 400 500 600Capacity (t/d)
FF/BF
1414
0.000001
0.00001
0.0001
0.001
0.01
0.1
1
10
100
0 5 10 15 20 25Capacity (t/h)
DXN
(ng-
TEQ
/m3 [N
])
0 100 200 300 400 500 600Capacity (t/d)
ESP/EPMCThe OthersNot Installed
Fig. Scatter Plot of DXN vs. Treatment Capacityof MSW Incinerators
(Data of ND are plotted at 0.000001ng-TEQ/m3[N] expediently.)
15
15637
146
80
455
370
0 0000 002 142 25
323
87 90
100
200
300
400
500
600
700
800
≦0.1 0.1< ≦1 1< ≦5 5< ≦10 10< ≦40 40< ≦80 80<
DXN (ng-TEQ/m3[N] )
Num
ber o
f Fur
nace
s (―
)
15
2 <
4 <
≦ 2
≦ 4
Capacity (t/h)
Fig. Histogram of DXN Concentrationin Industrial Waste Incineration Facilities (2003)
*
(*Not Facilities)
16
Waste Plastics790 Facilities
Waste Oil600 Facilities
DXNAverage 1.19 ng-TEQ/m3[N]Median 0.23 ng-TEQ/m3[N]
DXNAverage 0.77 ng-TEQ/m3[N]Median 0.07 ng-TEQ/m3[N]
3(0 %)
320(53 %)
13(2 %)
105(18 %)
159(26 %)
331(42 %)
252(32 %)
166(21 %)
1(0 %)
34(4 %)
6(1 %)
16
≦0.1
≦1
≦5
≦10
≦40
≦80
0.1<
1<
5<
10<
40<
80<
DXN
(ng-TEQ/m3[N])
Fig. DXN Concentration in Industrial Waste Incineration Facilities (Waste Plastics, Waste Oil) (2003)
17
Sludge594 Facilities
The Others1,152 Facilities
DXNAverage 0.64 ng-TEQ/m3[N]Median 0.04 ng-TEQ/m3[N]
DXNAverage 1.86 ng-TEQ/m3[N]Median 0.33 ng-TEQ/m3[N]
2(0 %)
419(36 %)
10(1 %)
74(6 %)
352(31 %)
348(58 %)
145(24 %)
88(15 %)
1(0 %)
12(2 %)
5(0 %)
290(25 %)
17
Fig. DXN Concentration in Industrial Waste Incineration Facilities (Sludge, The Others) (2003)
≦0.1
≦1
≦5
≦10
≦40
≦80
0.1<
1<
5<
10<
40<
80<
DXN
(ng-TEQ/m3[N])
18
Cleanup and Removal of Disused Incineration Facilities Contaminated by DXN
Disused Municipal Waste Incineration Facilities:Approx. 500 Facilities
Disused Industrial Waste Incineration Facilities:Approx. 3,800 Facilities
(Dec. 1, 2003)18
REMAINING PROBLEM
19
Table. Trend of Number of Operating and Disused Industrial Waste Incineration Facilities
Dec.1, 2003--
(523)(1,833)2,356
4013,872---Total
48253(1,044)(1,534)2,578Dec.1, 2002
501,387
24311
49246
101282
1291,393
(521)(3,421)3,942Dec.1, 2001
(554)(3,705)4,259Dec.1, 2000
(545)(3,942)4,487Dec.1, 1999
(653)(3,840)4,493Dec.1, 1998
----5,757Dec.1, 1997
New Operation
Disuse(Pause)(Work)Operation
19
20
2. Control Technologies in MSW Thermal Treatment
2.1. Thermal Treatment Process
20
21
Stoker Incineration
21
22
Kawasaki-Sun-type Reciprocating Stoker
22
23
A Concept of the Kawasaki-advanced Stoker
Flue Gas Re-circulation
Water Cooling of Grates Hydration of Bottom Ash
Parallel Flow Type
Water Cooling of Refractory Panel
Boiler Condition6MPa×450℃
SCR(approx. 170℃)
180 ℃
23
24
Annex 1.
24
25
Advanced Thermal Treatment of MSW
Gasification and Melting Systems
Gasification and Syngas ProductionSystems
Shaft Furnace Type
Rotary Kiln Type
Stoker Type
Shaft Furnace Type
Rotary Kiln Type
Advanced Stoker Systems
25
Fluidised Bed Type
26
Gasification and Melting System
Kawasaki Shaft Furnace Gasification and Melting System
26
27
Gasification and Melting System
Fluidized Bed Gasificationand Melting System
27
28
2. Control Technologies in MSW Thermal Treatment
2.2. Flue Gas Treatment Process
28
29
Flue Gas Treatment Process
29
3030
3131
3232
3333
3434
35
Recent Dioxin DataIncinerating Capacity Flow Dioxin Data
ACR : Activated Carbon Reactor/ReductionSCR : Selective Catalytic Reactor/Reduction
500 t/ 24 h × 3:
40 t/ 24 h × 2:
10 t/ 8 h × 2:
Furnace → Boiler → FF → WS → SCR → Stack:
ND - 0.07 ng-TEQm3[N]
Furnace → Water Spray → FF → ACR → Stack:
↑ Activated Carbon 0.0008 - 0.04 ng-TEQm3[N]
Furnace → Water Spray → FF + FF → Stack:
↑ (↑) Activated CarbonND - 0.0002 ng-TEQm3[N]
35
36
Other Techniques for Flue Gas Treatment
1. Double Filtrations (1st FF + 2nd FF) and Utilization of Additives : A
2. Utilization of Na Compounds (ex. NaHCO3) Instead ofCa Compounds : A
3. Ceramic Filters or Cyclones at Temperatures of approx. 800 ℃ : P
4. Electron Beam (EB) : P
5. Electro Dynamic Venturi (EDV) : P
( A : Actual Equipment ; P : Pilot Equipment )
36
37
SamplingPeriod
6 h – 4 weeks
6 h – 4 weeks・Sampling Equipment(See Fig.1)
・AMESAAdsorption
Becker MesstechnikGmbh (Germany)
・Sampling Equipment(See Fig.2)
・DMSAdsorption
Dioxin Monitoring System (Austria)
CharacteristicMethodMaker
37
Table. Gas Sampling Equipment for DXN Monitoring in the EU
*
*Adsorption Method for Sampling of Dioxins and Furans
Fig.1 AMESA Fig.2 DMS
38
Laser Ionization → TOFMS 1 min
2 – 6 h
20 s
15 – 60 min
15 min
20 s
Detection Period
10,000 ng/m3PCB
0.05 ng/m3P5CDF
Detection Limit
10,000 ng/m3PCB
80 ng/m3CBzUV ionization→ TOFMS
(*Adsorption)Mitsubishi
HeavyIndustry, Ltd.
80 ng/m3CBzCPh
・GDX-2000Adsorption →
ECDNKK - ToaDKK,
Ltd.
500 ng/m3T3CPh・CP-2000APCI ionization→ ITMS
Hitachi, Ltd.
CharacteristicCom-Pound
MethodMaker
Table. Gas Monitors in Japan for Dioxin Surrogate Compounds
38
*
39
2. Control Technologies in MSW Thermal Treatment
2.3. Treatment of Incineration Residues
39
40
Fly Ash Treatment Equipment for Dechlorination of DXN
40
41
Ash Melting System
Plasma-type Oil Burner-type
41
42
Other Countermeasures for DXN Abatement in MSW Treatment
① Wide-area Treatment Systemin Waste Management
② Non-combustion Treatment(ex. Bio-treatment)
42
43
An Idea of Wide-area-treatment System by RDF (Refuse-derived Fuel) in MSW Management43
44
Transforming Waste into Fuel
Refuse-derived Fuel (RDF) Production Plant
44
45
Fluidized Bed Incineration
Internal Circulation FluidizedBed-type Boiler
Fluidized Bed Incinerator
45
46
Annex 2.
46
47
The Overview of the Commercial RDF Power Plant (The City of Omuta)
47
48
Gasifying Waste (Bio-treatment of Garbage, Grass, and Trees)Organic Waste Gasification System
48
49The Overview of the Pilot Plant (Kyoto City)
49
50
The Overview of the Fermentation Vessel (Kyoto City)
50
51
3. Examples of Retrofitting of MSW Incineration Facilities in Japan
51
52
Fig. The Sectional Outline of the Plant A before Retrofitting (200 t/d × 3) 52
ESP Wet Scrubber
53
Fig. The Sectional Outline of the Plant A after Retrofitting (200 t/d × 3) 53
SCR Wet ScrubberFFSpray Gas
CoolerRetrofitting of Firing System
54
Table. DXN Data before and afterRetrofitting of the Plant A (200 t/d × 3 )
After RetrofittingBefore Retrofitting
-
0.014 ng/g
0.020 ng/g
0.00034 ng-TEQ/m3
Concentration
Bottom Ash 1.52.40.022 ng/g
2.3210-Total
0.7420012 ng/gFly Ash
0.00229.51.5 ng-TEQ/m3Flue Gas
Emission Factor
(μg-TEQ/t-waste)
Emission Factor
(μg-TEQ/t-waste)
Concentration
54
*
*Fly ash treatment equipment for dechlorination of DXN was installed.
55
Fig. The Sectional Outline of the Plant B before Retrofitting (200 t/d × 3) 55
ESP Wet Scrubber
56
Fig. The Sectional Outline of the Plant B after Retrofitting (200 t/d × 3) 56
SCRWet
ScrubberFFSpray Gas
CoolerRetrofitting of Firing System
5757
Furnace #1 : 0.0014 ng-TEQ/m3[N]
Furnace #2 : 0.00039 ng-TEQ/m3[N]
Furnace #3 : 0.00065, 0.00029 ng-TEQ/m3[N]
(Before Retrofitting : 0.78 - 2.7 ng-TEQ/m3[N])
Table. DXN Data at the Outlet of SCR after Retrofitting of the Plant B (200 t/d × 3 )
58
Table. The Costs of Retrofitting MSW Incineration Facilities
80 t/d × 3
Plant D
200 t/d × 3
Plant B
-1,4101,6901,160SGH + SCR
1,3952,9501,4303,350ESP → Spray Gas Cooler + FF
300 t/d × 2200 t/d × 3Capacity
Plant CPlant AFacility
4,360
-
-
-
Fly Ash De-chlorination Equipment --1,100
1,4703,6607,340Total
7540410Injection Unit of Activated Carbon
-5001,320Retrofitting of Firing System
58
*1 Fabric Filter with dosage of Slaked Lime*2 Steam Gas Heater*3 Selective Catalytic Reactor/Reduction
(Million Yen)
*1
*2
*3
59
CONCLUSIONS
1. Reduction target of DXN emission in Japan was achieved.
2. The problem of cleanup and removal ofdisused incineration facilities is remaining.
3. Advanced thermal treatment of MSW is in operation in Japan.
4. Abatement techniques of DXN in flue gas are adopted as actual equipment or pilot equipment.
5. Retrofitting costs of MSW incineration facilities varied site by site.
59
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