Waste gasification vs. conventional Waste-to-Energy: a comparative evaluation of two commercial technologies

A number of waste gasification technologies are currently proposed as an alternative to conventional Waste-to-Energy (WtE) plants. Assessing their potential is made difficult by the scarce operating experience and the fragmentary data available. After defining a conceptual framework to classify and assess waste gasification technologies, this paper compares two of the proposed technologies with conventional WtE plants. Performances are evaluated by proprietary software developed at Politecnico di Milano and compared on the basis of a coherent set of assumptions. Since the two gasification technologies are configured as “two-step oxidation” processes, their energy performances are very similar to those of conventional plants. The potential benefits that may justify their adoption relate to material recovery and operation/emission control: recovery of metals in non-oxidized form; collection of ashes in inert, vitrified form; combustion control; lower generation of some pollutants.     

Energy from gasification of solid wastes

Gasification technology is by no means new: in the 1850s, most of the city of London was illuminated by "town gas" produced from the gasification of coal. Nowadays, gasification is the main technology for biomass conversion to energy and an attractive alternative for the thermal treatment of solid waste. The number of different uses of gas shows the flexibility of gasification and therefore allows it to be integrated with several industrial processes, as well as power generation systems. The use of a waste-biomass energy production system in a rural community is very interesting too. This paper describes the current state of gasification technology, energy recovery systems, pre-treatments and prospective in syngas use with particular attention to the different process cycles and environmental impacts of solid wastes gasification.     

Waste management from pulp and paper production in the European Union

Eleven million tonnes of waste are produced yearly by the European pulp and paper industry, of which 70% originates from the production of deinked recycled paper. Wastes are very diverse in composition and consist of rejects, different types of sludges and ashes in mills having on-site incineration treatment. The production of pulp and paper from virgin pulp generates less waste but the waste has similar properties to waste from the production of deinked pulp, although with less inorganics. Due to legislation and increased taxes, landfills are quickly being eliminated as a final destination for wastes in Europe, and incineration with energy recovery is becoming the main waste recovery method. Other options such as pyrolysis, gasification, land spreading, composting and reuse as building material are being applied, although research is still needed for optimization of the processes. Due to the large volumes of waste generated, the high moisture content of the waste and the changing waste composition as a result of process conditions, recovery methods are usually expensive and their environmental impact is still uncertain. For this reason, it is necessary to continue research on different applications of wastes, while taking into account the environmental and economic factors of these waste treatments.     

Optimal utilization of waste-to-energy in an LCA perspective

Energy production from two types of municipal solid waste was evaluated using life cycle assessment (LCA): (1) mixed high calorific waste suitable for production of solid recovered fuels (SRF) and (2) source separated organic waste. For SRF, co-combustion was compared with mass burn incineration. For organic waste, anaerobic digestion (AD) was compared with mass burn incineration. In the case of mass burn incineration, incineration with and without energy recovery was modelled. Biogas produced from anaerobic digestion was evaluated for use both as transportation fuel and for heat and power production. All relevant consequences for energy and resource consumptions, emissions to air, water and soil, upstream processes and downstream processes were included in the LCA. Energy substitutions were considered with respect to two different energy systems: a present-day Danish system based on fossil fuels and a potential future system based on 100% renewable energy. It was found that mass burn incineration of SRF with energy recovery provided savings in all impact categories, but co-combustion was better with respect to Global Warming (GW). If all heat from incineration could be utilized, however, the two alternatives were comparable for SRF. For organic waste, mass burn incineration with energy recovery was preferable over anaerobic digestion in most impact categories. Waste composition and flue gas cleaning at co-combustion plants were critical for the environmental performance of SRF treatment, while the impacts related to utilization of the digestate were significant for the outcome of organic waste treatment. The conclusions were robust in a present-day as well as in a future energy system. This indicated that mass burn incineration with efficient energy recovery is a very environmentally competitive solution overall.     

Comparing Waste-to-Energy technologies by applying energy system analysis

Even when policies of waste prevention, re-use and recycling are prioritised a fraction of waste will still be left which can be used for energy recovery. This article asks the question: How to utilise waste for energy in the best way seen from an energy system perspective? Eight different Waste-to-Energy technologies are compared with a focus on fuel efficiency, CO₂ reductions and costs. The comparison is carried out by conducting detailed energy system analyses of the present as well as a potential future Danish energy system with a large share of combined heat and power as well as wind power. The study shows potential of using waste for the production of transport fuels. Biogas and thermal gasification technologies are hence interesting alternatives to waste incineration and it is recommended to support the use of biogas based on manure and organic waste. It is also recommended to support research into gasification of waste without the addition of coal and biomass. Together the two solutions may contribute to alternate use of one third of the waste which is currently incinerated. The remaining fractions should still be incinerated with priority to combined heat and power plants with high electric efficiency.     

Modeling and comparative assessment of municipal solid waste gasification for energy production

Gasification is the thermochemical conversion of organic feedstocks mainly into combustible syngas (CO and H₂) along with other constituents. It has been widely used to convert coal into gaseous energy carriers but only has been recently looked at as a process for producing energy from biomass. This study explores the potential of gasification for energy production and treatment of municipal solid waste (MSW). It relies on adapting the theory governing the chemistry and kinetics of the gasification process to the use of MSW as a feedstock to the process. It also relies on an equilibrium kinetics and thermodynamics solver tool (Gasify®) in the process of modeling gasification of MSW. The effect of process temperature variation on gasifying MSW was explored and the results were compared to incineration as an alternative to gasification of MSW. Also, the assessment was performed comparatively for gasification of MSW in the United Arab Emirates, USA, and Thailand, presenting a spectrum of socioeconomic settings with varying MSW compositions in order to explore the effect of MSW composition variance on the products of gasification. All in all, this study provides an insight into the potential of gasification for the treatment of MSW and as a waste to energy alternative to incineration.     

Energy recovery from municipal waste: a case study for a middle-sized Italian district

This paper reports the main outcome of research to compare and assess the merits of alternative strategies for energy recovery from municipal solid waste downstream of material recovery for an Italian province. Strategies analysed are based on well-established combustion technologies available at the commercial scale in the Italian market in comparison with an innovative but not yet proven option of refuse derived fuel gasification and subsequent co-combustion of syngas in a combined cycle power plant. The comparison is made using mass and energy balances, environmental assessment and economic analysis. From an energetic point of view, the best strategy is the one based on the refuse derived fuel gasification, which, on the contrary, does not show interesting environmental results. In this perspective, the best results are from strategies based on a dedicated plant, particularly when unsorted residual waste collected downstream of material recovery is used. Finally, from an economic point of view, the strategy with gasification allows the highest revenues from the sale of energy.     

Energy recovery from solid waste fuels using advanced gasification technology

Since the mid-1980s, TPS Termiska Processer AB has been working on the development of an atmospheric-pressure gasification process. A major aim at the start of this work was the generation of fuel gas from indigenous fuels to Sweden (i.e. biomass). As the economic climate changed and awareness of the damage to the environment caused by the use of fossil fuels in power generation equipment increased, the aim of the development work at TPS was changed to applying the process to heat and power generation from feedstocks such as biomass and solid wastes. Compared with modern waste incineration with heat recovery, the gasification process will permit an increase in electricity output of up to 50%. The gasification process being developed is based on an atmospheric-pressure circulating fluidised bed gasifier coupled to a tar-cracking vessel. The gas produced from this process is then cooled and cleaned in conventional equipment. The energy-rich gas produced is clean enough to be fired in a gas boiler (and, in the longer term, in an engine or gas turbine) without requiring extensive flue gas cleaning, as is normally required in conventional waste incineration plants. Producing clean fuel gas in this manner, which facilitates the use of efficient gas-fired boilers, means that overall plant electrical efficiencies of close to 30% can be achieved. TPS has performed a considerable amount of pilot plant testing on waste fuels in their gasification/gas cleaning pilot plant in Sweden. Two gasifiers of TPS design have been in operation in Grève-in-Chianti, Italy since 1992. This plant processes 200 tonnes of RDF (refuse-derived fuel) per day. It is planned that the complete TPS gasification process (including the complete fuel gas cleaning system) be demonstrated in several gas turbine-based biomass-fuelled power generating plants in different parts of the world. It is the aim of TPS to prove, at commercial scale, the technical feasibility and economic advantages of the gasification process when it is applied to solid waste fuels. This aim shall be achieved, in the short-term, by employing the cold clean product gas in a gas boiler and, in the longer-term, by firing the gas in engines and gas turbines. A study for a 90 MWth waste-fuelled co-generation plant in Sweden has shown that, already today, gasification of solid waste can compete economically with conventional incineration technologies.     

Current EU-27 technical potential of organic waste streams for biogas and energy production

Anaerobic digestion of organic waste generated by households, businesses, agriculture, and industry is an important approach as method of waste treatment – especially with regard to its potential as an alternative energy source and its cost-effectiveness. Separate collection of biowaste from households or vegetal waste from public green spaces is already established in some EU-27 countries. The material recovery in composting plants is common for biowaste and vegetal waste. Brewery waste fractions generated by beer production are often used for animal feeding after a suitable preparation. Waste streams from paper industry generated by pulp and paper production such as black liquor or paper sludge are often highly contaminated with toxic substances. Recovery of chemicals and the use in thermal processes like incineration, pyrolysis, and gasification are typical utilization paths. The current utilization of organic waste from households and institutions (without agricultural waste) was investigated for EU-27 countries with Germany as an in-depth example. Besides of biowaste little is known about the suitability of waste streams from brewery and paper industry for anaerobic digestion. Therefore, an evaluation of the most important biogas process parameters for different substrates was carried out, in order to calculate the biogas utilization potential of these waste quantities. Furthermore, a calculation of biogas energy potentials was carried out for defined waste fractions which are most suitable for anaerobic digestion. Up to 1% of the primary energy demand can be covered by the calculated total biogas energy potential. By using a “best-practice-scenario” for separately collected biowaste, the coverage of primary energy demand may be increased above 2% for several countries. By using sector-specific waste streams, for example the German paper industry could cover up to 4.7% and the German brewery industry up to 71.2% of its total energy demand.     

Energy recovery from sewage sludge by means of fluidised bed gasification

Because of its potential harmful impact on the environment, disposal of sewage sludge is becoming a major problem all over the world. Today the available disposal measures are at the crossroads. One alternative would be to continue its usage as fertiliser or to abandon it. Due to the discussions about soil contamination caused by sewage sludge, some countries have already prohibited its application in agriculture. In these countries, thermal treatment is now presenting the most common alternative. This report describes two suitable methods to directly convert sewage sludge into useful energy on-site at the wastewater treatment plant. Both processes consist mainly of four devices: dewatering and drying of the sewage sludge, gasification by means of fluidised bed technology (followed by a gas cleaning step) and production of useful energy via CHP units as the final step. The process described first (ETVS-Process) is using a high pressure technique for the initial dewatering and a fluidised bed technology utilising waste heat from the overall process for drying. In the second process (NTVS-Process) in addition to the waste heat, solar radiation is utilised. The subsequent measures--gasification, gas cleaning and electric and thermal power generation--are identical in both processes. The ETVS-Process and the NTVS-Process are self-sustaining in terms of energy use; actually a surplus of heat and electricity is generated in both processes.     

Material and energy recovery from Automotive Shredded Residues (ASR) via sequential gasification and combustion

Shredding is the common end-of-life treatment in Europe for dismantled car wrecks. It produces the so-called Automotive Shredded Residue (ASR), usually disposed of in landfill. This paper summarizes the outcome of a study carried out by Politecnico di Milano and LEAP with the support of Actelios SpA on the prospects of a technology based on sequential gasification and combustion of this specific waste stream. Its application to the treatment of ASR allows the recovery of large fractions of metals as non-oxidized, easily marketable secondary raw materials, the vitrification of most of the ash content and the production of power via a steam cycle. Results show that despite the unfavourable characteristics of ASR, the proposed technology can reach appealing energy performances. Three of four environmental impact indicators and the cumulative energy demand index are favourable, the main positive contributes being electricity production and metal recovery (mainly aluminium and copper). The only unfavourable indicator is the global warming index because, since most of the carbon in ASR comes from fossil sources, the carbon dioxide emissions at the stack of the thermal treatment plant are mainly non-renewable and, at the same time, the avoided biogas production from the alternative disposal route of landfilling is minor.     

Waste plastics recycling by an entrained-flow gasifier

We studied an entrained-flow gasification process which efficiently converts waste plastics to energy at a high energy recovery rate. Waste plastics, after being shredded to <8 mm or <14 mm, were fed into an entrained-flow gasifier with air and oxygen. In the gasifier, organic substances were pyrolyzed, partially combusted, and then converted into synthetic gas (CO, H₂) at a high temperature (over 1600 K). The clarified gasification characteristics were that the lower heat value (LHV) of the product gas was over 4.2 MJ/Nm³ and the cold gas efficiency was approximately 60%. Other inert substances in the wastes such as ashes and metals were melted into slag and condensed on bag filters. The bag filters and a water scrubber removed impurities such as dusts, heavy metals, and hydrogen halides from the product gases. Solid hydrocarbons, which include char and soot, were removed at a hot cyclone and on the bag filters. Received: July 19, 2000 / Accepted: October 3, 2000     

Energy implications of the thermal recovery of biodegradable municipal waste materials in the United Kingdom

Waste management policies and legislation in many developed countries call for a reduction in the quantity of biodegradable waste landfilled. Anaerobic digestion, combustion and gasification are options for managing biodegradable waste while generating renewable energy. However, very little research has been carried to establish the overall energy balance of the collection, preparation and energy recovery processes for different types of wastes. Without this information, it is impossible to determine the optimum method for managing a particular waste to recover renewable energy. In this study, energy balances were carried out for the thermal processing of food waste, garden waste, wood, waste paper and the non-recyclable fraction of municipal waste. For all of these wastes, combustion in dedicated facilities or incineration with the municipal waste stream was the most energy-advantageous option. However, we identified a lack of reliable information on the energy consumed in collecting individual wastes and preparing the wastes for thermal processing. There was also little reliable information on the performance and efficiency of anaerobic digestion and gasification facilities for waste.     

A technical, economic, and environmental analysis of energy production from newspaper in Ireland

The production of newspaper corresponds to 37 kg per person per annum in Ireland. Newspaper becomes a waste product in a short period of time; only 13% of domestic waste paper is recycled (data on newspaper is not available). Four scenarios, which generate energy from newspaper, are analysed. These scenarios may be summarised as follows: lignocellulosic biomass conversion to ethanol (transport fuel); co-digestion with the organic fraction of municipal solid waste and production of CH4-enriched biogas (transport fuel); co-firing with the residue of municipal solid waste in an incinerator; and gasification of newspaper as a sole fuel. Two of the scenarios involve transport fuel production; two involve the production of electricity and heat. Two of the scenarios involve newspaper as the sole ingredient; two involve co- utilisation of newspaper with another waste stream. Assuming no economic market for heat, then only the transport scenarios have the potential to be economic; indeed the biogas scenario is shown to be extremely competitive generating a potential profit of euro 227/t newspaper. A greenhouse-gas analysis indicates that the biogas scenario generated the best net greenhouse-gas savings. However when a market for heat is available, gasification was shown to be most advantageous.     

Comparative assessment of municipal sewage sludge incineration,gasification and pyrolysis for a sustainable sludge-to-energy management in Greece

For a sustainable municipal sewage sludge management, not only the available technology, but also other parameters, such as policy regulations and socio-economic issues should be taken in account. In this study, the current status of both European and Greek Legislation on waste management, with a special insight in municipal sewage sludge, is presented. A SWOT analysis was further developed for comparison of pyrolysis with incineration and gasification and results are presented. Pyrolysis seems to be the optimal thermochemical treatment option compared to incineration and gasification. Sewage sludge pyrolysis is favorable for energy savings, material recovery and high added materials production, providing a ‘zero waste’ solution. Finally, identification of challenges and barriers for sewage sludge pyrolysis deployment in Greece was investigated.     

Long-term affected energy production of waste to energy technologies identified by use of energy system analysis

Affected energy production is often decisive for the outcome of consequential life-cycle assessments when comparing the potential environmental impact of products or services. Affected energy production is however difficult to determine. In this article the future long-term affected energy production is identified by use of energy system analysis. The focus is on different uses of waste for energy production. The Waste-to-Energy technologies analysed include co-combustion of coal and waste, anaerobic digestion and thermal gasification. The analysis is based on optimization of both investments and production of electricity, district heating and bio-fuel in a future possible energy system in 2025 in the countries of the Northern European electricity market (Denmark, Norway, Sweden, Finland and Germany). Scenarios with different CO₂ quota costs are analysed. It is demonstrated that the waste incineration continues to treat the largest amount of waste. Investments in new waste incineration capacity may, however, be superseded by investments in new Waste-to-Energy technologies, particularly those utilising sorted fractions such as organic waste and refuse derived fuel. The changed use of waste proves to always affect a combination of technologies. What is affected varies among the different Waste-to-Energy technologies and is furthermore dependent on the CO₂ quota costs and on the geographical scope. The necessity for investments in flexibility measures varies with the different technologies such as storage of heat and waste as well as expansion of district heating networks. Finally, inflexible technologies such as nuclear power plants are shown to be affected.     

Thermal valorization of post-consumer film waste in a bubbling bed gasifier

The use of plastic bags and film packaging is very frequent in manifold sectors and film waste is usually present in different sources of municipal and industrial wastes. A significant part of it is not suitable for mechanical recycling but could be safely transformed into a valuable gas by means of thermal valorization. In this research, the gasification of film wastes has been experimentally investigated through experiments in a fluidized bed reactor of two reference polymers, polyethylene and polypropylene, and actual post-consumer film waste. After a complete experimental characterization of the three materials, several gasification experiments have been performed to analyze the influence of the fuel and of equivalence ratio on gas production and composition, on tar generation and on efficiency. The experiments prove that film waste and analogue polymer derived wastes can be successfully gasified in a fluidized bed reactor, yielding a gas with a higher heating value in a range from 3.6 to 5.6 MJ/m³ and cold gas efficiencies up to 60%.     

An LCA model for waste incineration enhanced with new technologies for metal recovery and application to the case of Switzerland

A process model of municipal solid waste incinerators (MSWIs) and new technologies for metal recovery from combustion residues was developed. The environmental impact is modeled as a function of waste composition as well as waste treatment and material recovery technologies. The model includes combustion with a grate incinerator, several flue gas treatment technologies, electricity and steam production from waste heat recovery, metal recovery from slag and fly ash, and landfilling of residues and can be tailored to specific plants and sites (software tools can be downloaded free of charge). Application of the model to Switzerland shows that the treatment of one tonne of municipal solid waste results on average in 425 kg CO₂-eq. generated in the incineration process, and 54 kg CO₂-eq. accrue in upstream processes such as waste transport and the production of operating materials. Downstream processes, i.e. residue disposal, generates 5 kg CO₂-eq. Savings from energy recovery are in the range of 67 to 752 kg CO₂-eq. depending on the assumptions regarding the substituted energy production, while the recovery of metals from slag and fly ash currently results in a net saving of approximately 35 kg CO₂-eq. A similar impact pattern is observed when assessing the MSWI model for aggregated environmental impacts (ReCiPe) and for non-renewable resource consumption (cumulative exergy demand), except that direct emissions have less and no relevance, respectively, on the total score. The study illustrates that MSWI plants can be an important element of industrial ecology as they provide waste disposal services and can help to close material and energetic cycles.     

Modeling microbiological and chemical processes in municipal solid waste bioreactor,part I: Development of a three-phase numerical model BIOKEMOD-3P

The numerical computer models that simulate municipal solid waste (MSW) bioreactor landfills have mainly two components – a biodegradation process module and a multi-phase flow module. The biodegradation model describes the chemical and microbiological processes. The models available to date include predefined solid waste biodegradation reactions and participating species. Some of these models allow changing the basic composition of solid waste. In a bioreactor landfill several processes like anaerobic and aerobic solids biodegradation, nitrogen and sulfate related processes, precipitation and dissolution of metals, and adsorption and gasification of various anthropogenic organic compounds occur simultaneously. These processes may involve reactions of several species and the available biochemical models for solid waste biodegradation do not provide users with the flexibility to simulate these processes by choice. This paper presents the development of a generalized biochemical process model BIOKEMOD-3P which can accommodate a large number of species and process reactions. This model is able to simulate bioreactor landfill operation in a completely mixed condition, when coupled with a multi-phase model it will be able to simulate a full-scale bioreactor landfill. This generalized biochemical model can simulate laboratory and pilot-scale operations in order to determine biochemical parameters important for simulation of full-scale operations.     

Steam gasification of tyre waste, poplar, and refuse-derived fuel: a comparative analysis

In the field of waste management, thermal disposal is a treatment option able to recover resources from "end of life" products. Pyrolysis and gasification are emerging thermal treatments that work under less drastic conditions in comparison with classic direct combustion, providing for reduced gaseous emissions of heavy metals. Moreover, they allow better recovery efficiency since the process by-products can be used as fuels (gas, oils), for both conventional (classic engines and heaters) and high efficiency apparatus (gas turbines and fuel cells), or alternatively as chemical sources or as raw materials for other processes. This paper presents a comparative study of a steam gasification process applied to three different waste types (refuse-derived fuel, poplar wood and scrap tyres), with the aim of comparing the corresponding yields and product compositions and exploring the most valuable uses of the by-products.