Process and technological aspects of municipal solid waste gasification. A review

The paper proposes a critical assessment of municipal solid waste gasification today, starting from basic aspects of the process (process types and steps, operating and performance parameters) and arriving to a comparative analysis of the reactors (fixed bed, fluidized bed, entrained bed, vertical shaft, moving grate furnace, rotary kiln, plasma reactor) as well as of the possible plant configurations (heat gasifier and power gasifier) and the environmental performances of the main commercially available gasifiers for municipal solid wastes. The analysis indicates that gasification is a technically viable option for the solid waste conversion, including residual waste from separate collection of municipal solid waste. It is able to meet existing emission limits and can have a remarkable effect on reduction of landfill disposal option.     

Comparing the greenhouse gas emissions from three alternative waste combustion concepts

Three alternative condensing mode power and combined heat and power (CHP) waste-to-energy concepts were compared in terms of their impacts on the greenhouse gas (GHG) emissions from a heat and power generation system. The concepts included (i) grate, (ii) bubbling fluidised bed (BFB) and (iii) circulating fluidised bed (CFB) combustion of waste. The BFB and CFB take advantage of advanced combustion technology which enabled them to reach electric efficiency up to 35% and 41% in condensing mode, respectively, whereas 28% (based on the lower heating value) was applied for the grate fired unit. A simple energy system model was applied in calculating the GHG emissions in different scenarios where coal or natural gas was substituted in power generation and mix of fuel oil and natural gas in heat generation by waste combustion. Landfilling and waste transportation were not considered in the model. GHG emissions were reduced significantly in all of the considered scenarios where the waste combustion concepts substituted coal based power generation. With the exception of condensing mode grate incinerator the different waste combustion scenarios resulted approximately in 1 Mton of fossil CO₂-eq. emission reduction per 1 Mton of municipal solid waste (MSW) incinerated. When natural gas based power generation was substituted by electricity from the waste combustion significant GHG emission reductions were not achieved.     

CFD simulation of MSW combustion and SNCR in a commercial incinerator

A CFD scheme was presented for modeling municipal solid waste (MSW) combustion in a moving-grate incinerator, including the in-bed burning of solid wastes, the out-of-bed burnout of gaseous volatiles, and the selective non-catalytic reduction (SNCR) process between urea (CO(NH₂)₂) and NO_x. The in-bed calculations provided 2-D profiles of the gas–solid temperatures and the gas species concentrations along the bed length, which were then used as inlet conditions for the out-of-bed computations. The over-bed simulations provided the profiles of incident radiation heat flux on the top of bed. A 3-dimensional benchmark simulation was conducted with a 750 t/day commercial incinerator using the present coupling scheme incorporating with a reduced SNCR reduction mechanism. Numerical tests were performed to investigate the effects of operating parameters such as injection position, injection speed and the normalized stoichiometric ratio (NSR) on the SNCR performance. The simulation results showed that the distributions of gas velocity, temperature and NO_x concentration were highly non-uniform, which made the injection position one of the most sensitive operating parameters influencing the SNCR performance of moving grate incinerators. The simulation results also showed that multi-layer injections were needed to meet the EU2000 standard, and a NSR 1.5 was suggested as a compromise of a satisfactory NO_x reduction and reasonable NH₃ slip rates. This work provided useful guides to the design and operation of SNCR process in moving-grate incinerators.     

Trace element partitioning in ashes from boilers firing pure wood or mixtures of solid waste with respect to fuel composition,chlorine content and temperature

Trace element partitioning in solid waste (household waste, industrial waste, waste wood chips and waste mixtures) incineration residues was investigated. Samples of fly ash and bottom ash were collected from six incineration facilities across Sweden including two grate fired and four fluidized bed incinerators, to have a variation in the input fuel composition (from pure biofuel to mixture of waste) and different temperature boiler conditions. As trace element concentrations in the input waste at the same facilities have already been analyzed, the present study focuses on the concentration of trace elements in the waste fuel, their distribution in the incineration residues with respect to chlorine content of waste and combustion temperature.Results indicate that Zn, Cu and Pb are dominating trace elements in the waste fuel. Highly volatile elements mercury and cadmium are mainly found in fly ash in all cases; 2/3 of lead also end up in fly ash while Zn, As and Sb show a large variation in distribution with most of them residing in the fly ash. Lithophilic elements such as copper and chromium are mainly found in bottom ash from grate fired facilities while partition mostly into fly ash from fluidized bed incinerators, especially for plants fuelled by waste wood or ordinary wood chips. There is no specific correlation between input concentration of an element in the waste fuel and fraction partitioned to fly ash. Temperature and chlorine content have significant effects on partitioning characteristics by increasing the formation and vaporization of highly volatile metal chlorides. Zinc and cadmium concentrations in fly ash increase with the incineration temperature.     

Treatment of hazardous waste incineration wastewater

This article outlines the general design concepts and new chemistry necessary to achieve truly cost-effective management of an important part of the hazardous waste incineration system—i.e., the unit operations needed to treat wastewater generated by rotary kiln incinerators burning wastes containing halogens and heavy metals.     

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.     

On-site remediation of PCB contamination using transportable incineration systems

Many Superfund or hazardous waste sites prove to be excellent candidates for remediation using transportable incineration. Transportable incineration has been selected as the alternative of choice to remediate numerous sites throughout the United States. There are a number of firms that provide mobile and transportable incineration equipment and services. A variety of treatment systems are available, including rotary kilns, fluidized beds, and infrared incinerators. Roy F. Weston, Inc., has been instrumental in the development, design, permitting, construction, performance testing, and operation of hazardous and toxic waste thermal treatment systems. Weston owns and operates two high-temperature transportable incineration systems (TISs). The first system is Weston's seven-ton-per-hour (tph) TIS-5. The second is the TIS-20, with a design capacity of up to 30 tph. These units are typical rotary kiln incinerators, the most flexible, adaptable type of incineration unit. This article discusses Weston's use of these incinerators to remediate soils at sites contaminated with polychlorinated biphenyls (PCBs).     

The estimation of N2O emissions from municipal solid waste incineration facilities: The Korea case

The greenhouse gases (GHGs) generated in municipal solid waste (MSW) incineration are carbon dioxide (CO₂), methane (CH₄), and nitrous oxide (N₂O). In South Korea case, the total of GHGs from the waste incineration facilities has been increasing at an annual rate 10%. In these view, waste incineration facilities should consider to reduce GHG emissions.This study is designed to estimate the N₂O emission factors from MSW incineration plants, and calculate the N₂O emissions based on these factors. The three MSW incinerators examined in this study were either stoker or both stoker and rotary kiln facilities. The N₂O concentrations from the MSW incinerators were measured using gas chromatography-electron capture detection (GC-ECD) equipment.The average of the N₂O emission factors for the M01 plant, M02 plant, and M03 plant are 71, 75, and 153 g-N₂O/ton-waste, respectively. These results showed a significant difference from the default values of the intergovernmental panel on climate change (IPCC), while approaching those values derived in Japan and Germany. Furthermore, comparing the results of this study to the Korea Energy Economics Institute (KEEI) (2007) data on waste incineration, N₂O emissions from MSW incineration comprised 19% of the total N₂O emissions.     

Application of the dynamic model of Saeman to an industrial rotary kiln incinerator: Numerical and experimental results

In order to simulate granular materials structure in a rotary kiln under the steady-state regime, a mathematical model has been developed by Saeman (1951). This model enables the calculation of the bed profiles, the axial velocity and solids flow rate along the kiln. This model can be coupled with a thermochemical model, in the case of a reacting moving bed. This dynamic model was used to calculate the bed profile for an industrial size kiln and the model projections were validated by measurements in a 4 m diameter by 16 m long industrial rotary kiln. The effect of rotation speed under solids bed profile and the effect of the feed rate under filling degree were established. On the basis of the calculations and the experimental results a phenomenological relation for the residence time estimation was proposed for the rotary kiln.     

Co-generation based energy recovery from municipal solid waste integrated with the existing energy supply system

The SISMan (Simple Integrated System Management) decision-aid model is introduced in this paper. The SISMan model is used in a demonstration of evaluating the viability of adding an Energy-from-Waste (EfW) plant to an existing municipal energy supply system. The integrated system utilizes co-generation in heat and electricity production. The evaluation is carried out by calculating the energy and money flows for the integrated system and comparing the results to the original system values. No "competing technologies" to the EfW alternative are presented; the evaluation is carried out simply by comparing the original ("existing") system flows to the integrated system flows. The results show that in certain conditions it is feasible to integrate an EfW plant with the existing municipal energy supply system in Finland. However, the conditions for a viable integration may not be so easy to fulfill.     

Gasification of dried sewage sludge: status of the demonstration and the pilot plant

The disposal of sewage sludge from municipal waste water treatment plants is suffering from raising costs.The gasification is an alternative way of treatment, which can reduce the amount of solid residues that must be disposed from a water treatment plant. The produced gas can be used very flexible to produce electrical energy, to burn it very cleanly or to use it for upgrading.The gasification in the fluidised bed and the gas cleaning with the granular bed filter has shown successful operation. A demonstration plant in Balingen was set up in 2002 and rebuilt to a larger throughput in 2010. As a next step a demonstration plant was built in Mannheim and is now at the end of the commissioning phase. Nowadays the product gas is blended with biogas from sludge fermentation and utilized in a gas engine or combustion chamber to produce heat. In the future the process control for a maximized efficiency and the removal of organic and inorganic impurities in the gas will be further improved.     

Numerical simulation of municipal solid waste combustion in a novel two-stage reciprocating incinerator

A mathematical model was presented in this paper for the combustion of municipal solid waste in a novel two-stage reciprocating grate furnace. Numerical simulations were performed to predict the temperature, the flow and the species distributions in the furnace, with practical operational conditions taken into account. The calculated results agree well with the test data, and the burning behavior of municipal solid waste in the novel two-stage reciprocating incinerator can be demonstrated well. The thickness of waste bed, the initial moisture content, the excessive air coefficient and the secondary air are the major factors that influence the combustion process. If the initial moisture content of waste is high, both the heat value of waste and the temperature inside incinerator are low, and less oxygen is necessary for combustion. The air supply rate and the primary air distribution along the grate should be adjusted according to the initial moisture content of the waste. A reasonable bed thickness and an adequate excessive air coefficient can keep a higher temperature, promote the burnout of combustibles, and consequently reduce the emission of dioxin pollutants. When the total air supply is constant, reducing primary air and introducing secondary air properly can enhance turbulence and mixing, prolong the residence time of flue gas, and promote the complete combustion of combustibles. This study provides an important reference for optimizing the design and operation of municipal solid wastes furnace.     

Environmental impact of incineration of calorific industrial waste: Rotary kiln vs. cement kiln

Rotary kiln incinerators and cement kilns are two energy intensive processes, requiring high temperatures that can be obtained by the combustion of fossil fuel. In both processes, fossil fuel is often substituted by high or medium calorific waste to avoid resource depletion and to save costs. Two types of industrial calorific waste streams are considered: automotive shredder residue (ASR) and meat and bone meal (MBM). These waste streams are of current high interest: ASR must be diverted from landfill, while MBM can no longer be used for cattle feeding. The environmental impact of the incineration of these waste streams is assessed and compared for both a rotary kiln and a cement kiln. For this purpose, data from an extensive emission inventory is applied for assessing the environmental impact using two different modeling approaches: one focusing on the impact of the relevant flows to and from the process and its subsystems, the other describing the change of environmental impact in response to these physical flows. Both ways of assessing emphasize different aspects of the considered processes. Attention is paid to assumptions in the methodology that can influence the outcome and conclusions of the assessment. It is concluded that for the incineration of calorific wastes, rotary kilns are generally preferred. Nevertheless, cement kilns show opportunities in improving their environmental impact when substituting their currently used fuels by more clean calorific waste streams, if this improvement is not at the expense of the actual environmental impact.     

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.     

Feasibility of energy recovery from municipal solid waste in an integrated municipal energy supply and waste management system.

A decision-support model for determining the feasibility of a planned energy-from-waste (EfW) investment for an integrated waste management and energy supply system is presented. The aim is to present an easy-to-understand, inexpensive and fast-to-use tool to decision-makers for modelling and evaluating different kinds of processes. Special emphasis is put on forming the model and interpretation of the results of the example case. The simple integrated system management (SISMan) model is presented through a practical example of the use of the model. In the example the viability of the described system is studied by comparing five different cases including different waste-derived fuels (WDF), non-segregated municipal solid waste (MSW) being one of the fuel options. The nominal power output of the EfW plant varied in each case according to the WDF classification. The numeric values for two main variables for each WDF type were determined, the WDF price at the gate of the EfW plant and the waste management fee (WMF) according to the 'polluter pays' -principle. Comparison between the five cases was carried out according to two determinants, the WMF related to each case and the recovery rate related to each case. The numeric values for the constants and variables used in the calculations were chosen as realistically as possible using available data related to the issue. In the example of this paper, the mass-incineration solution ('pure' MSW as a fuel) was found to be the most viable solution for the described system according to the calculations. However, the final decision of the decision-makers might differ from this in the real world due to extra 'fuzzy' information that cannot be reliably included in the calculations. This paper shows that certain key values of modelled systems can be calculated using an easy-to-use tool at the very early stages of a larger design process involving municipal and business partners. The use of this kind of tools could significantly decrease the overall design costs of large systems in the long run by cutting out irrational system options at the very beginning of the planning.     

Energy from Waste – Clean,efficient, renewable: Transitions in combustion efficiency and NOx control

Traditionally EfW (Energy from Waste) plants apply a reciprocating grate to combust waste fuel. An integrated steam generator recovers the heat of combustion and converts it to steam for use in a steam turbine/generator set. This is followed by an array of flue gas cleaning technologies to meet regulatory limitations.Modern combustion applies a two-step method using primary air to fuel the combustion process on the grate. This generates a complex mixture of pyrolysis gases, combustion gases and unused combustion air. The post-combustion step in the first pass of the boiler above the grate is intended to “clean up” this mixture by oxidizing unburned gases with secondary air.This paper describes modifications to the combustion process to minimize exhaust gas volumes and the generation of noxious gases and thus improving the overall thermal efficiency of the EfW plant. The resulting process can be coupled with an innovative SNCR (Selective Non-Catalytic Reduction) technology to form a clean and efficient solid waste combustion system.Measurements immediately above the grate show that gas compositions along the grate vary from 10% CO, 5% H₂ and 0% O₂ to essentially unused “pure” air, in good agreement with results from a mathematical model. Introducing these diverse gas compositions to the post combustion process will overwhelm its ability to process all these gas fractions in an optimal manner. Inserting an intermediate step aimed at homogenizing the mixture above the grate has shown to significantly improve the quality of combustion, allowing for optimized process parameters. These measures also resulted in reduced formation of NO_x (nitrogenous oxides) due to a lower oxygen level at which the combustion process was run (2.6 vol% O_2, wet instead of 6.0 vol% O_2, wet).This reduction establishes optimal conditions for the DyNOR? (Dynamic NO_x Reduction) NO_x reduction process. This innovative SNCR technology is adapted to situations typically encountered in solid fuel combustion. DyNOR? measures temperature in small furnace segments and delivers the reducing reagent to the exact location where it is most effective. The DyNOR? distributor reacts precisely and dynamically to rapid changes in combustion conditions, resulting in very low NO_x emissions from the stack.     

Characterization of municipal solid waste combustion in a grate furnace

The objective of this paper is to evaluate the combustion process of municipal solid waste combustion in a grate furnace both experimentally and numerically by using data of a reference experiment with over-stoichiometric primary air supply. Measurements were carried out inside the combustion chamber of a pilot plant by monitoring temperatures and sampling gaseous combustion products along the bed surface. The data were assessed using elemental and energy balances. Experimental data of the axial temperature profiles of the flue gas, the fuel bed and the grate bars, as well as local gas flows and the flue gas composition measured above the fuel bed along the grate were used to describe the conversion process, including drying and carbon burnout. These data served as input to model the thermo- and fluid dynamic processes of the gas phase above the bed inside the combustion chamber. For this purpose the commercial code FLUENT was employed to carry out the simulations. Thus, the turbulent temperature, flow and species distributions in the combustion chamber of the pilot waste incinerator TAMARA were predicted. The results of the FLUENT modeling showed that under the prevailing conditions the flue gas burnout is almost completed before entering the first flue due to high temperatures, effective mixing and sufficient residence times of the flue gas inside the combustion chamber. This agrees well with the experimental results inside the first flue. On the basis of the above mentioned results, design and parametric studies can be carried out in a more efficient way by saving cost and time.     

The use of commercial and industrial waste in energy recovery systems - A UK preliminary study

With 2020 energy targets set out by the EU fast approaching, the UK is trying to source a higher proportion of its energy from renewable resources. Coupled with this, a growing population and increasing trends in consumer demand have resulted in national waste loads increasing. A possible solution to both issues is energy-from-waste (EfW) technologies. Many studies have focused on municipal solid waste (MSW) as a potential feedstock, but appear to overlook the potential benefits of commercial and industrial waste (C&IW). In this study, samples of C&IW were collected from three North West waste management companies and Lancaster University campus. The samples were tested for their gross and net calorific value, moisture content, ash content, volatile matter, and also elemental composition to determine their suitability in EfW systems. Intra-sample analysis showed there to be little variation between samples with the exception two samples, from waste management site 3, which showed extensive variation with regards to net calorific value, ash content, and elemental analysis. Comparisons with known fuel types revealed similarities between the sampled C&IW, MSW, and refuse derived fuel (RDF) thereby justifying its potential for use in EfW systems. Mean net calorific value (NCV) was calculated as 9.47 MJ/kg and concentrations of sulphur, nitrogen, and chlorine were found to be below 2%. Potential electrical output was calculated using the NCV of the sampled C&IW coupled with four differing energy generation technologies. Using a conventional incinerator with steam cycle, total electrical output was calculated as 24.9 GWh, based on a plant operating at 100,000 tpa. This value rose to 27.0 GWh when using an integrated gasification combined cycle. A final aspect of this study was to deduce the potential total national electrical output if all suitable C&IW were to be used in EfW systems. Using incineration coupled with a steam turbine, this was determined to be 6 TWh, 1.9% of the national demand thereby contributing 6.5% towards the UK’s 2020 renewable electricity target.     

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.     

Alternative strategies for energy recovery from municipal solid waste Part B: Emission and cost estimates

This two-part paper assesses four strategies for energy recovery from Municipal Solid Waste (MSW) by dedicated Waste-To-Energy (WTE) plants. In strategy 1, the residue of Material Recovery (MR) is fed directly to a grate combustor, while in strategy 2 the grate combustor comes downstream of light mechanical treatment. In strategies 3 and 4, the MR residue is converted into Refuse Derived Fuel (RDF), in a fluidized cumbuster bed. The results of Part A, devoted to mass and energy balances, clearly show that pre-treating the MR residue in order to increase the heating value of the feedstock fed to the WTE plant has marginal effects on the energy efficiency of the WTE plant. When considering the efficiency of the whole strategy of waste management, the energy balances show that the more thorough the pre-treatment, the smaller the amount of energy recovered per unit of MR residue. Starting from the heat/mass balances illustrated in Part A, Part B examines the environmental impacts and economics of the various strategies by means of a Life Cycle Assessment (LCA). Results show that treating the MR residues ahead of the WTE plant does not provide environmental or economic benefits. RDF production worsens almost all impact indicators because it reduces net electricity production and thus the displacement of power plant emissions; it also increases costs, because the benefits of improving the quality of the material fed to the WTE plant do not compensate the cost of such improvement.