Gasification and its emission characteristics for dried sewage sludge utilizing a fluidized bed gasifier

Various research has attempted to determine the proper treatment of sewage sludge, including thermal technologies. Efficient thermal technologies have been focused on because of their energy saving/energy recovery. Gasification technology can be considered one of these approaches. In this study, the characteristics of gasification reactions were investigated with the aim of finding fundamental data for utilizing sewage sludge as an energy source. For the experiments on sewage sludge gasification reaction characteristics, a laboratory-scale experimental apparatus was set up with a fluidizing bed reactor of 70-mm inner diameter and 600-mm total height using an electric muffle furnace. The experimental materials were prepared from a sewage treatment plant located in Seoul. The reaction temperature was varied from 630 to 860°C, and the equivalence ratio from 0.1 to 0.3. The gas yields, compositions of product gas, and cold gas efficiencies of product gas were analyzed by GC/TCD and GC/FID installed with a carboxen-1000 column. The experimental results indicated that 800°C, ER 0.2 was an optimum condition for sewage sludge gasification. The maximum yield of product gas was about 44%. Producer gas from experiments was mainly composed of hydrogen, carbon monoxide, carbon dioxide, and methane. The cold gas efficiency of sewage sludge gasification was about 68%. The H₂/CO ratio and CO/CO₂ ratio were about 1.1 and 1.4, respectively, in optimum reaction conditions. Gaseous pollutants such as SO₂, HCl, NH₃, H₂S, and NO₂ were also analyzed at various gasification/combustion conditions, and their gaseous products were compared, showing significantly different oxidized product distributions.     

Evaluation of waste pyrolysis characteristics in a pressurized fluidized bed reactor

To obtain the distribution of fuel components to gas, tar and char in a pressurized fluidized bed waste pyrolyzer, experiments were conducted with a laboratory scale fluidized bed reactor. Waste samples were fed batchwise from the top of the reactor into the fluidized bed of silica sand and pyrolyzed by nitrogen/nitrogen-O2 gas and the effects of pressure, particle size, heating rate and oxygen addition were investigated. In the case of rubber, the char yield tended to increase a little and the tar yield decrease over the pressure of 304-709 kPa. In comparison with the thermogravimetry data it was clearly demonstrated that the char yield from fluidized bed pyrolysis is much lower. A small amount of oxygen addition decreased both tar and char yields but its further increase did not affect them very much.     

Design and first experimental results of a bubbling fluidized bed for air gasification of plastic waste

Plastic wastes have an especially high potential for use as alternative fuels, considering their high heating value and their large and stable availability. They could be used in electricity production based on gasification technologies, wherein electricity is produced in engines by means of the conversion of plastic wastes into a valuable gas. However, there are still some technical barriers to overcome before this technology can access the commercial stage, and further scientific research is needed to gain deeper understanding of the process and to be able to control and optimize it. This research presents the design and first experimental results of a bubbling fluidized bed gasifier conceived for the gasification of actual plastic residues. The experimental tests revealed that the selection and design of the reactor were adequate and proved some of the advantages of using plastic as a fuel, related in part to the absence of ashes and char. A valuable syngas over 5 MJ/m³ was generated, which contained a considerable fraction of methane as well as hydrogen and carbon monoxide as main combustible gases. The highest efficiency was achieved when the equivalence ratio was increased to 0.35, reaching 61 % in terms of cold gas efficiency and 66 % carbon conversion.     

Gasification of waste plastics by steam reforming in a fluidized bed

The process of producing synthetic gas from waste plastics by steam reforming was investigated. To evaluate this process, the steam reforming of the oils derived from low-density polyethylene and polystyrene were carried out using a laboratory-scale fluidized bed of Ni-Al₂O₃ catalysts. The performance of gasification in terms of carbon conversion, gas yield, and gas compositions was examined. Although oils derived from plastics contain many kinds of heavy hydrocarbons and aromatics, they were well gasified at temperatures above 1023 K with a steam/carbon ratio of 3.5 and a weight hourly space velocity of 1 h⁻¹. The hydrogen content of the product gas was very high at approximately 72 vol% for polyethylene-derived oil and 68 vol% for polystyrene-derived oil. These compositions agreed well with the values calculated from chemical equilibrium.     

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%.     

Combustion characteristics of paper mill sludge in a lab-scale combustor with internally cycloned circulating fluidized bed

After performing a series of batch type experiments using a lab-scale combustor, consideration was given to the use of an internally cycloned circulating fluidized bed combustor (ICCFBC) for a paper mill sludge. Operation parameters including water content, feeding mass of the sludge, and secondary air injection ratio were varied to understand their effects on combustion performance, which was examined in terms of carbon conversion rate (CCR) and the emission rates of CO, C(x)H(y) and NO(x). The combustion of paper mill sludge in the ICCFBC was compared to the reaction mechanisms of a conventional solid fuel combustion, characterized by kinetics limited reaction zone, diffusion limited reaction zone, and transition zone. The results of the parametric study showed that a 35% water content and 60 g feeding mass generated the best condition for combustion. Meanwhile, areal mass burning rate, which is an important design and operation parameter at an industrial scale plant, was estimated by a conceptual equation. The areal mass burning rate corresponding to the best combustion condition was approximately 400 kg/hm(2) for 35% water content. The secondary air injection generating swirling flow enhanced the mixing between the gas phase components as well as the solid phase components, and improved the combustion efficiency by increasing the carbon conversion rate and reducing pollutant emissions.     

Treatment of tar pond sludge in a circulating fluidized bed combustor

A series of tests to burn mixtures of tar pond sludge and coal was carried out using a mini‐circulating fluidized bed combustor (mini‐CFBC). During the tests, carbon dioxide, oxygen, carbon monoxide, sulfur dioxide, and nitrogen oxides in the flue gas were monitored continuously. Stack gas sampling was carried out for hydrochloric acid, metals, particulate matter, volatile organic compounds (VOCs), total hydrocarbons, semivolatile organic compounds (SVOCs), dioxins and furans (PCDD/Fs), and polychlorinated biphenyls (PCBs). Results showed that hydrochloric acid, mercury, particulate matter, PCDD/F, and metal concentrations were all below both the current limits and the gas‐release limits to be implemented in 2008 in Canada. The new 2008 emissions limits will reduce the maximum allowable concentrations of most pollutants by half. Thus, the maximum concentration for particulate matter will be 5 mg/m³ (from the current maximum concentration of 10 mg/m³);the maximum concentration for hydrochloric acid will be 5 mg/m³ (from 10 mg/m³); and the‐maximum concentration for dioxins and furans will be 0.032 ng/m toxic equivalent (from 0.08 ng/mcurrently). Sulfur capture efficiency was 89–91 percent. The percentage of fuel nitrogen converted to nitrogen oxides was of the order of 4.7 to 6.1, which is significantly lower than that of conventional pulverized coal‐fired boilers and well within the normal range for fluidized bed combustors (FBCs). PCB and polycyclic aromatic hydrocarbon (PAH) emissions levels were comparable or lower than levels reported in the literature for industrial‐scale FBCs. VOC concentrations were low except for benzene, for which the concentration was higher than that reported for pulverized coal‐fired utility boilers. In addition, carbon monoxide concentration was high at 1,200 to 2,200 parts per million. However, these carbon monoxide concentrations are typical of the mini‐CFBC firing coal. The trials showed that for 10 percent by weight tar pond sludge mixed with 90 percent by weight coal, the combustion was both stable and efficient. The tests demonstrated that CFBC technology is an environmentally sound option for eliminating tar pond waste sludge. © 2005 Wiley Periodicals, Inc.     

循环流化床锅炉灰渣物化性能分析

以石家庄热电厂改造工程拟选用的燃煤及石灰石粉试烧所产生的灰渣实验数据为基础,从灰渣的常量化学成分、颗粒组成、干密度、含水量、透水性、抗剪性等方面,对循环流化床锅炉灰渣的物化性能进行了初步分析。     

Application of a gas-solid fluidized bed separator for shredded municipal bulky solid waste separation

A laboratory-scale gas-solid fluidized bed separator able to separate fractions of 5.6-50mm was used for separation of shredded municipal bulky waste (SBW) into combustibles and incombustibles. In batch-scale tests, it was found that accumulation of SBW in the bottom of the bed significantly reduced the separation efficiency. In this study, stirring was shown to be effective in preventing this accumulation. Flexible sheet materials such as paper and film plastics also significantly decreased the separation efficiency. In batch-scale tests, an overall efficiency of 90% was obtained when flexible materials such as film plastics and paper were excluded from the feed SBW. In continuous feeding tests, purities of the float and sink fractions attained 95% and 86% efficiencies, respectively, with an overall efficiency of 79%. The effect of feedstock shape on separation efficiency was also investigated. This study revealed that large particles can be properly separated on the basis of density, while the shape of the material significantly influenced behavior in the fluidizing bed.     

Co-firing of paper mill sludge and coal in an industrial circulating fluidized bed boiler

Co-firing of coal and paper mill sludge was conducted in a 103 MWth circulating fluidized bed boiler to investigate the effect of the sludge feeding rate on emissions of SOx, NOx, and CO. The preliminary results show that emissions of SOx and Nx decrease with increasing sludge feeding rate, but CO shows the reverse tendency due to the decrease in combustion temperature caused by a large amount of moisture in the sludge. All emissions met the local environmental requirements. The combustion ashes could be recycled as feed materials in the cement manufacturing process.     

以焦末为载体的生物流化床处理生活污水研究

以焦末为载体的生物流化床反应器处理模拟生活污水,考察了水力停留时间HRT、曝气强度、进水COD浓度、回流速率和进水pH值等因素对生物流化床短期内的影响.现条件下,生物流化床处理模拟生活污水的最佳工艺条件为:HRT 2.5～3.0 h、曝气强度45.9 m3/(m2·h)、进水COD浓度不超过2 000 mg/L、回流液速2.48 cm/s、pH值7.0～8.0,此时COD去除率达90％以上.     

The mixing and segregation characteristics of rice straw in a cylindrical bubbling fluidized bed

In the present study, an experiment was performed to investigate the mixing and segregation characteristics of standard sand and rice straw particles in a cylindrical bubbling fluidized bed. The mass ratio (rice straw/standard sand = 0.5–1.25 %) of two particles and superficial gas velocity (0.13–0.18 m/s) were changed as experimental variables. The pressure drop curve and Kramer’s equation were used to determine the minimum fluidization velocity and mixing index, respectively. In all cases, the mixing index was the lowest at U/U _mf = 1.15. Based on the point of U/U _mf = 1.15, the segregation region and mixing region were observed. In the segregation region, mass ratio of 0.75 % showed the lowest mixing index. At the U/U _mf = 1.23 which was selected as the starting of fast pyrolysis considering residence time and the previous fast pyrolysis experiment, mass ratio of 1.25 % showed the highest mixing index which was 0.90.     

Integrated drying and incineration of wet sewage sludge in combined bubbling and circulating fluidized bed units

An original integrated drying and incineration technique is proposed to dispose of sewage sludge with moisture content of about 80% in a circulating fluidized bed. This system combines a bubbling fluidized bed dryer with a circulating fluidized bed incinerator. After drying, sewage sludge with moisture less than 20% is transported directly and continuously from the fluidized bed dryer into a circulating fluidized bed incinerator. Pilot plant results showed that integrated drying and incineration is feasible in a unique single system. A 100 t/d Sewage Sludge Incineration Demonstration Project was constructed at the Qige sewage treatment plant in Hangzhou City in China. The operational performance showed that the main operation results conformed to the design values, from which it can be concluded that the scale-up of this technique is deemed both feasible and successful.     

Nitrogen evolution during the co-combustion of hydrothermally treated municipal solid waste and coal in a bubbling fluidized bed

Nitrogen evolution was studied during the co-combustion of hydrothermally treated municipal solid wastes (HT MSW) and coal in a bubbling fluidized bed (BFB). HT MSW blending ratios as 10%, 20% and 30% (wt.%) were selected and tested at 700, 800, 900 °C. Emissions of NO and N₂O from blends were measured and compared with the results of mono-combustion trials. Moreover, concentrations of precursors like NH₃ and HCN were also quantified. The results are summarized as follows: NO emissions were predominant in all the cases, which rose with increasing temperature. The blending of HT MSW contributed to the NO reduction. N₂O emissions decreased with temperature rising and the blending of HT MSW also presented positive effects. At 30% HT MSW addition, both NO and N₂O emissions showed the lowest values (391.85 ppm and 55.33 ppm, respectively at 900 °C). For the precursors, more HCN was detected than NH₃ and both played important roles on the gas side nitrogen evolution.     

An innovative example of herb residues recycling by gasification in a fluidized bed

A utilization way of herb residues is designed to convert herb residues to gas fuel in industrial-scale by a circulating fluidized bed gasifier in this paper. The product gas is used in the production of Chinese medicine, and the heat of the flue gas from the boiler can be used in herb residues drying to realize the energy recycling and no herb residues discharge. The gasification characteristics of herb residues in the circulating fluidized bed of 300 kg/h were investigated for about 200 h. The results indicated that the gas composition and tar yield were affected by biomass flow rate, equivalence ratio (ER), moisture content and char circulating. The lower heating value of product gas was 4–5 MJ/m³ using herb residues as feedstock. When mean biomass flow rate was at 5.5 kg m^?2 s^?1 and ER at 0.35, the product gas reached a good condition with lower heating value of 4.89 MJ/m³ and cold gas efficiency of 62.36%. When the moisture content changed from 12.5% to 18.7%, the concentrations of H₂, CO and CO₂ changed from 4.66% to 6.92%, 11.23% to 10.15%, and 16.55% to 17.82% respectively, and the tar content in gas decreased from 15.1 g/m³ to 14.4 g/m³ when the moisture content increased from 12.5% to 15.4%. There are metal oxides in the ash of herb residues, especially CaO, MgO, K₂O, Al₂O₃, and Fe₂O₃ which have obvious function on tar catalytic decomposition. The ash that attaches to the char particles can decrease the tar yield and improve the quality of gas after returning to the gasifier.     

Valorisation of waste tyre by pyrolysis in a moving bed reactor

The aim of this work is to assess the behaviour of a moving bed reactor, based on a screw transporter design, in waste tyre pyrolysis under several experimental conditions. Waste tyre represents a significant problem in developed countries and it is necessary to develop new technology that could easily process big amounts of this potentially raw material. In this work, the influence of the main pyrolysis process variables (temperature, solid residence time, mass flow rate and inert gas flow) has been studied by a thorough analysis of product yields and properties. It has been found that regardless the process operational parameters, a total waste tyre devolatilisation is achieved, producing a pyrolytic carbon black with a volatile matter content under 5 wt.%. In addition, it has been proven that, in the range studied, the most influencing process variables are temperature and solid mass flow rate, mainly because both variables modify the gas residence time inside the reactor. In addition, it has been found that the modification of these variables affects to the chemical properties of the products. This fact is mainly associated to the different cracking reaction of the primary pyrolysis products.     

Characterisation of polycyclic aromatic hydrocarbons in flue gas and residues of a full scale fluidized bed combustor combusting non-hazardous industrial waste

This paper studies the fate of PAHs in full scale incinerators by analysing the concentration of the 16 EPA-PAHs in both the input waste and all the outputs of a full scale Fluidized Bed Combustor (FBC). Of the analysed waste inputs i.e. Waste Water Treatment (WWT) sludge, Refuse Derived Fuel (RDF) and Automotive Shredder Residue (ASR), RDF and ASR were the main PAH sources, with phenanthrene, fluoranthene and pyrene being the most important PAHs. In the flue gas sampled at the stack, naphthalene was the only predominant PAH, indicating that the PAHs in FBC’s combustion gas were newly formed and did not remain from the input waste. Of the other outputs, the boiler and fly ash contained no detectable levels of PAHs, whereas the flue gas cleaning residue contained only low concentrations of naphthalene, probably adsorbed from the flue gas. The PAH fingerprint of the bottom ash corresponded rather well to the PAH fingerprint of the RDF and ASR, indicating that the PAHs in this output, in contrast to the other outputs, were mainly remainders from the PAHs in the waste inputs. A PAH mass balance showed that the total PAH input/output ratio of the FBC ranged from about 100 to about 2600 depending on the waste input composition and the obtained combustion conditions. In all cases, the FBC was clearly a net PAH sink.     

Modeling of mercury sorption by activated carbon in a confined,a semi-fluidized,and a fluidized bed

A process model was developed to simulate elemental mercury sorption by activated carbon in three distinct beds, namely a confined, a semi-fluidized, and a fluidized bed. The model involved the coupling of a kinetic model based on the mechanisms of surface equilibrium and external mass transfer, and a material balance model based on the tank-in-series approach. For surface equilibrium, three different equilibrium laws were used in the model, namely the Henry's Law, the Langmuir isotherm and the Freundlich isotherm. Literature mercury sorption data were used to determine the best-fit values of parameters for these equilibrium expressions. The parameter-fitted model was then used to simulate mercury sorption processes in the three distinct beds. The simulation parameters were mercury concentration, gas flow rate, adsorption temperature and the degree of semi-fluidization. The simulation results have indicated that the model is capable of describing the literature available mercury sorption data. All the three surface equilibrium laws appear to simulate the adsorption profiles equally well mainly because the sorption process occurs in an extremely low concentration range. The simulation results for the three distinct beds have suggested that the confined bed has the best mercury control performance; however, it generates the highest pressure-drop across the bed. A fluidized bed creates the least pressure drop; however, its sorption performance is poor. A semi-fluidized bed offers acceptable performance with affordable pressure-drops and can be a practical candidate for the process.     

Polycyclic aromatic hydrocarbon (PAH) emission from co-firing municipal solid waste (MSW) and coal in a fluidized bed incinerator

Polycyclic aromatic hydrocarbons (PAH) emissions from a commercial municipal solid waste incinerator (MSWI) were studied. A MSW–coal mixture and coal only were used as fuel for the fluidized bed incinerator. Seven sampling points were chosen according to the classified four PAH emission pathways: flue gas, residue, ash and water. The mixture of MSW and coal resulted in PAH emission more than that of coal only, and PAH emission increased with increasing MSW mass percentage. Calcium oxide (CaO) or calcium carbonate (CaCO₃) was added as a desulfurizer. PAH emission also changed with different desulfurizers because of their different influences on heat balance. The PAH toxic equivalent (TEQ) of all operating conditions was also examined, showing that total daily PAH emission from MSWI can be determined.     

Using multivariate regression modeling for sampling and predicting chemical characteristics of mixed waste in old landfills

Municipal solid waste landfills pose a threat on environment and human health, especially old landfills which lack facilities for collection and treatment of landfill gas and leachate. Consequently, missing information about emission flows prevent site-specific environmental risk assessments. To overcome this gap, the combination of waste sampling and analysis with statistical modeling is one option for estimating present and future emission potentials. Optimizing the tradeoff between investigation costs and reliable results requires knowledge about both: the number of samples to be taken and variables to be analyzed.This article aims to identify the optimized number of waste samples and variables in order to predict a larger set of variables. Therefore, we introduce a multivariate linear regression model and tested the applicability by usage of two case studies. Landfill A was used to set up and calibrate the model based on 50 waste samples and twelve variables. The calibrated model was applied to Landfill B including 36 waste samples and twelve variables with four predictor variables.The case study results are twofold: first, the reliable and accurate prediction of the twelve variables can be achieved with the knowledge of four predictor variables (Loi, EC, pH and Cl). For the second Landfill B, only ten full measurements would be needed for a reliable prediction of most response variables. The four predictor variables would exhibit comparably low analytical costs in comparison to the full set of measurements. This cost reduction could be used to increase the number of samples yielding an improved understanding of the spatial waste heterogeneity in landfills.Concluding, the future application of the developed model potentially improves the reliability of predicted emission potentials. The model could become a standard screening tool for old landfills if its applicability and reliability would be tested in additional case studies.