Fluidized bed gasification of waste-derived fuels

Five alternative waste-derived fuels obtained from municipal solid waste and different post-consumer packaging were fed in a pilot-scale bubbling fluidized bed gasifier, having a maximum feeding capacity of 100 kg/h. The experimental runs utilized beds of natural olivine, quartz sand or dolomite, fluidized by air, and were carried out under various values of equivalence ratio. The process resulted technically feasible with all the materials tested. The olivine, a neo-silicate of Fe and Mg with an olive-green colour, has proven to be a good candidate to act as a bed catalyst for tar removal during gasification of polyolefin plastic wastes. Thanks to its catalytic activity it is possible to obtain very high fractions of hydrogen in the syngas (between 20% and 30%), even using air as the gasifying agent, i.e. in the most favourable economical conditions and with the simplest plant and reactor configuration. The catalytic activity of olivine was instead reduced or completely inhibited when waste-derived fuels from municipal solid wastes and aggregates of different post-consumer plastic packagings were fed. Anyhow, these materials have given acceptable performance, yielding a syngas of sufficient quality for energy applications after an adequate downstream cleaning.     

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.     

Fluid bed gasification – Plasma converter process generating energy from solid waste: Experimental assessment of sulphur species

Often perceived as a Cinderella material, there is growing appreciation for solid waste as a renewable content thermal process feed. Nonetheless, research on solid waste gasification and sulphur mechanisms in particular is lacking. This paper presents results from two related experiments on a novel two stage gasification process, at demonstration scale, using a sulphur-enriched wood pellet feed.Notable SO₂ and relatively low COS levels (before gas cleaning) were interesting features of the trials, and not normally expected under reducing gasification conditions. Analysis suggests that localised oxygen rich regions within the fluid bed played a role in SO₂’s generation. The response of COS to sulphur in the feed was quite prompt, whereas SO₂ was more delayed. It is proposed that the bed material sequestered sulphur from the feed, later aiding SO₂ generation. The more reducing gas phase regions above the bed would have facilitated COS – hence its faster response. These results provide a useful insight, with further analysis on a suite of performed experiments underway, along with thermodynamic modelling.     

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.     

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.     

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.     

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.     

Co-gasification of solid waste and lignite - a case study for Western Macedonia

Co-gasification of solid waste and coal is a very attractive and efficient way of generating power, but also an alternative way, apart from conventional technologies such as incineration and landfill, of treating waste materials. The technology of co-gasification can result in very clean power plants using a wide range of solid fuels but there are considerable economic and environmental challenges. The aim of this study is to present the available existing co-gasification techniques and projects for coal and solid wastes and to investigate the techno-economic feasibility, concerning the installation and operation of a 30MW(e) co-gasification power plant based on integrated gasification combined cycle (IGCC) technology, using lignite and refuse derived fuel (RDF), in the region of Western Macedonia prefecture (WMP), Greece. The gasification block was based on the British Gas-Lurgi (BGL) gasifier, while the gas clean-up block was based on cold gas purification. The competitive advantages of co-gasification systems can be defined both by the fuel feedstock and production flexibility but also by their environmentally sound operation. It also offers the benefit of commercial application of the process by-products, gasification slag and elemental sulphur. Co-gasification of coal and waste can be performed through parallel or direct gasification. Direct gasification constitutes a viable choice for installations with capacities of more than 350MW(e). Parallel gasification, without extensive treatment of produced gas, is recommended for gasifiers of small to medium size installed in regions where coal-fired power plants operate. The preliminary cost estimation indicated that the establishment of an IGCC RDF/lignite plant in the region of WMP is not profitable, due to high specific capital investment and in spite of the lower fuel supply cost. The technology of co-gasification is not mature enough and therefore high capital requirements are needed in order to set up a direct co-gasification plant. The cost of electricity estimated was not competitive, compared to the prices dominating the Greek electricity market and thus further economic evaluation is required. The project would be acceptable if modular construction of the unit was first adopted near operating power plants, based on parallel co-gasification, and gradually incorporating the remaining process steps (gas purification, power generation) with the aim of eventually establishing a true direct co-gasification plant.     

Co-gasification of municipal solid waste and material recovery in a large-scale gasification and melting system

This study evaluates the effects of co-gasification of municipal solid waste with and without the municipal solid waste bottom ash using two large-scale commercial operation plants. From the viewpoint of operation data, there is no significant difference between municipal solid waste treatment with and without the bottom ash. The carbon conversion ratios are as high as 91.7% and 95.3%, respectively and this leads to significantly low PCDD/DFs yields via complete syngas combustion. The gross power generation efficiencies are 18.9% with the bottom ash and 23.0% without municipal solid waste bottom ash, respectively. The effects of the equivalence ratio are also evaluated. With the equivalence ratio increasing, carbon monoxide concentration is decreased, and carbon dioxide and the syngas temperature (top gas temperature) are increased. The carbon conversion ratio is also increased. These tendencies are seen in both modes.Co-gasification using the gasification and melting system (Direct Melting System) has a possibility to recover materials effectively. More than 90% of chlorine is distributed in fly ash. Low-boiling-point heavy metals, such as lead and zinc, are distributed in fly ash at rates of 95.2% and 92.0%, respectively. Most of high-boiling-point heavy metals, such as iron and copper, are distributed in metal. It is also clarified that slag is stable and contains few harmful heavy metals such as lead. Compared with the conventional waste management framework, 85% of the final landfill amount reduction is achieved by co-gasification of municipal solid waste with bottom ash and incombustible residues. These results indicate that the combined production of slag with co-gasification of municipal solid waste with the bottom ash constitutes an ideal approach to environmental conservation and resource recycling.     

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.     

Two stage fluid bed-plasma gasification process for solid waste valorisation: technical review and preliminary thermodynamic modelling of sulphur emissions

Gasification of solid waste for energy has significant potential given an abundant feed supply and strong policy drivers. Nonetheless, significant ambiguities in the knowledge base are apparent. Consequently this study investigates sulphur mechanisms within a novel two stage fluid bed-plasma gasification process. This paper includes a detailed review of gasification and plasma fundamentals in relation to the specific process, along with insight on MSW based feedstock properties and sulphur pollutant therein. As a first step to understanding sulphur partitioning and speciation within the process, thermodynamic modelling of the fluid bed stage has been performed. Preliminary findings, supported by plant experience, indicate the prominence of solid phase sulphur species (as opposed to H₂S) - Na and K based species in particular. Work is underway to further investigate and validate this.     

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.     

End-of-life vehicle recycling and automobile shredder residue management in Japan

The Japanese Government introduced the Law on Recycling of End-of-Life Vehicles (ELV Recycling Law) in 2002. This law requires manufacturers to retrieve chlorofluorocarbons (CFCs), airbags, and automobile shredder residue (ASR) from ELVs and to properly recycle the remaining materials. This framework is compared with European ELV directives. Pilot-scale incineration plant testing has revealed a greater formation of by-product persistent organic pollutants (POPs) during the primary combustion of ASR compared to normal municipal solid waste. This may be attributed to the abundance of chlorine, Cu, and Fe in ASR, as Cu and Fe have been found to catalyze the formation of POPs under certain conditions. However, most by-product POPs were destroyed by the secondary combustion, and almost all were removed after flue gas treatment. The direct melting system is a shaft-type gasification and melting technology that has proved effective in many municipal solid waste applications. This system can be applied to ASR recycling for effective decomposition of brominated flame retardants and polybrominated dioxins.     

Mathematical modelling of MSW incineration on a travelling bed

The rising popularity of incineration of municipal solid waste (MSW) calls for detailed mathematical modelling and understanding of the incineration process. In this paper, governing equations for mass, momentum and heat transfer for both solid and gaseous phases in a moving bed in a solid-waste incineration furnace are described and relevant sub-models are presented. The burning rates of volatile hydrocarbons in the moving bed of solids are limited not only by the reaction kinetics but also the mixing of the volatile fuels with the under-fire air. The mixing rate is averaged across a computation cell and correlated to a number of parameters including local void fraction of the bed, gas velocity and a length scale comparable to the particle size in the bed. A correlation equation is also included to calculate the mixing in the freeboard area immediately next to the bed surface. A small-scale fixed bed waste incinerator was built and test runs were made in which total mass loss from the bed, temperature and gas composition at different locations along the bed height were measured. A 2-D bed-modelling program (FLIC) was developed which incorporates the various sub-process models and solves the governing equations for both gases and solids. Thermal and chemical processes are mainly confined within a layer about 5-9 times in thickness of the averaged particle size in the burning bed. For a large part of the burning process, the total mass loss rate was constant until the solid waste was totally dried out and a period of highly rising CO emission followed. The maximum bed temperature was around 1200 K. The whole burning process ended within 60 min. Big fluctuations in species concentration were observed due to channelling and subsequent 'catastrophic' changes in the local bed conditions. Reasonably good agreement between modelling and measurements has been achieved. Yet the modelling work is complicated by the channelling phenomenon in the bed. Numerical simulations without consideration of the channelling effect produced very good agreement with experiments concerning the total mass loss, but significant discrepancy exists for temperature and gas composition profiles. Transient phenomena such as the breaking of waste particles and the "catastrophic" creation of new burning channels occurring during waste incineration is a vital area requiring further investigation at the fundamental level. The underlying theory of bed behaviour must be extended to include these transient events.     

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.     

Application of the WAMED model to landfilling

A cost methodology is proposed for evaluating the ecological-economic efficiency of a municipal solid waste management scheme based on the recommendations of cost-benefit analysis and the full-cost accounting methodology for municipal solid waste management. The methodology employs the previously introduced waste managements’ efficient decision (WAMED) model and the company statistical business tool for environmental recovery (COSTBUSTER) indicator. A case study presents the practical application of the proposed cost-benefit analysis-based theory to the landfilling concept currently applied in Kalmar, Sweden. It is concluded that the presented provisions for evaluation of the ecological-economic efficiency of a municipal solid waste management scheme reflect a novel integrated approach to solving the problem of simultaneously decreasing the negative impacts of municipal solid waste on the environment and the health of the population while providing an information support tool for decision making in municipal solid waste management at regional and municipal levels to improve small-and medium-sized company competitiveness in particular.     

Prediction of syngas quality for two-stage gasification of selected waste feedstocks

This paper compares the syngas produced from methane with the syngas obtained from the gasification, in a two-stage reactor, of various waste feedstocks. The syngas composition and the gasification conditions were simulated using a simple thermodynamic model. The waste feedstocks considered are: landfill gas, waste oil, municipal solid waste (MSW) typical of a low-income country, the same MSW blended with landfill gas, refuse derived fuel (RDF) made from the same MSW, the same RDF blended with waste oil and a MSW typical of a high-income country. Energy content, the sum of H2 and CO gas percentages, and the ratio of H2 to CO are considered as measures of syngas quality. The simulation shows that landfill gas gives the best results in terms of both H2+CO and H2/CO, and that the MSW of low-income countries can be expected to provide inferior syngas on all three quality measures. Co-gasification of the MSW from low-income countries with landfill gas, and the mixture of waste oil with RDF from low-income MSW are considered as options to improve gas quality.     

Catalyst durability in steam reforming of thermally decomposed waste wood

Thermal gasification and reforming technologies applicable over a wide temperature range were investigated for high efficiency and for the calorific value of the gas evolved from organic waste such as woody debris. The durability of the reforming catalyst and the availability of catalyst regeneration were investigated using laboratory-scale catalytic reformers and a gasifier. Commercial Ni-based catalyst and calcined limestone (CaO) were applied to the reforming reaction. The results of woody waste gasification and reforming revealed the hydrogen concentration produced to be sustained at a high catalyst temperature of 1123 K, which prevented the catalyst from deactivating. The results also indicated that catalyst regeneration by air oxidation at the same temperature would be effective for enhancing catalytic activity.     

Biomass waste gasification - can be the two stage process suitable for tar reduction and power generation?

A pilot scale gasification unit with novel co-current, updraft arrangement in the first stage and counter-current downdraft in the second stage was developed and exploited for studying effects of two stage gasification in comparison with one stage gasification of biomass (wood pellets) on fuel gas composition and attainable gas purity. Significant producer gas parameters (gas composition, heating value, content of tar compounds, content of inorganic gas impurities) were compared for the two stage and the one stage method of the gasification arrangement with only the upward moving bed (co-current updraft). The main novel features of the gasifier conception include grate-less reactor, upward moving bed of biomass particles (e.g. pellets) by means of a screw elevator with changeable rotational speed and gradual expanding diameter of the cylindrical reactor in the part above the upper end of the screw. The gasifier concept and arrangement are considered convenient for thermal power range 100-350 kW_th. The second stage of the gasifier served mainly for tar compounds destruction/reforming by increased temperature (around 950 °C) and for gasification reaction of the fuel gas with char. The second stage used additional combustion of the fuel gas by preheated secondary air for attaining higher temperature and faster gasification of the remaining char from the first stage. The measurements of gas composition and tar compound contents confirmed superiority of the two stage gasification system, drastic decrease of aromatic compounds with two and higher number of benzene rings by 1-2 orders. On the other hand the two stage gasification (with overall ER = 0.71) led to substantial reduction of gas heating value (LHV = 3.15 MJ/Nm³), elevation of gas volume and increase of nitrogen content in fuel gas. The increased temperature (>950 °C) at the entrance to the char bed caused also substantial decrease of ammonia content in fuel gas. The char with higher content of ash leaving the second stage presented only few mass% of the inlet biomass stream.