Plasma treatment of air pollution control residues

Air pollution control (APC) residues from waste incineration have been blended with silica and alumina and the mix melted using DC plasma arc technology. The chemical composition of the fully amorphous homogeneous glass formed has been determined. Waste acceptance criteria compliance leach testing demonstrates that the APC residue derived glass releases only trace levels of heavy metals (Pb (<0.007mg/kg) and Zn (0.02mg/kg)) and Cl(-) (0.2mg/kg). These are significantly below the limit values for disposal to inert landfill. It is concluded that plasma treatment of APC residues can produce an inert glass that may have potential to be used either in bulk civil engineering applications or in the production of higher value glass-ceramic products.     

Treatment and use of air pollution control residues from MSW incineration: an overview

This work reviews strategies for the management of municipal solid waste incineration (MSWI) residues, particularly solid particles collected from flue gases. These tiny particles may be retained by different equipment, with or without additives (lime, activated carbon, etc.), and depending on the different possible combinations, their properties may vary. In industrial plants, the most commonly used equipment for heat recovery and the cleaning of gas emissions are: heat recovery devices (boiler, superheater and economiser); dry, semidry or wet scrubbers; electrostatic precipitators; bag filters; fabric filters, and cyclones. In accordance with the stringent regulations in force in developed countries, these residues are considered hazardous, and therefore must be treated before being disposed of in landfills. Nowadays, research is being conducted into specific applications for these residues in order to prevent landfill practices. There are basically two possible ways of handling these residues: landfill after adequate treatment or recycling as a secondary material. The different types of treatment may be grouped into three categories: separation processes, solidification/stabilization, and thermal methods. These residues generally have limited applications, mainly due to the fact that they tend to contain large quantities of soluble salts (NaCl, KCl, calcium compounds), significant amounts of toxic heavy metals (Pb, Zn, Cr, Cu, Ni, Cd) in forms that may easily leach out, and trace quantities of very toxic organic compounds (dioxin, furans). The most promising materials for recycling this residue are ceramics and glass-ceramic materials. The main purpose of the present paper is to review the published literature in this field. A range of studies have been summarized in a series of tables focusing upon management strategies used in various countries, waste composition, treatment processes and possible applications.     

Aggregate material formulated with MSWI bottom ash and APC fly ash for use as secondary building material

The main goal of this paper is to obtain a granular material formulated with Municipal Solid Waste Incineration (MSWI) bottom ash (BA) and air pollution control (APC) fly ash to be used as secondary building material. Previously, an optimum concrete mixture using both MSWI residues as aggregates was formulated. A compromise between the environmental behavior whilst maximizing the reuse of APC fly ash was considered and assessed. Unconfined compressive strength and abrasion resistance values were measured in order to evaluate the mechanical properties. From these results, the granular mixture was not suited for certain applications owing to the high BA/APC fly ash content and low cement percentages used to reduce the costs of the final product. Nevertheless, the leaching test performed showed that the concentrations of all heavy metals were below the limits established by the current Catalan legislation for their reutilization. Therefore, the material studied might be mainly used in embankments, where high mechanical properties are not needed and environmental safety is assured.     

Life cycle assessment of disposal of residues from municipal solid waste incineration: recycling of bottom ash in road construction or landfilling in Denmark evaluated in the ROAD-RES model

Two disposal methods for MSWI bottom ash were assessed in a new life cycle assessment (LCA) model for road construction and disposal of residues. The two scenarios evaluated in the model were: (i) landfilling of bottom ash in a coastal landfill in Denmark and (ii) recycling of bottom ash as subbase layer in an asphalted secondary road. The LCA included resource and energy consumption, and emissions associated with upgrading of bottom ash, transport, landfilling processes, incorporation of bottom ash in road, substitution of natural gravel as road construction material and leaching of heavy metals and salts from bottom ash in road as well as in landfill. Environmental impacts associated with emissions to air, fresh surface water, marine surface water, groundwater and soil were aggregated into 12 environmental impact categories: Global Warming, Photochemical Ozone Formation, Nutrient Enrichment, Acidification, Stratospheric Ozone Depletion, Human Toxicity via air/water/soil, Ecotoxicity in water/soil, and a new impact category, Stored Ecotoxicity to water/soil that accounts for the presence of heavy metals and very persistent organic compounds that in the long-term might leach. Leaching of heavy metals and salts from bottom ash was estimated from a series of laboratory leaching tests. For both scenarios, Ecotoxicity(water) was, when evaluated for the first 100 yr, the most important among the twelve impact categories involved in the assessment. Human Toxicity(soil) was also important, especially for the Road scenario. When the long-term leaching of heavy metals from bottom ash was evaluated, based on the total content of heavy metals in bottom ash, all impact categories became negligible compared to the potential Stored Ecotoxicity, which was two orders of magnitudes greater than Ecotoxicity(water). Copper was the constituent that gave the strongest contributions to the ecotoxicities. The most important resources consumed were clay as liner in landfill and the groundwater resource which was potentially spoiled due to leaching of salts from bottom ash in road. The difference in environmental impacts between landfilling and utilization of bottom ash in road was marginal when these alternatives were assessed in a life cycle perspective.     

The use of volcanic soil as mineral landfill liner--III. Heavy metals retention capacity.

The volcanic soil of Southern Chile was tested for its heavy metal retention capacity. The maximum uptakes for CrO4(2-) (CrVI), Cu(2+), Zn(2+) and Pb(2+) were determined to be 2.74, 5.32, 5.86 and 7.44 mg g(-1), respectively. At a slightly alkaline pH value (7.5), it seems that a precipitation-adsorption process was responsible for the Cu(2+) and Zn(2+) uptake onto volcanic soil. All the determined values are of the same order of magnitude as natural zeolites heavy metals adsorption capacities. In addition, the heavy metals diffusion model through a 1 m volcanic soil mineral liner shows breakthrough times of 21.6, 10.2 and 8.9 years, for Pb(2+), Zn(2+) and Cu(2+), respectively, confirming the trend obtained in the adsorption isotherms. The natural volcanic soil of Southern Chile is an interesting material for possible use as landfill mineral basal sealing. It has an appropriate sealing potential (average Kf value of 5.85 x 10(-9) m s(-1)) and a heavy metals retention capacity comparable with natural zeolites. About two-thirds of the agricultural land in Chile (approximately 0.4 million km2) is derived from volcanic ash, suggesting an important soil volume for future landfill projects, that could be obtained in sufficient quantities from urban building activities.     

Case study: Using soil washing/leaching for the removal of heavy metal at the twin cities army ammunition plant

COGNIS TERRAMET® soil leaching and Bescorp soil washing systems have been successfully combined to remediate an ammunition test burn area at the Twin Cities Army Ammunition Plant (TCAAP), New Brighton, Minnesota. This cleanup is the first in the country to successfully combine these two technologies, and it offers a permanent solution to heavy metal remediation. Over 20,000 tons of soil were treated in the project. The cleaned soil remained on-site, and the heavy metal contaminants were removed, recovered, and recycled. Eight heavy metals were removed from the contaminated soil achieving the very stringent cleanup criteria of <175 ppm for residual lead and achieving background concentrations for seven other project metals (antimony, cadmium, chromium, copper, mercury, nickel, and silver). Initial contaminant levels were measured as high as 86,000 ppm lead and 100,000 ppm copper, with average concentrations over 1,600 ppm each. In addition, both live and spent ordnance were removed in the soil treatment plant to meet the cleanup criteria. By combining soil washing and leaching, COGNIS and Bescorp were able to assemble a process which effectively treats all the soil fractions so that all soil material can be returned on-site, no wastewater is generated, and the heavy metals are recovered and recycled. No hazardous waste requiring landfill disposal was generated during the entire remedial operation.     

Air pollution control residues from waste incineration: current UK situation and assessment of alternative technologies

Current disposal options for APC residues in the UK and alternative treatment technologies developed world-wide have been reviewed. APC residues are currently landfilled in the UK where they undergo in situ solidification, although the future acceptability of this option is uncertain because the EU waste acceptance criteria (WAC) introduce strict limits on leaching that are difficult to achieve. Other APC residue treatment processes have been developed which are reported to reduce leaching to below relevant regulatory limits. The Ferrox process, the VKI process, the WES-PHix process, stabilisation/solidification using cementitious binders and a range of thermal treatment processes are reviewed. Thermal treatment technologies convert APC residues combined with other wastes into inert glass or glass-ceramics that encapsulate heavy metals. The waste management industry will inevitably use the cheapest available option for treating APC residues and strict interpretation and enforcement of waste legislation is required if new, potentially more sustainable technologies are to become commercially viable.     

Stabilization/solidification of MSW incineration residues from facilities with different air pollution control systems. Durability of matrices versus carbonation

This paper discusses the stabilisation/solidification process with Portland cement applied to municipal solid waste incineration residues. Two types of residues were considered: fly ash (FA) produced in an electrostatic precipitator, and air pollution control (APC) residues from a semi-dry scrubber process. Cement pastes with different percentages of FA and APC residues were characterised according to their physical properties, the effect of the hydration products and their leaching behaviour. Portland pastes prepared with APC residues showed a rapid setting velocity in comparison with setting time for those pastes substituted with FA residues. Portland cement hydration was retarded in FA pastes. Leaching test results showed that heavy metals (such as Zn, Pb and Cd) and sulphates are immobilised within the paste, whereas chlorides are only partially retained. The carbonation process increases the leachability of S04(2-) and heavy metals such as Zn and Cr.     

Effects of limestone addition and sintering on heavy metal leaching from hazardous waste incineration slag

Hazardous waste incineration (HWI) in rotary kilns and the disposal of the residual slag on landfills play an important role in German waste treatment. In order to save disposal costs the elution behaviour of HWI-slag should be further optimised. Quality-improved slag may be disposed off on cheaper landfill sites still applying to landfill regulations. In a new process-integrated approach hazardous waste is mixed with limestone, which initiates chemical reactions with heavy metals in the rotary kiln yielding new compounds of different solubility. In this work HWI-slag/limestone mixtures are thermally treated and then examined by elution tests. Experimental data indicate that the heavy metals pertinent to landfill class assignment of a HWI-slag share a solubility minimum at a CaO-content of about 15%. Such improved HWI-slags are allowed to be disposed off on cheaper landfill sites. Furthermore, a new combination of thermodynamic calculation methods is applied to predict heavy metal solubility for different process conditions. Used models hold the opportunity to explain the tendencies of heavy metal leaching and propose plausible chemical reactions. With it, a new tool to examine the impact of temperature treatment and slag composition on heavy metal elution from HWI-slag is presented.     

Assessment of long-term pH developments in leachate from waste incineration residues.

Environmental assessment of residue disposal needs to account for long-term changes in leaching conditions. Leaching of heavy metals from incineration residues are highly affected by the leachate pH; the overall environmental consequences of disposing of these residues are therefore greatly influenced by changes in pH over time. The paper presents an approach for assessing pH changes in leachate from municipal solid waste incineration (MSWI) air-pollution-control (APC) residues. Residue samples were subjected to a stepwise batch extraction method in order to obtain residue samples at a range of pH values (similar to common pH-dependence tests), and then on these samples to determine leaching of alkalinity as well as remaining solid phase alkalinity. On a range of APC residues covering various pretreatment and disposal options, this procedure was used to determine leachable and residual alkalinity as a function of pH. Mass balance calculations for typical disposal scenarios were used to provide data on pH as a function of the liquid-to-solid (L/S) ratio in the leaching system. Regardless of residue type and pretreatment, pH was found to stay above 7 for L/S ratios up to about 2000 L kg(-1) corresponding to about 100,000 years in typical landfill scenarios. It was found that pH changes were mainly governed by alkalinity decreases from leaching processes rather than neutralization reactions. The results suggest that leaching testing for assessment purposes should be carried out in the alkaline range, for example, at pH 9. The paper offers a thorough basis for further modelling of incineration residue leaching and for modelling the environmental consequences of landfilling and utilization of these residues.     

Solidification/stabilisation of air pollution control residues using Portland cement: Physical properties and chloride leaching

Portland cement (CEMI) was used to solidify air pollution control (APC) residues from an energy-from-waste plant burning municipal solid waste. APC residue/CEMI mixes were prepared with CEMI additions ranging from 0 to 50 weight% (wt%) of total dry mass and water/solids ratios between 0.40 and 0.80. Isothermal conduction calorimetry was used to assess the effect of APC residues on the hydration of CEMI. Although up to 30wt% additions of APC residues accelerated CEMI hydration, the total heat of hydration during the initial 98h was significantly reduced. Higher levels of APC residues severely inhibited CEMI hydration. The consistence, setting time, compressive strength, porosity and chloride leaching characteristics of the solidified products were determined. As might be expected, increasing the CEMI addition and reducing the water content resulted in increased compressive strengths. All mixes achieved compressive strengths greater than 1MPa at 7 and 28days but only 50wt% samples did not show significant strength reduction when tested after immersion in water. Monolithic leaching tests indicated low physical immobilisation of chloride in the CEMI solidified APC residues, with chloride leaching in excess of relevant UK landfill waste acceptance criteria (WAC). The results of this study show that greater than 50% CEMI additions would be required to effectively treat APC residues to meet current WAC limits.     

Assessment of the possible reuse of MSW coming from landfill mining of old open dumpsites

The present study addresses the theme of recycling potential of old open dumpsites by using landfill mining. Attention is focused on the possible reuse of the residual finer fraction (<4 mm), which constitutes more than 60% of the total mined material, sampled in the old open dumpsite of Lavello (Southern Italy). We propose a protocol of analysis of the landfill material that links chemical analyses and environmental bioassays. This protocol is used to evaluate the compatibility of the residual matrix for the disposal in temporary storages and the formation of “bio-soils” to be used in geo-environmental applications, such as the construction of barrier layers of landfills, or in environmental remediation activities. Attention is mainly focused on the presence of heavy metals and on the possible interaction with test organisms. Chemical analyses of the residual matrix and leaching tests showed that the concentration of heavy metals is always below the legislation limits. Biological acute tests (with Lepidum sativum, Vicia faba and Lactuca sativa) do not emphasize adverse effects to the growth of the plant species, except the bioassay with V. faba, which showed a dose–response effect. The new developed chronic bioassay test with Spartium junceum showed a good adaptation to stress conditions induced by the presence of the mined landfill material. In conclusion, the conducted experimental activities demonstrated the suitability of the material to be used for different purposes.     

Belgian MSWI fly ashes and APC residues: a characterisation study

Municipal Solid Waste Incineration (MSWI) produces different sorts of residues, bottom ash, fly ashes and Air Pollution Control (APC) residues. Generally, fly ashes and APC residues are mixed at the MSWI plant and manage as a sole residue. In this study, fly ashes and APC residues have been sampled separately at different Belgian MSWI plant and analysed by X-ray fluorescence in order to highlight the composition differences that may appear between the solids. Ca and Cl are found to be the major elements in most of the samples. Lithophilic elements, such as Al and Si, are richer in furnace and boiler ashes, as can be expected. Leaching tests also show differences between the residues; leachates from furnace and boiler ashes are alkaline while those from bag filter residues present a pH value of 6, which impacts the leaching of heavy metals (Pb and Zn). The results suggest that it could be advantageous to manage fly ashes and APC residues separately by adjusting the treatment to their specificities.     

Assessment of benefits and risks of landfill materials for agriculture in Eritrea

In Eritrea, farmers have applied landfill materials as fertiliser to their fields for several decades. A sampling scheme in the landfill site of Asmara and selected farmers' fields was carried out to investigate the benefits and risks of using landfill materials for agriculture. Soil samples were collected from farmers' fields (7 samples) and from the Asmara landfill site (12 samples). The samples were analysed for major plant nutrients, heavy metals (Cd, Cr, Cu, Pb, Ni, Hg and Zn), and some physical properties. Nearly 65% (by weight) of the total landfill material mined from the landfill site constituted waste fractions of various substances. The remaining 35% was composed of soil-like materials, which are apparently used to fertilize agricultural soils. The average organic matter, total nitrogen, and available phosphorus contents of soils with landfill material measured 2.4%, 0.13%, and 45 mg kg(-1), respectively. However, soils without landfill material consisted of 1.1 % organic matter, 0.04% total N, and <40 mg kg(-1) of available P. Except for Hg, all the other heavy metals in the landfill site showed values above the permissible limits. In particular, the average concentrations of Cu (913 mg kg(-1)) and Pb (598 mg kg(-1)) in the landfill site were nine-fold and four-fold greater than the allowable limits, respectively. It is, therefore, suggested that composting fresh organic wastes should be considered and tested as an alternative material for fertilising agricultural soils and to maintain the quality of the environment.     

Alterations of municipal solid waste incineration residues in a landfill

Fresh municipal solid waste incineration residues (MSWIR) and a drilling core of 2-10 years old landfilled MSWIR were investigated to determine the alterations due to weathering in a landfill. Physical and geochemical properties and transformations of major components and heavy metals were analyzed for fresh and landfilled residues. Carbonates and hydroxides (10-12vol%) as major mineralogical compositions in the 8-10 years weathered MSWIR were observed by modal analysis of thin sections. Three step sequential extractions indicated that reducible phases, mainly the Fe, Al and Mn hydroxides increased with depth in the landfill. A pH controlled leaching test (including availability test and pH dependent leaching test) was then conducted. Results indicated lower concentrations of leachable contents at pH values from 6 to 10 for the four elements (Pb, Zn, Al and Fe) in the 8-10 years landfilled residues than in the fresh and 1-2 years landfilled residues. This means that 8-10 years weathered MSWIR became more stable than fresh landfilled residues. The reasons for the stabilization of these elements might be the hydration of Al and Fe during weathering in the landfill, which then results in the heavy metals adsorptions of these minerals.     

Percolation and batch leaching tests to assess release of inorganic pollutants from municipal solid waste incinerator residues

In this study, percolation and batch leaching tests were considered in order to characterize the behaviour of air pollution control (APC) residues produced in a municipal solid waste incinerator (MSWI) as a function of the liquid to solid ratio (L/S). This waste is hazardous, and taking into account their physical and chemical properties, leaching of contaminants into the environment is the main concern. In our work the leaching behaviour of toxic heavy metals (Pb, Zn, Cr, Ni and Cu) and inorganics associated with soluble salts (Na, K, Ca and Cl) was addressed. Although pH of the leaching solution is the most important variable, L/S may also play an important role in leaching processes. In our work, results from column and batch tests were compared in terms of concentration (mg/L) and releasing (mg/kg). The APC residues revealed to be hazardous according to both tests, and both Pb and Cl⁻ far exceeded the regulatory thresholds. The material exhibits high solubility, and when the liquid to solid ratio was high, more than 50% can be solubilised. The patterns of release may be in some cases availability or solubility controlled, and the former was easier to identify. When the results from column and batch experiments were compared by representing the cumulative released amounts (in mg/kg) as a function of L/S, both curves match for Zn, Ni, Cu, K, Na, Cl and Ca, but for Cr and Pb a significant difference was observed. In fact, the column experiments revealed that under percolation conditions it should be expected slow releasing of Pb along time. From this study, it can be concluded that the released amounts obtained in batch experiments for a certain L/S should be considered as the worst case for medium term. Some simple models proposed on the literature and based on local equilibrium assumption showed good fitting to experimental data for soluble species (non-reactive solutes).     

Optimizing the APC residue washing process to minimize the release of chloride and heavy metals

An optimization of the air pollution control (APC) residue washing process was carried out to minimize the release of chloride and heavy metals. Taking into account economic parameters such as the consumption of water and reaction time, the best relation found was a S/L ratio of 1/3 during 1 h. At a laboratory scale and according to the values obtained for chloride and heavy metals, the APC residue is classified as non-special according to Catalonian Regulations (Spain). Moreover, the pH of the solution, when MgSO(4) is added during the washing process, may be controlled by the formation of gypsum. In these conditions, the concentration of heavy metals will decrease as a consequence of the formation of their respective insoluble hydroxides. Therefore, the counter-current batch washing process with the addition of small amounts of MgSO(4) is revealed as an economically feasible treatment of the APC residue. This washed residue is ready to be used as secondary material or to be landfilled safely.     

On the ASR and ASR thermal residues characterization of full scale treatment plant

In order to obtain 85% recycling, several procedures on Automotive Shredder Residue (ASR) could be implemented, such as advanced metal and polymer recovery, mechanical recycling, pyrolysis, the direct use of ASR in the cement industry, and/or the direct use of ASR as a secondary raw material. However, many of these recovery options appear to be limited, due to the possible low acceptability of ASR based products on the market. The recovery of bottom ash and slag after an ASR thermal treatment is an option that is not usually considered in most countries (e.g. Italy) due to the excessive amount of contaminants, especially metals. The purpose of this paper is to provide information on the characteristics of ASR and its full-scale incineration residues. Experiments have been carried out, in two different experimental campaigns, in a full-scale tyre incineration plant specifically modified to treat ASR waste.Detailed analysis of ASR samples and combustion residues were carried out and compared with literature data. On the basis of the analytical results, the slag and bottom ash from the combustion process have been classified as non-hazardous wastes, according to the EU waste acceptance criteria (WAC), and therefore after further tests could be used in future in the construction industry. It has also been concluded that ASR bottom ash (EWC – European Waste Catalogue – code 19 01 12) could be landfilled in SNRHW (stabilized non-reactive hazardous waste) cells or used as raw material for road construction, with or without further treatment for the removal of heavy metals. In the case of fly ash from boiler or Air Pollution Control (APC) residues, it has been found that the Cd, Pb and Zn concentrations exceeded regulatory leaching test limits therefore their removal, or a stabilization process, would be essential prior to landfilling the use of these residues as construction material.     

Characterization of a mineral waste resulting from the melting treatment of air pollution control residues

Air pollution control (APC) residues which are generated by municipal solid waste (MSW) incineration show a high-level of pollution potential. In order to stabilize such APC residues, the French power supply company (EDF) is developing a thermal treatment process which leads to the production of a vitrified material. A structural characterization of the vitrified product was carried out by applying complementary investigation methods: XRD, SEM, Raman spectroscopy, EPMA, and data interpretation methods such as mineralogical analysis and principal component analysis (PCA). The major phase of the material was a solid solution of melilite type composed of five end-members: gehlenite (44%), åkermanite (25%), ferri-gehlenite (5%), sodamelilite (14%) and hardystonite (11%). The minor phases identified were spinels and pyroxenes.An ANC leaching test was performed in order to observe the treatment effect on pollutant release. The natural pH was close to 10, and the major element release was less than in the case of untreated APC. This was a consequence of melilite formation. The effect of pH was fundamental for heavy metals release: lower solubilization occurs at pH 10 than at APC’s natural pH (11–12).     

Effects of residues from municipal solid waste landfill on corn yield and heavy metal content

The effects of residues from municipal solid waste landfill, Khon Kaen Municipality, Thailand, on corn (Zea mays L.) yield and heavy metal content were studied. Field experiments with randomized complete block design with five treatments (0, 20, 40, 60 and 80% v/v of residues and soil) and four replications were carried out. Corn yield and heavy metal contents in corn grain were analyzed. Corn yield increased by 50, 72, 85 and 71% at 20, 40, 60 and 80% treatments as compared to the control, respectively. All heavy metals content, except cadmium, nickel and zinc, in corn grain were not significantly different from the control. Arsenic, cadmium and zinc in corn grain were strongly positively correlated with concentrations in soil. The heavy metal content in corn grain was within regulated limits for human consumption.