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.     

国内城市生活垃圾焚烧飞灰研究现状及进展

随着我国经济快速发展及城市化水平提升,城市生活垃圾产量越来越大,焚烧逐渐成为城市生活垃圾处理的主要方式.但焚烧会产生大量的垃圾焚烧飞灰(以下简称飞灰),飞灰属于危险废物.论述了飞灰的来源、成分、特性及危害,介绍了飞灰的处理处置技术:水泥固化技术、化学药剂稳定化技术、熔融固化技术、水热稳定化技术和水泥窑协同处理技术,并分...     

Properties of concrete containing scrap-tire rubber--an overview

Solid waste management is one of the major environmental concerns in the United States. Over 5 billion tons of non-hazardous solid waste materials are generated in USA each year. Of these, more than 270 million scrap-tires (approximately 3.6 million tons) are generated each year. In addition to this, about 300 million scrap-tires have been stockpiled. Several studies have been carried out to reuse scrap-tires in a variety of rubber and plastic products, incineration for production of electricity, or as fuel for cement kilns, as well as in asphalt concrete. Studies show that workable rubberized concrete mixtures can be made with scrap-tire rubber. This paper presents an overview of some of the research published regarding the use of scrap-tires in portland cement concrete. The benefits of using magnesium oxychloride cement as a binder for rubberized concrete mixtures are also presented. The paper details the likely uses of rubberized concrete.     

Combustion characteristics of Malaysian municipal solid waste and predictions of air flow in a rotary kiln incinerator

Malaysia is in dire need of alternatives to landfilling for solid waste management. Recently, landfills have faced the problems of overfilling, overflowing of leachates leading to pollution of water resources, and uncontrolled dust emissions adversely affecting the local environment. With the rising cost of urbanization coupled with the high rate of waste generation, one possible method of waste treatment that is receiving particular attention by the government is incineration. Incineration of solid waste is rather new in Malaysia, with limited usage in handling small sources of waste generation such as the municipal solid waste (MSW) of resort islands; however, its potential in ameliorating the problems associated with solid waste treatment may make it an attractive alternative to landfill. This article presents the results of test runs conducted to investigate the performance of a locally designed and manufactured rotary kiln incinerator (RKI). The test runs were conducted using MSW collected from the Shah Alam municipality. The combustion efficiency was analyzed by looking at the temperature profiles and chemical species concentrations. To complement the combustion characteristics measurements, predictions of the air flow in the incinerator during the process were also investigated. The overall performance of the RKI suggests that it is suitable for treating MSW.     

The practice and challenges of solid waste management in Singapore

This paper presents an overview of the current solid waste management situation in Singapore and provides a brief discussion of the future challenges. Singapore is a small island city-state with a large population, warm climate and high humidity. Over the past two to three decades, rapid industrialization and economic development have caused a tremendous increase in solid waste generation. The yearly disposed solid waste increased from 0.74 million tonnes in 1972 to 2.80 million tonnes in 2000. Solid waste management in Singapore has traditionally been undertaken by the Ministry of Environment (ENV), with the participation of some private sectors in recent years. The hierarchy of solid waste management in Singapore is waste minimization (reduce, reuse and recycle or so-called 3 Rs), followed by incineration and landfill. As land is extremely scarce and only one newly constructed offshore landfill site is available, solid waste incineration has been identified as the most preferred disposal method. Waste minimization, the utilization of incineration ashes, industrial waste management are regarded to be the major challenges in the future.     

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).     

Recycling MSWI bottom and fly ash as raw materials for Portland cement

Municipal solid waste incineration (MSWI) ash is rich in heavy metals and salts. The disposal of MSWI ash without proper treatment may cause serious environmental problems. Recently, the local cement industry in Taiwan has played an important role in the management of solid wastes because it can utilize various kinds of wastes as either fuels or raw materials. The objective of this study is to assess the possibility of MSWI ash reuse as a raw material for cement production. The ash was first washed with water and acid to remove the chlorides, which could cause serious corrosion in the cement kiln. Various amounts of pre-washed ash were added to replace the clay component of the raw materials for cement production. The allowable limits of chloride in the fly ash and bottom ash were found to be 1.75% and 3.50% respectively. The results indicate that cement production can be a feasible alternative for MSWI ash management. It is also evident that the addition of either fly ash or bottom ash did not have any effect on the compressive strength of the clinker. Cement products conformed to the Chinese National Standard (CNS) of Type II Portland cement with one exception, the setting time of the clinker was much longer.     

Utilization of bottom ash from the incineration of separated wastes as a cement substitute.

Waste incineration is still an essential technology in the concept of integrated waste management. Most of the combustion residues are incinerator bottom ash. It has been discovered that incinerator bottom ash from the incineration of separated waste in the primary chamber of the modular two-stage incinerator mainly consists of metal oxides, especially SiO2 and CaO, in proportions that are quite similar to those in cement and so the feasibility of its application as a substitute for cement in concrete was investigated. It was found that after 28 days, the flexural and compressive strengths of the binder using bottom ash were practically comparable with those of a pure cement mixture. The results show that it is reasonable to use a binder containing incinerator bottom ash for applications in which an early-stage lower strength of concrete element is acceptable.     

An alternative method for the treatment of waste produced at a dye and a metal-plating industry using natural and/or waste materials.

The aim of this study was to develop cost-effective, appropriate solidification technologies for treating hazardous industrial wastes that are currently disposed of in ways that may threaten the quality of local groundwater. One major objective was to use materials other than cement, and preferably materials that are themselves wastes, as the solidification additives, namely using wastes to treat wastes or locally available natural material. This research examines the cement-based and lime-based stabilization/solidification (S/S) techniques applied for waste generated at a metal-plating industry and a dye industry. For the lime-based S/S process the following binder mixtures were used: cement kiln dust/ lime, bentonite/lime and gypsum/lime. For the cement-based S/S process three binder mixtures were used: cement kiln dust/cement, bentonite/cement and gypsum/cement. The leachability of the wastes was evaluated using the toxicity characteristic leaching procedure. The applicability and optimum weight ratio of the binder mixtures were estimated using the unconfined compressive strength test. The optimum ratio mixtures were mixed with waste samples in different ratios and cured for 28 days in order to find the S/S products with the highest strength and lowest leachability at the same time. The results of this work showed that the cement-and lime-based S/S process, using cement kiln dust and bentonite as additives can be effectively used in order to treat industrial waste.     

Technological opportunity identification of cement kiln co-processing based on the gap between science and technology

Journal of Material Cycles and Waste Management - Cement kiln co-processing (CKC) is a promising technology for solid waste treatment, which can achieve both goals of energy saving for cement...     

日本生活垃圾焚烧灰渣的资源化利用

日本生活垃圾的焚烧率高达80％,对焚烧灰渣的处理也比较先进,其资源化利用方式主要有在熔融设施进行熔融处理后制成熔融灰渣、作为水泥原料及路基材料等.介绍了日本生活垃圾焚烧灰渣的产生及资源化利用情况,以期对我国处理焚烧灰渣有所借鉴.     

余热电站系统中的水泥窑余热锅炉

主要介绍了应用于水泥窑余热电站系统中的余热锅炉的特点及在设计、应用中应注意的问题。     

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.     

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.     

Municipal solid waste management in China: a comparative analysis

This paper illustrates an overview of the past and present MSWM strategies in China. A comparison is made with MSWM in China, and other developed and developing countries to identify and analyze the problems of existing MSWM, and evaluate some effective suggestion to overcome the limitations. Rapid urbanization and economic growth are the main factors of increasing MSW generation in China. The generating MSW has 55.86 % food waste with high moisture contain due to unavailable source separation. Chinese MSWM is dominated by 60.16 % landfilling, whereas incineration, untreated discharge, and other treatments are 29.84, 8.21, and 1.79 %, respectively. In 2014, a total of 604 sanitary landfills, 188 incineration plants, and 26 other units were used for MSWM. With the magnitude of timing, the increasing rate of incineration unit and disposal capacity is higher than the landfill. In 2004–2014, the disposal capacity of landfill and incineration is increased from 68.89 to 107.44 and 4.49 to 53.3 million tons, respectively. However, the heating value in the majority of Chinese incineration plants is 3000–6700 kJ/kg and the inappropriate leachate treatment can be found in 47 % landfill sites. A proper taxation system for MSW disposal is not fully implemented in China, which has a negative impact on overall MSW recycling. From the comparative study of MSWM, it is revealed that the source separation MSW collection, high energy recovery from incineration plants, appropriate leachate treatment, effective landfill location and management, increase waste recycling and proper taxation system for MSW disposal are essential to improve MSWM in China.     

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.     

Glass recycling in cement production--an innovative approach

An innovative approach of using waste glass in cement production was proposed and tested in a laboratory and cement production plant. The laboratory characterization of 32 types of glass show that the chemical composition of glass does not vary significantly with its color or origin but depends on its application. The alkali content of glass, a major concern for cement production varies from 0 to 22%. For the glass bottles mainly found in Hong Kong waste glasses, the alkali content (Na2O) ranges from 10 to 19% with an average around 15%. There is no significant change of the SO2 content in the gas exhaust of the rotary kiln when about 1.8 t/h of glass bottles were loaded along with the 280-290 t/h raw materials. The content of NOx, mainly depends on the temperature of the kiln, does not show significant change either. The SO3 content of the clinker is comparable with that obtained without the loading of glass. The alkaline content shows a slight increase but still within three times the standard deviation obtained from the statistical data of the past year. The detailed analysis of the quality of the cement product shows that there is not any significant impact of glass for the feeding rate tested.     

Utilization of industrial by-products for the production of controlled low strength materials (CLSM)

Industrial by-products were used for the production of controlled low-strength material (CLSM). CLSM, also known as 'flowable fill' is used as a replacement of compacted soil in cases where the application of the latter is difficult or impossible. The low mechanical requirements (compared with structural concrete) enable the use of industrial by-products for the production of CLSM. In this study cement kiln dust, asphalt dust, coal fly ash, coal bottom ash and quarry waste were tested for the possibility of producing CLSM with large proportions of those wastes. The results showed that in most cases, CLSM with good properties could be made with significant amounts of dust (25-50%w), especially when the dust has some cementing or pozzolanic potential as do fly ash and cement kiln dust.     

Contribution to closing the loop on waste materials: valorization of bottom ash from waste-to-energy plants under a life cycle approach

Incineration has undergone several technology improvements, reducing air emissions and increasing the efficiency of energy and material recovery; however, there is still a long way to go. To analyze the environmental impacts of waste incineration, this study assessed 15 waste fractions that compose municipal waste in Spain, which are grouped as non-inert materials (plastics, paper, cardboard and organic matter), unburned materials (glass and Al) and ferrous materials. Additionally, this paper evaluates the valorization of bottom ash (BA) to produce steel, aluminum and cement in these recycled/recoverable waste fractions. The results depend on the input waste composition and the heating value (HHV) and showed that ferrous and unburned materials had the worst environmental performance due to the null HHV. The valorization of BA in steel, Al and cement production significantly reduced the environmental impact and the consumption of resources. BA recycling for secondary steel and Al production would improve the environmental performance of the combustion of unburned materials and ferrous materials, whereas the use of BA in cement production diminished the consumption of NR for non-inert materials. This is of great interest for organic matter and PC, waste with a low energy production and high heavy metal and sulfur content.     

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.