Alternative strategies for energy recovery from municipal solid waste Part A: Mass and energy balances

This two-part paper assesses four strategies for energy recovery from municipal solid waste (MSW) by dedicated waste-to-energy (WTE) plants generating electricity through a steam cycle. The feedstock is the residue after materials recovery (MR), assumed to be 35% by weight of the collected MSW. In strategy 1, the MR residue is fed directly to a grate combustor. In strategy 2, the MR residue is first subjected to light mechanical treatment. In strategies 3 and 4, the MR residue is converted into RDF, which is combusted in a fluidized bed combustor. To examine the relevance of scale, we considered a small waste management system (WMS) serving 200,000 people and a large WMS serving 1,200,000 people. A variation of strategy 1 shows the potential of cogeneration with district heating. The assessment is carried out by a Life Cycle Analysis where the electricity generated by the WTE plant displaces electricity generated by fossil fuel-fired steam plants. Part A focuses on mass and energy balances, while Part B focuses on emissions and costs. Results show that treating the MR residue ahead of the WTE plant reduces energy recovery. The largest energy savings are achieved by combusting the MR residue "as is" in large scale plants; with cogeneration, primary energy savings can reach 2.5% of total societal energy use.     

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.     

Material and energy recovery in integrated waste management systems: project overview and main results

This paper describes the context, the basic assumptions and the main findings of a joint research project aimed at identifying the optimal breakdown between material recovery and energy recovery from municipal solid waste (MSW) in the framework of integrated waste management systems (IWMS). The project was carried out from 2007 to 2009 by five research groups at Politecnico di Milano, the Universities of Bologna and Trento, and the Bocconi University (Milan), with funding from the Italian Ministry of Education, University and Research (MIUR). Since the optimization of IWMSs by analytical methods is practically impossible, the search for the most attractive strategy was carried out by comparing a number of relevant recovery paths from the point of view of mass and energy flows, technological features, environmental impact and economics. The main focus has been on mature processes applicable to MSW in Italy and Europe. Results show that, contrary to a rather widespread opinion, increasing the source separation level (SSL) has a very marginal effects on energy efficiency. What does generate very significant variations in energy efficiency is scale, i.e. the size of the waste-to-energy (WTE) plant. The mere value of SSL is inadequate to qualify the recovery system. The energy and environmental outcome of recovery depends not only on "how much" source separation is carried out, but rather on "how" a given SSL is reached.     

Material and energy recovery in integrated waste management systems: the potential for energy recovery

This article is part of a set of six coordinated papers reporting the main findings of a research project carried out by five Italian universities on "Material and energy recovery in Integrated Waste Management Systems (IWMS)". An overview of the project and a summary of the most relevant results can be found in the introductory article of the series. This paper describes the work related to the evaluation of mass and energy balances, which has consisted of three major efforts (i) development of a model for quantifying the energy content and the elemental compositions of the waste streams appearing in a IWMS; (ii) upgrade of an earlier model to predict the performances of Waste-to-Energy (WtE) plants; (iii) evaluation of mass and energy balances of all the scenarios and the recovery paths considered in the project. Results show that not only the amount of material available for energy recovery is significantly higher than the Unsorted Residual Waste (URW) left after Separate Collection (SC), because selection and recycling generate significant amounts of residues, but its heating value is higher than that of the original, gross waste. Therefore, the energy potential of what is left after recycling is always higher than the complement to 100% of the Source Separation Level (SSL). Also, increasing SSL has marginal effects on the potential for energy recovery: nearly doubling SSL (from 35% to 65%) reduces the energy potential only by one fourth. Consequently, even at high SSL energy recovery is a fundamental step of a sustainable waste management system. Variations of SSL do bring about variations of the composition, heating value and moisture content of the material fed to WtE plants, but these variations (i) are smaller than one can expect; (ii) have marginal effects on the performances of the WtE plant. These considerations suggest that the mere value of SSL is not a good indicator of the quality of the waste management system, nor of its energy and environmental outcome. Given the well-known dependence of the efficiency of steam power plants with their power output, the efficiency of energy recovery crucially depends on the size of the IWMS served by the WtE plant. A fivefold increase of the amount of gross waste handled in the IWMS (from 150,000 to 750,000 tons per year of gross waste) allows increasing the electric efficiencies of the WtE plant by about 6-7 percentage points (from 21-23% to 28.5% circa).     

Simulation of the flue gas cleaning system of an RDF incineration power plant

Because of the stringent pollutant emission standards introduced with the European Union guidelines for waste incineration, it is very important to optimize the flue gas cleaning systems which are able to result in a low environmental impact according to the emission limits. In this paper a thermochemical model has been proposed for the simulation of the flue gas cleaning system of an RDF incineration plant. The model simulates the operation of the flue-gas treatment section and the combustion section by using a simplified approach. The combustion includes the grate incinerator and the post-combustion chamber, while the cleaning section includes the NO(x) reduction process (urea injection) and the scrubbing of SO(2) and HCl (Ca(OH)(2) as sorbent). The modelling has been conducted by means of ASPEN PLUS code. The simulation results have been validated with the operating data. The model proposed by the authors can be a useful tool in both evaluating the efficiency of the gas cleaning system by verifying the environmental pollution of an incinerator power plant in nominal operating conditions and in forecasting the efficiency of the cleaning system in off-design operating conditions.     

Hot waste-to-energy flue gas treatment using an integrated fluidised bed reactor

This paper describes an innovative process to increase superheated steam temperatures in waste-to-energy (WTE) plants. This solution is mainly characterised by a fluidised bed reactor in which hot flue gas is treated both chemically and mechanically. This approach, together with gas recirculation, increases the energy conversion efficiency, and raises the superheated steam temperature without decreasing the useful life of the superheater. This paper presents new experimental data obtained from the test facility installed at the Hera S.p.A. WTE plant in Forlì, Italy; discusses changes that can be implemented to increase the duration of experimental testing; offers suggestions for the design of an industrial solution.     

Perspectives and limits for cement kilns as a destination for RDF

RDF, the high calorific value fraction of MSW obtained by conventional separation systems, can be employed in technological plants (mainly cement kilns) in order to obtain a useful energy recovery. It is interesting and important to evaluate this possibility within the general framework of waste-to-energy solutions. The solution must be assessed on the basis of different aspects, namely: technological features and clinker characteristics; local atmospheric pollution; the effects of RDF used in cement kilns on the generation of greenhouse gases; the economics of conventional solid fuels substitution and planning perspectives, from the point of view of the destination of RDF and optimal cement kiln policy. The different experiences of this issue throughout Europe are reviewed, and some applications within Italy are also been considered. The main findings of the study are that the use of RDF in cement kilns instead of coal or coke offers environmental benefits in terms of greenhouse gases, while the formation of conventional gaseous pollutants is not a critical aspect. Indeed, the generation of nitrogen oxides can probably be lower because of lower flame temperatures or lower air excess. The presence of chlorinated micro-pollutants is not influenced by the presence of RDF in fuel, whereas depending on the quality of the RDF, some problems could arise compared to the substituted fuel as far as heavy metals are concerned, chiefly the more volatile ones.     

CCA-treated wood disposed in landfills and life-cycle trade-offs with waste-to-energy and MSW landfill disposal

Chromated copper arsenate (CCA)-treated wood is a preservative treated wood construction product that grew in use in the 1970s for both residential and industrial applications. Although some countries have banned the use of the product for some applications, others have not, and the product continues to enter the waste stream from construction, demolition and remodeling projects. CCA-treated wood as a solid waste is managed in various ways throughout the world. In the US, CCA-treated wood is disposed primarily within landfills; however some of the wood is combusted in waste-to-energy (WTE) facilities. In other countries, the predominant disposal option for wood, sometimes including CCA-treated wood, is combustion for the production of energy. This paper presents an estimate of the quantity of CCA-treated wood entering the disposal stream in the US, as well as an examination of the trade-offs between landfilling and WTE combustion of CCA-treated wood through a life-cycle assessment and decision support tool (MSW DST). Based upon production statistics, the estimated life span and the phaseout of CCA-treated wood, recent disposal projections estimate the peak US disposal rate to occur in 2008, at 9.7 million m(3). CCA-treated wood, when disposed with construction and demolition (C&D) debris and municipal solid waste (MSW), has been found to increase arsenic and chromium concentrations in leachate. For this reason, and because MSW landfills are lined, MSW landfills have been recommended as a preferred disposal option over unlined C&D debris landfills. Between landfilling and WTE for the same mass of CCA-treated wood, WTE is more expensive (nearly twice the cost), but when operated in accordance with US Environmental Protection Agency (US EPA) regulations, it produces energy and does not emit fossil carbon emissions. If the wood is managed via WTE, less landfill area is required, which could be an influential trade-off in some countries. Although metals are concentrated in the ash in the WTE scenario, the MSW landfill scenario releases a greater amount of arsenic from leachate in a more dilute form. The WTE scenario releases more chromium from the ash on an annual basis. The WTE facility and subsequent ash disposal greatly concentrates the chromium, often oxidizing it to the more toxic and mobile Cr(VI) form. Elevated arsenic and chromium concentrations in the ash leachate may increase leachate management costs.     

Material and energy recovery in integrated waste management systems. An evaluation based on life cycle assessment

This paper reports the environmental results, integrated with those arising from mass and energy balances, of a research project on the comparative analysis of strategies for material and energy recovery from waste, funded by the Italian Ministry of Education, University and Research. The project, involving the cooperation of five University research groups, was devoted to the optimisation of material and energy recovery activities within integrated municipal solid waste (MSW) management systems. Four scenarios of separate collection (overall value of 35%, 50% without the collection of food waste, 50% including the collection of food waste, 65%) were defined for the implementation of energetic, environmental and economic balances. Two sizes of integrated MSW management system (IWMS) were considered: a metropolitan area, with a gross MSW production of 750,000 t/year and an average province, with a gross MSW production of 150,000 t/year. The environmental analysis was conducted using Life Cycle Assessment methodology (LCA), for both material and energy recovery activities. In order to avoid allocation we have used the technique of the expansion of the system boundaries. This means taking into consideration the impact on the environment related to the waste management activities in comparison with the avoided impacts related to the saving of raw materials and primary energy. Under the hypotheses of the study, both for the large and for the small IWMS, the energetic and environmental benefits are higher than the energetic and environmental impacts for all the scenarios analysed in terms of all the indicators considered: the scenario with 50% separate collection in a drop-off scheme excluding food waste shows the most promising perspectives, mainly arising from the highest collection (and recycling) of all the packaging materials, which is the activity giving the biggest energetic and environmental benefits. Main conclusions of the study in the general field of the assessment of the environmental performance of any integrated waste management scheme address the importance of properly defining, beyond the design value assumed for the separate collection as a whole, also the yields of each material recovered; particular significance is finally related to the amount of residues deriving from material recovery activities, resulting on average in the order of 20% of the collected materials.     

Environmental analysis of a construction and demolition waste recycling plant in Portugal – Part II: Environmental sensitivity analysis

Part I of this study deals with the primary energy consumption and CO₂eq emissions of a 350 tonnes/h construction and demolition waste (CDW) recycling facility, taking into account incorporated, operation and transportation impacts. It concludes that the generated impacts are mostly concentrated in operation and transportation, and that the impacts prevented through material recycling can be up to one order of magnitude greater than those generated.However, the conditions considered for the plant’s operation and related transportation system may, and very likely will, vary in the near future, which will affect its environmental performance. This performance is particularly affected by the plant’s installed capacity, transportation fuel and input CDW mass. In spite of the variations in overall primary energy and CO₂eq balances, the prevented impacts are always higher than the generated impacts, at least by a factor of three and maybe even as high as 16 times in particular conditions. The analysis indicates environmental performance for variations in single parameters, except for the plant’s capacity, which was considered to vary simultaneously with all the others. Extreme best and worst scenarios were also generated to fit the results into extreme limits.     

Life cycle assessment of sewage sludge co-incineration in a coal-based power station

A life cycle assessment was conducted to evaluate the environmental and economic effects of sewage sludge co-incineration in a coal-fired power plant. The general approach employed by a coal-fired power plant was also assessed as control. Sewage sludge co-incineration technology causes greater environmental burden than does coal-based energy production technology because of the additional electricity consumption and wastewater treatment required for the pretreatment of sewage sludge, direct emissions from sludge incineration, and incinerated ash disposal processes. However, sewage sludge co-incineration presents higher economic benefits because of electricity subsidies and the income generating potential of sludge. Environmental assessment results indicate that sewage sludge co-incineration is unsuitable for mitigating the increasing pressure brought on by sewage sludge pollution. Reducing the overall environmental effect of sludge co-incineration power stations necessitates increasing net coal consumption efficiency, incinerated ash reuse rate, dedust system efficiency, and sludge water content rate.     

Waste battery treatment options: Comparing their environmental performance

Waste consumer batteries are recycled using different routes based on hydrometallurgical and pyrometallurgical processes. Two hydrometallurgical and two pyrometallurgical treatment scenarios are compared starting from an average composition of Belgian waste batteries. The environmental performance is compared using life cycle analysis (LCA). The recycling rate is studied through mass balance calculation.Each treatment scenario results in a specific recycling rate. The environmental impact and benefits also vary between the treatment options. There is no such thing as a typical hydrometallurgical or pyrometallurgical treatment. When applying a hydrometallurgical treatment scenario, the focus lies on zinc and iron recycling. When allowing manganese recycling, the energy demand of the hydrometallurgical process increases considerably. Both pyrometallurgical options recycle zinc, iron and manganese. According to the LCA, none of the treatment scenarios performs generally better or worse than the others. Each option has specific advantages and disadvantages. The Batteries Directive 2006/66/EC sets out a recycling rate of 50% for consumer waste batteries. Based on metal recycling alone, the mass balances show that the target is difficult to obtain.     

Fundamental study of the behavior of chlorine during the combustion of single RDF

A fundamental study of the combustion characteristics and the de-HCl behavior of a single refuse-derived fuel (RDF) pellet was carried out to explain the de-HCl phenomena of RDF during fluidized bed combustion and to provide data for the development of high efficiency power generation technology using RDF. In this research, combustion and pyrolysis experiments were carried out in an electrical furnace using a series of model and actual RDF samples. The de-HCl capability of Ca(OH)2 in RDF was evaluated by measuring the emission fraction of HCl in the flue gas and the capture fraction of Cl in the residue. It was found that the capture fraction of Cl components in the residue increased from 0 to nearly 70% when the molar ratio of Ca/Cl was changed from 0 to around 13. Apparently, the capture fraction also decreased with increasing oxygen concentration in the feed gas. The devolatilization process of RDF was confirmed to be a very important part of de-HCl process. The effect of temperature profile of the RDF pellet on the de-HCl process, as it varies with the heating rate of RDF and the oxygen concentration in the vicinity of the sample, is discussed.     

Review and meta-analysis of 82 studies on end-of-life management methods for source separated organics

This article reports on a literature review and meta-analysis of 82 studies, mostly life cycle assessments (LCAs), which quantified end-of-life (EOL) management options for organic waste. These studies were reviewed to determine the environmental preferability, or lack thereof, for a number of EOL management methods such as aerobic composting (AC), anaerobic digestion (AD), gasification, combustion, incineration with energy recovery (often denoted as waste-to-energy incineration), mechanical biological treatment, incineration without energy recovery (sometimes referenced by just the word “incineration”), and landfill disposal with and without energy recovery from generated methane. Given the vast differences in boundaries as well as uncertainty and variability in results, the LCAs among the 82 studies provided enough data and results to make conclusions regarding just four EOL management methods – aerobic composting, anaerobic digestion, mass burn waste-to-energy (WTE), and landfill gas-to-energy (LFGTE). For these four, the LCAs proved sufficient to determine that aerobic composting and anaerobic digestion are both environmentally preferable to either WTE or LFGTE in terms of climate change impacts.For climate change, LCA results were mixed for WTE versus LFGTE. Furthermore, there is a lack of empirically reliable estimates of the amount of organics input to AD that is converted to energy output versus remaining in the digestate. This digestate can be processed through aerobic composting into a compost product similar to the compost output from aerobic composting, assuming that the same type of organic materials are managed under AD as are managed via AC. The magnitude of any trade-off between generation of energy and production of compost in an AD system appears to be critical for ranking AC and AD for differing types of organics diversion streams. These results emphasize how little we generally know, and exemplify the fact that in the reviewed literature no single EOL management method consistently topped all other management options across all environmental impacts, and that future studies must strive to match existing analytical boundaries and alternatives assessed to increase knowledge if as a community we expect to be able to make even more generalized conclusions.     

Mass,energy and material balances of SRF production process. Part 2: SRF produced from construction and demolition waste

In this work, the fraction of construction and demolition waste (C&D waste) complicated and economically not feasible to sort out for recycling purposes is used to produce solid recovered fuel (SRF) through mechanical treatment (MT). The paper presents the mass, energy and material balances of this SRF production process. All the process streams (input and output) produced in MT waste sorting plant to produce SRF from C&D waste are sampled and treated according to CEN standard methods for SRF. Proximate and ultimate analysis of these streams is performed and their composition is determined. Based on this analysis and composition of process streams their mass, energy and material balances are established for SRF production process. By mass balance means the overall mass flow of input waste material stream in the various output streams and material balances mean the mass flow of components of input waste material stream (such as paper and cardboard, wood, plastic (soft), plastic (hard), textile and rubber) in the various output streams of SRF production process. The results from mass balance of SRF production process showed that of the total input C&D waste material to MT waste sorting plant, 44% was recovered in the form of SRF, 5% as ferrous metal, 1% as non-ferrous metal, and 28% was sorted out as fine fraction, 18% as reject material and 4% as heavy fraction. The energy balance of this SRF production process showed that of the total input energy content of C&D waste material to MT waste sorting plant, 74% was recovered in the form of SRF, 16% belonged to the reject material and rest 10% belonged to the streams of fine fraction and heavy fraction. From the material balances of this process, mass fractions of plastic (soft), paper and cardboard, wood and plastic (hard) recovered in the SRF stream were 84%, 82%, 72% and 68% respectively of their input masses to MT plant. A high mass fraction of plastic (PVC) and rubber material was found in the reject material stream. Streams of heavy fraction and fine fraction mainly contained non-combustible material (such as stone/rock, sand particles and gypsum material).     

Automotive shredder residue (ASR) characterization for a valuable management

Car fluff is the waste produced after end-of-life-vehicles (ELVs) shredding and metal recovery. It is made of plastics, rubber, glass, textiles and residual metals and it accounts for almost one-third of a vehicle mass. Due to the approaching of Directive 2000/53/EC recycling targets, 85% recycling rate and 95% recovery rate in 2015, the implementation of automotive shredder residue (ASR) sorting and recycling technologies appears strategic. The present work deals with the characterization of the shredder residue coming from an industrial plant, representative of the Italian situation, as for annual fluxes and technologies involved. The aim of this study is to characterize ASR in order to study and develop a cost effective and environmentally sustainable recycling system. Results show that almost half of the residue is made of fines and the remaining part is mainly composed of polymers. Fine fraction is the most contaminated by mineral oils and heavy metals. This fraction produces also up to 40% ashes and its LHV is lower than the plastic-rich one. Foam rubber represents around half of the polymers share in car fluff. Moreover, some chemical–physical parameters exceed the limits of some parameters fixed by law to be considered refuse derived fuel (RDF). As a consequence, ASR needs to be pre-treated in order to follow the energy recovery route.     

Mass,energy and material balances of SRF production process. Part 1: SRF produced from commercial and industrial waste

This paper presents the mass, energy and material balances of a solid recovered fuel (SRF) production process. The SRF is produced from commercial and industrial waste (C&IW) through mechanical treatment (MT). In this work various streams of material produced in SRF production process are analyzed for their proximate and ultimate analysis. Based on this analysis and composition of process streams their mass, energy and material balances are established for SRF production process. Here mass balance describes the overall mass flow of input waste material in the various output streams, whereas material balance describes the mass flow of components of input waste stream (such as paper and cardboard, wood, plastic (soft), plastic (hard), textile and rubber) in the various output streams of SRF production process. A commercial scale experimental campaign was conducted on an MT waste sorting plant to produce SRF from C&IW. All the process streams (input and output) produced in this MT plant were sampled and treated according to the CEN standard methods for SRF: EN 15442, EN 15443. The results from the mass balance of SRF production process showed that of the total input C&IW material to MT waste sorting plant, 62% was recovered in the form of SRF, 4% as ferrous metal, 1% as non-ferrous metal and 21% was sorted out as reject material, 11.6% as fine fraction, and 0.4% as heavy fraction. The energy flow balance in various process streams of this SRF production process showed that of the total input energy content of C&IW to MT plant, 75% energy was recovered in the form of SRF, 20% belonged to the reject material stream and rest 5% belonged with the streams of fine fraction and heavy fraction. In the material balances, mass fractions of plastic (soft), plastic (hard), paper and cardboard and wood recovered in the SRF stream were 88%, 70%, 72% and 60% respectively of their input masses to MT plant. A high mass fraction of plastic (PVC), rubber material and non-combustibles (such as stone/rock and glass particles), was found in the reject material stream.     

Simulation of a waste incineration process with flue-gas cleaning and heat recovery sections using Aspen Plus

In the present paper, the modeling of a dual-purpose plant for the production of electrical and thermal energy from the heat treatment of solid wastes is presented. Particularly, the process has been modeled by using the Aspen Plus Shell, with the aim of performing a study about the applicability of this software in the simulation of a solid waste incineration process, which involves complex gas-solid reactions where the solids are referred to as "non-conventional". The model is developed to analyze and quantify the expected benefits associated with refuse derived fuel (RDF) thermal utilization; thus attention is focused on the performance of the energy recovery section.     

Characterization of municipal solid waste combustion in a grate furnace

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

Comparative environmental analysis of waste brominated plastic thermal treatments

The aim of this research activity is to investigate the environmental impact of different thermal treatments of waste electric and electronic equipment (WEEE), applying a life cycle assessment methodology. Two scenarios were assessed, which both allow the recovery of bromine: (A) the co-combustion of WEEE and green waste in a municipal solid waste combustion plant, and (B) the staged-gasification of WEEE and combustion of produced syngas in gas turbines. Mass and energy balances on the two scenarios were set and the analysis of the life cycle inventory and the life cycle impact assessment were conducted. Two impact assessment methods (Ecoindicator 99 and Impact 2002+) were slightly modified and then used with both scenarios. The results showed that scenario B (staged-gasification) had a potentially smaller environmental impact than scenario A (co-combustion). In particular, the thermal treatment of staged-gasification was more energy efficient than co-combustion, and therefore scenario B performed better than scenario A, mainly in the impact categories of "fossil fuels" and "climate change". Moreover, the results showed that scenario B allows a higher recovery of bromine than scenario A; however, Br recovery leads to environmental benefits for both the scenarios. Finally the study demonstrates that WEEE thermal treatment for energy and matter recovery is an eco-efficient way to dispose of this kind of waste.