THERMOSELECT - Gasification Technologies Council

THERMOSELECT - Gasification Technologies Council

THERMOSELECT
THERMOSELECT – An Advanced Field Proven High Temperature Recycling Process
THERMOSELECT S.A.
October 12-15,
2003
Via Naviglio Vecchio 4
6600 Locarno
Switzerland
1
PRESENTATION OUTLINE
THERMOSELECT
• Company Information
• Technology
• Karlsruhe Plant / Germany
• ASR Processing (Automotive Shredder Residue)
• Chiba + Mutsu Plant / Japan
2
COMPANY INFO
THERMOSELECT
¾ Company founded in 1989
¾ 1989 – 1991:
degasification,
Laboratory scale studies of waste
carbonization and gasification
¾ 1991 – 1992:
scale
Development and erection of an industrial
pilot plant in Fondotoce / Italy
¾ 1992 – 1998:
optimization
demonstration
Fondotoce plant operation, process
and technology
¾ 1998 – 1999:
Erection of commercial plants in Karlsruhe /
Germany and in Chiba /Japan
¾ 150 employees, headquarter in Locarno /Switzerland,
manufacturing subsidiary in Dottikon / Switzerland
¾ Licensees:
• JFE Engineering, Japan (Kawasaki Steel + NKK)
• Daewoo Engineering, Korea
3
PROCESS OVERVIEW
THERMOSELECT
H2, CO, CO2, H2O
Waste of all kinds
Synthesis Gas
Production of
1200°C
High Temperature
Reactor
Quench
Synthesis gas scrubbing
Hydrogen
Methanol
Ammonia
or
Power
generation
Scrubber
Sulfur
Process water treatment
Degassing Channel
Clean water
Salt
Press
O2
Homogenization reactor
Zinc Concentrate
2000°C
1600°C
Metals and
Minerals
Oxygen facility
4
SYNTHESIS GAS SCRUBBING
THERMOSELECT
Safety Flare
Syn. gas
Acidic Scrubber
Quench
Heat Exchanger
Degassing
Filter
Feed tank
Alkaline Scrubber
Water lock
De-dusting stage
Desulfurization
Filtration
Filtrate
Regeneration
Sludge
Additive, new
Sedimentation
Additive
Iron Chelate
Sludge
Filtration
Drying
Air
Filtrate
Sludge back feed
Raw water buffer
Syn. gas
scrubbing
Water
treatment
Oxidation
Sulfur
Pure syn. gas
Products
5
THERMAL TREATMENT, GASIFIER
THERMOSELECT
Exothermic Reactions
CO2
CO
2nCO2 + mH2O
C + O2
C + 1/2 O2
2 CnHm + (2n + m/2) O2
Endothermic Reactions
1200 °C
Quench
C + H2O
CO + H2O
C + CO2
CnHm + nH2O
CO + H2
CO2 + H2
2 CO (Boudouard)
nCO + (n + m/2)H2
Controlled injection of
oxygen is used to gasify
organic components at
temperatures up to 2000°C.
The produced synthesis gas
is primarily composed of
H2, CO, CO2
1600 °C
Metal and mineral
constituents are molten
Burner / oxygen lances
2000 °C
Melt cooling
6
SYNTHESIS GAS SHOCK COOLING
THERMOSELECT
The synthesis gas produced
in the gasifier is shockcooled in the quench
immediately downstream.
Cooling takes place in less
than 30 ms.
Quench
1200 °C
Cooling
water
(pH value < 3)
30 ms
70 °C
7
TYPICAL GRANULATE COMPOSITION
THERMOSELECT
Metal and mineral granulate is ready for reuse.
The vitreous mineral granulate leachability
complies with strictest regulations.
Typical metal granulate (wt%)
Typical mineral granulate (wt%)
8
THERMAL TREATMENT, GASIFIER COOLING
THERMOSELECT
The reactor wall consists of a
thermally-insulating refractory lining.
Refractory
The highly stable refractory material is
protected by a slag coating of vitrified
mineral melt.
Inner Cooling
Gasifier interior
Liquid mineral melt runs off the slag
coating.
Slag coating
Outer Cooling
Cooling Elements with Slag Coating
Gasifier Bottom
9
THERMOSELECT PROCESS
9
9
9
9
THERMOSELECT
High Temperature Recycling (> 99.5% Material Recovery)
Lowest Emissions (Dioxin Destroyer, Total << 1 µg/Mg)
Synthesis gas for flexible utilisation (Power, Hydrogen ...)
on site or over-fence
Broad range of wastes can be processed, EC directive:
“If hazardous wastes with a content of more than 1% of
halogenated organic substances, expressed as chlorine,
are incinerated, the temperature has to be raised to 1’100
°C for at least two seconds“
9
Current plants are operated on:
¾ MSW Japan, low inerts, high moisture (Chiba & Mutsu)
¾ MSW Germany, high inerts (Karlsruhe)
¾ Industrial waste Japan (Chiba)
¾ ASR, high Chlorine, high LCV (Karlsruhe & Chiba)
¾ RDF, high LCV (Karlsruhe)
10
MASS BALANCE
THERMOSELECT
Typical mass balance for
Municipal Solid Waste
(MSW)
Oxygen, Natural Gas, Additives
514 kg
Waste
1000 kg
Compression
Degassing
Synthesis Gas Scrubbing
Gasification
Melting
Homogenization
Mineral Material
230 kg
Metals
29 kg
Purified
Synthesis Gas
890 kg
Process Water Treatment
Sulfur
2 kg
Zinc
Salt
Concentrate 10 kg
3 kg
Clean Water
(cooling
tower)
350 kg
11
DIVERSION FROM LANDFILL
THERMOSELECT
Concrete
Sand-Blasting
Road Construction
Vitreous Mineral Granulate
approx. 20-25 % of Input
Iron-Copper Alloy
approx. 1- 3 % of Input
Salt
approx. 1 % of Input
Sulfur
approx. 0.2 - 0.3 % of Input
Zinc-Concentrate
approx. 0.2 - 0.3 % of Input
Metallurgy
Chemical Industry, Additive for
Metallurgy
Chemical Industry,
i.e. Sulfuric Acid Production
Zinc-Recovery
12
ENERGY BALANCE
THERMOSELECT
4 line plant
gas engine power generation
12 MJ/kg Waste
Electricity 1033 kWh/Mg
Synthesis Gas 2423 kWh/Mg
Surplus
Electricity
705 kWh/Mg
Input total
3733 kWh/Mg
Heat Loss
Gas Engines
930 kWh/Mg
Plant E-consumption
328 kWh/Mg
Heat used
internally
460 kWh/Mg
1310 kWh/Mg Rejected Heat
and Plant Requirement
(Evap.)
13
KARLSRUHE
THERMOSELECT
Karlsruhe - Germany
Company:
TESS (Thermoselect Südwest)
Status:
in service
Start-up:
Feb. 1999
Capacity:
225‘000
Mg/a
No. of lines:
3 lines
10 Mg/h each
Heating value:
12‘000
kJ/kg
Syn. gas utilization: steam vessel & steam turbine,
district heating
14
1 4 -Au g -2 0 0 3
7 -Au g -2 0 0 3
3 1 -Ju l-2 0 0 3
2 4 -Ju l-2 0 0 3
1 7 -Ju l-2 0 0 3
1 0 -Ju l-2 0 0 3
3 -Ju l-2 0 0 3
2 6 -Ju n -2 0 0 3
1 9 -Ju n -2 0 0 3
1 2 -Ju n -2 0 0 3
5 -Ju n -2 0 0 3
2 9 -M a y-2 0 0 3
2 2 -M a y-2 0 0 3
1 5 -M a y-2 0 0 3
Throughput [k g/h]
KARLSRUHE – MSW OPERATION DATA
THERMOSELECT
30000
25000
20000
15000
10000
5000
0
15
KARLSRUHE – MSW OPERATION DATA
THERMOSELECT
35000
70
30000
60
25000
50
20000
40
15000
30
Waste [kg/h]
10000
20
Syngas [Nm3/h]
5000
10
Steam [t/h]
M
ay
-0
3
23
-
M
ay
-0
3
22
-
M
ay
-0
3
21
-
M
ay
-0
3
20
-
M
ay
-0
3
0
19
-
18
-
M
ay
-0
3
0
16
Plant Performance Karlsruhe 2002
THERMOSELECT
Overall
1%
23%
0%
0%
Train 1
1%
26%
1%
7%
Train 2
1%
31%
1%
7%
Train 3
1%
27%
1%
7%
76%
66%
62%
65%
100,100
3,535
35,009
1,236
30,691
1,084
34,400
1,215
Forced Outage Rate
0%
9%
10%
10%
Availability
77%
67%
63%
66%
Rated Capacity (mmscf)
9,308
3,103
3,103
3,103
Annual Loading Factor
38%
40%
35%
39%
Product not required
Planned Outages
Outage Power unit (part of planned outage)
Unplanned Outages
Onstream
Yearly Throughput
(metric tons)
(mmscf)
17
THERMOSELECT PLANTS
THERMOSELECT
Kawasaki Steel Chiba Plant - Japan
Company:
Kawasaki Steel Corporation
Status:
In service
Start-up:
Sept. 1999
Capacity:
100‘000
Mg/a
No. of lines:
2 lines
6.25 Mg/h each
Heating value:
8‘500
kJ/kg
Syn. gas utilization: One Jenbacher Gas Engine
and in CC power plant
18
Se
p
O 99
kt
N 99
ov
D 99
ez
Ja 99
n
Fe 00
b
M 00
rz
Ap 00
r
M 00
ai
Ju 00
n
Ju 00
Au l 00
g
Se 00
p
O 00
kt
N 00
ov
D 00
ez
Ja 00
n
Fe 01
b
M 01
rz
Ap 01
r
M 01
ai
Ju 01
n
Ju 01
Au l 01
g
Se 01
p
O 01
kt
N 01
ov
D 01
ez
Ja 01
n
Fe 02
b
M 02
rz
Ap 02
r
M 02
ai
Ju 02
n
Ju 02
Au l 02
g
Se 02
p
O 02
kt
N 02
ov
D 02
ez
Ja 02
n
Fe 03
b
M 03
rz
03
tons/d
CHIBA - THROUGHPUT
300
150
Household
Waste
THERMOSELECT
350
(construction debris, waste plastics, sludge, waste papers, waste woods)
Industrial Waste
250
200
Line 2
100
50
Line 1
0
19
Plant Performance Chiba 2002
THERMOSELECT
Overall
0%
6%
1%
Train 1
0%
6%
6%
Train 2
0%
9%
4%
94%
88%
88%
75,552
2,668
37,563
1,327
37,989
1,342
Forced Outage Rate
1%
6%
4%
Availability
94%
88%
88%
Rated Capacity (mmscf)
4,125
2,062
2,062
Annual Loading Factor
65%
64%
65%
Product not required
Planned Outages
Unplanned Outages
Onstream
Yearly Throughput
(metric tons)
(mmscf)
20
KARLSRUHE PLANT – SHREDDER DUST PROCESSING
THERMOSELECT
End-of-life vehicles
ASR / Shredder-dust
THERMOSELECT
EU end-of-life directive for
vehicles, recycling rates:
¾ 2006 – 85%
¾ 2015 – 95%
21
SHREDDER DUST TEST
THERMOSELECT
Test Procedure:
- Throughput: 428 t ASR
- Time period: 66 h, ca. 3 days from 27.-29. of November 2002
- Mixture: 40 - 55 Gew.-% ASR, mixed with MSW
- Throughput per line: approx. 7.8 t/h (up to 4.3 t/h ASR)
Sampling /Analysis:
- Air emissions
- Granulate
- Sulfur
- Zink concentrate
- mixed salt
22
KARLSRUHE PLANT – SHREDDER DUST COMPOSITION
Parameter
Heating value, LCV
Ignition residue 550°C
Water
Hydrocarbons
Iron
Chloride
Fluoride
Sulfur
Copper
Zinc
Chromium
Tin
Barium
Lead
Antimon
Arsenic
Cadmium
Mercury
kJ/kg
weight-%
weight-%
mg/kg DS
weight-% DS
weight-% DS
weight-% DS
weight-% DS
g/kg DS
g/kg DS
g/kg DS
g/kg DS
g/kg DS
g/kg DS
mg/kg DS
mg/kg DS
mg/kg DS
mg/kg DS
MSW
Literature
7,000 - 10,000
25 - 35
2-5
0.1 - 1
0.01 - 0.02
0.05 - 0.5
0.1 - 2
0.4 - 4
0.2 - 2
0.05 - 0.5
0.1 - 1
0.2 - 2
o.A.**
1-8
3 - 30
0.3 - 10
THERMOSELECT
Trial operation 11/2002
Sample 1 Sample 2 Sample 3
16,940
10,280
11,350
79.3
79.6
79.6
11.8
20.5
23.9
10,500
12.0
10.7
26.6
1.8
1.72
3.18
0.01
0.02
0.01
0.2
0.3
0.2
8.4
3.6
25.6
14.0
9.9
13.5
0.6
0.3
0.5
0.03
0.003
0.01
0.31
0.202
0.42
4.4
2.7
2.4
94
72
226
11.6
10.0
16.5
21.8
25.1
31.3
2.1
4.1
2.6
Sample 4
14,920
78.8
16.4
13.36
3.52
0.01
0.2
5.3
15.0
0.4
0.05
0.56
4.7
512
13.1
37.3
1.6
23
0%
Current emissions are displayed at www.thermoselect-karlsruhe.de
Dioxins / Furans
Sum
Heavy Metals
Cadmium /
Thallium
Total C
Mercury
HF
HCl
CO
NOx
SOx
20%
3
3
3
0,0021 ngTE/m
0,0087 mg/m
0,000014 mg/m
3
3
0,82 mg/m
3
0,03 mg/m
3
3
3
2 mg/m
3
3
3
3
0.01 mg/m
0.2 mg/m
2 mg/m
0, 01 mg/m
3
0,01 ngTE/m
3,24 mg/m
10 mg/m
3
3
3
3
70 mg/m
10 mg/m
52,3 mg/m
3
0.0023 mg/m
0,05 mg/m
nn
3
3,5 mg/m
0,31 mg/m
3 mg/m 3
40%
Dust
ASR TEST – EMISSIONS (average per day)
THERMOSELECT
100%
Law
80%
Permit
60%
Average
2002
ASR
Test
24
ASR TEST – MINERAL GRANULATE COMPOSITION
500%
THERMOSELECT
green - reference before test (MSW)
red - during test (ASR/MSW)
400%
300%
200%
100%
Tin
Zinc
Mercury
Nickel
Copper
Iron
Chromium
Cadmium
Lead
Arsenic
Antimon
0%
25
ASR TEST – MINERAL GRANULATE LEACHABILITY
THERMOSELECT
300%
green - reference before test (MSW)
red - during test (ASR/MSW)
200%
100%
Tin
Zinc
M ercury
Nickel
Copper
Cobalt
Iron
Chrom ium
Cadmium
Lead
Arsenic
Antimon
0%
26
THERMOSELECT PLANTS
THERMOSELECT
Mitsubishi Materials Mutsu Plant - Japan
Company:
Mitsubishi Materials Corporation
Status:
In service
Commercial op.:
April 1st, 2003
Capacity:
140
Mg/d
No. of lines:
2 lines
2.9 Mg/h each
Heating value:
7.1 – 9. 3 MJ/kg
Syn. gas utilization: Two Jenbacher Gas Engines
1.2 MW each
27
CONCLUSIONS
THERMOSELECT
9
Thermoselect plants are extremely environmental friendly
in terms of emissions and resource recovery
9
The Thermoselect process has a multipurpose capability,
various types of wastes with a broad range of heating
values and compositions can be processed in a single
plant
9
With three commercial plants in operation, Thermoselect
technology is now proven
9
Currently, four further plants are under construction in
Japan
28