FG Cleaning Waste

You might also like

Download as pdf or txt
Download as pdf or txt
You are on page 1of 8

W A S T E I N C I N E R A T I O N

that in practice the waste remaining after

A modern flue-gas sorting has to be disposed of by inciner-


ation.

cleaning system for The shortage of suitable landfills makes


incineration – within the framework of total
waste management – the only practicable

waste incineration solution. Nevertheless, a common criticism


of this solution is that a third of the waste
still remains afterwards, mainly in the form of

plants slag. This is only half the truth. While it is


true that incineration reduces the waste to
just a third of its mass, it reduces it at the
same time to one tenth of its volume, and
Since 1990, waste incineration plants in Germany have had to comply with this is what matters most in the context of
Europe’s strictest emissions legislation – a clean-air decree known as landfilling.
the ‘17th BImSchV’. Building on the clean-air limits contained in the 1986
German decree ‘TA-Luft’, it also forms the core of the European Union’s New legislation is more rigorous
guideline for the thermal treatment of hazardous waste that took effect Legislation and regulations applying to
in 1993. Total Cleaning and Recycling (TCR) is a process, developed by waste incineration plants have become far
ABB, which ensures compliance with the ‘17th BImSchV’, in some cases more stringent in recent years. The German
guaranteeing results well below the limits given in it. Because TCR clean-air decree ‘TA-Luft’ was passed in
systems are of modular design, they can be easily retrofitted to older 1986, and in 1990 the emission limits were
incineration plants. Results from a full-scale demonstration system in reduced once more through a further
operation in Hobro, Denmark, confirm the good performance of the new decree known as the ‘17th BImSchV’. The
ABB technology. European Union guideline for the thermal
treatment of hazardous waste that has

P ublic approval of municipal waste inciner-


ation plants is low mainly as a result of the
the impact this pollutant has on the environ-
ment.
existed since 1993 is also largely based on
the stipulations contained in the ‘17th
BImSchV’. Table 1 shows how the limits for
pollutants emitted by facilities that were built More recently, a general rethinking of the emissions and pollutants have been
back in the 1970s and early 1980s. This has situation has become apparent. The con- reduced since the 1986 decree.
led, understandably, to criticism of thermal sensus is that the thermal treatment of the Besides fulfilling these requirements,
disposal as such and fuelled an ongoing waste after sorting – and its avoidance, plant operators are also making a strong
debate about the best way to change the where possible, in the first place – should be effort to utilize the energy produced by the
public’s ‘use and throw-away’ mentality. For tied into a total waste management pro- thermal process and to recover and recycle
some time now, society has perceived gramme. A new German decree regulating the residual materials. The extremely low
waste incineration as a mainstay of this atti- the disposal of domestic waste (‘TA Sied- emission levels have a political goal, namely
tude. lungsabfall’) points the way. This makes it to gain public acceptance of thermal waste
In Germany even new, stricter legislation, unlawful to dump materials with an organic disposal. Although they should not be seen
calling for a drastic two-stage reduction in content of more than 5 percent, meaning as a solution to the overall emissions situ-
flue-gas emissions from waste incineration ation as it applies in Germany, they are
plants and upgrading of older plants in the inevitably providing new benchmarks for
short term has not been able to change this industry as a whole.
perception. Dr. Jürgen Gottschalk
Waste incineration plants equipped with Dr. Peter Buttmann Modern flue-gas cleaning with TCR
modern flue-gas cleaning technology emit ABB Umwelttechnik GmbH The more stringent regulations have led the
practically no dioxins into the atmosphere. environmental control industry to step up its
On the contrary, they act as dioxin sinks, Torgny Johansson development programmes in a dramatic
destroying the dioxins which are naturally ABB Fläkt Industri AB way.
present in the waste and actually lessening ABB has developed its own advanced

ABB Review 1/1996 29


W A S T E I N C I N E R A T I O N

Incineration Bag filter Scrubber Filsorption SCR denox

Ammonia
Natural
H2O gas

Activated
coke

Milk of lime Mixture of


activated
coke and
lime 2

To incinerator

Hg-bearing
activated carbon
Heavy-metal
condensate 3 Gypsum 6
Glass
granules 30 Quantity in kg per tonne of waste
Hydrochloric acid 15 Lime sludge

Vitrification HCl production Gypsum production

TCR process, with resource recovery, for flue-gas cleaning in waste incineration plants 1

process, which it calls Total Cleaning and bag filter, where the dust is removed. The containing heavy metals is also removed
Recycling, or TCR. high efficiency of the bag filter has a very with the dust.
As the process schematic 1 of the positive effect on the performance of the In the first scrubber, quenching is fol-
modular TCR facility shows, the flue gas scrubbing stages, and especially on the lowed by wash-out of the hydrochloric acid
first passes from the incineration grate recovery of resources from the scrubbing (HCl) under acidic conditions. The second
to the heat-recovery boiler and then to a liquids. The majority of the particulate scrubber absorbs the sulfur dioxide. This
solves the initial problem of removing the
principal acidic constituents of the flue

Table 1: gas. In addition, the first scrubber dissolves


Allowed pollutant emissions for waste incineration plants and separates the gaseous heavy metals
(in mg/Nm3, dry, 11 % O2) – average daily values and mean value (eg, mercury) and the residual heavy metal
during sampling
particles.

Pollutants TA Luft ’86 17th BlmSchV EU Guideline The scrubbing stages are followed by
a second bag filter in which a process
Dust 30 10 10 known as filsorption – a name taken from
Carbon monoxide 100 50 50
filtration and adsorption – takes place. The
Organic materials (C tot) 20 10 10
Sulfur oxides as SO2 100 50 50 filsorption filter uses a mixture of activated
Gaseous anorg. comp. of chloride as HCl 50 10 10 coke and lime hydrate, and is largely
Gaseous anorg. comp. of fluorine as HF <5 1 1 responsible for the exceptionally good
Nitrogen oxides as NO2 500 200 –
clean-gas data. It is especially good at
Cd, Tl Y 0.2 0.05 0.05 adsorbing dioxins and furans as well as any
Hg 0.05 0.05 residual mercury left after scrubbing, while it
Sb, As, Pb, Cr, Co, Cu, Mn, Ni, V, Sn – 0.5 0.5 also removes any harmful acids, dust and
Dibenzodioxins/-furans
heavy metals still present. As a result, clean-
in ng/Nm3, dry, 11 % O2 – 0.1 0.1
(Toxic equivalent (TE) in accordance with NATO-CCMS gas values even lower than the detection
limits are achieved.

30 ABB Review 1/1996


W A S T E I N C I N E R A T I O N

Filsorption is offered by ABB as its pre- • The sorbent material used in the filsorp- Further development
ferred alternative to coke bed filters. With tion process is led directly back to the of the dual-alkali process
reactors containing several hundred cubic furnace in order to destroy the dioxins ABB has developed a particularly interesting
meters of activated coke, the latter repre- and furans contained in it. Alternatively, variation of the TCR process for washing
sent a genuine fire hazard. Both processes the material can be vitrified together with out the harmful acidic gases. It combines
employ the highly efficient technology the dust collected in the first filter. the ABB spray scrubber 2 with the dual-
known generically as adsorption. The TCR concept is so new that all the alkali process developed by ABB especially
A direct comparison shows the filsorp- modules making up the facility could not yet for waste incineration plants.
tion process to be better not only in terms of be installed and used together in the same The state of the art is to separate the
safety but also with regard to dust, heavy incineration plant. However, each individual acidic gases hydrogen chloride (HCl) and
metal and carbon monoxide emissions. module has been tested in the field on a sulfur dioxide (SO2) in consecutive scrub-
With regard to all the other components, the large scale. The flue-gas cleaning system, bing stages. Prior to the absorption (ie, dur-
two processes perform at similar levels. for example, is operating in several plants, ing quenching) the flue gas is cooled to its
The denox stage, which employs selec- and reliable emission data with this system wet-bulb temperature by co-current spray-
tive catalytic reduction (SCR), is usually is now readily available. ing of a liquid into the flue-gas flow. In the
positioned by ABB at the end of the flue-
gas cleaning process. The filsorption filter
upstream provides optimum protection for ABB spray scrubber used in combination with the dual-alkali process 2
for washing out harmful acidic gases
the catalyst. Since the denox process can
take place at a temperature of 200 ˚C or 1 Quenching stage 2 HCl stage 3 SO2 stage
lower, long residence times are possible.
Reasons can also be given, however, for
installing the catalyst immediately after the
scrubbers. In this case, a combined catalyst
is used. It first reduces the nitrogen oxides
(NOx) and then oxidizes the organic sub-
stances, in particular the dioxins and furans.
3
The operating temperature with this con-
figuration is about 300 ˚C. Its advantage is
that the dust collected in the filter is prac-
tically free of dioxins.
The residues produced by flue-gas clean-
ing are treated in different process stages:
• The fly ash from the incinerator and the
dust collected in the first bag filter are 2
passed through the DEGLOR process
[1], in which an electrically heated fur-
1
nace melts them into a harmless glassy
slag suitable for use in, eg, sand-blasting
or road construction, plus a ‘heavy metal
concentrate’ which can be processed in
specialized metallurgical plants.
• The draw-off from the scrubbing process
can be treated in different stages (distil-
lation, evaporation, crystallization, filtra-
tion, etc) to recover valuable resources.
Some possible products are hydrochloric
acid, sodium chloride for chlorine-
alkali electrolysis, and gypsum (eg, for
use in manufacturing wall-board).

ABB Review 1/1996 31


W A S T E I N C I N E R A T I O N

Flue-gas Limestone Soda


outlet

Flue-gas
inlet

Lime Gypsum Soda Limestone


Spray scrubber mixing sedimen- mixing sedimen-
SO2 stage tank tation tank tank tation tank

Gypsum
dewatering stage Gypsum

Flow chart of the dual-alkali system developed by ABB. Gypsum is precipitated by this patented process. 3

first scrubber the HCl in the flue gas is uses limestone rather than a caustic soda Important benefits in respect of the SO2
absorbed by an acidic solution comprising solution. Another reason for this preference separation are:
HCl and water. At the top of the HCl stage is that many operators prefer gypsum • Since a clear solution is used, the resis-
very fine droplets of the scrubbing agent are (CaSO4 • 2 H2O) to sodium sulfate as an tance to mass transfer during the ab-
sprayed into the gas flow in the counter-cur- end-product, since the former has more sorption process and oxidation to sulfate
rent direction. The diluted hydrochloric acid commercial uses. is very low.
that is produced collects at the bottom of Although the above considerations • The ratio of the liquid to flue gas in the
the tank and is pumped back to the nozzle weigh heavily, scrubbers using a caustic scrubber is small.
level in the circuit. The scrubbing liquid is soda solution have several clear technologi- • There is only a small pressure drop; the
drawn off and replaced by fresh water cal advantages over those which use lime- residence time is short.
according to the acid concentration. The stone, particularly in the areas of operation To be able to take advantage of the bene-
drawn-off liquid can be processed to obtain and reliability. These benefits can be sum- fits of a scrubber that uses a caustic
concentrated hydrochloric acid, etc. marized as follows: soda solution and produce gypsum at
In the second scrubbing stage the sulfur • All feed material and reaction products the same time, ABB has further develo-
dioxide is absorbed by mixing caustic soda are in the form of aqueous solutions; no ped the so-called dilute mode dual-
or lime hydrate (calcium hydroxide) with the solids are involved. alkali process, modifying it for flue-gas
scrubbing agent to keep it neutral. Use • No protection against erosion has to be cleaning in waste incineration plants. In
of crushed limestone (CaCO3) as a neutral- provided. this process 3 , which has been pat-
izing agent is also possible. Continuous • Since there are no sediments, the liquid ented, the solution drawn off from the
measurement of the pH value is necessary does not have to be circulated to prevent neutral SO2 stage of the scrubber has
in this stage. sedimentation. lime hydrate (Ca(OH)2) added to it.
The type of neutralizing agent chosen will • Only minimal maintenance of the Through this simple ion interchange,
generally depend on the overall costs. Cal- demister is required. gypsum is precipitated and the caustic
cium hydroxide and limestone being much • The alkaline stage can be installed simply soda solution is regenerated:
cheaper than caustic soda, incineration on top of the acid stage, saving floor
plant operators often prefer a scrubber that space as well as costs. Na2SO4 + Ca(OH)2 ––> CaSO4 + 2NaOH

32 ABB Review 1/1996


W A S T E I N C I N E R A T I O N

Although it is usual for the lime hydrate to tation of the sulfate). One of the main goals plant. In addition, the theoretical risk of the
be added in the dry state, lime milk or even of the development work was to ensure that gypsum quality varying was far greater, due
slaked quicklime can also be used. the process has only a minimal effect on the mainly to the operating conditions in a
In a second stage, a very small quantity availability and operation of the scrubber. waste incineration plant fluctuating more
of soda (Na2CO3) is added to the solution This is often the key to reliable operation of strongly than in a power station, where the
regenerated with lime hydrate in order to the incineration plant. The separate process quality of the coal remains relatively con-
replace the Na+ ions lost during the pro- stages also provide numerous possibilities stant. The recovery of products from waste
cess. The use of soda, which is relatively for optimizing plant operation, for example incineration is also a political issue, since
cheap, also has the effect of softening the through the installation of intermediate stor- they are automatically considered to be
regenerated solution according to age tanks or the use of parallel or common ‘dirtier’ than the same material originating
systems for more than one incineration line. from other sources. The goal was to
Na2CO3 + Ca2+ ––> CaCO3 + 2Na+ The scrubber may also be operated with achieve a gypsum quality that would allow
just fresh caustic soda solution if required. disposal in Class I landfills as per the
before it passes back to the scrubber, thus An installation of the type described has German ‘TA Siedlungsabfall’ decree. This
reducing the risk of sedimentation in the been built in the Hobro waste incineration reduces the cost of landfilling substantially,
scrubber cycle. plant in Denmark, allowing full-scale field compared with the alternative of gypsum
The calcium carbonate which is pro- experience to be gained for the first time disposal in Class II landfills, as is usually
duced is precipitated, separated from the with this technology. necessary when the calcium salts come
clear regenerated solution and re-used in Initially, the quality of the gypsum pro- from a treatment plant in which the waste-
the effluent treatment plant. duced in the Hobro plant was evaluated water is still contaminated with heavy
The regeneration process for recovering under the assumption that it would probably metals.
the caustic soda solution takes place in a be disposed of in landfills. This assumption The results from the Hobro demonstra-
separate plant and therefore has no in- was made on the basis of the quantity pro- tion plant were promising from the begin-
fluence on the availability of the scrubber duced in a waste incineration plant usually ning, and gypsum suitable for Class I landfil-
and the chemical reactions. Oxidation of the being much smaller than the amount pro- ling could be produced immediately and
remaining sulfite to sulfate takes place in a duced, for example, in a coal-fired power without problems. The requirements for
separate oxidation tank located in the outlet
of the scrubber’s SO2 stage. Complete
oxidation is easily achieved since both the Separation of sulfur dioxide with the ABB spray scrubber 4
sulfite and the sulfate are present in the (N.tr. = standard condition, dry gas)
dissolved state.
Green SO2, inlet Red SO2, outlet Blue SO2, theoretical equilibrium

2Na2SO3 + O2 ––> 2Na2SO4


mg/m3, N.tr. 600

Control of this process is also easy. The 1500


dose rate for the regenerated NaOH sol- 500
ppm,tr.
ution passed back to the scrubber is con-
trolled via the pH value in the scrubber cir-
400
cuit, while the amount to be drawn off is
1000
regulated according to the level of the liquid
300
in the system. Control of the lime feed rate
is also relatively simple, regulation taking SO2
place in direct proportion to the amount of 200
SO2 separated. This is possible due to the 500
stoichiometric ratio being close to unity. 100
In terms of operating reliability, the com-
bination of NaOH scrubber and dual-
0
alkali system offers good flexibility due to 6.1 6.3 6.5 6.7
separate stages being used for scrubbing, pH
oxidation and NaOH recovery (with precipi-

ABB Review 1/1996 33


W A S T E I N C I N E R A T I O N

Additional optimization of the scrubber


was not necessary. The principal lesson
Hobro has taught is therefore that scrubber
operation is not affected at all by the oper-
ation of the dual-alkali system. From this it
can be concluded that all sodium-based
ABB scrubbers can be retrofitted with a
dual-alkali system. As a rule, other, non-
ABB scrubbers using a caustic soda sol-
ution can also be brought up to the stan-
dard required for retrofitting with an ABB
dual-alkali system.
The demister flushing system in the
Hobro plant was shut down completely for
several weeks, during which time no trace
of sedimentation could be detected. Like-
wise, there were no signs of incrustation in
the scrubber. This shows how effective the
soda is at softening the regenerated caustic
soda solution.

Dual-alkali system
The experience gained in the Hobro inciner-
ation plant mainly concerns the dual-alka-
li system, in which the entire liquid flow from
the scrubber is treated. The tests have
shown that the scrubber and regeneration
system can handle all the operating con-
ditions that could arise in practice. Full-scale
operation was especially important for the
way it helped with the design and fine-tun-
ing of the control system.
Operation on this scale is also necessary
Filsorption stage with scrubber using a sodium hydroxide solution, 5 to obtain reliable mass balances for the
as retrofitted recently in the waste incineration plant at Zirndorf in Germany
combined scrubber and regeneration
system. Tests were carried out both with dry
construction-quality gypsum could also be Operating experience in slaked lime and lime milk.
fulfilled from the start. At about the same the Hobro waste incineration plant Full-scale trials are also important as they
time, several countries began to require provide experience with operation of the in-
waste incineration plants to produce recy- Scrubber dividual components. The only component
clable end-products only. In view of this, The scrubber, which uses a caustic soda that has had to be replaced during the pro-
special emphasis was placed on demon- solution, is a proven ABB design with more gramme is the gypsum dewatering system.
strating the Hobro plant’s capability for pro- than 65 modules; 15 of these are part of the Because the gypsum crystals obtained with
ducing construction-quality gypsum (eg, for waste incineration flue-gas cleaning pro- the new system are considerably larger than
wall-board). cess. Since the scrubber was optimized for those obtained with similar systems and
Tables 2 and 3 compare the achieved this application from the start, emission with the pilot installation in the ABB re-
gypsum quality with the requirements for values are very low 4 . Features that make search center in Växjö, Sweden, the drum
Class I and II landfilling as well as for wall- a decisive contribution to the good results filter had to be replaced by a band filter. The
board manufacture. It can be seen that all include the design of the nozzle lances and advantage of the larger crystals in terms of
the requirements are easily satisfied. the intermediate bottoms. dewatering, washing properties and gyp-

34 ABB Review 1/1996


W A S T E I N C I N E R A T I O N

sum purity were recognized at an early


stage and subsequently put to good use, as Table 2:
the gypsum quality data given in Tables 2 Eluate analysis for gypsum: requirements and results
at Hobro waste incineration plant, Denmark
and 3 show.
Hobro Requirements, Requirements,
The trend to zero emissions results Class I landfill Class II landfill

Operators of waste incineration plants pH 10.3 5.5 – 13 5.5 – 13


equipped with advanced flue-gas cleaning Conductivity µS/cm 2,000 < 10,000 < 50,000
Pb mg/l < 0.1 < 0.2 < 1
technology target zero emissions as their
Cd mg/l < 0.05 < 0.05 < 0.1
operational goal. A prerequisite for this, be- Hg µg/l < 0.5 < 5 < 20
sides high-performance wet scrubbing and Zn mg/l < 0.1 < 2 < 5
F mg/l 4.8 < 5 < 25
catalytic reduction of the nitrogen oxides, is
a filter with a ‘safeguard’ function. The de-
scribed filsorption process performs this
task in an ideal way.
Considerable experience with the new Table 3:
technology is available in Germany, es- Gypsum composition: requirements and results at Hobro waste
incineration plant
pecially with the systems installed in waste
incineration plants in Ingolstadt, Zirndorf Hobro Requirements
results for wall-board
and Bonn. Other installations are currently
under construction or at the planning Gypsum content % 96.8 > 95
stage. All existing German waste inciner- pH 7.6 5–8
Magnesium oxide % 0.005 < 0.1
ation plants have to comply with the 17th Potassium oxide % 0.0002 < 0.06
BImSchV decree by 1996. Chloride ppm 70 < 100
Calcium sulfite % 0.1 < 0.5
The plant in Zirndorf 5 is unique in a Aluminium oxide % 0.023 < 0.3
number of ways. For example, it is the first Iron (III) oxide % 0.031 < 0.15
Silicon dioxide % 0.11 < 2.5
one in Germany to feed the spent sorbent
Ca and Mg carbonate % 0.91 < 1.5
from the filsorption stage back to the incin-
erator. This procedure was approved by the
authorities because the dioxins are de-
stroyed in the furnace and the mercury is
discharged from the acidic scrubber. As a Table 4:
Clean-gas emissions at Zirndorf and Uppsala waste incineration plants
result, an additional residual material has
been avoided. Pollutants Zirndorf Uppsala Relevant limit
The Zirndorf incineration plant [2] was flue-gas rate: flue-gas rate: in 17th
30,000 Nm3/h 200,000 Nm3/h BlmSchV
shut down for a short time in 1990 because mg/m3 mg/m3 mg/m3
the dioxin values measured at the plant
were too high. Installation of an NaOH Total carbon C < 2 nm* 10
Hydrogen chloride HCl < 1 < 1 10
scrubber and filsorption stage took about
Sulfur dioxide SO2 < 2 10 50
four months, and the plant went back on
Hydrogen fluoride HF < 0,1 < 0.1 1
stream in 1991. Nitrogen oxides NOx 425* nm* 200
September 1992 also saw a retrofitted fil- Mercury Hg < 0.006 < 0.001 0.05
sorption stage begin operating in the waste Cadmium and thallium Cd + Tl < 0.002 nm* 0.05
Residual heavy metals 0.011 < 0.02 0.5
incineration plant in Uppsala, Sweden. This
Total dust < 0.6 < 1 10
plant is about seven times larger than the
one in Zirndorf. Table 4 compares the gas ng/m3 TE ng/m3 TE ng/m3 TE
emissions of the two plants with the limits Dioxins/furans PCDD/PCDF < 0.006 < 0.02 0.1
specified by the 17th BImSchV decree.
* The retrofit made no provisions for reduction of this pollutant
It can be seen that several of the values
(nm = not measured)
for clean gas (an exception is the NOx, due

ABB Review 1/1996 35


W A S T E I N C I N E R A T I O N

München Süd, Germany’s first district heating plant based on waste incineration to be equipped with the SCR denox system 6

to the Zirndorf installation only starting up in Waste incineration plants as References


February 1995) lie considerably below the dioxin sinks [1] I. Joichi, J. Balg, C. Wieckert: Detoxifi-
given limits, also that the scale-up did not Waste incineration plants have become a cation of municipal waste incineration resi-
lead to any notable increase in the figures. permanent fixture of modern refuse disposal dues by vitrification. ABB Review 6/7-95,
In the meantime, results from several programmes and are unlikely to be replaced 9–16.
years of large-scale selective catalytic re- by alternative technologies. [2] G. Jungmann: Pollutant emissions re-
duction of NOx in the waste incineration Since the 17th BImSchV decree, all the duced by retrofitting waste incineration
sector have also become available. The first concerns about waste incineration plants plants. ABB Review 2/93, 15–20.
plant in Germany to be equipped with this can be safely said to be no longer based on
technology is the München Süd waste in- fact. Modern waste incineration plants emit Authors’ addresses
cineration facility 6 , in which the flue-gas practically no dioxins; in fact, they act as Dr. Jürgen Gottschalk
exits at a rate of 2 × 240,000 Nm3/h. In this dioxin sinks, since they destroy those dio- Dr. Peter Buttmann
plant the NOx reduction takes place down- xins naturally present in waste. Also, by ABB Umwelttechnik GmbH
stream of a dry flue-gas cleaning process making the organic part of landfilled waste P.O. box 260
with bag filter. Since being installed in 1990 inert they prevent chemical reactions from D-35510 Butzbach
the SCR system has operated trouble-free occurring that could otherwise last dec- Germany
and still works with its original catalysts. ades, possibly with pollutants escaping un- Telefax: +49 6033 60011
A guarantee value of 70 mg/m was given
3
controllably into the environment.
for the NOx emissions in the clean gas. State-of-the-art flue-gas cleaning tech- Torgny Johansson
(This compares with a maximum value of nology for waste incineration plants is today ABB Fläkt Industri AB
600 mg/m3 in the raw gas.) In practice, the new benchmark by which all other in- S-35187 Växjö
NOx values of 50 to 60 mg/m3 are achieved dustrial sectors have to measure their clean Sweden
for the clean gas. air performance. Telefax: +46 470 365 50

36 ABB Review 1/1996

You might also like