German Experience:

MSW Solutions for Industries &

Urban Centres in India

Waste-to-Energy Options

WASTECH

Gandhinagar November 2014

Dr Juergen Porst

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Dr Juergen Porst DR PORST INTERNATIONAL Environmental Consulting Bangalore INDIA

CURRENT SITUATION MSW India:

Approach not up-to-date

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Existing landfills Urban Centre

Daily MSW generation

Garbage transport

� Currently no further treatment of waste at existing landfills

& no capping (inadequate management)

� Negative environmental impact, health risks

� Neighbour protests against existing landfills

� No land for more landfills available

⇒ Avoid / Abandon landfilling

⇒ Re-claim areas of existing landfills

Solution for MSW:

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Existing landfills Daily MSW generation

Garbage transport

SEGREGATION

WASTE INCINERATION

Waste-to-Energy

German TECHNOLOGY

Bio-degradables Non-bio-degradables

RDF

URBAN BIO-MINING

Anaerobic

Treatment,

Composting

Garbage

transport

Capping landfills

- No odour, dust, etc.

-Leachate

minimisation

- No environmental

impact

- Less health risks

Inerts

Important Issues & Requirements

System capabilities:

• Highly flexible systems

• High energy co-generation

• Sturdy equipment

• Largely simple technology

• Automated but not too much

• Technical robustness

• Long-life cycle

• Same systems for unsegregated waste or RDF

• Low footprint

Challenging Indian conditions:

• High moisture content

• Varying MSW composition

• Fluctuating quantities

• Calorific value low

• Inconsistencies in waste delivery

• Climate (dry / wet waste)

• Unskilled labourers

• Decentralised solutions needed

• Segregation: yes or no

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Incineration (W-t-E Systems)

Made in Germany

• Most advanced State-of-the art

• Most recent technology

• 100 % Environment friendly through zero emission

• Full air pollution control

• In line with all German and EU-Standards

• Residues for re-use, not for landfilling

• Small decentralised plants

• Very long life time, sturdy & stable plants

• Small Footprint (3-5 ac)

• Energy Co-generation (heat,

steam, hot water, electricity)

• Technically suitable &

economically viable

• All kinds of incinerable waste

MSW, HW, BMW, etc.

• Very high flexibility

• Fully sustainable

• World-wide usage

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LOCATION & CAPACITIES OF

W-2-E PLANTS IN GERMANY Technologies applied: 95% of waste - W-t-E - Incineration with energy recovery

• 50 plants – combined heat and electric power

• 10 plants – only electric power

• 9 plants* – only heat or process steam

*) 7 plants delivering steam to neighbouring manufacturing plant

Energy production of German W2E plants (without RDF)

Value 2005 2006 2007 2008 increase

2005 to 2008

Heat exp. [mil MWh] 13.19 13.72 13.75 14.44 + 9.5 %

Generator output [MW] 1 210 1 250 1 330 1 440 + 19.0 %

Power prod. [mil MWh] 5.51 6.26 6.93 7.35 + 33.3 %

Power exp. [mil MWh] 3.95 4.54 5.16 5.50 + 39.1 %

EU waste directive:

• Hierarchic approach: prevention // reuse // recycling // recovery // disposal

German implementation:

• Source separation, e.g. packaging, paper, glass, WEEE

• Generation of secondary raw materials, e.g. glass, paper, plastics, scrap, metals, bio-materials, textiles

• Untreated municipal waste banned from landfilling since 2005

• Energy recovery of remaining residual waste

• Production of refuse derived fuels (RDF) and secondary recovered fuel (SRF)

Waste management: the European strategy

Waste-to-energy and recycling in Europe 2008

Waste-to-energy and recycling do not interfere

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4P015

Start of drying process 1 1

End of drying, gasification and start of primary combustion,

2 2

Primary combustion: conversion of solid organic matter into gases

3 3

Complete oxidation of organic matter 4 4

Secondary combustion: Oxidation of gasesous matter with additional combustion air

5 5

1 1

5 5

3 3 2 2

4 4

Combustion: drying, gasification, oxidation

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Big W-t-E Plants

The Nuremberg plant: Location: Downtown Nürnberg Operation since: 2001 Troughput: 205.000 t/y. Products: Steam Customers: Local power company, district heating

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Small Decentralised Modular Plants – Recently Developed

by a German Company

Incinerator / Boiler Systems Taylor made for moved bed incinerators

Waste Incineration Energy Recovery Clean Air Technology

Michaelis Energy from Waste Systems

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MICHAELIS Decentralised W-t-E Plant Hanoi Vietnam 500 & 1000 TPD (recent)

ENERGY RECOVERY

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ENERGY RECOVERY

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Energy Recovery: -300 kg of industrial waste substitute about 1 MW primary energy => which equals approx. 100 l oil or about 100 m³ natural gas

~ 60 - 70 % Heat

~ 8 - 17% Electrical Output

~ 70-80 %

Energy Utilization

100 %

Fuel Energy

~15-25 % Boiler Losses

Further Losses

Optimised Energy Utilisation by Cogeneration

Solution for Urban Centres in

India incl. Industries

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Solution for Municipal MSW Mgt

MSW unsegregated

(900-1,000 kcal/kg)

MSW segregation: 1) RDF (for incineration)

(>2,500 kcal/kg) <20%

2) Compostable (bio-degradeable) for composting (fertilizer, soil conditioner) for sale

3) Inerts (for re-use)

Incineration - Waste-to-energy

200-250, 500, 1000 TPD Plant

Addition of high calorific waste

(plastics, MSW, manufacturing wastes,

STP-sludge, BMW, etc.)

� Simple & rigid construction (flexible): use of standard units, modular systems

� Post-combustion chamber: elimination of all odour & organic matter

� Generation of energy: electric power production, external use of heat and steam (marketable)

� Low space requirement: 2 stage incineration, integrated in 1 housing, compact construction in containers (2-3 acres)

� 100% environmental friendly: complete air pollution control, zero-emission

� Easy operation: automatic function control, large openings for firing and ash discharge, optionally automatic charging & de-ashing systems

� Low operation & maintenance costs: all important components are clearly arranged and easy accessible

� Made in Germany quality: extremely long-life cycle

� Approved and patented products: comply with various standards (DIN/EN, VDE, TUV Certified ISO 9001 : 2000)

KEY BENEFITS OF SMALL W-t-E

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Process Data per Modular Unit Waste characteristics Mass flow (kg/h) Up to 8,300 Assumed calorific value (kJ/kg / kcal/kg) 6,500 / 2,500 Incinerator Temperatures Outlet – main combustion chamber (°C) approx. 950 Outlet – secondary combustion chamber SCC (°C) > 1,100 Residence time Solids – main combustion chamber (min) approx. 30 Flue gas-SCC at 850 °C (sec) > 2.0 Deliverables - Energy • Possible heat production: 2,600 kWh/h • Possible steam mass flow: 3 t/h or • Possible hot water / cooling energy / thermal oil: 2,600 kWh/h

MODULAR WASTE

TREATMENT SYSTEM (200 TPD unit)

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MODULAR WASTE

TREATMENT SYSTEM (200 TPD unit)

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Consumables per t of waste 200 TPD unit • Electrical power (KW/h / t waste): 55 => depending on waste composition

• Water (m³/t waste): 0.05

• Natural gas or Diesel oil (m³/h (kg/h) / t waste): 0-50 => depending on moisture content in waste

• Additives (kg/t waste): 10

Residuals per t of waste • Ash from incinerator (kg / t waste) 100 - 200 => depending on ash content in waste)

• Filter residuals (kg / t waste): 30 Space required per line: L x W x H: 35 x 20 x 7 m Plus storage space for waste (segregation, shredder, etc.) 5 ac

Comprehensive Waste Mgt Solutions

for a Typical Indian City

Shredder

Magnetic Separator

Disc Separator

2/3 Dryers (coarse/fine fraction)

Emission Control for Dryers

Drum Separator Hand sorting station

Bailing press for recyclables Conveyers

Incinerator/gasifying System (incl feeder/de-

ashing) Steam Boiler Steam engine / turbine

Hot air exchanger

Direct injection Emission Control Absorber Emission control

Fan & stack Automated control

system

Waste-to-Energy Plant: All Modular Components, 400 – 1000 TPD

W-t-E Solutions for segregated high

calorific value waste (non-hazardous)

Dryers Emission Control for Dryers

Incinerator/gasifying System (incl feeder/de-

ashing) Steam Boiler Steam engine / turbine

Hot air exchanger

Direct injection Emission Control

Absorber Emission control Fan & stack

Automated control system

Waste-to-Energy Plant: All Components, 200 – 500 TPD

Solutions for hazardous waste

management

• Incineration in rotary

kilns

• Co-processing in

cement kilns

Conclusion

Lessons Learned in Germany since >20 years (started 1978)

• Full recycling and waste abatement systems implemented

• “Hot” solutions for residual and industrial wastes

• Incinerators with maximum pollution control (all kind of emissions = zero)

• Costly solutions however, maximum

• Making use of calorific value of wastes

• No more new space/land used for more landfills

COMPANY INTRODUCTION

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WASTE INCINERATION

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Waste Incineration Energy Recovery Clean Air Technology

Introduction of Michaelis GmbH & Co. KG Würzburg, Germany (close to Frankfurt) � Since more than 70 years � Over 1,000 incinerators & flue gas cleaning

systems worldwide � Offices and workshops in Würzburg (close to

Frankfurt),Germany � Engineering, manufacturing,

implementation, commissioning under one responsibility

� Service group

Waste Incineration Energy Recovery Clean Air Technology

Worldwide more than 1.000 systems Service Spots

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30 years of experience as environmental consultant:

• Own company in Germany: Chemical Lab, Testing Facilities

• Environmental Consulting since 1982 in Europe and over 30 Developing Countries

Working for:

• Since 1987: GIZ German International Cooperation (Frankfurt, New Delhi, Bangalore)

• Government of Bavaria, Government of Karnataka (DFEE, KSPCB)

• State Governments in India (CPCB, SPCBs)

• Pollution control in private sector companies: Industries, production sector

• Since 2011 for German Companies on the Indian Market

• Since 2001based in Bangalore (since 2011 as Independent Consultant)

• Water and Waste Management, Recycling, Green Manufacturing, Technology Transfer

• KSPCB-HAWA Project: Hazardous Waste Management System for Karnataka - Development of TSDF (Model Landfill) for Hazardous Waste at Dobbasapete (Tumkur) 2001 - 2010

Background Dr Juergen Porst

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THANK YOU FOR YOUR KIND

ATTENTION

www.michaelis-systems.de

mail@drporst.net

Dr Juergen Porst DR PORST INTERNATIONAL Environmental Consulting Bangalore INDIA