SINTEF Energiforskning AS EXAMPLE OF FP5 PROJECTS Presentation given at the EMINENT Seminar in Brno, 31 March 2005 by Jens Hetland Ph.D. Senior Scientist

SINTEF Energiforskning AS

EXAMPLE OF FP5 PROJECTS

Presentation given at the EMINENT Seminar in Brno, 31 March 2005by

Jens Hetland Ph.D.Senior Scientist and Professor

Department of Energy Processese-mail: [email protected]


Projects granted

Part B Thematic programme Energy, environment and sustainable development: Key action 5 + 6:

681 projects

Reference is made to: http://www.cordis.lu/eesd/src/proj_eng.htm

http://dbs.cordis.lu/EN_GLOBALsearch.html


Technologies deemed promising

RES technologies Wind power (8) Bioenergy – CHP (8) Solar induced power (4)

Fossil based energy technologies Coal fired power plants (1) Natural gas fired power plants with CO2 capture (4)

Fuel cells (1)

… sustainability, emissions and efficiency:

Assessments

Technologies

Dossier


FP5 EcoWaste: No NNE5-2001-00702

ADVANCED GASIFICATION AND THERMAL PLASMA CRACKING - PYROARC®

Thermo-chemical Multi-processing of Solid Waste Materials featuring Recovery of Gas, Heat, Metals and Minerals with

Complete Volume Reduction and Residue Stabilisation


Characteristic features:

1. Volume reduction2. Multi-processing3. Emissions4. Leaching resistance 5. Energy utilisation


Landfill allowances

represent an obstacle

Inorganic

Recoverable

0%

25%

30%

100%

Flyash

Conventional technology

Metals Bottomslag

Organic

Wastecomposition

SludgeMetals

2%8%

Non-leachable

slag20%

Bottomash

Refused waste composition

PyroArc

PLASMA TECHNOLOGIES AS


Electronic waste has a valorising

potential

Potential: 1. low calorific fuel gas 2. leaching resistant slag 3. molten metal 4. heat

PLASMA TECHNOLOGIES AS Opportunities70% of initial heating capacity

LHV ~ 3.6 – 4 MJ/mN3

Only basic molecules due to plasma cracking

12-15% H2, 17-22% CO plus CO2, N2 and H2O

Slag formers needed for some wastes. If slag turns alkaline the leaching resistance suffers

20% of heating capacity is sensible heat (eventually steam and low grade heat)

Metals with affinity to oxygen lower than iron are recovered in molten phase (Cu, Au, Ag, Ni, Pt)

Volatile metals – dust of Zn and Pb

E-mail: [email protected]


- Household waste (MSW)- Impregnated wood- Tires- Car fluff- Electronic waste- Refrigerators- Simulated hospital waste- Batteries- PCB- Chlorinated hydrocarbons (CFC) and

hydrogenatated chloro-fluor carbons (HCFC)- Oil filters- Paint, glue etc.- Asbestos

The following types of waste have been verified through successful test-runs in a 500 kg/h pilot test rig:

Tested materials


up to pure PCB oils

Freons

Energy [email protected]


Electric power supply

Secondary air

Gas cooling and cleaning

Solid waste

Filter cake Clean fuel gas

Hot water/ steam

Thermal plasma

generator

Air supply

Decomposition reactor

Metals and minerals in

molten phase

PRODUCTS

Preheated blast air

Advanced recovery PyroArc®



Gasifier

Plasma generator

Decomposition reactor

Mixing zone

Feed

Core Technology



Electric Arc15.000 - 20.000ºC

(25.000 - 35.000ºF)

3.000 - 4.000ºC

(5.500 - 7.000ºF)

MagneticCoil

MagneticCoil

Gas

Electrode ElectrodeGas

PLASMA TECHNOLOGIES AS Thermal Plasma

• Cracking hazardous gas forms a harmless fuel gas

• Electric power demand: 3-8% of energy charged to the process



PLASMA TECHNOLOGIES AS Decomposition-destruction Chamber

Decomposition Chamber Mixing zone Plasma

generator

Fuel gas

Secondary air (Oxygen) (Steam)

Gas from shaft gasifier 500-800 C, Liquid and gasoues waste

1200 C Retention time:

0.3 –0.6 s

CnHm (CL, S, N) ---> CO, CO2, H2, H2O, (HCl, H2S, N2)

Oxidation ratio:

Liquid waste

0.2< CO2/CO+CO2<0.4

500 o

Thermal cracking controlled by keeping the oxidation rate

R = CO2/[CO2+CO]

within a range α < R < β

< α HCN may be formed

If R

> β NOx may be formed



Component Comment/ amount of air

Limitations Recorded

Limit Unit Mean time

Mean Highest

Cd Cd andTi 0.05 mg/mN3 0.000037 0.000043

CO 30 min. decided by gas engine

3000 mg/mN3 h 3000

50

60 Dioxin 0.1 ng/mN

3 0.05 0.05 HCl 30 min.

inorganic chlorine

60 mg/mN3 h 1.3 1.5

HCl inorganic chlorine

10 mg/mN3 d <0.2 <0.2

HF 30 min. inorganic fluor

4 mg/mN3 h - -

HF inorganic fluor 1 mg/mN3 d 0.06 0.2

Hg 0.05 mg/mN3 d 0.001 0.01

Instov 30 min. 30 mg/mN3 h 1.7 1.9

Instov 10 mg/mN3 d - -

Metals div. metals 0.5 mg/mN3 0.0075 0.0084

NOx as NO2 400 mg/mN3 h 4

NOx 200 mg/mN3 d 80

SO2 30 min. 200 mg/mN3 h 152 350

SO2 50 mg/mN3 d 100 -

TOC 30 min. 20 mg/mN3 h -

TOC (iii) Basically CH4 + C6H6

10 mg/mN3 d <0.020

PLASMA TECHNOLOGIES AS Emissions- recorded at tannery plant

High allowance limit of CO due to the ICC engine

Initial sulphur problem is now resolved



•65-75% lower gas flow than that of incineration processes (same input)

•Abscence of tar makes down-stream gas cleaning easy

Furthermore:•Substantial reduction potential for

mercury exists as mercury emission is prone to depend more on gas volume than on mercury content

Gas Cleaning



Typical results from comparing MSW Leaching resistance (mg/kg) of slag:

Technology PyroArc MSW

Bottom ash, conventional technology MSW

Dutch U1 limits

Elements mg/kg mg/kg mg/kg As <0.01 0.14 0.3 Ba 0.017 190 4 Cd <0.0007 2.4 0.1 Co 0.0014 1.9 0.2 Cr 0.75 1.4 1 Cu 0.071 375 0.35 Hg N/A N/A 0.005 Ni 0.19 12 0.35 Pb 0.01 49 0.8 V <0.1 0.75 0.7 Zn 0.08 1120 1.4

According to Dutch U1-standard (CEN TC 292)


Leach Resistant Slag



Quenching/ scrubbing

Filtering

Industrial waste feedstock10500 ton p.a. @ HV=6 MWh/h

8.34 MWElectric power supply0.34 MW

Heat loss0.15 MWHeat loss

0.07 MWHeat loss0.08 MW

Pre-heated blast air450 C

Heat loss0.07 MW

Fuel gas cooler2.71 MW

5 MW

Exhaust heat2.49 MW

Gross electricpower2.385 MW

Exhaust gas


Estimated efficiencies- ECO-WASTE with complete vitrification

Total thermal

efficiency

84.0%

Net electric efficiency 22.1%

Gross electric efficiency 28.6%

0 4020 8060 100


Conclusion • unique capability of receiving and treating any

waste material (except nuclear) with hardly any adverse environmental impact;

• capacity of recovering metals, minerals, energy and gas;

• ability of reducing waste volume to practically zero level leaving only stabilised slag with high leaching resistance.



1. The Norwegian Research Council for support under the DEBORA-programme on distributed energy

2. The European Commission for funding support of ECO-WASTE - a combined research and demonstration project

3. EnviroArc Technologies AS for providing proprietary information

[email protected] Tel. +47-73 59 77 64

[email protected] Tel. +47-24 11 12 54


Acknowledgements

Documents

SINTEF Energiforskning AS EXAMPLE OF FP5 PROJECTS Presentation given at the EMINENT Seminar in Brno, 31 March 2005 by Jens Hetland Ph.D. Senior Scientist