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The EU-Project RECOFUEL Part 1: Production of SBS ® Part 2: Use of SBS ® in PC and CFB-plants

The EU-Project RECOFUEL Part 1: Production of SBS ® Part 2: Use of SBS ® in PC and CFB-plants. Part 1: Production of SBS ®. Two quality groups, two trade marks since 1995/1998. SBS ®. BPG ®. B rennstoff aus p roduktionsspezifischen G ewerbeabfällen. S ubstitut b renn s toff.

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The EU-Project RECOFUEL Part 1: Production of SBS ® Part 2: Use of SBS ® in PC and CFB-plants

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  1. The EU-Project RECOFUEL Part 1: Production of SBS® Part 2: Use of SBS® in PC and CFB-plants

  2. Part 1: Production of SBS®

  3. Two quality groups, two trade markssince 1995/1998 SBS® BPG® Brennstoff ausproduktionsspezifischenGewerbeabfällen Substitutbrennstoff High calorific fractions (HCF) sorted out from poste-use waste Source seperated wastes / production residues

  4. 5 different qualitiesfor different customers SBS 1power plants lignite BPG 1 power plants BPG 2cement kilns BPG 3lime kilns SBS 2cement kilns hard coal different high-calorific fractions from -MSW -demolition wastes residues from paper productionrejects,punchings,photography paper,blocks,wet-strength paper,cellulose cloths etc. paper wastesas BPG 1,plastics- resins- polyacrylic- polyester- polyolefine- PUR - etc.fibre fabrics carpets etc. low ash plastics- resins- polyacrylic- polyester- polyolefine- PUR - etc. see SBS 1

  5. mechanical-biological treatment plant high calorific fraction (HCF1) high calorific fraction (HCF2) LFP-sorting construction and demolition wastes high calorific fraction (HCF3) SBS® high calorific fraction (HCF4) bulky wastes high calorific fraction (HCF5) commercial wastes high calorific fraction (HCF6) composting Input materialsfor SBS® SBS®-production QA ofSBS® Quality Assurance of HCF`s

  6. Specifications for BPG® and SBS®

  7. Bulky/Commer- cial waste feeding biomass water MSW feeding biol. drying residues/ MSWI screening Fe-/ NF- seperation Fe-/ NF- metals Fe-/ NF- seperation NIR- seperation New plant (ABA) SRF-plant (AKEA) fine grinding storage/ loading SRF`s: BPG® and SBS® HCF NF-seperation size reduction Fe-seperation Fe-/ NF- metals Production wastes feeding Prior size reduction- windshifting disturbent materials LFP-residues, production w. feeding NIR-seperation residues Waste treatment center VZEK, ErftstadtFlow-sheet (12/2005)

  8. Near Infrared-System Computer (NIR) Camera Feeding Nozzle Pipes Control System Positive fraction Acceleration conveyor Nozzles Sorting residues Positive fraction  SBS® Sorting residues  MSWI HCF-Sorting with NIR-systemspositive separation

  9. Development of input materials for SBS®1E [weight %]

  10. Extended QMS for the production of SBS® Process-chain QA-chain Acceptance area Input control Positive sorting of HCF Process control SBS®-Production Process control Product control: Internal and external SBS®-Storage ISO 9001  EFB  RAL-GZ 724  CEN TC 343 

  11. Regular sampling during production Analysis of H2O in the plant Single samples are combined to 500-Mg-mixed-samples,.... Sampling behind last step of size reduction ... and are analysed by an external laboratory : Every 1.500 Mg additional parameters are analysed: Delivery to the customer Analysis report – Number ... 1.500-Mg-analysis for BPG and SBS Parameter: ds, H2O, Cl, Ash, NCV, F, ... HM Group I-III: As, Be, Cd, Co, Cu, Hg, Mn, Mo, Ni, Pb, Sb, Se, Sn, Te, Tl, V, Zn Ash: Al2O3, CaO, Fe2O3, K2O, MgO, Na2O, P2O5, SiO2, SO3, TiO2, ZnO Analysis report – Number ... 500-Mg-analysis for BPG and SBS  Parameter: ds, H2O, Cl, Ash, NCV + 2 HM (changing monthly) Quality/product control

  12. Development of SBS1Erftstadt-qualityShort analysis and elementary analysis

  13. Development of Cl-values of SBS®since 1997 (n = 919, 10/2007) First trials with NIR Effect of German landfill-directive

  14. Development of parameterswith slagging, fouling- or corrosion-potential for SBS®1 (08/2007)

  15. Biogenic share of SBS®1ErftstadtResults Dissolution method(prCEN/TS 15440)

  16. realistic fossil share realistic fossil share 120 110 100 90 80 70 60 50 40 30 SBS1 BPG2 Hard coal Natural gas Light fuel oil Lignite Heavy fuel oil Energy specific CO2-emissionsof different fuels t CO2/TJ CO2-reduction:0,75(HC) - 1(BC) t CO2 /SBS(with 50% biomass content) 16

  17. Part 2: Use of SBS® in Pulverized Coal- and Circulating Fluidized Bed-plants within the RECOFUEL-project

  18. EU-Project RECOFUELProduction of SRF (SBS®) and use in lignite boilers • term • duration 36/48 month • start June 2004 • partner • consortium 12 partner of 6 EU-states • coordinator REMONDIS • issues • sustainable production of SRF`s suitable for power plants • environmental acceptability and technological feasibility • accompanying research • european technology transfer

  19. Project RECOFUELmain issues of the partners • REMONDIS SRF-production + coordination • RWE Power large-scale demonstration co-combustion • University Stuttgart lab tests + simulation • INFA balances of SRF-production • KEMA ash properties + corrosion • TAUW quality control in the power plant • CESI corrosion • Åbo Akademi Process SFR properties + ash • University of Athens combustion model • VINCA mill measurements • ESSENT technology transfer • PPC technology transfer

  20. PC-plant of RWE Powerin Weisweiler Source: RWE Power

  21. PC-plant of RWE Power in WeisweilerFeeding device for paper sludge (incl. 3 hoppers) Source: RWE Power

  22. Co-combustion of SBS® with lignitein Weisweiler SRFdelivery cooling tower Fluff SBS-delivery: average 20-25 Mg/h maximum 50 Mg/h boilers with primary DENOX: 2 x 600 MWel hopper REAdesulphorisation lignite supply 1200 Mg/h Source: RWE Power electrostatic filter 8 coal mills

  23. Trials at WeisweilerPP in 2005 SBS®1: 4200 Mg, 12,5 Mg/h (up to 4% thermal share) Paper sludge during SBS®1: ca. 13000 Mg Lignite during SBS®1: ca. 345 000 Mg Steam data: 530°Cel., 169 bar • Test and measurement plan: • Input and output analysis of SBS®1 production • Fuel input analysis at the power plant • Analysis of the biogenic content • Investigation of fuel preparation and mill behaviour • Emission measurement in flue gas • Flue gas composition • HCl-measurement in the raw gas • Furnace measurements • O2- and temperature meas. before/after mill • Analysis combustion residues • First investigations of the corrosion potential Source: IVD, University Stuttgart

  24. Direct co-combustion of SBS®1 in Weisweiler Source: RWE Power

  25. Evaluation of SBS®-co-incinerationin Weisweiler • quality of SRF (SBS®) • delivery and transfer • feeding and dosing • combustion behaviour (ignition and burnout) • fixing of heavy metals etc. in ash and gypsum • flue gas cleaning system • emissions according 17. BImSchV (WID) • landfilling characteristics of combustion residues Co-incineration of SBS® in lignite power plants is technically and environmentally feasible Source: RWE Power

  26. Motivation: Missing longterm permission in PC-plant of Weisweiler Existing feeding technology in CFB/CHP-plant Berrenrath Existing longterm permission for SBS®-use in Berrenrath Consequences: Additional administrative work (Consortium and EC) Increased knowledge about corrosion risk with respect to two technologies Use of the potential of lignite burning PC-power plants in West-Germany postphoned Use of the potential of CFB-plants stabilized Extension of the projectto a new power plant and a duration of 48 months

  27. Berrenrath Power Plant Source: RWE Power

  28. Co-combustion installationsof the Berrenrath Power Plant sewage sludge pulverized lignite coke (activated carbon) run-of-mine-lignite SBS®1 Source: RWE Power

  29. SUPERHEATER 4 SUPERHEATER 3 SUPERHEATER 2 ECONOMIZER AIR PREHEATER CFB boiler (CHP)in Berrenrath • BERRENRATH CFB (ca. 300 MWtherm) • Steam data : • 77.8 kg/s • 510 ºC • 90 bar • Fuels : • Lignite • Sewage sludge • Lignite sludge • Demolition wood • SRF (up to 25% thermal share) Source: RWE Power

  30. NIR-technology is the key to select suitable high calorific fractions from MSW, bulky waste and mixed commercial wastes NIR-technology in development (improvements of selectivity) Modern treatment-technology is the basis for good chemical und physical fuels properties QMS according RAL-GZ 724/CEN TC 343 can improve the reliability of fuel properties Improved SBS®1-qualities even after effectiveness of landfill directive Very low Cl-values (mean of 3 assays < 0,5% of d.s., max < 0,7% of d.s.) requested by RWE Power New location for longterm-tests: CHP-plant in Berrenrath (CFB-techn.) Interesting CO2-reduction potential: 1t CO2/t SBS®1 Summarypart 1-2

  31. Acknowledgment The RECOFUEL-project is funded by the European Commission under the Sixth Framework Programme European Commission Directorate-General for Energy and Transport and Intelligent Energy Europe Thank you!

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