Gasification as means of Waste-to-Energy - Main Parameters and application -

Transcription

1 Gasification as means of Waste-to-Energy - Main Parameters and application - 9 th ISWA Beacon Conference in Malm, Sweden 18 th NOV Block 4: Gasification NIPPON STEEL & SUMIKIN ENGINEERING CO., LTD Nobuhiro Tanigaki 1

2 Contents 1. Company Introduction Company Profile Business Field 2. Technical Introduction of Direct Melting System (DMS) Process Flow Gasifier References 3. Parameters and DMS Application Parameters Advantages Application of DMS Gasification Application Example 4. Summary and Conclusions 2

3 1. Company Overview 3

4 1.1. NSENGI Company Profile Company name: Headquarters: Technical Center: Launched Total Revenue: (consolidated NIPPON STEEL & SUMIKIN ENGINEERING Co., Ltd Osaki, Shinagawa-ku, Tokyo Japan Nakabaru, Tobata-ku, Kitakyushu-shi, Fukuoka Japan 2006 (Spun off from NIPPON STEEL CORPORATION) 100 % owned by NSSMC 2,199 m (as of 31 Mar. 2014) Capital Stock: 105 m (as of 31 Mar. 2014) Number of Employees: (consolidated) 4,106 (As of 31 Mar. 2014) Note: Exchange rate : JPY/EUR = Headquarters Technical Center 4

5 1.2. Environmental Solutions Division Business Line-up Waste Gasification and Melting Technology (Direct Melting System (DMS)) The world s highest number of facilities (42 orders) The world s largest facility capacity (230,000 t/annual) The world s longest-term operation (35 years) Waste tire Pyrolysis Technology Produce Syngas, carbon, steel wire, oils and wax More than 10 years commercial operation Biomass to Ethanol Technology Biomass Gasification Soil remediation Groundwater cleaning Grate System, Flue Gas Cleaning System etc SBENG (Direct Melting System) (Waste Tire Pyrolysis plant) 5

6 2. Technical Introduction of Direct Melting System 6

7 2.1. Process Flow - Direct Melting System - No pre-treatment Application of European Standard >28% power generation Steam Turbine Coke and Limestone Waste Pit Gasifier O2-PSA Forced Draft Fan (FDF) Recyclables Combustion Cyclone Chamber Water Granulator Slag Metal Boiler Gas Cooler Combustion Air Draft Fan (CDF) Magnetic Separator Stack Baghouse SCR ID Fan Fly Ash Wet Scrubber Landfilling Re-Heater Gasification/Material Recovery Flue Gas Cleaning/ Energy Recovery 7

8 2.2. Gasifier - Co-gasification - Flexibility of Processed Waste No Pretreatment (Max. 800 mm) Co-gasification Sewage sludge Bottom ash Landfill Waste Clinical Waste Syngas High Syngas NCV Continuous syngas measuring Approx. 5.9 MJ/m 3 N based on 9.1 MJ/kg-waste refer to N.Tanigaki et. al. Waste Management High Temperature & Reducing Atmosphere Produced by coke burning heat Toxic heavy metals are volatilized and distributed to fly ash. Few toxic heavy metals remain in slag and metal ,800 Material and Energy Recycling from Waste 8

9 2.3. References in Japan and South Korea Akita City, Akita Pref Kamaishi City, Iwate Pref Kita-kyushu City Shin-Moji Plant, Fukuoka Pref Kazusa Clean System Co., Ltd. Chiba Pref Ibaraki City, Osaka Pref. 28 Narumi Clean System Co., Ltd. Nagoya City, Aichi Pref. 43 references 36 years operation 10, ,000 t/a 9

10 2.3. References - Shin-Moji Plant- Location / Purchaser Kitakyushu City, Japan Fuel Municipal solid waste Incombustibles Sewage sludge Capacity 3 x 10 t/h kj/kg Largest gasification Plant in operation Year of Start Up 2007 NSENGI Scope of Supply Full Turn key Operation & Maintenance 10

11 3. Parameters and DMS Application 11

12 Parameters -Waste Compositions (Example)- Plant A Plant B Waste to be MSW Moisture % a.r Proximate Combustibles % a.r Analysis Ash % a.r C % a.r H % a.r Ultimate N % a.r Analysis O % a.r Cl % a.r S % a.r Paper % d.b Vinyl and Plastics % d.b Physical Wood % d.b Components Biowaste % d.b Incombustibles % d.b Others % d.b Lower Heating Value MJ kg -1 a.r refer to N.Tanigaki et. al. Waste Management & Research 12

13 Parameters - Operating Data - Unit plant A plant B MSW thoughput t h Coke kg t-msw Natural gas injection m 3 N t-msw Syngas Temperature C Slag produced kg t-msw Metal produced kg t-msw CO Concentration in the Syngas % d.b CO 2 Concentration in the Syngas % d.b Temperature at the outlet of Combustion Chamber C Carbon Conversion Ratio % ER Gross Power Generation kwh to-msw *1: Operating data of plant A and B are the average data from Sep. to Nov *2: Power generations are the average value with 100% load. refer to N.Tanigaki et. al. Waste Management & Research 13

14 3.2. Advantages and the Application Strength Waste Flexibility - Co-gasification of various waste (clinical, sludge, etc) - landfill reclamation is one of the options Recyclables (Slag and Metal) - minimizing final landfill amount, reducing landfill cost - recycling valuables from waste without any post-treatment Changing Boundary Conditions 1. Higher Gate Fee 2. Reduce landfill Cost Operation know-how - long-term operating experiences (36 years) Weakness CAPEX - Approx.10% more expensive than conventional OPEX ( EUR/t) - Additional utilities - Oxygen consumption (parasitic load) Capacity 14 t/h is the maximum in our references. In the same boundary condition, it is not so economically competitive. Other Factors 14

15 Conventional Boundary Condition Conventional Boundary Condition : Feedstock : Power : Residues : Recyclables APC Residues MSW RDF C&I Waste Landfill Site Residues WtE Plant Power Industries Bottom ash Recycling Facility (Aging / Maturing) Bottom ash Recycled in the market Grid 15

16 Application of DMS Gasification Expanded Boundary Condition Recycled Zero Waste Clinical Waste APC Residues MSW Conventional Boundary Condition RDF C&I Waste : Feedstock : Power : Residues : Recyclables Landfill Site Landfill Waste DMS Plant Hazardous waste Industries Power Sludge Recycled in the market Slag / Metal Grid WWTP 16

17 Application of DMS Gasification 1. Higher Gate Fee Recycled Zero Waste Clinical Waste MSW RDF C&I Waste : Feedstock : Power : Residues : Recyclables APC Residues Landfill Site Landfill Waste DMS Plant Hazardous waste Industries 2. Reduce landfill Cost Power Sludge Recycled in the market 1. Higher Gate Fee Slag / Metal Grid WWTP 17

18 Higher Gate Fee -Clinical Waste / Sewage Sludge- 1. Higher Gate Fee Clinical Waste DMS Plant 500 EUR/t x 1% approx. 5 EUR/t Gate fee up Sludge 1. Higher Gate Fee WWTP 18

19 Higher Gate Fee -Landfill Waste Reclamation- 1. Higher Gate Fee Excavation Transportation Landfill Site Landfill Waste DMS Plant Oversized Landfill waste <200mm Waste 19

20 Reduce Landfill Cost - material recycle- Construction of New Landfill Site should also be avoided metal Materials of Iron industries Counterweight for construction machine Landfill Site No Waste DMS Plant 2. Reduce landfill Cost Interlocking block Asphalt paving Recycled in the market Slag Slag / Metal Slag Concrete block Soil Natural sand 20

21 Application Example - Narumi Plant - Location / Purchaser Nagoya City, Japan Fuel Municipal solid waste Bottom ash Incombustibles Combustibles Capacity 2 x 11 t/h kj/kg Year of Start Up 2009 NSENGI Scope of Supply Full Turn key BOT Operation & Maintenance Bottom ash recycling is not allowed The municipality has no landfill site Need solutions. Co-Gasification and recycling 87% reduction of final landfill amount 21

22 (1) PlantPAD Application Example - Operating Support - Monitored operating condition remotely Inspection data is recorded Checking operating data - ITV - Historical trend data - On-time operating condition easier maintenance management (2) Predictive Operation System Many operating records can predict the operating conditions. Several parameters are picked up for predictive operation. These supporting system lead easier O&M of gasification technology 22

23 4. Summary and Conclusion NIPPON STEEL & SUMIKIN ENGINEERING (NSENGI) has the largest and longest references of Waste Gasification and Melting Technology. This Direct Melting System has been already adapted to European Standard. High temperature gasification process Direct Melting System leads waste flexibility and production of Recyclables (high quality slag and metal). Waste Flexibility and Recycling materials from waste have possibility to expand the boundary conditions of waste management scheme. Especially, 1) Gate fee increase by other waste processing, and 2) Reducing landfill amount (furthermore considering new landfill site ) are important factors to consider this type of gasification. Direct Melting System can be an alternative thermal treatment for material and energy recovery from waste. 23

24 Thank you very much for your attention Contact: M. Sc. Nobuhiro Tanigaki Chief Technical Manager NIPPON STEEL & SUMIKIN ENGINEERING CO., LTD. European Office Am Seestern 8, Dusseldorf, Germany 24