October 10, 2014

The 2014 Bi-annual Meeting of WTERT Columbia University

Recent developments of WTE in Italy and the MatER model

Prof. Stefano Consonni

Dept of Energy - Politecnico di Milano / MatER with contributions from ingg. G. Bortoluzzi and M. Zatti

MatER

POLITECNICO DI MILANO

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Total production 170 Mt

Waste production in Italy (2010)

Includes demolition and commercial waste nearly 60% recycled about 10% to landfill

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Materials collected separately at the source

Evolution of total MSW production and Separate Collection

Production and Separate Collection

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34% 35% 38% 40% 42%

Evolution of Separate Collection

Materials collected separately at the source

mass % of Separate Collection refers to materials collected at the source --> different from recycling

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kg per capita of "fresh" MSW disposed in landfill

222 197 180

Per capita production and SC

Materials collected separately at the source

In 2012, "fresh" MSW to landfill (per capita): - UE-28 160 kg - US 388 kg

179 189 199 202 206

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Energy recovery   2012   2013  Number of plants [#]   49   48  Amount of treated waste [Mton]   5,17   5,40  Electrical production [GWhe]   3.828   4.234  Electrical production [kWhe]   741   785  Thermal production [GWhton]   1.718   2.473  Thermal production [kWht/ton]   332   458  

WTE plants

Capoterra

Macomer

Gioia Tauro

Melfi

Massafra

Acerra

Pozzilli

Colleferro

S. Vittore

Tolentino Montale

Livorno Poggibonsi

Ospedaletto

Schio

Ferrara

Ravenna

Coriano Forlì

Venezia Padova

Trieste

Torino

Vercelli

Granarolo

Piacenza

Parma Modena

Bolzano

Busto Arsizio Como

Milano

Sesto S. Giovanni

Trezzo d’Adda Cremona

Dalmine

Brescia Bergamo

Parona Corteolona

Desio

Valmadrera

Statte

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Breakdown of WTE plants feedstock

Amount of total waste treated

Number of plants in operation

49 52 50 51 51 53 53

about 20% of MSW production

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Energy production

GWhel GWhth

GW

h

4000 GWhel is about 1.2% of total electricity demand in Italy Under reasonable, "non-aggressive" assumptions, could go up to 4-5%

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WTE technologies

Gasification Fluidized bed Rotating drum Grate

Rat

ed C

apac

ity

[t/d

ay]

Evolution of thermal treatment technologies (from ENEA, waste-to-energy report 2012)

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Flue gas treatment technologies

Dry Semi-dry Wet Combined

Rat

ed C

apac

ity

[t/d

ay]

Evolution of flue gas treatment technologies (from ENEA, waste-to-energy report 2012)

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Recent WTE plants: Torino

Graphic courtesy of TRM SpA - Ing. V.M. Fasone

Treatment capacity, ton/yrTreatment capacity, ton/hrDesign LHV, MJ/kgCombustion power, MWLHV

Boiler exit temperature, °CStack temperature, °CSteam generation, ton/hSteam conditions at turbine inletCondensation pressure, barGross power output, MWe

Net power output, MWe

64.5055.50

0.06

190

420°C, 60 bar

120

Torino WTE plant

206.25

263.43

421,000

11.0067.5

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Recent WTE plants: Torino

Flue gas IN

Fly ashes discharg

e

RSP discharg

e

Air

To the recirculating

fumes fan

Electrostatic

precipitator

External economizer

SCR system

flue gas/condensate heat exchanger

Bag filter

Urea tanks

Dry reactor

Fan

Stack

Bicarbonate tank Activated carbons tank

Methane

Methane

Ammonia

Urea thermal decompositio

n unit

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Recent WTE plants: Parma

●  2 lines with grate combustors + integrated boiler ●  single turbo-generator and air-cooled condenser ●  SNCR with 25% NH3 solution ●  "double" flue gas treatment:

–  injection of lime+active carbon –  1st bag filter –  NaHCO3+carbon –  2nd bag filter –  injection of NH3 solution –  SCR –  low temp heat recovery

Commercial operation started April 2014

Feedstock ton/yr LHVMJ/kg

"Dry" fraction 70,000 15.50Commercial waste 18,000 17.00Waste from recycling plants 15,000 20.00Sanitary waste 7,000 22.00Dried sludge 20,000 10.50Total 130,000 15.803

Combustion power, MWLHV

Boiler exit temperature, °CStack temperature, °CSteam generation, ton/hSteam conditions at turbine inletCondensation pressure, bar

Power output summer winterElectricity (gross), MWe 17.80 12.50Heat to district heating, MWt 0.00 40.00

Boiler and power cycle71.33

79.35

0.10

190

400°C, 45 bar

130

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Recent WTE plants: Parma

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Recent WTE plants: Parma

Line 1 Line 2HCl 8.0 0.74 1.31HF 1.0 0.04 0.04SO2 40.0 1.25 2.12NOx 70.0 25.48 26.97NH3 - 0.04 0.03CO 30.0 4.15 5.43TOC 10.0 0.04 0.02Particulate matter 5.0 0.39 0.22

daily averagesJan-Aug 2014emission

limitspecies

mg per m3n dry, 11% O2

Emissions at the stack

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www.mater.polimi.it

MatER Research Center (Material and Energy from Refuse) is a project carried out by LEAP (Piacenza Energy and Environment Laboratory) with the scientific support of the Energy Department and Civil and Environmental Engineering Department of Politecnico di Milano

MatER Research Center

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MATTER + ENERGY IN

MATTER OUT

WORK OUT

HEAT OUT

HEAT OUT

17

The MatER approach

Fluxes IN / OUT are not an option: setting them to zero brings to death

Fluxes of mass and energy IN and OUT (waste ?) are an ESSENTIAL ingredient of life

17

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Position in waste hierarchy BENEFITS: - resource savings - raw materials consumption reduction - energy consumption reduction

Landfill (INERT

residues)

Re-use

Recycling

Energy Recovery

Reduction

PROBLEMS/HURDLES: - coordination of different subjects - complex management - costs

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MatER point of view

BOTH material recovery AND energy recovery

are essential for Sustainability .

Material Recovery

Sustainability

Energy Recovery

Re-use

Reduction of waste production

Integrated system: 1) Reduction 2) Re-use 3) Recovery 4) Inerts disposal

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The MatER team Prof. Stefano Consonni

Prof. Michele Giugliano

Prof. Stefano Cernuschi

Eng. Mario Grosso

Eng. Lucia Rigamonti

Eng. Frederico Viganò

Eng. Giulio Bortoluzzi

Eng. Irene Sterpi

Eng. Matteo Zatti

Eng. Emanuele Martelli

Eng. Laura Biganzoli Eng.

Daniele Di Bona

Eng. Marco Gabba

DIRECTOR

SCIENTIFIC BOARD

MatER TEAM

OTHER STAFF

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Visiting Faculty

Prof. Andrzej Bialowiec from Univ. of Wroclaw, Poland to MatER

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Examples of MatER projects

1)  WTE integrated with biogas production 2)   Steam reheat as means to improve efficiency (and

reduce environmental footprint) 3)   Evaluate energy recovery coefficient R1 (as defined

by EU directive) 4)   Biogas upgrade 5)   Emissions of ultrafine particles 6)  Modeling Mechanical Biological Treatment (MBT) 7)   Evaluate performances of Integrated Waste

Management Systems (IWMSs)

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STACK

DEAERATOR FWH

EVAECO

FGR

WASTE

PRIMARYAIR AIR PREHEATERS

STEAM DRUM

GRATE FURNACE

SH1

BOTTOMASH

SECONDARY AIR

CONDENSATE PREHEATEREPS SCR

FABRIC FILTER

ASH ASH

ASH

EVA

FGR FAN

COMBUSTOR

SH2

TO STACK

APH

BIOGASANAEROBIC DIGESTOR

AIR

ASH

External superheating with Biogas

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“Full” steam reheat

STACK

DEAERATOR FWH

EVA

ECO

FGR

WASTE

PRIMARYAIR

EVA

AIR PREHEATERS

ASH

STEAMDRUM

GRATEFURNACE

SH

RH

BOTTOMASH VAPOR FROM

ASHQUENCHING

ASH

CONDENSATE PREHEATER

SCR

FABRIC FILTER

ASH ASHSECONDARYAIR

EPS

EVA

FGR FAN

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Ew3 Ew1

Ew4

Plant boundaries

System boundaries considered for the R1 index calculation

Boiler

Turbine + generator

Flue gases treatment

Sludge dryer

Ew2

Ef

Ei

Eth,p

Eel,p Eel,exp

Ew5

Eel,aux

R1 index calculation

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Biogas upgrade

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Emissions of ultrafine particles

4.000.000

10.000

21.000.000

150.000

14.000

51.000.00045.000.000

1.300.000

4.50011.000

4.000

42.00090.000

17.000.000

500.000

32.000

81.000.000

52.000.000 67.000.000

18.000

7.000

70.000

270.000

43.000.000

Ambie

nt ai

r

Woo

d pell

et bo

iler

Close

d fire

place

Light

fuel

oil bo

iler

Natural g

as bo

iler

WTE

1

WTE

2

WTE

3

WTE

4

Diesel

w/o D

PF

Diesel

w DPF

Gasoli

ne co

nv

Gasoli

ne D

I

Part

icle

s cm

-3 (

log

scal

e)

WTE

Heatingboilers

Dieselvehicles

Gasolinevehicles

*DPF = diesel particulate filter

570.000

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Basic mechanism of bio-drying

(partial) oxidation of Organic Volatiles is the driving force of bio-drying

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An Italian case study - MBT 1

URW sent to storage area in storage pit shredder

100,0% Biodrying

100,0%

Process losses

22,3%

Thin rotary screen

Magnetic Separator

Eddy current Separator

Balistic Separator

77,7%

NIR for PET separation

NIR for HDPE

separation

NIR for LDPE

separation

SRF

Thin fraction

Ferrous metals

Non ferrous metals

Heavy fraction

LDPE

HDPE PET

Landfill

73,5% 100,0% 100,0%

26,5%

31,9%

28,7% 37,2%

34,1% 45,8% 44,8% 1,7%

1,7%

1,8%

1,4%

5,3%

5,4%

22,2%

21,8%

19,6%

19,4%

2,6% 2,5% 1,3%

18,3%

18,1%

14,8%

14,5%

9,4%

9,4% 27,7% 27,4%

RED efficiencies 2011 (SC = 55,6%) BLUE efficiencies 2020 (SC = 65,7%)

1,4% 44,1% 43,1%

42,3% 41,7%

5,4% 5,1%

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An Italian case study - MBT 1

Separate collection

Possible multimaterial

separation

Recycle Secondary raw

material

Selection

Recovery residues

URW

34,3 %

65,7%

MBT plant SRF

MBT residues

Material to recycle

11,7%

9,4%

4,1%

Total residues

Organic and green

treatment

23,9%

41,8% 9,4%

32,4%

Process losses

~ 10%

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The MatER model

1)   Combination of a variety of competences: recycling, energy systems, evaluation of environmental impact, technical-economic evaluation, etc.

2)   Involvement of major waste management companies 3)   Support of national federation 4)   Combination of routine activities (website, events, participation to

meetings/debates) with research and educational activities 5)   Address also actual operational and design issues 6)   Communicate with administrators, politicians, administrators,

environmentalists, etc. 7)   Involve sponsors in all major decisions 8)   Team of motivated, enthusiastic, (young) people

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Conclusions

Thank you for your attention !

www.mater.polimi.it