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SRF-production and use in CHP-plants,
example EU-project RECOMBIO
REcovered fuels COMbined with BIOmass
Brussels, 22.04.2015
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland2
Contents
Part 1:Project introduction
Part 2:Production of BIOBS in Erftstadt
Part 3:Use of BIOBS
Part 4:Messages – Closing remarks
Part 5:Back-up
Part 1:
Project introduction
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland4
Aims/targetsof RECOMBIO
Combined use of bio-residues and Solid Recovered Fuels
Enlarged fuel basis
Increased flexiblity of fuel-producers and users
Improved combustion behaviour of fuel mixture
Creation of regional fuel markets
High efficient combined heat and power generation and high availability using bio-residues and SRF in CHP-plants (> 7.500h/a)
Demonstration of a sustainable and short-term available fuel production and utilisation
Cost-effective CO2-reduction
No “food or fuel”-problematic
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland5
Project RECOMBIOPartners
• REMONDIS SRF-production + coordination
• RWE Power SRF-use
• University Stuttgart lab. and full scale measurements
• Forschungszentrum Karlsruhe lab. and full scale measurements
• ECN ash properties, corrosion, fuel characterisation
• L & T SRF-production
• Stora SRF-use
• VTT lab. and full scale measurements
• Metso additives, corrosion
• TiTech/TOMRA (Norway) optical sorting technology (NIR)
• JRC (Belgium) Life Cycle Analyses
• Turow/PGE (Poland) dissemination
Total funding: 4,04 Mio € , 01.01.2010 – 31.12.2013, two demonstration cases
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland6
Project RECOMBIOTarget area in terms of electric efficiency and steam temperature
Target area: efficiency > biomass plants and >> municipal solid waste incinerators
15
20
25
30
35
40
45
50
350 400 450 500 550 600 650 700
Steam temperature, °C
Grate fired CHP MSW incinerator420°C, 60 bar
Fluidised bed CHP for SRF470°C, 65 bar
Ultra super critical coal fired PF700°C, 330 bar
Super critical coal fired CFB580°C, 275 bar
Grate firing for MSW
Fluidised bed for waste
Biomass combustion
Coal fired condencing mode
power plants
Grate fired CHP for biomass500°C, 70 bar
TARGET AREA:
BFB CHP for biomass520°C, 120 bar
Electric efficiency, %
CFB545°C, 165 bar
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland7
Demonstration case Finland:SRF-production in Kerava/Turku – SRF-use in Anjalankoski
SRF-production
SRF-use
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland8
Demonstration case Germany:SRF-production in Erftstadt – SRF-use in Wachtberg/Berrenrath
SRF-production
SRF-use
Part 2:
Production of BIOBS
by REMONDIS GmbH Rheinland
in Erftstadt (case Germany)
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland10
Three quality groups of SRFsince 1995/1998/2009
Brennstoff ausProduktionsspezifischen
Gewerbeabfällen
BPG®
Source seperated
wastes /
production residues
High calorific fractions
(HCF)
sorted out from
poste-use waste
SBS®
SubstitutBrennStoff
High calorific
fractions with a high
biogenic content and
different biowastes
BIOBS
BIOBrennStoff
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland11
SRF-quality BIOBSinput materials
BIO
BS
-pro
du
ctio
n
BIOBS
high calorific fraction
(HCFBW)
high calorific fraction
(HCFMSW)
sreening overflow
Quality Assurance of Input
QA of
BIOBS
bulky waste
mechanical-biological
treatment plant (MSW)
composting
used wood
different biowastes
different other wastes
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland12
QMSfor the production of SRF in Erftstadt
Acceptance area
Positive sorting of HCF
SRF-production
Process-chain
SRF-storage
QA-chain
Input control
Process control
Process control
Product control:
Internal and external
ISO 9001: EFB: RAL-GZ 724 and 727: CEN/TC 343:
QMS is the fundament for reliable SRF-qualities
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland13
Online-analysis with NIR-devicenew position since 04/2012: product stream - 100%
New position after promising results of TAMARA-trials
(SRF-layer ca. 15 cm)
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland14
Online-analysis with NIR-deviceanalytical results of total Cl for BIOBS in comparision
„Baseline“ for inorganic Cl is not constant during the year (0,10 – 0,21%),
Cl-average NIR (0,30% ds) and laboratory (0,30% ds, n = 18) are well comparable
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland15
Online-analysis with NIR-deviceinformation for the control personnel (examplary lot)
Prevention of longer periods with higher Cl-values possible
BIOBS, 13-04196-001
0,00
0,10
0,20
0,30
0,40
0,50
0,60
0,70
0,80
0,90
1,00
1,10
1,20
20.1
2.1
2 1
8:0
0
20.1
2.1
2 1
8:3
0
20.1
2.1
2 1
9:2
6
20.1
2.1
2 1
9:5
7
20.1
2.1
2 2
0:2
7
20.1
2.1
2 2
0:5
7
20.1
2.1
2 2
1:2
7
20.1
2.1
2 2
1:5
7
20.1
2.1
2 2
3:2
6
20.1
2.1
2 2
3:5
6
21.1
2.1
2 1
:27
21.1
2.1
2 1
:57
21.1
2.1
2 2
:27
21.1
2.1
2 3
:26
21.1
2.1
2 3
:57
21.1
2.1
2 4
:27
21.1
2.1
2 5
:08
21.1
2.1
2 5
:38
21.1
2.1
2 6
:38
21.1
2.1
2 7
:11
8.1
.13 2
1:0
0
8.1
.13 2
1:2
8
8.1
.13 2
1:4
3
8.1
.13 2
1:5
8
9.1
.13 1
4:3
1
9.1
.13 1
5:0
1
9.1
.13 1
5:3
5
9.1
.13 1
6:1
1
9.1
.13 1
6:4
1
9.1
.13 1
7:1
1
9.1
.13 1
8:0
2
9.1
.13 1
8:3
2
9.1
.13 1
9:3
6
9.1
.13 2
0:0
6
9.1
.13 2
0:3
6
9.1
.13 2
1:0
6
9.1
.13 2
1:4
3
29.1
.13 1
9:2
2
29.1
.13 2
0:0
3
29.1
.13 2
0:4
4
29.1
.13 2
1:3
5
29.1
.13 2
2:0
6
29.1
.13 2
2:3
8
1.2
.13 0
:38
1.2
.13 1
:09
1.2
.13 1
:39
1.2
.13 2
:09
1.2
.13 2
:39
1.2
.13 3
:09
1.2
.13 3
:39
Production period: 20.12.2012 - 31.01.2013
Cl [%
ds
]
Measured NIR-value
Average
Limit value according contract
Estimated value of inorganic Cl
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland16
Quality of SBS®1Erftstadt and BIOBScompared to Rhenish lignite (03/2014)
Classification code according EN 15359 of SBS®1 and BIOBS: NCV: 4; Cl: 2; Hg: 1
Unit Lignite from the Rhine,
Mean
(Berrenrath/Wachtberg)
SBS 1,
Mean
2010 - 2013
SBS 2,
Mean
2010 - 2013
BIOBS,
Mean
2010 - 2013
Short analysisNet. Calorific Value MJ/kg o.s. 10,1 13,2 18,2 11,9
H2O % o.s. 54 24,8 16,4 24,7
Ash % o.s. 2,5 9,5 10,1 11,0
Chlorine % o.s. 0,02 0,36 0,74 0,23
Volatile % o.s. 23,5 53,5 60 52,7
Elementary analysis
C % o.s. 30,5 35,3 39,2 32,5
H % o.s. 2,2 4,5 5,6 4,1
O % o.s. 10,3 23,8 26,8 26,2
N % o.s. 0,4 1,4 1,0 1,2
S % o.s. 0,2 0,2 0,3 0,1
Addtional parameters
Biogenic C % of TC 0 74,3 50 84,4
Chlorides mg/kg d.s. 300 2.005 1.655 1.575
Al mg/kg d.s. 750 5.550 5.685 4.700
K mg/kg d.s. 215 2.160 1.610 3.190
Na mg/kg d.s. 1.400 2.665 2.213 1.420
Pb (50th. Percentile) mg/kg d.s. 1 75 65 45
Zn (50th. Percentile) mg/kg d.s. 3,5 275 350 210
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland17
Energy specific CO2-emissionsof different fuels
17
t CO2/TJ
CO2-reduction: >= 1(BC) t CO2 /SBS1 or BIOBS
Emission factors of SRF certified according to RAL-GZ 724
20
40
60
80
100
120
0
realistic
fossil share
Part 3:
Use of BIOBS
(case Germany)
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland19
Use of BIOBS in CHP-plant Berrenrath
CFB combustion
system
2 x 166 MWth
ηCHP = 83%
Used amount of BIOBS: ca. 20.740 Mg (2011 – 2012), silo of new feeding system with wrong ratio height / diameter: ca. 1,3
Source:
RWE Power
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland20
Location of Berrenrath and Wachtbergin the Rhenish Lignite Mining Area
CFB combustion
system
2 x 235 MWth
ηCHP = 81,8%
Source:
RWE Power
Used amount of SRF: ca. 14.350 Mg of BIOBS (2010 – 2013)
and ca. 564.000 Mg of SBS®1 (2003 – 2015),
old feeding system with appropriate ratio height / diameter: <0,5
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland21
Results Life Cycle Assessment of the JRC-EUfocus Erftstadt-Berrenrath/Wachtberg
Observation of the effects of sorting/treatment in Erftstadt and of the output on
combined energetic use of certified SRF in co-incineration plants (brown
coal power plants) and residuals from sorting in MSWI`s
substantial recycling of plastics, Fe-/Non-iron metals, …
Regarding all 15 LCA-categories according to ISO 14400 and ILCD handbook for
compared to using primary resources (brown coal, primary plastics, primary
metals, …) production and use of SRF is a successful combination of
recycling and resource strategies
Demonstration case Finland: improvements for 11 of 15 categories
Demonstration case Germany: improvements for 15 of 15 categories, CO2-
reduction effect ca. 2000g CO2/kWhel (by aggregating effects of all measures to the
functional unit kWhel)
Treatment technology in Erftstadt (MBS-plant) is a sustainable contribution to
reach the environmental aims of modern resource and energy management
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland22
SummaryRECOMBIO
NIR-technology
is the key to produce high-quality fuels based on high calorific waste fractions
can be used/developed as an online-analysis-system for NCV, Cl and H2O
Certified SRF`s (i.e. RAL-GZ 724) guarantee a high quality reliabilty and ensure an environmently friendly use in cement industries and power plants
Fuel-quality is the decisive tool for high efficiency
About 1t CO2 reduction/t SBS or BIOBS in brown-coal substitution or
Results of external LCA by the JRC Ispra on behalf of the EU-Commission taking intoaccount 15 life cycle impact categories shows environmental sustainability; thismeans that co-incineration of quality assured SRF is ecologically useful
No “food or fuel“-problematic
Production and use of SRF is recommended for other (EU-) countries (i.e. GB, PL)
European potential SRF co-incineration cement and power plants: 15 - 30 Mio t /a
MSW-Incinerators as the last step of modern waste management (ultima ratio)
Part 4:
Messages
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland24
MessagesSRF and Recycling (04/2015)
Carefull planning of MSWI-capacities (experiences DE, NL, ...)
International cooperation to
develop resource-infrastructure in EU (waste-collection, sorting, recycling, SRF-production)
use existing MSWI/Waste-to-Energy capacities
EU-funding for sorting, recycling, SRF-production and efficienttechnologies (CHP) and not for MSWI-projects with low efficiencies (i.e. EFRE)
“Re-animation“ of ETS for CO2
New European SRF-demonstration projects (Horizon 2020) to supportinternational exchange, Mediterranean MS (i.e. Italy, Spain, ...) and toallocate reliable knowledge about innovative technologies (gasification, liquefaction, …)
Thank you for your attention !
Thank you to the COM/DG ENER for funding the RECOMBIO-project
Anjalankoski, Finland
Part 5:
Back-Up
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland27
Waste sorting and SRF-productionsimplified flow-sheet for BIOBS-production (status 04/2012)
MSW
Bulky waste
Sorting plant (ABA)
feeding
screeningFe-/ NF-
separation
Fe-/ NF-
separation
Fe-/ NF-
metals
biol. drying residues to MSWI
NIR-
separation
surplus water
to WWTPfeeding
SRF-plant (AKEA)
Production
specific
wastes,
biowastes
feeding
Secondary size
reduction
Prior size
reduction-windshifting
disturbent
materials/residues
Fe-separation
NF-separation
windshifting BIOBSstorage/
loading
Fe-/ NF-
metals
HCF`s
NIR-
quality control
screeningFe-/ NF-
separation
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland28
Windshifting2 t/h test device and heavy fraction
Intentions:
1.) Reduced energy consumption (fine crushing not necessary)
2.) Improved SRF-quality (Cr, Cu, Pb, ..., disturbing materials)
3.) Increased recycling rate
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland29
New windshifting-system 2 x 10 t/h since 02/2012: 100% of product stream
Positive influence on SRF-quality and recycling rate
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland30
Outputas a result of sorting and treatment in Erftstadt
Residues to MSWI`s are more homogeneous than without sorting/treatment
Output ABA/AKEA 2009:
ca. 146.000t/a
64.541 t
54.413 t
191 t
832 t
4.158 t
1.330 t
948 t
19.606 t
SBS, BIOBS
To MSWI
Plastic (PVC)
NF-metals / Aluminium
Fe-Metals
Inert
Excess water
Drying losses
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland31
CO2-effectas a result of sorting and treatment in Erftstadt
Decisive way to increase CO2-reduction:
increase SRF- and recycling-rates
Contribution of output-streams to CO2-reduction ABA/AKEA 2009:
ca. 80.000 t/a or 0,55t CO2/t Input
64.751 t
8.064 t
191 t
2.495 t 4.158 t
SBS, BIOBS
To MSWI
Plastic (PVC)
NF-metals / Aluminium
Fe-Metals
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland32
Development of Cl-values of SBS®Erftstadt
Internal / external supervision (n = 1.721, 04/2015)
Effect of German
landfill-directive
First trials with NIR-
sorting
Effect of increasing
input competitionStart of NIR-
online analysis
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland33
Quality development of BIOBS for parameterswith slagging-/corrosion-potential (incl. 07/2013)
Consequence of adapted recipe, improved QA, .....
0
1.000
2.000
3.000
4.000
5.000
6.000
Al K Na Cl Chlorides
mg
/kg
ds
Mean 2010 Mean 2011
Mean 2012 Mean 2013
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland34
Development of Hg-valuesfor BIOBS (incl. 07/2013, n = 119)
classification according EN 15359:
class 1 for Hg, values comparable to coal
0,000
0,005
0,010
0,015
2009 2010 2011 2012 2013
mg
/MJ
Median 80th Perc.
Linear (Median) Linear (80th Perc.)
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland35
Development of important factorsinfluencing the SRF-market in Germany (01/2014)
Current German RE-legislation counterproductive for ETS and efficient use of SRF
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland36
Location of Berrenrath and Wachtbergin the Rhenish Lignite Mining Area
Source:
RWE Power
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland37
Market development of SRF/RDF in Germanybased on production specific wastes and HCF`s (03/2014)
Sum of cement and big power plants stable – dominating industrial power plants
22.04.2015 | Dr.-Ing. Th. Glorius, SRF-Workshop ERFO
REMONDIS GmbH Rheinland38
Recommendationsto develop a sustainable SRF-market
Governmental activities:
Implementation of a gradually increasing landfilling tax
Implementation of a CO2-tax for primary resources to overcome problems of CO2-certificate market
Support of energy-efficient reliable technologies (CHP) and/or innovative technologies (gasification, liquefaction) to use the potential of SRF also for transport fuels
Producers:
Activities to achieve/increase acceptance i.e. by implementing reliable QMS (CEN/TC 343) – and certification of SRF (i.e. RAL-GZ 724)
Producers and users:
Intensive cooperation
Information of population and (local) politicians
How to reach the goals the RED
without SRF?
How to reach the recycling targets
without SRF?