1

THERMOSELECT

THERMOSELECT – An Advanced Field Proven High Temperature Recycling Process

THERMOSELECT S.A.

Via Naviglio Vecchio 46600 LocarnoSwitzerlandOctober 12-15,

2003

2

THERMOSELECTPRESENTATION OUTLINE

• Company Information

• Technology

• Karlsruhe Plant / Germany

• ASR Processing (Automotive Shredder Residue)

• Chiba + Mutsu Plant / Japan

3

THERMOSELECTCOMPANY INFO

Company founded in 1989

1989 – 1991: Laboratory scale studies of waste degasification, carbonization and gasification

1991 – 1992: Development and erection of an industrial scale pilot plant in Fondotoce / Italy

1992 – 1998: Fondotoce plant operation, process optimization and technology demonstration

1998 – 1999: Erection of commercial plants in Karlsruhe / Germany and in Chiba /Japan

150 employees, headquarter in Locarno /Switzerland, manufacturing subsidiary in Dottikon / Switzerland

Licensees:• JFE Engineering, Japan (Kawasaki Steel + NKK)• Daewoo Engineering, Korea

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THERMOSELECTPROCESS OVERVIEW

Zinc Concentrate

Salt

Clean water

Sulfur

Synthesis Gas Production ofHydrogen Methanol Ammonia

or Power

generation

O2Press

Degassing Channel

Oxygen facility

Homogenization reactor

QuenchHigh Temperature Reactor

Waste of all kinds

Process water treatment

Synthesis gas scrubbing

Metals and Minerals

1600°C2000°C

1200°C

Scrubber

H2, CO, CO2, H2O

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THERMOSELECTSYNTHESIS GAS SCRUBBING

Syn. gas Quench Acidic Scrubber Alkaline Scrubber De-dusting stage Desulfurization Drying

Safety Flare

Heat Exchanger

Filter

Degassing

Feed tank

Water lock Filtration

Sludge

Filtrate

Additive, new

Filtration Filtrate

Sludge

Sedimentation

Regeneration Air

AdditiveIron Chelate

Syn. gasscrubbing

Watertreatment Products

Sulfur Pure syn. gas

Raw water buffer Oxidation

Sludge back feed

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THERMOSELECTTHERMAL TREATMENT, GASIFIER

1200 °C

1600 °C

2000 °C

Quench

Burner / oxygen lances

Melt cooling

Exothermic ReactionsC + O2C + 1/2 O22 CnHm + (2n + m/2) O2

Endothermic ReactionsC + H2O CO + H2OC + CO2CnHm + nH2O

CO2CO2nCO2 + mH2O

CO + H2CO2 + H22 CO (Boudouard)nCO + (n + m/2)H2

Controlled injection of oxygen is used to gasify

organic components at temperatures up to 2000°C.

The produced synthesis gas is primarily composed of

H2, CO, CO2

Metal and mineral constituents are molten

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THERMOSELECTSYNTHESIS GAS SHOCK COOLING

Quench

1200 °C

70 °C

Cooling water (pH value < 3)

30 ms

The synthesis gas produced in the gasifier is shock-

cooled in the quench immediately downstream.

Cooling takes place in lessthan 30 ms.

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THERMOSELECTTYPICAL GRANULATE COMPOSITION

Typical metal granulate (wt%) Typical mineral granulate (wt%)

Metal and mineral granulate is ready for reuse.

The vitreous mineral granulate leachability complies with strictest regulations.

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THERMOSELECTTHERMAL TREATMENT, GASIFIER COOLING

Refractory

Gasifier interior

The reactor wall consists of a thermally-insulating refractory lining.

The highly stable refractory material is protected by a slag coating of vitrified

mineral melt.

Liquid mineral melt runs off the slag coating.

Inner Cooling

Outer Cooling

Slag coating

Cooling Elements with Slag Coating

Gasifier Bottom

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THERMOSELECTTHERMOSELECT PROCESS

High Temperature Recycling (> 99.5% Material Recovery)

Lowest Emissions (Dioxin Destroyer, Total << 1 µg/Mg)

Synthesis gas for flexible utilisation (Power, Hydrogen ...)on site or over-fence

Broad range of wastes can be processed, EC directive:

“If hazardous wastes with a content of more than 1% of halogenated organic substances, expressed as chlorine, are incinerated, the temperature has to be raised to 1’100 °C for at least two seconds“

Current plants are operated on:

MSW Japan, low inerts, high moisture (Chiba & Mutsu)MSW Germany, high inerts (Karlsruhe)Industrial waste Japan (Chiba)ASR, high Chlorine, high LCV (Karlsruhe & Chiba)RDF, high LCV (Karlsruhe)

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THERMOSELECTMASS BALANCE

Waste1000 kg

Oxygen, Natural Gas, Additives514 kg

Mineral Material230 kg

Metals29 kg

Sulfur2 kg

Zinc Concentrate3 kg

Salt10 kg

Clean Water (cooling tower)350 kg

Purified Synthesis Gas890 kg

Synthesis Gas Scrubbing

Process Water TreatmentCompressionDegassing

GasificationMeltingHomogenization

Typical mass balance for Municipal Solid Waste

(MSW)

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THERMOSELECTDIVERSION FROM LANDFILL

Vitreous Mineral Granulateapprox. 20-25 % of Input

Iron-Copper Alloyapprox. 1- 3 % of Input

Sulfurapprox. 0.2 - 0.3 % of Input

Saltapprox. 1 % of Input

Zinc-Concentrateapprox. 0.2 - 0.3 % of Input

Metallurgy

Chemical Industry, Additive forMetallurgy

Chemical Industry, i.e. Sulfuric Acid Production

Zinc-Recovery

ConcreteSand-BlastingRoad Construction

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THERMOSELECTENERGY BALANCE

Input total

3733 kWh/Mg

1310 kWh/Mg Rejected Heat and Plant Requirement (Evap.)

Synthesis Gas 2423 kWh/Mg

Surplus Electricity

705 kWh/Mg

Heat used internally460 kWh/Mg

Plant E-consumption 328 kWh/Mg

Heat LossGas Engines930 kWh/Mg

Electricity 1033 kWh/Mg

4 line plantgas engine power generation

12 MJ/kg Waste

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THERMOSELECTKARLSRUHE

Karlsruhe - Germany

Company: TESS (Thermoselect Südwest)

Status: in service

Start-up: Feb. 1999

Capacity: 225‘000 Mg/a

No. of lines: 3 lines 10 Mg/h each

Heating value: 12‘000 kJ/kg

Syn. gas utilization: steam vessel & steam turbine,

district heating

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THERMOSELECTKARLSRUHE – MSW OPERATION DATA

0

5000

10000

15000

20000

25000

30000

15-M

ay-2

003

22-M

ay-2

003

29-M

ay-2

003

5-Ju

n-20

03

12-J

un-2

003

19-J

un-2

003

26-J

un-2

003

3-Ju

l-200

3

10-J

ul-2

003

17-J

ul-2

003

24-J

ul-2

003

31-J

ul-2

003

7-A

ug-2

003

14-A

ug-2

003

Thro

ughp

ut [k

g/h]

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THERMOSELECTKARLSRUHE – MSW OPERATION DATA

0

5000

10000

15000

20000

25000

30000

35000

18-M

ay-03

19-M

ay-03

20-M

ay-03

21-M

ay-03

22-M

ay-03

23-M

ay-03

0

10

20

30

40

50

60

70

Waste [kg/h]Syngas [Nm3/h]

Steam [t/h]

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Plant Performance Karlsruhe 2002 THERMOSELECT

Overall Train 1 Train 2 Train 3Product not required 1% 1% 1% 1%Planned Outages 23% 26% 31% 27%Outage Power unit (part of planned outage) 0% 1% 1% 1%Unplanned Outages 0% 7% 7% 7%

Onstream 76% 66% 62% 65%

Yearly Throughput (metric tons) 100,100 35,009 30,691 34,400(mmscf) 3,535 1,236 1,084 1,215

Forced Outage Rate 0% 9% 10% 10%

Availability 77% 67% 63% 66%

Rated Capacity (mmscf) 9,308 3,103 3,103 3,103

Annual Loading Factor 38% 40% 35% 39%

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THERMOSELECTTHERMOSELECT PLANTS

Kawasaki Steel Chiba Plant - Japan

Company: Kawasaki Steel Corporation

Status: In service

Start-up: Sept. 1999

Capacity: 100‘000 Mg/a

No. of lines: 2 lines 6.25 Mg/h each

Heating value: 8‘500 kJ/kg

Syn. gas utilization: One Jenbacher Gas Engine

and in CC power plant

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THERMOSELECTCHIBA - THROUGHPUT

0

50

100

150

200

250

300

350

Sep 99

Okt 99

Nov 99

Dez 99

Jan 0

0Feb

00Mrz

00Apr

00Mai

00Ju

n 00

Jul 0

0Aug

00Sep

00Okt

00Nov

00Dez

00Ja

n 01

Feb 01

Mrz 01

Apr 01

Mai 01

Jun 0

1Ju

l 01

Aug 01

Sep 01

Okt 01

Nov 01

Dez 01

Jan 0

2Feb

02Mrz

02Apr

02Mai

02Ju

n 02

Jul 0

2Aug

02Sep

02Okt

02Nov

02Dez

02Ja

n 03

Feb 03

Mrz 03

tons

/d

Line 2

Line 1

Household Waste

Industrial Waste (construction debris, waste plastics, sludge, waste papers, waste woods)

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Plant Performance Chiba 2002 THERMOSELECT

Overall Train 1 Train 2Product not required 0% 0% 0%Planned Outages 6% 6% 9%Unplanned Outages 1% 6% 4%

Onstream 94% 88% 88%

Yearly Throughput (metric tons) 75,552 37,563 37,989(mmscf) 2,668 1,327 1,342

Forced Outage Rate 1% 6% 4%

Availability 94% 88% 88%

Rated Capacity (mmscf) 4,125 2,062 2,062

Annual Loading Factor 65% 64% 65%

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THERMOSELECTKARLSRUHE PLANT – SHREDDER DUST PROCESSING

End-of-life vehicles

ASR / Shredder-dust

THERMOSELECT

EU end-of-life directive forvehicles, recycling rates:

2006 – 85%2015 – 95%

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THERMOSELECTSHREDDER DUST TEST

Test Procedure:

- Throughput: 428 t ASR

- Time period: 66 h, ca. 3 days from 27.-29. of November 2002

- Mixture: 40 - 55 Gew.-% ASR, mixed with MSW

- Throughput per line: approx. 7.8 t/h (up to 4.3 t/h ASR)

Sampling /Analysis:

- Air emissions- Granulate - Sulfur- Zink concentrate- mixed salt

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THERMOSELECTKARLSRUHE PLANT – SHREDDER DUST COMPOSITION

Trial operation 11/2002Sample 1 Sample 2 Sample 3 Sample 4

Heating value, LCV kJ/kg 7,000 - 10,000 16,940 10,280 11,350 14,920Ignition residue 550°C weight-% 79.3 79.6 79.6 78.8Water weight-% 25 - 35 11.8 20.5 23.9 16.4Hydrocarbons mg/kg DS - 10,500Iron weight-% DS 2 - 5 12.0 10.7 26.6 13.36Chloride weight-% DS 0.1 - 1 1.8 1.72 3.18 3.52Fluoride weight-% DS 0.01 - 0.02 0.01 0.02 0.01 0.01Sulfur weight-% DS 0.05 - 0.5 0.2 0.3 0.2 0.2Copper g/kg DS 0.1 - 2 8.4 3.6 25.6 5.3Zinc g/kg DS 0.4 - 4 14.0 9.9 13.5 15.0Chromium g/kg DS 0.2 - 2 0.6 0.3 0.5 0.4Tin g/kg DS 0.05 - 0.5 0.03 0.003 0.01 0.05Barium g/kg DS 0.1 - 1 0.31 0.202 0.42 0.56Lead g/kg DS 0.2 - 2 4.4 2.7 2.4 4.7Antimon mg/kg DS o.A.** 94 72 226 512Arsenic mg/kg DS 1 - 8 11.6 10.0 16.5 13.1Cadmium mg/kg DS 3 - 30 21.8 25.1 31.3 37.3Mercury mg/kg DS 0.3 - 10 2.1 4.1 2.6 1.6

Parameter MSW Literature

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THERMOSELECT

0%

20%

40%

60%

80%

100%D

ust

SOx

NO

x

CO

HC

l

HF

Mer

cury

Tota

l C

Cad

miu

m /

Thal

lium

Sum

Hea

vy M

etal

s

Dio

xins

/ Fu

rans

Law

0,31

mg/

m3

3,5

mg/

m3 52

,3 m

g/m

3

3,24

mg/

m3

0,05

mg/

m3

nn

0.00

23 m

g/m

3

0,82

mg/

m3

0,00

0014

mg/

m3

0,00

87 m

g/m

3

0,00

21 n

gTE

/m3

Permit

Average2002

ASR Test

ASR TEST – EMISSIONS (average per day)

Current emissions are displayed at www.thermoselect-karlsruhe.de

3 m

g/m

3

10 m

g/m

3

70 m

g/m

3

10 m

g/m

3

2 m

g/m

3

0.2

mg/

m3

0.01

mg/

m3

2 m

g/m

3

0, 0

1 m

g/m

3

0,03

mg/

m3

0,01

ngT

E/m

3

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THERMOSELECTASR TEST – MINERAL GRANULATE COMPOSITION

0%

100%

200%

300%

400%

500%

Ars

enic

Ant

imon

Lead

Cad

miu

m

Chr

omiu

m

Iron

Cop

per

Nic

kel

Mer

cury

Zinc Tin

green - reference before test (MSW)

red - during test (ASR/MSW)

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THERMOSELECT

0%

100%

200%

300%

Ars

enic

Ant

imon

Lead

Cad

miu

m

Chr

omiu

m

Iron

Cop

per

Nic

kel

Mer

cury

Zinc Tin

Cob

alt

green - reference before test (MSW)

red - during test (ASR/MSW)

ASR TEST – MINERAL GRANULATE LEACHABILITY

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THERMOSELECTTHERMOSELECT PLANTS

Mitsubishi Materials Mutsu Plant - Japan

Company: Mitsubishi Materials Corporation

Status: In service

Commercial op.: April 1st, 2003

Capacity: 140 Mg/d

No. of lines: 2 lines 2.9 Mg/h each

Heating value: 7.1 – 9. 3 MJ/kg

Syn. gas utilization: Two Jenbacher Gas Engines

1.2 MW each

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THERMOSELECTCONCLUSIONS

Thermoselect plants are extremely environmental friendly in terms of emissions and resource recovery

The Thermoselect process has a multipurpose capability, various types of wastes with a broad range of heating values and compositions can be processed in a single plant

With three commercial plants in operation, Thermoselect technology is now proven

Currently, four further plants are under construction in Japan