ECO ASIA CONFERENCETheme : Innovation, Development and Exchange of Green Tech
(Session II – Waste Management and Recycling)
27th October,2011
1Copyright 2011 © JFE Engineering Corporation All Rights Reserved
Hajime FUKAI
Waste-to-Energy TechnologyDevelopment in Japan
– for obtaining Clean Environment –
CONTENTS
WASTE MANAGEMENT~ Transition History and the Future ~
Copyright 2011 © JFE Engineering Corporation All Rights Reserved 2
1.Waste Management Trajectory2.Facts & Figures of Waste Management3.Thermal Treatment of MSW4.Pollution Control Technology
– WtE in the City –5.Emerging Technology
Part 1.Waste Management Trajectory
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41900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000 2010
NOWASTEMANAGEMENT
MODERN WASTE MANAGEMENT
RECYCLE
START WASTE MANAGEMENT
+ 1880s~ PANDEMIC (CHOLERA, PEST, etc.)+ OPEN BURNING+ UNSANITARY ENVIRONMENT
-1900
+ 1900 WASTE CLEANSING LAW> LOCAL GOVERNMENT RESPONSIBILITY> INCINERATION AS PRIORITY
+ 1903 Mechanical INCINERATOR Start
WASTE INCREASE BY GOOD ECONOMYRAISED IMPROPER TREATMENT
+ 1970 WASTE MANAGEMENT ANDPUBLIC CLEANSING LAW
+ Waste-to-Energy Plant START
+1991 Promotion Law+1995 Container/Packaging+1998 Home Appliance+2000 Recycle Basic Law+2000 Construction /Food /Car
YEAR
2020
+ 1990 DIOXIN Guideline+ 1999 DIOXIN Law
PROTECT HUMAN HEALTHfrom UNSANITARY ENVIRONMENT
To SUSTAINABLE SOCIETY
THERMAL RECYCLING
EMISSION CONTROL
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Waste Management Trajectory in JAPAN
Pest, Odor, Soil/Water Pollution, Fire ⇒ Decades-long Pollution
■Organics in Landfill
Difficult to Secure New Landfill■Limited Land Area
Direct Disposal
Domestic Waste Landfill
■Methane from Landfill Cause of Global Warming(CH4 has 21 times larger effect as CO2 )
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Why Thermal Treatment? (Disadvantage of Direct Disposal)
Waste Process Flow
Segregation
“R”educe
Collection, Transport, Storage
“R”ecycle, “R”euse (resource recovery)
(thermal recovery)
Intermediate Treatment
Final Disposal
Process for SAFE final disposal
Thermal Treatment
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Position / Meaning of Thermal Treatment (as an Intermediate Treatment)
Part 2.Facts and Figures of
Waste Management
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25
30
35
40
45
50
55
60
1985 1987 1989 1991 1993 1995 1997 1999 2001 2003 2005 2007 20090.8
0.9
1.0
1.1
1.2
1.3
1.4
1.5
BubbleEconomy
3R PolicyRecycle policy
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MSW Volume TrendM
SW V
olum
e (m
illio
n t/
year
)
Per
Capi
ta R
ate
of M
SW (
kg/d
ay/p
erso
n)
Fiscal Year Source : Ministry of Environment(Japan)
Per Capita Rate of MSW
MSW Volume
122122130133138145153160165172178172 116
18
15.715.614.8
141413.813.212.812.9
11.7
12.8
18.7
0
100
200
300
1997 1999 2001 2003 2005 2007 20090
7
14
21
3R Policy
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Landfill Lifetime ExtensionRem
aini
ng C
apac
ity (
mill
in m
3)
Rem
aini
ng Y
ears
Fiscal Year Source : Ministry of Environment(Japan)
Remaining Years
Remaining Capacity
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Waste Flow in Japan
data FY:2008Source : Ministry of Environment(Japan)
Unit: million tons
Total Waste Volume
48.1(100%)
Planned Treatment
45.2(94%)
IntermediateTreatment
42.0(87%)
Direct Recycling2.4 (5%)
Reclamation4.5 (9%)
Group Collection2.9 (6%)
Direct Final Disposal0.8 (2%)
Final Disposal4.7 (10%)
"R"EDUCEWith
Thermal Treatment32.8
(68%)
"R"ECYCLE9.8
(20%)
LANDFILL5.5 (12%)
Recycling42%
Landfilling38%
ThermalTreatment
20%
33 million tons of MSW per yearGoes To
1,243 Thermal Treatment plants
Recycling20%
Landfilling12%
ThermalTreatment
68%
Source: CEWEP
Source: Ministry of Environment
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Treatment Proportion
Recycling34%
Landfilling54%
ThermalTreatment
12%
29 million ton/y - MSWWith 85 plants
Source: USEPA
60 million ton/y - MSWWith 420 plants
1970 Waste Management Act
1990 Publication of Dioxin Emission Standards
2000 Low concerning Special Measures against Dioxins ⇒Below 0.1ng-TEQ/Nm3
1991 Partial Revision of Waste Disposal Act & Waste Management Act
Y-city (900tpd) F-city (600tpd) T-city (600tpd) Y-city (1,200tpd) O-city (900tpd)
1952 Waste Disposal Act
LHV
of W
aste
(kJ
/kg)
2000
4,000
6000
8000
10,000
12000
14000
1965 1970 1975 1980 1985 1990 1995 2000 2005
History of Major Updates on Environmental Acts in Japan
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Waste Heat Value Trajectory in Japan
LHV : Lower Heat Value
LHV history of MSW in Design condition●
Hu=max■
Hu=ave▲
Hu=min
Y-City
F-CityO-City
T-City
Part 3.Thermal Treatment
of MSW
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Incinerator Waste Incinerator with Moving Grate
( Facilitate together with Incinerator )
Stoker
Gasification & Melting Furnace
Fluidized Bed
Kiln Incineration in Revolution Cylinder
Incineration by touch with Fluidized Hot Sands
Direct Melting from Waste to Slag/Metal
Shaft type
Fluidized Bed type
Kiln type
Ash Melting Furnace Melting Ash by means of Electricity or Fuel
Melting in Cylindrical Shaft with Auxiliary Heat SourceGasification by Fluidized Bed and Melting with its Own HeatGasification by Kiln and Melting with its Own Heat
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Stoker (sometimes with Ash Melting) is Most Popularly Adopted in Japan.And is followed by various Types of Gasification.
TYPES of Thermal Treatment
1970 1980 1990 2000 2010
STOKER
Gasification & Melting FurnaceFluidized Bed
Dioxin Laws& Regulations (98% Reduction achieved
from ’97 to ‘03)▲Dioxins issue & RDF emerged
Guideline to Facilitate Melting Furnace
New Generation STOKER
▲Modern Mechanical Incinerator
STOKER+Ash Melting
▲Waste-to-Energy start
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History of Thermal Treatment
▲2000
▲1997
198 199
191
184 185177 176 175 172
169
16521692
1436 13291295
1230 1205 1185 1164 1133
150
170
190
210
500
800
1100
1400
1700
161514
131110
86
22
9291878377
7058
46
1722
0
5
10
15
20
25
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
Fiscal Year
0
50
100
Source : Ministry of Environment (Japan)
Plan
t N
umbe
r
Tota
l Cap
acity
(,0
00 t
/day
)
Plant Number
Total capacity
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Two Major Thermal Treatment - Stoker and Gasification -
STOKER
GASIFICATION
Total capacity
Plant Number
Hopper
Waste feeder
Stoker Grate
Boiler
Two WayFlue Gas System
Waste To Flue Gas Treatment
Bottom ash
Chute
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Stoker Furnace
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Typical Flow of Stoker
Slag and MetalSlag and Metal
Secondary TuyereSecondary Tuyere
Main TuyereMain Tuyere
Third TuyereThird Tuyere
WasteWaste Coke & LimestoneCoke & Limestone(Sub(Sub--materials)materials)
Coke LayerCoke Layer
Gasifying LayerGasifying Layer(Drying and Pyrolysis zone)(Drying and Pyrolysis zone)
FreeboardFreeboard(Gas reforming zone)(Gas reforming zone)
Molten Slag BasinMolten Slag Basin
((High temperature High temperature melting zone)melting zone)
Combustion GasCombustion Gas
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Gasification and Direct Melting Furnace
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Typical Flow of Gasification
MSW 1.5m3
(1t)MSW 1.5m3
(1t)
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Gasification REDUCES Ash to Landfill
0.19m3
Ash Fly Ash
0.05m3
Fly AshSlag&
Metal0.05m3
Recycle0.24m3
to Landfill
to Landfill
Waste TYPICAL CONTENTS OF the WASTE
GASIFI- CATION STOKER
High LHV Waste
- Disposed Plastic- ASR- RDF
○ ○
Moist Waste- Kitchen Garbage- Sludge ○ ○
Waste with Ash
- Slag from Incinerator- Excavated Landfill Waste- MBT Residual waste
○ -
Hazardous Waste
- Medical Waste- etc. ○ -
Ash
Water
Water VolatilesCombustibles
Fixed Carbon
Ash
Coke
Gasification VERY WIDE range of WASTE can be applied
to Gasification by means of COKE additive rate.
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Gasification for Wide Range of Waste
Stoker SystemStoker SystemStoker System Gasification SystemGasification SystemGasification System
CONVENTIONAL TechnologyWell PROVEN with 40 years operation
EMERGING TechnologyPROVEN with 10years
WIDE range of CAPACITY Very WIDE range of Waste Type
Discharge ash and fly ash to landfill Less Discharge without ashOnly fly ash to landfill
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Thermal Treatment Technologies
Part 4.Pollution Control Technology
-- WtE in the City --
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Item Emission Standard (Japan) Measured Value
Dioxins
> 4 t/h 0.1ng/Nm3
> 0.05 ng/Nm32<x t/h<4 1 ng/Nm3
< 2 t/h 5 ng/Nm3
Particulate
> 4 t/h 0.04g/Nm3
Bag Filter 0.002 - 0.007 g/Nm32<x t/h<4 0.08g/Nm3
< 2 t/h 0.15g/Nm3
Hydrogen ChlorideHCl
700 mg/Nm3 (O2 12%)( approx. 430ppm )
Dry (Semi-Dry) 20 - 50 ppm
Wet 20 - 30 ppm
Sulfur OxidesSOx
K – Value( specified in each area )
20 - 30 ppm
Nitrogen OxidesNOx
250 ppm( O2 12% )
Non-Catalyst 50 – 100 ppm
Catalyst 20 – 50 ppm
Combustion Control 80 – 100 ppm
Furnace Water Spray 60 – 80 ppm
Flue gas recirculation 60 – 80 ppm
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Japanese Emission Standard, Actual Emission & Treatment Process
Waste receivingIncinerator & Boiler Gas cooling Flue gas treatment
AC injector
Bag filter
Gas cooling tower
Homogenizing wastes by crane
Sufficient capacity of waste pit Flue gas Temp = Above 850 deg.C
Residence Time = more than 2 sec.Turbulence
Removing Dust in boiler
3. Dioxin removal by Activated Carbon
1. Dioxin reduction control
Dioxin conc. 0.1ng-TEQ/mN3
Water
2. Inhibit Dioxin re-generation by quenching flue gas temp.
3Ts
4. Dioxin decomposition by SCR
Stack
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Reducing DIOXINs
27Combustion and post-combustion Zone
Achieves “3T” to suppress Dioxin formation
T1 :
High temperature (850 to 950 deg C)T2 :
Retention time(2sec)T3 :
Turbulence
Secondary Combustion ZoneFor unburned gas :
Oxidation reaction2CO+O2 → 2CO2For combustion gas :
Reduction reactionNOx +NH3 →
N2+H2
O
Drying Zone
Intermediate ceiling
Combustion gasO2 , NOx, CO2
Unburned gasCO, H2 , NH3
Achieves complete combustion
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Combustion Mechanism
No. Facility
Applied Technologies for reducing DXNs emissionEmission Standard
ng-TEQ/Nm3
Measured Resultng-TEQ/Nm3Two-way
Flue Gas Furnace
Hybrid ACC
Boiler + Gas Cooling Tower
Activated Carbon
InjectionSCR
1 S-City90 t/d ×
3 ○ ○ ○ ○ ○ 0.10.000430.000430.0027
2 K-City140 t/d ×
2 ○ ○ ○ ○ ○ 0.05 0.00870.0027
3 O-City450 t/d ×
2 ○ ○ ○ ○ ○ 0.1 0.00000650.0008
4 K-City150 t/d ×
1 ○ ○ ○ 0.1 0.017
5 R-City90 t/d ×
2 ○ ○ ○ ○ ○ 0.1 0.0160.028
6 Y-City400 t/d ×
3 ○ ○ ○ ○ ○ 0.10.000260.000210.00045
7 M-City135 t/d ×
3 ○ ○ ○ ○ ○ 0.10.0027
0.030.0028
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Dioxin Actual Measurement
School
WtE Plant Hospital
Train Station
Date Completed: March 1991Capacity : 300ton/day x 2 lines
Power Output : 11,000 kW
M‐plant
500m
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Surrounding of WtE Plant ( case1 )
Date Completed: January 1997Capacity : 300ton/day x 2 lines
Power Output : 12,300 kW
300m
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Surrounding of WtE Plant ( case2 )
School
WtE Plant Hospital
Train Station
E‐plant
Part 5.Emerging Technology
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Higher Efficiency Waste-to-Energy
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Low Temperature Economizer
High Temperature & High Pressure Boiler
Low Air-Ratio Combustion(High Temperature Air / Flue Gas Recirculation)
More Stable CombustionLess Heat Loss
Conventional Technologies
Low Air-Ratio Combustion
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Blow Out
Soot GenerationSpot ExcessTemperature
ConventionalTechnology
Unstable Combustionwith Low Air-Ratio
High Temperature Air
LatestTechnology
STABLE Combustion with Low Air-Ratio
High Temp. Air Layer
AirGrateWaste
High-temperature air injectionFlue gas recirculation
33
Higher Efficiency Waste-to-Energy
304
plants443
plants(36%)
NoHeat Utilization
Power Generation
Generation Capacity
1,673MW
Subsidy to High Efficiency Waste-to-Energy(Subsidy Rate 1/3→1/2)
Plant Capacity(t/d)
Power Generation Efficiency (%)
150~200 15.5200~300 17300~450 18.5
Only 24% of total plants have power generation
Subsidy Tariff Table
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Power Generation Efficiency=Generation Power×100
Input Energy ( Waste + Fuel )
(24%)PlantNumber
1243
Policy in Waste ManagementAgainst Global Warming
496
plants(40%)
Other Heat Utilization
Combination of MSW and Sewerage(Energy Efficiency Improvement)
■Kitchen Waste
Digester Tank Gas Holder
Steam Turbine Generator
■Sewage
Turbine Exhaust Condenser
Steam
DigestiveSludge
Waste to Energy■MSW
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Sewerage
Sludge
Sludge Fuel
Waste Heat
Sludge Dryer
Bio Gas
Treated Water
Earthquake Debris On-Site Treatment Plant(Sendai City)
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TreatmentVolume : 70,000 ton / 2.5 years
Construction : May. 2011 to Sep. 2011Operation : Oct. 2011 to Mar. 2014
Debris
Gas Treatment
Furnace
Crushing
Crushed Debris
We deeply appreciate the Kizuna our friends around the world have shown and I want to thank every nation, entity, and you personally, from the bottom of my heart.
the bonds of friendship
37
Thank you
38