Pyrolysis Gasification & Melting Process

��T oyohashi R21 PlantT oyohashi R21 Plant ��

Mitsui Recycling ����

Delivered on March 2000

1984 -

1994-1998

Siemens

Mitsui1994 - 2000

License Granted in 1991

Yokohama Plant and Chiba Plant ��24t/d ��

Ulm Plant��2 00kg/h ��

Fürth Plant��4 80t/d ��

Yame Seibu Plant��2 20t/d ��

1998/8 Gas leakagetrouble at Fürth

Investigationproved no change required to design of Yame Seibu Plant

Mitsui Recycling 21Development History of R21

Mitsui Recycling 21

For: Yame Seibu Regional Administrative Association110 ton/day ××2 ��rainsStart Const. 1997��Completed March 2000

For: Ebetsu City70 ton/day ××2 trainsStart Const. 2000��Completed Nov. 2002

For: Koga City and One City, Four Towns’ Waste Disposal Cooperative130 ton/day ××2 trainsStart Const. 2000��Completed March 2003

Owner: Nishi Iburi Regional UnionOperator: Nishi Iburi Kankyo Co. Ltd105 ton/day ××2 trainsStart Const. 2001��Completed March 2003

For: Kyohoku RegionalAdministrative Association80 ton/day ××2 trainsStart Const. 2001��Completed March 2003

For: Toyohashi City200 ton/day ××2 trainsStart Const. 1998��Completed March 2002

Construction Record of R21

R21 Projects Status as of May 20, 2003

Retension time of waste in Prolysis Drum is about 1 hour,w hich homogenizes the composition of Pyrolysis Gas and Carbon against waste composition changes.

Waste is shredded into less than 200mm in length to enable its efficient pyrolysis

Pyrolysis Drum

Combustion Chamber

W.H.BoilerFlue Gas

CoolerNo.1 Bag

Filter

Induced Draft Fan

Stack

Waste

High Temp.AirHeater

High Temp.Air

Pyrolysis Gas

Carbon

High Temp.Air

Steam (40ata, 400�)

Fly AshSolid Sorting

Aluminum Steel Slag

Shredder

Electric Power Gene.

Solid Residue is cooled down to 80�in Solid Residue Cooling Drum and sorted into Steel, Aluminum, and Carbon.

Pyrolysis Gas and Carbon are burnt at 1,300�in High Temperature CombustionChamber.High Temperature Combustion will lead to the reduction of DXNs generation rate. (Water Cooled Wall Type � Prolongation of refractory life)

Heat for pyrolysis is generated at High Temp. Air Heater, not requesting suppemental fuel as long as the lower heat value of waste is more than about 1600kcal/kg

Dechlorination Residue is the only material to be sent to Land DisposalHigher Volume Reduction Ratio can be attained.

HC� < 50ppm SOx < 50ppm NOx < 100ppm DXNs < 0.1ng/Nm3

Dust < 0.01g/Nm3

DXNs �Polychlorinated- dibenzo-p-dioxin

No.2 BagFilter

Lime Hydrate

DechlorinationResidue Treat.

Land Disposal

520�

300�

450�-10mmAq

1300�

250�170�

Toyohashi R21 Process Flow

Process Flow of Pyrolysis Gasificaton & Melting Facility

Pretreatment

Bulky Waste Disposal Facility

Pyrolysis Gas

H.T. Air Htr.

W.H.B

H.T.CombusChamber

Slag

Dust (to H.T. Combus. Chamber)

Dechlorination Residue

Exhaust Gas

Stack

No.2 Bag FilterNo.1 Bag Filter

Generator

Turbine

BFWSteam

Heating Air

Refuse Bunker

Shredder

Air

Pyrolysis Drum

Preshredder Waste Conveyor

Shredder

Incombustible Waste Bunker

Pyrolysis Carbon(to H.T. Combus.Chamber)

SteelAluminum

Pyrolysis

Sorting of Solid Residue

Combustion

High Temperature AirRecovery Treatment

Electricity Generation

TOYOHASHI R21 Trend Data on Treated Amount of Waste

0

20,000

40,000

60,000

80,000

100,000

120,00020

02.4

2002

.5

2002

.6

2002

.7

2002

.8

2002

.9

2002

.10

2002

.11

2002

.12

Time

Mon

thly

Tea

ted

Am

ount

(T

/M)

0

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

90,000

Cum

ulat

ive

Tre

ated

Am

ount

(T

)

NO.1 Train Monthly Treated Amount

NO.1 Train Cumulative Treated Amount

NO.2 Train Monthly Treated Amount

NO.2 Train Cumulative Treated Amount

NO.1&2 Train Cumulative Treated Amount

No.1 Train Planned Maintenance

No.2 Train Planned Maintenance

NO.1 Train Planned Maintenance

NO.2 Train Planned Maintenance

TOYOHASHI R21 was turnovered to TOYOHASHI CITYat the end of March, 2002

Conventional IncineratorConventional Incinerator

The formation of dioxins

The increase in CO�� Emit.

����Next generation of the waste treatment facilitiesPyrolysis Gasification & Melting Process���� Mitsui Recycling 21

Gasification melting furnaceGasification melting furnace

Reduction of dioxinsSteel and

Aluminum

Slag

Hightemp.

combustion��������������

with nosupplementalenergy supply

GasLowtemp.

pyrolysis������������

Effective use

Carbon

Waste

Fuel derived from refuse by gasification

Stable combustion at low air ratio

Waste

Nonflammables Ash

Final disposal ��Landfill��

Flue gasIncinerator������������

Recover valuable materials

Flue gas

������������������

PyrolysisPyrolysis DrumDrum

Mitsui Recycling 21Specific Components of R21: Pyrolysis Drum

A-A section

waste Hot Air (Lower temperature side)

Hot Air (Higher temperature side)

Pyrolysis Gas

Pyrolysis carbon & Waste

������������������

PyrolysisCarbon

Primary Air

Secondly Air

Thirdly Air

PyrolysisGas

Dust

Flue Gas

Slag

High Temperature

Air Heater

Mitsui Recycling 21Specific Components of R21: Furness and Air Heater

High Temperature

Combustion Chamber

Operation Results of Yame Seibu Clean Center� Emission level:Guarantee vs Actual

Items Regulatory Standard Guaranteed Value Actual 2002 Average

Hcl 430 ppm 50 ppm ND

SO x 500 ppm 50 ppm ND

NO x 250 ppm 100 ppm 47 ppm

CO 100 ppm 10 ppm 0~1 ppm

Dust 0.04 g/m3N 0.01 g/m3N ND

DXNs 1 ng-TEQ/m3N 0.1 ng-TEQ/m3N 0.007 ng-TEQ/m3N

TOYOHASHI R21 Flue Gas Emission Data

Operation Results of Yame Seibu Clean Center� Utility Cost

2800 Yen/ton2800 Yen/ton3400 Yen/tonTotal

30 Yen/ton30 Yen/ton30 Yen/ton��W ater

1090 Yen/ton870 Yen/ton1540 Yen/ton��Chemicals

700 Yen/ton890 Yen/ton990 Yen/ton��E lectric

1000 Yen/ton1060 Yen/ton830 Yen/ton��F uel

200220012000�F iscal Year

Recovery of valuable resourcesNon-oxidized steel, non-molten aluminum : ReuseYame C.C. Metals: Confirm the recovery of high quality steel and

aluminum, sold out at the market price

Slag : Reuse as a asphalt composite materialYame C.C. Slag : Meeting the requirements of the Environmental

Notice No.46 for elusion test as the soil fit for agricultural useNIPPON HODOO Co., Ltd. receives the slag as the asphalt composite material at the market price.

������������������Recycle of Materials in Marketable Quality Mitsui Recycling 21

slagslagRecovered AluminumRecovered Aluminum Reuse of slagReuse of slagRecovered IronRecovered Iron

Comparison between conventionals and new process

Gasification & Conventionals �Ash-melting Ash-melting

initial cost ��� 120�150 100 150running cost ��� 120�150 100 150maintenance cost ��� 120�150 100 150number of operator 100 100 150plant area ��� 120�150 100 150recycle material Fe, Al, slag slagvolume reduction ratio ��� 1/100�1/150 1/10�1/30 1/50�1/00 �

dumping material salt, part of ash *1 salt, ash, salt, part of ash, unburnables unburnables

content of flue gasNox ppm �100�150 �100�150 �100�150Sox ppm ��30��50 ��30��50 ��30��50

Hc� ppm ��50�100 ��50�100 ��50�100Dust g/Nm3 � � 0.1 � � 0.1 � � 0.1 Co ppm ��10 ��50 ��50

Dxn gas side ng-TEQ/Nm3 � 0.1 � 0.1 � 0.1 solid side ng-TEQ/g 0.1�0.5 1� 5� � � 1�2� total discharge rate ì g-TEQ/t-waste 1�5 10�50 10�30

*1 MES is developing new technology that salt and part of ash are not necessary to be dumped.

unit Conventionals

Pyrolysis Drum

Hear Exchanger

Induced Draft FanStack

Waste

Pyrolysis Carbon

High Temperature Air

Solid Sorting System

Aluminum&Others

Shredder

Bag Filter

Dechlorination Chemical &

Activated Carbon

Land Fill

���S Carbonizing Process FlowSuitable for Low LHV Waste (Food Waste)

Pyrolysis Carbon & Flue Gas

Iron & Aluminum �Pyrolysis Carbon

Ash

Iron Pyrolysis Carbon (*1)

Flue Gas CoolerCombustion Furnace

Hot Water Generator

Fuel

Anti-Steam Plume System

Hot Water

High Temperature Air Furnace

Ash Treatment System

950 �

(*1) Potential Users

�Cement Manufacturer

����Electric Furnase Steel Maker

����Fertilizer Manufacturer

�Collected as resources �

Collected Flammable Waste

Flammable Resources (Used paper, Used cloth, Trey, etc).

(Flammable Bulky Waste)

(Nonflammable Bulky Waste)

Bulky Waste Processing Facilities (Shredding and Iron Sorting �

�Waste which can be Repaired �

�R e s idue �

Flammable Waste Processing Facilities�Pyrolysis, Combustion and Melting )

�Iron, Aluminum & Mixed Metals �

Recycle Facilities (Sorting/Pressing)

Re-used byResidents

Yame Seibu Clean Center Yame Seibu Recycle Plaza

�I r o n �

Sold as resources

Waste Treatment System of Yame Seibu Regional Administrative Association

Collected Nonflammable & Bulky Waste

Delivered Nonflammable & Bulky Waste

�Nonflammable & Bulky Waste Sorting Residue �

Delivered Flammable Waste

Nonflammable Resources (Can, Bottle, etc).

Sold as resources

Sold as resources

Sold as resources

Sold as resources

Send to landfill

Stock Yard (Stock)Work Shop (Repair/Stock)

(Can, Bottle, etc)(Paper, Cloth, Trey, etc)

(Furniture, etc)�M o lten Slag �

�D e -chloreResidue �

Dust RemovalBag Filter

DechlorinationBag Filter

HTCC

Flue GasCooler

HTAH

System Configuration of R21 Main Equipment

Stack

Power Generation & Hot Water Production

Dechlorination ChemicalHigh Temperature Air(Return)

shredder

����PyrolysisPyrolysis Gasification & Melting ProcessGasification & Melting Process ����

GasificationGasification Combustion & Melting Flue Gas CleaningFlue Gas Cleaning

Mitsui Recycling 21

SolidSorting

Waste

High Temperature Air(Supply)

Pyrolysis Gas

Pyrolysis Gas ��Flue Gas

Aluminum��Steel ��Carbon

Ash

Slag

Ash

Steam

InducedDraht Fan

Pyrolysis Drum

Carbon + Debris

Heavy Metal Fixing

-3-

WHB

Slag for Asphalt Pavement

Aluminum & Steel

ProcessProcessProcessProcessProcessProcess

Gasification and Combustion Stability of R21

0

1

2

3

4

5

6

7

8

9

10

19-1-00 22:00 20-1-00 0:00 20-1-00 2:00 20-1-00 4:00 20-1-00 6:00 20-1-00 8:00 20-1-00 10:00 20-1-00 12:00

TIME

0

0,5

1

1,5

2

2,5

3

3,5

4

4,5

5

OU

TLE

T A

IR F

LOW

RA

TE

FR

OM

DR

UM

[Nm

3/h

x 10

000]

PYROLYSIS GAS TEMP [� x 100]

TEMP. AT BTM. OF FURNACE [� x 1000]

REFUSE BUNKER DRAIN SUPPLY [l/h x 1000]

REFUSE FEED RATE [t/h]

OUTLET AIR TEMP. FROM DRUM [� x 100]

OUTLET AIR FLOW RATE FROM DRUM [Nm3/h x 10000]

PYROLYSIS GAS TEMP

OUTLET AIR FLOW RATE FROM DRUM

REFUSE BUNKER DRAIN SUPPLY

TEMP. AT BTM. OF FURNACE1333[�]

26271[Nm3/h]

OUTLET AIR TEMP. FROM DRUM

451[�]

291[�]

REFUSE FEED RATE4.01[t/h]

Excellent stability can be obtained even for the sudden waste composition change

(water injection) as shown below.

22:00 0:00 2:00 4:00 6:00 8:00 10:00 12:00

� � � � � � � �� � � � � � � � �� V SV S �� � � � � � � � �� � � � � � � � � � �� � �

��� � � � � � � �� � � � � � � �

��� � � � � � � �� � � � � � � �

0

5

1 0

1 5

0 0 / 1 / 1 7 2 3 :0 0 0 0 / 1 / 1 8 0 :0 0 0 0 / 1 / 1 8 1 :0 0 0 0 / 1 / 1 8 2 :0 0

� �� �

O2�

��

�%�

0

5

1 0

1 5

CO�

��

ppm�

O2 1

2%�

��

�

O 2 � � [ % ] Q I 6 0 0 5 - 1

C O � � [ p p m ] Q I 6 0 0 4 - 1 B

� � �� � � � � � � � � �� � �� � � � � � � � � �0 0 / 0 1 / 1 7 2 3 :0 0 � 0 0 / 0 1 / 1 8 1 1 :0 0 D C S � � � � �0 0 / 0 1 / 1 7 2 3 :0 0 � 0 0 / 0 1 / 1 8 1 1 :0 0 D C S � � � � ���

0

5

1 0

1 5

0 0 / 1 / 1 7 2 3 :0 0 0 0 / 1 / 1 8 1 :0 0 0 0 / 1 / 1 8 3 :0 0 0 0 / 1 / 1 8 5 :0 0 0 0 / 1 / 1 8 7 :0 0 0 0 / 1 / 1 8 9 :0 0 0 0 / 1 / 1 8 1 1 :0 0

� �� �

����

���� [pp

m] [

%][p

pm]

[%]

C O � � [ p p m ] Q I 6 0 0 4 - 1 B

O 2 � � [ % ] Q I 6 0 0 5 - 1

�� ��

� � � � � � � � � � � � � 1 9 �

� � � � �

� 2 � � � � � � � � � � � � � � � �

� 2 � � � � � � �

� � � � � � � � �

Fluidized Bed Type

Enlarged

O2 Concentration

CO Concentration

O2 Concentration

CO Concentration

Mitsui R21 DCS DATA From 00/01/17 23:00 to 00/01/18 11:00

Attachment 2 Mitsui R21 vs. Fluidized Bed TypeTrend Data on Flue Gas Composition �� Combustion Stability

Comparison of new process

unit Kiln type Fludized Bed Shaft

initial cost [-] 100 100 150

running cost [-] 100 120 150

number of operator [-] 100 120 150

plant area [-] 100 100 120

recycle material Fe, Al, slag Fe, Al, slag mixed metal

volume reduction ratio [-] 1/100..1/150 1/100..1/150 1/50..1/100

dumping material slag

content of flue gas

Nox ppm <100..150 <100..150 <100..150

Sox ppm <�30..�50 <�30..�50 <�30..�50

Hc� ppm <�50..100 <�50..100 <�50..100

Dust g/Nm3 � < 0.1 < 0.1 < 0.1

Co ppm <�10 <�30 <�30

Dxn

gas side ng-TEQ/Nm3 � < 0.1 � < 0.1 < 0.1

solid side ng-TEQ/g � < 0.1 � < 1� � < 1�

total discharge rate ì g-TEQ/t-waste � < 1..2� � < 5� � < 5�

auxilially fuel no required cokes

operation technique easier harder more harder

Comparison of conventional process

unit Fludized Bul Stoker

initial cost ��� 100 100

running cost ��� 100 100maintenance cost ��� 100 120

number of operator ��� even even

plant area 100 100recycle material ��� unburnables

volume reduction rate 1-30 1-10

dumping material fly ask bottom & fly ash

content of flue gas

Nox ppm �100�150 �100�150Sox ppm ��30��50 ��30��50

Hc� ppm ��50�100 ��50�100

Dust g/Nm3 � � 0.1 � � 0.1 Co ppm ��50 ��50

Dxn

gas side ng-TEQ/Nm3 � � 0.1 � � 0.1 solid side ng-TEQ/g � � 1� 5� � � 1� 5� total discharge rate ì g-TEQ/t-waste 10�30 30�50

operation technique easier harder

start & stop Daily start & stop is possible harder

suitable capacity t/day �100�300 �300

Pyrolysis Drum

Induced Draft FanStack

Waste

Pyrolysis Carbon

High Temperature Air

Solid Sorting System

Aluminum&Others

Shredder

Bag Filter

Dechlorination Chemical & Activated Carbon

Land Fill

R 2 1 S Carbonizing Process FlowSuitable for High LHV Waste (ASR)

Pyrolysis Carbon & Flue Gas

Iron & Aluminum �Pyrolysis Carbon

Ash

Iron Pyrolysis Carbon (*1)

Flue Gas Cooler

Combustion Furnace

Fuel

Anti-Steam Plume

System

High TemperatureAir Furnace

Ash Treatment System

High Temp. Air Heater

Boiler

Steam

(*1) Potential Users

�Cement Manufacturer

����Electric Furnace Steel Maker

����Fertilizer Manufacturer

950 �