OPTIMIN: Innovative Bottom Ash Treatment for Resourcing different

Mineral Components as ConstructionMaterial

Stefan Lübben(Climate Protection Management)

2nd International VDI Conference, 11./12.10.2016

2nd International VDI Conference

Metals and Minerals Recovery from IBA 11. - 12. October 2016

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1. Initial situation around IBA in Hamburg2. Reasons for changing3. Project „OPTIMIN“4. Further ideas

Structure

1) Development of the incinerationcapacities in Hamburg

Incineration plantContract with SRH until 2016

Incineration plantContract with SRH until 2019,45% ownership

SRH-owned incineration plantCapacity: 180,000 tons/a

Hamburg

SRH-owned incineration plantCapacity: 320,000 tons/a

Plant in Stellingen was closed on 21.06.2015 – after 42 years

2014: Capacity for incineration ~ 1 Mio. t/a2017: Capacity for incineration ~ 0,6 Mio. t/a

At the end of 2016 we will stopour supply to WtE Stapelfeld

1) Quantity of IBA from household-waste in Hamburg in 2015

2nd International VDI Conference

Metals and Minerals Recovery from IBA 11. - 12. October 2016

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Lower Saxony, Hamburg, Schleswig-Holstein supply the waste

4 incineration plants

Raw ash (IBA)

Treatment plants withcalcination / maturingRecycling of Fe- andNF-metals

Storage of refining slag

Trading and sale as a secondary constructionmaterial / disposal on a landfill

1) IBA as a secondary raw material

IBA as base layerbeneath pavement

CTA Hamburg 2015

Decreasingapplication ofIBA as baselayer withoutbinding agent:2001 = 98%, 2004 = 95%,2008 = 74%

Correspondingincrease in application asbase layer withbinding agent

2nd International VDI Conference

Metals and Minerals Recovery from IBA 11. - 12. October 2016

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1. IBA should be used as a secondary raw material forconstruction

2. SRH as a public enterprise has to be a front-runnerfor sustainability and is in the public eye

3. Dumping the IBA is more expensive than its usageas a construction material

4. Current drafts of the „Mantelverordnung“ offer morestringent conditions for some parameters, e.g.- chlorides- sulfates- Antimon- …

5. If we do not act very soon, we have to dispose theIBA in the near future

2) Reasons for changing…

Results from a finished project (r³ - ATR):

During treatment, the TARTECH plant generates mass flowswith 0-2 / 2-5 / 5-18 / 18-45 mm particle size for an optimizedmetal recovery

These mass flows are mostly free of metals and free of finestparticles with their high content of chlorides and sulfates. Theyare completely different to the common IBA

Dividing into several cornsize-ranges might be the opening in their usage as components in the concrete and tarmac industry

Frac

tion

2 -5

mm

Frac

tion

5 -1

8mm

2) Reasons for changing…

2nd International VDI Conference

Metals and Minerals Recovery from IBA 11. - 12. October 2016

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2) Reasons for changing…

Chloride and Sulfate Content of IBA according to the sieve fraction

High content of salts is the major problem of IBA as construction material

[Eluat nach DIN EN 12457-4 (S4-Verfahren, Feststoff-Flüssigkeit 1:10, 24h Überkopfschüttler) ,Koch, S. 2016: Untersuchung der Depo-nierbarkeit ausgewählter Siebschnitte von aufbereiteter Schlacke der Hamburger Müllverbrennung, Masterarbeit TU Braunschweig]

LAGA M20Z 1.2

Close cooperation between the producer of the IBA, the treatment plants, the trader, the potential consumers (suppliers of building materials) and thescientific world

The interests of all members of the value chain areinvolved in the project

Only uncalcinated IBA is used because it is much easier to devide it into its components

Run-time of the BMBF-Project: 1/2016 – 6/2018Subsidies 570.000 €, total costs 1.000.000 €

The amount of metals needs to be reduced to the absolute minimum, because they interfere the application of IBA asa building material

The amount of glass should be reduced

3) OPTIMIN: Optimization of thematerial recycling of mineralresidues from waste treatment

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3) OPTIMIN: Optimization of thematerial recycling of mineralresidues from waste treatment

Targets of this project: Washing out the particles < 200 µm to remove the

chlorides, sulfates and the easy leachable metals Dividing the washed mineral components into cornsize-

ranges which fit to the requirements of concrete andasphalt industry

Making and proving adapted mixtures to identify themaximum possible content of IBA components

Production of reference blocks from concrete and test-plots of tarmac pavement

Production of a filter cake in a screen filter press fromparticles < 200 µm

Tests whether these finest particles can be included in the production of cement clinker

Grain size0,71-1mm0-0,71mm

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Verticalplunger jig

3) OPTIMIN: Optimization of thematerial recycling of mineralresidues from waste treatment

Feed-hopper

Discharge-valve

Counter flow water

Overflow: lightweightfraction, water

PurifiedmineralmatterMetal concentrate

Bräumer, M.(2009): Vertikalsetzmaschine zur Aufbereitung von Stoffgemischen zu Ersatzbrennstoffen.- In: Thomé-Kozmiensky K.J.

und M. Beckmann: Erneuerbare Energien, Band 2, TK-Verlag

3) Plunger Jig

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3) Output of the Jig

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3) Output of the JigCoarse Fraction

unburnt

glass

brickfragments

pottery

Al

Fe

nonferrousmetals

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First Screening (Mass-%)

Unknown: Why do we find those fibers?

3) Output of the JigCoarse and Fine Fraction

mm 0-0,16

0,16-0,8

0,8-1,6

1,6-3,15

3,15-5

5-8 >8

Coarse 0,5 1,3 8,8 10,2 7,5 18,6 53,1

Fine 28,4 63,3 7,2 0,8 0,1 0,2 0,1

3) Saltiness of the Jig Output

2nd International VDI Conference

Metals and Minerals Recovery from IBA 11. - 12. October 2016

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These are the first results, only two sample drawings The jig is in the test phase, nothing is representative!

1.233

451

50 mg/l = Target Value (LAGA M 20 for Z 1.2)

3) Employment for the mineralfractions

2nd International VDI Conference

Metals and Minerals Recovery from IBA 11. - 12. October 2016

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Raw IBA

Washing / Jig

Recovery of non-ferrous metals

Mineral fraction< 0,2 mm

Mineral fraction2 - 5 mm5 – 11mm

11 – 16mm

Mineral fraction2 - 8 mm

8 – 16 mm16 – 32 mm

Mineral fraction0,2 - 2 mm

4) Further Ideas

Pictures left side:above: IBA < 63 µm from TARTECH-BETA-Linebelow: normal Cement

Picture above: Shearing test with referenceblock made from 90% liquid sludge and10% IBA < 710 µm from the BETA-line

Fotos: Claus Gronholz

www.optimin.de

Thank you for listening !Dr. Stefan Lübben

s.luebben@srhh.deStadtreinigung Hamburg

Recycling -for a sustainable world