p. 20 Operating resources - MVB · 2010 3,429 5,083 810 327 2011 1,321 4,9082) 2,214 840 420 p. 20...

Müllverwertung Borsigstraße GmbHBorsigstraße 6 • 22113 Hamburg • Telephone: 040/731 89-0 • Email: [email protected] • www.mvb-hh.de

in conjunction with Vattenfall Europe New Energy GmbH

2012

34

Year Slag Scrap Hydrochloric Gypsummetal acid

Mg Mg Mg Mg2009 61,223 9,114 4,097 1,1342010 63,936 9,825 3,387 1,0152011 65,295 10,152 4,526 1,025

Flow chart 1 and line 2

Year Ammonia Condensate Furnace Unhydrated Electricity Electricitywater coke lime Consumption Purchase

Mg Mg Mg Mg MWh MWh2009 1,275 952,433 299 578 31,718 31,7182010 1,099 903,659 295 533 30,204 20,1142011 1,257 907,421 303 558 32,361 8,6661)

Year Boiler Flue Filter Calcium Cleaningparticulates particulates particulates chloride salts residues

Mg Mg Mg (solid) Mg Mg2009 3,253 4,924 757 3542010 3,429 5,083 810 3272011 1,321 4,9082) 2,214 840 420

p. 20 Operating resources*

p. 4 Flow chart

p. 15 Residual waste***

* annual quantities supplied, 1) start-up of own power production

** annual quantities supplied

*** annual quantities supplied 2) Quantities of dust have only been recorded per line since mid-2011.

p. 10 By-products**

Impregnated activated carbon1

Ammoniawater

Grate

Slagtreatment

Bag-housefilter

SO2scrubber

HClscrubber

WaterLimemilk

Clean gas

Flue

HCltreatment Gypsum

treatment

SNCR

District heating (base load for Hamburg)

Condensate

Induceddraught

Furnacecoke2

Waste Boiler

1 dosing only with Hg inputs2 continual dosing

Müllverwertung Borsigstraße

35

Environmental aspects line 1 and line 2

The core indicators under EMAS III for the incineration lines 1 and 2 from 2009 to 2011 are shown below.

Our environmental performance at a glance

Energy efficiency

Steam production (MWh/Mgwaste) 2.54 2.46 2.48

Own steam requirements* (MWh/Mgwaste) 0.63 0.68 0.77

Primary energy input (Heating oil) (MWh/Mgwaste) 0.02 0.04 0.03

Electricity purchased (MWh/Mgwaste) 0.10 0.06 0.03

Proportion of renewable energies (%) 22.40 25.80 35.20in purchased electricity

Material efficiency

Ammonia water (kg/Mgwaste) 3.9 3.4 3.8

Furnace coke (kg/Mgwaste) 0.9 0.9 0.9

Unhydrated lime (kg/Mgwaste) 1.8 1.6 1.7

Water

Total water requirements (m3/Mgwaste and scrap wood) 0.22 0.20 0.17

By-product/waste

Slag (kg/Mgwaste) 188.4 197.5 195.7

Boiler particulates (kg/Mgwaste) 10.0 10.6 4.0

Filter particulates (kg/Mgwaste) 15.2 15.7 6.6

Flue ash (kg/Mgwaste) - - 14.7

Biological diversity

Area used (developed) (m2/Mgwaste and scrap wood) 0.13 0.13 0.12

Emissions

CO2* emissions (kg/Mgwaste) - - -

SO2 emissions (kg/Mgwaste) 0.024 0.019 0.021

NOx emissions (kg/Mgwaste) 0.441 0.433 0.420

Particulate emissions (kg/Mgwaste) 0.001 0.001 0.001

This indicator is taken into consideration for all three incineration lines together.

* CO2 emissions are not significant in this context. The reason for this, among others, is that the domestic refuse incineration line is a waste incineration plant and is not governed by the provisions ofthe Greenhouse Gas Emission Trading Act (TEHG).


RECYCLING TO THE HIGHEST STANDARDS

2009 2010 2011

* incl. own electricity production

Line 3Line 1/Line 2

Energy efficiency

Steam

Dosingsilo

Boiler

Inert material(sand)

Bag-housefilter

Cyclone

Cleaned gas

Flue

Rotaryreactor

Electricity

Turbine

Screening machine

Mixture hydratedlime +5%

furnace coke

Induceddraught

Scrap wood

Circulatingfluidized

bed boiler

Air condenser

Condensate Generator

Tapping point for district heat extraction

Our system:

economically sound. The ope-

rating profit in 2011 is evidence

of the high energy and material

utilisation of the treated waste

and biomass. The best long-term

proof of the effective exploitation

of waste for energy lies in the fact

that we have reliably covered the

base load requirements for district

heating in Hamburg since 1994. It

has also been possible to meet the

ambitious targets to make the bio-

mass CHP plant economically effi-

cient. We hope to achieve even greater

economic efficiency under the auspi-

ces of Vattenfall Europe New Energy

GmbH, by collaborating even more clo-

sely with our „sister companies“ MVR

Müllverwertung Rugenberger Damm

GmbH & Co. KG (MVR) and VERA

Klärschlammverbrennung GmbH (VERA).

More intensive cooperation, the exchange

of information and opinions, and the collec-

tive deployment of personnel in some areas

enable us to work even more effectively, to

make use of our combined expertise and to

save on costs. This helps us to achieve our

targets for environmental protection and

occupational safety.

MVB has published annual environmental state-

ments since 1996. The present environmental

statement meets the requirements of the eco-

audit directive and will continue to be updated in

the future.

Since 2003, Müllverwertung Borsigstraße GmbH has been an

approved environment partner of the Urban Development and

Environment Agency (Behörde für Stadtentwicklung und Umwelt)

of the Free and Hanseatic City of Hamburg. In 2011, MVB was a

partner in the „Environment partnership programme: Project

2011“ as part of the „Hamburg - European Green Capital“ initia-

tive, see page 29.

The business strategy of MVB is the thermal treatment of waste

and biomass at a low cost and with maximum availability. Our

aim is to use our plants on the Borsigstraße site to generate

district heating and electricity and to produce recyclable

materials, thus largely preventing waste. High standards of

security, occupational safety and environmental compatibili-

ty must be maintained during this process. In this way we

combine good economic and ecological sense!2

Flow chart line 3

Year Condensate Hydrated lime Sand Electricity Electricitywith furnace coke Generation Purchase

Mg Mg Mg MWh MWh2009 16,120 1,000 1,366 159,423 14,0202010 17,848 1,057 1,567 149,227 13,3092011 23,111 1,058 1,736 154,085 13,854

Year Bed ash Flue ash Cleaning(fine) (coarse) residuesMg Mg Mg Mg

2009 6,417 4,967 6,978 742010 7,332 5,578 7,734 1042011 7,507 7,110 8,411 123


p. 7 Flow chart

p. 14 Residual waste**

3231

Business objective, environmental policy

Our system: economically sound

* annual quantities supplied


Deliveries (vehicles/day) 150

Tipping areas 12

Stacking volume bunker m3 approx. 20,000

Crane systems 2

Bulk items grinder 2

Waste receipt/storage

DMV1: AMV2:Dust mg/m3 5 3

HCl (hydrogen chloride) mg/m3 5 5

SO2 (sulphur dioxide) mg/m3 30 30

HF (hydrogen fluoride) mg/m3 0.8 0.8

NOx (nitrogen oxide) mg/m3 120 100

Ctot (total carbon) mg/m3 5 5

CO (carbon monoxide) mg/m3 50 50

Hg (mercury) mg/m3 0.03 0.02

Cd+Ti mg/m3 0.01 0.002

Sb+As+Pb+Cr+Co+Cu+Mn+Ni+V+Sn mg/m3 0.1 0.038

As+BaP+Cd+Co+Cr mg/m3 0.02 0.02of which BaP mg/m3 0.01 0.01

Dioxins and furans ng/m3 0.1 0.05

Emissions limits, accepted levels

Thermal output MW 53

Waste throughput normal Mg/h 21.5

Live steam pressure bar 19

Live steam temperature °C 380

Live steam volume Mg/h max. 73

Volume flow flue gas m3/h approx. 85,000

Steam producer


Tipping areas 2

Payload (net) Mg ca. 3,000

Stocks for d ca. 4–5

fully automated crane systems with motorised grapple, feed hopper, disc screen/magnetic screen, trough chain conveyor to dosing silo Pcs. 2 each

Fuel receipt/storage

4 hot oil burners (2 start-up, 2 load burners), pressure pulverizer

Thermal output MW 62.7

Fuel throughput (normal) Mg/h 18



Flue gas temperature at boiler end °C 135–145

Volume flow flue gas Nm3/h 105,000

Steam producer

DMV1:Particulate mg/m3 5

HCI (hydrogen chloride) mg/m3 10

SO2 (oxides of sulphur) mg/m3 50

HF (hydrogen fluoride) mg/m3 1

NOx (oxides of nitrogen) mg/m3 140

Ctot (total carbon) mg/m3 10

CO (carbon monoxide) mg/m3 50

Hg (mercury) mg/m3 0.01

Cd, TI mg/m3 0.01

Sb+As+Pb+Cr+Co+Cu+Mn+Ni+V+Sn mg/m3 0.1

As+BaP+Cd+Co+Cr mg/m3 0.02of which BaP mg/m3 0.01

Dioxins and furans ng/m3 0.05


Design Semi-dry

Filter chambers Pcs. 6

Fibrous filter Hoses 3,840

Filter hose material PPS/PTFE needle felt

Chimney height m 80

Flue gas treatment

Output MW 20

Exhaust steam pressure bar ca. 0.08

Steam turboset

2 lines, Fa. Steinmüller, feed grate. Nominal data per line:

Nominal data per line:

Selective non-catalytic reduction (SNCR)

• Ammonia water % 25

Furnace coke injection mg/Nm3 ca. 200• Depending on boiler


2-stage HCI scrubber Mg/h 0.9• Production of raw acid

1-stage SO2 scrubber kg/h 90• Gypsum extraction

Chimney height m 80

Flue gas treatment

1 daily mean values or mean values over sampling period 2 annual mean values

1 daily mean values or mean values over sampling period

Environmental aspects line 3

Electricity supply (MWh/Mgscrap wood) 1.02 0.97 0.81

Steam supply (MWh/Mgscrap wood) 0.003

Primary energy input (Heating oil) (MWh/Mgscrap wood) 0.03 0.06 0.03

Electricity purchased (MWh/Mgscrap wood) 0.09 0.09 0.09


33

The core indicators under EMAS III for incineration line 3 from 2009 to 2011 are shown below.

Material efficiencyHydrated lime with furnace coke (kg/Mgscrap wood) 6.4 6.9 6.6

Sand (kg/Mgscrap wood) 8.7 10.2 10.9

WaterTotal water requirements (m3/Mgwaste and scrap wood) 0.22 0.20 0.17

WasteBed ash fine (kg/Mgscrap wood) 40.9 47.9 47.0

Bed ash coarse (kg/Mgscrap wood) 31.7 36.4 44.5

Flue ash (kg/Mgscrap wood) 44.5 50.5 52.6

Biological diversityArea used (developed) (m2/Mgwaste and scrap wood) 0.13 0.13 0.12

EmissionsEmissions of CO2* emissions (kg/Mgscrap wood) - - -

Emissions of SO2 emissions (kg/Mgscrap wood) 0.012 0.017 0.013

Emissions of NOx emissions (kg/Mgscrap wood) 0.570 0.601 0.535

Particulate emissions (kg/Mgscrap wood) 0.003 0.005 0.001



* CO2 emissions are not significant in this context. The reason for this, among others, is that the biomass incineration line is not governed by the provisions of the Greenhouse Gas Emission Trading Act (TEHG).


2009 2010 2011

Basic data lines 1, 2 and 3

Volume of waste (design) Mg/a 320,000

Time availability % >90

District heating production MWh/a 600,000

Steam production Mg/a 1,000,000

Scrap wood quantity, cl. A1–A4 Mg/a ca. 160,000

Efficiency rate (el.) % ca. 33

Steam production (max.) Mg/h ca. 90

District heat extraction (poss.) Mg/h max. 20

Total employees (of which 2 trainees) 98

Employees L1 to L3

Performance (own requirements) MW 3

Steam turboset

Following energy recovery in

the form of electricity and heat,

the remaining waste substances

are turned into products as much

as possible. By using the best avai-

lable technologies, in the course of

thermal recovery and flue gas treat-

ment we produce residual materials

of high quality, which are then fed

back into the business cycle.

Our employees have a duty to act in a

responsible manner with regard to occupational safety and plant safety. Training

and induction programmes take place on a regular basis. Safety-oriented wor-

king methods protect employees and the environment by minimising acci-

dents and disruptions to operations that may cause emissions of harmful

substances.

Giving priority to plant safety, occupational safety and environmen-

tal protection consistently ensures a high level of plant availabi-

lity, thus improving the efficiency of material and energy utili-

sation. High availability also means lower requirements for

primary energy and thus further reduces CO2. Operations

at MVB are effluent-free, use few raw materials and

comply with a high standard of noise control.

Needless to say, there is strict adherence to all

laws, guidelines and regulations for the protec-

tion of the environment. The environmental

policy of MVB is designed to maintain high

standards and to remedy any existing

weaknesses.

Keeping employees, the general

public, the experts and the

supervisory authorities acti-

vely and openly informed is

an integral part of our

environmental policy.

Excellent

environmen-

tal and occu-

pational safety

Thermal waste

treatment meets sub-

stantially higher envi-

ronmental requirements

than other systems and thus

is a convincing alternative, par-

ticularly in ecological terms.

Waste incineration provides enough

heating for around 54,000 homes. In

2010, a steam turbine was put into ope-

ration to cover a proportion of our own

electricity requirements. Some of the steam

generated in the domestic refuse incineration

line is expanded and then re-used in-house. This

allows approximately 12,600 Mg CO2 to be saved

annually. Constructed as the third line in 2005, the

biomass CHP plant supplies approximately 160,000

MWh of CO2-neutral electricity. Fossil fuels are replaced

by renewable primary products (such as wood, paper etc.),

thus making vital contributions to climate conservation.

3

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Our facility lies east of the city of Hamburg in the

Hamburg-Billbrook industrial zone. It is bordered by

Borsigstraße to the north, by railway tracks to the east

and by the premises of AVG Abfall-Verwertungs-

Gesellschaft mbH to the south and west.

The area of land owned by MVB amounts to 68,135 m2

in total, of which approximately 61,300 m2 are develo-

ped.

MVB is set up to handle an annual throughput of

around 320,000 Mg of residential waste. Energy is

recovered from this mass in two incineration lines,

each with a grate firing system and a steam generator,

each in turn with an hourly throughput of 21.5 Mg of

waste.

Energy in the form of heat is released in the combu-

stion gases during the burning of the waste. This heat

is used to turn the completely desalinated water (con-

densate) into steam inside the steam generator; this is

then released into the local district heating system.

Some of the heat generated is used to cover MVB's

own requirements.

4

Systems engineering waste recovery

Rubbish has what it takes: energy and raw materials

Flow chart (see p. 34)

Flue gas purification starts inside the boiler in tandem with combustion and ener-

gy recovery, thanks to the design of an optimised incineration process. Nitrogen

oxides are converted into elemental nitrogen and water by the injection of

ammonia water in the SNCR method. There is a flue gas purification system

downstream of each incineration line. Furnace coke is added to the flue gas

after its discharge from the boiler. Heavy metals and organic compounds

accumulate in the furnace coke. Dust particles from the flue gas and

the laden coke are deposited on the surface of the hose on the

fibrous filter and disposed of.

In order to separate the readily soluble halogen compounds

from chlorine, fluorine, bromine and iodine, the flue gas

undergoes further purification as it passes through the

two-stage HCl scrubber into which water is injected.

The noxious gases are dissolved in the many dro-

plets of water and thus removed from the flue

gas.

Lime milk is used in the subsequent single-

stage SO2 scrubber to bind the sulphur

oxides (SO2/SO3). These react with

sulphur compounds in the flue gas

to form calcium sulphate, better

known as gypsum.

The results of emission

measurements are

shown on page 17.

5

Sorting and post-processing: The biomass fuel (quality-assured scrap wood in classes A1 - A4)

is delivered in the form of wood chips, brought from the supplies hall and tipped into the wood

bunker. The wood chips are post-processed in disc screens to separate the oversized pieces and

in magnetic screens to remove iron particles. The removed impurities are reprocessed

separately. Chain trough conveyors transport the fuel to the dosing silo.

More conveyor systems take it from here to the boiler.

Incineration: During combustion in the circulating fluidized bed boi-

ler, air is blown into the solid fuel (wood chips) and the bed

material (inert, i.e. no longer reactive, sand with ash com-

ponents) from below via the wind box, so that it is loo-

sened and almost completely carried away by the

vertical flow of gas.

Consistent combustion occurs during the upward

movement at a temperature of � 850 °C. The hot flue gases and the particles car-

ried along then flow through the hot gas cyclone, where centrifugal force separates the

coarse components from the flue gas and feeds them back into the fluidized bed combusti-

on system. The heat from the material and the flue gas is used to produce hot steam

(500 °C, 90 bar). The two superheaters in the flue gas flow and the two in the layer of

sand (Intrex) are used, among other things, for this purpose.

Energy generation: The steam produced in the fluidized bed boiler is used in the steam

turboset to generate 20 MW of electricity. The condensing turbine has an interposed

gear unit to drive a 10 kV generator. The steam is condensed inside an air condenser.

It is possible to extract up to 20 Mg/h of heat energy in the form of steam. There is

a diagram of the sequence of processes in the biomass CHP plant (line 3) on

page 32.

6

Systems engineering biomass CHP plant

The biomass CHP plant: how it works

Flow chart (see p. 32)

Flue gas purification: The entrained-flow adsorption method is used to treat flue gases. Coarse

particles are separated out in two cyclones. The remaining dust-like and gaseous harmful substances

contained in the flue gas are separated out according to the principle of conditioned dry sorption by

using a rotor in conjunction with a fibrous filter. The flue gas purification plant is next to the induced

draught fan and the 80-metre high chimney. Emission measuring equipment is located in the clean

gas channel between fan and chimney. The results of emission measurements in line 3 are shown on

page 18. The residues from combustion and flue gas purification are collected in two residue silos

and duly disposed of by external specialist companies in accordance with regulations.

7

The steam supplied by MVB serves to ensure

that base load network supplies are covered.

Biomass recovery: Scrap wood chips are

used for heat recovery in the MVB biomass

CHP plant (line 3). The calorific value depends

on the quality of the fuel. On average it is

around 13 MJ/kg.

The steam is superheated in the line 3 fluidized

bed boiler to produce 20 MW (20,000 kW) of

electricity by means of a condensing turbine.

Waste recovery: The energy

released during recovery is mainly

used to produce thermal heat. The

volume and quality of the waste

supplied play a major role here.

Most of the residual waste supplied to

MVB consists of combustible material

and has a similar calorific value to

lignite (energy content). The line 1 and

2 steam generators are designed to

take waste with calorific values ranging

from 6.5 to 12 MJ/kg. By way of compa-

rison, lignite has a calorific value of

approximately 10 MJ/kg.

The heat produced during incineration is

used to generate steam from fully desali-

nated water. The steam generators at MVB

reach a very high efficiency rate of around

87 %.

A small portion of the steam is used to gene-

rate electricity for our own requirements. The

remaining steam is fed into the local district

heating network in the form of heating steam

via Tiefstack power plant.

8

Energy: heat andpower for Hamburg

Steam supply L1/L2, L3, electricity supply L3

Energy products

Year Steam output L1/L2 L3 Electricity output L3MWh MWh MWh

2008 746,440 - 159,280

2009 736,340 - 159,420

2010 685,350 - 149,230

2011 697,906 552 130,180

A small portion of the electricity produced is used to cover our own require-

ments. The remaining electricity is transformed from 10 kV to 110 kV and fed

into the local high voltage network. The legislative authorities have given

priority to the marketing of renewable energies in order to facilitate

sustainable energy supplies in the interests of climate protection and

environmental conservation. Payment is made for the power fed

into the grid by MVB on this legal basis.

It is possible to extract up to 20 Mg/h of heat energy in the

form of steam. The first phase of construction for

district heat extraction started up in December 2011.

It is possible to feed 632 Mg of steam into the

district heating network.

A new district heating line designed to

optimise the hydraulic connector is

being built in 2012 on the MVB site at

the thermoforming plant in

Borsigstraße (see page 28).

9

During waste incineration and flue gas treatment at

MVB, the following materials are produced in marketa-

ble quality: slag, metal scrap, acid and gypsum.

Slag: The non-combustible components of waste and the

inert materials produced during incineration are known

generally as grate ash and slag. This slag is washed in more

water in the slag remover on discharge in order to reduce the

content of readily soluble salts. The slag is then broken up and

sieved. Scrap iron and non-iron metals are separated out during

slag treatment and re-used as primary products in metallurgical

works. The end product thus achieved yields a fully tested and

licensed building material, similar to a mineral compound made of

treated building waste and natural products.

Our slag is of high quality as a result of wet scrubbing and costly

mechanical handling. The soluble salt content is comparatively low and

the residual removable metal content is virtually 0 %.

The slag meets the relevant current technical guidelines and terms of deli-

very and is used predominantly to build roads and sidewalks. In 2011 it was

possible to market it all via Hanseatisches Schlackenkontor

(www.schlackenkontor.de).

Scrap iron: Only a small amount of slag sticks to the scrap, which is extracted

by magnets. This is how the scrap produced by MVB meets the standards of

purity required by scrap merchants for scrap from waste incineration plants and

can be re-used in steelmaking without hesitation.

10

Materials: for the buildingtrade and industry

Material products

By-products (see p. 34)

Non-iron metals: An eddy current method is used to isolate and

recover well over 90 % of the non-ferrous (not extractable by

magnet) metals from the slag. These metals are predominantly alu-

minium, copper and brass, with some chrome steel as well. The scrap

mixture is handed over to an external company.

Hydrochloric acid: The acid wash produces 10 to 12 % raw hydrochloric

acid during flue gas purification. This is refined into 30 % hydrochloric

acid (HCI) in a rectification system independent of the incineration plant.

Unwanted inorganic and organic impurities are isolated during several treat-

ment phases, before HCI gas is produced from the pretreated acid in a distil-

lation process. Precise operation of the HCl rectification system and stringent

controls ensure that the quality of the hydrochloric acid complies with

DIN EN 939.

Gypsum: A gypsum suspension is discharged from the SO2 wet scrubber and gypsum

is extracted from this. In order to remove readily soluble salts, the gypsum is washed

in a centrifuge and its moisture content reduced to under 10 %. The quality of the gyp-

sum produced is very good. Since operations began, the parameters to be monitored

have always been considerably lower than the guide values given in a study on FGD

gypsum (gypsum from power station flue gas desulphurisation systems) and

natural gypsum. It is supplied to the building industry for the produc-

tion of gypsum plaster.

11

Waste supply L 1/L2

Incineration serves not only to dispose safely of waste, it also pro-

vides considerable amounts of thermal heat. Apart from usable

energy, most of which is CO2-neutral (the biogenic proportion is

around 60 %), the recovered resources (iron and non-iron

metals) and products also make a contribution to a positive cli-

mate balance.

In 2011, MVB accepted 333,641 Mg of waste, thus exceeding

the designated volume of 320,000 Mg/a.

The volume of waste supplied has developed as follows:

12

Environmental factors

Waste incineration: a contri-bution to climate protection

Year Waste supplyMg

2008 331,2912009 324,9982010 323,678

2011 333,641

The biomass CHP plant (line 3) operated by MVB burns Class A1 - A4 scrap wood chips.

Long-term supplies for the plant are guaranteed within the Hamburg/Schleswig-Holstein

region by Biomasse Einkauf Nord GmbH. Scrap wood processing facilities are located in

and around Hamburg. Construction timber (e.g. roof trusses, windows, doors) and sorted

bulk items are processed into wood chips.

In 2011, 159,814 Mg of class A1 - A4 scrap wood chips (without oversized particles) were

delivered.

MVB is allowed to accept hazardous waste with the following waste code numbers for

the biomass CHP plant:

13

Wood deliveries: the end of the wall unit

Waste code number Description of waste

15 01 10* Packaging containing residues of or contami-nated by dangerous substances

17 02 04* Glass, plastic and wood containing or conta-minated with dangerous substances

19 12 06* wood containing dangerous substances

20 01 37* wood containing dangerous substances

Waste code numbers

14

Residual waste:playing it safe

Harmful substances from refuse and biomass (scrap wood), which cannot be

made to simply disappear by means of thermal waste recovery, are concen-

trated in a small residual waste fraction as much as possible. These residu-

es are securely and correctly stored underground with the utmost care.

Dust: The whole amount of dust and ashes extracted in the boilers and

during flue gas treatment is used and recycled as a fill material in salt

mines. Only small amounts of cleaning residues have to be dumped in a

landfill.

Fine combustion bed ash: The sand used in fluidized bed combustion

is taken to an above-ground site for professional disposal and recy-

cling. It is used to seal the surfaces of landfill sites or to revegetate

them.

Coarse combustion bed ash: The coarse components (e.g. stones,

metal parts, deposits) collected in the sand bed of the fluidized bed

boiler are continuously extracted and re-used as alternative land-

fill construction materials.

Residual waste L3 (see p. 32)


Calcium chloride salts: Calcium chloride occurs in solid form in the

hydrochloric acid rectification system. Halogens such as bromine, iodine

and fluorine in particular, but also ammonia compounds are extracted

during the processing of materials by the calcium chloride salts and

safely deposited in depleted salt caverns.

Raw acid: Apart from a small amount, it was possible in 2011 to distill

all the 10 to 12 % raw hydrochloric acid into 30 % hydrochloric acid.

15

Residual waste L1/L2 (see p. 34)

Emissions by MVB remain at a very low level. Some of the mea-

sured values lie below their respective detection limit. The emis-

sion loads and the specific (volume-related) values were well below

permitted levels (cf. graphics) in 2011 as well. Virtually all the per-

mitted load is utilised for the nitrogen oxides alone (L1/2: approx.

90 % and L3: approx. 64 %). Apart from this, levels of utilisation lie

between approx. 4 % and approx. 29 %. It must be noted at the same

time that some MVB limit values are significantly lower than the legally

prescribed values designated in the 17th Federal Emission Control Act

(BImSchV). With correspondingly low emission volumes, every anomaly

leads to comparatively high percentage changes.

A detailed illustration of MVB emissions can be found on our homepage

(www.mvb-hh.de).16


Emissions: far below permitted levels

Emission concentrations L 1/L2

17

Year NOx1) CO Dust Ctot HCI SO2 HF Cd/TI Hg Sb,...,Sn PCDD/F As,...,BaP

kg kg kg kg kg kg kg kg kg kg mg kg

Annual load 2011 140,207 19,712 357 934 289 6,841 57 0.9 5.6 9.9 20.2 2.6

Limit value (Annual load) 156,1281) 74,460 4,468 7,446 7,446 44,676 1,192 2.98 29.78 56.59 75 30

Utilisation of 2008 97.8% 21.7% 13.2% 5.3% 3.9% 15.8% 4.4% 30.0% 15.6% 21.5% 11.0% 9.3%

load limit value 2009 91.7% 19.8% 9.8% 3.9% 3.9 % 17.8% 5.5% 29.3% 18.6% 17.0% 16.5% 8.6%

2010 89.8% 21.7% 4.8% 3.8% 3.8% 14.1% 3.6% 28.4% 24.8% 15.3% 16.0% 7.5%

2011 89.7% 26.5% 8.0% 12.5% 3.9% 15.3% 4.8% 29.0% 18.8% 17.5% 26.9% 8.6%

Emission loads L 1/L2

1) max. value; limit value depends on number of operating hours

Permitted limit value under 17th Federal Emission ControlAct (BImSchV)

Measurements 2008-2011 (2011 also given in figures)

Cd/TI(MVS)

Hg(DMV)

Sb,...,Sn(MVS)

PCDD/F(Dioxine, Furane)

(MVS)

As,...,BaP(MVS)

mg/Nm3 ng/Nm3 µg/Nm3

0.0006

0.0039

0.0069

1.8

SO2

(DMV)NOx

(DMV)CO

(DMV)

mg/Nm3

mg/Nm3

97.5

10.0

Dust(DMV)

Ctot

(DMV)HCl(DMV)

HF(MVS)

4.8

0.7

0.20.3

0.014

Limit value approval: Dailymean value (DMV) and meanvalue of samples (MVS)

50

20

2,5

2

1,5

1

0,5

0

0,1

0,06

0,05

0,04

0,03

0,02

0,01

0

200

120

100

80

60

40

20

0

0,5

0,1

0,05

0,04

0,03

0,02

0,01

0

0.04

10

5

1,2

0,9

0,6

0,3

0

Emission concentrations L 3

18Permitted limit value under 17th Federal Emission ControlAct (BImSchV)

Measurements 2008-2011 (2011 also given in figures)

Cd/TI(MVS)

Hg(DMV)

Sb,...,Sn(MVS)

PCDD/F(Dioxine, Furane)

(MVS)

As,...,BaP(MVS)

mg/Nm3 ng/Nm3 µg/Nm3

0.0008 0.00020

0.0108

2.3

SO2

(DMV)NOx

(DMV)CO

(DMV)

mg/Nm3

mg/Nm3

88.8

17.0

Dust(DMV)

Ctot

(DMV)HCl(DMV)

HF(DMV)

3.1

0.4

4.1

0.0*

0.3

0.007

Limit value approval: dailymean values (DMV) and meanvalue of samples (MVS)

Year NOx CO Dust Ctot HCI SO2 HF Cd/TI Hg Sb,...,Sn PCDD/F As,...,BaPkg kg kg kg kg kg kg kg kg kg mg kg

Annual load 2008 100,673 19,607 69 344 1,171 3,375 138 0.4 0.004 5.1 0.3 1.3

2009 89,499 13,529 419 558 1,396 1,885 70 0.6 0.070 7.7 0.8 1.6

2010 91,998 16,541 695 278 1,946 2,571 69 0.6 0.139 9.2 1.3 1.7

2011 85,467 16,362 196 262 2,684 2,030 0* 0.5 0.131 7.1 0.5 1.5

Limit value (Annual load) 135,000 – – – – – – – – – – –

Utilisation of 2008 68.2% – – – – – – – – – – –

load limit value 2009 61.4% – – – – – – – – – – –

2010 64.4% – – – – – – – – – – –

2011 63.4% – – – – – – – – – – –

Emission loads L 3


200

140

100

80

60

40

20

0

10

5

2,2

0,9

0,6

0,3

0

0,5

0,1

0,05

0,04

0,03

0,02

0,01

0

50

20

2,5

2

1,5

1

0,5

0

0,1

0,06

0,05

0,04

0,03

0,02

0,01

0

* No measurable emissions in 2011.The measurements are essentiallywithin the detection limit of themeasuring equipment.

As a result of improvements in plant

engineering (including combustion

performance control), it was possible

to further reduce the use of primary

energy - heating oil - compared with the

previous year.

Of the steam produced in the two waste

incineration lines in 2011, 255,464 MWh

was used for our own needs to operate

auxiliary plants (e.g. HCl treatment plant,

cold water unit etc.) and 698,458 MWh

was supplied to the district heating

system.

In 2011, electricity consumption for the

operation of the two waste recovery lines

was 32,361 MWh and for Line 3 (biomass

CHP plant) 13,854 MWh. Our own electrici-

ty generation plant produced 23,695 MWh.

The regenerative portion of all the electrici-

ty purchased was 31.5 %.

For various reasons MVB must also use primary

energy (heating oil) as well as waste and biomass.

If necessary, heating oil is used to guarantee the

requisite minimum combustion temperature in

the boilers and to ensure that the boiler plants

can be heated and started up following downti-

mes in a controlled manner that produces few

emissions.

Need for energie: as low as possible

Primary energy L 1/L2 and L3

Year Heating oil Heating oilMWh MWh

2008 9,820 7,246

2009 5,657 5,313

2010 13,236 8,444

2011 9,785 5,183

Year Own steam requirementsMWh

2008 191,310

2009 206,249

2010 218,907

2011 232,290

Own steam requirements L 1/L2

19

Operating resources include all the materials that are required to maintain

processes. The use of essential operating resources for lines 1 and 2 can be

seen on page 34, and for line 3 on page 32.

Water: MVB's concept for all three incineration lines is based, among other

things, on an effluent-free industrial water cycle. Water is only discharged into the

public sewage network (after previous analysis) if the capacity of the rainwater

retention basin is exhausted as a result of exceptionally heavy rainfall. Sewage is

discharged into the public sewer. Total water consumption on all three lines is shown

in the table below. Water for firefighting can be taken from the Tiefstack canal in the

event of fire.

Water consumption L1 to L3

Year Condensate Rain/ Drinking Water Dischargeprocess water extraction mixed

water Tiefstack watercanal sewer

m3 m3 m3 m3 m3

2009 968,553 232,140 14,400 94,000 1,350

2010 921,507 231,200 15,600 82,000 4,840

2011 930,532 238,300 12,000 70,000 1,409

20


Operating resources: no more than necessary

Operating resources L1/L2 (see p. 34)

In contrast to lines 1 and 2, sand is needed for biomass incineration (line 3).

This serves as a heat transfer medium and ensures optimal burnout during

combustion in the circulating fluidized bed boiler. The quality of the sand and,

above all, the grain size distribution are vital to the transfer of heat from the fur-

nace to the evaporating water. It is essential to replace the sand regularly due to

impurities in the wood chips (e.g. nails, hardware, stones). To do this, part of the

sand is extracted from the lower area of the boiler and replaced with new sand, or

the used sand is sifted and partly fed back into the cycle. The combustion bed ash

that is no longer usable is recycled. We check the combustion bed ash regularly to

ensure that we replace only as much sand as is necessary.

21

Operating resources L3 (see p. 32)

MVB is located east

of the city of Hamburg in

the Hamburg-Billbrook indu-

strial zone. Noise emissions are

relatively high around this industrial

zone with its high volume of traffic. MVB is

well within all the relevant noise limits of the

Workplace Ordinance (Arbeitsstättenverordnung),

both within the boundaries of its site and indoors.

In 2011, operations were interrupted a total of 21 times on the

two waste incineration lines (L1/L2), including 2 planned stoppages

on each incineration line (inspections). Records show 13 interruptions to

operations (including 2 planned stoppages) at the biomass CHP plant (L3).

None of the unplanned stoppages were hazardous incidents as defined by the

German statutory order on hazardous incidents and they had no repercussions bey-

ond the boundaries of the plant. It was possible to rectify the consequences of the

technical faults without any problem. None of the faults had a detrimental impact

on the environment.

No serious accidents occurred at work in the year 2011.

Noise, disturbances, accidents:everything under control

22


MVB operations have not only had direct consequences for the envi-

ronment - as already described - but also indirect ones. An overall review

of environmental matters was therefore carried out with the approval of MVB.

It is on this basis that MVB continuously tracks all the environmental aspects of its

activities in line with the EU directive:

a) The direct environmental impacts are balanced annually and their progress tracked on an

ongoing basis.

b) The indirect environmental impacts include noise emissions by external delivery vehicles.

Sanitation department of Hamburg only uses low-noise, low-emission vehicles pursuant to

article 49 app. XXI road traffic licensing regulations (StVZO) and Directive 92/97 EEC. The

sanitation department of Hamburg thus meets the basic requirements of „Der blaue

Engel“ (The Blue Angel) environmental label. 23

Delivery vehicles:quieter is better

In keeping with the idea of being proactive rather than reactive („Agieren statt reagieren“), MVB's active pro-

tection of the environment makes a vital contribution to the conservation of our natural resources and to the

security of our organisation. In order to achieve this aim MVB has an integrated management system, which

applies occupational safety and risk management practices with due consideration for the

requirements of environmental conservation, and which continues

to be developed on an ongoing basis.

All employees make an active contribution to environmental conservation and occupational safety

measures. It is ensured that there is due compliance with legal, official and in-house requirements on

two operational levels.

Level 1: Working procedure documents set down the following in writing: basic principles; integrated

management; environmental policy, targets and programmes; guidelines on occupational safety and

health protection („Arbeitssicherheit und Gesundheitsschutz“); regulation of set-up and processes;

allocation of responsibilities and powers.

Level 2: Operation instructions; instructions in the event of hazardous incident; detailed regulations

on work flows and actions.

The Technical Director assumes overall responsibility for environmental protection at MVB. He is

responsible for developing, implementing and observing the relevant legal and official requirements

for environmental protection and occupational health and safety. Various instruments of support

24

Management system

Safeguarding Success:Systematic Management

have been introduced at MVB, including an environment committee, an occupational safety commit-

tee and regular training and induction programmes. The suggestions and ideas scheme and the invol-

vement of the Works Council continue to be important for overall success. The Director delegates

essential management responsibilities in this area to the Head of Operations Control, who assumes

the role of hazardous incident and emissions control officer at the same time. He is responsible for

the structure, maintenance and ongoing development of the environment and safety management

system. He deals with the appointments of officers required by law and coordinates the activities of

external officers.

Other employees are appointed to be in charge of radiation protection and matters relating to occu-

pational safety. MVB has appointed external personnel to fill the roles of hazardous goods officer and

occupational safety specialist. The established committees provide advice on and monitor the

accomplishment of tasks and make sure that the workforce and the Works Council are duly involved.

25

A company policy along the lines of the policy

of Vattenfall Europe AG has been drawn up to

stress the fact that occupational safety and

health protection are a priority at MVB.

Corporate philosophy

Occupational safety and health protection are key

elements of corporate culture at Müllverwertung

Borsigstraße GmbH. Our working environment is

characterised by responsibility, openness and

respect for the individual. Everyone who works at

MVB has the opportunity to develop both personal-

ly and professionally within a safe, healthy and sti-

mulating environment. An important aspect of our

corporate policy is to be a leading company in the

fields of occupational safety and health protection. A

continuous improvement process ensures ongoing

high standards of quality in matters of health and

safety.

Our commitment to health and safety finds its expressi-

on in the following principles:

• Occupational health and safety are incorporated within

our corporate strategy and help to safeguard the welfare

of employees and, as a result, the economic success of the

company.

• We act in accordance with relevant legal requirements

and industry standards.

• Each one of our managers and the employees themselves

are responsible for protecting the people who work for the

company from accidents and health hazards.

• All our employees have the knowledge, understanding and

freedom for working safely.

26

Occupational safety, health protection

Safety management: „SAFE in MVB“

Concrete objectives and guidelines have been laid down for policy

implementation:

Targets

A) Occupational safety:

At MVB we believe that any accident is preventable. We do not restrict our-

selves to accidents that must be reported. Based on the trend in accident

statistics in recent years, there can only be one target for MVB: 0 accidents.

We hope to achieve this by means of:

• Direct investigation into, and assessment of, near-accidents and minor

accidents

• Regular information on current accident statistics on a notice on the safety

information board

• Consistent implementation of monthly briefings

• Implementation of in-house training courses/action days with greatest

possible participation

• Continuation of the „moderated hazard assessment“ concept by direct line

managers with their staff

• Continuation of a staff bonus for 365 days of accident-free working

B) Health protection:

Reduction of sick days due, for example, to common colds and increase in health

awareness.

We hope to achieve this by means of:

• Prompt information on the exact date for free flu vaccination

• Provision of massages

• Continuation of offer of free attendance at courses to stop smoking

• Offer of free weekly exercise class

Review

In 2006, the MVB management system was reviewed in matters of occupational health and

safety by Hamburg's Office for Occupational Safety (Amt für Arbeitsschutz der Hansestadt

Hamburg). The repeat audit by the chemical industry

employers liability insurance association took place at the

end of 2009*. Both institutions came to the conclusion that

the system meets the requirements of the health and safety

guidelines of the chemical industry employers liability insuran-

ce association (BG Chemie)/OHSAS 18001:2007 and the

Hamburg occupational safety model and that it is practised

throughout the company.

*(first done in 2006)

27

It goes without saying that MVB complies with the highest standards of environmental pro-

tection. But there is nothing that cannot be further improved. This is why we are always see-

king opportunities to improve environmental impact even further and to detect and elimina-

te any weak points. Environmental targets and programmes will continue to be annually

updated in the future. Our efforts are focused mainly on the following areas and subjects:

Energy savings: Another compressor in the compressed air production system is to be fitted

with a frequency converter. Energy savings of approx. 240,000 kWh/a are expected. The project

could be completed by the end of 2011.

MVB is investigating whether existing mercury vapour lamps (400 W each) can be replaced by

LED lights. Among others, mercury vapour lamps are installed in the tipping hall, the refuse bun-

ker, the slag storage facility and outdoors. The first mercury vapour lamps are due to be replaced

by LED lights in the M workshop in 2012. Due to the adverse ambient conditions in the aforemen-

tioned areas, there are plans to review the operating experience of other plants prior to changeo-

ver. (2012, Head of Operations)

Climate protection: The first phase of construction for district heat extraction from line 3 started

in December 2011. It was possible to supply 552 MWh of steam produced by CO2-neutral means into

the district heating network. A district heating circular pipeline designed to optimise the hydraulic

connector is being built in 2012 on the MVB site at the thermoforming plant in Borsigstraße. It is desi-

gned to feed approx. 118 GWh/a of district heating into the grid. This saves around 23,600 Mg of CO2 a

year when compared with the production of district heating in a CHP plant. (2012, Head of Operations)

Air quality control: Work was started in 2010 to replace the three diesel forklift trucks operated at MVB

with electric ones. One forklift was replaced by an electric forklift truck in 2010. This enabled around

10 Mg of CO2 a year to be saved. Noise and additional exhaust emissions were reduced at the same time.

One diesel forklift truck was scrapped in 2011. The last diesel forklift truck is due to be replaced by an elec-

tric one in 2012. (2012, Head of Operations)

Conservation of resources: A disproportionately large number of work gloves made of leather was used

in 2009. A poster campaign was used to bring down the rate of consumption.

Around 38 % fewer leather work gloves were used in 2010. The campaign was extended to the multi-pur-

pose gloves used at MVB.

The use of work gloves decreased further in 2011. In 2011, around 45 % fewer leather gloves were used

than in 2009 and around 40 % fewer multi-purpose gloves than in 2010. The poster campaign is set to

be continued in subsequent years. This brings the project to completion.

In March 2011, MVB brought in two blue bins („Blaue Tonne“) for the collection of paper and card. The col-

lected material is given to WERT Wertstoff-Einsammlung GmbH, a subsidiary of Hamburg's public sanita-

tion department (Stadtreinigung Hamburg), for recycling. In 2011, around 70 m3 of paper and card were

collected and sent for recycling. The collection is set to be continued in subsequent years. This brings the

project to completion.

28

Environmental targets: it just gets better

Environmental targets

29

Since 2003, Müllverwertung Borsigstraße GmbH has

been an approved environmental partner of the Urban

Development and Environment Agency (Behörde für

Stadtentwicklung und Umwelt (BSU)) of the Free and

Hanseatic City of Hamburg. In 2011, MVB was a partner in

the „Environment partnership programme: Project 2011“ as

part of the „Hamburg - European Green Capital“ initiative.

The following measures have been approved by the BSU

within the framework of the environmental partnership:

• Long-standing award of the EMAS certificate (Eco-

Management and Audit Scheme run by the EU) by an external

environmental auditor and certification under DIN ISO 14001

• The optimisation of compressed air supplies

- reduction of required pressure levels

- purchase of two new heat-regenerative adsorption dryers

to replace two cold-regenerative dryers

- reduction of compressed air consumption for the acoustic

temperature measurement system

- it was possible to save around 1,000,000 kWh/a of electricity

• Commissioning of a 3MWel steam turbine plant for our own electricity

production. The steam is expanded in the turbine and used again in the

downstream plants.

Around 12,600 Mg of CO2/a is saved in this way.

MVB is an environmental partnerof the City of Hamburg

Environment partnership: Project 2011

30

Tested – certified

GEPRÜFTE INFORMATIONREG.NO. D-131-00007

This consolidated envi-

ronmental statement was

approved by MVB Müll-

verwertung Borsigstraße GmbH

in April 2012 and declared valid by

the environmental auditor. The next

consolidated environmental statement will

be submitted in 2013.

Contact persons:

Statement of the environmental auditor on evaluation and validation work (pursuant to

Directive (EC) no. 1221/2009): The signee, Stefan Krings, EMAS environmental auditor with the

registration number DE-V-0168 accredited and approved for but not limited to area 38.2 (NACE code)

(waste treatment and disposal), confirms having carried out an assessment as to whether the orga-

nisation, as listed in the updated environmental statement 2011 by the organisation Müllverwertung

Borsigstraße GmbH, Borsigstraße 6, 22113 Hamburg with the registration number D-131-00007, meets

all the requirements of Directive (EC) no. 1221/2009 by the European Parliament and the Council

dated 25 November 2009 of the voluntary participation of organisations in a community system for

an Eco-Management and Audit Scheme (EMAS).

By signing this statement, it is confirmed that

• The process of evaluation and validation was carried out in full compliance with the requi-

rements of Directive (EC) no. 1221/2009

• The findings of the evaluation and validation confirm that there is no evidence of

non-compliance with the relevant environmental regulations

• The data and information in the consolidated environmental statement 2012

by the organisation Müllverwertung Borsigstraße GmbH give a reliable, cre-

dible and truthful picture of all the activities of the organisation within

the area specified in the environmental statement.

Ratingen, 30.5.2012

Stefan Krings

Official environmental auditor

(DE-V-0168)

Dipl.-Betriebsw. Jörg Mischer

Commercial Director

Phone: 040/731 89-100

Dr.-Ing. Martin Mineur

Technical Director

Phone: 040/731 89-100

Dipl.-Ing. Wolfgang Schmidt

Head of Operations

Phone: 040/731 89-102

Dipl.-Ing. Dirk Seger

Head of Operations Control

Phone: 040/731 89-104

Declaration of validity

Line 3Line 1/Line 2

Energy efficiency

Steam

Dosingsilo

Boiler

Inert material(sand)

Bag-housefilter

Cyclone

Cleaned gas

Flue

Rotaryreactor

Electricity

Turbine

Screening machine

Mixture hydratedlime +5%

furnace coke

Induceddraught

Scrap wood

Circulatingfluidized

bed boiler

Air condenser

Condensate Generator

Tapping point for district heat extraction

Our system:

economically sound. The ope-

rating profit in 2011 is evidence

of the high energy and material

utilisation of the treated waste

and biomass. The best long-term

proof of the effective exploitation

of waste for energy lies in the fact

that we have reliably covered the

base load requirements for district

heating in Hamburg since 1994. It

has also been possible to meet the

ambitious targets to make the bio-

mass CHP plant economically effi-

cient. We hope to achieve even greater

economic efficiency under the auspi-

ces of Vattenfall Europe New Energy

GmbH, by collaborating even more clo-

sely with our „sister companies“ MVR

Müllverwertung Rugenberger Damm

GmbH & Co. KG (MVR) and VERA

Klärschlammverbrennung GmbH (VERA).

More intensive cooperation, the exchange

of information and opinions, and the collec-

tive deployment of personnel in some areas

enable us to work even more effectively, to

make use of our combined expertise and to

save on costs. This helps us to achieve our

targets for environmental protection and

occupational safety.

MVB has published annual environmental state-

ments since 1996. The present environmental

statement meets the requirements of the eco-

audit directive and will continue to be updated in

the future.

Since 2003, Müllverwertung Borsigstraße GmbH has been an

approved environment partner of the Urban Development and

Environment Agency (Behörde für Stadtentwicklung und Umwelt)

of the Free and Hanseatic City of Hamburg. In 2011, MVB was a

partner in the „Environment partnership programme: Project

2011“ as part of the „Hamburg - European Green Capital“ initia-

tive, see page 29.

The business strategy of MVB is the thermal treatment of waste

and biomass at a low cost and with maximum availability. Our

aim is to use our plants on the Borsigstraße site to generate

district heating and electricity and to produce recyclable

materials, thus largely preventing waste. High standards of

security, occupational safety and environmental compatibili-

ty must be maintained during this process. In this way we

combine good economic and ecological sense!2

Flow chart line 3

Year Condensate Hydrated lime Sand Electricity Electricitywith furnace coke Generation Purchase

Mg Mg Mg MWh MWh2009 16,120 1,000 1,366 159,423 14,0202010 17,848 1,057 1,567 149,227 13,3092011 23,111 1,058 1,736 154,085 13,854

Year Bed ash Flue ash Cleaning(fine) (coarse) residuesMg Mg Mg Mg

2009 6,417 4,967 6,978 742010 7,332 5,578 7,734 1042011 7,507 7,110 8,411 123


p. 7 Flow chart

p. 14 Residual waste**

3231

Business objective, environmental policy

Our system: economically sound

* annual quantities supplied



Tipping areas 12

Stacking volume bunker m3 approx. 20,000

Crane systems 2

Bulk items grinder 2

Waste receipt/storage

DMV1: AMV2:Dust mg/m3 5 3

HCl (hydrogen chloride) mg/m3 5 5

SO2 (sulphur dioxide) mg/m3 30 30

HF (hydrogen fluoride) mg/m3 0.8 0.8

NOx (nitrogen oxide) mg/m3 120 100

Ctot (total carbon) mg/m3 5 5

CO (carbon monoxide) mg/m3 50 50

Hg (mercury) mg/m3 0.03 0.02

Cd+Ti mg/m3 0.01 0.002

Sb+As+Pb+Cr+Co+Cu+Mn+Ni+V+Sn mg/m3 0.1 0.038

As+BaP+Cd+Co+Cr mg/m3 0.02 0.02of which BaP mg/m3 0.01 0.01

Dioxins and furans ng/m3 0.1 0.05


Thermal output MW 53

Waste throughput normal Mg/h 21.5



Live steam volume Mg/h max. 73

Volume flow flue gas m3/h approx. 85,000

Steam producer


Tipping areas 2

Payload (net) Mg ca. 3,000

Stocks for d ca. 4–5

fully automated crane systems with motorised grapple, feed hopper, disc screen/magnetic screen, trough chain conveyor to dosing silo Pcs. 2 each

Fuel receipt/storage

4 hot oil burners (2 start-up, 2 load burners), pressure pulverizer

Thermal output MW 62.7

Fuel throughput (normal) Mg/h 18



Flue gas temperature at boiler end °C 135–145

Volume flow flue gas Nm3/h 105,000

Steam producer

DMV1:Particulate mg/m3 5

HCI (hydrogen chloride) mg/m3 10

SO2 (oxides of sulphur) mg/m3 50

HF (hydrogen fluoride) mg/m3 1

NOx (oxides of nitrogen) mg/m3 140

Ctot (total carbon) mg/m3 10

CO (carbon monoxide) mg/m3 50

Hg (mercury) mg/m3 0.01

Cd, TI mg/m3 0.01

Sb+As+Pb+Cr+Co+Cu+Mn+Ni+V+Sn mg/m3 0.1

As+BaP+Cd+Co+Cr mg/m3 0.02of which BaP mg/m3 0.01

Dioxins and furans ng/m3 0.05


Design Semi-dry

Filter chambers Pcs. 6


Filter hose material PPS/PTFE needle felt

Chimney height m 80

Flue gas treatment

Output MW 20

Exhaust steam pressure bar ca. 0.08

Steam turboset

2 lines, Fa. Steinmüller, feed grate. Nominal data per line:

Nominal data per line:

Selective non-catalytic reduction (SNCR)

• Ammonia water % 25

Furnace coke injection mg/Nm3 ca. 200• Depending on boiler


2-stage HCI scrubber Mg/h 0.9• Production of raw acid

1-stage SO2 scrubber kg/h 90• Gypsum extraction

Chimney height m 80

Flue gas treatment

1 daily mean values or mean values over sampling period 2 annual mean values

1 daily mean values or mean values over sampling period

Environmental aspects line 3

Electricity supply (MWh/Mgscrap wood) 1.02 0.97 0.81

Steam supply (MWh/Mgscrap wood) 0.003

Primary energy input (Heating oil) (MWh/Mgscrap wood) 0.03 0.06 0.03

Electricity purchased (MWh/Mgscrap wood) 0.09 0.09 0.09


33

The core indicators under EMAS III for incineration line 3 from 2009 to 2011 are shown below.

Material efficiencyHydrated lime with furnace coke (kg/Mgscrap wood) 6.4 6.9 6.6

Sand (kg/Mgscrap wood) 8.7 10.2 10.9

WaterTotal water requirements (m3/Mgwaste and scrap wood) 0.22 0.20 0.17

WasteBed ash fine (kg/Mgscrap wood) 40.9 47.9 47.0

Bed ash coarse (kg/Mgscrap wood) 31.7 36.4 44.5

Flue ash (kg/Mgscrap wood) 44.5 50.5 52.6

Biological diversityArea used (developed) (m2/Mgwaste and scrap wood) 0.13 0.13 0.12

EmissionsEmissions of CO2* emissions (kg/Mgscrap wood) - - -

Emissions of SO2 emissions (kg/Mgscrap wood) 0.012 0.017 0.013

Emissions of NOx emissions (kg/Mgscrap wood) 0.570 0.601 0.535

Particulate emissions (kg/Mgscrap wood) 0.003 0.005 0.001



* CO2 emissions are not significant in this context. The reason for this, among others, is that the biomass incineration line is not governed by the provisions of the Greenhouse Gas Emission Trading Act (TEHG).


2009 2010 2011

Basic data lines 1, 2 and 3

Volume of waste (design) Mg/a 320,000

Time availability % >90

District heating production MWh/a 600,000

Steam production Mg/a 1,000,000

Scrap wood quantity, cl. A1–A4 Mg/a ca. 160,000

Efficiency rate (el.) % ca. 33

Steam production (max.) Mg/h ca. 90

District heat extraction (poss.) Mg/h max. 20

Total employees (of which 2 trainees) 98

Employees L1 to L3

Performance (own requirements) MW 3

Steam turboset

Müllverwertung Borsigstraße GmbHBorsigstraße 6 • 22113 Hamburg • Telephone: 040/731 89-0 • Email: [email protected] • www.mvb-hh.de

in conjunction with Vattenfall Europe New Energy GmbH

2012

34

Year Slag Scrap Hydrochloric Gypsummetal acid

Mg Mg Mg Mg2009 61,223 9,114 4,097 1,1342010 63,936 9,825 3,387 1,0152011 65,295 10,152 4,526 1,025

Flow chart 1 and line 2

Year Ammonia Condensate Furnace Unhydrated Electricity Electricitywater coke lime Consumption Purchase

Mg Mg Mg Mg MWh MWh2009 1,275 952,433 299 578 31,718 31,7182010 1,099 903,659 295 533 30,204 20,1142011 1,257 907,421 303 558 32,361 8,6661)

Year Boiler Flue Filter Calcium Cleaningparticulates particulates particulates chloride salts residues

Mg Mg Mg (solid) Mg Mg2009 3,253 4,924 757 3542010 3,429 5,083 810 3272011 1,321 4,9082) 2,214 840 420


p. 4 Flow chart

p. 15 Residual waste***

* annual quantities supplied, 1) start-up of own power production


*** annual quantities supplied 2) Quantities of dust have only been recorded per line since mid-2011.

p. 10 By-products**

Impregnated activated carbon1

Ammoniawater

Grate

Slagtreatment

Bag-housefilter

SO2scrubber

HClscrubber

WaterLimemilk

Clean gas

Flue

HCltreatment Gypsum

treatment

SNCR

District heating (base load for Hamburg)

Condensate

Induceddraught

Furnacecoke2

Waste Boiler

1 dosing only with Hg inputs2 continual dosing

Müllverwertung Borsigstraße

35

Environmental aspects line 1 and line 2

The core indicators under EMAS III for the incineration lines 1 and 2 from 2009 to 2011 are shown below.


Energy efficiency

Steam production (MWh/Mgwaste) 2.54 2.46 2.48

Own steam requirements* (MWh/Mgwaste) 0.63 0.68 0.77

Primary energy input (Heating oil) (MWh/Mgwaste) 0.02 0.04 0.03

Electricity purchased (MWh/Mgwaste) 0.10 0.06 0.03


Material efficiency

Ammonia water (kg/Mgwaste) 3.9 3.4 3.8

Furnace coke (kg/Mgwaste) 0.9 0.9 0.9

Unhydrated lime (kg/Mgwaste) 1.8 1.6 1.7

Water

Total water requirements (m3/Mgwaste and scrap wood) 0.22 0.20 0.17

By-product/waste

Slag (kg/Mgwaste) 188.4 197.5 195.7

Boiler particulates (kg/Mgwaste) 10.0 10.6 4.0

Filter particulates (kg/Mgwaste) 15.2 15.7 6.6

Flue ash (kg/Mgwaste) - - 14.7

Biological diversity

Area used (developed) (m2/Mgwaste and scrap wood) 0.13 0.13 0.12

Emissions

CO2* emissions (kg/Mgwaste) - - -

SO2 emissions (kg/Mgwaste) 0.024 0.019 0.021

NOx emissions (kg/Mgwaste) 0.441 0.433 0.420

Particulate emissions (kg/Mgwaste) 0.001 0.001 0.001


* CO2 emissions are not significant in this context. The reason for this, among others, is that the domestic refuse incineration line is a waste incineration plant and is not governed by the provisions ofthe Greenhouse Gas Emission Trading Act (TEHG).


RECYCLING TO THE HIGHEST STANDARDS

2009 2010 2011

* incl. own electricity production

p. 20 Operating resources - MVB · 2010 3,429 5,083 810 327 2011 1,321 4,9082) 2,214 840 420 p. 20...

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