Mr. John ThomasUSAID Low Emissions Asian Development (LEAD) Program

29 January 2015

Waste to EnergySession - I

Session 1

• Introduction to Waste to Energy concept

• Energy generation potential from Wastes

• Waste to Energy technologies:

• Combustion; Gasification, Pyrolysis, Thermolysis, Pyro Thermic, Anaerobic Digestion, Landfill Gas, Waste Heat Recovery

• Technology Selection Criteria

• Challenges for WtE operators

• Govt schemes/ incentives

Waste Management Hierarchy

Technologies Overview

Thermal Conversion: Combustion

� Thermal conversion of a feedstock utilizing excess air oroxygen as oxidant to generate heat.

Waste-to-Energy Incinerator with Pollution Controls

THERMAL TREATMENT

TECHNOLOGIES

Source: Bilitewski

ES10

Slide 7

ES10 The most common technology for the incineration of MSW is the grate system combined with a combustion chamber. In Germany more

than 90 % of the MSW incinerators are grate firing systems. These systems require minimal pre-processing and occur in facilities of

varying grate size from 2 t/h to more than 40 t/h.Emmanuel Serna, 5/26/2010

Thermal Conversion: Gasification

� Gasification is a process that uses high temperatures(without combustion) to decompose materials to producesynthetic gas.Temperature > 1300oF

� It takes place in the presence of limited amounts of oxygen

Thermal Conversion: Pyrolysis

� It is defined as the thermal decomposition of carbon-basedmaterials in an oxygen-deficient atmosphere using heat toproduce syngas.No air or oxygen is present and no directburning takes place.The process is endothermic.

� Lower temperature than gasification (750 – 1500oF)

PYROLYSIS:

Case Study: Plastic Oil substitutes Heavy Fuel Oil in Steel Industry

Syngas

Syngas

Main product of gasification and

pyrolysis

Caloriific Value: approx. 13

MJ/kg, half of natural gas

It is used as a fuel to generate electricity or

steam

It is used to produce

synthetic diesel

Syngas

Biochemical conversion: Anaerobic Digestion

� “An anaerobic digester is an air tight, oxygen‐free containerthat is fed an organic material, such as animal manure or foodscraps.

� A biological process occurs to this mixture to producemethane gas, commonly known as biogas, along with anodor‐reduced effluent. Microbes break down manure intobiogas and a nutrient‐rich effluent.”

Anaerobic Digestion

Overall scheme for Anaerobic digestion

1st Phase- hydrolysis of complex organic materials,

i.e.,carbohydrates,fats,proteins, nitrogen compounds,salts

etc. into soluble organic compounds, i.e., sugars,fatty

acids,amino acids etc.

2nd Phase- soluble organic compounds are reduced to

simpler compounds, i.e., organic acids (acetic acid,

propionic acid etc.) , simpler alcohols and acetone.

3rd Phase- Organic acids ,mainly acetic acid and certain

other oxidised compounds are converted to methane and

carbon dioxide by methanogenic bacteria.

ANAEROBIC DIGESTION: INTEGRATED USLM*

* Urban Solid & Liquid Waste Management

Integrated Sewage And Solid Waste Management

For all new urban development, it makes sense to Integrate Sewage/Solid Waste System

19

SAVE WATER , SAVE ENERGY ------- SAVE ENVIRONMENT

High Collection Cost Drain To Nallahs

Water + Energy +

Compost

Solid

Waste

Open Landfill

Sewage

Population

Sewage + Solid Waste

Optimum CAPEX

Lower OPEX

Attractive ROI

Zero discharge & More Sustainable

Renewable energy: Solar & Biogas

Applicable for Centralized/ decentralized

Sewage + Solid Waste �Water + Energy + Compost

ADVANTAGES

.

Biogas from Industrial wastes

LIKELY CAPACITIESLIKELY CAPACITIESLIKELY CAPACITIESLIKELY CAPACITIES

o Distilleries effluent : 1 MW / 30 kL

o Dairies (milk processing) : 100 kW / 3 lakh litres

o Paper Mills (Black Liq. +) : 1 MW / 60 TPD paper

o Slaughterhouse waste : 100 kW / 10-12 TPD

o Poultry droppings : 1 MW / 1 Million birds

o Cattle dung : 100 kW / 25 TPD

Biogas from Industrial Wastes

o 1.5 MW power from food processing and sugarindustry solid waste

o Four biogas projects for bagasse / straw wash-water in paper mills

o About 20 projects for heat and/or power fromstarch industry effluents

o Over 250 distilleries generating biogas for heatand/or power from their spent wash/effluent

o Demonstration projects for converting biogas intobio-CNG

Global Methane Initiative – Meeting of Agr. Sub-Committee November 12, 2010

Biomethanation of bagasse wash-water at Tamil

Nadu Newsprint and Papers Company

Global Methane Initiative – Meeting of Agr. Sub-Committee November 12, 2010

2 MW biogas power at a distillery

Landfill Gas

� Landfill gas (LFG)-to-energy is a form of anaerobic digestionand is a biological treatment method ofWTE.

� LFG is created during the decomposition of organicsubstances in MSW when it is dumped, compacted, andcovered .

Landfill Gas

� LFG-to-energy as a method of WTE conversion does notrequire new technology, but instead depends on harnessingthe methane (CH4), carbon dioxide (CO2), and nitrogen (N2)that is and always has been created by MSW

� LFG-to-energy is economically attractive because unlike otherWTE conversion technologies, it does not require a newfacility. Gas can be collected from an existing landfill and eitherused as is, upgraded to a higher quality gas, or converted toenergy through combustion, a gas turbine, or a steam turbine

Landfill Gas Process Flows

Waste-to-Energy Plant

TECHNOLOGY SELECTION CONSIDERATIONS

ECONOMY

ENVIRONMENT

ENERGY

• CO2 Control

• DXNs Control

• Emission Control

• Landfill Control

• Cost Control

• Profit

• Growth

• Energy Recovery

• High Efficiency

• Utilization / Sale

Waste characteristics

• waste type

• waste quality

• waste contents

Criteria For Selection of WTE

CRITERIA INCINERATIONANAEROBIC

DIGESTION

GASIFICATION/

PYROLYSIS

Power generationSteam Turbine Gas Turbine Gas/ Steam Turbine

Efficiency85-90% (based on

calorific value)

50-60% (based on

volatiles)

90 -95% (based on

calorific value)

Residue Ash Digested slurry Ash, Char

Residue DisposalLandfill Farm land

Reuse possible, as

road material

Relative Capital

Cost Very High Medium Very High

O&MHigh Low

Limited (few moving

parts)

Commercial

viability

Less viable owing to

costly downstreamair

pollution control Readily viable Varies considerably

Criteria for Selection of WTE

THERMOLYSIS: (Polymer Waste to Fuel)

• THERMOLYSIS and HYDROGENATION are

getting much attention for producing fuel

from Polymer Waste.

• The Synthetic Diesel produced from

Polyethylene (PE) has greatly enhanced

properties over conventional Diesel fuel.

• Thermolysis is performed at a temperature

lower than 500oC and in absence of oxygen

(Horvat & Ng 1999)

THERMOLYSIS Versus INCINERATIONTHERMOLYSIS INCINERATION

PRINCIPLEPhysico-chemical transformation of

organic matter into coal,

hydrocarbons, gas and water Thermal destruction of material

OPERATING

CONDITIONSWithout oxygen,at temperature of

about 500oC in an airtight enclosure

At temperature of 900-1000oC, with

oxygen carrying air, in a static or

rotating furnace.Waste INPUT

LIMITATIONS None In humidity

ENERGY RECOVERY Production of fuel (Coal and

hydrocarbons)

On site continuous production either

electricity or heat generated

GAS PROCESSING

Supply and production of Synthetic

Gas,emission treatment, dry or semi-

dry

Requires process equipment, either

humid or semi-humid, to control

emissions

DIOXIN EMISSIONSNone Possible, treated by gas treatment

34© UNEP 2006

Waste Heat Recovery

Source and QualityS. No Source of Waste Heat Quality of Waste Heat

1 Heat in flue gases The higher the temperature, the greater

the potential value for heat recovery

2 Heat in vapour streams As above but when condensed, latent heat

also recoverable

3 Convective & radiant heat lost

from exterior of equipment

Low grade – if collected may be used for

space heating or air preheats

4 Heat losses in cooling water Low grade – useful gains if heat is

exchanged with incoming fresh water

5 Heat losses in providing

chilled water or in the disposal

of chilled water

1.High grade if it can be utilized to reduce

demand for refrigeration

2.Low grade if refrigeration unit used as a

form of Heat pump

6 Heat stored in products

leaving the process

Quality depends upon temperature

7 Heat in gaseous & liquid

effluents leaving process

Poor if heavily contaminated & thus

requiring alloy heat exchanger

35 Contd.

Green Power (Waste Heat Recovery Power Plant)

Sustainability Initiative

� Clinker process generates waste heat.

� Using waste heat Waste Heat Recovery power plants

(WHRP) can

• Generate green power without fuel

• Conserve fossil fuels and water

• Reduces CO2 emissions

� WHRP are highly capital intensive: Rs 9-10 Cr/MW

� Indian Cement industry committed to low carbon

economy

• Installed 140 MW WHRPs

• Achieved CO2 reduction: 385000 Ton

• Potential to generate 1000 MW power

Shree has installed largest WHR based Power plant, in World

Cement Industry after China

Hazardous Wastes and Energy Recovery potentialSustainability Initiative

About 7.66 million tonnes per annum

hazardous waste generated from about

40,722 industries of which

� Landfillable – 3.39 Mn TA

�Recyclable – 3.61 Mn TA

� Incinerable – 0.65 Mn TA

Source: CPCB

Alternative Fuels: Energy from any Waste

Sustainability Initiative

� Kilns are the best sustainable solution for disposal of hazardous

waste.

� Use of Hazardous waste for co-processing can potentially save

0.43 Mn tonne of Coal yearly.

� Municipal Waste alone can generate 9 Mn Tonne of Residue Derived

Fuel (RDF) to replace 4.5 Mn Tonne of coal for cement plant

operation.

Pioneers in AFR utilization: Holcim & Utratech

Cement Industry & Alternative Fuels

Sustainability Initiative

� Cement production an energy intensive process.

� Reliant on coal from Coal India, no new coal linkage post

2007.

� Alternate Source : Use of AFR, Petcoke, Coal Import.

� R&D : On compatibility of AFR material.

� Successfully developed Petcoke- A refinery waste as a

strong alternative of Coal.

� Results: Conservation of fossil fuels and overcome

disposal problem of petcoke.

Shree Cements was first to pioneer the use the Pet-coke in Kilns

Example of effective utilization of waste and byproduct leveraging a cement factory

廃タイヤ、鋳物砂 下水汚泥、浄水汚泥

塗料残留物 都市ごみ焼却灰

高炉スラグ、製鋼スラグ 蒸留酒残渣、廃ガラス

集塵灰 肉骨粉、プラスチック

製紙汚泥、焼却灰 建設発生土

建設廃材

石炭灰、排煙脱硫石こう 廃油、廃触媒

汚泥

焼却灰、廃プラスチック 廃溶剤、廃触媒

廃プラスチック

非鉄鉱さい 焼却灰、廃溶剤

廃プラスチック

古畳 廃プラスチック

セメント工場セメント工場セメント工場セメント工場

自動車業界

鉄鋼業界

製紙業界

電力業界

地方自治体

食品業界

建設業界

石油業界

廃棄物処理業界 化学業界

精錬業界 印刷業界

農業住宅業界

Automobile

industry

Steel

industry

Paper

industry

Electricity

industry

Waste disposal

industry

Refining

industry

Housing

industry

Local

government

Food

industry

Construction

industry

Petroleum

industry

Chemical

industry

Printing

industry

Agriculture

Waste tire, molding sand

Cement

factory

Paint residue

Blast-furnace slag,

steelmaking slag

Fly ash

Paper-making sludge,

incineration ash

Coal ash,

flue-gas gypsum

Incineration ash,waste plastic

Sewage sludge,

water purification sludge

Municipal waste

incineration ash

Distilled liquor residue,

waste glass

Meat and bone meal,

plastic

Soil put out in

construction

Construction and

demolition waste

Waste oil, waste catalyst

Sludge

Waste solvent,

waste catalyst

Waste plastic

Nonferrous slag

Waste tatami mat

Incineration ash,waste solvent

Waste plastic

Waste plastic

Source: Adapted from Sameshima (2009), presented at the Inaugural Meeting of the Regional 3R Forum in Asia in November 2009 in Tokyo.

Co-processing: Factors to be considered

• Suitability of substance for co-processing

• Operating condition

• Trial run

• Environmental impacts and rules for

emissions

• Quality assurance of the end product

• Assured supply in required quantity and

quality

WtE – Emerging Trends

� Waste-to-energy in general relates to any waste treatment that creates

energy in the form of electricity or heat from a waste source that would have

been disposed of in landfill.

� An Energy-from-Waste plant operates by using the waste and converting

them into usable high-energy in various forms such as petroleum

substitutes, heating and electricity source.

� Waste-to-energy market is being driven by increasing government concerns

about energy security and independence, the rising energy prices, volatility

of fuel costs, and government incentives on renewable energy.

WtE – Emerging Trends

� Europe and USA will continue to dominate the waste-to-energy markets

due to many policy initiatives. Asia Pacific is gaining momentum and is

slowly catching up in this regard. However more work needs to be done on

the regulatory front. Key opportunities thus lie in Asia Pacific and Eastern

European countries.

� Though Asia has large potential, investment is relatively slower than that of

its North American or European counterparts. However countries such as

Taiwan, Thailand, Singapore and Malaysia offer good short-term

opportunities, while China and India dominate the medium and long-

term horizon.

Govt. Schemes

Ministry of New and Renewable Energy

Bio-energy Technology Development Group

Ministry of New and Renewable Energy

Bio-energy Technology Development Group

Biogas Programmes:

• National Biogas and Manure Management Programme

(NBMMP).

• Biogas Based Distributed/Grid Power Generation

Programme.

• Demonstration of Integrated Technology Package on

Biogas-Fertilizer Plants (BGFP) for Generation,

Purification/ Enrichment, Bottling and Piped Distribution

of Biogas.

• Establishment of Business Model for Demonstration of an

Integrated Technology Package for creation of smokeless

villages using biogas/ bio-energy systems and meeting ‘Life-

line Energy’ envisaged in ‘Integrated Energy Policy’

2/5/2015 45

Biogas based Distributed/ Grid Power

Generation Programme:Central Financial Assistance

Power generating

capacity

Biogas plant

capacity

CFA/subsidy limited to the

following ceiling or 40% of the

cost of the system whichever

is less.

3 -20 kW 25 cu. m to 85 cu.m Rs.40,000 per kW

>20 kW to 100 kW Any combination of

above plants or

alternate capacity

/design

Rs.35,000 per kW

>100 kW to 250 kW Any combination of

above plants or

alternate capacity /

design

Rs.30,000 per kW

Govt. schemes/ incentives

Central Financial assistance based on type of waste

� The eligibility criteria for type of waste are as follows:

� Projects based on any bio-waste from urban, agricultural, industrial/agro –industrial sector (excluding bagasse).

� Projects for co-generation /power generation and production of bio-CNG from biogas.

� Mixing of other wastes of renewable nature, including rice husk, bagasse, sewage, cow-dung, other biomass and industrial effluents (excluding distillery effluents)will be permissible.

� Biogas generation projects based on distillery effluents and projects based on wastes from fossil fuels and waste heat (flue gases) shall not be supported.

� Municipal Solid Waste based projects selected through transparent competitive procedure would only be eligible for central financial assistance.

� In MSW to Power projects, any waste of renewable nature or biomass can be mixed to the extent of 25 % based on gross Calorific Value. Use of a maximum of 25 % conventional fuels would be allowed in Biomass Co-generation (Non-Bagasse) projects based on agricultural wastes and residues other than bagasse.

Ref: http://mnre.gov.in/file-manager/offgrid-wastetoenergy/programme_energy-urban-industrial-agriculture-wastes-2013-14.pdf

Public Opposition

� Environmental groups often form opposition against new WtE plants regardless of technology used

� Need to understand the impact this may have on permitting process, utility process and financing options

� Understand timeline for public notification

Technical and Performance Issues

� System must meet performance criteria to remain economically viable

� Newer, more experimental systems are risky because they have no demonstrated performance records

Facing Challenges

Scale Issues

� Long term growth must be considered when determining applicable size of plant

� Smaller scale projects have higher levelized costs of production

Feedstock Supply

� Supply risks / backward linkages

� Price fluctuations

Facing Challenges

CONTACT

NAME

Mr. John Thomas

USAID LEAD Program

(USAID Contractor)

Email: bob.johnthomas69@gmail.com

Tel: + 91-9958176767