Waste-to-Energy Technology Development in Japan – for ... · Gas cooling. Flue gas treatment. AC...

ECO ASIA CONFERENCETheme : Innovation, Development and Exchange of Green Tech

(Session II – Waste Management and Recycling)

27th October，2011

1Copyright 2011 © JFE Engineering Corporation All Rights Reserved

Hajime FUKAI

Waste-to-Energy TechnologyDevelopment in Japan

– for obtaining Clean Environment –

CONTENTS

WASTE MANAGEMENT～ Transition History and the Future ～

Copyright 2011 © JFE Engineering Corporation All Rights Reserved 2

１．Waste Management Trajectory２．Facts & Figures of Waste Management３．Thermal Treatment of MSW４．Pollution Control Technology

– WtE in the City –５．Emerging Technology

Part 1.Waste Management Trajectory


41900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000 2010

NOWASTEMANAGEMENT

MODERN WASTE MANAGEMENT

RECYCLE

START WASTE MANAGEMENT

+ 1880s~ PANDEMIC (CHOLERA, PEST, etc.)+ OPEN BURNING+ UNSANITARY ENVIRONMENT

-1900

+ 1900 WASTE CLEANSING LAW> LOCAL GOVERNMENT RESPONSIBILITY> INCINERATION AS PRIORITY

+ 1903 Mechanical INCINERATOR Start

WASTE INCREASE BY GOOD ECONOMYRAISED IMPROPER TREATMENT

+ 1970 WASTE MANAGEMENT ANDPUBLIC CLEANSING LAW

+ Waste-to-Energy Plant START

+1991 Promotion Law+1995 Container/Packaging+1998 Home Appliance+2000 Recycle Basic Law+2000 Construction /Food /Car

YEAR

2020

+ 1990 DIOXIN Guideline+ 1999 DIOXIN Law

PROTECT HUMAN HEALTHfrom UNSANITARY ENVIRONMENT

To SUSTAINABLE SOCIETY

THERMAL RECYCLING

EMISSION CONTROL


Waste Management Trajectory in JAPAN

Pest, Odor, Soil/Water Pollution, Fire ⇒ Decades-long Pollution

■Organics in Landfill

Difficult to Secure New Landfill■Limited Land Area

Direct Disposal

Domestic Waste Landfill

■Methane from Landfill Cause of Global Warming(CH4 has 21 times larger effect as CO2 )


Why Thermal Treatment? (Disadvantage of Direct Disposal)

Waste Process Flow

Segregation

“R”educe

Collection, Transport, Storage

“R”ecycle, “R”euse (resource recovery)

(thermal recovery)

Intermediate Treatment

Final Disposal

Process for SAFE final disposal

Thermal Treatment


Position / Meaning of Thermal Treatment (as an Intermediate Treatment)

Part 2.Facts and Figures of

Waste Management


25

30

35

40

45

50

55

60

1985 1987 1989 1991 1993 1995 1997 1999 2001 2003 2005 2007 20090.8

0.9

1.0

1.1

1.2

1.3

1.4

1.5

BubbleEconomy

3R PolicyRecycle policy


MSW Volume TrendM

SW V

olum

e (m

illio

n t/

year

)

Per

Capi

ta R

ate

of M

SW (

kg/d

ay/p

erso

n)

Fiscal Year Source : Ministry of Environment(Japan)

Per Capita Rate of MSW

MSW Volume

122122130133138145153160165172178172 116

18

15.715.614.8

141413.813.212.812.9

11.7

12.8

18.7

0

100

200

300

1997 1999 2001 2003 2005 2007 20090

7

14

21

3R Policy


Landfill Lifetime ExtensionRem

aini

ng C

apac

ity (

mill

in m

3)

Rem

aini

ng Y

ears

Fiscal Year Source : Ministry of Environment(Japan)

Remaining Years

Remaining Capacity


Waste Flow in Japan

data FY:2008Source : Ministry of Environment(Japan)

Unit: million tons

Total Waste Volume

48.1(100%)

Planned Treatment

45.2(94%)

IntermediateTreatment

42.0(87%)

Direct Recycling2.4 (5%)

Reclamation4.5 (9%)

Group Collection2.9 (6%)

Direct Final Disposal0.8 (2%)

Final Disposal4.7 (10%)

"R"EDUCEWith

Thermal Treatment32.8

(68%)

"R"ECYCLE9.8

(20%)

LANDFILL5.5 (12%)

Recycling42%

Landfilling38%

ThermalTreatment

20%

33 million tons of MSW per yearGoes To

1,243 Thermal Treatment plants

Recycling20%

Landfilling12%

ThermalTreatment

68%

Source: CEWEP

Source: Ministry of Environment


Treatment Proportion

Recycling34%

Landfilling54%

ThermalTreatment

12%

29 million ton/y - MSWWith 85 plants

Source: USEPA

60 million ton/y - MSWWith 420 plants

1970 Waste Management Act

1990 Publication of Dioxin Emission Standards

2000 Low concerning Special Measures against Dioxins ⇒Below 0.1ng-TEQ/Nm3

1991 Partial Revision of Waste Disposal Act & Waste Management Act

Y-city (900tpd) F-city (600tpd) T-city (600tpd) Y-city (1,200tpd) O-city (900tpd)

1952 Waste Disposal Act

LHV

of W

aste

(kJ

/kg)

2000

4,000

6000

8000

10,000

12000

14000

1965 1970 1975 1980 1985 1990 1995 2000 2005

History of Major Updates on Environmental Acts in Japan


Waste Heat Value Trajectory in Japan

LHV : Lower Heat Value

LHV history of MSW in Design condition●

Hu=max■

Hu=ave▲

Hu=min

Y-City

F-CityO-City

T-City

Part 3.Thermal Treatment

of MSW


Incinerator Waste Incinerator with Moving Grate

( Facilitate together with Incinerator )

Stoker

Gasification & Melting Furnace

Fluidized Bed

Kiln Incineration in Revolution Cylinder

Incineration by touch with Fluidized Hot Sands

Direct Melting from Waste to Slag/Metal

Shaft type

Fluidized Bed type

Kiln type

Ash Melting Furnace Melting Ash by means of Electricity or Fuel

Melting in Cylindrical Shaft with Auxiliary Heat SourceGasification by Fluidized Bed and Melting with its Own HeatGasification by Kiln and Melting with its Own Heat


Stoker (sometimes with Ash Melting) is Most Popularly Adopted in Japan.And is followed by various Types of Gasification.

TYPES of Thermal Treatment

1970 1980 1990 2000 2010

STOKER

Gasification & Melting FurnaceFluidized Bed

Dioxin Laws& Regulations (98% Reduction achieved

from ’97 to ‘03)▲Dioxins issue & RDF emerged

Guideline to Facilitate Melting Furnace

New Generation STOKER

▲Modern Mechanical Incinerator

STOKER+Ash Melting

▲Waste-to-Energy start


History of Thermal Treatment

▲2000

▲1997

198 199

191

184 185177 176 175 172

169

16521692

1436 13291295

1230 1205 1185 1164 1133

150

170

190

210

500

800

1100

1400

1700

161514

131110

86

22

9291878377

7058

46

1722

0

5

10

15

20

25

2000 2001 2002 2003 2004 2005 2006 2007 2008 2009

Fiscal Year

0

50

100

Source : Ministry of Environment (Japan)

Plan

t N

umbe

r

Tota

l Cap

acity

(,0

00 t

/day

)

Plant Number

Total capacity


Two Major Thermal Treatment - Stoker and Gasification -

STOKER

GASIFICATION

Total capacity

Plant Number

Hopper

Waste feeder

Stoker Grate

Boiler

Two WayFlue Gas System

Waste To Flue Gas Treatment

Bottom ash

Chute


Stoker Furnace


Typical Flow of Stoker

Slag and MetalSlag and Metal

Secondary TuyereSecondary Tuyere

Main TuyereMain Tuyere

Third TuyereThird Tuyere

WasteWaste Coke & LimestoneCoke & Limestone(Sub(Sub--materials)materials)

Coke LayerCoke Layer

Gasifying LayerGasifying Layer(Drying and Pyrolysis zone)(Drying and Pyrolysis zone)

FreeboardFreeboard(Gas reforming zone)(Gas reforming zone)

Molten Slag BasinMolten Slag Basin

((High temperature High temperature melting zone)melting zone)

Combustion GasCombustion Gas


Gasification and Direct Melting Furnace


Typical Flow of Gasification

MSW 1.5m3

(1t)MSW 1.5m3

(1t)


Gasification REDUCES Ash to Landfill

0.19m3

Ash Fly Ash

0.05m3

Fly AshSlag&

Metal0.05m3

Recycle0.24m3

to Landfill

to Landfill

Waste TYPICAL CONTENTS OF the WASTE

GASIFI- CATION STOKER

High LHV Waste

- Disposed Plastic- ASR- RDF

○ ○

Moist Waste- Kitchen Garbage- Sludge ○ ○

Waste with Ash

- Slag from Incinerator- Excavated Landfill Waste- MBT Residual waste

○ －

Hazardous Waste

- Medical Waste- etc. ○ －

Ash

Water

Water VolatilesCombustibles

Fixed Carbon

Ash

Coke

Gasification VERY WIDE range of WASTE can be applied

to Gasification by means of COKE additive rate.


Gasification for Wide Range of Waste

Stoker SystemStoker SystemStoker System Gasification SystemGasification SystemGasification System

CONVENTIONAL TechnologyWell PROVEN with 40 years operation

EMERGING TechnologyPROVEN with 10years

WIDE range of CAPACITY Very WIDE range of Waste Type

Discharge ash and fly ash to landfill Less Discharge without ashOnly fly ash to landfill


Thermal Treatment Technologies

Part 4.Pollution Control Technology

-- WtE in the City --


Item Emission Standard (Japan) Measured Value

Dioxins

> 4 t/h 0.1ng/Nm3

> 0.05 ng/Nm32<x t/h<4 1 ng/Nm3

< 2 t/h 5 ng/Nm3

Particulate

> 4 t/h 0.04g/Nm3

Bag Filter 0.002 - 0.007 g/Nm32<x t/h<4 0.08g/Nm3

< 2 t/h 0.15g/Nm3

Hydrogen ChlorideHCl

700 mg/Nm3 (O2 12%)( approx. 430ppm )

Dry (Semi-Dry) 20 - 50 ppm

Wet 20 - 30 ppm

Sulfur OxidesSOx

K – Value( specified in each area )

20 - 30 ppm

Nitrogen OxidesNOx

250 ppm( O2 12% )

Non-Catalyst 50 – 100 ppm

Catalyst 20 – 50 ppm

Combustion Control 80 – 100 ppm

Furnace Water Spray 60 – 80 ppm

Flue gas recirculation 60 – 80 ppm


Japanese Emission Standard, Actual Emission & Treatment Process

Waste receivingIncinerator & Boiler Gas cooling Flue gas treatment

AC injector

Bag filter

Gas cooling tower

Homogenizing wastes by crane

Sufficient capacity of waste pit Flue gas Temp = Above 850 deg.C

Residence Time = more than 2 sec.Turbulence

Removing Dust in boiler

3. Dioxin removal by Activated Carbon

1. Dioxin reduction control

Dioxin conc. 0.1ng-TEQ/mN3

Water

2. Inhibit Dioxin re-generation by quenching flue gas temp.

3Ts

4. Dioxin decomposition by SCR

Stack


Reducing DIOXINs

27Combustion and post-combustion Zone

Achieves “3T” to suppress Dioxin formation

T1 ：

High temperature （850 to 950 deg C）T2 ：

Retention time（2sec）T3 ：

Turbulence

Secondary Combustion ZoneFor unburned gas ：

Oxidation reaction２CO＋O2 → ２CO2For combustion gas ：

Reduction reactionNOx ＋NH3 →

N2＋H２

O

Drying Zone

Intermediate ceiling

Combustion gasO2 , NOx, CO2

Unburned gasCO, H2 , NH3

Achieves complete combustion


Combustion Mechanism

No. Facility

Applied Technologies for reducing DXNs emissionEmission Standard

ng-TEQ/Nm3

Measured Resultng-TEQ/Nm3Two-way

Flue Gas Furnace

Hybrid ACC

Boiler + Gas Cooling Tower

Activated Carbon

InjectionSCR

1 S-City90 t/d ×

3 ○ ○ ○ ○ ○ 0.10.000430.000430.0027

2 K-City140 t/d ×

2 ○ ○ ○ ○ ○ 0.05 0.00870.0027

3 O-City450 t/d ×

2 ○ ○ ○ ○ ○ 0.1 0.00000650.0008

4 K-City150 t/d ×

1 ○ ○ ○ 0.1 0.017

5 R-City90 t/d ×

2 ○ ○ ○ ○ ○ 0.1 0.0160.028

6 Y-City400 t/d ×

3 ○ ○ ○ ○ ○ 0.10.000260.000210.00045

7 M-City135 t/d ×

3 ○ ○ ○ ○ ○ 0.10.0027

0.030.0028


Dioxin Actual Measurement

School

WtE Plant Hospital

Train Station

Date Completed: March 1991Capacity : 300ton/day x 2 lines

Power Output : 11,000 kW

M‐plant

500m


Surrounding of WtE Plant ( case1 )

Date Completed: January 1997Capacity : 300ton/day x 2 lines

Power Output : 12,300 kW

300m


Surrounding of WtE Plant ( case2 )

School

WtE Plant Hospital

Train Station

E‐plant

Part 5.Emerging Technology


Higher Efficiency Waste-to-Energy


Low Temperature Economizer

High Temperature & High Pressure Boiler

Low Air-Ratio Combustion(High Temperature Air / Flue Gas Recirculation)

More Stable CombustionLess Heat Loss

Conventional Technologies

Low Air-Ratio Combustion

Copyright 2011 © JFE Engineering Corporation All Rights Reserved

Blow Out

Soot GenerationSpot ExcessTemperature

ConventionalTechnology

Unstable Combustionwith Low Air-Ratio

High Temperature Air

LatestTechnology

STABLE Combustion with Low Air-Ratio

High Temp. Air Layer

AirGrateWaste

High-temperature air injectionFlue gas recirculation

33

Higher Efficiency Waste-to-Energy

304

plants443

plants(36％)

NoHeat Utilization

Power Generation

Generation Capacity

1,673MW

Subsidy to High Efficiency Waste-to-Energy(Subsidy Rate 1/3→1/2)

Plant Capacity(t/d)

Power Generation Efficiency (%)

150～200 15.5200～300 17300～450 18.5

Only 24% of total plants have power generation

Subsidy Tariff Table


Power Generation Efficiency＝Generation Power×100

Input Energy ( Waste + Fuel )

（24％）PlantNumber

1243

Policy in Waste ManagementAgainst Global Warming

496

plants（40％）

Other Heat Utilization

Combination of MSW and Sewerage(Energy Efficiency Improvement)

■Kitchen Waste

Digester Tank Gas Holder

Steam Turbine Generator

■Sewage

Turbine Exhaust Condenser

Steam

DigestiveSludge

Waste to Energy■MSW


Sewerage

Sludge

Sludge Fuel

Waste Heat

Sludge Dryer

Bio Gas

Treated Water

Earthquake Debris On-Site Treatment Plant(Sendai City)


TreatmentVolume : 70,000 ton / 2.5 years

Construction : May. 2011 to Sep. 2011Operation : Oct. 2011 to Mar. 2014

Debris

Gas Treatment

Furnace

Crushing

Crushed Debris

We deeply appreciate the Kizuna our friends around the world have shown and I want to thank every nation, entity, and you personally, from the bottom of my heart.

the bonds of friendship

37

Thank you

38

Waste-to-Energy Technology Development in Japan – for ... · Gas cooling. Flue gas treatment. AC...

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