Chemical Physical Treatment Plant – Evaporation Plant
1 Used Hazardous Waste Incineration Plant 30.000 t / year
– Chemical Physical Treatment Plant – Evaporation Plant
Price: € 8,9 Mill. EXW Germany “as it is”.
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Photos: attached.
Viewing: to be agreed with us.
Specification: attached.
Remarks: The dismanzling and montage could be arranged by us at extra costs.
- Hazardous Waste Incineration Plant
- Chemical-Physical Treatment Plant
- Evaporation Plant
Hazardous Waste
Incineration Plant
Environmentally friendly waste disposal
The safe, environmentally friendly way to dispose of hazardous waste materials
Thermal treatment or recycling of hazardous waste is an indispensable part of a modern, environmentally friendly waste disposal concept. This fulfills the following functions:
- reduction of the quantity and volume of waste materials treated (70-80% less weight, 85-90% less volume),
- as complete oxidation of the organic components in the waste material as possible and their conversion into simple, natural final products, such as carbon dioxide and water,
- concentration of traces of heavy metals in the residues from flue gas purification and therefore reduction in their volume,
- production of ash and slag with as low a pollutant content as possible, which can be materially recycled or deposited as waste in an environmentally compatible way and
- the best possible utilization of the energy generated during incineration.
GSB operates an incineration plant with a connected flue gas purifying plant, which is designed for an annual capacity of around 30,000 tons of liquid, pasty and solid hazardous waste materials. Thanks to the innovative technology the emission values of this plant are much lower than the strict legal requirements.
Thermal treatment
The hazardous waste materials are passed into the rotary kiln and the combustion chamber connected downstream via storage tanks, drum elevator and mixing bunker. The hazardous waste materials are incinerated at temperatures between 950°C and 1250°C. The flue gases from the rotary kiln and post combustion chamber are then used for energy production.
Environmental protection
All the flue gases from incineration of the hazardous waste are cleaned in a modern purification plant using a new unique method.
Energy generation
The waste heat produced during the thermal treatment is used for electrical power generation. The complete plant in Schwabach is supplied with power generated in this way, and power is also delivered to the public network.
Safety
All waste material receiving and disposal areas are provided with seals of steel and plastic which protect the soil and underground water from chlorinated hydrocarbons. The complete treatment process is controlled from the control room.
The for incineration of hazardous waste materials is considered to be exemplary throughout Europe. Safety, environmental protection and cost-effective operation are perfectly adapted to each other.
What is hazardous waste?
Industry
Waste disposal management
Craft sector
Trade
Hazardous waste materials are solid, liquid, gaseous or sludgy residues with particularly high pollutant contents which cannot be recycled or disposed of via the normal domestic waste disposal system owing to their hazardous potential. These materials include not only contaminated waste from production in industry or trade, from purification of waste water or exhaust air, but also problematic waste materials from private households which may not be disposed of together with domestic waste. Examples of waste materials requiring special monitoring include, for example, electroplating sludges, pickling solutions, acids and alkalies or oil sludges – also paint residues, contaminated solvents and filter fabric from flue gas purifying plants. All these waste materials must be specially disposed of in order to avoid hazardous effects an the environment.
Waste disposal of hazardous materials mainly involves the chemical conversion or destruction of pollutants. The aim is to reduce contamination of air, soil and water as far as possible. For this purpose the following processes are used:
Chemical-physical:
Chemical containers for chemical_physical treatment
e.g. pickling solutions from galvanising shops, acids and alkalies, water/sludge mixtures from industrial waste water purification
Separation of oil/water:
Partial view of an industrial waste water treatment plant
e.g. oil separators from petrol filling stations or workshops, coolants and lubricants from metal processing (drilling, turning, milling)
Thermal:
Rotary kiln for thermal waste destruction
e.g. paints and lacquers (not hardened), overstored drugs, cleaning agents, solvents, spray cans with residues, pipe cleaning agents
Waste dump:
The waste dump is the last link in the waste disposal chain
e.g. contaminated building rubbish, contaminated soil, (e.g. following an accident with hazardous products), solid residues from industrial waste water plants
Serious changes in the market have been brought about through legislation and economic developments. This has resulted in a considerable change in the flow of materials so that GSB now finds it necessary to close down the, despite its ultra-modern technology. Therefore the incineration plant with all auxiliary facilities and supplementary installations is now for sale.
The incineration plant
1 Bunker
2 Crane installation
3 Rotary kiln
4 Post combustion chamber
5 Safety outlet
6 Steam boiler (30 bar)
7 Electrostatic precipitator
8 Steam boiler (6 bar)
9 Wet scrubbers (4-step)
10 Induced draught fan 1
11 Nitrogen oxides removal
12 Fluidized bed absorber
13 Fabric filters baghouse
14 Induced draught fan 2
15 Stack
1. Receipt of waste material and
preliminary treatment
The plant is run continuously in three shift operation throughout the year. It is designed for the following gross heat loads:
- maximum load 58.0 GJ/hr
- normal load 43.5 GJ/hr
Approx. 75% of the total heat is introduced into the rotary kiln. At full power 17 t/hr of steam are generated at a pressure of 28 bar and a steam temperature of 320°C.
Liquid waste materials, which are delivered in road tanks, can usually be taken into the tank farm. Miscible liquids, such as solvents and waste oils, are first sieved and then passed into the tanks (1100 m³). For Non-combustible liquids requiring thermal treatment tanks with a capacity of 125 m³ are available. Non-neutral liquids can be neutralised – a corrosion-resistant tank (15 m³) is provided for this purpose.
Non-miscible liquid waste materials, such as silver bronze, heavy oil residues and special batches, which are highly contaminated with pollutants, can be passed, unmixed, into tanks of total capacity 130 m³, and from here they are charged directly into the incinerator. All normal liquid waste materials are mixed in intermediate tanks of capacity 45 m³ and then passed to the burners.
Non-miscible special batches are charged directly into the incinerator via a drum elevator. Empty drums are shredded by rotary shears and the residues burnt out in the rotary kiln.
Drum storage facilities for approx. 600 drums and small containers are available. Drums with solid and pasty contents are also stacked in the drum store, passed to the rotary shears – complete with their contents, and then mixed with other waste materials in the bunker.
Solid and pasty waste materials, which are supplied in containers and open vehicles, are passed to a receiving bunker (approx. 500 m³). From there a crane takes up the waste material mixture and distributes this to the rotary kiln.
2. Site plan
The incineration plant
3. Preparation and charging
Incineration takes place in a rotary kiln with downstream-connected post combustion chamber. In this chamber the waste gases have a long retention time at suitably high temperatures.
Approx. 60% of the rotary kiln capacity is charged with solid waste materials and approx. 40% with liquid waste materials or emulsion sludge via the burners, or with special batches via the drum elevator. The rotary kiln and post combustion chamber are designed for continuous operation between 900 and 1250°C. Normal operation is between 1050 and 1250°C.
Homogenised (or otherwise pretreated) solid and pasty, non-pumpable waste materials are charged into the rotary kiln from a bunker. Charging takes place separately from either the receiving bunker (main quantity), the cassette for emptified containers or the special batch cassette.
From the tank farms
- liquid, highly combustible waste materials are generally passed to the rotary kiln,
- poorly combustible waste materials to the afterburning chamber,
- non-combustible waste materials to the afterburning chamber and
- special batches, such as organic and inorganic acid mixtures, to the afterburning chamber or rotary kiln.
The drum elevator is suitable for containers of up to 200 kg total weight.
The special batch station is intended for direct injection of liquid hazardous waste.
Pumpable sludges can be passed into a sludge silo by means of an eccentric screw pump. The sludge from this silo is pumped into the bunker via the rotary shears (shredder). Contact with the low calorific value sludges reduces the danger of ignition during shredding of the small containers. Special batches bypass the intermediate tank and are passed from the tank farms directly to the burners or injection lances.
4. Rotary kiln
Solid and pasty waste materials for incineration are passed from the charging hopper into the rotary kiln.
The rotary kiln is an incinerating apparatus for simultaneous incineration of solid, pasty and liquid waste materials. It is slightly inclined in the direction of transport and is lined with refractory material. Ash/ slag can be discharged both dry and together with molten material. The rotary kiln is fitted with welded cast steel barrel rings which are supported an rollers. The position of the kiln is fixed by a pressure roller station.
Uniform loading of the rollers is guaranteed by the longitudinal guide of the kiln. The rotary kiln is driven via a ring gear, pinion gear, spur gear and an adjustable motor. On the inlet and outlet sides the kiln is fitted with a seal. This ensures that the quantity of infiltrated air into the kiln is extremely low.
The retention time in the rotary kiln is 30 to 60 minutes for solid materials. Combustion is controlled in such a way that the waste material is first dried and ignited in the first third of the kiln. In the main combustion zone (middle third) complete incineration takes place. Waste material containing coarse lumps requires reheating in the afterburning zone (last third) for complete burn-out. Camera monitoring is used to control the combustion zones. The minimum temperature is 900°C and is controlled by a pyrometer. The normal temperature is 1050°C.
Combustion air required for the rotary kiln is taken from the bunker area. In this way a practically dust-free atmosphere is provided, and annoyance in the surroundings through bad smells is reduced.
The slag or ash from the rotary kiln is passed from the kiln to the wet slag removing unit. From here the residues are passed to further Systems via a vibrating sieve. A magnetic separator over the conveyor belt removes fine scrap metal from the slag/ash. This fine scrap, together with the coarse scrap is supplied for steel production via a scrap merchant.
The incineration plant
5. Post combustion chamber
Flue gases pass from the rotary kiln into the heated section of the post combustion chamber. This guarantees complete burn-out of the flue gases (complete Oxidation at a sufficiently high temperature, with sufficient turbulence and a long enough retention time).
Liquid materials are injected directly into the post combustion chamber. Incineration temperatures of between 1050 and 1200°C also destroy dioxins and furans.
The flue gas post combustion chamber is designed in such a way that the retention time of the flue gases in the chamber is at least 3 seconds. With max. load of the combustion chamber and an average waste gas temperature of 1000°C the flue gas flow rate of 3.5 m/sec is not exceeded.
The chamber is provided with all the inspection, control and cleaning openings required for Operation and maintenance, as well as Pressure relief facilities.
6. Steam generation and energy production
Heat is utilized in the steam generator, which is fitted with vertical passes and is designed as a natural circulation boiler. Heat is transferred mainly by radiation – at the end of the boiler increasingly also by convection.
The boiler, which has been specially designed for hazardous waste incineration plants, consists of eight flue gas passes. In the 8t” boiler pass a water preheater (economizer) is located. Three tube walls are constructed as superheaters.
Energy recovery takes place via a turbogenerator. A bleeding condensing turbine is coupled with a power generator via a gear drive. This generates approx. 2 MW electrical power. About 1 MW is consumed internally in the plant, the excess power of up to approx. 1 MW being fed into the public power supply network. The extracted steam is used as process steam. In addition to this the incineration plant also has its own steam
requirements for feed water preheating, fuel nebulization and warming the pipes and tanks in the tank farm. The building central heating system is also supplied with heat from the heating condensers. An emergency power Diesel unit with 1 MVA (800 kW) and an auxiliary steam boiler with 5 bar are available for plant standstill and start-up procedures.
For dedusting the waste heat boiler is fitted with steam blowers, tapping devices and typhons (sonic dedusting). The boiler dust separated in the boiler is added to the incineration ash/slag.
The incineration plant
7. Flue gas purification
Low limit values for emission from hazardous waste incineration plants are a clear sign of a responsible attitude towards natural living principles. As one of the most modern plants of its type the Schwabach flue gas purifying plant represents a big step forward in environmental protection in Europe and sets high standards for this technology.
The flue gases produced from the incineration of about 30,000 tons of hazardous waste per year are cleansed in three purification steps. Through the high efficiency of the plant emission values are partly well below the strict limit values applicable in Germany.
Step 1: Electrostatic precipitator and heat recovery
Immediately following the steam generator the waste gases, which have been cooled down to approx. 300°C, enter the electric dust precipitator (electro-filter). This dedusting unit consists of three independent electric fields operating at 40,000 volts d.c. The dust is ionised, electrically charged and deposited an precipitation plates. These are vibrated at regular intervals to release the dust. In this filter the dust content is reduced to well below 50 mg/m³. The discharged dust from the electrostatic precipitator is passed to a silo by a pressure conveyor. This has a capacity of 50 m³ and is emptied every 6 days an average.
From the electrostatic precipitator the flue gases pass into a much smaller waste heat boiler. The flue gases are cooled from approx. 300°C to approx. 220°C. Here, too, steam at a pressure of 6 bar is generated and this is used mainly as process steam.
Step 2: Wet scrubbing
After removal of dust particles via the electrostatic precipitator the gas is cooled down to 150°C. Chlorinated and fluorinated hydrocarbons are separated in a two-step venturi scrubber. The downstream-connected combination scrubber removes sulphur dioxide from the flue gas with a radial flow step and a filling material step. Through the multi-step conception of the wet scrubber a utilizable partial stream is obtained from the first step. After distillation production of marketable crude hydrochloric acid is possible.
Step 3: Removal of nitrogen oxides
Ammonia solution in vapour form is mixed with the flue gas, heated to 320°C, in order to reduce the nitrogen oxides. In the catalyst nitrogen oxides are converted to elemental nitrogen – as this occurs in the natural atmosphere. A special characteristic here is that through the exceptional size of the catalyst a large part of the dioxines and furans is also destroyed in the oxidation zone.
Step 4: Lime/activated carbon afterpurification
Fine purification of the flue gas is carried out in a fluidized bed absorber operating with lime and activated carbon. Through intensive mixing of the filter material with the flue gas organic pollutants can be removed by adsorption and chemisorption. Using this technique organic pollutants, such as dioxins and furans are separated to give values well below currently applicable limit values.
At the same time residues of metals in vapour form, such as mercury, are also reliably removed. A fabric filter baghouse collects the lime and activated carbon particles, most of which are then returned to the fluidized bed plant.
To ensure that the flue gas purifying plant can be supplied with the necessary operating materials, and that residual materials can be stored and processed, the following secondary plants are installed:
- fly ash silo storage,
- emergency condensation,
- washing water neutralisation and buffer,
- ammonia storage and dosing,
- fresh Sorbalit silo storage and dosing,
- silo storage of used adsorbent material and oil mixing station,
- air compression plant.
Further treatment plants
Chemical-physical treatment
In this plant treatment of inorganic liquids, such as sand collector residues, neutral sludges and neutral concentrates,emulsions for preliminary treatment, acids and acid waste materials, as well as GSB’s own waste water is mainly carried out. This is achieved mainly by
- neutralisation,
- nitrate and cyanide oxidation and m chromium reduction -heavy metal precipitation. Thus, for example, through the addition of chlorine bleaching liquor non-toxic cyanate is formed from cyanide-containing concentrates, or heavy metals are converted into insoluble compounds through the use of sodium sulphide.
In this treatment sludges are produced which are dewatered by means of chamber filter presses. The filter cakes are deposited an hazardous waste landfills. The exhaust air produced is treated by a two-step waste gas washing process. The waste water from this process is passed to a biological waste water purifying plant and then to a municiple sewage plant.
Treatment of oil-water mixtures
Organic waste water is fed to a chemical-physical treatment plant. Oil-water mixtures are separated by the addition of chemicals and flocculating agents, into
- an oil Phase, which is used as a fuel
- a waste water phase, which is passed to the biological waste water treatment plant and
- a sludge phase, which is first mechanically dewatered
and then passed to the thermal treatment plant.
Evaporation plant
In the three-step evaporation plant for problem waters pollutant-containing leachate water from our own hazardous waste landfills and cleaning water from the flue gas washing plant is treated. In addition the following materials are also treated:
- concentrates from municipal waste landfill,
- waste waters which are difficult or impossible to treat by a chemical-physical process,
- hazardous waste materials containing ammonia or copper,
- waste water containing complexing agents,
- spent liquors and
- waste waters from the surface treatment industry.
After the evaporation process a condensate of industrial process water quality is obtained from these Problem and drainage waters. The purified water flows over several safety barriers to the sewage plant. The crystallizate, in which the pollutant-containing salts are bound, is packed in bulk bags and transported to an underground disposal facility. Underground storage in containments guarantees that no pollutants can enter water circulation systems.
Plant engineering
Annual throughput – 30,000 tons/annum
Daily output – approx. 120 tons
Hourly average – 5 tons/hr
Heat load – 58 GJ/hr (max.)
Tank farm with 20 tanks of total volume approx. 1,500 m³ for liquid waste materials
3 storage depots for approx. 200 tons of waste in drums or other containments
4 bunkers for solid/pasty materials with a total volume of 580 m³
Incineration plant with rotary kiln technology and post combustion chamber
Rotary kiln – diameter 4 meters, length 12 meters
Post combustion chamber – diameter 5.6 meters, height 22 meters
Boiler for steam generation
2 MW turbine for power generation
Slag/ash loading with separation of metallic scrap by a magnetic separator
4-step flue gas purifying plant, consisting of an electric dust precipitation unit, wet scrubbers, catalytic nitrogen oxide removal
plant and a dry adsorption step with fluidized bed reactor and fabric filter baghouse.
Products and residual materials
Process steam – 17 tons/hr (28 bar, 320°C)
Electric power:
2 MW for internal use and supply to the public network.
Approx. 6 MW long-distance energy for internal use and supply to the public network.
Electrical peak load – 2.5 MVA
Installed driving power – 1.5 MW
Average own requirements – 0.9 MW
Approx. 8000 tons/annum slag/ash for recycling and use in landfill construction
Approx. 1,000 tons/annum filter dust
Approx. 5,000 tons/annum waste gas washing water
Approx. 250 tons/annum coarse and fine metallic scrap for recycling in the scrap metal trade
Approx. 35,000 m³/hr purified waste gases
Technical Data
1. General details
1.1 General management
Own planning in cooperation with Energie Consulting München, Fichtner & Lurgi
1.2 Official approval authority:
Government of Central Franconia
1.3 Supervisory authority:
Bavarian Agency for Environmental Protection
1.4 Construction costs:
Incineration plant: 30 million €
New waste gas purifying plant: 28 million €
1.5 Commissioning:
New construction of incineration plant: 1986-1988
New construction of flue gas purifying plant:
1994-1995
1.6 Annual operation under full load:
approx. 8,000 hrs/annum
2. Waste material quantities for processing:
Waste material types (example 2003) tons/annum
- External deliveries:
* solid/pasty waste materials 11,400
* liquid waste materials 17,000
- Internal deliveries:
* solid/pasty waste materials 4,600
* Additional materials, spray water 1,800
- Waste material to other GSB locations: 4,000
Total throughput: 30,800
3. Throughput and geometry
Max. throughput: 35,000 tons/annum
Throughput in 2002: 30,300 tons/annum
Throughput in 2003: 30,800 tons/annum
Total area of plant: 13,150 m²
Overall height
not including stack: approx. 40 meters
4. Delivery and storage
4.1. Weighing equipment:
Manufacturer: Schenck AG
Construction: Weighbridge
Number: 2 (incoming and outgoing goods)
4.2. Bunkers for solid and pasty waste materials
Receiving bunker:
Manufacturer: Deutsche Babcock Anlagen GmbH
Capacity: 500 m³
Number of tipping points: 3
Mixingbunkers:
Manufacturer: Deutsche Babcock Anlagen GmbH
Capacity: 50 m³
Number of tipping points: 1
4.3. Silo for liquid and pumpable pasty waste materials
Tank farm:
Manufacturer: Deutsche Babcock Anlagen GmbH
Capacity: 1,500 m³
Discharging equipment: Pumping
Intermediate tanks:
Manufacturer: MFT
Capacity: 75 m³
Discharging equipment: Pumping
5. Waste material preparation
5.1. Shredding units
Drum shredding:
Manufacturer: Svedala Lindemann GmbH
Construction: Rotary shears
Number: 1
Throughput: 200 units/day
6. Charging
6.1. Waste material crane
Manufacturer: PS-Fördertechnik
Construction: Shell gripper
Number: 1
Lifting force: 2 tons
Handling power: 4 tons/hr
Gripper capacity: 1 m³
Span width: 8 meters
Hoisting height: 25 meters
6.2. Charging device
Sludges and pasty material
Manufacturer: Putzmeister Maschinenfabrik GmbH
Construction: Pump
Drums/small packages up to 30 kg
Larger drums are shredded with the rotary shears
and charged via the bunker and gripper
Construction: drum elevator
Liquid and pasty waste materials
Manufacturer: MFT
Construction: Solvent burner, waste water lance
6.3. Burner
Manufacturer: MFT
Construction: Steam nebulizer
Number: 2
Heating power: approx. 7 MW per burner
Fuel: Liquid waste material, oil
Fuel consumption: 1 t/hr per burner
Number of ventilators per burner: 1
Volume flow per ventilator: 6,000 m³/hr
6.4. Air supply
Primary air supply: via rotary kiln end wall
Manufacturer: Deutsche Babcock Anlagen GmbH
Primary air quantity: 1,000 – 15,000 m³/hr
Primary air temperature: 120 – 200°C
Secondary air supply: as burner air
Manufacturer: MFT
Secondary air quantity: 1,000 – 5,000 m³/hr
Secondary air temperature: ambient temperature
7 Heating
7.1. Rotary kiln
Number of lines: 1
Throughput per line: (solid) 3 t/hr
(liquid) 3 x 0.5 t/hr
Average calorific value: 12,000 kJ/kg
Average proportion with
calorific value > 11,000 kJ/kg: 10%
Combustion power: 5 MW
Manufacturer: Deutsche Babcock Anlagen GmbH
Length: 12 m
Diameter (outside): 4 m
Inclination: 2.5°
Speed: 0.05 – 1.5 min-1
7.2. Combustion chamber
Combustion chamber temperature: 950 – 1200°C
Retention time: 3.5 sec
Flow control – fuel/waste gas: parallel flow
Construction material for side walls:
Resistal K80C (Al2O3)
7.3. Slag removal unit
Manufacturer: Deutsche Babcock Anlagen GmbH
Construction: Wet slag/ash removal unit
Number per line: 1
Clinker/ash throughput: 1 t/hr
Technical Data
8. Steam generator
8.1. Boiler
Manufacturer: VKW
Construction: Boiler, 8 passes
Heating area: 1,098 m²
Boiler drum capacity: 9.7 m³
Feed water quantity: 17.4 t/hr
Injection water quantity: 3 t/hr
Feed water temperature: 135°C
Steam temperature: 320°C
Nominal pressure: 28 bar
Design pressure: 41 bar
Hot steam quantity: 17.4 t/hr
Permissible hot steam quantity: 17.4 t/hr + 10%
Heating surface cleaning:
1. Steam-soot blower
2. Compressed air impact cylinder
3. Sonic blow-off
9. Heat utilisation
9.1. Steam supply
Total production: 148,000 t/annum
Of these
Steam for power generation: 17.4 t/hr
Steam for evaporation of drainage water: 1.5 t/hr
Steam for operative heat requirements: 2.5 t/hr
9.2. Power generation Turbine
Manufacturer: AEG
Number: 1
Absorption capactiy (hot steam quantity): 17.4 t/hr
Operating pressure: 27 bar
Take-off pressure: 4.5 bar
Exhaust steam pressure: 0.4 – 0.7 bar
Operating temperature: 320°C
Take-off temperature: 160°C
Speed: 12,000 min-1
9.3. Generator
Manufacturer: AEG
Number: 1
Gross electricity output
(= nominal power of turbine): 2500 kW
Nominal power: 2000 kW
Total production: 13,700 MWh/annum
Own consumption: 9,700 MWh/annum
10. Waste gas purification
10.1. Complete plant
Process supplier: Lurgi GmbH
Number of lines: 1
Components per line:
electrostatic precipitator for dedusting
4-step flue gas scrubbing plant:
ist and 2nd step: Venturi scrubber (acid)
3rd step: Radial flow scrubber (basic)
4t” step: Packed column scrubber (basic)
Nitrogen removal catalyst (SCR-Denox)
Circulated fluidized bed absorber
(open hearth furnace coke/
hydrated lime mixture)
Volume flow of waste gas per line:
moist 40,000 m³/hr
dry 35,000 m³/hr
Temperature of crude gas (from boiler): 320°C
Temperature of pure gas (from stack): 115°C
10.2. Dedusting
Electrostatic precipitator
Manufacturer: Deutsche Babcock Anlagen GmbH
Operating voltage: 40 kV
Dimensions (I x w x h): 12.3 m x 10.8 m x 3.5 m
Precipitation area: 2424 m²
Separating power: 200 kg/hr
10.3. Wet scrubbing
Acid scrubbing step
Manufacturer: Lurgi GmbH
Construction: 2-step venturi scrubber
Absorption agent: H2O
Removed solution quantity: 0.5 m³/hr
Basic scrubbing step
Manufacturer: Lurgi GmbH
Construction:
2-step radial flow scrubber,
packed column scrubber
Absorption agent: NaOH
Throughput of absorption agent: 200 kg/hr
Removed solution quantity: 0,5 m³/h
10.4. Adsorption
Circulated fluidized bed absorber
Manufacturer: Lurgi GmbH
Dimensions: dia. 2.4 m, h = 16 m
Additive: open hearth furnace coke/
Hydrated lime mixture
Additive consumption: 13.5 kg/hr
Separating power: 99.9
Fabric filter baghouse
Manufacturer: Lurgi GmbH
Number of chambers: 4
Dimensions: dia. 150 mm, I = 5.8 m
Number of filter-bags: 4 x 144 filter bags
Filter area: 4 x 394 m²
10.5. SCR nitrogen oxide removal gas preheater
Manufacturer: Seibold & Partner
Heating power: 400 kW
Ammonia solution injection
Manufacturer: Lurgi GmbH
Ammonia solution consumption: approx. 9,5 Itrs/hr
Ammonia concentration: 25
Catalyst (2 modules)
Manufacturer: BASF
Dimensions (I x w x h):
2.0 m x 4.2 m x 1.0 m per module
Volume: 8.4 m³ per module
Carrier material: Titanium dioxide
Operating temperature: 280°C
Flue gas throughput: moist 45,000 m³/hr
10.6. Dosage of auxiliary agents
Auxiliary agent: Sodium thiosulphate – step 4
(iodine, bromine separation)
Sodium sulphide (Hg separation in step 3)
Dithiocarbamate solution (Hg precipitation)
Concentration: variable
Container construction: transport container (IBC)
Capacity: 1 m³
Specific requirement: variable
Dosing equipment: dosing pump
Technical Data
11. Induced draught fan
Manufacturer: Deutsche Babcock Anlagen GmbH
Number: 2
Volumetric displacement: 55,000 m³/hr
12. Stack
Manufacturer: Stock
Construction: Steel
Height: 65 m
Diameter: 1.5 m
13. Measurement and control technology
Manufacturer:
Incineration: ABB Umwelttechnik GmbH
Flue gas purification: Siemens AG
14. Treatment and utilisation of residues
14.1. Clinker and boiler ash
Quantity: approx. 8,000 t/annum
Preparation
Components: after discharge from
slag/ash removal unit -
metal separation
Type of waste disposal: Removal to
hazardous waste landfill,
underground storage
Storage
Charching
Incineration
Energy production
14.2. Filter dust
Quantity: approx. 1400 t/annum
Type of utilisation: mine filling
14.3. Waste water from wet absorption unit
Quantity: 6,700 m³/annum
Preparation
Components: Washing water (step 1 and 2)
washing water (step 3 and 4)
is mixed and neutralised
Type of utilisation: mine filling for conditioning
of filter dusts
14.4. Residual materials from adsorption
Quantity: approx. 110 t/annum
Preparation
Components: spent adsorption agent
(HOK/hydrated lime mixture)
Type of utilisation: mine filling together with
filter dust
Flue gas purification
Technical Data
15. Technical data of plant
Year of construction:
Incineration and energy parts 1988
Waste gas purification according to
17th BimSchV 1995
(BImSchV = Bundes-Immissionsschutz-Verordnung
= German Federal Pollution Protection Directive)
Manufacturer:
Incineration and energy parts
Deutsche Babcock / ABB
Flue gas purification according to
17th BimSchV LURGI
Plant data:
Annual throughput 30,000 t/annum
Hourly throughput – max. 5 t/hr
Thermal output 58 GJ/hr
Waste heat utilisation/steam output 17.4 t/hr
(at 28 bar/320 °C)
Max. electrical power 2 MW
Yearly availability > 7,500 hrs
Regular inspection times 2 x < 3 weeks/annum
16. Details of operating personnel
The incineration plant requires the following
personnel:
1 Plant manager (Engineer)
1 Plant engineer (Foreman/technician/engineer)
1 Plant technician (Technician)
4 Shift foremen (Skilled workmen/foremen/technicians)
26-28 workers (Skilled workmen, with technical training)
17. Details of waste materials processed
Solid hazardous waste 50 – 60%
e.g. oil sludges and greases
bitumen and tar waste
pharmaceutical products
waste materials from exhaust air
and waste water purification
oil-contaminated operating materials
Liquid and pasty waste materials
(combustible) 30 – 35%
e.g. waste oil, petrol
paints, lacquers
solvents (e.g. benzene, toluene)
liquid waste materials from chemical
production
chlorinated liquids and solvents
Liquid and pasty waste materials
(non-combustible) 5 – 10
e.g. washing solutions, liquors
waste water from chemical / pharmaceutical industry
electroplating baths, liquors, cyanide
solutions
concentrates containing complexing agents
Special batches (liquid) 5 – 10
e.g. acids
acid-solvent mixtures
reaction solutions
strongly smelling liquids
Special batches (in drums) 5 – 10
e.g. chemicals
agricultural pesticides
PCB-containing waste materials
batteries
spray cans
waste materials from laboratories,
doctors’ practices
hospitals
waste materials in powder form
used medicines, pharmaceutical products
18. Legal requirements
The plant fulfills all currently valid national and European legal requirements in all respects, including the
following regulations:
Waste material legislation:
Kreislaufwirtschafts- und Abfallgesetz, TA-Abfall
(Material circulation management and waste materials law, technical directive an waste material)
Pollution protection:
17t” BImSchV, 2000/76/EG
(Directive for plants used for incineration of waste materials),
12t” BImSchV, RL 96/82/EG (Seveso 2)
(Accident directive)
Industrial law:
GefStoffV (German hazardous materials directive),
TRGS (Technical rules for hazardous materials),
Protection of labour and places of work,
TRD (Technical rules for pressure vessels),
DampKV (Steam boiler directive),
Operating safety directive
19. Construction data
Hazardous waste incineration:
Control rooms and electric power buildings:
Walls of reinforced concrete prefabricated units, ceilings and floors of reinforced concrete, outside walls
with lining sheet with trapezoidal corrugations
Boiler house:
Steel construction with double lining sheet with trapezoidal corrugations
Stores, courtward roofing:
Steel construction an reinforced concrete supports,
with single lining sheet with trapezoidal corrugations
Flue gas purification:
Switch and control rooms:
Walls of reinforced concrete prefabricated units, ceilings and floors of reinforced concrete, outside walls
plastered, with heat insulation
Process hall:
Steel construction with double lining sheet with trapezoidal corrugations, insulated
Machine and process technology:
Steel construction independent of the building, with
operating levels
Both plant parts are equipped with separate control systems, compressed air, lighting, heating, fire
alarm and fire extinguishing equipment. The sound
emission at a distance of 50 meters is less than 50
dB(A). Electrical power is supplied by 3 transformers (each 1 MVA, 20 KV / 0.4 KV)
Technical Data
Operating materials for the hazardous waste incineration plant (annual quantities)
Flue gas purification
Operating material Unit Quantity 2003 Quantity 2002
Water f. flue gas purification (f. washing circulation systems) m³ 69,606 58,730
Cooling water for flue gas purification (neutralisation) m³ 10,146 9,438
Caustic soda (50%) for flue gas purification t 1,395 1,090
Ammonia solution t 54 68
Adsorbent mixture t 120 118
Dithiocarbamate (Hg-precipitation) t 11 9.6
Sodium sulphide (Hg-precipitation) t approx. 10 approx. 10
Sodium thiosulphate t 32 8.1
Natural gas for surface burner m³ 230,187 217,224
Incineration
Operating material Unit Quantity 2003 Quantity 2002
Water loss through wet slag/ash removal m³ 4,849 4,739
N2 (tank farm from waste gas purification plant) m³ 34,540 25,028
Energy utilisation
Operating material Unit Quantity 2003 Quantity 2002
Caustic soda for feed water treatment t 15.96 19.12
Hydrochloric acid for feed water treatment t 17.04 19.8
Other chemicals for feed water treatment t approx. 1 approx. 1
Additive for boiler cleaning t 10 10
“Water loss from steam system + deionised water plant
(Feed water treatment)” m³ 8,567 12,369
Emission data
Design data, legal emission limit values and practical values from the Schwabach flue gas purifying plant
Pollutant concentration in flue gas related to standard conditions in mg/m³ i.N.
Design data Total limit values Practical values 2003
Crude gas mean Crude gas max. Crude gas peak Pure gas Pure gas
HMV DMV Yearly mean value
Electrostatic filter
Dust 10,000 50
Dust 10 50 5 30 10 1.2
HCI 3,000 8,000 18,000 5 60 10 0.7
HF 150 400 1 4 1 < 0.02
SOx 500 1,000 25 200 50 3.3
NOx 250 400 2000 100 400 200 110
Corg 10 10 30 10 1.2
Cd 0.5 0.02 0.05 0.05 0.011
Hg 1 5 0.05 0.05 0.03 0.004
S. SM 3 5 0.5 0.5 0.5 0.022
Dioxins/F. 10 ng/m³ i.N. 25 ng/m³ i.N. 0.1 ng.. 0.1 ng.. 0.011 ng/m³ i.N.
Legend
S. SM: Total heavy metals Sb, As, Pb, Cr, Cu, Mn, Ni, V, Sn
HMV: Half-hour mean value
DMV: Daily mean value
SOx: SO2/SO3, calculated as SO2
NOx: NO/NO2, calculated as NO2
Corg: Total content of organic carbon
i.N.: Normated standard conditions
Emissions and residues
Emission data related to 11% O2 by vol.
(Values from the year 2003)
Parameter Unit Pure gas Stipulated values
(17th BImSchV)
Total dust mg/m³ 1.2 10
Carbon monoxide CO¹ mg/m³ 7.0 50
Total Carbon C¹ mg/m³ 1.2 10
Nitrogen oxides NOx¹ mg/m³ 110 200
Sulphur dioxide SO2¹ mg/m³ 3.3 50
Hydrogen cloride HCI¹ mg/m³ 0.7 10
Hydrogen fluoride HF2 mg/m³ < 0.02 1
Mercury Hg¹ mg/m³ 0.004 0.03
Cadmium/Thallium Cd/TI2 μg/m³ 0.011 0.05
other heavy metals² μg/m³ 0.022 0.5
Dioxins, Furans² PCDD/PCDF ng TE/m³ 0.011 0.1
¹Annual mean values
²Mean values for discontinous measurements
Elemental composition of residues
(Values for 2003)
Element Unit Ash/slag Filter dust
Loss of ignition % 1.17 2.5
Mercury mg/kg < 0.1 10.3
Cadmium mg/kg 14.4 1,150
Arsenic mg/kg 9.5 38
Lead mg/kg 980 5,700
Chromium mg/kg 1,270 1,150
Cobalt mg/kg 310 82.8
Copper mg/kg 5,900 5,460
Nickel mg/kg 910 910
Zinc mg/kg 5,090 5,730
Tin mg/kg 920 1,620
Beryllium mg/kg 1 1
Dioxins/Furans TE ng/kg 11 218
Antimony mg/kg 175 150
Vanadium mg/kg 800 96
Thallium mg/kg < 10 < 10