L’inceneritore di Vienna architetto...

L’inceneritore diVienna

architettoHunderwasser

Rifiuti “difficili”

compositiinseparabiliirriciclabili

non riusabili

RifiutiParametri tal quale

(Milano)D.M. 2/2/98 organico carta plastica vetro legno

P.C.I. (MJ/Kg) 10 15 3 11 40 - 16

% - - 30 20 10 8 4

Umidità (tot mass) 35% 25% 70% 15% 6% 2,2% 23%

CI 0,5% 0,9%

Z 0,2% 0,6%

Ceneri 20% 20% 3,5% 5% 10% 94% 100%

Pb (volatili) 180 200

Cr 100

Cu (sol.) 100 300

Mn 400

Ni 25 40

As 0,6 9

Cd + Hg 2,5 7

T ram. 1100 °C

- percentuali in massa umida

- valori in mg/Kg secco

CDR

TIPOLOGIA ρ, kg/m3 ϕ, mm

Fluff 200 0÷50

Addensato 500 16x20

Balle 250 800x1000x1000

Rifiuti

Selezione

Pirolisi

Gasificazione

Bio-Gasificazione

CombustioneINTERNA ESTERNA

Forni a griglia• Potenzialità

• 10÷1000 t/giorno (min 100 t/giorno avanzato)

• Tipologia 1: griglia fissa-mobile (a rulli, a barrotti)

• Alimentazione aria

• sottogriglia (primaria)

• sopragriglia (secondaria)

• Alimentazione rifiuto• tramoggia superiore

• Tempo di residenza

• 30÷60 minuti

• Tipologia 2: verticale-orizzontale

• Tipologia 3: a forno - a caldaia

• Tipologia 4: con/senza ricircolo fumi

Schemi riportati in letteratura / 1Chapter 2

PJ/EIPPCB/WI_Draft_2 Version March 2004 39

Waste feeding

Feeder table

Secondary airSecondary

air

Slag discharge

Sewage

sludge

feeder

Drying

De-gassing

WasteFlue gas

Exhaust

Incineration

Primary air

Figure 2.6: Example of an incineration chamber

Source [1, UBA, 2001]

The detailed design of a combustion chamber is usually linked to the grate type. Its precise

design demands certain compromises as the process requirements change with the fuel

characteristics. Each supplier has their own combination of grate and combustion chamber, the

precise design of which is based on the individual performance of their system and their specific

experiences. European operators of MSW have found no fundamental advantage or

disadvantage for the different designs of the combustion chamber.

In general, three different designs can be distinguished. The nomenclature comes from the flow

direction of the flue-gases in relation to the waste flow: unidirectional current; counter current

and medium current (see Figure 2.7).

Unidirectional current, co-current, or parallel flow furnace:

In a co-current combustion arrangement, primary combustion air and waste are guided in a

co-current flow through the combustion chamber. Accordingly, the flue-gas outlet is located at

the end of the grate. Only a comparatively low amount of energy is exchanged between the

combustion gases and the waste on the grate.

The advantage of unidirectional current concepts is that the flue-gas has the longest residence

time in the ignition area and that it must pass through the maximum temperature. To facilitate

ignition, the primary air must be pre-warmed with very low heat values.

Counter-flow or counter current furnace:

Waste with a higher water content and a comparatively low calorific value is preferably

incinerated in a counter current combustion arrangement because the hot flue-gases facilitate

drying and ignition of the waste. In this case, primary combustion air and waste are guided in a

Schemi riportati in letteratura / 2Chapter 2

36 Version March 2004 PJ/EIPPCB/WI_Draft_2

In general, one can differentiate between continuous (roller and chain grates) and discontinuous

feeder principles (push grates) see Figure 2.4.

Figure 2.4: Different grate types


Different grate systems can be distinguished by the way the waste is conveyed through the

different zones in the combustion chamber. Each has to fulfil requirements regarding primary

air feeding, conveying velocity and raking, as well as mixing of the waste. Other features may

include: additional controls, or a more robust construction to withstand the severe conditions in

the combustion chamber.

2.2.5.2.1 Rocking grates

[4, IAWG, 1997] The grate sections are placed across the width of the furnace. Alternate rows

are mechanically pivoted or rocked to produce an upward and forward motion, advancing and

agitating the waste.

2.2.5.2.2 Reciprocating grates

[4, IAWG, 1997] Many modern facilities (for municipal wastes) use reciprocating grates. The

quality of burnout achieved is generally good.

This design consists of sections that span the width of the furnace but are stacked above each

other. Alternate grate sections slide back and forth, while the adjacent sections remain fixed.

Waste tumbles off the fixed portion and is agitated and mixed as it moves along the grate.

Numerous variations of this type of grate exist, some with alternating fixed and moving

sections, others with combinations of several moving sections to each fixed section. In the latter

case, the sections can either move together or at different times in the cycle.

There are essentially two main reciprocating grate variations:

1. Reverse reciprocating grate:

The grate bars oscillate back and forth in the reverse direction to the flow of the waste. The

grate is sloped from the feed end to the ash discharge end and is comprised of fixed and moving

grate steps.

2. Push forward grate:

The grate bars form a series of many steps that oscillate horizontally and push the waste in the

direction of the ash discharge.

Schemi riportati in letteratura / 3

Chapter 2


2.2.5 Grate incinerators

Grate incinerators are widely applied for the incineration of mixed municipal wastes. Other

wastes commonly treated in grate incinerators, often as additions with MSW, include:

commercial and industrial non-hazardous wastes, sewage sludges and certain clinical wastes.

Grate incinerators usually have the following components:

• waste feeder

• incineration grate

• bottom ash discharger

• incineration air duct system

• incineration chamber

• auxiliary burners.

Figure 2.3 shows an example of a grate incinerator:

Figure 2.3: Grate, furnace and heat recovery stages of an example municipal waste incineration

plant


Griglia mobile

• Carico termico

• fino a 1 MKcal/m2h

• Carico meccanico

• fino a 300 Kg/m2

• Griglie a movimento alternato

• Pendenza

• fino al 35%

• Passaggio aria tra elementi

• Raffreddamento aria primaria / acqua

Camera di combustione• Stadi in serie

• Essiccazione, Gasificazione, Pirolisi, Combustione

• Aria primaria: minima possibile

• temperatura bassa

• processi di riduzione

• Aria secondaria

• Equicorrente: basso preriscaldamento

• Controcorrente: favorisce essiccazione

• Adiabaticità

• spinta per bassi poteri caloriferi

• Post-Combustione

• 3 secondi

• circa 1000 °C

Camere di combustione

Chapter 2


counter current flow arrangement through the combustion chamber and the flue-gas outlet is

located at the front end of the grate.

Special attention must be paid to avoid the passage of unburned gas streams. As a rule, counter-

flow current concepts require higher secondary or upper air additions.

Medium-current or centre-flow furnace:

The composition of municipal solid waste varies considerably and the medium current concept

is a compromise for a wide feed value spectrum. A good mixture of all partial flue-gas currents

must be considered through mixture-promoting contours and/or secondary air injections. In this

case, the flue-gas outlet is located in the middle of the grate.

Figure 2.7: Various furnace designs with differing direction of the flue-gas and waste flow

[1, UBA, 2001]

2.2.5.5 Incineration air feeding

The incineration air fulfils the following objectives:

• provision of oxidant

• cooling

• avoidance of slag formation in the furnace

• mixing of flue-gas.

Air is added at various places in the combustion chamber. It is usually described as primary and

secondary, although tertiary air, and re-circulated flue-gases are also used.

The primary air is generally taken from the waste bunker. This lowers the air pressure in the

bunker hall and eliminates most odour emissions from the bunker area. Primary air is blown by

fans into the areas below the grate, where its distribution can be closely controlled using

multiple wind boxes, and distribution valves.

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• Regolazione temperatura

• locale (raffreddamento)

• complessiva (eccesso d’aria)

• Compartimentata nei vari settori

• Regolata (serrande)

• Pulizia griglia

• Aria secondaria

• Alto livello di miscelazione

• 50÷100 m/s

• senza sacche fredde

• Aria totale

• min 6% (30% EA) - 15% (vecchi impianti)

Sistema di alimentazione

• Tramoggia

• carico primario

• tronco cono rovesciato

• Canale di carico

• serranda esclusione

• perdita di carico fumi

• Alimentatore

• a pistone, a griglia

• azionato idraulicamente

ScorieChapter 2


Figure 2.5: Example of a type of ash remover used at a grate incinerator


2.2.5.4 Incineration chamber and boiler

Combustion takes place above the grate in the incineration chamber (see Figure 2.6). As a

whole, the incineration chamber typically consists of a grate situated at the bottom, cooled and

non-cooled walls on the furnace sides, and a ceiling or boiler surface heater at the top. As

municipal waste generally has a high volatile content, the volatile gases are driven off and only

a small part of the actual incineration takes place on or near the grate.

The following requirements influence the design of the incineration chamber:

• form and size of the incineration grate - the size of the grate determines the size of the

cross-section of the incineration chamber

• vortexing and homogeneity of flue-gas flow - complete mixing of the flue-gases is essential

for good flue-gas incineration

• sufficient residence time for the flue-gases in the hot furnace - sufficient reaction time at

high temperatures must be assured for complete incineration

• partial cooling of flue-gases - in order to avoid fusion of hot fly ash at the boiler, the flue-

gas temperature must not exceed an upper limit at the incineration chamber exit, typically

between 650 and 700 ºC.

Sistemi ausiliari• Ricircolo fumi

• 15÷20% portata totale

• riduzione T e NOX

• Preriscaldo aria

• 100÷150 °C

• essiccazione / ignizione

• Regolazione e controllo

• visivo

• telecamere

• termocoppie

• chimico

• Arricchimento O2

• con ricircolo / zona primaria

Altri impianti / 1Chapter 2


Figure 2.17: Fluidised bed gasifier with high temperature slagging furnace

Source [68, Ebara, 2003]

This process is designed to generate syngas from plastic packaging waste or other high calorific

waste material. The main components of the process are a fluidised bed gasifier and a second

stage high temperature gasifier. The fluidised bed enables rapid gasification of comparatively

heterogeneous materials, which are pelletised for smooth feeding. Several per cent of non-

combustible components, even metal pieces, are acceptable, as the ash is continuously

discharged from the fluidised bed. The high temperature gasifier is designed as cyclone, to

collect the fine ash particles on the wall. After vitrification the slag is discharged though a water

seal. Both reactors are operated under elevated pressure, typically 8 bar.

A first plant of this technology was under commercial operation in year 2001 to treat plastic

packaging waste. The capacity of this demonstration plant is 30 tonnes per day. An additional

plant of 65 tonnes per day started operation in 2002. The syngas produced is fed to an adjacent

ammonia production plant. Other similar plants are under construction. [68, Ebara, 2003]

Other variations on gasification processes have been tried and are being developed, for a variety

of waste stream.

2.2.8.3 Pyrolysis

[1, UBA, 2001] Pyrolysis is the degassing of wastes in the absence of oxygen, during which

pyrolysis gas and a solid coke are formed. The heat values of pyrolysis gas typically lies

between 5 and 15 MJ/m! based on municipal waste and between 15 and 30 MJ/m! based on

RDF. In a broader sense, “pyrolysis” is a generic term including a number of different

technology combinations that constitute, in general, the following technological steps:

Altri impianti / 2

Chapter 2


secondary air into the post combustion chamber. Due to the high temperatures and the

secondary air introduction, the combustion of the exhaust gases is completed and organic

compounds (e.g. PAHs, PCBs and dioxins) including low molecular weight hydrocarbons, are

destroyed. In several countries exemptions from the 1100 °C rule are granted, on the basis of

studies demonstrating that lowering the temperature in the PCC does not influence the quality of

air emissions.

2.2.6.2 Drum kiln with post-combustion chamber for hazardous waste incineration

For the incineration of hazardous waste, a combination of drum-type kilns and post-combustion

chambers has proven successful, as this combination can treat solid, pasty, liquid, and gaseous

wastes uniformly (see Figure 2.10).

Figure 2.10: Drum-type kiln with post-combustion chamber


Drum-type kilns between 10 and 15 metres in length, and with a length to diameter ratio usually

in the range of 3 to 6, and with an inner diameter between one and five metres are usually

deployed for hazardous waste incineration.

Some drum-type kilns have throughputs of up to 70000 tonnes/yr each. In correlation to the

average heat value of the waste, where heat recovery is carried out steam generation increases

correspondingly.

Drum-type kiln plants are highly flexible in terms of waste input characteristics. The following

range is usual in the composition of the waste input menu:

• solid wastes : 10 – 70 %

• liquid wastes: 25 – 70 %

• pasty wastes: 5 – 30 %

• barrels: up to 15 %.

To protect the drum-type kilns from temperatures of up to 1200 °C, it is equipped with

refractory bricks. Bricks with a high content of Al2O3 and SiO2 are used. The decision

Altri impianti / 3

Chapter 2


Figure 2.21: Pyrolysis on a grate with directly connected high-temperature incineration


Pyrolysis on a grate with directly connected high-temperature incineration (see Figure 2.21) was

developed from conventional grate incineration but with the objective of producing a liquid

melt. The wastes are first pyrolysed on a grate by direct heating. This heat originates from a

partial incineration of the pyrolysis gases with pure oxygen. In a second step, the products,

pyrolysis gas, coke and inert substances are combusted or melted, respectively, at high

temperatures in a directly connected drum-type kiln. The accumulating melt residue contains

glass, stones, metals and other inert materials and is different from the corresponding product of

process 1 above.

Figure 2.22: The RCP process


The RCP process (see Figure 2.22) is a development of the pyrolysis on a grate with directly

connected high-temperature incineration process. The molten bottom ash is depleted of metallic

Altri impianti / 4Chapter 2


Figure 2.21: Pyrolysis on a grate with directly connected high-temperature incineration


Pyrolysis on a grate with directly connected high-temperature incineration (see Figure 2.21) was

developed from conventional grate incineration but with the objective of producing a liquid

melt. The wastes are first pyrolysed on a grate by direct heating. This heat originates from a

partial incineration of the pyrolysis gases with pure oxygen. In a second step, the products,

pyrolysis gas, coke and inert substances are combusted or melted, respectively, at high

temperatures in a directly connected drum-type kiln. The accumulating melt residue contains

glass, stones, metals and other inert materials and is different from the corresponding product of

process 1 above.

Figure 2.22: The RCP process


The RCP process (see Figure 2.22) is a development of the pyrolysis on a grate with directly

connected high-temperature incineration process. The molten bottom ash is depleted of metallic

Altri impianti / 5

Chapter 2


• smouldering process: Formation of gas from volatile waste particles at temperatures

between 400 and 600 °C

• pyrolysis: Thermal decomposition of the organic molecules of the waste between 500 and

800 °C resulting in formation of gas and a solid fraction

• gasification: Conversion of the carbon share remaining in the pyrolysis coke at 800 to

1000 °C with the help of a gasification substance (e.g. air or steam) in a process gas (CO,

H2)

• incineration: Depending on the technology combination, the gas and pyrolysis coke are

combusted in a incineration chamber.

Two pyrolysis plants for municipal waste treatment are operational in Germany, and another

was due to start up at the end of 2003 in France. Other pyrolysis projects exist in Europe and

elsewhere (notably in Japan) receiving certain specific types or fractions of waste, often after

pretreatment.

Pyrolysis plants for waste treatment usually include the following basic process stages:

1 preparation and grinding: the grinder improves and standardises the quality of the waste

presented for processing, and so promotes heat transfer

2 drying (depends on process): a separated drying step improves the LHV of the raw

process gases and increase efficiency of gas-solid reactions within the rotary kiln

3 pyrolysis of wastes, where in addition to the pyrolysis gas a solid carbon-containing

residue accumulates which also contains mineral and metallic portions

4 secondary treatment of pyrolysis gas and pyrolysis coke, through condensation of the

gases for the extraction of energetically usable oil mixtures and/or incineration of gas

and coke for the destruction of the organic ingredients and simultaneous utilisation of

energy.

Figure 2.18: Structure of a pyrolysis plant for municipal waste treatment


Altri impianti / 6

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Riferimenti bibliografici

Edificio Expo, c/ Inca Garcilaso s/n, E-41092 Seville – Spain Telephone: direct line (+34-95) 4488-284, switchboard 4488-318. Fax: 4488-426. Internet: http://eippcb.jrc.es; Email: [email protected]

EUROPEAN COMMISSION DIRECTORATE-GENERAL JRC JOINT RESEARCH CENTRE Institute for Prospective Technological Studies (Seville) Technologies for Sustainable Development European IPPC Bureau

Integrated Pollution Prevention and Control

Draft Reference Document on the Best Available Techniques for Waste Incineration

Draft March 2004

Edificio Expo, c/ Inca Garcilaso s/n, E-41092 Seville – Spain Telephone: direct line (+34-95) 4488-284, switchboard 4488-318. Fax: 4488-426. Internet: http://eippcb.jrc.es; Email: [email protected]

EUROPEAN COMMISSION DIRECTORATE-GENERAL JRC JOINT RESEARCH CENTRE Institute for Prospective Technological Studies (Seville) Technologies for Sustainable Development European IPPC Bureau

Integrated Pollution Prevention and Control

Draft Reference Document on the Best Available Techniques for Waste Incineration

Draft March 2004

Riferimenti bibliografici

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L’inceneritore di Vienna architetto...

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