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Pyrolysis Gasification & Melting Process
��T oyohashi R21 PlantT oyohashi R21 Plant ��
Mitsui Recycling ����
Delivered on March 2000
1984 -
1994-1998
Siemens
Mitsui1994 - 2000
License Granted in 1991
Yokohama Plant and Chiba Plant ��24t/d ��
Ulm Plant��2 00kg/h ��
Fürth Plant��4 80t/d ��
Yame Seibu Plant��2 20t/d ��
1998/8 Gas leakagetrouble at Fürth
Investigationproved no change required to design of Yame Seibu Plant
Mitsui Recycling 21Development History of R21
Mitsui Recycling 21
For: Yame Seibu Regional Administrative Association110 ton/day ××2 ��rainsStart Const. 1997��Completed March 2000
For: Ebetsu City70 ton/day ××2 trainsStart Const. 2000��Completed Nov. 2002
For: Koga City and One City, Four Towns’ Waste Disposal Cooperative130 ton/day ××2 trainsStart Const. 2000��Completed March 2003
Owner: Nishi Iburi Regional UnionOperator: Nishi Iburi Kankyo Co. Ltd105 ton/day ××2 trainsStart Const. 2001��Completed March 2003
For: Kyohoku RegionalAdministrative Association80 ton/day ××2 trainsStart Const. 2001��Completed March 2003
For: Toyohashi City200 ton/day ××2 trainsStart Const. 1998��Completed March 2002
Construction Record of R21
Retension time of waste in Prolysis Drum is about 1 hour,w hich homogenizes the composition of Pyrolysis Gas and Carbon against waste composition changes.
Waste is shredded into less than 200mm in length to enable its efficient pyrolysis
Pyrolysis Drum
Combustion Chamber
W.H.BoilerFlue Gas
CoolerNo.1 Bag
Filter
Induced Draft Fan
Stack
Waste
High Temp.AirHeater
High Temp.Air
Pyrolysis Gas
Carbon
High Temp.Air
Steam (40ata, 400�)
Fly AshSolid Sorting
Aluminum Steel Slag
Shredder
Electric Power Gene.
Solid Residue is cooled down to 80�in Solid Residue Cooling Drum and sorted into Steel, Aluminum, and Carbon.
Pyrolysis Gas and Carbon are burnt at 1,300�in High Temperature CombustionChamber.High Temperature Combustion will lead to the reduction of DXNs generation rate. (Water Cooled Wall Type � Prolongation of refractory life)
Heat for pyrolysis is generated at High Temp. Air Heater, not requesting suppemental fuel as long as the lower heat value of waste is more than about 1600kcal/kg
Dechlorination Residue is the only material to be sent to Land DisposalHigher Volume Reduction Ratio can be attained.
HC� < 50ppm SOx < 50ppm NOx < 100ppm DXNs < 0.1ng/Nm3
Dust < 0.01g/Nm3
DXNs �Polychlorinated- dibenzo-p-dioxin
No.2 BagFilter
Lime Hydrate
DechlorinationResidue Treat.
Land Disposal
520�
300�
450�-10mmAq
1300�
250�170�
Toyohashi R21 Process Flow
Process Flow of Pyrolysis Gasificaton & Melting Facility
Pretreatment
Bulky Waste Disposal Facility
Pyrolysis Gas
H.T. Air Htr.
W.H.B
H.T.CombusChamber
Slag
Dust (to H.T. Combus. Chamber)
Dechlorination Residue
Exhaust Gas
Stack
No.2 Bag FilterNo.1 Bag Filter
Generator
Turbine
BFWSteam
Heating Air
Refuse Bunker
Shredder
Air
Pyrolysis Drum
Preshredder Waste Conveyor
Shredder
Incombustible Waste Bunker
Pyrolysis Carbon(to H.T. Combus.Chamber)
SteelAluminum
Pyrolysis
Sorting of Solid Residue
Combustion
High Temperature AirRecovery Treatment
Electricity Generation
TOYOHASHI R21 Trend Data on Treated Amount of Waste
0
20,000
40,000
60,000
80,000
100,000
120,00020
02.4
2002
.5
2002
.6
2002
.7
2002
.8
2002
.9
2002
.10
2002
.11
2002
.12
Time
Mon
thly
Tea
ted
Am
ount
(T
/M)
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
Cum
ulat
ive
Tre
ated
Am
ount
(T
)
NO.1 Train Monthly Treated Amount
NO.1 Train Cumulative Treated Amount
NO.2 Train Monthly Treated Amount
NO.2 Train Cumulative Treated Amount
NO.1&2 Train Cumulative Treated Amount
No.1 Train Planned Maintenance
No.2 Train Planned Maintenance
NO.1 Train Planned Maintenance
NO.2 Train Planned Maintenance
TOYOHASHI R21 was turnovered to TOYOHASHI CITYat the end of March, 2002
Conventional IncineratorConventional Incinerator
The formation of dioxins
The increase in CO�� Emit.
����Next generation of the waste treatment facilitiesPyrolysis Gasification & Melting Process���� Mitsui Recycling 21
Gasification melting furnaceGasification melting furnace
Reduction of dioxinsSteel and
Aluminum
Slag
Hightemp.
combustion��������������
with nosupplementalenergy supply
GasLowtemp.
pyrolysis������������
Effective use
Carbon
Waste
Fuel derived from refuse by gasification
Stable combustion at low air ratio
Waste
Nonflammables Ash
Final disposal ��Landfill��
Flue gasIncinerator������������
Recover valuable materials
Flue gas
������������������
PyrolysisPyrolysis DrumDrum
Mitsui Recycling 21Specific Components of R21: Pyrolysis Drum
A-A section
waste Hot Air (Lower temperature side)
Hot Air (Higher temperature side)
Pyrolysis Gas
Pyrolysis carbon & Waste
������������������
PyrolysisCarbon
Primary Air
Secondly Air
Thirdly Air
PyrolysisGas
Dust
Flue Gas
Slag
High Temperature
Air Heater
Mitsui Recycling 21Specific Components of R21: Furness and Air Heater
High Temperature
Combustion Chamber
Operation Results of Yame Seibu Clean Center� Emission level:Guarantee vs Actual
Items Regulatory Standard Guaranteed Value Actual 2002 Average
Hcl 430 ppm 50 ppm ND
SO x 500 ppm 50 ppm ND
NO x 250 ppm 100 ppm 47 ppm
CO 100 ppm 10 ppm 0~1 ppm
Dust 0.04 g/m3N 0.01 g/m3N ND
DXNs 1 ng-TEQ/m3N 0.1 ng-TEQ/m3N 0.007 ng-TEQ/m3N
Operation Results of Yame Seibu Clean Center� Utility Cost
2800 Yen/ton2800 Yen/ton3400 Yen/tonTotal
30 Yen/ton30 Yen/ton30 Yen/ton��W ater
1090 Yen/ton870 Yen/ton1540 Yen/ton��Chemicals
700 Yen/ton890 Yen/ton990 Yen/ton��E lectric
1000 Yen/ton1060 Yen/ton830 Yen/ton��F uel
200220012000�F iscal Year
Recovery of valuable resourcesNon-oxidized steel, non-molten aluminum : ReuseYame C.C. Metals: Confirm the recovery of high quality steel and
aluminum, sold out at the market price
Slag : Reuse as a asphalt composite materialYame C.C. Slag : Meeting the requirements of the Environmental
Notice No.46 for elusion test as the soil fit for agricultural useNIPPON HODOO Co., Ltd. receives the slag as the asphalt composite material at the market price.
������������������Recycle of Materials in Marketable Quality Mitsui Recycling 21
slagslagRecovered AluminumRecovered Aluminum Reuse of slagReuse of slagRecovered IronRecovered Iron
Comparison between conventionals and new process
Gasification & Conventionals �Ash-melting Ash-melting
initial cost ��� 120�150 100 150running cost ��� 120�150 100 150maintenance cost ��� 120�150 100 150number of operator 100 100 150plant area ��� 120�150 100 150recycle material Fe, Al, slag slagvolume reduction ratio ��� 1/100�1/150 1/10�1/30 1/50�1/00 �
dumping material salt, part of ash *1 salt, ash, salt, part of ash, unburnables unburnables
content of flue gasNox ppm �100�150 �100�150 �100�150Sox ppm ��30��50 ��30��50 ��30��50
Hc� ppm ��50�100 ��50�100 ��50�100Dust g/Nm3 � � 0.1 � � 0.1 � � 0.1 Co ppm ��10 ��50 ��50
Dxn gas side ng-TEQ/Nm3 � 0.1 � 0.1 � 0.1 solid side ng-TEQ/g 0.1�0.5 1� 5� � � 1�2� total discharge rate ì g-TEQ/t-waste 1�5 10�50 10�30
*1 MES is developing new technology that salt and part of ash are not necessary to be dumped.
unit Conventionals
Pyrolysis Drum
Hear Exchanger
Induced Draft FanStack
Waste
Pyrolysis Carbon
High Temperature Air
Solid Sorting System
Aluminum&Others
Shredder
Bag Filter
Dechlorination Chemical &
Activated Carbon
Land Fill
���S Carbonizing Process FlowSuitable for Low LHV Waste (Food Waste)
Pyrolysis Carbon & Flue Gas
Iron & Aluminum �Pyrolysis Carbon
Ash
Iron Pyrolysis Carbon (*1)
Flue Gas CoolerCombustion Furnace
Hot Water Generator
Fuel
Anti-Steam Plume System
Hot Water
High Temperature Air Furnace
Ash Treatment System
950 �
(*1) Potential Users
�Cement Manufacturer
����Electric Furnase Steel Maker
����Fertilizer Manufacturer
�Collected as resources �
Collected Flammable Waste
Flammable Resources (Used paper, Used cloth, Trey, etc).
(Flammable Bulky Waste)
(Nonflammable Bulky Waste)
Bulky Waste Processing Facilities (Shredding and Iron Sorting �
�Waste which can be Repaired �
�R e s idue �
Flammable Waste Processing Facilities�Pyrolysis, Combustion and Melting )
�Iron, Aluminum & Mixed Metals �
Recycle Facilities (Sorting/Pressing)
Re-used byResidents
Yame Seibu Clean Center Yame Seibu Recycle Plaza
�I r o n �
Sold as resources
Waste Treatment System of Yame Seibu Regional Administrative Association
Collected Nonflammable & Bulky Waste
Delivered Nonflammable & Bulky Waste
�Nonflammable & Bulky Waste Sorting Residue �
Delivered Flammable Waste
Nonflammable Resources (Can, Bottle, etc).
Sold as resources
Sold as resources
Sold as resources
Sold as resources
Send to landfill
Stock Yard (Stock)Work Shop (Repair/Stock)
(Can, Bottle, etc)(Paper, Cloth, Trey, etc)
(Furniture, etc)�M o lten Slag �
�D e -chloreResidue �
Dust RemovalBag Filter
DechlorinationBag Filter
HTCC
Flue GasCooler
HTAH
System Configuration of R21 Main Equipment
Stack
Power Generation & Hot Water Production
Dechlorination ChemicalHigh Temperature Air(Return)
shredder
����PyrolysisPyrolysis Gasification & Melting ProcessGasification & Melting Process ����
GasificationGasification Combustion & Melting Flue Gas CleaningFlue Gas Cleaning
Mitsui Recycling 21
SolidSorting
Waste
High Temperature Air(Supply)
Pyrolysis Gas
Pyrolysis Gas ��Flue Gas
Aluminum��Steel ��Carbon
Ash
Slag
Ash
Steam
InducedDraht Fan
Pyrolysis Drum
Carbon + Debris
Heavy Metal Fixing
-3-
WHB
Slag for Asphalt Pavement
Aluminum & Steel
ProcessProcessProcessProcessProcessProcess
Gasification and Combustion Stability of R21
0
1
2
3
4
5
6
7
8
9
10
19-1-00 22:00 20-1-00 0:00 20-1-00 2:00 20-1-00 4:00 20-1-00 6:00 20-1-00 8:00 20-1-00 10:00 20-1-00 12:00
TIME
0
0,5
1
1,5
2
2,5
3
3,5
4
4,5
5
OU
TLE
T A
IR F
LOW
RA
TE
FR
OM
DR
UM
[Nm
3/h
x 10
000]
PYROLYSIS GAS TEMP [� x 100]
TEMP. AT BTM. OF FURNACE [� x 1000]
REFUSE BUNKER DRAIN SUPPLY [l/h x 1000]
REFUSE FEED RATE [t/h]
OUTLET AIR TEMP. FROM DRUM [� x 100]
OUTLET AIR FLOW RATE FROM DRUM [Nm3/h x 10000]
PYROLYSIS GAS TEMP
OUTLET AIR FLOW RATE FROM DRUM
REFUSE BUNKER DRAIN SUPPLY
TEMP. AT BTM. OF FURNACE1333[�]
26271[Nm3/h]
OUTLET AIR TEMP. FROM DRUM
451[�]
291[�]
REFUSE FEED RATE4.01[t/h]
Excellent stability can be obtained even for the sudden waste composition change
(water injection) as shown below.
22:00 0:00 2:00 4:00 6:00 8:00 10:00 12:00
� � � � � � � �� � � � � � � � �� V SV S �� � � � � � � � �� � � � � � � � � � �� � �
��� � � � � � � �� � � � � � � �
��� � � � � � � �� � � � � � � �
0
5
1 0
1 5
0 0 / 1 / 1 7 2 3 :0 0 0 0 / 1 / 1 8 0 :0 0 0 0 / 1 / 1 8 1 :0 0 0 0 / 1 / 1 8 2 :0 0
� �� �
O2�
��
�%�
0
5
1 0
1 5
CO�
��
ppm�
O2 1
2%�
��
�
O 2 � � [ % ] Q I 6 0 0 5 - 1
C O � � [ p p m ] Q I 6 0 0 4 - 1 B
� � �� � � � � � � � � �� � �� � � � � � � � � �0 0 / 0 1 / 1 7 2 3 :0 0 � 0 0 / 0 1 / 1 8 1 1 :0 0 D C S � � � � �0 0 / 0 1 / 1 7 2 3 :0 0 � 0 0 / 0 1 / 1 8 1 1 :0 0 D C S � � � � ���
0
5
1 0
1 5
0 0 / 1 / 1 7 2 3 :0 0 0 0 / 1 / 1 8 1 :0 0 0 0 / 1 / 1 8 3 :0 0 0 0 / 1 / 1 8 5 :0 0 0 0 / 1 / 1 8 7 :0 0 0 0 / 1 / 1 8 9 :0 0 0 0 / 1 / 1 8 1 1 :0 0
� �� �
����
���� [pp
m] [
%][p
pm]
[%]
C O � � [ p p m ] Q I 6 0 0 4 - 1 B
O 2 � � [ % ] Q I 6 0 0 5 - 1
�� ��
� � � � � � � � � � � � � 1 9 �
� � � � �
� 2 � � � � � � � � � � � � � � � �
� 2 � � � � � � �
� � � � � � � � �
Fluidized Bed Type
Enlarged
O2 Concentration
CO Concentration
O2 Concentration
CO Concentration
Mitsui R21 DCS DATA From 00/01/17 23:00 to 00/01/18 11:00
Attachment 2 Mitsui R21 vs. Fluidized Bed TypeTrend Data on Flue Gas Composition �� Combustion Stability
Comparison of new process
unit Kiln type Fludized Bed Shaft
initial cost [-] 100 100 150
running cost [-] 100 120 150
number of operator [-] 100 120 150
plant area [-] 100 100 120
recycle material Fe, Al, slag Fe, Al, slag mixed metal
volume reduction ratio [-] 1/100..1/150 1/100..1/150 1/50..1/100
dumping material slag
content of flue gas
Nox ppm <100..150 <100..150 <100..150
Sox ppm <�30..�50 <�30..�50 <�30..�50
Hc� ppm <�50..100 <�50..100 <�50..100
Dust g/Nm3 � < 0.1 < 0.1 < 0.1
Co ppm <�10 <�30 <�30
Dxn
gas side ng-TEQ/Nm3 � < 0.1 � < 0.1 < 0.1
solid side ng-TEQ/g � < 0.1 � < 1� � < 1�
total discharge rate ì g-TEQ/t-waste � < 1..2� � < 5� � < 5�
auxilially fuel no required cokes
operation technique easier harder more harder
Comparison of conventional process
unit Fludized Bul Stoker
initial cost ��� 100 100
running cost ��� 100 100maintenance cost ��� 100 120
number of operator ��� even even
plant area 100 100recycle material ��� unburnables
volume reduction rate 1-30 1-10
dumping material fly ask bottom & fly ash
content of flue gas
Nox ppm �100�150 �100�150Sox ppm ��30��50 ��30��50
Hc� ppm ��50�100 ��50�100
Dust g/Nm3 � � 0.1 � � 0.1 Co ppm ��50 ��50
Dxn
gas side ng-TEQ/Nm3 � � 0.1 � � 0.1 solid side ng-TEQ/g � � 1� 5� � � 1� 5� total discharge rate ì g-TEQ/t-waste 10�30 30�50
operation technique easier harder
start & stop Daily start & stop is possible harder
suitable capacity t/day �100�300 �300
Pyrolysis Drum
Induced Draft FanStack
Waste
Pyrolysis Carbon
High Temperature Air
Solid Sorting System
Aluminum&Others
Shredder
Bag Filter
Dechlorination Chemical & Activated Carbon
Land Fill
R 2 1 S Carbonizing Process FlowSuitable for High LHV Waste (ASR)
Pyrolysis Carbon & Flue Gas
Iron & Aluminum �Pyrolysis Carbon
Ash
Iron Pyrolysis Carbon (*1)
Flue Gas Cooler
Combustion Furnace
Fuel
Anti-Steam Plume
System
High TemperatureAir Furnace
Ash Treatment System
High Temp. Air Heater
Boiler
Steam
(*1) Potential Users
�Cement Manufacturer
����Electric Furnace Steel Maker
����Fertilizer Manufacturer
950 �
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