AlterNrg Planta Japon

 

18th Annual North American Waste-to-Energy Conference

A  LEADING PROVIDER OF CLEAN ENERGY SOLUTIONS

Orlando, Orlan do, Florid Florida a

- May 13, 2010

 

HISTORY OF PDMR DEVELOPMENT

2005 • Eco Vall Valley ey – botto bottom m shap shape e remodeled & refractory structure of PFMR changed • Refract Refractory ory mate materia rials ls of of Afterburner changed

1997 2001

• PD PDMR MR Deve Develo lopme pment nt Agreement -Hitachi Metals Metal s & W PC

• Miham Mihama-M a-Mika ikata ta –  construction began

1999

2003

• Yoshii Yoshii – one yea yearr of MSW tes testin ting g • Eco Val Valle ley y – 7 mee meeti tings ngs wi with th Residents

• Eco Val Valle ley y - op oper erat atio ional nal (ASR & MSW) • Miham Mihama-M a-Mik ikat ata a –  operational (MSW & Sludge)

2000

2004

• Yo Yoshi shiii – JWRF JWRF certi certifi ficat catio ion n received in September • Eco Vall Valley ey – cons constru tructio ction n began began • MihamaMihama-Mik Mikata ata – pre present sentati ation on to government

• Eco Vall Valley ey – free freeboa board rd refractory replaced

1998

2002

• WPC Te Test stin ing g – Madi Madison son PA • Yo Yoshi shiii Test Test P Plan lantt Construction • Eco Vall Valley ey - en envi viro ronme nment ntal al assessment

• Plasm Plasma a Compo Compone nent nt Manufacturing Agreement –  Hitachi Metals & WPC • Eco Vall Valley ey – co commi mmissi ssion oning ing • Miha Mihamama-Mi Mikat kata acommissioning

2007 • Eco Vall Valley ey – te temp mpera eratu ture re control changed during commercial operation

2006 • Plant Plant to tour urs s begi begin n • Eco Vall Valley ey – re refr frac acto tory ry materials of Afterburner changed • Miha Mihamama-Mi Mikat kata a – 3 yea yearr guarantee ended

2

 

ADVANTAGE OF PDMR

Gasification/melting Gasification/me lting zone combined-type combined-ty pe shaft furnace

1.

Simpl imple es str truc ucttur ure e – no inte nterna nall drive unit

2.

High High volu volume me of ac accu cumu mula late ted d heat – MSW can can also be treated

3.

Melting zone 1, 1,550 C or higher – high quality quality slag and metal are discharged

After burner 1. Temper emperatu ature: re: 8 850~ 50~950 950 C 2. Residenc Residence e time: 2 seconds seconds or more 󰂰

* Dioxins are destroyed by intense heat

󰂰

Gasification Zone

Plasma Torch & Coke Bed 1.

Out utpu putt easi easilly adj djus uste ted d

2.

Smoo mooth continuous discharge discharg e of molten slag and metal

Melting Zone

3

 

THE JAPANESE FACILITIES

Hitachi Metals’ Eco-Valley Utashinai WTE Facility

Hitachi Metals’ Mihama-Mikata WTE Facility

4

 

ECO – VALL VALLEY EY UTASHINAI UTASHINAI WTE WTE FACILITY FACILITY •

The la large rgest st fa facil cility ity is n name amed d Ec Eco-V o-Vall alley ey a and nd iis s lo locat cated ed iin n Uta Utashi shinai nai,, Hokkaido. Built over two years, it was commissioned in 2002 and has been fully operational since 2003

•

The Ec Eco-V o-Val alley ley wa was s des design igned ed tto op proc rocess ess MSW and aut auto os shre hredde dderr residue

•

Ec Ecoo-V Val alle ley y is op oper erat atin ing gw wit ith h 8 Ma Marc rc-3 -3a aP Pla lasm sma a Sy Syst stem ems s  –

Two operating gasification islands with four torches each

Specifications of the Eco-Valley, Utashinai Facility Design Capacity Number of trains

165 metric tons/Day (24 hours) of auto-shredder residue as fuel 2 trains operating at 82.5 metric

Power Generated

tons per 24 hours/train 7.9MW

Power Exported

4.3MW Inside the Eco Valley, Utashinai Facility

5

 

UTASHINAI PROCESS FLOW DIAGRAM

6

 

OPERATIONAL ISSUE #1: BOTTOM DIAMETER TOO LARGE Original

Modified Reduced Bottom Diameter Plasma Torches

Blind/cold spots cause slag to harden

󰀲󰀳󰀰󰀰 󰁭 󰁭

󰀱󰀶󰀰󰀰 󰁭 󰁭

Uniform hot zone creates continuous slag flow

7

 

OPERATIONAL ISSUE #1: BOTTOM DIAMETER TOO LARGE

Slag Close-up Below Torch Tuyeres Slag Tapping Tapping – smooth flow flow Slag Buildup on Reactor Bottom Section

8

 

OPERATIONAL ISSUE #2: INCORRECT REFRACTORY First Layer Second Layer  

Third Layer

Original

Freeboard Zone

Structure

Material

st

1  layer Freeboard Zone

3 layers

nd

2  layer rd

3  layer st

1  layer Gasification

3 la ers

one Melting Zone

Gasification Zone

SiO2 /Al2O3 

insulation High Almina

2  layer

SiC

Very short life span in the Melting and Gasification Zones 

High Almina

nd

SiO2 /Al2O3 

rd

insulation

st

SiC

2  layer 3  layer 1  layer

3 la ers

st

nd

3 layers

High Almina

 

Material

st

1  layer

insulation

rd

1  layer

Structure

High Almina

nd

3  layer 2 layers plus water wall

Improvement

nd

 

rd

3  layer 2 layers plus water wall

1st layer nd

2  layer

SiC High Almina

Life span increased to 4 years in the Melting and Gasification Zones 

First Layer Second Layer

Melting Zone 9

 

OPERATIONAL ISSUE #3: PARTICULATE CARRY-OVER PDMR

After burner MSW & ASR Secondary air for combustion Syngas

A

B

Clean gas

Water seal

Improvement Method A:

feed pipe for prevention of sh short ort pass

B:

Temperature Co Control ntrol of exiting syngas 1000°C 750~800°C

Effect   ash carry-over was reduced by 50%  feed pipe melted

• •

 not molten but accumulated inside  not molten and not accumulated

• •

10

 

OPERATIONAL ISSUE #3: PARTICULATE CARRY-OVER Slag and Ash Accumulation Inside the Afterburner

Before modification modification – large accumulation accumulation

After modification modification – accumulation accumulation reduced reduced

11

 

SUMMARY OF ECO VALLEY EXPERIENCE 1.

Ec Eco oV Val alle ley ye ex xpe peri rien ence ced dm man any yp pro robl blem ems sw wit ith hA ASR SR in th the ee ear arly ly yea earr of operation, which led to numerous improvements

2.

Ec Eco o Va Valllley ey ha has s es esta tabl blis ishe hed d tthe he PD PDMR MR sy syst stem em fo forr us use e with ith M MSW SW

3.

Ec Eco oV Val alle ley yh has as co cont ntin inue ued d co comm mmer erci cial al oper operat atio ion nw wit ith h MS MSW Ws sin ince ce 20 2003 03

. 5.

  Plas asma ma torc torche hes sa are re prov roven to be rre eliab iable and rob robust

12

 

NEXT GENERATION GASIFER DESIGN

•

Al Alter ter NRG Cor Corp. p. pu purch rchase ased dW West esting inghou house se P Pla lasma sma Co Corpo rporat ration ion in 20 2007 07

•

Al Alter ter wo worke rked d clo closel sely yw with ith Hit Hitach achii Me Metal tals s to und unders erstan tand d op opera eratio tion n of Utashinai

•

ReRe-wo work rk of tthe he o orig rigina inall des desig ign n thr throug ough h 200 2008/2 8/2009 009 tto o in incor corpor porate ate U Utas tasha hanai nai experience

•

Use of advanced en ineerin tools to enhance desi n further

•

Str Strate ategic gic pa partn rtners ership hips sw with ith engi enginee neerin ring g com compan panie ies s an and d ma mater terial ial sup supply ply companies (e.g. refractory)

•

Mod Modifi ificat cation ions s an and d im impro prove vemen ments ts to pil pilot ot pl plant ant iin n Ma Madi dison son WI tto o fu furth rther er prov prove e new design elements

13

 

UTASHINAI ISSUES ADDRESSED IN NEXT GENERATION DESIGN •

Issue 1 – Bottom d diiameter s siizing  – Using available thermal modeling tools,  – Comparison of existing existing plant data  – Approximation of steady steady state heat flux to ensure internal internal temperature temperature is well above ash melting point  – Validation/testing in our pilot plant

•

Issue 2 – Refractory  – Approximation of slag freezing plane through through thermal modeling work work (Hatch)  – Working with Saint Gobain Gobain on best suited materials selection  conductive inner layer, similar to Eco-Valley

•

Issue 3 – Carryover issues  – Internal partial water water quench solidifies molten and sticky particulate  – CFD work work ensures that bulk gas flow is cold enough prior to any cha changes nges in direction  – Drop tube design available for suitable feedstocks, minimizing entrainment entrainment of fines

14

 

ENHANCED GASIFIER DESIGN

FEED INPUT

GAS COOLING

GAS CLEAN-UP

SYNGAS

POWER DROP  TUBE

ETHANOL WIDE FREEBOARD

DIESEL HYDROGEN

air feed

STEAM

plasma torch SMALLER BOTTOM

metal and slag output 15

 

SOLUTIONS TO PROBLEMS IN CURRENT DESIGN Issue #1 (Bottom Diameter) & #2 (Refractory): Thermal modeling Work

Prediction of slag freezing plane (emulating Eco Valley refractory performance)

Finite Element Analysis for vessel mechanical integrity 16

 

SOLUTIONS TO PROBLEMS IN CURRENT DESIGN

Issue #3 (Particulate Carryover): CFD Modeling Mode ling – gas flo flows, ws, temp temperatu eratures res

Optimization of flow reducing High velocity zones, minimizing carryover 17

 

FURTHER INVESTIGATION OF PROBLEMS

Particulate Removal  Syngas Cleanup Compression 

Madison Gasification Facility (WPC) Oxygen Blown Operation  Biomass Fed  Ethanol Production Facility (Coskata) 18

 

COMPARISON OF TECHNOLOGIES

Plasma Gasification

Incineration

750-1400⁰F

Up to 2,192⁰F

Inert, non-hazardous glassy slag

Carbon char, silicon, metals and glass

Hazardous Fly Ash and Incinerator Bottom Ash

Pre-processing is minimal with shredding

Pre- proce processing ssing is necess necessary ary in most cases as MSW is too heterogeneous

Sorting

An  carbon-based material

Feedstock

Carbon material Coke is added to aid the reactions

MSW M Me edical W aste Se Sewa e Sludge

Syngas Composition

Carbon Monoxide and Hydrogen

Methane, Carbon Monoxide, and Hydrogen

Not produced

Typical Size (commercially)

Up to 250tpd (750-1000tpd in development)

Up to 300tpd

Up to 3,000tpd

Typical Uses Use s

Melting incinerator ash, destroying hazardous and medical waste, processing municipal solid waste

Make charcoal from wood, process tires and produce carbon black, steel and fuel, created activated carbon

Waste disposal and to generate power & heating

Temperature

2,000-2,500⁰F

Pyrolysis

(gasification zone)

By-product Feedstock Preparation

19

 

ENERGY RECOVERY FROM FROM WASTE WASTE – PLASMA GASIFICATION GASIFICATION IS CLEAN •

ENSR ENSR vali validat dated ed Alter Alter NRG NRG’s ’s anti anticip cipate ated d emis emissio sions ns levels levels for a 750tpd 750tpd MSW integrated gasification combined cycle (IGCC) facility which concluded that emissions for NOx, PM, SO2, HCl, CO, Hg and PCDD/PCDF would all be lower that EPA regulated standards and lower than six recently approved incineration facilities in the USA

Com Anticipated arison arison of Reso Resourc urce e Recov ReIGCC cover erWTE Incine Incinerat rator or Permi Permitte tted d (US Emissi EmiEPA ssions ons Limits Limits to to Alter NRG Emissions Levels Units)

 

CO EMISSIONS 2

Third party comparison of life cycle CO2 equivalent emissions of landfill, Landfill with flaring, Waste to Energy, Energy, and Plasma Gasification Combined Cycle Scientific Certificat Certification ion Systems report, January 2010

Twenty year accumulated GHG loading for four waste disposal options. Results compared com pared on a basis of 274,550 metric tonnes of MSW per year. The zero axis on the chart represents emission level form baseload regional grid emissions in the Northeastern Power Coordinating Council (NPCC) National Energy Reliability Council (NERC) subregion. The main advantage of PGCC is derived from its i ts ability to operate with combined cycle power island.

21

 

VITRIFIED SLAG MIHAMA-MIKATA VITRIFIED Slag from the Mihama-Mikata facility has been put through a number of leachate tests including the Japanese JLT-46, NEN-7341 and the American TCLP analysis. These tests were conducted by two independent laboratories Shimadzu Techno-Research Inc. and ALS Laboratory Group. The results show that the Mihama-Mikata slag components are below the test detection limitsthe and the slag is considered non-leaching. Below is a chart showing some of the results from JLT-46 tests MIHAMA-MIKATA SLAG JLT-46 TEST RESULTS Heavy Metal

Unit

Method Detection Limit

Average Measured Meas ured Value of Slag

JLT-46 Limit

rsen c Cadmium

mg mg/L

. 0.001

< .