The Urban Nexus Da Nang/Vietnam June, 26 2014

Licence Partner of
MYT Business Unit
The Urban Nexus Da Nang/Vietnam June, 26th 2014
Dipl.-Ing. (FH) Martin Schaub WEHRLE Umwelt GmbH
[email protected]
www.wehrle-umwelt.com
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Da Nang June, 26th 2014
WEHRLE’s history in MBT Technology
Milestones in the history of the WEHRLE-WERK AG and
WEHRLE Umwelt GmbH
2002
Transfer of the Environmental Branch
of
WEHRLE-WERK
AG
into
the
subsidiary company WEHRLE Umwelt
GmbH (WUG), Foundation of WEHRLE
China
1980
Begin of business in the field of
Environmental Protection Technologies
(Waste Water Treatment, Sludge
Treatment) in a WEHRLE-WERK AG
branch
1927–2005
Expanding business of WEHRLE-WERK
AG with various products: Boilers,
Combined Heat-and-power stations,
Thermal treatment of household refuse
and toxic waste, Energy recovery from
biomass
1920
Transformation into a stock corporation
“WEHRLE-WERK AG”
End
19. Cty
Begin of manufacturing of low pressure
boilers
1860
Foundation of the locksmith’s trade
"Wilhelm Wehrle"
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Da Nang June, 26th 2014
WEHRLE’s history in MBT Technology
WEHRLE Umwelt GmbH today:
 more 25 years of experience in the waste water business
 100% subsidiary company of WEHRLE-WERK AG
 60 employees
 waste water treatment for the industry and leachate from landfills
 plants for mechanical- biological treatment of solid waste and
organic matter (AD technology)
 potable water processing plants
 More than 200 references world-wide
 Turn over 13-18 Mil. €
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Da Nang June, 26th 2014
WEHRLE’s history in MBT Technology
Environmental Technologies of WEHRLE Umwelt GmbH
Aerobic waste water treatment
Physical–chemical water
treatment
Membrane bioreactor
Membrane units (Ultra-,
Nanofiltration, Reverse Osmosis)
WEHRLE Loop Reaktor (WLR)
Activated Carbon plant
Sequencing-Batch-Reactor (SBR)
Ammoniak stripping plants
Anaerobic waste water treatment
Digestion of solid waste
EGSB reactor (BIODIGAT® SB)
Mechanical biological treatment of
mixed solid waste (MYT)
(BIOMEMBRAT®)
Anaerobic Filter (BIODIGAT® AF)
Anaerobic (BIODIGAT® AS)
Mechanical biological treatment of
mixed solid waste (Dry
Digestion)
Mechanical biological treatment of
high organic waste (Wet
Digestion)
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Da Nang June, 26th 2014
WEHRLE’s history in MBT Technology
Municipal Solid Waste Kahlenberg
ZAK-Concept
Mechanical
pretreatment
Mixed
MSW
Paper, packaging
Metal
separation
Biologcical decomposition
Off-gas treatment
Biological drying
Mechanical
separation
Electric current
Co-generation
Heat
Anaerobic digestion
Aerobic waste
water treatment
Inerts
Solid recovered fuel
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Da Nang June, 26th 2014
WEHRLE’s history in MBT Technology
WEHRLE‘s history in MBT Technology
February 1997
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for the world’s first pilot plant for “Percolation”
(Commissioning and Operation 1997-1999)
July 1999
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for a technical Percolation plant (Throughput: 20,000 tons/year MSW)
(Commissioning and Operation 2000-2002)
July 2002
Commissioning of the Biological Drying Pilot Plant
July 2004
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for a technical Percolation plant (Throughput: 100,000 tons/year MSW)
(Commissioning 2006)
Feb 2010 - Aug 2010
Commissioning and Operation of the BIODAMP Plant in Thailand
July 2012
Order of an important International Pharmaceutical Company
for a technical Wet Digestion Plant (Throughput: 70,000 tons/year)
January 2013
Order for Engineering Services for the MYT Plant Symevad
(Northern France)
June 2013 - Oct 2013
Commissioning and Operation of the BIODAMP Pilot Plant in China
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Da Nang June, 26th 2014
WEHRLE’s history in MBT Technology
WEHRLE‘s history in MBT Technology
Percolation Pilot Plant
Company: ZAK, Ringsheim
Location:
Kahlenberg, Germany
Input:
1 ton/day
Municipal Solid Waste (MSW)
Year:
1997
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Da Nang June, 26th 2014
WEHRLE’s history in MBT Technology
WEHRLE‘s history in MBT Technology
February 1997
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for the world’s first pilot plant for “Percolation”
(Commissioning and Operation 1997-1999)
July 1999
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for a technical Percolation plant (Throughput: 20,000 tons/year MSW)
(Commissioning and Operation 2000-2002)
July 2002
Commissioning of the Biological Drying Pilot Plant
July 2004
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for a technical Percolation plant (Throughput: 100,000 tons/year MSW)
(Commissioning 2006)
Feb 2010 - Aug 2010
Commissioning and Operation of the BIODAMP Plant in Thailand
July 2012
Order of an important International Pharmaceutical Company
for a technical Wet Digestion Plant (Throughput: 70,000 tons/year)
January 2013
Order for Engineering Services for the MYT Plant Symevad
(Northern France)
June 2013 - Oct 2013
Commissioning and Operation of the BIODAMP Pilot Plant in China
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Da Nang June, 26th 2014
WEHRLE’s history in MBT Technology
WEHRLE‘s history in MBT Technology
Percolation Demonstration Plant
Company:
ZAK, Ringsheim
Location:
Kahlenberg, Germany
Input:
20,000 tons/year
Municipal Solid Waste (MSW)
Year:
2000
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Da Nang June, 26th 2014
WEHRLE’s history in MBT Technology
WEHRLE‘s history in MBT Technology
February 1997
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for the world’s first pilot plant for “Percolation”
(Commissioning and Operation 1997-1999)
July 1999
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for a technical Percolation plant (Throughput: 20,000 tons/year MSW)
(Commissioning and Operation 2000-2002)
July 2002
Commissioning of the Biological Drying Pilot Plant
July 2004
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for a technical Percolation plant (Throughput: 100,000 tons/year MSW)
(Commissioning 2006)
Feb 2010 - Aug 2010
Commissioning and Operation of the BIODAMP Plant in Thailand
July 2012
Order of an important International Pharmaceutical Company
for a technical Wet Digestion Plant (Throughput: 70,000 tons/year)
January 2013
Order for Engineering Services for the MYT Plant Symevad
(Northern France)
June 2013 - Oct 2013
Commissioning and Operation of the BIODAMP Pilot Plant in China
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Da Nang June, 26th 2014
WEHRLE’s history in MBT Technology
WEHRLE‘s history in MBT Technology
Biological Drying Pilot Plant
Company:
ZAK, Ringsheim
Location:
Kahlenberg, Germany
Input:
10,000 tons/year
Municipal Solid Waste (MSW)
Year:
2002
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Da Nang June, 26th 2014
WEHRLE’s history in MBT Technology
WEHRLE‘s history in MBT Technology
February 1997
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for the world’s first pilot plant for “Percolation”
(Commissioning and Operation 1997-1999)
July 1999
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for a technical Percolation plant (Throughput: 20,000 tons/year MSW)
(Commissioning and Operation 2000-2002)
July 2002
Commissioning of the Biological Drying Pilot Plant
July 2004
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for a technical Percolation plant (Throughput: 100,000 tons/year MSW)
(Commissioning 2006)
Feb 2010 - Aug 2010
Commissioning and Operation of the BIODAMP Plant in Thailand
July 2012
Order of an important International Pharmaceutical Company
for a technical Wet Digestion Plant (Throughput: 70,000 tons/year)
January 2013
Order for Engineering Services for the MYT Plant Symevad
(Northern France)
June 2013 - Oct 2013
Commissioning and Operation of the BIODAMP Pilot Plant in China
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Da Nang June, 26th 2014
WEHRLE’s history in MBT Technology
WEHRLE‘s history in MBT Technology
MYT® Plant „MBT Kahlenberg“
Company:
ZAK, Ringsheim
Location:
Kahlenberg, Germany
Input:
100,000 tons/year
Municipal Solid Waste (MSW)
Year:
2006
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Da Nang June, 26th 2014
WEHRLE’s history in MBT Technology
WEHRLE‘s history in MBT Technology
February 1997
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for the world’s first pilot plant for “Percolation”
(Commissioning and Operation 1997-1999)
July 1999
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for a technical Percolation plant (Throughput: 20,000 tons/year MSW)
(Commissioning and Operation 2000-2002)
July 2002
Commissioning of the Biological Drying Pilot Plant
July 2004
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for a technical Percolation plant (Throughput: 100,000 tons/year MSW)
(Commissioning 2006)
Feb 2010 - Aug 2010
Commissioning and Operation of the BIODAMP Plant in Thailand
July 2012
Order of an important International Pharmaceutical Company
for a technical Wet Digestion Plant (Throughput: 70,000 tons/year)
January 2013
Order for Engineering Services for the MYT Plant Symevad
(Northern France)
June 2013 - Oct 2013
Commissioning and Operation of the BIODAMP Pilot Plant in China
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Da Nang June, 26th 2014
WEHRLE’s history in MBT Technology
WEHRLE‘s history in MBT Technology
BIODAMP Pilot Plant Thailand
Company:
WEHRLE Umwelt GmbH
Location:
Petchaburi, Thailand
Input:
3 tons/day
Municipal Solid Waste (MSW)
Year:
2010
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Da Nang June, 26th 2014
WEHRLE’s history in MBT Technology
WEHRLE‘s history in MBT Technology
February 1997
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for the world’s first pilot plant for “Percolation”
(Commissioning and Operation 1997-1999)
July 1999
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for a technical Percolation plant (Throughput: 20,000 tons/year MSW)
(Commissioning and Operation 2000-2002)
July 2002
Commissioning of the Biological Drying Pilot Plant
July 2004
Order of Zweckverband Abfallbehandlung Kahlenberg (ZAK)
for a technical Percolation plant (Throughput: 100,000 tons/year MSW)
(Commissioning 2006)
Feb 2010 - Aug 2010
Commissioning and Operation of the BIODAMP Plant in Thailand
July 2012
Order of an important International Pharmaceutical Company
for a technical Wet Digestion Plant (Throughput: 70,000 tons/year)
January 2013
Order for Engineering Services for the MYT Plant Symevad
(Northern France)
June 2013 - Oct 2013
Commissioning and Operation of the BIODAMP Pilot Plant in China
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The grounds of the Zweckverband Abfallbehandlung Kahlenberg 18
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Landfill from 1973 - 2005: Disposal of about 6 Mio. tons of waste
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The landfill after renaturation: Habitat for many rare animals and plants
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Merops Apiaster
Conservation area and goal for family outings
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Zweckverband Abfallbehandlung Kahlenberg (ZAK)
• ZAK is a special purpose association formed in a legal communal
cooperation between the counties Emmendingen(EM) and
Ortenaukreis (OG)
• ZAK is based in Ringsheim (Germany)
• ZAK serves 570,000 residents -> producing about 100,000 tons of
household waste per year
• ZAK‘s function: Waste management of the delivered waste via
recycling, maximum yield extraction of biogas & RDF and disposal
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ZAK
State of
BadenWürttemberg
Location of the ZAK in Germany
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Household Waste
Bio-Waste
Packaging
Paper
Glass
About 20 drop-off points (excavated ground, construction rubble, used tires,
electronic waste, matured wood, lop, bulky waste)
Two extra pick-ups per year (bulky waste, lop, special waste)
Commercial waste (third party private)
Waste management in the ZAK linked districts
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Mechanical – Biological Waste Treatment Trials
• 1996 - Fermentation trials on a semi-technical scale
(No appropriate technology available, extreme amount of procedural
deficiencies)
• Parallel development of the ZAK-Process
(MBT treatment of household waste including household bio-waste)
– Material utilisation and landfilling (e.g. inert material and metals)
– Energy utilisation (RDF, Biogas)
– Operational efficiency (reduction of mass, minimalisation of non-treated
residue and bio-waste, energy self-sufficient MBT)
– Ecology (encapsulation, air and water treatment, saving fossil fuels)
• 2000 - 2003 - Large Pilot/Demonstration-Plant
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View of the Demonstration-Plant
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constituents
Household Waste
RDF
Water
MBT
Minerals
Metals
Benefit / Value for use
Biogas
Rest
Losses
Waste breakdown
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Mechanical – Biological
Waste Treatment
MBT – Kahlenberg
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Process steps of the MBT Kahlenberg:
Mechanical Preparation
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Building 1: Waste acceptance bunker - approx. 100,000 tons
household waste per year from 570,000 residents
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Building 2: View of the mechanical preparation step
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Heavy mineral fraction sorted out
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„Can scrap“
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Process steps of the MBT Kahlenberg:
Biological Conversion
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DAMP® - Defined Aerobic Mixing Process
Waste
Process water
Agitator
Screw Press
Solids
Press water
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DAMP-Reactor Design Figures:
• 6 concrete DAMP-Reactors
• Filling Volume 250 m³ (each)
• Retention Time in DAMP 2-3 days
Aggregates of the Biological Conversion step: DAMP-Reactor
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Fundamental and conceptional further
developments (Percolation / DAMP):
• Goal: Determine and set RDF and Bio-Gas output rates
• Grade size reduction / homogenisation (Slurry-Mix)
• Reduction of toxic substances
• Aerobic pre-treatment – ideal for Biological Drying
• Remaining material includes useful organics for the
Biological Drying step
elements:
- percolator / DAMP / mixer
- biogas fermenter
- waste water cleaning system
- presses
Aggregates of the Biological Conversion step: Agitator
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Aggregates of the Biological Conversion step: Planetary Gearbox38
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Discharge from the biological conversion step,
reduced in size, washed and homogenized
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Aggregates of the Biological Conversion step: Dewatering Press
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Mechnical-physical water treatment
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CHP Plant
Aggregates of the biological conversion step: Biogas fermenters 42
Da Nang June, 26th 2014
Process steps of the MBT Kahlenberg:
Biological Drying
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Demands on the input material:
• loose, homogeneous, air-flow-friendly material
• defined consistant moisture content
(approx. 55% - 60% dry substance)
• aerobic pre-treated material
• microbiological useful organic content
• controlled air, solids and energy management
Aggregates of the Biological Drying step: Drying tunnel
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Biological Drying tunnel (equipped with moving-floor)
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Aggregates of the Biological Drying step: Discharge Machine
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Aggregates of the Biological Drying step: Conveyors und discharge
machine, completely enclosed and evacuated
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Output of the Biological Drying step
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Process steps of the MBT Kahlenberg:
Air Treatment
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Air Treatment Basics
•
Preferably tight encapsulation of all machines and controlled and
monitored air extraction
•
Preferably airtight building construction
•
Multiple use of extracted air volume
•
Differentiated, flexible air treatment processes
•
Consequential cleanliness and maintenance of all equipment
•
Minimise emission exposure to personnel
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fresh air
facility buildings (machine halls)
enclosures of machinery
(point sources)
collected exhaust air (point sources and buildings)
ventilation
supply air
excess air
DAMP / MZR
drying tunnels
alkaline air
scrubbing
acid air scrubbing
air moistening
regenerative thermal oxidizer
biofilter
clean air
Air flow concept of the MBT Kahlenberg
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Aggregates of the Air Treatment step: Humidifier, waschers
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Aggregates of the Air Treatment step: Bio filters
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Regenerative Thermal Oxidation (RTO)
Aggregates of the Air Treatment step: RTO
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Process steps of the MBT Kahlenberg:
Mechanical Material Separation
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Goals:
• specified, homogeneous RDF
• defined inert material
• scrap metal
Demands on the input material:
• loose, homogeneous and free-flowing
material
• specified consistant moisture content
(>85 % dry)
• absolute dustproof encapsulation
• trouble free „just in time“ logistics
View of the Mechanical Material Separation step
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Controlling of the separation quality
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MYT® Maximum Yield Technology
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Da Nang June, 26th 2014
MBT Kahlenberg
The important products generated from the treatment
of about 100,000 tons/a of household waste
Plant operating time: 5 days/week, 2 shifts
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Products of the Mechanical Separation step:
EBS (Refuse Derived Fuel) mid caloric range (~13,000 MJ/ton)
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Products of the Mechanical Separation step:
EBS (Refuse Derived Fuel) mid caloric range (~14,000 MJ/ton)
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Products of the Mechanical Separation step:
EBS (Refuse Derived Fuel) high caloric range (~16,000 MJ/ton)
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•
•
•
Fuel or mineral optimized produktion
Landfilling according legal Landfill Directives
Separation accurancy adjustable „at the touch of a button“
Products of the Mechanical Separation step:
Mineralstoffe (Mineral fraction)
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Da Nang June, 26th 2014
Further development of the energy concept
Power
Plants
RDF
Cement
Plants
Vehicles
Power Grid
BT
Electricity
Biogas
CHP
Plant
BT
Heating
Gas
Network
Heating
Network
MYT®
Obtain max. Energy
potential
Efficient use
of Energy
Energy – and
Environmental
Management
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Da Nang June, 26th 2014
Example MBT Kahlenberg
Energy potential out of approx. 120,000 tons household waste
Hu about 7,000 MJ/ton, Hu about 235,000 MWh/year
Energy potential / Heating value (MWh/a)
250,000
235,000
200,000
165,000
150,000
100,000
40,000
50,000
30,000
25,000
Losses
House load MYT®
0,000
Energy potential
total
Energy carrier
RDF
Energy carrier
Biogas
MYT® works on its own energy and covers its energy needs
completely through the use of regenerative energy sources
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Da Nang June, 26th 2014
Example MBT Kahlenberg
Annual CO2 - savings from about 120,000 tons household waste
- Electricity from Biogas (pp) – RDF instead of coal
90,000
80,000
20,000
70,000
Tons per Year
60,000
50,000
40,000
62,000
30,000
20,000
10,000
0,000
RDF instead of coal
Electricity from Biogas (pp)
Climate friendly electricity and heat is obtained from the energy
carriers biogas and high-biomass content RDF
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Da Nang June, 26th 2014
Waste fees Baden-Württemberg
Comparison of the waste fees for a
4 person model household in 2013
in Baden-Württemberg
The Ortenaukreis has a simple and clear
waste management concept and tariff system
The waste fees are low!
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Da Nang June, 26th 2014
Simple waste management concepts – low efforts needed for logistic and sorting
systems reduced costs helps keep waste collection fees low.
Short waste treatments times – keeps machine size to a minimum
= lower investment costs.
Complete and flexible use of the energy potential.
Energy carriers adapted to the needs of the energy user.
Well thought out design and tried and proven technology.
High operational reliability means long term operational success.
Modular concept – using tried and proven machines.
Small and large sized plants economically viable.
Experienced specialized companies guarantee
an easy and secure new project implementation.
Flexible site location – in the center of the waste collection area
within direct vacinity to the energy users – economic logistic concepts.
Ecologically sound low-emission technology – site acceptance even
in direct vicinity to populated areas.
Operators profit from the training and consultation of ZAK.
New plants can be operated with own personnel and in an exemplary manner.
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Licence Partner of
MYT Business Unit
Fueling the Future!
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Da Nang June, 26th 2014