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REMONDIS GmbH
The EU-Project RECOFUEL
Part 1:
Part 2:
Production of SBS®
Use of SBS® in PC and CFB-plants
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
REMONDIS GmbH
Part 1:
Production of SBS®
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
Two quality groups, two trade marks
since 1995/1998
REMONDIS GmbH
BPG®
Brennstoff aus
produktionsspezifischen
Gewerbeabfällen
Source seperated
wastes /
production residues
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
SBS®
Substitutbrennstoff
High calorific fractions
(HCF)
sorted out from
poste-use waste
3
5 different qualities
for different customers
REMONDIS GmbH
BPG 1
BPG 2
BPG 3
power plants
cement kilns
lime kilns
residues from
paper
production
rejects,
punchings,
photography
paper,
blocks,
wet-strength
paper,
cellulose
cloths etc.
paper
wastes
as BPG 1,
plastics
- resins
- polyacrylic
- polyester
- polyolefine
- PUR
- etc.
fibre fabrics
carpets etc.
low ash
plastics
- resins
- polyacrylic
- polyester
- polyolefine
- PUR
- etc.
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
SBS 1
SBS 2
power plants
lignite
cement kilns
hard coal
different
high-calorific
fractions
from
-MSW
-demolition
wastes
see SBS 1
4
Input materials
for SBS®
REMONDIS GmbH
mechanical-biological
treatment plant
high calorific fraction (HCF1)
LFP-sorting
construction and
demolition wastes
high calorific fraction (HCF3)
high calorific fraction (HCF4)
bulky wastes
high calorific fraction (HCF5)
commercial wastes
SBS®-production
high calorific fraction (HCF2)
SBS®
QA of SBS®
high calorific fraction (HCF6)
composting
Quality Assurance of HCF`s
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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Specifications
for BPG® and SBS®
REMONDIS GmbH
Parameter
Unit
BPG 1
power
plants
BPG 2
cement
kilns
BPG 3
lime kilns
SBS 1
SBS 2
power
cement kilns/ power
plants (BC)
plants (HC)
NCV
Cl
F
H2O
MJ/kg
%
%
%
16 - 20
< 1,0
< 0,05
< 35
20 - 24
< 1,0
< 0,05
< 20
23 - 27
< 1,0
< 0,05
< 12,5
13 - 18
< 0,7
< 0,05
< 35
18 - 23
< 1,0
< 0,05
< 20
S
%
< 0,2
< 0,3
< 0,3
< 0,5
< 0,8
Ash
%
< 20
< 15
<9
< 20
< 15
As
Be
Cd
Co
Cr
Cu
Hg
Mn
Ni
Pb
Sb
Se
Sn
Te
Tl
V
mg/kg ds
mg/kg ds
mg/kg ds
mg/kg ds
mg/kg ds
mg/kg ds
mg/kg ds
mg/kg ds
mg/kg ds
mg/kg ds
mg/kg ds
mg/kg ds
mg/kg ds
mg/kg ds
mg/kg ds
mg/kg ds
< 10
<1
<9
< 12
< 120
< 400
< 0,5
< 100
< 50
< 100
< 120
<4
< 70
<4
<1
< 15
< 10
<1
<9
< 12
< 120
< 400
< 0,5
< 100
< 50
< 100
< 120
<4
< 70
<4
<1
< 15
< 10
<1
<9
< 12
< 120
< 400
< 0,5
< 100
< 50
< 100
< 120
<4
< 70
<4
<1
< 15
< 10
<1
<9
< 12
< 250
< 1.000
< 1,0
< 400
< 160
< 400
< 120
<5
< 70
<5
<1
< 25
< 10
<1
<9
< 12
< 250
< 1.000
< 1,0
< 400
< 160
< 400
< 120
<5
< 70
<5
<1
< 25
(*): values for digestion with aqua regia in a closed microwave system
REMONDIS GmbH
ThermWert
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
Dr. Glorius
Spezifikation.xls, Stand: 01.01.2007
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Waste treatment center VZEK, Erftstadt
Flow-sheet (12/2005)
REMONDIS GmbH
Bulky/Commercial waste
feeding
biomass
water
MSW
feeding
screening
biol. drying
Fe-/ NFseperation
residues/ MSWI
Fe-/ NFmetals
Fe-/ NFseperation
New plant (ABA)
NIRseperation
SRF-plant (AKEA)
storage/
loading
fine grinding
HCF
SRF`s:
BPG® and SBS®
NF-seperation
Production
wastes
size reduction
Fe-seperation
feeding
Prior size
reduction-
LFP-residues,
feeding
production w.
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
Fe-/ NFmetals
disturbent
materials
windshifting
NIR-seperation
residues
7
HCF-Sorting with NIR-systems
positive separation
REMONDIS GmbH
Near Infrared-System
Computer (NIR)
Camera
Nozzle Pipes
Control System
Feeding
Acceleration conveyor
Positive
fraction
Nozzles
Sorting residues
Positive fraction
Sorting residues
 SBS®
 MSWI
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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Development of input materials
for SBS®1E [weight %]
REMONDIS GmbH
Input Material
2004
2007
2005
Weisweiler Weisweiler
2006 Berrenrath
(projected)
Production specific waste (high Al-content)
30
0
0
0
Production specific waste (low Al-content)
0
25
10
10
70
75
38
40
High Calorific Fraction from bulky waste
0
0
50
46
High Calorific Fraction from mixed commercial waste
0
0
2
4
High Calorific Fraction from MSW
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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Extended QMS
for the production of SBS®
REMONDIS GmbH
Process-chain
QA-chain
Acceptance area
Input control
Positive sorting of HCF
Process control
SBS®-Production
Process control
SBS®-Storage
ISO 9001
EFB
RAL-GZ 724
CEN TC 343




Product control:
Internal and external
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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Quality/product control
REMONDIS GmbH
Sampling behind last step
of size reduction
Delivery to the customer
Regular sampling
during production
Analysis of H2O in the plant
Single samples are combined to
500-Mg-mixed-samples,....
Every 1.500 Mg additional
parameters are analysed:
... and are analysed by
an external laboratory :
Analysis report – Number ...
1.500-Mg-analysis
for BPG and SBS
Parameter:
ds, H2O, Cl, Ash, NCV, F, ...
HM Group I-III:
As, Be, Cd, Co, Cu, Hg, Mn, Mo,
Ni, Pb, Sb, Se, Sn, Te, Tl, V, Zn
Ash:
Al2O3, CaO, Fe2O3, K2O, MgO,
Na2O, P2O5, SiO2, SO3, TiO2, ZnO
Analysis report – Number ...
500-Mg-analysis
for BPG and SBS 
Parameter:
ds, H2O, Cl, Ash, NCV
+ 2 HM (changing monthly)
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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Development of SBS1Erftstadt-quality
Short analysis and elementary analysis
REMONDIS GmbH
Unit
Lignite from the
Rhine (Inden),
Mean
SBS 1
Mean
2004 - 2005
SBS 1
Mean
2006
SBS 1
Mean
2007
Short analysis
Net. Calorific Value
H2O
Ash
Chlorine
Volatile
MJ/kg o.s.
% o.s.
% o.s.
% o.s.
% o.s.
8,15
58,8
3,0
0,02
n.a.
14,1
29
10,3
0,34
55
13,6
22,7
9,6
0,42
57
14,2
21,5
9,4
0,35
49,2
% o.s.
% o.s.
% o.s.
% o.s.
% o.s.
24,8
2,2
10,6
0,4
0,2
33,5
5,5
20,3
0,5
0,1
32,8
4,7
28,4
1,5
0,2
37,2
5,3
24,6
1,4
0,2
Elementary analysis
Corg
H
O
N
S
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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Development of Cl-values of SBS®
since 1997 (n = 919, 10/2007)
REMONDIS GmbH
Median
Average
80%-Perc.
3,00
% of ds
2,50
2,00
1,50
1,00
0,50
0,00
1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007
First trials with NIR
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
Effect of German
landfill-directive
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Development of parameters
with slagging, fouling- or corrosion-potential for SBS®1
mg/kg ds
(08/2007)
REMONDIS GmbH
20.000
18.000
16.000
14.000
12.000
10.000
8.000
6.000
4.000
2.000
0
Mean
Mean
Mean
Mean
Al
K
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
Na
2004
2005
2006
2007
Cl
Chlorides
14
Biogenic share of SBS®1Erftstadt
Results Dissolution method (prCEN/TS 15440)
REMONDIS GmbH
[%] 80,00
70,00
60,00
50,00
40,00
30,00
20,00
10,00
0,00
75,0
63,4
28,2
74,5
63,8
32,7
Biogenic C Biogenic C Biomass
Biomass
Share
Share
2005 [% of 2006 [% of content
content biomass of biomass of
ds]
ds]
2005 [% of 2006 [% of NCV 2005 NCV 2006
ds]
ds]
[J% (waf)] [J% (waf)]
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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Energy specific CO2-emissions
of different fuels
REMONDIS GmbH
SBS1
BPG2
Natural gas
Light fuel oil
Heavy fuel oil
Hard coal
realistic
fossil
share
Lignite
t CO2/TJ
120
110
100
90
80
70
60
50
40
30
CO2-reduction:
0,75(HC) - 1(BC) t CO2 /SBS(with 50% biomass content)
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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REMONDIS GmbH
Part 2:
Use of SBS®
in Pulverized Coaland Circulating Fluidized Bed-plants
within the
RECOFUEL-project
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
EU-Project RECOFUEL
Production of SRF (SBS®) and use in lignite boilers
REMONDIS GmbH



term
 duration
 start
partner
 consortium
 coordinator
36/48 month
June 2004
12 partner of 6 EU-states
REMONDIS
issues
1. sustainable production of SRF`s suitable for power plants
2. environmental acceptability and technological feasibility
3. accompanying research
4. european technology transfer
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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Project RECOFUEL
main issues of the partners
REMONDIS GmbH
• REMONDIS
SRF-production + coordination
• RWE Power
large-scale demonstration co-combustion
• University Stuttgart
• INFA
lab tests + simulation
balances of SRF-production
• KEMA
ash properties + corrosion
• TAUW
quality control in the power plant
• CESI
• Åbo Akademi Process
corrosion
SFR properties + ash
• University of Athens
combustion model
• VINCA
mill measurements
• ESSENT
technology transfer
• PPC
technology transfer
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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PC-plant of RWE Power
in Weisweiler
REMONDIS GmbH
Source:
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
RWE Power
PC-plant of RWE Power in Weisweiler
Feeding device for paper sludge (incl. 3 hoppers)
REMONDIS GmbH
Source:
RWE Power
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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Co-combustion of SBS® with lignite
in Weisweiler
REMONDIS GmbH
SRF
deliveryFluff
cooling tower
SBS-delivery:
average 20-25 Mg/h
maximum 50 Mg/h
hopper
boilers with
primary DENOX:
2 x 600 MWel
REA
desulphorisation
lignite supply
1200 Mg/h
Source:
8 coal mills
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
electrostatic filter
RWE Power
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Trials at Weisweiler
PP in 2005
REMONDIS GmbH
SBS®1:
Paper sludge during SBS®1:
Lignite during SBS®1:
Steam data:
4200 Mg, 12,5 Mg/h (up to 4% thermal share)
ca. 13000 Mg
ca. 345 000 Mg
530°Cel., 169 bar
Test and measurement plan:
• Input and output analysis of SBS®1 production
• Fuel input analysis at the power plant
• Analysis of the biogenic content
• Investigation of fuel preparation and mill behaviour
• Emission measurement in flue gas
- Flue gas composition
- HCl-measurement in the raw gas
• Furnace measurements
• O2- and temperature meas. before/after mill
• Analysis combustion residues
• First investigations of the corrosion potential
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
Source: IVD, University Stuttgart
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Direct co-combustion
of SBS®1 in Weisweiler
REMONDIS GmbH
Source:
RWE Power
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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Evaluation of SBS®-co-incineration
in Weisweiler
REMONDIS GmbH
 quality of SRF (SBS®)
 delivery and transfer
 feeding and dosing
 combustion behaviour (ignition and burnout)
 fixing of heavy metals etc. in ash and gypsum
 flue gas cleaning system
 emissions according 17. BImSchV (WID)
 landfilling characteristics of combustion residues
Co-incineration of SBS® in lignite power plants is
technically and environmentally feasible
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
Source:
RWE Power
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Extension of the project
to a new power plant and a duration of 48 months
REMONDIS GmbH
 Motivation:
 Missing longterm permission in PC-plant of Weisweiler
 Existing feeding technology in CFB/CHP-plant Berrenrath
 Existing longterm permission for SBS®-use in Berrenrath
 Consequences:
 Additional administrative work (Consortium and EC)
 Increased knowledge about corrosion risk with respect to two
technologies
 Use of the potential of lignite burning PC-power plants in WestGermany postphoned
 Use of the potential of CFB-plants stabilized
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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Berrenrath Power Plant
REMONDIS GmbH
Source:
RWE Power
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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Co-combustion installations
of the Berrenrath Power Plant
REMONDIS GmbH
sewage sludge
pulverized lignite coke
(activated carbon)
run-of-minelignite
SBS®1
Source:
RWE Power
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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CFB boiler (CHP)
in Berrenrath
REMONDIS GmbH
BERRENRATH CFB
(ca. 300 MWtherm)
Steam data :
• 77.8 kg/s
• 510 ºC
• 90 bar
Fuels :
• Lignite
• Sewage sludge
• Lignite sludge
• Demolition wood
• SRF (up to 25%
thermal share)
SUPERHEATER 4
SUPERHEATER 3
SUPERHEATER 2
ECONOMIZER
AIR PREHEATER
Source:
RWE Power
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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Summary
part 1-2
REMONDIS GmbH
 NIR-technology is the key to select suitable high calorific fractions
from MSW, bulky waste and mixed commercial wastes
 NIR-technology in development (improvements of selectivity)
 Modern treatment-technology is the basis for good chemical und
physical fuels properties
 QMS according RAL-GZ 724/CEN TC 343 can improve the reliability of
fuel properties
 Improved SBS®1-qualities even after effectiveness of landfill directive
 Very low Cl-values (mean of 3 assays < 0,5% of d.s., max < 0,7% of
d.s.) requested by RWE Power
 New location for longterm-tests: CHP-plant in Berrenrath (CFB-techn.)
 Interesting CO2-reduction potential: 1t CO2/t SBS®1
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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REMONDIS GmbH
Acknowledgment
The RECOFUEL-project is funded by the European Commission under the
Sixth Framework Programme
European Commission Directorate-General for Energy and Transport
and
Intelligent Energy Europe
Thank you!
Dr.-Ing. Th. Glorius, QUOVADIS-Workshop, Rome, 23.-25.10.2007
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