ifrf totem 46, 21-22 november 2019 pisa, italy

47
KIT Die Forschungsuniversität in der Helmholtz-Gemeinschaft Institut für Technische Chemie (ITC) www.kit.edu Assessment of Alternative Thermal Waste Treatment Technologies with focus on Chemical Recycling of Plastic Waste Prof. Dr.-Ing. Helmut Seifert IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

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Page 1: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

KIT – Die Forschungsuniversität in der Helmholtz-Gemeinschaft

Institut für Technische Chemie (ITC)

www.kit.edu

Assessment of Alternative

Thermal Waste Treatment Technologies with

focus on Chemical Recycling of Plastic Waste

Prof. Dr.-Ing. Helmut Seifert

IFRF TOTeM 46, 21-22 November 2019

Pisa, Italy

Page 2: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 2 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Outline

I. Studies overview

II. Thermochemical Processes

III. Possibilities for process evaluation

IV.Examples for the different process types

V. An evaluation approach for mixed waste(MSW)

VI.Techno-Economical Assessment for Chemical

Recycling of plastic waste fractions

VII.Conclusion

Page 3: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 3 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Project Teams

1.) Alternative Thermal Waste Treatment Technologies

Japan Consult

Prof. Dr.-Ing. Helmut Seifert

Dr. rer. nat. Jürgen Vehlow

Prof. Dr.-Ing.

Karl Thomé-Kozmiensky

Dipl.-Volksw., Dipl.-Geogr. Ralf

Georg Eyssen

Prof. Dr.-Ing. Peter Quicker

RWTH Aachen

for UBA / Germany

Page 4: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 4 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

und

BKV GmbH

Mainzer Landstr. 55

D–60329 Frankfurt

PlasticsEurope AISBL

Avenue E. Van Nieuwenhuyse 4/3

B-1160 Brussels

prepaired for

Prof. Dr.-Ing. Dieter Stapf

Prof. Dr.-Ing. Helmut Seifert

M.Sc. Manuela Wexler

Projectpartner for Analysis of the plasic waste:

2.) Thermal Processes for Chemical

Recycling of Plastic Waste

Page 5: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 5 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Projects goal

Evaluation of the state-of-the-art for

Alternative Thermal Waste Treatment Processes

Evaluation of therm.Processes for chemical recycling of plastic waste

Thematic focus

Mixed residual waste

Plastic waste fractions

Geographical focus

Europe (esp. Germany) and Japan

Method

Extended international literature study

Survey with questionnaire and interviews with suppliers and operators

Site visits in Germany (partly with product sampling)

Projects Overview

Page 6: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 6 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Thermochemical Processes

Page 7: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 7 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Prof. Dr.-Ing. Helmut Seifert

High Temperature Processes

0 1 2

0

500

1000

1500

Stoichiometry

λ

T/°C

Te

mp

era

ture

allothermal

Gasification autothermal

Gasification

lean

Combustion

1250

750

Combustion

Pyrolysis

Gasification

Page 8: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 8 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Classification of Thermochemical Processes

Allothermal

Gasification

VTC 180-250

H2O Steam

Partial

Oxidation //

Autothermal

Gasifiction

0,2… l …0,5

Total

Oxidation //

Combustion

1… …2,5 l

Plasma Processes

0

100

200

300

400

500

600

700

800

900

1.000

1.100

1.200 …

Heat Addition of H2O Addition of O2 T [°C]

(Drying)

Torrefaction

LTP <500

MTP 500-800

HTP >800

Pyrolysis

Autothermal Conditions

2.000 – 10.000 Electricity

Liquefaction

TDH 150-200 HTC 170-250 HTU 250-350

HTV 600-700

H2O flüssig

H

2O überkritisch

Allothermal Conditions

Page 9: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 9 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Classification of Alterantive Thermal Waste Treatment Processes

Pyrolysis

Gasification

Plasma processes

Liquefaction

Upstream Process

Sub-Step of Combustion/Melting Processes

Part of Staged Combustion Processes

Upstream Process

Sub-Step of Combustion/Melting Processes

Stand-Alone Gasification (Syngas Production)

Sub-Step for Gas Syngas Treatment

Sub-Step for Slag Vitrification

Stand-Alone Pyrolysis

Page 10: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 10 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Possibilities for Process Evaluation

Page 11: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 11 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Development Status (VDI 3460)

DS Criteria Requirements

1

Plant/process Bench-scale tests, assessment of material and energy balances

Input/output materials Descriptive analysis of input and output materials (quality/quantity)

Market potential Assessment of market potential of a full-scale plant based on bench-scale test results

Scale-up Description of risks and opportunities of a scale-up, design of a pilot plant

2

Plant/process Steady-state operation of a pilot plant, material and energy balances

Input/output materials Analysis of input and output materials, discussion of input materials

Market potential Prediction of market potential of a full-scale plant

Scale-up Description of the technical conditions for a scale up, design of pilot plant

Operation Assessment of potential operating problems

3

Plant/process Stead-state operation of a pilot plant over a prolonged period, emission measurements,

validation of the material and energy balances derived from pilot-scale testing

Input/output materials Testing of the process-specific products for their environmental relevance and utilisation options

Market potential Description of market potential of a full-scale plant

Scale-up Technical and economic interpretation of the results related to a full-scale plant

Operation Assessment of expected run time, plant availability and service life of a planned full-scale plant

4

Plant/process Normal operation of a full-scale plant over a period of one to two years,

confirmation of material and energy balances, emission values

Input/output materials Demonstration of the suitability of the plant for the planned input materials, marketing potential

Market potential Validation of capital and operating costs (business plan)

Operation Demonstration of availability and runtime

5

Plant/process Normal operation of full-scale plant over several years, assessment of environmental relevance of the

process and plant

Input/output materials Demonstration of disposal of input materials, demonstration of the marketing of products

Market potential Traceable description of capital and operating costs over several years

Operation Optimisation of resource and energy efficiency, availability and runtime, e.g. by engineering, management

and/or logistical measures

5

4

3

2

1

Page 12: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 12 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Complexity and Benefit of the Process

Characterization

Conversion

volatiles

Pyrolysis

Conversion

Fixed carbon

C-Gasification,

„Burn-out“

Thermal Process

Required Pretreatment

Benchmark: WtE

Dry

ing

Com

paction

Conditio

nin

g

Cru

shin

g

Fe r

ecovery

NF

re

covery

Sla

g v

itrifiva

tio

n

Oth

er

pro

ducts

Energ

y u

tiliz

ation

Benefit & Products

Process A

Process B

Additional effort Benefit

Page 13: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 13 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Examples for some Processtypes

Page 14: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 14 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Classification

Pyrolysis

Gasification

Plasma processes

Liquefaction

Upstream Process

Sub-Step of Combustion/Melting Processes

Part of Staged Combustion Processes

Upstream Process

Sub-Step of Combustion/Melting Processes

Stand-Alone Gasification (Syngas Production)

Sub-Step for Gas Syngas Treatment

Sub-Step for Slag Vitrification

Stand-Alone Pyrolysis

Page 15: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 15 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Contherm Pyrolysis Hamm, Germany

Pyrolysis – Upstream Process

Verbindungsleitung

Pyrolyse - Kraftwerk

5 DS

Pyrolysis 500 °C

Co-incineration of gas and

external conditioned coke

in hardcoal boiler

RDF Input

Page 16: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 16 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Classification

Pyrolysis

Gasification

Plasma processes

Liquefaction

Upstream Process

Sub-Step of Combustion/Melting Processes

Part of Staged Combustion Processes

Upstream Process

Sub-Step of Combustion/Melting Processes

Stand-Alone Gasification (Syngas Production)

Sub-Step for Gas Syngas Treatment

Sub-Step for Slag Vitrification

Stand-Alone Pyrolysis

Page 17: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 17 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Siemens Schwel-Brenn process / MES R21

Pyrolysis – Sub-Step of Combustion/Melting Processes

3 DS

5

Pyrolysis 500 °C

Combustion > 1.300 °C

Pyrolysis drum

Vitrified slag

Page 18: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 18 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Classification

Pyrolysis

Gasification

Plasma processes

Liquefaction

Upstream Process

Sub-Step of Combustion/Melting Processes

Part of Staged Combustion Processes

Upstream Process

Sub-Step of Combustion/Melting Processes

Stand-Alone Gasification (Syngas Production)

Sub-Step for Gas Syngas Treatment

Sub-Step for Slag Vitrification

Stand-Alone Pyrolysis

Page 19: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 19 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Pyrolysis Burgau, Germany

Pyrolysis – Stand-Alone Pyrolysis

5 DS

Pyrolysis 500 °C

Combustion 1,300 °C

Coke with

NF-metals

Sorted out furniture

Page 20: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 20 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Classification

Pyrolysis

Gasification

Plasma processes

Liquefaction

Upstream Process

Sub-Step of Combustion/Melting Processes

Part of Staged Combustion Processes

Upstream Process

Sub-Step of Combustion/Melting Processes

Stand-Alone Gasification (Syngas Production)

Sub-Step for Gas Syngas Treatment

Sub-Step for Slag Vitrification

Stand-Alone Pyrolysis

Page 21: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 21 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Energos

Gasification – Part of Staged Combustion Processes

1 Rohabfall-Bunker

2 Schredder

3 Metallabscheider

4 Polypgreifer-Kran

5 Brennstoffbunker

6 Einfülltrichter

7 Primärkammer zur Vergasung

8 Nachbrennkammer

9 Dampfkessel

10 Kalk- und Kohlesilo

11 Gewebefilter

12 Silo Abgasreinigungsrückstand

13 Saugzug

14 Kamin

15 Bettaschelogistik

16 Dampfturbine

17 Luftkondensator

RDF input

5 DS

Gas combustion in secondary

chamber (900 -1,100 °C)

Gasification /understoichiometric

combustion on the grate (900 °C), l = 0,5

Page 22: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 22 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Classification

Pyrolysis

Gasification

Plasma processes

Liquefaction

Upstream Process

Sub-Step of Combustion/Melting Processes

Part of Staged Combustion Processes

Upstream Process

Sub-Step of Combustion/Melting Processes

Stand-Alone Gasification (Syngas Production)

Sub-Step for Gas Syngas Treatment

Sub-Step for Slag Vitrification

Stand-Alone Pyrolysis

Page 23: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 23 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Envirotherm: CFB-Gasification Rüdersdorf, Germany

Gasification – Upstream Process

Input #2

Ash rich mineralic

Residues

Input #1

RDF

5 DS

Circulating fuidized bed gasification

(900-950 °C )

Gas to calciner of cement kiln

(900-900 °C )

Solid residues

to raw meal mill

Page 24: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 24 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Classification

Pyrolysis

Gasification

Plasma processes

Liquefaction

Upstream Process

Sub-Step of Combustion/Melting Processes

Part of Staged Combustion Processes

Upstream Process

Sub-Step of Combustion/Melting Processes

Stand-Alone Gasification (Syngas Production)

Sub-Step for Gas Syngas Treatment

Sub-Step for Slag Vitrification

Stand-Alone Pyrolysis

Page 25: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 25 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Nippon Steel

Direct Melting Systems (DMS)

Gasification – Sub-Step of Combustion/Melting Processes

Addition of

5-10 wt.-% Coke

and Lime

5 DS

„Air“ with O2 content

of 36 % 1,800 °C

940 °C

Page 26: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 26 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Classification

Pyrolysis

Gasification

Plasma processes

Liquefaction

Upstream Process

Sub-Step of Combustion/Melting Processes

Part of Staged Combustion Processes

Upstream Process

Sub-Step of Combustion/Melting Processes

Stand-Alone Gasification (Syngas Production)

Sub-Step for Gas Syngas Treatment

Sub-Step for Slag Vitrification

Stand-Alone Pyrolysis

Page 27: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 27 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

SVZ Fixed bed gasification, Germany

Gasification – Stand-Alone Gasification (Syngas Production)

5 DS

1,000-1,300 °C

Raw gas to

methanol plant

Pellets Briquettes

Oxygen

Page 28: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 28 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Classification

Pyrolysis

Gasification

Plasma processes

Liquefaction

Upstream Process

Sub-Step of Combustion/Melting Processes

Part of Staged Combustion Processes

Upstream Process

Sub-Step of Combustion/Melting Processes

Stand-Alone Gasification (Syngas Production)

Sub-Step for Gas Syngas Treatment

Sub-Step for Slag Vitrification

Stand-Alone Pyrolysis

Page 29: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 29 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Diesel West Ennigerloh, Germany

Liquefaction

0 ES

„Start-up“ oil

Catalytical tribochemical

Conversion at 320 °C

Page 30: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 30 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

An Evaluation Approach

Page 31: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 31 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Evaluation

Complexity

Erfolgt im thermischen Prozess

Optional erforderliche Vorbehandlung (je nach Edukteigenschaften)

Optional erzeilbarer Nutzen (z.B. durch Aufbereitung und Verbrennung von Pyrolysekoks, nachrüstbare Metallabscheidung)

xxx Erfolgt in nachgeschalteter Anlage

CONTHERM 5Kessel Kohlekraftwerk

Siemens Schwel-Brenn / MES R21 5) 3/5 235 DM 1998

Burgau 5 199

Energos 11) 5 60-70

Envirotherm/Rüdersdorf 9) Zuschlag 5 30Drehrohr Zementwerk

SVZ-Festbettvergasung 5

JFE Gasifying and Direct Melting System 6) 5

AlterNRG (Westinghouse) GT 4 75-110 8)

C.H.O. Power (Europlasma) 3

Dieselwest 0 200

Tro

ckn

un

g

Ko

mp

akti

eru

ng

1)

Au

fber

eitu

ng

2)

Zer

klei

ner

un

g

En

ergi

ever

sorg

un

g

Fe-

Ab

sch

eid

un

g

NE-

Ab

sch

eid

un

g

Ver

glas

un

g Sc

hla

cke

Wei

tere

Pro

du

kte

3)

Entw

ickl

un

gsst

ufe

(lau

t V

DI

34

60

)

Beh

and

lun

gsko

sten

(H

ers

tell

era

nga

be

n)

Verfahren T K A Z NRG Fe NE V P ES €/Mg

MVA

Thermisches Hauptverfahren

Entgasung Vergasung C-Fix

ZUSATZAUFWAND BEHANDLUNGSTIEFE & NUTZEN

WtE

Page 32: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 33 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Evaluation for Mixed Residual Waste (MSW)

Interesting fields for alternative thermal processes

Upstream processes in connection with cements kilns, power plants etc.

Treatment of special fractions, e.g.

- with high pollutant content (e.g. chlorine)

- very low/high heating values

- high ash content

Achievement special features, like vitrified slag

Problematic applications

? Stand alone facilities with no inertization / no product usage

? One-step low temperature processes with high effort for product treatment

Page 33: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 34 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Selection of Processes Suitable for Plastic Waste Criteria, procedure, results

October 2018

35 Gasification Processes

4 Gasification & Melting Processes

6 Metallurgical Processes

4 Plasma Processes

29 Pyrolysis Processes

6 Liquefaction Processes

3 (4) Gasification Processes:

British-Gas Lurgi (BGL)

SVZ (Schwarze Pumpe, Germany)

Circulating Fluidized Bed

CEMEX (Rüdersdorf, Germany)

bioliq Entrained Flow

KIT (Karlsruhe, Germany)

ThermochemicalConvesion Process

Capacity 1 t/h

TRL 6?

Balance calculable?

Green

Yellow

Red

Red

Black

Yes

No

Yes

Yes

No

No

Yes

Process flow chartcomplete?

WhiteNo

Yes

Scaleability

Data Availability

No

Descriptiveness

Risk / Readyness

FlexibilityPlastic waste and TRL 3?

Page 34: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 35 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019 20.11.2019

Page 35: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 36 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Scope Overview Waste-to-chemicals process chains

for plastic waste-recycling

August 7, 2018

Techno-Economical Assessment

Feedstock

Residual Household Waste

Sorting Residues DS

Shredder residues E+E

Shredder residues from large shredders

Construction waste, incl. EPS/XPS

Feedstock Processing

Mechanical Pretreatment

Pyrolysis

(bioliq plant, Karlsruhe)

Cryogenic Grinding

Thermochemical Conversion

Circulating Fluidized Bed CEMEX, Rüdersdorf

British-Gas Lurgi (BGL) SVZ, Schwarze Pumpe

Entrained Flow

bioliq plant, Karlsruhe

Syngas Processing

Tar Removal

Particles Removal

Gas Scrubbing

Water-Gas Shift

Secondary Filtration (Activated Carbon)

Synthesis Feedstock

MeOH - Synthesis

Steamcracking

Balance Balance Balance

Gasification

Page 36: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 37 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Plastic Waste-to-Chemicals Process Chain

Example: Waste-to-Methanol (general)

mechanical fluidized bed multi-step

pretreatment gasification syngas purification

pretreatment conversion upgrading

CO2, CO, H2, CH4,

tar components,

H2S, HCl, Hg, …

H2:CO = 2:1,

tar free,

contaminats

concentrations

below 0.1ppm, …

Household

collection waste

Gasifier

feedstock Raw syngas

On-spec feed to

methanol synthesis

Page 37: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 38 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Circulating Fluidized Bed CFB Gasification

of Automotive Shredder Residues ASR

Feedstock Fluidized

Bed

Gasifier

Syngas

Oxygen

Steam

Ash

Page 38: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 39 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Syngas Conditioning and Purification

Page 39: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 40 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Gasification of ASR in a CFB-Gasifier

Page 40: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 41 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Gasification of ASR in a CFB-Gasifier

Syngas

mC, total 4.8 t/h *without composites, compounds, …

ASR

mC, total 7.4 t/h

Plastic Fraction ~ 35 wt.-%

mC from Plastic ~ 5.6 t/h*

Page 41: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 42 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Gasification of ASR in a CFB-Gasifier

Syngas

mC, total 4.8 t/h *without composites, compounds, …

ASR

mC, total 7.4 t/h

Plastic Fraction ~ 35 wt.-%

mC from Plastic ~ 5.6 t/h*

Total processing cost

211 €/tASR

Page 42: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 45 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Summary & Conclusions

Page 43: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 46 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Process Overview: Economics** Shredder Residues large shredders (ASR)

**) unit size ca. 100 MW / ca. 15 t/h of ASR

Process Pretreatment Conversion Upgrading

Total

processing

cost

Revenues*

[€/tASR] [€/tASR] [€/tASR] [€/tASR] [€/tASR]

Gasification -28 112 127 211 - 97

Pyrolysis -28 152 124 - 86

*) Syngas @ 200 €/t

Naphtha @ 500 €/t

Page 44: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 47 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Process Overview: Economics** Shredder Residues large shredders (ASR)

**) unit size ca. 100 MW

Process Pretreatment Conversion Upgrading

Total

processing

cost

Revenues*

[€/tASR] [€/tASR] [€/tASR] [€/tASR] [€/tASR]

Gasification -28 112 127 211 - 97

Pyrolysis -28 152 124 - 86

*) Syngas @ 200 €/t

Naphtha @ 500 €/t

Processing cost in the range of incineration

market gate fees

Page 45: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 48 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Process Overview: Readiness & Risk Technology Readiness Level TRL

TRL 3: applied research

TRL 5: large scale prototype

TRL 6: prototype system

TRL 7: demonstration system

TRL 8: first of a kind commercial system

TRL 9: full commercial application

Process Pretreatment

Feedstock Conversion

Upgrading

Rawgas / crude

Product

utilization

Fixed Bed

Gasifcation (BGL) 9 8 7

MeOH-

Synthesis

Fluidized Bed

Gasification (CFB) 9 8 - 9 7

MeOH-

Synthesis

Entrained Flow

Gasification (EFG) 5 - 6 6 9

MeOH-

Synthesis

Pyrolysis 9 5 - 6 3 Steamcracker

Economical attractiveness

vs. technology readiness

Page 46: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 49 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Conclusion

Alternative thermal waste treatment processes…

… can make sense in case of

- special framework conditions or regulations (like in Japan),

- special waste fractions (plastic waste, pollutant content, ash content etc.),

- (upstream) in connection with other thermal plants (cement & power plants)

… normally require high effort

- waste pretreatment

- product treatment

- additives (e.g. coke, lime, oxygen)

- of money

… is state of the art for the treatment of

mixed municipal solid waste

Chemical Recycling of plastic waste

- can be economically operated in special processes in the near future

Waste incineration

Page 47: IFRF TOTeM 46, 21-22 November 2019 Pisa, Italy

ITC 50 Prof. Dr.-Ing. Helmut Seifert – IFRF TOTeM 46 Pisa,Italy 21./22.November 2019

Prof. Dr.-Ing. Helmut Seifert

Institut für Technische Chemie (ITC)

Karlsruher Institut für Technologie (KIT)

www.itc.kit.de

ProjectReport No. 29217 UBA Germany

Thank you for your Attention!