1. No category

Composting and Biodrying of MSW
and SOW with the Gore Cover System
Franz Vogel
UTV AG
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
UTV AG
UTV AG
1996
1998
2000
2002
2007
Establishment of UTV, first project in Bremen for MSW stabilization
First project with 10.000tpy
25 project in operation
17. September, commissioning of the first plant in North America
more than 50 plant in operation worldwide
2011
Largest MSW facility started operation with 2.000to / day
2012
Largest Facility with 1,0 Mio tons treatment capacity is under construction
2014
Over 120 plants in operation treating 15.000to per day
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover System
1996 to Present
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
Biological treatment process
The GORE® Cover System
ePTFE
expanded polytetrafluoroethylene
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
160.000tpy 64 heaps 50m x 8m, 8 weeks treatment time
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
KATJA CHRISTOF
GORE® Cover
Waste input and output
Separated
Waste
Biosolids
Municipal Solid
Waste
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
Typical layout of a GORE® Cover MBT
(Mechanical Biological Treatment Plant)
Step 1
Reception
Pre treat
Separation
Step 2
Step 3
e.g.21 days
Additional 3 weeks for e.g.
CLO or higher
stabilisation
Step 4
Sorting
Aearation and controle
Post treatment
collection
tank
Compost like output
(CLO)
Leachate collection
Further treatment (RDF) or landfill
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
A few out of 150 + installation with GORE® COVER
Spain, 190.000 tpy MSW plant
America, 210.000 tpy compost plant
America, 160.000 tpy compost plant
Plants:
Waste to Energy
Composting
Recycling Parks
MBA Parks
Sorting, Recycling
Hungary, 160.000 tpy total MSW plant
© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
Hungary, 150.000 tpy MSW plant
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GORE® Cover
Reduction of MSW towards landfill by meeting national or international legislation
100%
…. Mio tons per year MSW (Municipal Solid Waste)
(initially)
EU landfill directive (1999/31/EC)
Recyclables (Paper, Cardboard, Plastic,
Metal, Textile…) to be reused in the industry (potential
income stream) Revenue to the plant owner
Stabilization of the organic
matter
Production of Compost
RDF (Refuse Derived Fuel)
to be used e.g. cement industry as
alternative fuel)
Energetic use
(CLO (Compost Like Output))
Landfills <… Mio ton per year (more
< 25- 35 %
efficient compactable material -> expansion of life time of existing
landfills factor 5-10)
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
Stabilization and Drying process
with the GORE® Cover technology
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
Definition
Stabilization
Bio drying
only part of stabilizing
MSW before landfill
Mechanical Treatment (Separation of
sources)
Biological Treatment – hygienisation,
stabilisation, drying
Fraction < 80 mm, <60 mm or < 40 mm
Duration 21- 77 days (!)
Separate approach fraction > 80 mm in
order to generate RDF (Bio drying) with
its characteristics (size, humidity,
Calorific Value)
Land filling of stabilized organic (AT4, AT7,
IR1000, BMW100, GP21 etc.
Process of composting biodegradable
waste – Heat – by forced aeration
Evaporate Surface Water and humidity of
the biomass (loss of humidity – reduction
of weight)
Average 5 - 21 days (size !!!)
Increasement of Calorific Value
RDF accord. To Dir. 2000/76 CE
Short time process
No stabilization
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE Fabrics Division
Solid Waste Treatment
Biodrying or drying history with Partners
1994
2001
2003
2004
Frist Drying of waste BioE, Italy
Portoguaro, RDF production
Hungary, Baja 12 kta
Largest WTE Plant 200.000 tpy, Neumünster, Germany, Biodegma
production 150 kta of RDF, 14,5 MJ
2004
2010
2011
2012
2013
Miscolcz Study on RDF USING Laminates
Plants in Hungary starting RDF production
Cement Industry request in Poland (3 plants)
Catania plant started operation, production of CDR
Additional Plant established in Poland
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
ŚLADEM ODPADÓW Z EQUIPO
BOA
Bailing
Overscreen
fraction
> 80 mm
Collection of
MSW
Sorting
Vecoplan
Biodrying
RDF
Vecoplan
Drum dryer
Cement plant
< 80 mm
Underscreen
fraction
0/80 mm
Biostabilisation
Landfilling
0/80 mm
AT4 <10 mg
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
Definition RDF and legal background
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
Warszawa
approx. 180.000 tpy
Material size
0/300 mm
Input humidity
55 - 60 %
Pre treatment
sorting, separation fraction 0/80 mm
Treatment time:
63 days
Turning
two times
Output humidity:
25 – 30 %
AT4
<10 mg O2 kg/DM
Further treatment
Land filling
0/80 mm fraction
Construction time:
4 months for the biological process
Owner
Community
Price:
tipping approx 50 €/t
Landfill tax
4-5 €/t 20/80 mm stabilized fraction
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
Warszawa 34 heaps 40 x 8 x 2,7
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
Warszawa – stabilizing the 0/80 mm fraction AT4
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
Biodrying of the 80/300 mm fraction
Material size
80/300 mm
Input humidity
~ 40 %
Treatment time:
14 days
Turning
none
Output humidity:
< 20 %
Further treatment
Post grinding
< 30 mm fraction
Burning value:
15/18 MJ (due to sep collection)
Construction time of the plant: 4 months
Owner
private
Customer
CEMEX / Kujawy
Price:
8-10 €/t of dried material
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover Biodrying
Separate installation, Poland
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover Biodrying
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
Drying steps
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover Biodrying
Poland
Material size
80/300 mm ??
Input humidity
~45 %
Treatment time:
21 days
Turning
none
Output humidity:
< 20 %
Further treatment
Screen
<20 mm to be used as landfill recovery
Post grinding
< 30 mm fraction
Burning value:
15/18 MJ (due to sep collection)
Owner
private
Customer
KUJAWY (end-user of the bio dried material)
Price:
7-11 €/t of dried material
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
Recycling Park 150.000 tons per year MSW + SOW
Total input at the front gate:
150.000 tpy , Hungary, Zohid
~300.000 inhabitants
Input:
MSW Municipal Solid Waste and SOW
Waste from separate collection
Pre treatment (Recyclables):
75.000 tpy
Separation of PET, Plastic, Glass,
Paper/Cardboard, FE/NE in total > 50%
– sold to the recycling market
RDF (Refuse Derived Fuel):
20.000 tpy
energetic use, cement industry
Mass reduction MSW:
SOW:
10.000 tpy
10.000 tpy
Landfilled at the end of process
35.000 tpy
Construction time:
weight reduction during biological process
Production of high end quality compost
1,3 t/m³ of material (!)
11 months for two plants (Mechanical Pre Treatment,
biological part and post treatment, two landfills)
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
GORE® Cover MSW application
Recycling Park, MSW at the tipping floor
© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
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GORE® Cover
Recycling Park 160.000 tons per year MSW + SOW
Reception, pre treatment building
Fraction < 100 mm forwarded to GORE® Cover
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
Recycling Park 160.000 tons per year MSW + SOW
Fraction < 100 mm after GORE® Cover
Fraction 30 - 100 mm after screening
Post grinding < 30 mm fraction RDF
< 30 mm RDF
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
Zöld Hid Regio Kft, Municipal Solid Waste (separate collection included)
Start of Operation: July 2010
MSW
150.000 t/year
Pre-treatment:
Shreddering /Screening
< 100 mm
Humidity: 45 - 55 %
Calorific Value: 5 - 6 MJ/kg
> 100 mm
Humidity 15-30%
Calorific Value: 17 MJ/kg
Treatment GORE® Cover:
21 days
Humidity:
Calorific value:
< 30 mm
< 25%
<7 MJ/kg
Landfill
Treatment GORE® Cover:
8-10 days
30 – 100 mm
Humidity:
18-22 %
Calorific Value: 16-17 MJ/kg
RDF sold to Cement Industry
Humidity: 10-20%
Calorific Value: 22 MJ/kg
RDF sold to Cement Industry
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
Recycling Park 620.000 tons per year MSW
Total input at the front gate:
Input:
620.000 tpy , Italy, Sicily
MSW (no separate collection)
Pre treatment:
Separation of PET, Plastic, Glass,
Paper/Cardboard, FE/NE in total > 50% of
the input material – sold to the recycling market
Input towards Biological treatment:
~310.000 tpy
Mass reduction MSW:
~90.000 tpy
weight reduction during biological process
RDF (Refuse Derived Fuel):
~70.000 tpy
energetic use, cement industry
Input towards landfill at the end
~150.000 tpy
(> 25 mm fraction)
Construction time:
20 months – not finished yet (incl. Mechanical Pre
Treatment, biological part and post treatment)
Surface (Receptioin, Meachanical pre treatment area)
Surface biological treatment area (GORE® Cover)
Surface post treatment
- 1.000 m²
Invest mechanical pre treatment
Invest biological part
- 10.000 m²
- 14.400 m²
- 21,0 M €
- 11,7 M €
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
Typical layout of a GORE® Cover MBT
Reception encapsulated
Reception
Pre treat
Separation
Sorting
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
Typical layout of a GORE® Cover MBT
Encapsulated pre treatment
Reception
Pre treat
Separation
Sorting
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
Typical layout of a GORE® Cover MBT
Recycables and pre treatment
Reception
Pre treat
Separation
Sorting
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
Typical layout of a GORE® Cover MBT
Organic fraction after pre treatment towards drying, stabilizing
Reception
Pre treat
Separation
Sorting
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
BioE - GORE® Cover
1.200 tpd = 375.000 ton per year Biological Treatment Stabilizing, Drying
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
BioE - GORE® Cover
1.200 tpd = 375.000 ton per year Biological Treatment Stabilizing, Drying
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
BioE - GORE® Cover
1.200 tpd = 375.000 ton per year Biological Treatment Stabilizing, Drying
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
UBA – Umweltbundesamt Case Study 2009
• Carbon Credits
• CO2 equivalent from single production facilities in
reference to the used composting technology
• NH3, CH4, Laughing Gas considered for CO2
• Reception, Mechanical treatment, Intensive Rot,
Maturation, Storage etc. according to the specifics fo the
systems
• Tunnel, Container, Building, Membrane, open windrow
• Cycle from Reception to final compost
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover system
• Tunnel, Container, Building, open windrow, Membrane
• Cycle from Reception to final compost
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
CO2 Equivalent from single production facilities
in reference to the used composting technology
150
Anl.+MA
Rec.+
Mech.
VFermentation
(Gärprod)
HR- Fresh
(FrischK)
IR
Compost
Maturation
NR (FertigK)
- Finished Compost
Storage
ZwLager
phases
CO2-Äquivalente, kg/Mg
125
16-20
weeks
100
16-20
weeks
8
weeks
75
8
weeks
50
3
weeks
25
0
KOA g, tg
(Bio+Grün)
(FrischK)
Building, Tunnel
KOA g, tg
(Bio+Grün)
(FertigK)
Building, Tunnel
KOA sM
(Bio+Grün)
Membrane
KOA o
(Bio+Grün)
KOA o
(Grün)
Open Windrow Open Windrow
KOA V+NR
(Bio+Grün)
Fermentation
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
UBA – Umweltbundesamt Case Study 2009
• It clearly indicates that static composting with positive
aeration using the semi permeable membrane has the
lowest possible emission rate compared to the other
technologies. In this case study, windrows at different
age stages of the decomposing process were taken into
consideration.
• The study demonstrated that use of membrane
technology reduced emissions from an industry average
of 47kg per tonne to 12 kg per ton.
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
Recycling Park 160.000 tons per year MSW + SOW
Total input at the front gate:
160.000 tpy , Hungary, Györ
~270.000 inhabitants
Input:
MSW Municipal Solid Waste and SOW
Waste from separate collection
Pre treatment (Recyclables):
55.000 tpy Separation of PET, Plastic, Glass,
Paper/Cardboard, FE/NE in total > 50%
– sold to the recycling market
RDF (Refuse Derived Fuel):
27.000 tpy energetic use, cement industry
Mass reduction MSW:
SOW:
28.000 tpy
20.000 tpy
weight reduction during biological process
Production of high end quality compost
Landfilled at the end of process
<30.000 tpy 1,3 t/m³/m² of material (!)
Construction time:
20 months (incl. Mechanical Pre Treatment,
biological part and post treatment, 7 ha landfill)
Surface (Receptioin, Meachanical pre treatment area)
Surface biological treatment area (GORE® Cover)
Surface post treatment
Invest total plant incl. Landfill
- 5.000 m²
- 6.300 m²
- 700 m²
- 20,3 M €
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
Typical layout of a GORE® Cover MBT
After biological treatment
Reception
Pre treat
Separation
Sorting
Overscreen – landfill or further separation
Fraction <12 mm Compost Like Output
(CLO)
High Calorific Fraction (RDF
material)
© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
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GORE® Cover
MSW after
drying
process
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
MSW – example LANDFILL REMEDIATION
Capacity:
110.000 tpy
Started:
2000 - 2007
Aim:
Stabilisation of the organic – usage of the
calorific fraction for incineration
• Landfill remediation due to contamination of the ground water in
the adjacency of Venetia
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
110.000 tpy Landfill remediation in Italy
Potential future application …
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
Landfill polluting the ground water at basis
Potential future application …
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
Excavating of the MSW from the landfill – grinding at site and
Potential future application …
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
Biological process under GORE® Cover
Potential future application …
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
After the treatment separation into fine organic fraction that is stabilized
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
And light fraction for the energetic use
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
MSW – Waste To Energy (WTE) Plattform
Germany: 210.000 tpy
Requirement:
14,5 MJ/t, 150 kta
max 1% chlorine
< 80 mm
Goal:
WTE
Time:
28 days
Supplying 17.000 homes with
energy and heat
Start:
May 2004
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
Neumünster
Operating since:
May 2004
Mechanical biological waste treatment – Process
Waste receiving
Shredding
Screening
Fraction > 80 mm:
Combustible treatment
Screening, Shredding, Metal
separation
Fraction < 80 mm
Metal separation,
Mixing and Moisturizing
PROCESS
Intensive rot (3-4 weeks)
Controlled, aerated
Fine / medium
fraction with
high energy
TEV
© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
After treatment
Screening, air separation,
density separation
Sand, Glass, Stones, Hard Materia
Light fraction – ~10 mj
Deposition
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WTE
GORE® Cover MSW experience drying / stabilization
Main advantages of Gore® Cover technology
• Odour reduction
greater 90% - high efficiency - VOC reduction
• Sustainability
in the market for 15+ years and growing strongly
long lasting time of the GORE Cover –
• Reputation
excellent – no failure in plants
• Treatment time
shortest, most secure and sustainable
• Space reduction
40.000 tpy, 3 weeks treatment time, <4.000 m² pure treatment area
• Operational cost
Investment cost
e.g. 40.000 tpy plant, 3 weeks, 2 (4) workers, little energy consumption
3,00 – 5,00 €/t on the GORE technology on a 10 y basis on GORE® Cover system
Solid track record
MSW (landfill, energetic use), SOW, BS, LR...
• Encapsulated System approval in more than 20 countries, BAT
• Diversity
from on-floor to total encapsulation...
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
GORE® Cover
GORE® Cover system
Limitation – GORE® Cover technology treatment
Throughput
> 2.000 tons per day on one single plant
Volume per module
150 m³ - 1.000 m³ of input material
Dimensions:
max 9 m in the width max 50,0 m in length and max 3,5 m in height
Climate
- 25°C on a permanent level requires higher performing system (cost)
Drying
from 7 to 21/28 days depending on input humidity (< 20% output humidity e.g. 4
weeks if input humidity is > 50%)
And
no miracles – waste treatment takes time! (RG, AT4, IR1000, BMW100...)
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential
www.kompostanlagen.de
Franz Vogel
UTV AG
Tel: +49 7223 8001505
info@kompostanlagen.de
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© UTV AG Am Alten Römerpfad 2 76534 Baden-Baden /// Company Confidential