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156 Evaluation of Opportunities for Converting Indigenous UK Wastes to Wastes and Energy AEA/ED45551/Issue 1 10.1.4 International Situation Gasification There are a few projects using the Energos technology for example the plant at Averøy in Norway. The Averøy plant opened in 2000 and processes 30,000 tonnes of MSW each year, the power output of which is used by a neighbouring factory. 289 A further Energos site in Norway is in Forus, receiving 40,000 tonnes per annum of residual waste since 2002. Japan has an established history of gasification, with the first Thermoselect plant built at Chiba in 1999 by Kawasaki Steel Corporation (now known as JFE). There are now seven plants (a total of 16 Thermoselect units) in operation with a total daily capacity of nearly 2,000 tonnes. The availability of the operating plants is about 80%. The syngas produced in the Thermoselect furnace is quenched and cleaned before it is used in gas turbines or engines. The amount of useful gas produced per tonne of MSW processed is much lower than in conventional combustion and steam generation units as cleaning a reducing gas is more complex than for combustion process gas. In the Thermoselect process waste is pushed through a heated tube. The residual char is gasified and the gases mixed, the gasification agent is oxygen which gives a high enough temperature to convert the ash to slag. The mixed gases then pass through a waste heat boiler and scrubber before being burned in a steam boiler. Currently electrical efficiencies are rather low at but the Japanese licensee is carrying out trials using the higher calorific value gases from the reactor with reciprocating engines and fuel cells rather than boilers, which should significantly improve the electrical efficiency of the process. Table 81 Thermoselect facility locations and specifications in Japan City Startup year Design Capacity (tonnes/day) Feedstock Syngas use Power generated Chiba 1999 2 x 165 MSW + Gas engine at steelworks Industrial Waste NA Mutsu 2003 2 x 70 MSW Gas engines 2 x 1.2 MW Kurashiki 2005 3 x 185 MSW + Gas engine at steelworks Industrial Waste NA Isahaya 2005 3 x 100 MSW Gas engines 5 x 1.6 MW Yokushima 2005 2 x 60 MSW Gas engines 0.9 x 2 MW Izumi 2005 1 x 95 Industrial Waste Boiler/Steam Turbine 1.7MW Yorii 2006 3 x 150 MSW + Industrial Waste Boiler/Steam Turbine 10.5 MW Ebara’s TwinRec is a fluidized bed gasification process with ash vitrification, designed for material recycling, energy recovery and detoxification of wastes. 290 This process is capable of treating shredded residues, waste plastics, electrical waste, industrial wastes, MSW and bio-solids. The gasifier allows separates the non-combustible portion, such as metallic proportions of the waste from the combustible portion. The former is recycled as valuable products from the bottom off-stream of the gasifier, and the latter is transferred as ash, char and combustible gas to the second stage. In the second stage, fuel gas 289 Homes to be powered by green power from waste, 16.04.2008, Ener.g, http://www.energ.co.uk/?OBH=490&ID=143 290 TwinRec Gasification and Ash Melting Technology – Now also established for Municipal Waste , A. Selinger, Ch. Steiner and K. Shin EBARA Corporation, WASTE 2003: 4th Int. Symposium on Waste Treatment Technologies, http://www.ebara.ch/downloads/EBARA%20Manuscript%20Sheffield%20IChemE%202003.pdf
Evaluation of Opportunities for Converting Indigenous UK Wastes to Wastes and Energy AEA/ED45551/Issue 1 and combustible material produced from the gasifier are burnt together in a cyclonic ash melting chamber at temperatures between 1350-1450ºC by the addition of secondary air. The particles are then collected on the walls, where they are vitrified and proceed slowly through the furnace. The good quality recovered metal components are sold into the metal markets. The molten glass products fulfil the stringent Japanese soil standard and are sold to the construction industry. The energy content of the shredder residue is converted to electricity and sold to the grid. There are numerous TwinRec Fluidized Bed and Gasification facilities in Japan. Several examples are: • Ube City plant has a capacity of 8.3 tonnes per hour over three process lines and has been commercial operation since 2003. The electricity output of the plant in is 4MW. 291 • Seki City plant has a capacity of 7 tonnes per hour, in commercial operation since 2003, with an electricity output. • Recently, the Kawaguchi plant was started, treating 18 tonnes per hour of municipal solid waste in three process lines (3 x 21 MW). Foster Wheeler, Lahti, Finland Lahti is a small town to the north of Helsinki. The town authority operates a 350MWth coal and natural gas fired CHP installation that provides electricity and district heating for the town. A 50MWth fuel-gas burner, supplied by a circulating fluid bed gasifier (see Figure 20), has been installed in place of one of the pulverised coal burners. A wide range of shredded fuels have been used with considerable success. Typical fuels are sorted domestic waste, tyres and plastic bottles, sleepers, debarker residues and sawdust. The feedstock is blended in an ‘A’ frame storage building with a traversing screw discharge. No gas clean up is used, acid gas emissions are controlled by source separation of the feedstock and dust from the gasifier is carried forward into coal fired boiler and mixes with the coal ash. A detailed case study for this installation and a similar installation at Zeltweg in Austria have been prepared by the IEA Thermal Treatment of Waste Task. 291 Ube, Japan, Plant Sheet, http://www.ebara.ch/downloads/ebara_plant_sheet_ube_twinrec.pdf 157
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