The Urban Nexus Da Nang/Vietnam June, 26 2014 Dipl.-Ing ... 2...Aerobic waste water treatment Anaerobic waste water treatment Digestion of solid waste ... Landfill from 1973 - 2005:

Da Nang June, 26th 2014

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The Urban Nexus Da Nang/Vietnam June, 26th 2014

Dipl.-Ing. (FH) Martin Schaub WEHRLE Umwelt GmbH

[email protected]

www.wehrle-umwelt.com

Licence Partner ofMYT Business Unit

WEHRLE’s history in MBT Technology

2002

1980

1927–2005

1920

End 19. Cty

1860

Transfer of the Environmental Branchof WEHRLE-WERK AG into thesubsidiary company WEHRLE UmweltGmbH (WUG), Foundation of WEHRLEChina

Begin of business in the field of Environmental Protection Technologies (Waste Water Treatment, Sludge Treatment) in a WEHRLE-WERK AG branch

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

Transformation into a stock corporation“WEHRLE-WERK AG”

Begin of manufacturing of low pressureboilers

Foundation of the locksmith’s trade"Wilhelm Wehrle"

Milestones in the history of the WEHRLE-WERK AG and

WEHRLE Umwelt GmbH

2Da Nang June, 26th 2014


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. €



Environmental Technologies of WEHRLE Umwelt GmbH

Membrane bioreactor (BIOMEMBRAT®)

EGSB reactor (BIODIGAT® SB)

WEHRLE Loop Reaktor (WLR)

Mechanical biological treatment of mixed solid waste (MYT)

Sequencing-Batch-Reactor (SBR)

Activated Carbon plant

Ammoniak stripping plants

Mechanical biological treatment of mixed solid waste (Dry

Digestion)Mechanical biological treatment of

high organic waste (Wet Digestion)

Membrane units (Ultra-, Nanofiltration, Reverse Osmosis)

Aerobic waste water treatment

Anaerobic waste water treatment Digestion of solid waste

Physical–chemical watertreatment

Anaerobic Filter (BIODIGAT® AF)

Anaerobic (BIODIGAT® AS)4



Municipal Solid Waste KahlenbergZAK-Concept

Biologcical decomposition

Anaerobic digestionAerobic waste

water treatment

Mechanical separation

Electric current

Biological drying

Off-gas treatment

Inerts Solid recovered fuel

Metalseparation

Mechanicalpretreatment

Paper, packaging

Heat

Co-generation

MixedMSW



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

WEHRLE‘s history in MBT Technology



Percolation Pilot Plant

Company: ZAK, Ringsheim

Location: Kahlenberg, Germany

Input: 1 ton/dayMunicipal Solid Waste (MSW)

Year: 1997















Percolation Demonstration Plant



Input: 20,000 tons/yearMunicipal Solid Waste (MSW)

Year: 2000















Biological Drying Pilot Plant




Year: 2002















MYT® Plant „MBT Kahlenberg“




Year: 2006















BIODAMP Pilot Plant Thailand

Company: WEHRLE Umwelt GmbH

Location: Petchaburi, Thailand

Input: 3 tons/dayMunicipal Solid Waste (MSW)

Year: 2010















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18The grounds of the Zweckverband Abfallbehandlung Kahlenberg


19Landfill from 1973 - 2005: Disposal of about 6 Mio. tons of waste


20The landfill after renaturation: Habitat for many rare animals and plants


21Conservation area and goal for family outings

Merops Apiaster


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Zweckverband Abfallbehandlung Kahlenberg (ZAK)

• ZAK is a special purpose association formed in a legal communalcooperation between the counties Emmendingen(EM) andOrtenaukreis (OG)

• ZAK is based in Ringsheim (Germany)

• ZAK serves 570,000 residents -> producing about 100,000 tons ofhousehold waste per year

• ZAK‘s function: Waste management of the delivered waste viarecycling, maximum yield extraction of biogas & RDF and disposal


23Location of the ZAK in Germany

ZAK

State of Baden-Württemberg


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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


26View of the Demonstration-Plant


27Waste breakdown

Biogas

MBT

RDF

Metals

Minerals

Water

Rest

Losses

Ben

efit

/ Val

ue fo

r use

constituents

Household Waste


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Mechanical – Biological Waste TreatmentMBT – Kahlenberg


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Process steps of the MBT Kahlenberg: Mechanical Preparation


30

Building 1: Waste acceptance bunker - approx. 100,000 tons household waste per year from 570,000 residents


31Building 2: View of the mechanical preparation step


32Heavy mineral fraction sorted out


33„Can scrap“


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Process steps of the MBT Kahlenberg: Biological Conversion


35

Solids

Press water

Process waterWaste

Agitator

Screw Press

DAMP® - Defined Aerobic Mixing Process


36Aggregates of the Biological Conversion step: DAMP-Reactor

DAMP-Reactor Design Figures:

• 6 concrete DAMP-Reactors

• Filling Volume 250 m³ (each)

• Retention Time in DAMP 2-3 days


37Aggregates of the Biological Conversion step: Agitator

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 theBiological Drying step

elements:

- percolator / DAMP / mixer

- biogas fermenter

- waste water cleaning system

- presses


38Aggregates of the Biological Conversion step: Planetary Gearbox


39

Discharge from the biological conversion step, reduced in size, washed and homogenized


40Aggregates of the Biological Conversion step: Dewatering Press


41Mechnical-physical water treatment


42Aggregates of the biological conversion step: Biogas fermenters

CHP Plant


43

Process steps of the MBT Kahlenberg: Biological Drying


44Aggregates of the Biological Drying step: Drying tunnel

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


45Biological Drying tunnel (equipped with moving-floor)


46Aggregates of the Biological Drying step: Discharge Machine


47Aggregates of the Biological Drying step: Conveyors und dischargemachine, completely enclosed and evacuated


48Output 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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facility buildings (machine halls)

collected exhaust air (point sources and buildings)

drying tunnels

supply airventilation

DAMP / MZR

alkaline air scrubbing

acid air scrubbing air moistening

clean air

biofilter

fresh air

excess air

regenerative thermal oxidizer

Air flow concept of the MBT Kahlenberg

enclosures of machinery (point sources)


52Aggregates of the Air Treatment step: Humidifier, waschers


53Aggregates of the Air Treatment step: Bio filters


54Aggregates of the Air Treatment step: RTO

Regenerative Thermal Oxidation (RTO)


55

Process steps of the MBT Kahlenberg: Mechanical Material Separation


56View of the Mechanical Material Separation step

Goals:

• specified, homogeneous RDF

• defined inert material

• scrap metal

Demands on the input material:

• loose, homogeneous and free-flowingmaterial

• specified consistant moisture content(>85 % dry)

• absolute dustproof encapsulation

• trouble free „just in time“ logistics


57Controlling of the separation quality


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MYT® Maximum Yield Technology


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MBT KahlenbergThe important products generated from the treatment

of about 100,000 tons/a of household waste

Plant operating time: 5 days/week, 2 shifts


60

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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BiogasRDF CHP Plant

Power Plants

Cement Plants

Electricity

Heating

Power Grid

Heating Network

BT

Gas Network

BT

Vehicles

Further development of the energy concept

MYT®

Obtain max. Energy potential

Efficient use

of Energy

Energy – and Environmental Management


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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

MYT® works on its own energy and covers its energy needscompletely through the use of regenerative energy sources

25,00030,00040,000

165,000

235,000

0,000

50,000

100,000

150,000

200,000

250,000

Energy potentialtotal

Energy carrierRDF

Energy carrierBiogas

Losses House load MYT®

Ener

gy p

oten

tial /

Hea

ting

valu

e (M

Wh/

a)


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Example MBT Kahlenberg Annual CO2 - savings from about 120,000 tons household waste

- Electricity from Biogas (pp) – RDF instead of coal

Climate friendly electricity and heat is obtained from the energy carriers biogas and high-biomass content RDF

62,000

20,000

0,000

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

90,000

Tons

per

Yea

r

RDF instead of coal Electricity from Biogas (pp)


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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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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.

Well thought out design and tried and proven technology.High operational reliability means long term operational success.

Complete and flexible use of the energy potential. Energy carriers adapted to the needs of the energy user.

Modular concept – using tried and proven machines.Small and large sized plants economically viable.

Experienced specialized companies guaranteean 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 evenin 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 ofMYT Business Unit

Fueling the Future!

Documents

The Urban Nexus Da Nang/Vietnam June, 26 2014 Dipl.-Ing ... 2...Aerobic waste water treatment Anaerobic waste water treatment Digestion of solid waste ... Landfill from 1973 - 2005: