energy from waste

08/04/2

technologies
for future generations.

AE&E AG & Co KG AE&E Inova GmbH AE&E Lentjes GmbH AE&E - Von Roll, Inc. Von Roll Inova Holding AG
www.aee-group.com

Waagner-Biro-Platz Waltherstrasse 51 Daniel-Goldbach-Strasse 19 302 Research Drive, Suite 130 Hardturmstrasse 127

A-8074 Raaba/Graz D-51069 Köln D-40880 Ratingen Norcross, Georgia 30092, USA CH-8037 Zurich
Phone: +43-316 501 0 Phone: +49-221 9682 0 Phone: +49-2102 16 60 Phone: +1-770 613 97 88 Phone: +41-44 277 11 11
Fax: +43-316 501 482 Fax: +49-221 9682 357 Fax: +49-2102 16 62 500 Fax: +1-770 613 98 60 Fax: +41-44 277 13 13
[email protected] [email protected] [email protected] [email protected] [email protected]
www.aee-austria.at www.aee-inova.de www.aee-lentjes.de www.aee-vonroll.com www.aee-vonrollinova.ch companies of AG
 Architecte: M.L. Arsène-Henri, Arsène-Henry et Tribaud
energy from waste
AE&E GROUP – ENERGY FROM WASTE CONTENTS
Thermal waste treatment plant at Perpignan, France.

– ALL FROM ONE SINGLE SOURCE

Combined expertise under one roof: With its companies specializing in thermal waste Energy from Waste 6
treatment, the AE&E Group is one of the world’s leading vendors of waste-to-energy All from one Source 7
systems. Whether you need to install a subsystem or order an entire plant as a turnkey Grate Combustion 8
delivery, require technical support or even want to outsource plant operation, we offer Circulating Fluidized Bed Technology 11
innovative approaches that meet your most demanding requirements in terms of quality, Flue Gas Treatment 12
economics and environmental safety. The AE&E Group is the reliable partner for sound Energy Recovery 14
solutions. Residue Treatment 15
Service and Plant Operation 16
You can rely on us. References 18

Austrian Energy & Environment • AE&E Inova • AE&E Lentjes • Von Roll Inova
energy &
environment
THE AE&E GROUP OFFERS CUSTOMIZED
COMPONENTS, SYSTEMS AND COMPLETE PLANTS.
AN EYE TO THE FUTURE

BOILERS FLUE GAS ENERGY FROM WASTE SERVICES EQUIPMENT With us as your ally, you have the combined knowledge and experience of four renowned
AND PLANTS CLEANING SYSTEMS companies at your disposal: High-tech from A to Z, innovative products and customized
services. Our staff continually analyze your needs to develop state-of-the-art facilities –
designing the future, today. Our forward-looking technology guarantees safe places to live
and non-polluting energy supplies for today and tomorrow.

Fluidized bed Wet and dry flue gas Grate technology Engineering Boiler manufacture
boilers desulphurization
Fluidized bed Maintenance and Coal gasification The leading environmental technology – sustainable, climate-friendly and efficient!
Industrial boilers Wet and dry flue technology servicing contracts
gas cleaning Valves
Conventional boilers Flue gas cleaning Modernization
Liquor recovery SCR/SNCR technology and revamping
boilers Residue treatment
Plant audits and
Heat recovery boilers Turnkey plants optimization
Boilers for Plant operations
grate technology (O&M contracts)
Combined cicled
power plants
Turnkey plants
 ENERGY FROM WASTE ALL FROM ONE SOURCE

06 Safe waste treatment and climate-friendly Innovative, integrated solutions made 07

energy to measure

Thermal treatment is not only the smartest way of We are the first place to come to for anything related
dealing with non-recyclable waste, it also makes the to thermal waste treatment. A full range of technolo-
most economical use of resources and is the most gies on offered from four established companies, plus
environmentally-friendly technology. Recovery of know-how in all relevant processes and experience
energy contained in waste makes it a key part of an accumulated in hundreds of plants all over the world –
integrated energy and environmental policy concept. that’s what makes us unique.

After steps towards avoidance and recycling of waste have Benefit from our combined expertise
been taken, thermal treatment is a final indispensable stage in Our comprehensive know-how guarantees our customers
modern, sustainable waste management. It offers a maximum sound and sustainable solutions both today and tomorrow. In
reduction of all pollutants and cuts waste volume by more than terms of engineering, we offer everything from master con-
90%. In this process, there is no release of pollutants into the cepts, design and construction to commissioning, from a sin-
environment, and valuable commodities such as iron, zinc, gle subsystem to a complete turnkey plant. Our service pro-
gypsum and hydrochloric acid are able to be reclaimed. gram extends from support and maintenance to plant manage-
ment and operation.
The waste-to-energy approach makes it possible to save cru-
cial fossil fuel resources such as coal, oil and gas. What is No other area of environmental engineering requires more use We offer solutions made to measure.
more, since 60% of the energy in waste comes from renew- of highly developed technologies than does that of thermal
able sources, the greatest part of the cycle is CO2-neutral. waste treatment. This holds true for every operation involved,
Additionally, thermal treatment reduces landfill burdens and from waste receiving and storage to combustion with energy
thereby cuts methane emissions, which are extremely harm- recovery, flue gas treatment and handling of residues. When it
Thermal waste treatment plant at Thun, Switzerland. ful to the global climate. In short, energy recovery from waste comes to maximum reliability, high efficiency, environmental
leads to a more-than-proportional reduction in greenhouse safety and process economics, we have the knowledge, the THERMAL WASTE Maximum inertization and reduction
TREATMENT of pollutant levels and waste volumes
gases. Emissions from waste-to-energy plants are as much as products and the experience to get the job done well.
a factor of four below those from conventional power plants.
Capital costs – the lowest in the renewable energy field – are Customized solutions for every need
FLUE GAS TREATMENT Pollution reduction, low emissions
also favor of this technology. Thermal waste treatment requires customized solutions which
take local circumstances into account at all times. Our wide
1000 kg waste
Waste-to-energy is safe, economical and helps protect our range of technologies and our experience worldwide enable us
environment, natural resources. to offer our customers the right design to meet any requirement, RESIDUE TREATMENT Removal of pollutants, recovery
of recyclables
no matter how complex.

Integrated customized solutions – guarantees instead of com- ENERGY RECOVERY Maximum efficiency in energy
recovery
promises.
2 MWh 0.7 MWh
heat energy From single systems to complete plants, we are your partner.

Waste – a valuable energy source.

 GRATE COMBUSTION

08 Proven technology, continuously improved 09

and optimized

Grate combustion is the most thoroughly tested Variants shaped by experience

technology in the treatment of thermal waste. For With some 500 plants in service, the AE&E Group is a world
over 70 years, this process has been successfully leader in grate combustion. Our customers benefit from the
employed in more than 1000 plants worldwide. most comprehensive know-how in the industry.
Systems have been continuously optimized, upgrad-
ed and adapted to changing constraints and increas- We deliver all components from a single source.
ingly tough standards. Today grate combustion is
the most advanced technology in terms of environ- Reciprocating grate
mental safety, reliability, flexibility and cost-effect- The reciprocating grate is made up of fixed and hydraulically
tiveness. driven moving rows of grate blocks that loosen, stoke and
transport the waste. The grate is also divided lengthwise into
Specially designed for waste treatment, our grate combustion multiple, individually controlled zones.
equipment offers high flexibility with regard to the fuels it hand- For high thermal loads, especially those containing conditioned
les. It is suitable for untreated domestic and industrial waste as waste with higher calorific values, water-cooled grate blocks
well as substitute fuels derived from conditioned waste. ensure optimum burnout and increased life time. The AE&E
Group offers reciprocating grates designed by Von Roll Inova,
Energy-from-waste plant at Dürnrohr, Austria. The grate: reliable, field-tested combustion technology AE&E Inova and AE&E Lentjes. 3-row reciprocating grate.
At the heart of the system is the grate. Waste metered from a
feed hopper is conveyed by the grate through the combustion Roller grate
chamber where it is burned, normally without additional fuels. The roller grate, a specialty of AE&E Lentjes, conveys waste
Primary combustion air is injected below the grate directly into over individually controlled, hydraulically driven rollers. As the
the fuel; secondary air (mixed with recirculated flue gas in rollers turn, the grate bars are continuously cooled outside the
some designs) enters the secondary combustible chamber combustion chamber.
from above the grate. The burned-out slag is discharged at the
end of the grate. The whole process, from waste metering to Maximum energy yield with custom-designed steam generators
grate speed and air supply, is under continuous control to The steam generator located downstream of the combustion
ensure optimum combustion. grate extracts energy from the hot combustion gases in the
form of steam or hot water. Our horizontal and vertical steam
The grate stands out for its robust construction and its resis- generators feature low contamination and good corrosion
tance to strongly heterogeneous waste . resistance, leading to long service life and high energy yields.

Optimized operation through precise control

Our intelligent combustion capacity control systems ensure
reliable automated operation, optimized combustion and con-
sistent heat output regardless of waste composition.
Control of the whole process ensures optimal combustion.
Roller grate.
 GRATE COMBUSTION CIRCULATING FLUIDIZED BED TECHNOLOGY

10 Robust hightech – for all kinds of waste Innovative design and high performance – 11
for maximum flexibility

Grate combustion guarantees the highest level of tech-

nology. One of its outstanding features is flexibility with The circulating fluidized bed used in the PowerFluid®
regard to fuels. The rugged construction of our grates system – a technology of AE&E Austria – is also suit-
allows domestic and industrial waste to be burned with- able for the thermal treatment of pretreated waste. It
out pretreatment. features high thermal capacity, handles a wide range
of calorific values and has pollution reduction integrat-
Thermal waste treatment plants using grate combustion are design- ed into the process.
ed with single or multiple trains, depending on plant size. These
installations can be decentralized systems, which handle waste Forward-looking technology, field-tested and proven
from and return energy to specific regions, industrial plants or even With its PowerFluid® fluidized bed, AE&E Austria offers the
large, centralized facilities. most thoroughly tested technology for this area of application.
The system has the following process-related features:
The proven grate concept has the following features:
Open nozzle grid
Suitable for untreated and pretreated waste Adiabatic primary and secondary combustion chambers
(except for hazardous waste) External cooler for bed material
Sturdy, reliable construction Hot-gas cyclone
Energy-from-waste-plant with grate combustion at Umeå, Sweden. Optimized combustion for maximum burnout and Energy-from-waste plant with circulating fluidized bed boiler at Neumünster, Germany.
extensive pollutant reduction Wide range of fuels for flexible operation
High energy recovery efficiency The inherent behavior of the circulating fluidized bed keeps
Precise control for safe, economical operation combustion efficiency high and emissions low. A single sys-
Extensive pool of experience acquired from tem can treat waste with low and very high calorific values.
hundreds of projects What is more, the combustion unit can process other fuels
such as biomass, sludge and even bituminous coal separately
Our engineers continuously share the experience they have acquir- or together with waste. These qualities ensure high flexibility
ed using various grate systems. In this way, each plant benefits and protect your investment.
from the know-how of the entire AE&E Group. The maximum in
experience with the world’s leading grate combustion process. Essential features of the PowerFluid® fluidized bed technology
for waste treatment include:
Principal data
Fuel: Untreated or pretreated waste Suitability for pretreated wastes up to
Calorific value range: 6 – 18 MJ/kg very high calorific values
Thermal capacity: 16 – 100 MW/train Utmost flexibility through capability of burning
a variety of fuels individually or in combination
Process control for low CO and NOx emissions
High thermal capacity per train
Compact design
Longitudinal section of thermal waste treatment plant. PowerFluid® circulating fluidized bed boiler.
Principal data
Fuel: Pretreated waste (substitute fuels,
rejects, etc.), sewage and paper-mill
sludges, coal, biomass
Calorific value range: 5 – 40 MJ/kg
Thermal capacity: 50 – 150 MW/train
 FLUE GAS TREATMENT

12 Reliable pollution reduction with 13

customized concepts

Flue gas treatment processes, developed in-house, Semi-dry flue gas treatment – simple and effective
remove all pollutants in an efficient, sustainable and The Turbosorp® process removes acidic pollutants from flue
reliable way. Customized concepts enable us to guar- gas by absorption on hydrated lime and heavy metals and
antee emission levels far beyond those of the world’s organic pollutants (dioxins, furans) by adsorption on lignite
toughest pollution standards. coke. No wastewater is discharged. The process stands out
for its compact design, reliable operation and compliance with
Flue gas treatment begins right in the combustion chamber, the strictest emission standards.
which is engineered to prevent most pollutants from being
generated in the first place. Downstream components conform Sodium bicarbonate – for efficiency and low residue levels
Flue gas treatment system at MHKW Mainz waste-to-energy plant, Germany.
with fuel properties, residue disposal practices and emission The sodium bicarbonate process is used wherever residue
limits. quantities must be kept as small as possible. Due to the very
high reactivity of sodium bicarbonate, only a small amount of
A toolbox full of innovative ideas it is required. The process is virtually independent of tempera-
Our documented performance record of about 200 sites, places ture and so offers maximum energy recovery.
us among the world’s top market leaders. Using tested and
innovative components, we design flue gas treatment sys- Denitrification – for conversion of toxic gases
tems optimized for your requirements. Our highly advanced We offer two proven approaches for the removal of nitrogen
flue gas treatment systems are based on interdisciplinary oxides (NOx) produced in combustion: SNCR (selective non-
expertise, the spirit of innovation, and decades of experience. catalytic reduction) and SCR (selective catalytic reduction).
Here is a summary of our key processes: In both processes, ammonia is used to reduce the nitrogen
oxides down to the natural air gases, nitrogen and water vapor.
Multistage wet scrubbing – for pollutant-free flue gases While the ammonia solution is injected directly into the com-
Wet scrubbing is an effective method for removing pollutants bustion chamber for SNCR, the SCR process takes place in a
and heavy metals from flue gas. The multi-stage wet scrubber catalyser.
Flue gas treatment system at AVS Zorbau energy-from-waste plant, Germany. reliably cleans even heavily burdened flue gases. Consumable
rates and residue quantities are minimized. Dioxin removal – adsorption and destruction
Organic toxins like dioxins and furans in flue gas are almost
totally removed by adsorption on activated carbon or lignite
coke or they are destroyed in a DeNOx catalyser.

Turbosorp® semi-dry flue gas treatment.

 ENERGY RECOVERY RESIDUE TREATMENT

14 Energy from waste – economical, reliable Byproducts – recovery of high-quality 15

and efficient substances

Recovery of the energy content of waste is a key Thermal waste treatment is efficient, but it does
aspect of thermal waste treatment. Energy from leave a variety of residues behind. These are however
waste is economically crucial to any sustainable of no real consequence since our processes generate
energy mix. As this process is low in emissions and only substances that with proper handling cannot
renewable to a great extent, it contributes to the release pollutants into the environment. What is
reduction of greenhouse gases. more, further treatment can recover recyclable prod-
ucts as well.
Maximum efficiency guaranteed
Energy of hot combustion gases, in the form of steam or hot Depending on the degree of pretreatment or conditioning,
Electric power – the useful energy completion to any energy mix. Acid fly ash washing recovers valuable zinc from residues.
water, is converted to marketable energy in a way that suits the thermal treatment may produce grate slag, bed ash, fly ash
location and the needs of the customer. and residues from flue gas treatment. These can be further
Of the energy initially contained in the waste, 60-100% is re- reduced through a range of proven processes.
covered (depending on the extraction of the heat contained in
the flue gas by condensation) and made available for use by Slag treatment preserves useful substances
households and industry. One kilogram of waste contains Ferrous and nonferrous metals can be recovered through
some 10,000 kilojoules of energy, enough to burn a 12 W ener- recycling using slag treatment. The slag which remains
gy-saving light bulb for 75 hours. Whether we supply electric meets regulatory quality standards, and most of it can be put
power and/or heat to a city or meet the energy requirements directly to use in the construction industry.
of an industrial plant, waste to energy is environmentally safe,
reliable and economical. Fly ash washing – high residue quality and product recovery
In conjunction with the wet scrubbing of flue gas, fly ash wash-
Energy the way you want it, highly efficient with combined ing can be carried out to extract salts and heavy metals. Zinc
heat and power generation can be recovered and recycled. The treated residues satisfy
Extracted energy is used in the way that best meets the needs the strictest eluate tests and can be safely disposed of in land-
of our customers. Cogeneration, the simultaneous production fills.
of electric power and heat, offers high efficiency and maxi-
mum energy yield. Using the latest technologies, we guaran- Solidification of residues
tee a consistent supply of energy. Untreated or washed residues from flue gas treatment can be
solidified with the aid of hydraulic binders in order to minimize
The choice is yours: pollutant leaching.
Efficient delivery of district and process heat for households and industry.
Heat
Steam or hot water as district heating for households and Wastewater treatment
businesses or as process heat for industrial use The effluent from flue gas scrubbing is purified in several sta- Acid fly ash washing in combination with flue gas scrubbing reduces dioxins.
Electric power ges. Not only are pollutants removed, but pure gypsum can
From steam-driven turbogenerators, for households, busi- also be recovered. As an alternative to the discharge of treated
nesses and industry wastewater, evaporation can be used to produce hydrochloric
Coldness acid or sodium chloride.
A useful energy alternative
 SERVICE AND PLANT OPERATION

16 Rely on us even after your plant 17

has been built

With our range of services from maintenance and Spare parts

modernization to the operation of thermal waste We provide original spare parts directly from stock. Prompt,
treatment plants, we are there for you even after the flexible delivery reduces your downtime and saves you the
start-up of your facility – any time you need us, costs of a spare parts stockroom.
around the clock.
Software solutions
Our plant service is outstanding Our software, developed especially for thermal waste treat-
Our commitment does not cease after the start-up of your plant. ment, ensures optimized operation of your plant and allows for
As a genuine partner, we continue to be at your complete the accurate control of maintenance as well as analysis of op-
disposal whenever you need us. Our range of services ex- erating data.
tends over the full life cycle of your facility.
We are committed . . . Training
With the overall aim of reducing downtime to a minimum, we Well-trained employees are crucial for trouble-free plant op-
deliver on-site support whether it be in the form of service and eration. With our Interactive Training System (ITS) and our own
maintenance, or the upgrading of your plant. simulator, your personnel gain the thorough knowledge neces-
sary for the smooth running of your plant.
You get the services you want, when you want them. Plant-specific training enhances operating reliability.
We can even operate your plant
Maintenance By order of a customer, we will also take on the operation of
We will be happy to carry out the total maintenance of your their plant and carry this out according to economic and envi-
facility. Maintenance and service agreements are available on ronmental principles. Decades of experience have taught us
request. how to engineer and run plants. What is more, we continu-
ously pass on new knowledge to our operating staff.
Plant optimization
Our experienced process engineers and lab specialists analyze Our long-time customers take satisfaction in knowing their
plant operations on-site and return specimens to our laboratory facilities are being run in accordance with the latest technical
for evaluation. Based on their findings, optimization concepts findings and in adherence to all safety regulations. They trust
are proposed and implemented for either your entire plant or us to operate their plants, keep operational availability high,
individual unit operations. and handle both the disposal of waste and the generation of
electric power and heat.
And if something goes wrong …
Malfunctions and unplanned stops can occur even with optimized
maintenance. Our on-site response is prompt, reliable and com-
. . . and competent! petent.

Modernization
The demands for efficient operation continually present new
We ensure safe, economical, environmentally-friendly operation of your plant.
challenges for plant managers. Our integral approaches enable
you to realize the full spectrum of efficiency and performance
improvement.
 REFERENCES

18 Some examples from among the approx. 500 thermal waste treatment plants engineered 19
and built by the four AE&E Group companies bear witness to our worldwide competence.

Lauta, Germany Hannover, Germany Taoyuan, Taiwan Alkmaar, Netherlands

Energy-from-waste plant with Energy-from-waste plant with Energy-from-waste plant with Energy-from-waste plant with
grate combustion grate combustion grate combustion grate combustion

Waste type: domestic and industrial waste Waste type: domestic and industrial waste Waste type: domestic and industrial waste Waste type: domestic and industrial waste
Throughput: 2 x 15 Mg/h Throughput: 2 x 18 Mg/h Throughput: 2 x 28 Mg/h Throughput: 3 x 18.5 Mg/h, 1 x 27.5 Mg/h
Thermal capacity: 2 x 39.6 MW Thermal capacity: 2 x 52.5 MW Thermal capacity: 2 x 75 MW Thermal capacity: 3 x 51 MW, 1 x 75 MW
Energy recovery: electric power Energy recovery: electric power Energy recovery: electric power Energy recovery: electric power
On stream: 2004 On stream: 2005 On stream: 2001 On stream: T1-3: 1992, T4: 2004

Vienna-Pfaffenau, Austria Leuna, Germany Madeira, Portugal Erfurt, Germany

Energy-from-waste plant with Energy-from-waste plant with Energy-from-waste plant with Energy-from-waste plant with
grate combustion grate combustion grate combustion grate combustion

Waste type: domestic and industrial waste Waste type: domestic and industrial waste Waste type: domestic and industrial waste Waste type: refused derived fuels
Throughput: 2 x 16 Mg/h Throughput: 1 x 25 Mg/h Throughput: 2 x 8 Mg/h Throughput: 1 x 9.75 Mg/
Thermal capacity: 2 x 40 MW Thermal capacity: 2 x 76.4 MW Thermal capacity: 2 x 17 MW Thermal capacity: 1 x 26 MW
Energy recovery: electric power and Energy recovery: electric power Energy recovery: electric power Energy recovery: electric power and
district heating On stream: T1: 2005, T2: 2007 On stream: 2003 steam for gas- and steamplant
On stream: 2008 On stream: 2007

Neumünster, Germany Mannheim, Germany Budapest, Hungary Lausanne, Switzerland

Energy-from-waste plant with Energy-from-waste plant with Energy-from-waste plant with Energy-from-waste plant with
fluidized bed technology grate combustion grate combustion grate combustion

Waste type: refused derived fuels, sludge, Waste type: domestic and industrial waste Waste type: domestic and industrial waste Waste type: domestic and industrial waste
coal, oil, gas Throughput: 2 x 25 Mg/h Throughput: 4 x 15 Mg/h Throughput: 2 x 10.5 Mg/h
Thermal capacity: 1 x 90 MW Thermal capacity: 1 x 66.7 MW Thermal capacity: 4 x 35 MW Thermal capacity: 2 x 40 MW
Energy recovery: electric power and Energy recovery: electric power and Energy recovery: electric power Energy recovery: electric power and
district heating process heat On stream: 2005 district heating
On stream: 2005 On stream MK4: 1997 On stream: 2006

Lenzing, Austria Salzbergen, Germany San Vittore, Italy Trondheim, Norway

Energy-from-waste plant with Energy-from-waste plant with Energy-from-waste plant with Energy-from-waste plant with
fluidized bed technology grate combustion grate combustion grate combustion

Waste type: refused derived fuels, plastics, Waste type: domestic and industrial waste Waste type: refused derived fuels, domes- Waste type: domestic and industrial waste
sludge, coal Throughput: 1 x 16 Mg/h tic and industrial waste Throughput: 1 x 15 Mg/h
Thermal capacity: 1 x 110 MW Thermal capacity: 1 x 46.7 MW Throughput: 4 x 12.5 Mg/h Thermal capacity: 1 x 45.8 MW
Energy recovery: electric power and Energy recovery: process steam for Thermal capacity: 4 x 52 MW Energy recovery: district heating
process steam refinery Energy recovery: electric On stream: 2007
On stream: 1998 On stream: 2004