Manejo integral del desarrollo de parques industriales para la generación eléctrica con aguas residuales y residuos solidos

SUSTAINABLE SOLUTIONS FOR THE 21ST CENTURY

“Integration of Water Treatment Systems
with Energy Derived from Municipal Wastes”

Andesco Conference
June 27. 2012
Cartagena, Columbia

Paul Hauck, P.E.
CDM Smith
1715 N. Westshore Boulevard
Suite 875
Tampa, Florida 33607
(813) 281-2900
hauckpl@cdmsmith.com

Presentation Outline

• Introduction
• Emerging paradigms
• Proven waste conversion technologies
• Marriage of WTE and water resources
• Emerging waste conversion technologies
• Synergistic opportunities

2

CDM Smith’s U.S. Waste-to-Energy Experience

3
Introduction

CDM Smith’s Florida Solid Waste Experience

4
Introduction

Intended Consequences of the
Integrated Solid Waste Management Hierarchy

5
Emerging Paradigms

The Three Rs of Recycling…Plus Two!

6
Emerging Paradigms

Modern Waste-to-Energy (WTE) in the US

• WTE disposes of 13% of the nation’s waste (U.S. EPA)
– 86 operating facilities
– 36 million people served
– 27 states
– Generation capacity in
excess of 2,700 MW
– 16 million MWhrs of
renewable power generated annually
– 259 million tons per year currently disposed of in landfills represents
an additional 142,450,000 MWhrs annually (equivalent to 16,261
MW of capacity)
• Most WTE facilities sell electricity to the local grid at lower prices
than Public Works facilities purchase at commercial rates

7
Proven Waste Conversion Technologies

WTE Capacity Factor is Among the Highest of
Renewable / Fossil Energy Options (24/7/365)
• Photovoltaic solar (northern latitudes) 12-15%
• Photovoltaic solar (southern latitudes) 18-20%
• Wind 20-40%
• Thermal solar (parabolic trough) 40%
• Natural Gas Combined Cycle 60-80%
• Biomass 60-85%
• Landfill Gas 80-95%
• Baseload Coal 80-90%
• Waste-to-Energy (WTE) 85–92%
• Hydroelectric 10-99%
Capacity Factor = actual kWhrs produced divided by kWhrs that would have
been produced if operated at design capacity over same period.
8

Modern WTE Trends – Improved Efficiency,
Attention to Aesthetics and Sustainability
•WTE facility expansions and new construction
•Attention to aesthetics/LEED®/innovation
•More stringent emission limits and GHG reporting
Increasing •MSW Higher Heating Value (HHV)
•Boiler/T-G availability
•Use of reclaimed water for cooling
•Gross/net electric generation
•Non-ferrous metal recovery
•Integrated solid waste management/eco-campus

•Resistance to WTE in established communities
•Air emissions
•Reagent consumption
•Water consumption
Decreasing •Lower payments for renewable electricity

9

Dominant WTE Technology in US
is Advanced Massburn Combustion
• ~75% are massburn facilities
• ~ 17% are refuse-derived fuel (RDF) facilities

Massburn WTE requires no pre-processing of MSW
10

Typical Massburn WTE Facility

11

Typical Massburn WTE Flow Diagram

12

Refuse Storage Pit at Massburn WTE Facility

Typically sized for
minimum of 3-days
storage, up to 7-days
maximum

13

Efficiency of Massburn WTE Technology
Results in Minimal Disposal of Residuals

Typical WTE Ash Residue
• 75% weight reduction
• 90% volume reduction

14

Grizzly Scalper “Overs”
(mostly ferrous metal greater than 6-inch size)

15

Metals Liberated by the Combustion Process
Can be Recycled for Additional Revenues
Ferrous metals Non-ferrous metals
everything…including the (aluminum, brass,
kitchen sink bronze, copper, gold,
silver, stainless)

16

Typical Non-ferrous Metals …
Liberated and Recovered After Combustion

Aluminum, brass, bronze, copper, gold, and silver

Dense
aluminum
nuggets
17

Recovered Products from
WTE Bottom Ash (European Experience)

18
InAshCo

Aluminum Products (light non-ferrous)
from WTE Bottom Ash (European Experience)

19
InAshCo

Heavy non-ferrous products
from WTE Bottom Ash (European Expereince)
primarily brass
and copper

20
InAshCo

Florida Waste-to-Energy Facilities
12 Facilities – 607 MW of Renewable Electricity

21

Hillsborough County Resource Recovery Facility
1,800 TPD – 46 MW

Original 1,200-TPD construction: 1987
600-TPD expansion completed: 2009

Compatible with the urban landscape
Commercial/industrial development has occurred around facility over 24 years!
22

Hillsborough County Resource Recovery Facility
1,800 TPD – 46 MW (Located Adjacent to WWTP)

8-MGD WWTP (AWTP)

1,800-TPD WTE

23

Pasco County Resource Recovery Facility
1,050 TPD – 30-MW Electrical

• Construction: 1989-1991
• $90M capital cost

24

Pasco County Florida
Integrated Solid Waste Management Campus

25

Lee County Resource Recovery Facility
1,800 TPD – 58-MW Electrical

• Original Construction 1994
• Original construction: 1994
• 636 TPD Expansion Completed 2006
• 636-TPD expansion completed: 2006
26

Lee County Florida ISWM Campus

27

Construction Underway of 3,000-TPD Massburn
WTE on Palm Beach County Florida Campus

• First new WTE facility
in the US in 16 years!

• Located adjacent to a
2,000 tpd RDF WTE
facility on an
Integrated Solid
Waste Management
Campus


Palm Beach County, Florida
New 3,000-TPD Massburn WTE Rendering
Incorporating Both Sustainability and Aesthetics

29

Proposed 3,000-TPD Massburn WTE Facility
Palm Beach County, Florida 2012

30

New 3,000-TPD Massburn WTE Rendering
Incorporating Rainwater Harvest of First 2” of Rain

2 MG

31

Hennepin County WTE Welcomes
Minnesota Twins into the Neighborhood!

HERC WTE Facility
(1987)

Target Field (2010)

32

Hennepin County WTE Facility…
Compatible with the Urban Landscape!

Hennepin Energy Recovery Center

33

Water – Energy Nexus
Water and Energy are Inextricably Linked!
• Water scarcity is the new paradigm for the 21st century!
• Lower quality water supply sources require higher levels
of treatment
• Higher levels of treatment require greater inputs of energy
– Pumping from greater depths / distances
– Membrane processes require energy for pressure
– Advanced disinfection treatments are often
electrically derived (ultraviolet light, ozone)
• Mutual benefits can be shared between solid waste and
water resource departments!

34
WTE and Water Resources

WTE and WWTP Facilities Make Good Neighbors

12-MGD WWTP (AWTP)

1,800 TPD/46 MW WTE Facility

35

Hillsborough County, Florida Utility Campus
WTE Integrated with Advanced Wastewater Treatment Plant

Municipal Excess Electricity
Solid Waste WTE Sold to Grid (~37 MW)

Electricity ~2.0 MW
Reclaimed ~ 1.1MGD Reclaimed Water Used at WTE Facility
Wastewater

• Cooling tower makeup ~1.02 MGD
• Scrubber dilution water ~ 0.056 MGD
• Plant wash down water ~ 0.011 MGD
• Equipment cooling water ~ 0.006 MGD
• Facility irrigation as needed
• Fire Protection as needed

Wastewater Reclaimed Water
AWTP Distribution System

36

Hillsborough County, Florida
Case Study – WTE and WWTP Synergy
Currently saving taxpayers an estimated
$600,000 a year in energy costs at AWTP
12 mgd AWTP

2 MW
~ 5 MW 1,800 tpd WTE
Facility
Future
37 MW
Currently
Sold to
Grid
Adjacent AWTP powered by energy from WTE (Aug 08), with an additional
5 MW soon to be used for other public works and buildings
37

Significant Potential Savings to Public Works
by Using Electricity from WTE Facility Internally
Potential Net Savings to Public Works
(1,800 TPD WTE with 4 cents / kWh spread)
$16.000.000
Potential Annual Savings

$14.000.000
Current use Future use of
$12.000.000 ~5% of net ~15% of net
$10.000.000 generation generation
$8.000.000
$6.000.000
$4.000.000
$2.000.000
$-
0 20 40 60 80 100
Percent of Electricity Used Internally

38

Additional Public Works Services to be
Powered by WTE in Near Future
Currently Future

• WTE • Warehouse

• AWTP • Jail

• Water • Animal
Treatment Services
Plant
• Elections
• Reclaimed Supervisor
Water Office
Pumps
• Environmental
Laboratory

39

WTE Integrated with WWTP and WTP

Municipal Solid Excess
Waste WTE Electricity
Sold to Grid

Wastewater

Electricity
Reclaimed water for
process and irrigation

WWTP Distribution System
Residuals

Electricity

Reclaimed water for
augmented water supply

Raw Water Potable Water
WTP Distribution
System


WTE Integrated with WWTP (with dewatered biosolids)

Excess Electricity
Municipal Solid WTE Sold to Grid
Waste

Discharge biosolids
directly into refuse pit or
blend with wood chips
Wastewater
Electricity
Reclaimed Water for
process and
Dewatered irrigation
biosolids @
15-20% solids



WTE Integrated with WWTP (with biosolids dried by
solar and non-thermal means)

Waste WTE Electricity
Sold to Grid

Wastewater
Windrow or Biosolids Electricity Reclaimed water
Solar Dryers Drying for process and
irrigation
Biosolids @ 15-
20% solids



WTE Integrated with WWTP (with biosolids dried by
heat via steam from WTE facility)

Waste
WTE Electricity
Sold to Grid
Discharge dry biosolids

Steam
(70 – 95%) directly into

Wastewater
refuse pit

Electricity
Reclaimed water for
Indirect Biosolids process and irrigation
Dryer Drying

Biosolids @
15-20% solids



WTE with WWTP, Anaerobic Digestion (Co-digestion)
& Thermal Drying for Fertilizer Production

Municipal Solid Electricity
Waste WTE Excess
Electricity
Excess dry Sold to Grid

Wastewater

Electricity
biosolids @ 70- Steam
95% solids Reclaimed Water for
discharged directly process and irrigation
into refuse pit

Wastewater Reclaimed
WWTP Water
Excess Biosolids Distribution
Biosolids

Biomethane
Effluent

Fertilizer Thermal
Dryer

Organic Food Waste Excess Biomethane
A/D CNG/LNG
FOG / High Strength Wastes (CO-DIGESTION) Soil Amendment


21st Century Sustainable Utility Campus

Integration of WTE with Water Resources

Solid Waste Excess Electricity to Grid
WTE
Electricity to
Utility Complex

Sanitary Waste Reclaimed Reclaimed Water to Grid
WWTP Water

Wet Potable Water
Excess Stormwater to Grid
Weather WTP
Storage Wells

45

Reclaimed Water Storage Reservoir
Pasco County Florida – Land O’Lakes WWTP

Wet Weather
Storage Reservoir

500,000,000 gallons of
storage constructed in 2009
with 5,000 gpm filtration on
withdrawal system

46

Estimated Size of Water Resource Treatment
Supplied by Electric Power from 1,000 TPD EfW

350 330

300
Million Gallons / Day

250

200
165
150
99
100
50 40
50
7
0
WTP AWWTP @ WTP Brackish WTP Seawater WRF Membrane WTP Thermal
Conventional @ 3,000 kWh per Membrane @ Membrance @ Direct Potable Distillation @
1,500 kWh per MG 5,000 kWh per 10,000 kWh per Reuse @ 12,500 75,000 kWh per
MG MG MG kWh per MG MG

47

Wastewater Treatment Plants Can Be Viewed As
Water/Biosolids/Energy Resource Centers

WTE
Solar and Wind

Organic
Waste
Energy (Heat, Power)

Wastewater

Biosolids & Nutrients
(Fuel & Fertilizer)
Reclaimed
Water

48
Synergistic Opportunities

Campus for Management of Solid Waste,
Recycling, and Water Resources
Reclaimed Water
Recycled
Potable Water Wastewater Yard & Wood Products
Biosolids Compost Facility
Treatment Plant Treatment Plant Waste Processing • compost
• mulch
Electricity • soil amendment
~
Compressed Air

Biosolids
Shredded Yard

Excess
Electricity
Combustibles & Wood Waste
•Chipped Tires
Cooling & Fire Protection •Chipped Wood
Used Tire / Bulky Waste • tire derived fuel
~ Wood & Yard Waste • crumb rubber
Resizing Facility
Electricity
Low Pressure Steam
& Compressed Air WTE
Waste-to-Energy
~
Combustibles
Construction & Demolition
Debris Processing Facility
• sand
• crushed asphalt
M
Not Requiring • crushed concrete

Concrete
Resizing

Gravel

Crushed
Sand,
• metals

Rejects
M
Ash • metals
M Steam Residue WTE Ash • recycled ash
Landfill Leachate to WWTP

Processing
Landfill Gas & Mined

- LF daily cover
Combustible Rejects

M Loop for M
Electricity
~ Facility
Combustibles

- road base
Industrial
Park Tenants
Rejects • plastics
M Electricity
MRF • glass
~ • paper
M • cardboard
Landfill Gas • metals
Reclaimed
Water Reuse Closed C&D / Inert
Active Landfill Ash Monofill
Landfill Landfill

49

STATE EMERGING (Higher Risk) PROVEN (Lower Risk)
of
TECHNOLOGY PILOT SCALE DEMONSTRATION MARKET ENTRY MARKET MARKET
PENETRATION MATURITY

Biomass Co-firing
Fluidized
Direct (utility Stoker
Bed
Combustion boilers)

Small Gasifier/
IC Engine
Biomass
Gasification Gasification –
& Pyrolysis Boilers, Kilns

Pyrolysis and
Depolymerization

Massburn WTE &
Other Conversion Processes 1
Waste-to- RDF Combustion2
Energy
Co- Digestion Anaerobic Digestion

1. Includes RDF gasification, plasma gasification, and pyrolysis
2. RDF = Refuse-derived fuel

50
Emerging Waste Conversion Technologies

(None Yet Commercially Demonstrated in US)
Thermal Processes
• Gasification (thermal, plasma, with or without vitrification)
• Pyrolysis / Torrifaction of biomass
Bio – Chemical Processes
• Anaerobic Digestion (co-digestion of WWTP biosolids and
organic wastes)
• Waste-to-Biofuels (ethanol, methanol, other alcohols)
• Depolymerization (synthetic diesel and gasoline)

51

Biomass-to-Ethanol Production Pathways

Grain Starch

Fermentation
Material
Cane Handling Alcohol
Alcohol
Sugar
& Refining
Refining
Processing

Biomass Cellulose Gasification

52

Ineos Waste-to-Biofuel Project Status
Indian River County, Florida
• CDM Smith supporting role
– DOE grant application: $50M awarded in 2009
– Prepared NEPA compliance/environmental permit applications
– Civil site/facility infrastructure design
• Anticipated startup 3Q 2012 with full production by 4Q 2012

53

Thank You for the Opportunity to Share
…and Imagineer!

Paul Hauck, P.E.
CDM Smith
1715 N. Westshore Boulevard, Suite 875
Tampa, Florida 33607
(813) 281-2900
hauckpl@cdmsmith.com

54
Conclusion

Historical Emission Trends from Large and Small
Municipal Waste Combustors

Pollutant 1990 Emissions 2005 Emissions Percent Reduction
(TPY) (TPY)
CDD/CDF TEQ Basis * 44 15 99+%
Mercury 57 2.3 96%
Cadmium 9.6 0.4 96%
Lead 170 5.5 97%
Particulate Matter 18,600 780 96%
HCL 57,400 3,200 94%
SO2 38,300 4,600 88%
NOx 64,900 49,500 24%

Source: EPA, August 2007
* Dioxin/furan emissions are in units of grams per year toxic equivalent quantity (TEQ), using
1989 NATO toxicity factors; all other pollutant emissions are in units of tons per year

56

Hillsborough County, Florida Case Study
Hillsborough County integrated solid waste management system
• 1,800 tpd Resource Recovery Facility (EfW)
• Two Transfer Stations with citizen drop off facilities for bulky waste, white goods, yard and wood waste
• Central processing facility for yard and wood waste (recycled as mulch, soil amendment or biomass fuel)
• Community Collection Centers (5) for drop off of solid waste materials
• Household Chemicals and Electronics Collection Centers (3) for citizen drop of materials (not available to
commercial customers)
• Waste Tire Processing Program (shredded into chips <2” in size) for recycling as alternate daily cover or
supplemental fuel at the EfW facility
• Class I raw waste landfill (179 acres)
• Collection services are provided by three private franchised contractors throughout the unincorporated
areas of the County:
– Residential collection of solid waste twice a week
– Residential collection of yard waste once a week
– Residential collection of curbside recyclables once a week (cardboard, newspaper, and mixed
paper; plastic and glass bottles, steel and aluminum containers)
• Posted FY 2011 full costs for the Solid Waste Management System are:
– Residential collection: $136.23 / HH / year
– Residential disposal: $94.94 / HH / year
– Residential recycling: $10.89 / HH / year
– Landfill disposal tipping fee: $63.96 / ton
– Tire disposal: $82.61 / ton
– Yard and wood waste disposal: $31.52 / ton

Hillsborough County RRF Fuels
Unacceptable Fuels Acceptable Fuel

Lead acid batteries Confidential documents

Hazardous waste Contraband

Nuclear waste Wood pallets

Radioactive waste Used tires (up to 3% monthly)

Sewage sludge C&D debris

Grease, scum, and grit Oil spill cleanup, used oil filters and
motor oil
Explosives, beryllium containing Items suitable for human, plant, and
wastes, asbestos floor covering animal consumption (foodstuffs, feeds,
pharmaceuticals)
58

Trend of MSW Higher Heating Value (HHV)
at Hillsborough County Florida EfW

59

Hillsborough County Florida EfW
FY 2011 Environmental Performance

60


61


62


63


64


65


66


67

Estimated Value of WTE Carbon Offsets

Based upon WTE availability of 90%, 0.25 ton CO2e/ ton
MSW, and $10.00 per ton CO2e
$3.000.000

$2.500.000

$2.000.000

$1.500.000

$1.000.000

$500.000

$-
0 500 1000 1500 2000 2500 3000
Size of WTE Facility (tons per day)
68
WTE Massburn Economics

Estimated Cost of Electricity from Massburn
WTE
Cost of Electricity Without Tipping Fee
$0,250

$0,200
$ / Wwh

$0,150

$0,100

$0,050

$-
0 500 1000 1500 2000 2500 3000 3500
WTE Facility Size (TPD)


US Massburn WTE Capital Cost History

$600.000 Existing Facility

PBC New WTE
$500.000 Proposed
Proposal
($ per Ton per Day Capacity)

RDF Prices
$400.000
Capital Cost

$300.000

Winning
$200.000
price
$100.000

$-
1975 1980 1985 1990 1995 2000 2005 2010 2015
Start of Construction


Water Consumption:
Wet versus Dry Cooling Systems

Air Cooled Condenser

City of Tampa Energy from Waste Facility
1,000 TPD – 22.5 MW
• Rebuilt as EfW: 1985
• Retrofit for CAAA: 1998-2001

Portions of this
facility are 35
years old and on
their third life!

72

Pinellas County Resource Recovery Facility
3,000 TPD – 75-MW Electrical Output

• 1,000-TPD expansion: 1987

This facility is 27
years old and
recently refurbished

73

WWTP, Biosolids, and Power Also Integrated
into Pasco County ISWM Campus
ASH MONOFILL

WTE
SCALES

MRF

Peaking
Biosolids
Stabilization Power
Plant
WWTP
(4 mgd)

74

Proposed Visitors Center

75

PBC New WTE Project – Sustainability Options
Recycled Water Supply Sources


PBC New WTE Project (2012)
Continuing the Trend to Lower Emission Limits
Emission Unit US EPA MACT PBC WTE Permit Limit
Units Mg/dscm 7% O2
Particulate 20 12
Cadmium 0.010 0.010
Lead 0.140 0.125
Mercury 0.050 0.025
Sulfur Dioxide 30 24
Hydrogen Chloride 25 20
Carbon Monoxide (4 hr) 100 100
Nitrogen Oxide (24 hr) 150 50

Nitrogen Oxide (annual) 90 45*
Dioxin/Furan ** 13 10
**ng/dscm 7%O2 * Month

Potential Annual Net Savings to Public Works
@ 4 Cents/kWh Spread

$30.000.000
Potential Annual Savings

500 TPD WTE
$25.000.000
1000 TPD
$20.000.000 WTE
1500 TPD
$15.000.000 WTE
2000 TPD
WTE
$10.000.000
2500 TPD
WTE
$5.000.000
3000 TPD
WTE
$-
0 20 40 60 80 100
Percent of WTE Electricity Used Internally

78

Municipal Utility Campus – Energy from Waste
WTE Integrated with WWTP (without biosolids)

Municipal Solid Excess Electricity
Waste WTE Sold to Grid

Wastewater

Electricity Reclaimed Water for
process and irrigation



Pasco County Southeast WWTP
Reclaimed Water Reservoir Filtration Skid

• 5,000 GPM
Filtration Skid

• Two parallel arrays
of “turbo-disc”
filter cartridges

• Backwash
discharged to ???

80

Regional Biosolids Processing Facility

81

Municipal Utility Campus
Optimizing Energy and Water Production
Water and electricity production can be
varied by time of day to meet peak demands

Electricity

Water Water

Electricity Water
Water
Production Production
Electricity Electricity

Off Peak Peak Electric Off Peak
Demand

Time of Day

82

Future WTE Plants Can Include Addition of
Material Recovery and Recycling Processes

Options for Recycling: Options for WTE
1. Single Stream MRF Basement Area:
2. Multi Stream MRF 1. Maintenance Shop
3. Mixed Waste MRF 2. Ash Processing
4. C&D Recycling 3. Special Recycling

Recycling WTE
Waste Basement Basement Area

Recycling Processes Tipping Building Refuse Building Boiler Building Air Pollution Control Bldg. Stack

83

Site Layout for Future
Integrated Solid Waste Management System
(Massburn WTE with Anaerobic Digestion, Composting,
C&D Recycling, and E-Waste Recycling)

Fabric Fabric Stack Fabric Fabric
Filter Filter Filter Filter
Electrical
Switchyard Fly Ash
Conveyor
SDA SDA SDA SDA
Ash
Processing
Bottom Ash Building
Turbine-Generator Combustor Combustor Combustor Combustor Conveyor
Building No. 1 No. 2 No. 3 No. 4

Food
Admin Control Municipal Solid Waste
Waste
Offices Room Refuse Pit
Pit
SDA
Anaerobic
Digestion
Maintenance &
Warehouse Elevated MSW Tipping Floor/Building Facility
SDA
Building Compost Facility Below

Entrance Ramp Exit Ramp

E-Waste
C&D Recycling Building
Recycling


US Department of Energy
Office of Energy Efficiency
and Renewable Energy 2005 New Industry – BioRefinery
PRODUCTS
Fuels:
– Ethanol
– Renewable Diesel
– Renewable Gasoline
– Hydrogen
S
U Power:
G – Electricity
A – Heat (co-generation)
R
Chemicals
or – Plastics
– Solvents
H
– Chemical Intermediates
Y
Biomass D Conversion – Phenolics
R – Adhesives
Feedstock O Processes – Furfural
C – Fatty Acids
– Trees A – Acetic Acid
R
– Enzymatic Fermentation – Carbon Black
– Grasses – Gas/Liquid Fermentation
B – Paints
– Agricultural Crops O – Acid Hydrolysis/Fermentation – Dyes, Pigments, and Ink
– Agricultural Residues N
– Gasification – Detergent
S – Etc.
– Forest Residues – Pyrolysis
– Animal Wastes Food, Feed, Fuel,
– Combustion
– Municipal Solid Waste Fiber, & Fertilizer
– Co-firing
85

Only Time Will Tell…
Enhanced Revenues of Ethanol from MSW
• Potentially 2-3 times the revenue stream of electricity

86

Manejo integral del desarrollo de parques industriales para la generación eléctrica con aguas residuales y residuos solidos

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