Cheng 2007
Cheng 2007
Cheng 2007
7510 9 ENVIRONMENTAL SCIENCE & TECHNOLOGY / VOL. 41, NO. 21, 2007
FIGURE 1. Schematic diagram of the incineration facility (a) and integrated feeder and dryer (b).
The coarse dust was separated from the flue gas by two Table 1 summarizes the key parameters of the grate-CFB
cyclone units with a gas-solid separation efficiency of 98- incinerator and the power generation system of the Chang-
99%, which were constructed with fire-resistant and wear- chun MSW power plant. Full-scale testing of the waste-to-
resistant materials. Thereafter, acidic gases (HCl, Cl2, and energy facility was conducted between August and November
SO2) in the flue gas were removed through a dry scrubber, 2005 to examine the operating characteristics of the grate-
where a slurry of hydrated lime was sprayed into the hot flue CFB incinerators. Emissions of air pollutants were also
gas to absorb the pollutants. The heat of the flue gas was measured to check the performance of the air pollution
used to evaporate all the water droplets, leaving a non- control equipments. The sampling and analysis of particulate
saturated flue gas to exit the scrubber. Activated carbon could matters, CO, O2, SO2, NOx, HCl, Hg, Cd, Pb, and dioxins, in
also be added, if necessary, for the removal of dioxins and the flue gas at the inlet of the stack were carried out according
some heavy metals (e.g., mercury). The resulting dry material, to standard methods specified by the State Environmental
including fly ash, was collected in a downstream particulate Protection Administration of China (16), following procedures
control device (a fabric filter). The cyclone collector and fabric similar to those used by Liu and Liu (10). Loss on ignition
filter were designed to catch approximately equal volumes of the bottom ash was measured at 600 ( 25 °C for 3 h to
of dust; this configuration reduced the cost while maintaining determine the completeness of combustion.
a high overall dust removal efficiency. The bottom ash drained
from the furnace bottom and the fly ash collected in the Results and Discussion
particulate matter control devices were conveyed to a storage Incinerator Performance. Under typical operating condi-
silo. The purified flue gas was exhausted to the atmosphere tions, MSW with a water content of ∼50% was fed at a rate
through a stack. of 180 kg/min to each grate-CFB incinerator. The thickness
VOL. 41, NO. 21, 2007 / ENVIRONMENTAL SCIENCE & TECHNOLOGY 9 7511
TABLE 2. Mass Balance of Two 260 Ton/Day Grate-CFB Incinerators for MSW Incineration (in 24 h)a
fuel (ton/day) fly ash (ton/day)
date MSW lignite bottom ash (ton/day) from cyclone from fabric filter solid residue to fuel ratio (%)
Aug 5, 2005 406 143 81 32 37 27
Aug 19, 2005 415 133 78 31 42 28
Nov 14, 2005 491 121 78 27 43 24
Nov 15, 2005 502 135 77 22 31 20
Nov 16, 2005 478 115 78 26 22 21
av 458 129 78 28 35 24
a Hydrated lime and activated carbon added for pollution control end up as fly ash, and their masses are included in the solid residue.
TABLE 3. Fuel (MSW and Coal) Consumption of Changchun MSW Power Plant and Electricity Generation in 2005 and 2006
operation period July to Sept, 2005 Oct to Dec, 2005 Jan to June, 2006 July to Dec, 2006 total
MSW incinerated (ton) 28831 35013 70380 66945 201169
lignite burned (ton) 10471 11431 18341 20132 60375
coal equivalent (29 300 kJ/kg) consumed (ton) 4789 5228 8388 9208 27613
coal equivalent to MSW fuel ratio 0.17 0.15 0.12 0.14 0.14
total fuel (coal + MSW) energy (million kWh) 72.85 83.69 150.97 153.60 461.10
electricity generated (million kWh) 9.85 11.52 23.49 22.68 67.53
fuel-to-electricity generation efficiency (%) 13.5 13.8 15.6 14.8 14.6
electricity supplied to public grid (million kWh) 7.40 8.96 18.63 18.01 53.00
electricity consumed within facility (million kWh) 2.45 2.56 4.86 4.67 14.54
ratio of net electricity generation (%) 75.1 77.8 79.3 79.4 78.5
of the MSW layer (bulk density: ∼350 kg/m3) on the drying Comparison of the sizes of the bed materials and the solid
grate was 0.35 m, and the residence time was 11.5 min. residues from the grate-CFB incinerator with those from a
Thermal radiation from the furnace to the MSW layer was conventional coal-fired CFB boiler is shown in Table S3 of
640 kW. Assuming that 90% of the heat was absorbed by the the Supporting Information. The bed materials, bottom ash,
water in the MSW, this could cause evaporation of 7.6% of and fly ash all had larger size ranges in the grate-CFB
water in the MSW. Another 0.8% reduction in the moisture incinerators as compared to those of the coal-fired CFB boiler.
content of the MSW could be brought by drying air This could be attributed to the heterogeneous nature of the
(∼150 °C) passing through the MSW layer. The heat generated MSW and the fact that the wastes were not shredded before
due to local pyrolysis and combustion of MSW on the drying incineration. The bottom ash and fly ash are excellent civil
grate raised the temperature of MSW to 200-500 °C at the engineering materials for the construction of buildings and
exit end of the integrated feeder and dryer. Measurements roads, such as cement admixtures, concrete admixtures,
show that the moisture content in the MSW was typically walling material, road material, and construction backfill (20,
reduced to less than 10% before entering the combustion 21). After the separation of ferrous materials, the bottom ash
chamber (data not shown). Therefore, the combined effect and fly ash from the waste-to-energy facility were utilized
of heat radiation, drying, pyrolysis, and combustion during for the production of commercial floor tiles. Overall, MSW
feeding significantly reduced the moisture content of the incineration at the Changchun MSW power plant could save
MSW, making combustion of MSW with a high moisture more than 0.2 million m3 landfill space each year.
content possible. Table 3 summarizes the MSW incinerated and coal
In the CFB furnace, the solid fuels (MSW and coal) were consumed at the waste-to-energy facility in the second half
suspended by upward-blowing jets of air during the com- of 2005 and in 2006 as well as the electricity generation. The
bustion process. The combustion furnace and flue gas two grate-CFB incinerators incinerated 201 169 tons MSW
from July 2005 to December 2006. A total of 60 375 tons lignite
temperatures were controlled in the range of 800-900 °C,
was also consumed as supplementary fuel during this period.
with a flue gas residence time of no less than 2 s. Destruction
Coal apparently constituted 23.1% of the total fuel mass
of dioxins and other organochlorines was rapid at this
because the energy content (mean calorific value: 13 400
temperature range (17). Incomplete combustion and dioxin
kJ/kg) of the burned lignite is less than half of that of standard
formation would occur at lower temperatures (18, 19), while
coal equivalent (29 300 kJ/kg). When converted to the coal
NOx began to form at higher temperatures.
equivalent, the coal equivalent to MSW fuel ratio was only
Mass balance of the grate-CFB incinerators was charac- 0.14. A total of 67.53 million kWh electricity was generated
terized from August to November 2005. Table 2 shows the from the combustion of the MSW and lignite from July 2005
rates of fuel consumption and solid residue production of to December 2006. The overall fuel-to-electricity efficiency
the facility. Loss on ignition of the bottom ash ranged from was approximately 14.6%, which is less than half of the
0.3 to 1% in many random samples, which is indicative of average efficiency (33-35%) of modern coal-fired power
near complete fuel combustion. On average, the ratio of solid plants. This value is comparable to the actual plant efficiencies
residue to fuel mass was 24%, with a slightly greater (low 20% range) of biomass fueled power plants (22). There
production of bottom ash than fly ash. One reason for the are several reasons for the low efficiency of the waste-to-
high solid residue to fuel ratio was that poor quality lignite, energy facility. The capacity (6 MW) of the MSW power plant
having low heat values of 11 700-15 500 kJ/kg and ash is rather low as compared to coal-fired power plants that are
contents of >35%, was used as the supplementary fuel. typically in the 100-1500 MW range. A small capacity plant
Another factor is that MSW in Changchun contained a such as this one tends to be lower in efficiency because of
significant fraction (11.3%) of non-combustibles, as shown economic trade-offs (i.e., efficiency-enhancing equipment
in Table S1 of the Supporting Information. Incineration led cannot pay for itself in this case). The high moisture content
to an overall reduction of MSW and coal mass by 76%. (∼50%) in the MSW and increased excess air with feeding of
7512 9 ENVIRONMENTAL SCIENCE & TECHNOLOGY / VOL. 41, NO. 21, 2007
MSW further reduced the incinerator’s efficiency. If MSW
TEQ is defined as TEQ ) Σ(concentration of dioxin congeners × TEF), where TEF is the toxic equivalent concentration, defined as the relative potency of different dioxin congeners as compared to TCDD (2,3,7,8-
a Emission standards given in ref 16. b Analysis methods used for these pollutants are the standard ones set by the State Environmental Protection Administration of China. c Values for lead, cadmium, mercury,
and their compounds include both solid and gaseous phases. d Below the respective method detection limit. e According to ref 33. f Dioxin concentrations are corrected to dry gas, 11% O2, 0.1 MPa, and 273 K conditions;
and lignite were assumed to have identical fuel-to-electricity
0.2
0.1
1.6
1.0
80
75
<0.001d
<0.01d
<0.05d
170.3
0.086
40.1
63.0
16.4
<0.05d
136.9
0.220
25.4
80.1
13.6
the flue gas was also highly effective for the removal of dioxins
(and mercury and other heavy metals as well). Overall,
emissions of all air pollutants were much lower than the
national standards, indicating that the acidic gases, heavy
particulate matters (mg/m3)
NOx (mg/m3)
SO2 (mg/m3)
Cdc (mg/m3)
Pbc (mg/m3)
CO (mg/m3)
facility. The facility receives 30.00 Yuan RMB for each ton of
MSW disposed from the municipal government and 0.94 Yuan
RMB for each kilowatt-hour of electricity supplied to the
public electric grid from public utilities. The gross revenue
of the Changchun MSW power plant was approximately 38.6
VOL. 41, NO. 21, 2007 / ENVIRONMENTAL SCIENCE & TECHNOLOGY 9 7513
million Yuan RMB in 2006, 89.3% of which came from the waste-to-energy industry is growing quickly in China
electricity sales. (32).
As compared to the incineration facilities operating China is now the world’s second largest consumer of
imported equipments, domestic-built MSW power plants energy and third largest importer of oil. Waste-to-energy
such as the one described here are much more cost-effective. incineration, which is technically energy recovery rather than
An imported 600 ton/day waste-to-energy facility (2 × renewable energy per se and is being considered primarily
300 ton/day incinerators and 2 × 4.5 MW generators) costs for its ability to reduce the volume of waste requiring landfill
450-500 million Yuan RMB. In contrast, a comparable facility disposal, can play a small but not insignificant role in power
with domestic equipment designed by Tsinghua University generation. The challenge of MSW disposal and the demand
costs only 180-200 million Yuan RMB. For incineration for alternative energy sources are not unique in China; many
facilities designed and constructed in China, the costs of other developing countries face a similar situation. It is
operating and maintenance (training, fuel, and personnel) expected that the waste-to-energy technology described here
are both much lower as compared to the imported ones. The can also be a promising alternative to other developing
operating costs for imported incineration systems are 210- counties.
240 Yuan RMB/ton; if the maintenance costs are added, the
operating and maintenance costs ranged from 310 to 340 Note Added after ASAP Publication
Yuan RMB/ton (10). The operating cost of MSW incineration Reference 34 was modified in the version published ASAP
in the Changchun MSW power plant was only 50-60 Yuan October 4, 2007; the corrected version was published ASAP
RMB/ton (depreciation cost not included), and the main- October 5, 2007.
tenance cost was around 20 Yuan RMB/ton, which are
comparable to those of other domestic-built incinerators Supporting Information Available
(10).
Additional information on MSW characteristics generated
Perspective of Waste-to-Energy in China. Along with the in selected cities in China in comparison with those of other
continued urbanization in China, the quantity of MSW countries, elementary analysis of MSW from selected cities
generated increases rapidly. By 2015, MSW generation is of China, and comparison of mean diameters of the bed
expected to reach 179 million tons in China, and 60-70% of materials and solid residues from the grate-CFB incinerators
the MSW is to be disposed of in waste management facilities with those from a coal-fired CFB boiler.
(31). If 20% of the MSW generated is to be disposed of by
incineration, incineration facilities with a total capacity of
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