Solid recovered fuels in the cement industry--semi-automated sample preparation unit as a means for facilitated practical application.

One of the challenges for the cement industry is the quality assurance of alternative fuel (e.g., solid recovered fuel, SRF) in co-incineration plants--especially for inhomogeneous alternative fuels with large particle sizes (d95⩾100 mm), which will gain even more importance in the substitution of conventional fuels due to low production costs. Existing standards for sampling and sample preparation do not cover the challenges resulting from these kinds of materials. A possible approach to ensure quality monitoring is shown in the present contribution. For this, a specially manufactured, automated comminution and sample divider device was installed at a cement plant in Rohoznik. In order to prove its practical suitability with methods according to current standards, the sampling and sample preparation process were validated for alternative fuel with a grain size >30 mm (i.e., d95=approximately 100 mm), so-called 'Hotdisc SRF'. Therefore, series of samples were taken and analysed. A comparison of the analysis results with the yearly average values obtained through a reference investigation route showed good accordance. Further investigations during the validation process also showed that segregation or enrichment of material throughout the comminution plant does not occur. The results also demonstrate that compliance with legal standards regarding the minimum sample amount is not sufficient for inhomogeneous and coarse particle size alternative fuels. Instead, higher sample amounts after the first particle size reduction step are strongly recommended in order to gain a representative laboratory sample.

Design and quality assurance for solid recovered fuel.

This contribution describes the processing and the quality assurance of solid recovered fuel (SRF) that is increasingly used in a wide range of co-incineration plants. As an example, the preparation of municipal, commercial and industrial wastes for recovering of two different specifications of waste fuels (i.e. primary burner fuel and hot disc fuel used in cement industry) is reported and the multiple stage processing scheme used in SRF production is presented as well as the quality of SRF obtained. It will be shown, that removing of metals and sorting out of unwanted inert materials like stones, glass and concrete only after disintegration of the waste matrix during several crushing and separation steps can be carried out efficiently. In the following chapters, the quality assurance of SRF is demonstrated and described by using two different scenarios (i.e. different sizes of waste streams with different particle sizes, delivered to a cement plant by walking floor trucks). Based on CEN/TS-guidelines for SRF as well as national norms (ÖNORM), two sampling procedures and sample preparation schemes are elaborated for the scenarios and own practical experiences in quality assessment of heterogeneous waste fuels are reported. Finally, references are given on new, innovative laboratory equipment like cutting mills with attached cyclones and a mobile, hand-sized XRF-instrument for fast identification of extraneous materials removed from the laboratory sample prior to chemical analysis.

Land register of contaminated sites in an industrial Chilean region: identification and evaluation of suspected sites.

This work introduces the outcomes of the first process for the identification and evaluation of sites potentially contaminated in the Region of the Bio Bio, Chile. The methodology combined qualitative and quantitative elements from Austrian and German risk assessment procedures, calibrated and adapted to the Chilean reality. The developed process consists of collecting historical and current registers on soil use, effects of materials handling on the population's health, and the description of the site conditions. The first analytical step corresponds to an image algebra analysis, through which the most vulnerable areas of the region are established. The sites identified inside the most vulnerable areas are classified into five priority classes, giving an approximate degree of endangerment from these sites. Through the experience, from a total of 507 sites identified as suspicious of contamination, five sites were classified under the highest priority. The results of this analysis have allowed Chilean authorities to focus their resources on the detailed investigations to be carried out in the five priority locations, whilst planning the future strategy to follow for the practical management of all sites found as currently posing a risk to the environment and to the society.

Improving the adsorption capacity and solid structure of natural volcanic soil using a foaming-sintering process based on recycled polyethylene terephthalate (PET).

The volcanic soils of southern Chile have demonstrated a high capacity to adsorb environmental pollutants, but for an industrial application, a stable solid material is necessary. The objective of this work was to produce a stable ceramic material through a process involving volcanic soil-polyurethane foam produced with recycled polyethylene terephthalate (PET)-polyols, and further thermal treatment. The selected foam formulation with 35.4% volcanic soil (< 63 microm) seems to be the most suitable for thermal treatment, with temperature steps at 700, 850, 1000 and 1200 degrees C. The porous ceramic material obtained has a stable solid form and an improved chlorophenols adsorption capacity (comparable to natural zeolites) that makes it suitable for advanced wastewater treatment and landfill leachate depuration.

Lessons learned for a more efficient knowledge and technology transfer to South American countries in the fields of solid waste and contaminated sites management.

The present paper describes the development, performance and conclusions derived from three know-how and technology transfer projects to South American countries. The first project comprised a collaborative study by European and South American universities to find sustainable solutions for Chilean and Ecuadorian leather tanneries which had underachieving process performances. The second project consisted of investigations carried out in a Brazilian municipality to enhance its municipal solid waste management system. The final collaborative programme dealt with the initial identification, evaluation and registration of suspected contaminated sites in an industrial region of Chile. The detailed objectives, methods and procedures applied as well as the results and conclusions obtained in each of the three mentioned projects are presented, giving special attention to the organizational aspects and to the practical approach of each programme, concluding with their main advantages and disadvantages for identifying a set of qualitative and quantitative suggestions, and to establish transferable methods for future applications.

Investigations on mechanical biological treatment of waste in South America: towards more sustainable MSW management strategies.

This work presents an analysis on the suitability of mechanical biological treatment of municipal solid waste in South America, based on two previous experimental investigations carried out in two different countries. The first experiment was performed for determining the mass and volume reduction of MSW in the province of Concepción (Chile). The implemented bench-scale process consisted of a manual classification and separation stage, followed by an in-vessel biological degradation process. The second experiment consisted of a full-scale experiment performed in the city of Estrela (Brazil), where the existing municipal waste management facility was adapted to enhance the materials sorting and separation. Expressed in wet weight composition, 85.5% of the material input in the first experiment was separated for biological degradation. After 27 days of processing, 60% of the initial mass was reduced through degradation and water evaporation. The final fraction destined for landfilling equals 59% of the total input mass, corresponding to about 50% of the initial volume. In the second experiment, the fraction destined to landfill reaches 46.6% of the total input waste mass, whilst also significantly reducing the total volume to be disposed. These results, and the possible recovery of material streams suitable for recycling or for preparing solid recovered fuels, are the main advantages of the studied process.

Combined incineration of industrial wastes with in-plant residues in fluidized-bed utility boilers--decision relevant factors.

In Austria more than 50% of the high-calorific industrial residues and wastes generated are utilized for energy recovery in industrial utility boilers. This study investigated full-scale trials of combined incineration of in-plant residues with various industrial wastes. These trials were carried out in order to learn how the alternatively used fuel influences the incineration process itself as well as the quantity and quality of the various incineration products. The currently used fuel, which consisted of in-plant residues as well as externally acquired waste wood and the refuse-derived fuel (RDF) mixtures used during the full-scale trials are characterized in terms of material composition as well as chemical and physical parameters. An input-output mass balance for the incineration plant (two fluidized bed combustion units, 20 and 30 MW, respectively) has been established, based on the data collected during the full-scale incineration trials. Furthermore, pollutant concentrations in the off-gas as well as the solid incineration residue are reported. It is not only the pollutant content but also a variety of other internal as well as external factors that have to be considered if a company is to decide whether or not to thermally utilize specific waste types. Therefore a strengths and weaknesses profile for several types of waste and the specific industrial boiler is also presented.

The use of volcanic soil as mineral landfill liner--I. Physicochemical characterization and comparison with zeolites.

The main physicochemical characteristics of the volcanic soil of Southern Chile, with allophane as the main pedogenic mineral phase were analysed and compared with common zeolites (clinoptilolite) of the European market. The ultimate goal of this study was to test volcanic soil for the use as mineral landfill liner. The main results indicated that the clay and silt fractions together of the volcanic soil were between 38 and 54%. The buffering capacity of the volcanic soil was higher compared with the studied zeolites, whereas the cationic exchange capacity of the volcanic soil (between 5.2 and 6.5 cmol + kg(-1)) is of the same order of magnitude of the studied zeolites (between 9.7 and 11.4 cmol + kg(-1)). Moreover, the anionic exchange capacity of the volcanic soil was higher compared to the zeolites analysed. The hydraulic conductivity of the volcanic soil, measured in the laboratory at maximum proctor density, ranges between 5.16 x 10(-9) and 6.48 x 10(-9) m s(-1), a range that is comparable to the value of 4.51 x 10(-9) m s(-1) of the studied zeolite. The Proctor densities of the volcanic soil are in a lower range (between 1.11 and 1.15 g ml(-1)) compared with zeolites (between 1.19 and 1.34 g ml(-1)). The volcanic soil physicochemical characteristics are comparable to all the requirements established in the Austrian landfill directive (DVO, 2000). Therefore, the use as mineral landfill basal sealing of the analysed volcanic soil appears reasonable, having a pollutant adsorption capacity comparable to zeolites. It is of special interest for Southern Chile, because there are no alternative mineral raw materials for basal liners of landfills.

The use of volcanic soil as mineral landfill liner--III. Heavy metals retention capacity.

The volcanic soil of Southern Chile was tested for its heavy metal retention capacity. The maximum uptakes for CrO4(2-) (CrVI), Cu(2+), Zn(2+) and Pb(2+) were determined to be 2.74, 5.32, 5.86 and 7.44 mg g(-1), respectively. At a slightly alkaline pH value (7.5), it seems that a precipitation-adsorption process was responsible for the Cu(2+) and Zn(2+) uptake onto volcanic soil. All the determined values are of the same order of magnitude as natural zeolites heavy metals adsorption capacities. In addition, the heavy metals diffusion model through a 1 m volcanic soil mineral liner shows breakthrough times of 21.6, 10.2 and 8.9 years, for Pb(2+), Zn(2+) and Cu(2+), respectively, confirming the trend obtained in the adsorption isotherms. The natural volcanic soil of Southern Chile is an interesting material for possible use as landfill mineral basal sealing. It has an appropriate sealing potential (average Kf value of 5.85 x 10(-9) m s(-1)) and a heavy metals retention capacity comparable with natural zeolites. About two-thirds of the agricultural land in Chile (approximately 0.4 million km2) is derived from volcanic ash, suggesting an important soil volume for future landfill projects, that could be obtained in sufficient quantities from urban building activities.