Wet shaking table operating parameters optimization for maximizing metal recovery from incineration bottom ash fine fraction.

Municipal solid waste incineration bottom ash has emerged as a secondary source of valuable metals, including aluminum and copper. Specifically, the fine fraction, with a particle size less than two millimeters, exhibits average grades of 2.5 g/kg for copper and 10.0 g/kg for elemental aluminum. Gravimetric concentration equipment, such as wet shaking tables, is widely used in the mining and recycling industries to concentrate materials based on density. However, the optimization of these devices typically relies on a trial-and-error approach. This paper presents a statistical model that optimizes the crucial working parameters of the wet shaking table for recovering elemental aluminum in a light product mineral matrix and copper in a high-density product. The statistical analysis highlights that upper values of shaking amplitude are beneficial for both the recovery and grade of copper and aluminum in the obtained products. Conversely, variations in other parameters, such as wash water or desk tilt, yield contrasting effects on grade and recovery. By precisely adjusting the working parameters of the device, the analyses demonstrate that copper enrichment of up to 45 times can be achieved in the product smaller than 500 µm and up to 15 times in the 500-2000 µm product, resulting in the recovery of approximately 65 % of the total copper.

Tool for optimization of energy consumption of membrane-based carbon capture.

The reduction of CO2 emissions is a very challenging issue. The capture of CO2 from combustion processes is associated with high energy consumption and decreases the efficiency of power-producing facilities. This can affect the economy and in specific cases, such as waste-to-energy plants, also their classification according to legislation. To allow the minimization of energy consumption, an optimization tool for membrane-based post-combustion capture was developed. The approach allows finding optimal membrane properties, membrane areas, and pressures for individual separation stages from the point of view of energy consumption. The core of the approach is represented by a mathematical model of the separation system that is based on a network flow problem. The model utilizes external simulation modules for non-linear problems to enable finding globally optimal results. These external modules approximate non-linear dependencies with any desired precision and allow using different mathematical descriptions of individual membrane stages without making changes to the model. Moreover, it allows easy substitution of the external module by experimental data and the model can be easily modified for specific purposes such as decision making, designing the separation process, as well as for regulation of process parameters in the case of dynamic operation. The ability of the model to optimize the process was verified on a case study and the results show that the optimization can significantly reduce the energy consumption of the process. For separation of 90% of CO2 at the purity of 95% from initial flue gas with 13% CO2 with state-of-the-art membranes based on the Robeson upper bound and three-stage process, the minimum power consumption was 1.74 GJ/tCO2 including final CO2 compression.

Metal recovery from incineration bottom ash: State-of-the-art and recent developments.

Municipal solid waste incineration (MSWI) is one of the leading technologies for municipal solid waste (MSW) treatment in Europe. Incineration bottom ash (IBA) is the main solid residue from MSWI, and its annual European production is about 20 million tons. The composition of IBA depends on the composition of the incinerated waste; therefore, it may contain significant amounts of ferrous and non-ferrous (NFe) metals as well as glass that can be recovered. Technologies for NFe metals recovery have emerged in IBA treatment since the 1990s and became common practice in many developed countries. Although the principles and used apparatus are nearly the same in all treatment trains, the differences in technological approaches to recovery of valuable components from IBA - with a special focus on NFe metals recovery - are summarized in this paper.

Legal situation and current practice of waste incineration bottom ash utilisation in Europe.

Almost 500 municipal solid waste incineration plants in the EU, Norway and Switzerland generate about 17.6 Mt/a of incinerator bottom ash (IBA). IBA contains minerals and metals. Metals are mostly separated and sold to the scrap market and minerals are either disposed of in landfills or utilised in the construction sector. Since there is no uniform regulation for IBA utilisation at EU level, countries developed own rules with varying requirements for utilisation. As a result from a cooperation network between European experts an up-to-date overview of documents regulating IBA utilisation is presented. Furthermore, this work highlights the different requirements that have to be considered. Overall, 51 different parameters for the total content and 36 different parameters for the emission by leaching are defined. An analysis of the defined parameter reveals that leaching parameters are significantly more to be considered compared to total content parameters. In order to assess the leaching behaviour nine different leaching tests, including batch tests, up-flow percolation tests and one diffusion test (monolithic materials) are in place. A further discussion of leaching parameters showed that certain countries took over limit values initially defined for landfills for inert waste and adopted them for IBA utilisation. The overall utilisation rate of IBA in construction works is approximately 54 wt%. It is revealed that the rate of utilisation does not necessarily depend on how well regulated IBA utilisation is, but rather seems to be a result of political commitment for IBA recycling and economically interesting circumstances.

Fertilizer and Soil Solubility of Secondary P Sources-The Estimation of Their Applicability to Agricultural Soils.

The demand for phosphorus (P) sources is increasing with the growing world population, while objections to direct agricultural use of waste P sources, such as sewage sludge, are being raised. Therefore, the need arises to employ safe and efficient secondary P fertilizer sources, originating from P-rich wastes. These recycling sources are commonly tested in accordance with the current fertilizer rules, designed originally for conventional apatite-based P fertilizers. The behavior of sewage sludge ash, an inorganic recycling secondary P source, was investigated under soil-like conditions. Standardized soil P tests, including the soil buffering capacity test and the Olsen, the Mehlich3, and water extraction methods, were employed together with standardized fertilizer P-solubility tests by neutral ammonium citrate and 2% citric acid extraction. In addition, total content and the overall soil mobility of selected metallic elements present in sewage sludge ash were investigated. The suitability of standardized soil tests for the evaluation of recycling P sources was shown. An apparent influence of Ca:Al content ratio on sewage sludge ash behavior under different soil-like conditions shows the inadequacy of the current fertilizer test and the necessity to understand soil-like behavior of secondary P sources, when considering these as possible agricultural P bearers (fertilizers).

Material analysis of Bottom ash from waste-to-energy plants.

Bottom ash (BA) from waste-to-energy (WtE) plants contains valuable components, particularly ferrous (Fe) and non-ferrous (NFe) metals, which can be recovered. To assess the resource recovery potential of BA in the Czech Republic, it was necessary to obtain its detailed material composition. This paper presents the material composition of BA samples from all three Czech WtE plants. It was found that the BA contained 9.2-22.7% glass, 1.8-5.1% ceramics and porcelain, 0.2-1.0% unburnt organic matter, 10.2-16.3% magnetic fraction, 6.1-11.0% Fe scrap, and 1.3-2.8% NFe metals (in dry matter). The contents of individual components were also studied with respect to the BA granulometry and character of the WtE waste collection area.

Possibilities of mercury removal in the dry flue gas cleaning lines of solid waste incineration units.

Dry methods of the flue gas cleaning (for HCl and SO2 removal) are useful particularly in smaller solid waste incineration units. The amount and forms of mercury emissions depend on waste (fuel) composition, content of mercury and chlorine and on the entire process of the flue gas cleaning. In the case of high HCl/total Hg molar ratio in the flue gas, the majority (usually 70-90%) of mercury is present in the form of HgCl2 and a smaller amount in the form of mercury vapors at higher temperatures. Removal of both main forms of mercury from the flue gas is dependent on chemical reactions and sorption processes at the temperatures below approx. 340 °C. Significant part of HgCl2 and a small part of elemental Hg vapors can be adsorbed on fly ash and solid particle in the air pollution control (APC) processes, which are removed in dust filters. Injection of non-impregnated active carbon (AC) or activated lignite coke particles is able to remove mainly the oxidized Hg(2+) compounds. Vapors of metallic Hg(o) are adsorbed relatively weakly. Much better chemisorption of Hg(o) together with higher sorbent capacity is achieved by AC-based sorbents impregnated with sulfur, alkali poly-sulfides, ferric chloride, etc. Inorganic sorbents with the same or similar chemical impregnation are also applicable for deeper Hg(o) removal (over 85%). SCR catalysts convert part of Hg(o) into oxidized compounds (HgO, HgCl2, etc.) contributing to more efficient Hg removal, but excess of NH3 has a negative effect. Both forms, elemental Hg(o) and HgCl2, can be converted into HgS particles by reacting with droplets/aerosol of poly-sulfides solutions/solids in flue gas. Mercury captured in the form of water insoluble HgS is more advantageous in the disposal of solid waste from APC processes. Four selected options of the dry flue gas cleaning with mercury removal are analyzed, assessed and compared (in terms of efficiency of Hg-emission reduction and costs) with wet methods and retrofits for more efficient Hg-removal. Overall mercury removal efficiencies from flue gas can attain 80-95%, depending on sorbent type/impregnation, sorbent surplus and operating conditions.

The effect of transient operations on the levels and congener profiles of PCBz, PCPh and PCDD/F in raw flue gases of MSWI plant.

The concentrations and congener profiles of polychlorinated benzenes, phenols, dibenzo-p-dioxin and dibenzofurans, measured in raw flue gases of a real MSWI plant, are discussed in this paper. The data covers steady-state and transient operation conditions, including the memory effect period close to two shutdowns. The highest levels of concentrations of the pollutants were observed the first day after the shutdown with subsequent gradual decrease towards steady-state values. The conditions of the steady-state period prior to shutdown are decisive for the increase of start-up values, memory effect values and memory effect length. We found that the above-mentioned pollutants had a different length of the memory effect period. It can be concluded that under plant transient operation the formation of pollutants by the de novo synthesis is higher than under steady-state conditions.

Properties of municipal solid waste incineration ashes with respect to their separation temperature.

Fly ashes generated by power and heating plants are commonly used in the production of building materials in some countries, mainly as partial replacement of cement or aggregates in concrete. The ashes from municipal solid waste incinerators can be applied in a similar way. However, their chemical and mineralogical composition, granulometry and toxic constituents have to be taken into account. In this paper, four types of municipal solid waste incinerator (MSWI) ashes produced by the modern MSWI facility in Liberec, Czech Republic, were investigated. The relationship between the particular ash properties (morphology, chemical composition) and its separation temperature in the incinerator line is discussed. A coal fly ash (class F) is characterized as well, for a comparison because its utilization in building industry is more developed. The studied MSWI ashes exhibit high concentration of chlorides and sulfates which is an unfavourable feature for a potential concrete admixture. On the other hand, three of four ashes are found to be pozzolanic active and certain hydration reactions are indicated.

Effect of fuels and domestic heating appliance types on emission factors of selected organic pollutants.

This study reports on the first complex data set of emission factors (EFs) of selected pollutants from combustion of five fuel types (lignite, bituminous coal, spruce, beech, and maize) in six different domestic heating appliances of various combustion designs. The effect of fuel as well as the effect of boiler type was studied. In total, 46 combustion runs were performed, during which numerous EFs were measured, including the EFs of particulate matter (PM), carbon monoxide, polyaromatic hydrocarbons (PAH), hexachlorobenzene (HxCBz), polychlorinated dibenzo-p-dioxins and furans (PCDD/F), etc. The highest EFs of nonchlorinated pollutants were measured for old-type boilers with over-fire and under-fire designs and with manual stoking and natural draft. Emissions of the above-mentioned pollutants from modern-type boilers (automatic, downdraft) were 10 times lower or more. The decisive factor for emission rate of nonchlorinated pollutants was the type of appliance; the type of fuel plays only a minor role. Emissions of chlorinated pollutants were proportional mainly to the chlorine content in fuel, but the type of appliance also influenced the rate of emissions significantly. Surprisingly, higher EFs of PCDD/F from combustion of chlorinated bituminous coal were observed for modern-type boilers (downdraft, automatic) than for old-type ones. On the other hand, when bituminous coal was burned, higher emissions of HxCBz were found for old-type boilers than for modern-type ones.

Matrix effects on the de novo synthesis of polychlorinated dibenzo-p-dioxins, dibenzofurans, biphenyls and benzenes.

The formation of polychlorinated dibenzo-p-dioxins, dibenzofurans, biphenyls and benzenes in de novo synthesis experiments have been studied on model fly ashes with a wide range of matrices. The model fly ash consisted of 18 selected matrices with the addition of CuCl(2) x 2H(2)O, activated charcoal and NaCl. The studied matrices were not restricted to the commonly investigated matrices with defined chemical composition (silica gel, alumina, florisil) and industrially produced adsorbents with silicate structures (diatomaceous earths), but also included natural occurring matrices (clays, kaolin, bentonite and feldspars). In addition fly ashes from a hazardous waste incinerator were included in the study for comparison. Differences in the isomer composition (homologue profiles and isomer patterns) of the substances formed by de novo synthesis experiments are discussed in dependence on the chemical composition of the studied matrices. The de novo synthesis experiments on matrices with silicate structures resulted in high concentration of mainly perchlorinated aromatic compounds while for other matrices in particular alkaline matrices a homologue shift to lower chlorinated homologues and lower formation rates were found. The paper discusses the resulting PCDD/PCDF pattern and compares them to the PCDD/PCDF profile found in naturally occurring kaolin and ball clay (illite).