Waste Management & Research: The Journal for a Sustainable Circular Economy

The utilization of solid recovered fuels (SRF) for energy recovery has been increasing steadily in recent years, and this development is set to continue. In order to use SRF efficiently, it is necessary to define quality standards and introduce targeted quality assurance measures. SRF can be used both in mono-incineration and in co-incineration systems, for instance in power generation and cement plants; but as quality requirements differ, it is necessary to unambiguously define the term ‘solid recovered fuel’. The purpose of this article is to provide an overview of the origin, development and the current status of quality assurance for SRF. The basic principles of quality assurance for SRF are explained with reference to the development of the German RAL Quality Assurance System and in addition specifications that have emerged from European standardization work of CEN/TC 343 are analysed.

The waste treatment, particularly the thermal treatment of waste has changed fundamentally in the last 20 years, i.e. from facilities solely dedicated to the thermal treatment of waste to facilities, which in addition to that ensure the safe plant operation and fulfill very ambitious criteria regarding emission reduction, resource recovery and energy efficiency as well. Therefore this contributes to the economic use of raw materials and due to the energy recovered from waste also to the energy provision. The development described had the consequence that waste and solid recovered fuels (SRF) has to be evaluated based on fuel criteria as well. Fossil fuels – coal, crude oil, natural gas etc. have been extensively investigated due to their application in plants for energy conversion and also due to their use in the primary industry. Thereby depending on the respective processes, criteria on fuel technical properties can be derived. The methods for engineering analysis of regular fuels (fossil fuels) can be transferred only partially to SRF. For this reason methods are being developed or adapted to current analytical methods for the characterization of SRF. In this paper the possibilities of the energetic utilization of SRF and the characterization of SRF before and during the energetic utilization will be discussed.

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.

Mechanical processing using predominantly particle size and density as separation criteria is currently applied in the production of solid-recovered fuel or refuse-derived fuel. It does not sufficiently allow for the optimization of the quality of heterogeneous solid waste for subsequent energy recovery. Material-specific processing, in contrast, allows the separation criterion to be linked to specific chemical constituents. Therefore, the technical applicability of material-specific sorting of heterogeneous waste, in order to optimize its routing options, was evaluated. Two sorting steps were tested on a pilot and a large scale. Near infrared multiplexed sensor-based sorting devices were used (1) to reduce the chlorine (Cl) respectively pollutant content, in order to broaden the utilization options of SRF in industrial co-incineration, and (2) to increase the biogenic carbon (C_bio) content, which is highly relevant in the light of the EU emission trading scheme on CO₂. It was found that the technology is generally applicable for the heterogeneous waste fractions looked at, if the sensor systems are appropriately adjusted for the sorting task. The first sorting step allowed for the removal of up to 40% of the Cl freight by separating only 3 to 5% of the material mass. Very low Cl concentrations were achieved in the output stream to be used as solid-recovered fuel stream and additionally, the cadmium (Cd) and lead (Pb) concentration was decreased. A two- to four-fold enriched C_bio content was achieved by the second sorting step. Due to lower yields in the large-scale test further challenges need to be addressed.

Currently, in ten coal-fired power plants in Germany solid recovered fuels from mixed municipal waste and production-specific commercial waste are co-combusted and experiments have been conducted at other locations. Overall, in 2010 approximately 800 000 tonnes of these solid recovered fuels were used. In the coming years up to 2014 a slight decline in the quantity of materials used in co-combustions is expected. The co-combustion activities are in part significantly influenced by increasing power supply from renewable sources of energy and their impact on the regime of coal-fired power plants usage. Moreover, price trends of CO₂ allowances, solid recovered fuels as well as imported coal also have significant influence. In addition to the usage of solid recovered fuels with biogenic content, the co-combustion of pure renewable biofuels has become more important in coal-fired power plants. The power plant operators make high demands on the quality of solid recovered fuels. As the operational experience shows, a set of problems may be posed by co-combustion. The key factors in process engineering are firing technique and corrosion. A significant ecological key factor is the emission of pollutants into the atmosphere. The results of this study derive from research made on the basis of an extensive literature search as well as a survey on power plant operators in Germany. The data from operators was updated in spring 2011.

Cements with good technical properties have been produced in Europe since the nineteenth century and are now worldwide standardized high-quality mass products with enormous production numbers. The basic component for cement is the so-called clinker which is produced mainly from raw meal (limestone plus clay plus sands) in a rotary kiln with preheater and progressively with integrated calciner, at temperatures up to 1450 °C. This process requires large amounts of fossil fuels and is CO₂-intensive. But most CO₂ is released by lime decomposition during the burning process. In the 1980s the use of alternative fuels began – firstly in the form of used oil and waste tyres and then increasingly by pre-conditioned materials from commercial waste and from high calorific industrial waste (i.e. solid recovered fuel (SRF)) – as well as organic hazardous waste materials such as solvents, pre-conditioned with sawdust. Therefore the cement industry is more and more a competitor in the waste-to-energy market – be it for municipal waste or for hazardous waste, especially concerning waste incineration, but also for other co-incineration plants. There are still no binding EU rules identifying which types of SRF or hazardous waste could be incinerated in cement kilns, but there are some well-made country-specific ‘positive lists’, for example in Switzerland and Austria. Thus, for proper planning in the cement industry as well as in the waste management field, waste disposal routes should be considered properly, in order to avoid surplus capacities on one side and shortage on the other

The HOTDISC technology allows the use of Solid Recovered Fuel (SRF) of a coarse grain size in cement rotary kilns. A suitable medium-calorific SRF is produced by mechanical treatment of mixed municipal and commercial waste that was previously used in fluidized bed incineration systems. Through a modification of the production process the quality of the SRF could be improved and its energetic utilization within a cement kiln with an integrated HOTDISC technology was realized. In course of a material flow analysis changes in quality and mass due to planned process changes were simulated on a theoretical basis. Due to a good agreement of the mass and quality prediction with the real data of the material flow analysis conducted after the system implementation it can be stated that by simulation beforehand the security in planning increases while the economic risk can be significantly reduced. Both the material flow analysis as well as practical operational experience confirms that the industrially produced HOTDISC SRF is applicable and can be produced from mixed municipal and commercial solid waste. An improvement in quality of the produced HOTDISC SRF can be shown by positive changes of essential parameters. From a waste management perspective the production and energetic utilization of HOTDISC SRF is reasonable by all means. This is shown by the conduction of an energy and CO₂-balance. A growing international importance of the HOTDISC technology and the increased use of medium-calorific SRF are expected.

This article investigates greenhouse gas (GHG) emissions from commercial and industrial (C&I) waste treatment considering five sector-specific waste compositions and four different treatment scenarios in Germany. Results show that the highest share of CO₂-equivalent emissions can be avoided in each of the analysed industrial sectors if solid recovered fuel (SRF) is produced for co-incineration in cement kilns. Across all industries, emissions of approximately 680 kg CO₂-eq. Mg⁻¹ C&I waste can be avoided on average under this scenario. The combustion of C&I waste in waste incineration plants without any previous mechanical treatment generates the lowest potential to avoid GHG emissions with a value of approximately 50 kg CO₂-eq. Mg⁻¹ C&I waste on average in all industries. If recyclables are sorted, this can save emissions of approximately 280 kg CO₂-eq. Mg⁻¹ C&I waste while the treatment in SRF power plants amounts to savings of approximately 210 kg CO₂-eq. Mg⁻¹ C&I waste. A comparison of the treatment scenarios of the waste from these five sectors shows that waste treatment of the craft sector leads to the lowest CO₂-equivalent reduction rates of all scenarios. In contrast, the treatment of waste from catering sector leads to the highest CO₂-equivalent reduction rates except for direct incineration in waste incineration plants. The sensitivity analysis of the different scenarios for this paper shows that the efficiency and the substitution factor of energy have a relevant influence on the result. Changes in the substitution factor of 10% can result in changes in emissions of approximately 55 to 75 kg CO₂-eq. Mg⁻¹ in waste incineration plants and approximately 90 kg CO₂-eq. Mg⁻¹ in the case of cement kilns.

Although municipal solid waste (MSW) disposal in Europe and other developed countries has led to a widespread production of solid recovered fuel (SRF) and its incineration in various technical combustion processes, such developments have not yet occurred that widely in developing and transitional economies. This article puts mass-burn technologies and SRF into a China perspective, reviewing issues from technology application problems to emerging trends and future perspectives. Over the last two decades, growing waste volumes have prompted a move to waste incineration, especially in the large densely populated first-tier cities. However, with an organic fraction above 70% and a resulting water content of up to 65%, it is still argued that MSW in China is too moist for incineration. The introduction of mechanical biological treatment (MBT) or mechanical physical stabilization (MPS) technology for SRF production could provide the solution, either by offering further pre-drying options to mass-burn incinerators or by creating SRF to be burnt in co-incineration plants. First experiences of MBT and MPS technologies show promising results in terms of the capacity to deal with organic waste fractions, but the further disposal/utilization of the plants’ output stream has not yet been fully addressed.

To date, Korea has used four species of solid recovered fuels (SRFs) which have been certified by the Environmental Ministry of Korea: refuse-derived fuel (RDF), refused plastic fuel (RPF), tyre-derived fuel (TDF), and wood chip fuel (WCF). These fuels have been used in many industrial boilers. In this study, seven regulatory properties associated with each of the four species: particle size, moisture and ash content, lower heating value (LHV), total chlorine, sulfur, and heavy metals content (Pb, As, Cd, Hg, Cr) were analysed. These properties are the main regulation criteria for the usage and transfer of SRFs in Korea. Different properties of each SRF were identified on the basis of data collected over the last 3 years in Korea, and the manufacturing process problem associated with the production of SRFs were considered. It was found that the high moisture content of SRFs (especially WCF) could directly lead to the low LHV of SRFs and that the poor screening and sorting of raw materials could cause defective SRF products with high ash or chlorine contents. The information obtained from this study could contribute to the manufacturing of SRF with good quality.

By using waste materials as alternative fuels in metallurgical plants it is possible to minimize the traditionally used reducing agents, such as coke, coal, oil or natural gas. Moreover, by using waste materials in the metallurgical industry it is feasible to recover these materials as far as possible. This also represents another step towards environmental protection because carbon dioxide emissions can be reduced, if the H₂ content of the waste material is greater in comparison with that of the substituted fuel and the effects of global warming can therefore be reduced. In the present article various solid recovered fuels and their applications in the metallurgical industry are detailed.