Continuous in-line gasification/vitrification process for thermal waste treatment : process technology and current status of projects

Abstract The Thermoselect High Temperature Recycling process has been developed in order to make available a thermal waste treatment technology avoiding major problems as known from traditional techniques like landfills or ashes, filter dust and emission producing processes. It combines slow degassing with fixed bed oxygen blown gasification and mineral and metal residue melting in a closed loop system. Municipal, industrial and other kinds of waste are compacted to less than one fifth of their original volume by means of an armored hydraulic press, and then periodically pushed into an indirectly heated degasification channel. As the waste plugs are pushed down the channel in an oxygen-free environment, waste humidity is evaporated and the organic components in the refuse are partially degasified and to a certain extent converted into a carbon-like product as the temperature increases. This flaky product and the enclosed inorganic components such as metals and minerals are continuously fed into a high-temperature reactor (HTR). Pure oxygen is added in controlled quantities and reacts with the material following exothermic oxidisation reactions. Due to overall under-stoichiometric conditions, gasification products form a combustible synthesis gas. The heat of reaction leading to temperatures up to about 2000°C in the core of the lower HTR section acts to also smelt the metal and mineral components of the waste. Chlorinated hydrocarbons such as dioxins and furans are reliably destroyed along with other organic compounds in the gaseous and the liquid phase. Material conversion equilibria are assured due to high temperatures and sufficient residence times. The synthesis gas is purified before use as combustible or primary material. After long term operation of the industrial scale demonstration plant in northern Italy, recent orders of differently sized Thermoselect plants can be announced and are illustrated on the basis of three cases out of five [with Herten 225,000 Mg/a and Berlin 300,000 Mg/a] in Germany: (1) Karlsruhe plant, 3 lines, 225,000 Mg/a, under construction; (2) Ansbach plant, 1 line, 75,000 Mg/a, completely purchased in July 1997; (3) Hanau plant, 2 lines, 90,000 Mg/a, partially purchased in October 1997. The technical concepts of these projects are illustrated with special emphasis on the flexibility of tailor-made energy recovery solutions.