Global economics of bottom ash processing

CEWEP EAA Seminar From Ashes to Metals

5th 6th Sept. 2011 Copenhagen

Dr.- Ing. Ulrich Kohaupt Consultant to EAA

Outline:
-! General Conditions -! Technologies -! Flow sheet example -! Mass and value flow, earnings -! Costs, Investments -! Break-even -! Additional flow-sheets -! Conclusions
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Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

Municipal Solid Waste in Europe basic assumptions

People: Waste amount: 45% of all waste landfilled: 37% of all waste mechanically treated: 18% of all waste incinerated: Mass reduction: Incineration: Bottom Ash (BA) mass EU: Example used in this presentation: 11,25 mio t/a 50 t/h, which 120.000 t/a is the equivalent of: 480.000 t BA/a or 960.000 t inhabitants 3 500 mio (EU 27) 250 mio t/a = 0,5 t/a* Inhabitant 112,0 mio t/a 92,5 mio t/a 45,0 mio t/a 75%

Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

Metal Contents and Metal Values in Bottom Ash

Range Average percentage in percentage BA [%] in BA [%] metal distribution [%] Theoretical potential total values [!/t BA]

Metal

Value [!/t]

min Iron, ferrous 5 15% 10,00% 0,50% 1,50% 12,00% 83,33% 4,17% 12,50% 100,00% 80 500 500

max 300 1500 1500

min 8 2,5 7,5 18

max 30 7,5 22,5 60

Stainless Steel 0 0,8 % Non Ferrous NF SUM 0,5 3 %

Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

The generated economic added value depends on: a)!The availability of the required technology b) The willingness to make strategic investments

Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

Bottom Ash Treatment: 4 different scenarios

Available technologies - suspension magnet - magnetic drum - eddy current separator ECS - Inductive Sensoring - liberation Process scenarios 1) START: magnet, 1 screen, 1 ECS

2) DEVELOPED: magnets, 2 Screens, 2 ECS 3) ADVANCED: magnets, 2 screens, 3 ECS

4) INNOVATIVE: magnets, 2 screens, 3 ECS, 2 Inductive sorting, crushing circuit

Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

1) START: on coarse ferrous and non-ferrous recovery

Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

2) DEVELOPED: multiple screening, ferrous & non-ferrous recovery

Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

3) ADVANCED: multiple screening, ferrous & non-ferrous recovery

Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

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Example Developed Process

Total Investment needed for 50 t/h flow-sheet (2 screens, 2 magnets, 2 ECS)

Operating days per hours per month: Year: 20 2.400 number of Sum Invest units [!] 1 2 75.000 140.000

Flow rate per hour [t/ tonnage per hours per h]: year [t/a]: day: 50 120.000 10 Conveyor !* 50.000 50.000 Separation Machine !* technology Suspension magnet, 25.000 rectifier Magnetic drum, 20.000 feeder Eddy Current Separator, feeder 85.000 (Middle , + Low Frequency) 2 Screen 200.000

description Financing years 5 15.000 28.000 % 5% 1.875 3.500

50.000 50.000

2 1

270.000 250.000

54.000 50.000

6.750 6.250

total Sep Tech: 485.000 Plus Diverse costs 50% on Invest: TOTAL Invest [!]: 242.500 727.500 48.500 195.500 6.063 24.438

*= assumed costs

Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

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Example Developed Process

Assumed energy consumption and total energy costs per year

Power installed each machine

Total power

power consumption

Energy costs !/ kWh 0,08

Separation Technology Suspension magnet, rectifier Magnetic drum, feeder Eddy Current Separator, feeder (Middle , + Low Frequency) screen

kW 6 3 10 20

kW 6 6 20 20

kWh/ a 14.400 14.400 48.000 48.000

! 1.152 1.152 3.840 3.840

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Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

Total Power consumption Total Energy costs per year [kWh/ per year [!] a] 124.800 9.984

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Developed Process: Earnings and Costs (basis: 50 t/h)

30 25

Earnings, costs per ton [!/t]

20
Costs [!/t] DEVELOPED

15 10 5 0 0% 50% 100% 150% 200% 250%

100% mean a market with: 80!/t iron; 500 !/t Non--Ferrous

relative Metal value

Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

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Start Process: Earnings and Costs (basis: 50 t/h, Ferrous and coarse NF-metals)
30 25

Earning, costs per ton [!/t]

20 15
Costs [!/t] START

10 5 0 0% 50%

relative Metal value

100%

150%

200%

250%

100% means average scrap prices of 80!/t for Ferrous and 500 !/t for NonFerrous Metals

Bottom Ash Treatment Economics - Dr. Kohaupt / EAA

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Economics for different process layouts

Green to be filled Flow rate [t BA/h]: 50 Hours per day [h/d]: 10 days per month [d/M]: 20 hours per year [h/a]: 2.400 Flow rate per year [t/a]: 120.000 technical recovery recoverable rate values [!/a] 90% 864.000 60% 360.000 60% 180.000 1.404.000 maximum, theoretical market price metal value values per [!/t] year [!/a] [!/t BA] 80 8,0 960.000 500 5,0 600.000 500 2,5 300.000 Sum 15,5 1.860.000 Size metal distribution < 10 mm 10% 25% 5% suspension 10 50 mm (>30 mm)** > 50 mm magnet 50% 60% 32% 8% 50% 60% 25% -% 70% 80% 25% -% **: only for START

Metal content Ferrous (iron) [%]: 10,0% Non Ferrous Metal [%]: 1,0% Stainless Steel [%]: 0,5%

Value portion 1/2 1/3 1/6 1

Ferrous (iron): Non-Ferrous Metal: Stainless Steel:

100,00% 100,00% 100,00%

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Flow sheet:

START: Magnet, screen 30mm, 1 ECS

DEVELOPED: Magnets, 2 screen, 2 ECS

ADVANCED: Magnets, 2 Screens, 3 ECS

INNOVATIVE: Magnets, crusher, 2 screens, 3 ECS, 2 Inductions 10% ! 2.497.500 62.438 499.500 34.560 249.750 300.000 1.146.248 9,55 12,79 7,92 3,30 1,57

Investment - machinery: Financing: Description: Energy: Maintenance (10% Inv): Staff (3 / 5 pers): payment for supply*: TOTAL COSTS: total costs per t BA [!/t BA] earnings per tonne [!/t BA]: Iron 0,58 Non-Ferrous Metal 1,80 Stainless Earnings per year [!] BA treatment fee [!/t]*: direct advantage [!/t BA]: advantage per year Incl. landfill saved per ton Factor yearlyfees adv./Invest [!/t]

additional metal recovery due to liberation [%]: ! ! ! 540.000 727.500 997.500 13.500 24.438 31.188 108.005 195.500 249.500 6.912 9.984 12.288 54.000 72.750 99.750 180.000 180.000 180.000 362.417 3,02 2,38 6,48 2,25 285.120 -0,64 -77.297 -0,14 29,36 1.047.600 4,71 564.929 0,78 34,71 482.672 4,02 8,73 7,20 3,00 1.224.000 5,43 651.275 16 0,65 35,43 572.726 4,77 10,20

1.534.500 3,24 388.253 0,15 33,24

Conclusions
The metal potential in bottom ash is high and worth to be recovered. The price levels for metals are good today and will be increasing in the future due to a growing demand world-wide for raw materials. The level of technology used depends on local circumstances. But it can be safely stated that Ferrous and Non Ferrous recovery in the coarse size fraction is a must for every plant. Additional screening and sorting increases the output and the value of the NF-metals in specific. The need of inductive sensoring needs to be clarified from case to case and within the overall process. The potential for additional metal recovery is high and in many cases worth to be mechanically recovered. Even more important is the back office, which has to sell the products. Larger quantities allow higher values. Not only because the transport costs per ton are less but also due to better prices with larger quantities.

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Many thanks for your attention!

Dr.- Ing. Ulrich Kohaupt

raw Material processing

Korn-Recycling GmbH Albstadt www.korn-recycling.de Erftstr. 59 53879 Euskirchen Germany

ulrichkohaupt@gmx.net

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