Maximum Yield Technology Maximum Yield Technology

MYT® Business Unit extracts the maximum energy

Zweckverband Abfallbehandlung Kahlenberg (ZAK) © 2009 Zweckverband Abfallbehandlung Kahlenberg (ZAK), Ringsheim. (Kahlenberg Waste Treatment Association) All rights reserved: no part of this document may be duplicated or used in any form and raw material potential Bergwerkstraße 1 without written consent from ZAK. D-77975 Ringsheim Conzept: Georg Gibis, Ringsheim from residual household waste Germany Editorial work: Dr. Anja Biehler, Ringsheim Design: Atelier Eschbach (Eschbach studio), Ettenheim Telephone: +49 (0)7822 8946-0 Photos: Peter Ginter, Lohmar · Hanspeter Püschel, Offenburg Fax: +49 (0)7822 8946-46 Printed on chlorine-free bleached paper. E-Mail: [email protected] www.zak-ringsheim.de

Discover MYT®– the new, innovative waste treatment technology from Zweckverband Abfallbehandlung Kahlenberg (ZAK) (Kahlenberg Waste Treatment Association) Maximum Yield Technology

is a mature and operationally reliable technology. All the process steps are tried, tested and completely compatible with one another. is energy self-sufficient and virtually emission-free. is flexible and its modular set-up allows it to adapt to changing conditions. Table of Contents helps protect raw fossil fuel resources, avoids climate-harmful emissions and makes a significant contribution to the environment. MYT® inventor: is a sound and targeted further development of the “ZAK” process that Zweckverband Abfallbehandlung Kahlenberg 4 has already proven itself in practice, even as a large-scale technology Maximum Yield Technology – MYT® 6 treats waste, extracting energy and raw materials from it. MYT® Step 1: Waste Acceptance 10 MYT® Step 2: Mechanical Processing 11 MYT® Step 3: Biological Step 12 MYT® Step 4: Biological Drying 14 MYT® Step 5: Mechanical Material Separation 16 MYT® Water Treatment 18 MYT® Discharged Air Treatment 20 MYT® Future Market – Bioenergy 22 MYT® Climate Protection 24 MYT® Essential Points 26 Company Details 28

2 3 The inventor: Zweckverband Abfallbehandlung Kahlenberg

ZAK is developing the new, innovative procedure for waste treatment

The Kahlenberg Waste Treatment Since 1996, we have been The „Kahlenberg (ZAK) MBT Our know-how is based on over ZAK, with MYT® extracts the maxi- Association: Zweckverband Ab- working on mechanical biological Plant“ is operationally reliable 40 years of experience in disposal mum energy potential from residual fallbehandlung Kahlenberg (ZAK) treatment (MBT) technologies and treats over 100,000 tonnes of and waste treatment.. household waste. is a public company, supported with the aim of breaking waste residual household waste a year. by the counties of Ortenau and down into usable components, as Emmendingen. ZAK has spent opposed to landfill or incineration Our continuing Maximum Yield Technology – MYT® development 40 years working intensively in solutions. Energy Sources Metals Water Minerals the area of waste treatment. draws on the experience of our After a number of large-scale very successful operations in Our many years of experience technical pilot projects, the new, the past. in dealing with waste, and our patented „ZAK process“ was continuous search for solutions developed in 2003 and went to the complex problems rela- operational for the first time ted to its treatment, help us to with the „Kahlenberg (ZAK) MBT develop modern and innovative Plant“ project in 2006. technologies.

4 5 Maximimum Yield Technology

extracts the maximum raw material and energy potential from residual household waste

Maximum Yield Technology is Waste is made up of the same Waste contains: a new, innovative process for components world-wide. l Energy sources treatment and utilisation of (fuels, biogas) residual household waste. Although residual household waste varies on a regional and l Minerals MYT® aims to extract the com- international level, the essential l Water plete raw material and energy components of waste are the l Metals content of waste and to use the same the world over. energy potential as recyclable ® sources of energy. Instead of MYT breaks waste down into its landfill or incineration solutions, four components, treats them there is now the option of opti- according to their specific mate- mum economic exploitation of rial and extracts the maximum waste in the form of raw mate- potential from them. rials, quality-assured fuels and energy-rich biogas.

6 7 Maximimum Yield Technology

Completely compatible steps: economical, operationally reliable, low in emissions

Minerals Fuels Discharged Metals Metals Minerals air treatment Residual materials Metals Washing · Bio-filters Clean air Residual materials Regenerative Thermal Oxidation

Step 1 Step 2 Step 3 Step 4 Step 5 Fuels Mechanical Mechanical Waste acceptance pre-treatment Biological step Biological drying material separation Inspection Sieving · Classification Interim storage Drying Sieving · Classification Dosage Inspection Dosage · DAMP® Homogenisation Loading

Water treatment Biogas Water mechanical biological physical 8 Minerals 9 Step 1 Step 2

Waste acceptance Mechanical pre-treatment

Waste acceptance takes place in Mechanical pre-treatment breaks a hall. A first inspection selects the waste down automatically large unwanted materials and po- into individually defined fractions, tential recyclables hidden in the according to the material and waste, which are subsequently differences in size. The concepts recycled or disposed of. The ins- and aggregates used are based pected waste is continually fed to on ZAK’s years of experience. the mechanical processing step. They ensure secure operations The waste acceptance area is set and targeted separation of fuels, up simply and works efficiently. minerals, metals and the few non-recyclable residual materials contained in the waste. Large unwanted materials are Coarse grade minerals are already removed, recycled or disposed of. extracted and recycled at the first step.

10 11 Step 3

Biological step

Process water

The “biological step” ensures View of the agitator arm in the particularly efficient and stable Press aggregate for the new DAMP® process: process flows. Simple and robust microbially-convertible organic aggregates guarantee maximum materials remain in the solid material, operational security at simultane- thus optimising the next step of bio Waste Solid material logical drying. ously low investment and opera tional costs. Interim storage permits a flexible and consistent dosage for biolo- Press water gical process steps. The targeted Mixer reproduction of micro-organisms ensures high-level and constant DAMP® – Defined Aerobic Mixing Process biological activity. This results in ideal process conditions and optimised energy processes, even allowing for seasonal variations in temperature and fluctuations due ® to waste collection logistics. Added process water – circulated The new DAMP process leaves water – ensures appropriate microbially convertible organic In the new and intensively-tested and uniform consistency. After a materials in the solid material. DAMP® process – Defined Aerobic short retention time in the mixer, This ensures its optimised drying. Mixing Process – the waste is presses dewater the solid mate- The resulting press water is treated selectively reduced in size and rial which is ideally prepared for in several steps for energy extrac- homogenised. biological drying. tion and cleaning. 12 13 Step 4

Biological drying

Biological drying in the MYT® The biological drying concept Micro-organisms produce biogas, procedure dries the waste in an developed by ZAK on the basis clean the air and water, and also energy-efficient and economical of a series of tests and years of dry out the waste. way with the energy inherent in experience works efficiently and the waste. is reliable in practice. Intelligent concepts facilitate the inspection In tightly-closed concrete tunnels, and easy maintenance of the air flows through the waste closed aggregates. The compre- evenly and provides the micro- hensive enclosure reduces organisms with oxygen. The emissions and leads to clean micro-organisms feed on organic working conditions. components and produce thermal energy. This thermal energy Biological drying contributes evaporates the water contained another important component to in the solid material. the MYT® procedure, along with the special management of air, After a short treatment time, solid material and energy. a homogenous, dry and free- flowing solid material is produced. The dried solid material can be easily broken down into its components: energy sources, minerals and metals.

14 15 Step 5

Mechanical material separation

Mechanical material separation MYT® fuels MYT® minerals MYT® produces water, minerals, MYT® treats residual household MYT® extracts the following works fully automatically with a metals, fuels and biogas from waste on a material-specific basis, The composition of the energy- component shares from specially configured technology: Depending on national and residual household waste. The treats it and maximises the energy rich fuels is defined as follows: residual household waste: sieving and classification systems regional requirements and quantities vary depending on the and raw material yield. grade size range, chemical break down the dry, very homo- needs the minerals can either composition of the waste. composition, heating value be re-used or land filled. genous and free-flowing material and biomass share. These fuels into various sub-fractions. replace fossil-based resources, The high quality prevents Losses Residuals Metals Fuels help to protect the environment negative impacts on the environ 5 % 2 % 2 % 38 % With differentiated materials ment, even far lower than the handling, the energy-rich fuels, and support industry by supply- ing inexpensive energy. strict limits imposed by the minerals and the few remaining German landfill regulations. metals flow into the loading By producing economical fuels stations. from waste, the MYT® procedure not only makes an important con- Minerals tribution towards the recycling of residual household waste – it also MYT® extracts high-quality fuels 10 % marks a milestone in the supply and minerals. of alternative energy.

Water 38 % Biogas 16 5 % 17 Water treatment

The multi-level procedure cleans and recycles the process water

Water management constitutes a The process water from the complex and difficult task as part biological level is mechanically of the waste treatment process. and physically processed for the separation of crude and fibrous Processing conditions for modern, materials. mechanical-biological waste treatment procedures that are stable Micro-organisms living in biogas in the long term require multi-level fermenters generate biogas from water treatment concepts and organic compounds. Depending mature water management. on location and infrastructure, this can be fully exploited in ® The MYT technology introduces the form of electric and thermal a new component into the overall energy. water treatment procedure: the “optimised water path”. At the end of the MYT® water treatment procedure there is a The “optimised water path” choice of: is a practice-proven, mature procedure for extracting energy l clean water from the process water in which l water for agricultural irrigation the water is simultaneously l nutrient-rich water to be used cleaned. as liquid fertiliser in the agricultural industry

18 19 Abluftbehandlung

Intelligent air management is economical and virtually emission-free

ZAK’s discharged air concept is Polluted discharged air and pro- MYT® is virtually emission free setting standards in waste treat- cess air streams are captured in a and therefore has no impact on ment and waste recycling sys- targeted, individual manner and its neighbours. tems with its differentiated and recycled again. This is how the ® innovative technologies. MYT® process combines economi- MYT has no difficulty in meeting cal discharged air treatment with the strict regulations applicable The consistent enclosure for low discharged air volumes. in Germany and is well within all aggregates, fully completed legal requirements. procedural levels and process Discharged air with low-level steps as well as an intelligent air pollution is fed through humi MYT® creates highly-desirable management concept play a large difiers and bio-filters. This jobs. part in preventing emissions in biological procedure enables MYT® can be operated near an economical way. micro-organisms to clean the residential areas. Even rare plants discharged air most effectively. and animals can live without Air washers and a regenerative disruption in the direct vicinity of thermal oxidation system clean the plant. more severely polluted process air streams.

20 21 Future market – bioenergy

MYT develops residual household waste into an energy resource of the future

MYT® plants are energy-indepen- Additional benefits of MYT® MYT® produces alternative fuels, MYT® energy balance sheet dent and use regenerative energy energy products include reliable, which – for energy-intensive pro- MYT® extracts the following sources to meet the full range of flexible and needs-based trans- cesses in particular – bring about approximate energy shares from ® energy requirements. The MYT portability and its economical and a significant reduction in the 120,000 tonnes of residual house process also takes the maximum environmentally-friendly use. proportion of fossil-based energy hold waste with an energy potential energy potential from residual sources required. of about 230,000 MWh/year: household waste and makes all of ® it available for further utilisation. MYT produces bioenergy that 200.000 is used in an economical and Energy potential The proven MYT® technology, environmentally-friendly way. tried and tested logistics concepts Fuels ® and years of experience gained MYT produces bioenergy 150.000 Biogas by different fuel users confirm the that can be transported reliably, success of MYT®’s idea of looking flexibly and to suit needs. MYT® own requirements at residual household waste as an energy and raw material Losses 100.000 resource of the future. 30.000 25.000 165.000 40.000 50.000 235.000 all values in MWh/year

0 22 23 Climate protection CO2

reduces CO2-emissions and benefits

from the trade in CO2-permits

The MYT® technology extracts For power plants involved in biogas and biomass-rich fuels permit trading, the use of MYT® from residual household waste. fuels offers many ecological and These energy sources generate economical benefits. electrical and thermal energy that ® is environmentally friendly. Half of MYT fuels consist of biomass. If a power plant Electricity generation from biogas replaces a portion of its primary is climate-neutral as compared fossil fuels with renewable CO2-potential saving to the electricity mix in Germa- raw materials, there is a ® ® ny. The electrification of biogas from MYT fuels and MYT biogas corresponding reduction in the

reduces CO2’s negative impact on overall emission of CO2 impacting the climate. the climate. The power plant

80.000 thus emits less CO2 than it is ® The MYT procedure simultane- MYT® biogas entitled to – based on the number 70.000 ously produces solid fuels that of emission permits it has. The can be used to replace fossil fuels 60.000 power plant can then sell the MYT® fuels in power plants. This also prevents surplus emission permits for its 50.000 emissions of harmful CO2’s from own gain. primary fossil fuels. ® 40.000 MYT CO2 -potential saving: The replacement of fossil fuels (e.g. 30.000 coal) by MYT® electrical and MYT® thermal energy from approximately 20.000 120,000 tonnes of residual household 10.000 waste cuts more than 80,000 tonnes of harmful CO2 per year. 24 0 25 Essential points

Answers to questions from practical experience

Our experience tells us that the MYT® pays for itself The flexible choice of location, MYT® is operationally reliable MYT® is neighbour-friendly problems related to waste treat- either in the centre of waste ® ment and the ecological and eco- MYT works with a simple and collection areas or in the direct The modular set-up ensures that Extremely environmentally-friendly ® nomic consequences are similar efficient waste treatment concept: vicinity of the energy consumers, all MYT aggregates are practice- and virtually emission-free tech- the world over. We would, there- the small effort required for allows economical logistics. proven. Both large and small nology guarantees the acceptance fore, like to finish by summarising logistics and separation systems plants can be built without risk of locations in the immediate the various benefits of the MYT® reduces costs and, therefore, Finally, the raw materials and and operated without disruption. vicinity of residential areas. waste charges. energy sources extracted in the process as a way of answering ® ® MYT operators can benefit from MYT process, as well as the CO2 many of these questions. The short MYT® treatment time of ZAK’s practical experience in the We would be delighted to perso- emission permits saved, are all 10 days in total limits the plant marketable benefits. form of training and consultancy; nally answer your questions and size and reduces investment costs. they can successfully operate a appreciate your interest in these new MYT® plant in an exemplary issues. Fixed concepts, defined modules manner. and experienced specialist com- panies guarantee a fast, economical and secure implementation of MYT® projects. The modular set-up allows for flexibly adaptable sizes of operation: both small and large MYT® plants are economical and operationally reliable.

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