Maximum Yield Technology Maximum Yield Technology

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 operational 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

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