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TIRMEMallorca Waste to Energy Plant Relies on Yokogawa Integrated Control SystemExecutive SummaryFor an island like Mallorca, which is heavily de-pendent on tourism, protecting the landscape and countryside by having a waste management model based on zero dumping is not a whim, but an obligation. In pursuit of this goal, the construction of Mallorca’s first waste-to-energy (WTE) plant was approved in 1992, and the contract for its design, construction, and management was awarded to TIRME S.A. Construction of this environmentally advanced and economically viable facility at the Son Reus site was completed in 1996. Each of these first two lines (lines 1 and 2) is capable of handling 18.75 tons of municipal waste per hour, and the waste heat is used to drive a turbine and generator that produced 24 MW of electricity for the power grid. In 2007, work began to construct two additional 27 t/h lines (3 and 4), each of which has a water cooled grate firing system. Together, they are able to handle approximately 420,000 tons of solid waste per year. As this waste has an average calorific value of 8,500 kJ/kg, the two lines each have a thermal capacity of 140 MW(70MW+70MW). Producing 400 deg. C steam at 50 bar, they are able to generate 38 MW of electricity. With lines 3 and 4 now online, the Son Reus WTE plant now produces enough electricity to meet the needs of 53,000 households, and is equivalent to about 4.7% of Mallorca’s total power consumption. The ash (slag) from the combustion process is treated in a plant, and approximately 80% of the resulting material is used in cement and road construction materials.For this expansion of the Son Reus WTE facility, Yokogawa Iberia S. A was selected at the automation contractor, in which capacity it installed the CENTUM CS3000 production control system (PCS), ProSafe-RS safety instrumented system (SIS), Exaquantum process information management system (PIMS), the Plant Resource Manager (PRM) asset management system, and various FOUNDATION™ Fieldbus devices.The Challenges and the SolutionsSafe operationAs Mallorca’s population of 1,000,000 can swell to six times that figure during peak holiday periods, the TIRME WTE facility must be prepared to handle widely fluctuating volumes of waste. Add to that the fact that the waste itself is of many different types, which presents certain challenges in and of itself during the combustion phase. On average, the plant processes each year 200,000 tons of municipal waste, 6,000 tons of sludge from a wastewater treatment plant, 3,000 tons of sanitary waste, and 150,000 tons of refuse-derived fuel (RDF).The monitoring and control of the various processes that are employed at this WTE facility is very demanding and complex. Incoming waste must be weighed and unloaded from trucks before being fed in carefully controlled amounts to water-cooled grates in the furnaces on lines 3 and 4, where a minimum flue-gas temperature of 850 deg. C must be attained. Combustion air to each of the furnaces is supplied by independent primary and secondary combustion air systems, with the former drawing in air from the reception bunker (thus preventing the escape of odors), pre-heating it, and injecting it into the lower part of the furnace, and the latter feeding secondary air into the upper section of the furnace. Each furnace is fitted with two auxiliary burners to support the combustion process. The heat energy of the flue gasses from each of the furnaces is recovered in two boilers (one per furnace) that produce the steam (400 deg. C, 50 bar) needed to drive a turbine. The feed water supplied to the boilers is pre-treated at a desalination facility using reverse osmosis and resin ion exchange processes. Plant InformationLocation: Mallorca Island, SpainCapacity: 38 MWCompletion: October 2009Overview of processes at TIRME WTE facility13Success Story CollectionRenewable EnergyWaste-to-energy

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