Waste is our Energy / Hitachi Zosen Inova
Waste is our Energy
Hitachi Zosen Inova
We Build Turnkey EfW Plants with Our Own Technologies
Swiss clean-tech company Hitachi Zosen Inova (HZI) is a global technology leader for energy and material recovery from municipal solid waste (MSW), refused derived fuel (RDF) and organic waste. HZI acts as an engineering, procurement, and construction (EPC) contractor delivering complete turnkey plants. Our solutions are based on efficient and environmentally sound in-house technology, are thoroughly tested, can be flexibly adapted to user requirements, and cover the entire plant life cycle. HZI’s portfolio is rounded off with strong operation and maintenance (O&M) capabilities.
HZI’s customers range from experienced waste management companies and municipalities to up-and-coming partners in new markets worldwide. Our innovative and reliable solutions for grate combustion, anaerobic digestion, flue gas treatment, and material and energy recovery have been part of over 600 reference projects delivered since 1933.
Waste – A Global Challenge We Take On
The amount of waste worldwide is growing faster than the global population, with the production of municipal solid waste set to rise from 1.4 billion tons at present to 2.2 billion tons by 2025.
Less Landfill Capacity
A lack of landfill capacity, the negative environmental impact, urban hygiene, increasing costs, and tighter regulations require alternative solutions.
Demand for Energy and Resources
As natural resources become scarcer, the recovery of energy and raw materials from waste becomes more important.
Away from Landfill…
Landfills account for eight percent of the total greenhouse gas emissions. The negative impact on human habitat and the environment would be substantially reduced by replacing landfills. Landfill taxes and bans are supporting changes in waste management.
…to a Circular Economy.
Separate collection of direct recyclables and organic waste allows for material and energy recovery. Thermal treatment is used to recover energy and material from waste that cannot be recycled directly.
“Converting non-recyclable waste materials into electricity and heat
generates a renewable energy source and reduces carbon emissions by
offsetting the need for energy from fossil sources and reduces methane
generation from landfills.“
The United States Environmental Protection Agency
The first steps of a sustainable waste management system are the reduction and complete collection of waste, as well as the separation of waste fractions that have a market value for recycling.
…and Energy from Waste…
Recovery of materials and energy from waste using thermal and biological waste treatment is an integral part of any modern waste management system focused on maximizing utilization of all resources contained in the waste and minimizing the adverse impact on society and the environment.
…Serve to Protect Human Habitat…
EfW not only decreases the volume of waste, it saves natural resources such as land and water. It also protects the air and climate because EfW plants reduce the greenhouse gases coming from landfill.
…and Ensure Sustainable Recycling.
A modern waste management system not only focuses on protecting health and the environment, it also makes maximum use of waste to reduce the exploitation of our limited natural resources. Hitachi Zosen Inova has two first-class in-house technologies for sustainable waste management aimed at bringing the world closer to a circular economy.
Hitachi Zosen Inova – Portrait
“Hitachi Zosen Inova’s success is characterized by the combination
of a pioneering spirit, long-term technological expertise, and a
global focus. This is as true today as it was in 1933.”
Koichiro Anzai, Chairman of the HZI Supervisory Board
Pioneer in Thermal Waste Treatment
Hitachi Zosen Inova’s roots go back to the foundation of “L. von Roll Aktiengesellschaft” in 1933, set up to focus on thermal waste treatment. Six years later, it built its first plant in the Dutch city of Dordrecht.
Emphasis on Technology
From the very beginning, the Swiss company developed proprietary and improved technologies, including the reciprocating grate, advanced methods for flue gas cleaning, and processes for the recovery of materials from residues.
In 1960, Von Roll entered into a long-term license agreement with Hitachi Zosen Corporation, and opened its first offices in Germany and Japan. Subsidiaries were founded in France and Sweden in 1966, and in 1975 the company established a presence in the US. Since 2011, the renamed company and its subsidiary KRB have been part of Hitachi Zosen Corporation.
Reliability as a Commitment
As a licensee of the Von Roll technology, Hitachi Zosen Corporation implemented HZI’s core technology in more than 200 energy-from-waste plants in Japan, China, and other countries throughout East Asia. Hitachi Zosen Inova and Hitachi Zosen Corporation combine the competencies of two strong partners in the EfW sector.
First-Class Waste Management Technologies and Services
In addition to the HZI grate combustion technology, the Kompogas® and BioMethan technologies enhance Hitachi Zosen Inova’s portfolio, allowing the company to extend its position as one of the world’s leading providers of EfW plants and solutions. Offering both thermal and biological treatment of waste, Hitachi Zosen Inova is able to address the specific market requirements stemming from the separate collection of organic waste. HZI’s portfolio is completed with HZI KRB’s manufacturing capabilities and the construction and maintenance services of HZI Deutschland.
We Deliver Turnkey Plants
Engineering, Procurement and Construction
Hitachi Zosen Inova acts as a global EPC contractor for thermal and biological energy-from-waste plants. We are committed to delivering to our clients on schedule and within budget, and with a keen focus on safety and quality. We execute turnkey projects in international markets based on our wealth of experience in managing a wide range of projects, from equipment supply through to complete plant delivery.
Hitachi Zosen Inova assumes overall responsibility for the construction of complex EfW plants. The concept and plant design for integrated solutions are based on our highly reliable technologies. Our success comes from decades of experience in planning and building turnkey plants around the world. Our turnkey capabilities cover all relevant EPC tasks, ranging from engineering to plant commissioning. Leveraging its innovative spirit and project management competence, Hitachi Zosen Inova guarantees highly efficient, forward-looking solutions that fully meet customer needs. Our project teams assure smooth project progress, timely coordination of suppliers and subcontractors, and compliance with technical, commercial, and regulatory requirements.
Health and Safety
Our health and safety strategy focuses on providing a safe and healthy working environment for all our employees and partners, with the aim of zero incidents.
The quality of our products and services is a key element for the satisfaction of our clients. As quality is so essential to the success of our company, HZI introduced a comprehensive quality management system in accordance with the ISO 9001 standard back in 1992, and the system has been certified ever since.
All from a Single Provider
With us, your energy-from-waste projects are in good hands. We are capable of performing virtually any task relating to thermal and biological EfW. Our services include plant design and construction, plant operation, and maintenance and equipment servicing. We are there for you.
“Hitachi Zosen Inova is one of the major players on the market
and has in house proven technologies and relevant capabilities
for the supply of Turnkey EfW plants. We are operating EfW plants
that Hitachi Zosen Inova has delivered as a professional and
reliable EPC contractor.”
Jean Erkès, Senior Vice President Recycling and Recovery Projects, Suez
We Recover Energy and Material from MSW and RDF
Hitachi Zosen Inova’s Thermal EfW Technology
Long-term, proven EfW solution with grate combustion, energy utilization,
flue gas treatment, and material recovery.
Thermal EfW: Grate Combustion
“Reliable, well proven technology and innovative solutions from
HZI ensure highly efficient energy recovery combined with
optimal material recycling, and minimize the adverse impact on
the environment. We see this every day in our plant delivered
by Hitachi Zosen Inova”
Olli Alonhiemi, Managing Director, Westenergy Oy Ab
Thermal Treatment of Waste – an Efficient, Environmentally Sound Solution for Modern Cities
Mixed municipal solid waste or RDF from sorting plants is delivered to the site and stored in a bunker.
A crane both thoroughly mixes and feeds the waste into the feed hopper. From there it is pushed onto the grate by a ram feeder. A fully integrated control system ensures stable and efficient staged combustion, and optimized burn-off loss on the grate. Upon completion of the combustion, the residual ash falls into the wet or dry bottom ash extractor, from where it can be taken to a treatment facility for metal recovery and reuse of the inert material for road construction.
The flue gases from the combustion are cleaned to strictest standards in the downstream flue gas treatment system and are continuously monitored before being released into the atmosphere via the stack.
The energy in the flue gases is used to produce superheated steam, which is expanded in a turbine generator to generate electricity. Alternatively, the heat can be used for process steam supply, or also combined with the heat from flue gas condensation for district heating purposes.
Hitachi Zosen Inova’s thermal EfW plants are designed custom fit, for a big variety of heating values, through-puts, and methods of energy recovery. With HZI, you can rely on the experience we have gained in over 500 reference plants over more than 80 years, using our own technologies to deliver the highest energy efficiency and lowest residue production.
Reliable Technology – Continuously Improved and Optimized
Grate combustion is the best-proven thermal waste treatment technology and has been successfully deployed in well over 1,000 plants. Thanks to continuous optimization, today’s grate combustion is the most advanced technology with regard to environmental friendliness, operating reliability, flexibility, and cost effectiveness. The grate combustion technology we have developed in-house is specially designed for the thermal treatment of municipal solid waste and RDF.
Well-Proven Combustion Technology
A combustion system consists of various elements such as a feeding system, a combustion grate, primary and secondary air systems, ash extraction as well as an efficient and reliable boiler. A fully integrated control system ensures stable and efficient staged combustion, and optimized burn-off loss on the grate. The gases released from the waste in the bunker serve as primary air. Secondary air is mixed with recirculated flue gases above the grate. This assures complete combustion and lowest CO, NOx, and VOC emissions. Flue gas recirculation and low excess air enhance the energy efficiency of the plant.
The rugged construction of the grate and the heterogeneous waste fractions explain why grate combustion remains the most widespread method for thermal treatment of residual waste today. In fact, it forms the very heart of EfW plants, and is the technology of choice not only for untreated municipal and industrial wastes, but also for RDF and for pre-treated waste.
Conveying and Stoking to Perfection
From the feed hopper the ram feeder doses the waste onto the grate in a controlled way. The grate is composed of individual grate modules with alternating fixed and moving grate block rows. The hydraulically-driven moving grate blocks stoke the waste and convey it through the combustion chamber for optimum burn-out.
Individually Adapted Design
The number of grate modules depends on the specific throughput, the properties, and the calorific heating value of the waste. Various grate modules are assembled in rows and lines to suit each specific situation, with a capacity of between 4 and about 44 tons per hour. The air-cooled grate with its robust design has proven to be very reliable. Depending on the properties of the waste, it is the most favorable solution in terms of capital and maintenance costs. For high thermal loads with higher calorific values, water-cooled grate bars ensure optimum burn-out and an increased lifetime. They also offer a decisive advantage: In every zone, the airflow can be adjusted precisely to the combustion requirements.
Flue Gas Treatment
Clean Air Thanks to HZI Technologies
Emission limits for EfW plants are more stringent than for any other thermal power or process plant. This requires best available technologies (BAT) for pollution control. The pollutants introduced by the waste include combustion products like SOx, NOx, HCl, and HF, as well as substances such as heavy metals, dioxins, and dust. HZI offers a range of flue gas treatment processes that ensure complete cleaning in full accordance with the legal requirements.
Xerosorp® Dry Scrubbing – High Efficiency and Small Amounts of Residues
Our Xerosorp® process removes acidic gases by adsorption with sodium bicarbonate. In addition, activated carbon or coke can be injected for the removal of volatile organics and metals. Our Xerosorp+® process combines the advantages of the dry scrubbing process and the low temperature SCR DeNOx system for cases where highest removal efficiencies are required for fly-ash, acid gas, and NOx. Both the dry scrubbing and the SCR DeNOx processes operate at the same temperature, thus avoiding energy and heat losses. Maximum heat can be recovered prior to and after the Xerosorp+® process.
HZI SemiDry – Economic and Reliable
The HZI SemiDry process employs the principle of the circulating fluidized bed for efficient removal of acid gases by adsorption with hydrated lime. Recirculation of the reagents maximizes their use and provides excess reagent to capture contaminant peaks. In addition, activated carbon or coke can be injected for the removal of volatile organics and metals.
HZI Wet Scrubber – Pollutant-Free, Step by Step
Wet scrubbing is the most effective method for removing acid gases from even heavily burdened flue gases, and achieving lowest emission levels. The contaminants are captured by providing intensive contact between the flue gases and water, or by adjusting the pH through the addition of reagents.
HZI Condensing Scrubber – Higher Energy Efficiency
In addition to the advantages of the Wet Scrubber, the Condensing Scrubber allows for additional heat recovery by means of condensation of the water vapor contained in the flue gas. This delivers overall EfW plant energy efficiencies of up to 100 % or more with the use of the heat for district heating.
DYNOR® SNCR – Efficient NOx Removal
DYNOR® is the answer to Europe’s tightened nitrogen oxide limits. Simple in design and easy to install, our non-catalytic DYNOR® process closes the gap between the costly SCR process and the conventional SNCR process. It is an investment which pays off.
Economical, Reliable, and Efficient
Recovering the energy content of waste is the key aspect in EfW plants. As the thermal EfW process is low in emissions and renewable to a great extent, it contributes to the reduction of greenhouse gases. The recovered energy is used in the way that best meets the needs of the client. Cogeneration, the simultaneous production of electric power and heat, offers high efficiency and maximum energy yield.
Electric Power – Proven Base-Load Power
The electric power plant concept is reliable and easy to operate, and has been optimized continuously. Superheated steam from the boiler drives a steam turbine connected to a generator. The electricity produced by the generator is fed into a public electricity network. Within the turbine, the steam expands and cools down. Thereafter it is condensed in an air or water-cooled condenser. To close the cycle, the condensate is pumped back into the boiler as feedwater and converted to steam again.
Thermal Power – District Heating or Industrial Facilities
If there is a beneficial use for heat, the steam cycle can be adjusted in various ways depending on the amount and temperature level of the required heat. The heat may be supplied directly as process steam for industrial use, or transferred as hot water to public district heating networks.
Combined Heat and Power – Multipurpose Energy Recovery
While a higher heat demand reduces electricity production, it increases the total energy efficiency of the complete plant. A fully redundant system ensures safe and reliable supply of heat and power around the clock and throughout the year.
Combined Cold and Power – Feeding Public Networks
The combined cold and power plant concept allows the use of heat in countries where rather air conditioning is required than heating. The electricity produced by the generator is fed into a public electricity network. Part of the steam is extracted from the turbine at a higher pressure. It drives an adsorption chiller that converts the heat into cold water, which reaches the consumers via a district cooling network.
Reusing Most Materials
Thermal waste treatment plants produce bottom ash and flue gas treatment residues which can be either reused or landfilled. The bottom ash consists mostly of non-combustible waste components such as glass, minerals or scrap metals. The volume and nature of the residues produced in the flue gas cleaning depend mainly on the composition of the waste. With an intelligent secondary treatment process, large parts of these materials are reused.
InovaRe by HZI – Efficiently Recovering Metals from Waste
Maximum metal recovery to high standards of purity, less need for landfill, and a reduced burden on the environment: InovaRe enables valuable metals to be recovered from waste. Thermal treatment in the furnace is followed by a dry discharge of bottom ash, which is then processed. This allows metals such as iron, aluminum, zinc, copper, silver, and gold, to be recovered – all while maximizing energy efficiency and without additional emissions. The high level of purity achieved by this process means large volumes of precious materials can be recovered, creating a source of substantial earnings over the long term. InovaRe also makes a major contribution to saving resources and protecting the environment.
Fly Ash Washing – Stabilization and Product Recovery
If fly ash is collected separately from bottom ash and flue gas cleaning residues, two different methods may be applied to remove or immobilize fly ash contaminants. Acid washing of fly ash using acidic scrubber blowdown removes heavy metals in a recyclable form, and produces a fly ash which can be disposed of with the bottom ash. Neutral washing is followed by solidification to condition the fly ash into a leach-resistant matrix, which can then be used for construction purposes.
Effluent Treatment – Capture and Recycle Contaminants
The effluent treatment process neutralizes blowdown from wet flue gas scrubbers or from fly ash washing, and removes contaminants such as heavy metals, ammonia or persistent organic pollutants (POPs). Depending on the plant configuration, some contaminants such as mercury or zinc can be recovered for recycling. The only remaining components in the cleaned effluent are naturally occurring salts such as sodium and calcium chlorides and sulfates.
We Recover Energy and Material
from Organic Waste
Kompogas® Biological EfW Technology
Dry fermentation with steel or concrete digesters for energy and material recovery
and upgrading biogas to be fed into the natural gas grid.
Kompogas® – Dry Anaerobic Digestion
“The Kompogas® technology allows us to transform organic waste
energetically into biogas and energy, and to recycle the waste in
the form of solid and liquid fertilizer. With this technology, we are
contributing to sustainable waste management in the Botarell area.”
Hugo Urdaneta, Plant Manager, Kompogas® plant Botarell
Kompogas® is the Market and Technology Leader in Dry Fermentation Processes
The patented Kompogas® process is based on continuous dry fermentation of organic waste using a horizontal plug-flow digester. In this process the temperature in the digester is maintained at 55°Celsius. The average moisture of the fermenter’s content is around 75 % and the retention time is approximately 14 days. The Kompogas® process ensures that the organic waste is fully converted to biogas and that the digestate is completely sanitized. The continuous, horizontal plug-flow digester allows a high biogas yield and assures highest operating reliability thanks to simple and efficient control systems. A low-speed agitator ensures the optimum biogas conversion. The special design of the agitator paddles prevents sedimentation of heavy and undesired matter in the substrate. Fermentation involves various upstream and downstream processes. In the feed unit, the organic waste is shredded and metals and other non-digestibles are removed. A discharge pump withdraws the digestate. Around one-third is pumped back for inoculation. The rest is either dewatered to produce compost and liquid fertilizer or mixed with green waste using the liquid fertilizer free partial flow process.
The Core Component of the Patented Kompogas® Process
Our digesters are available in two series as concrete or steel digesters. Both series are equipped with the same robust agitator components and can be deployed for all input materials, bio-waste, green waste and organic elements from the general waste collection. Two, three or more digester modules can be combined to form larger plants.
Bio Gas Upgrade for Feed-in
HZI BioMethan delivers gas treatment facilities, which can also be installed as an upgrade to Kompogas® plants. Two different processes are used to separate CO2. One of these is pressure less amine scrubbing or alternatively a pressure controlled membrane process.
We Take Care of Your Plant
Hitachi Zosen Inova Service Group
Operation, maintenance, retrofit, manufacturing, spare parts,
and laboratory services
Hitachi Zosen Inova Service Group
Operation and Maintenance
For owners of EfW plants, the focus is on achieving maximum efficiency coupled with the highest economic benefit. HZI’s clients are benefiting at the best from their invest. We work together with our clients to develop an efficient strategy that will ensure their EfW plant performs optimally in terms of availability, waste throughput, and energy recovery. Remote support is possible with our special tool Pamela™. The plant can be monitored from our offices, giving us the full picture of all operational data. This allows us to make efficient decisions on interventions and optimizing the operating conditions. HZI’s interactive training tool ITS simulates plant operations, and also covers health and safety aspects.
Tighter legislation and more stringent environmental and economic requirements are constantly presenting new challenges for plant owners. Together with Hitachi Zosen Inova Kraftwerkstechnik, we provide holistic solutions and the latest technologies to help tap the full potential for efficiency and performance gains at any plant. This includes modernization for extended service life, emission reductions for maximum ecological compatibility, and increased efficiency and higher steam output through constant supervision of heat exchangers. We focus on leveraging our resources to maximize your plant’s performance.
“With the retrofit on the grate, boiler, bottom ash extractor, and
flue gas treatment executed by HZI, we will be able to operate
our plant for another 15 years with greater energy efficiency and
a higher recycling rate.”
Romano Wild, CEO of the EfW plant in Horgen
Hitachi Zosen KRB is specialized in manufacturing boilers parts and piping, and pride ourselves on maintaining long-standing partnerships with our customers. Since 1997, we have been providing products and services around thermal waste treatment to our customers in Switzerland and abroad. The spectrum includes manufacturing for steam generators, fabrication of membrane walls and tube bundles, cladding for boiler and combustion systems and constructing of standard or customized components.
Spare Parts Management
Spare parts management is complex, cost-intensive, and requires storage space. That is why it makes sense to entrust us with procuring and delivering wear components – we are quick, reliable, and experts in the field. Original spare parts are provided directly from stock. For our clients, this translates into savings in terms of expenditure and time.
HZI’s laboratory is equipped to meet the demands of EfW plant operators. Our range of services is as broad as the variety of questions arising in connection with thermal and biological waste treatment. We check compliance with emission limits and performance guarantees, measure the relevant process parameters, and carry out root cause analysis in cases of operational problems. We bring together all the relevant EfW testing and analytical methods under one roof, including sampling, measurements and analysis on site, leading to very quick turn-around times.
Hitachi Zosen Inova – Our Commitment
“What fascinates me about working at HZI is successfully tackling
complex projects in interdisciplinary teams.”
Tobias Ruchty, Project Manager, HZI
“Thanks to the implementation of Hitachi Zosen Inova’s sophisticated
HSE strategy, the incident statistics during the realization of
the Renergia project were much lower than is usually the case.”
Ruedi Kummer, CEO, Renergia Zentralschweiz AG
HZI as Employer
Our employees come first: They are the key to our outstanding solutions. We offer our highly trained and qualified employees a rewarding environment where motivation, team spirit, creative involvement, and a philosophy of leadership are all actively fostered and encouraged. We value our people, and draw our strength from their drive, their passion for engineering, consulting and project management, and their indepth expertise and experience.
HZI as Partner
We strive to be a trusted partner to our clients and stakeholders all over the world. With over 80 years of experience our aim is not only to build thermal and biological EfW plants worldwide, but also to be a fair partner towards our stakeholder Hitachi Zosen Corporation. The HZI commitment encourages us in the daily business and makes us a reliable partner for all kind of situations.
Code of Conduct
HZI will not tolerate discrimination, conflicts of interest, bribery and corruption, insider trading, political contributions, or non-compliance with the law. HZI and its employees respect the rules of fair competition and intellectual property rights. The business assets of HZI are used carefully and protected in accordance with good business practice.
Health, Safety and Environment
HZI’s HSE strategic and operational focus is on providing a safe and healthy working environment for all our employees and partners. HZI respects the natural environment, and we work to minimize our negative impact on it and our use of natural resources wherever possible. Built around our value of actively caring for our people and the environment, and coupled with our aim of zero incidents, our strategy is based on three core principles: competence, compliance, and community. Our HSE strategy, policies, and procedures provide orientation, but it is our actions that demonstrate how we actively care for all our employees and partners, ensuring that they return home safely to their families every day.