Techno-economic impact of lower emission standards for waste-to-energy acid gas emissions.

Acid gas removal is one of the main drivers of operating costs in the flue gas cleaning lines of waste-to-energy (WtE) plants. In the light of updated technical and normative references, such as the revised Best Available Technology reference document for waste incineration in the EU, plants are required to comply with increasingly lower emission limit values (ELV). In the case of existing WtE plants, this requires selecting the appropriate option among three alternatives: intensification of current operations, installation of additional equipment (retrofitting) or substitution of equipment (revamping). The identification of the most cost-effective solution to meet the new ELVs is thus paramount. In the present study, a comparative techno-economic assessment is performed with reference to the relevant options available to WtE plants equipped with a dry acid gas treatment system, explicitly taking into account the influence of several technical and economic variables by a sensitivity analysis. The results show that retrofitting based on furnace sorbent injection is a competitive option especially in the presence of high acid gas loads in the flue gas. Despite the high investment cost, revamping based on conversion to wet scrubbing can also reduce the overall cost of treatment compared to intensification, but only if no constraints are present on flue gas temperature downstream of the acid gas treatment. If flue gas reheating is needed, e.g., for the compatibility with a downstream DeNOx treatment or to avoid plume visibility at stack, the associated costs make revamping not competitive with retrofitting or intensification. Sensitivity analysis confirms that these findings are robust even in presence of relevant variations in cost entries.

Assessment of cross-media effects deriving from the application of lower emission standards for acid pollutants in waste-to-energy plants.

The recent release of the new European Commission reference document on the Best Available Techniques (BAT) for waste incineration has set ambitious targets for the control of the emission of pollutants. However, an improved performance of the existing flue gas treatment systems in waste-to-energy (WtE) facilities is usually associated to an increase of cross-media effects, i.e., additional indirect environmental impacts related to the increased consumption of reactants and to the increased generation of process residues/wastewater in flue gas treatment. The present study introduces an innovative approach to assess cross-media effects deriving from more stringent acid gas emission standards in the WtE sector. By coupling simplified process modelling and life cycle analysis, the proposed methodology links the higher removal efficiency required for flue gas treatment to the impacts related to the reactants supply and waste disposal chain. An application to the Italian WtE sector exemplifies the potential of the method. The results evidence that, in case of HCl emission setpoints lower than 1 mg/Nm3, the reduction of acidifying emissions at the WtE stacks can be offset by the increase of global warming and smog formation impacts in the supply chain of flue gas cleaning reactants. In case of setpoints lower than 0.5 mg/Nm3, even within the acidification category the increase of indirect impacts more than compensates the decrease of WtE emissions. The net environmental benefit is strongly affected by the type of acid gas removal technology adopted, with dry systems typically associated with a larger increase of cross-media burdens when required to perform at higher removal efficiencies.

Integrating Human Barriers in Human Reliability Analysis: A New Model for the Energy Sector.

Human reliability analysis (HRA) is a major concern for organizations. While various tools, methods, and instruments have been developed by the scientific community to assess human error probability, few of them actually consider human factors impact in their analysis. The active role that workers have in shaping their own performance should be taken into account in order to understand the causal factors that may lead to errors while performing a task and identifying which human factors may prevent errors from occurring. In line with this purpose, the aim of this study is to present a new methodology for the assessment of human reliability. The proposed model relies on well-known HRA methodologies (such as SPAR-H and HEART) and integrates them in a unified framework in which human factors assume the role of safety barriers against human error. A test case of the new method was carried out in a logistics hub of an energy company. Our results indicate that human factors play a significant role in preventing workers from making errors while performing tasks by reducing human error probability. The limits and implications of the study are discussed.

A methodology for Response Gap Analysis in offshore oil spill emergency management.

In case of offshore oil spills, the success of emergency response largely depends on the meteorological and oceanographic conditions during and after the spill, which are expressed by a set of different environmental factors. A "gap" in the response may be caused by unfavourable environmental factors that could limit its effectiveness or even impede it. In this context, Response Gap Analysis (RGA) studies identify the environmental factors negatively influencing the emergency response in a given sea area and aim at assessing the percentage of time during which the response would be without success or impossible to deploy. In the present study, a new RGA methodology is described, based on 11 environmental factors. Different oil spill response strategies are considered: mechanical recovery, application of dispersants by vessel and by aircraft, and in-situ burning. A case-study is presented to demonstrate the methodology and discuss the outcomes obtained by its application.

Economic and environmental benefits by improved process control strategies in HCl removal from waste-to-energy flue gas.

The control of HCl emission in waste-to-energy (WtE) facilities is a challenging flue gas treatment problem: the release of HCl from waste combustion is highly variable in time and the HCl emission standards are typically far lower in WtE than in any other industry. Traditional process control approaches in dry HCl removal processes are generally based on feeding a large excess of solid reactants to the system, to ensure robustness and a wide safety margin in the compliance to environmental regulations. This results in the production of a high amount of unreacted sorbents, strongly increasing the generation of solid wastes that need to be disposed. In the present study, an approach was developed to allow the implementation of improved control strategies for dry HCl abatement systems in operating full-scale facilities. Its objective is the reduction of the reactant feed and the waste production, while still providing an adequate safety margin for emission compliance. The approach was based on the reproduction of the behaviour of the real system in a virtual console that allows the extensive testing of alternative control strategies, limiting the need of demanding test-runs at the real plant. A test case on an Italian WtE facility demonstrated the capability of a control logic tuned in the virtual console to achieve a 13% reduction in the consumption of reactants and generation of process residues, with unchanged HCl removal efficiency. The results evidence the wide opportunities for optimisation of dry acid gas removal systems, in particular when multistage systems are implemented.

Techno-economic performance of HCl and SO2 removal in waste-to-energy plants by furnace direct sorbent injection.

With the impending release of Best Available Techniques (BAT) conclusions on waste incineration, existing European waste-to-energy (WtE) plants will be required to achieve a higher efficiency in the removal of several target pollutants, such as acid gases (above all, HCl and SO2). The direct injection of a sorbent in the furnace as a primary deacidification stage may be a cost-effective option to achieve the required performances. The present study investigated the furnace injection of a specific dolomitic sorbent, with the aim of identifying the techno-economic optimum for the sorbent feed rate considering different scenarios of flue gas composition. A full-scale test run campaign was carried out on two WtE plants and a phenomenological model linking HCl and SO2 conversion to reactant feed rate was developed. The model allowed assessing the cost-effectiveness of dolomitic sorbent furnace injection for WtE plants equipped with either a single or a two-stage acid gas treatment system. The addition of dolomitic sorbent resulted particularly suitable for WtE plants equipped with a single stage treatment coping with a high SO2 concentration in the flue gas, where the injection of dolomitic sorbent can increase the redundancy of flue gas treatment with a reduction of the total operating costs.

Techno-economic and environmental sustainability of biomass waste conversion based on thermocatalytic reforming.

The development and design of innovative biomass waste to energy conversion processes is a key issue to pursue the implementation of circular economy and to endorse a sustainable management of agricultural land. Assessing the environmental and economic sustainability of such processes is of paramount importance to prevent the trade-off of their impacts. The present study focused on a novel biomass waste to energy conversion process based on thermocatalytic reforming (TCR). Two different agricultural waste substrates (olive wood pruning and digestate) were selected as reference cases for conversion to energy and valuable material fractions. Mass and energy balances allowed the calculation of environmental and economic indexes considering alternative scenarios for the final use of the energy and of the products obtained from the TCR conversion (i.e. syngas, bio-oil and bio-char). A sensitivity analysis was carried out to assess the robustness of results. The overall performances of the TCR process resulted strongly related to the characteristics of the biomass waste and to the possible use of the product fractions obtained in the TCR process. The use of bio-char for soil amendment, allowed by the high quality of bio-char obtained from the TCR, was a key point to improve the expected environmental and economic sustainability of the conversion process.

Risk Management of Hazardous Materials in Manufacturing Processes: Links and Transitional Spaces between Occupational Accidents and Major Accidents.

Manufacturing processes involving chemical agents are evolving at great speed. In this context, managing chemical risk is especially important towards preventing both occupational accidents and major accidents. Directive 89/391/EEC and Directive 2012/18/EU, respectively, are enforced in the European Union (EU) to this end. These directives may be further complemented by the recent ISO 45001:2018 standard regarding occupational health and safety management systems. These three management systems are closely related. However, scientific literature tackles the researching of these accidents independently. Thus, the main objective of this work is to identify and analyse the links and transitional spaces between the risk management of both types of accident. Among the results obtained, three transitional spaces can be pointed out which result from the intersection of the three systems mentioned. Similarly, the intersection of these spaces gives shape to a specific transitional space defined by the individual directives linked to Directive 89/391/EEC. These results are limited from a regulatory and technical perspective. Thus, the results are a starting point towards developing models that integrate the management systems studied.

Comparison of alternative flue gas dry treatment technologies in waste-to-energy processes.

Acid gases such as HCl and SO2 are harmful both for human health and ecosystem integrity, hence their removal is a key step of the flue gas treatment of Waste-to-Energy (WtE) plants. Methods based on the injection of dry sorbents are among the Best Available Techniques for acid gas removal. In particular, systems based on double reaction and filtration stages represent nowadays an effective technology for emission control. The aim of the present study is the simulation of a reference two-stage (2S) dry treatment system performance and its comparison to three benchmarking alternatives based on single stage sodium bicarbonate injection. A modelling procedure was applied in order to identify the optimal operating configuration of the 2S system for different reference waste compositions, and to determine the total annual cost of operation. Taking into account both operating and capital costs, the 2S system appears the most cost-effective solution for medium to high chlorine content wastes. A Monte Carlo sensitivity analysis was carried out to assess the robustness of the results.

Assessment of fragment projection hazard: probability distributions for the initial direction of fragments.

The evaluation of the initial direction and velocity of the fragments generated in the fragmentation of a vessel due to internal pressure is an important information in the assessment of damage caused by fragments, in particular within the quantitative risk assessment (QRA) of chemical and process plants. In the present study an approach is proposed to the identification and validation of probability density functions (pdfs) for the initial direction of the fragments. A detailed review of a large number of past accidents provided the background information for the validation procedure. A specific method was developed for the validation of the proposed pdfs. Validated pdfs were obtained for both the vertical and horizontal angles of projection and for the initial velocity of the fragments.

Risk management of domino effects considering dynamic consequence analysis.

Domino effects are low-probability high-consequence accidents causing severe damage to humans, process plants, and the environment. Because domino effects affect large areas and are difficult to control, preventive safety measures have been given priority over mitigative measures. As a result, safety distances and safety inventories have been used as preventive safety measures to reduce the escalation probability of domino effects. However, these safety measures are usually designed considering static accident scenarios. In this study, we show that compared to a static worst-case accident analysis, a dynamic consequence analysis provides a more rational approach for risk assessment and management of domino effects. This study also presents the application of Bayesian networks and conflict analysis to risk-based allocation of chemical inventories to minimize the consequences and thus to reduce the escalation probability. It emphasizes the risk management of chemical inventories as an inherent safety measure, particularly in existing process plants where the applicability of other safety measures such as safety distances is limited.

Domino effect analysis using Bayesian networks.

A new methodology is introduced based on Bayesian network both to model domino effect propagation patterns and to estimate the domino effect probability at different levels. The flexible structure and the unique modeling techniques offered by Bayesian network make it possible to analyze domino effects through a probabilistic framework, considering synergistic effects, noisy probabilities, and common cause failures. Further, the uncertainties and the complex interactions among the domino effect components are captured using Bayesian network. The probabilities of events are updated in the light of new information, and the most probable path of the domino effect is determined on the basis of the new data gathered. This study shows how probability updating helps to update the domino effect model either qualitatively or quantitatively. The methodology is applied to a hypothetical example and also to an earlier-studied case study. These examples accentuate the effectiveness of Bayesian network in modeling domino effects in processing facility.

Bio-oils from biomass slow pyrolysis: a chemical and toxicological screening.

Bio-oils were produced from bench-scale slow-pyrolysis of three different biomass samples (corn stalks, poplar and switchgrass). Experimental protocols were developed and applied in order to screen their chemical composition. Several hazardous compounds were detected in the bio-oil samples analysed, including phenols, furans and polycyclic aromatic hydrocarbons. A procedure was outlined and applied to the assessment of toxicological and carcinogenic hazards of the bio-oils. The following hazardous properties were considered: acute toxicity; ecotoxicity; chronic toxicity; carcinogenicity. Parameters related to these properties were quantified for each component identified in the bio-oils and overall values were estimated for the bio-oils. The hazard screening carried out for the three bio-oils considered suggested that: (i) hazards to human health could be associated with chronic exposures to the bio-oils; (ii) acute toxic effects on humans and eco-toxic effects on aquatic ecosystems could also be possible in the case of loss of containment; and (iii) bio-oils may present a marginal potential carcinogenicity. The approach outlined allows the collection of screening information on the potential hazards posed by the bio-oils. This can be particularly useful when limited time and analytical resources reduce the possibility to obtain detailed specific experimental data.

The description of population vulnerability in quantitative risk analysis.

The description of the distribution of population in the potential impact areas of accident scenarios is of utmost importance for the assessment of the final consequences of potential accidents. Vulnerability centers (i.e., sites where the simultaneous presence of a relevant number of persons in a narrow area is anticipated) may play an important role in this framework. In this study a method for the correct and detailed description of offsite target population in potential impact areas of major accidents is developed. The method is aimed at supporting quantitative risk analysis studies, emergency planning, and land-use planning. An approach is suggested to define the population categories that should be taken into account and to provide criteria for indoor and outdoor population distribution in vulnerability centers. Case studies are also provided to understand the outcomes and the potentialities of the methodology.

Lessons learned from Toulouse and Buncefield disasters: from risk analysis failures to the identification of atypical scenarios through a better knowledge management.

The recent occurrence of severe major accidents has brought to light flaws and limitations of hazard identification (HAZID) processes performed for safety reports, as in the accidents at Toulouse (France) and Buncefield (UK), where the accident scenarios that occurred were not captured by HAZID techniques. This study focuses on this type of atypical accident scenario deviating from normal expectations. The main purpose is to analyze the examples of atypical accidents mentioned and to attempt to identify them through the application of a well-known methodology such as the bow-tie analysis. To these aims, the concept of atypical event is accurately defined. Early warnings, causes, consequences, and occurrence mechanisms of the specific events are widely studied and general failures of risk assessment, management, and governance isolated. These activities contribute to outline a set of targeted recommendations, addressing transversal common deficiencies and also demonstrating how a better management of knowledge from the study of past events can support future risk assessment processes in the identification of atypical accident scenarios. Thus, a new methodology is not suggested; rather, a specific approach coordinating a more effective use of experience and available information is described, to suggest that lessons to be learned from past accidents can be effectively translated into actions of prevention.

Cost-benefit analysis of passive fire protections in road LPG transportation.

The cost-benefit evaluation of passive fire protection adoption in the road transport of liquefied petroleum gas (LPG) was investigated. In a previous study, mathematical simulations of real scale fire scenarios proved the effectiveness of passive fire protections in preventing the "fired" boiling liquid expanding vapor explosion (BLEVE), thus providing a significant risk reduction. In the present study the economical aspects of the adoption of fire protections are analyzed and an approach to cost-benefit analysis (CBA) is proposed. The CBA model is based on the comparison of the risk reduction due to fire protections (expressed in monetary terms by the value of a statistical life) and the cost of the application of fire protections to a fleet of tankers. Different types of fire protections were considered, as well as the possibility to apply protections to the entire fleet or only to a part of it. The application of the proposed model to a real-life case study is presented and discussed. Results demonstrate that the adoption of passive fire protections on road tankers, though not compulsory in Europe, can be economically feasible, thus representing a concrete measure to achieve control of the "major hazard accidents" cited by the European legislation.

Thermal degradation of Fenitrothion: identification and eco-toxicity of decomposition products.

The thermal decomposition of Fenitrothion [phosphorothioic acid O,O-diethyl O-(3-methyl-4-nitrophenyl) ester] was investigated. Results obtained by different scale calorimetric techniques show that the thermal decomposition of Fenitrothion involves two main steps. Intermediate and final thermal degradation products formed during isothermal and adiabatic thermal decomposition experiments were identified. The eco-toxicological profile of the decomposition products was assessed experimentally and compared to results obtained with a predictive software (ECOSAR). A specific index was defined to assess the change in ecotoxicity profile of decomposition products with respect to the original compound.

Identification of fireproofing zones in Oil&Gas facilities by a risk-based procedure.

Fire is among the more dangerous accident scenarios that may affect the process and chemical industry. Beside the immediate and direct harm to workers and population, fire may also cause damages to structures, which may trigger escalation resulting in severe secondary scenarios. Fireproofing is usually applied to improve the capacity of structures to maintain their integrity during a fire. Past accidents evidenced that the available standards for fireproofing application in onshore chemical and process plants do not consider all the fire scenarios that may cause structural damage. In the present study a methodology was developed for the identification of the zones where fireproofing should be applied. The effect of both pool fires and jet fires was accounted. Simplified criteria, based on radiative heat intensity, were provided for the identification of the fire protection zones. A risk-based procedure was proposed for the selection of significant reference release scenarios to be used in the evaluation of worst credible fire consequences.

Industrial accidents triggered by lightning.

Natural disasters can cause major accidents in chemical facilities where they can lead to the release of hazardous materials which in turn can result in fires, explosions or toxic dispersion. Lightning strikes are the most frequent cause of major accidents triggered by natural events. In order to contribute towards the development of a quantitative approach for assessing lightning risk at industrial facilities, lightning-triggered accident case histories were retrieved from the major industrial accident databases and analysed to extract information on types of vulnerable equipment, failure dynamics and damage states, as well as on the final consequences of the event. The most vulnerable category of equipment is storage tanks. Lightning damage is incurred by immediate ignition, electrical and electronic systems failure or structural damage with subsequent release. Toxic releases and tank fires tend to be the most common scenarios associated with lightning strikes. Oil, diesel and gasoline are the substances most frequently released during lightning-triggered Natech accidents.