Thermal desorption facilities Table 3 describes the facilities that use thermal desorption processes to treat hazardous wastes. Table Description of thermal desorption facilities Facility Description Total Treatment Capacity Waste type and source Capacity to accept other waste Potential for upgrade or expansion Summary Veolia Thermal Desorption Plant, Brooklyn, VIC Natural gas fired thermal desorption plant 20,000 tpa Any hydrocarbon affected prescribed industrial wastes including soils. Sludges are limited in liquid content to about 50% due to the feeding system (conveyors). Predominantly Melbourne metro region. Additional volumes of prescribed industrial waste, ethers, organic solvents, contaminated soils A minor upgrade would be required to allow treatment of sludges that have a higher liquid content. Composition of the waste would affect the treatment time and therefore the throughput (i.e. the wetter the waste, the longer the treatment time). Minor plant modifications may also enable treatment of organic solvents and halogenated organic solvents. Licence changes would be required to treat wastes, minor technical changes to feed and thermal systems to take additional waste streams. The Veolia thermal desorption facility has reasonable capacity to take additional specific hazardous waste streams that are suitable for neutralisation. The facility treats the waste through a desorption process and does not destroy the waste, with residual material requiring disposal. Although costly, the facility could be relocated to another location to manage/treat specific stockpiles or waste streams. The estimated cost of relocation is approximately $500k. Incineration type facilities Table 4 describes the facilities that use combustion processes to treat hazardous wastes.
Table Description of incineration facilities Facility Description Total Treatment Capacity Waste type and source Capacity to accept other waste Potential for upgrade or expansion Summary Ace Waste Incinerator, Dandenong, VIC Stepped hearth incinerator 11,500 tpa Currently treats medical waste, solvents, oily rags and cartridges (50% is medical and pharmaceutical). Predominantly Melbourne metro region and pharmaceuticals from Australia’s east coast The facility currently treats about 3,500 tpa and has significant capacity to treat more of the same waste type plus additional sources such as more solvents or quarantine waste. Solid waste is preferred due to the stepped hearth process. Few modifications would be required to treat additional volume of solid hazardous waste. To take liquid waste, a liquid injection system would be required for the rotary kiln. This would be considered a major upgrade/redevelopment. Current focus is on using the facility’s current capacity. Ace Waste is considering the viability of a rotary kiln as a second chamber and also energy recovery options with a feasibility assessment of a boiler and turbine. This would be undertaken to accept more diverse liquid waste streams and enable an energy recovery option as a preferred approach to the waste hierarchy in Victoria. Approvals for the rotary kiln and energy recovery option would take approximately 12 months. The Ace Dandenong facility is a large five-hectare site providing a solid base for expansion in Victoria. The hazardous treatment facility has significant capacity to treat additional waste, though preferably solid waste due to the stepped hearth process. Major improvements have occurred on the site since acquisition in 2006 and Ace Waste is considering other approaches including rotary kiln and energy recovery options.
Ace Waste Incinerator, Willawong, QLD Stepped hearth incinerator 10,600 tpa Currently treats medical waste, quarantine waste, drugs, oil filters and solvents. Predominantly southeast Queensland and some volumes from Australia’s east coast The facility currently treats about 7,000 tonnes of waste per annum and has approximately 3,600 tpa additional capacity. It can treat additional volumes of similar waste if required. There are currently no plans to modify or upgrade this facility other than to consider energy recovery options. Energy recovery options would require a boiler and turbine to be retrofitted to the plant/site. This could be undertaken in approximately 12-24 months. The Ace Waste Willawong facility is currently a key hazardous treatment facility in Queensland and has additional capacity to treat similar types of waste (3,600 tonnes per annum). The process uses a stepped hearth systems so is not suitable for treatment of liquid waste. Dandenong, VIC incinerator operating at 1100 - 1200 °C. 70,000 tpa Facility recently commissioned taking contaminated soil and hazardous waste with a high calorific value. Mostly Victorian region. The facility can potentially take a broad range of hazardous waste types predominantly contaminated solid and liquid wastes. As this is a new facility, many wastes have not been applied at this stage. The current facility can take both a significant volume of similar waste and additional hazardous waste. The facility has continuous monitoring 24/7. The primary requirement will be licence amendments as materials are proven to be treated through the existing system. A small thermal facility that has potential capacity to treat additional hazardous waste streams. Veolia are interested in exploring these options.
Veolia Incinerator, Dry Creek, SA Stepped hearth incinerator. 4,000 tpa Currently treats medical, quarantine and some chemical wastes. SA region. The facility has a liquid injection feed and good emission controls so can take additional volumes of similar waste and other solid hazardous waste/ liquid streams. The plant has about 50% utilisation. The facility can treat additional quantities of hazardous waste with minimal modifications. Upsizing waste feed options could enable treatment of additional wastes that are problematic due to size or format. Modifications or treatment of different waste will require EPA approval and trials. A small thermal facility that has potential capacity to treat additional hazardous waste streams. Veolia are interested in exploring these options. Smelters Table 5 describes the facilities that use smelting processes to treat hazardous wastes. All smelting facilities in Australia are listed, however only those which treat hazardous wastes are summarised. Table Description of smelting facilities Facility Description Total Treatment Capacity Waste type and source Capacity to accept waste Potential for upgrade or expansion Summary Korea Zinc Smelter, Townsville, QLD 2 fluidised bed roasters 350,000 tpa sulphuric acid from local galvanizer, site’s own waste such as filter cloth Potential to take other hazardous waste streams in existing facility with 850 °C treatment Sun Metals have undertaken trials to treat other waste streams, however these have been expensive and timely to undertake. There is interest to The Zinc Smelter in Townsville has potential capacity to treat hazardous wastes in Northern Queensland that are
and filter cake. Local businesses in Townsville. and dry process emission controls. explore treatment of other reliable waste streams such as industrial/commercial wastes in the broader region. The cost and time frames for trialling treatment of alternative waste streams is a significant deterrent, although this has been undertaken and can be undertaken for commercially viable waste streams. commercially viable and appropriate for feed into the smelter. Pacific Aluminium Does not hazardous waste TEMCO Does not treat hazardous waste BHP Port Kembla Does not treat hazardous waste Arrium, Whyalla Does not treat hazardous waste Mt Isa Smelters Does not treat hazardous waste Queensland Nickel Industries Does not treat hazardous waste Nyrstar Hobart Zinc Smelter Does not treat hazardous waste Nyrstar Port Pirie Smelter Does not treat hazardous waste
Tomago Aluminium Does not treat hazardous waste BHP Olympic Dam Copper Smelter Does not treat hazardous waste BHP Kalgoorlie Nickel Smelter Does not treat hazardous waste Rotary furnaces and kilns Table 6 describes the facilities that use rotary furnaces or kilns to treat hazardous wastes. Description of rotary furnace and kiln facilities Facility Description Treatment Capacity Waste type and source Capacity to accept waste Potential for upgrade or expansion Summary Adelaide Brighton Cement Kiln, Birkenhead, SA Cement kiln – large single kiln 750,000 tpa Currently woodchip derived fuel, carbon powder, waste fuel and various miscellaneous wastes. Waste is approximately 23-24% of the The facility can take a diverse range of alternative waste such as medical waste, liquid and solid fuels and waste tyres. The primary focus on hazardous waste is material with Modifications can be made to the facility, which relate to the feed process into the kiln and waste handling/storage facilities/procedures. Adelaide Brighton would need to work with licensing authorities in SA to evaluate options and undertake a feasibility study. The company expressed Further evaluation of suitable problem waste streams should be considered and feasibility of the Birkenhead facility to be modified to take additional volumes. This will also need to include evaluation of air emission impacts.
fuel feed. Mostly local SA region relatively high calorific value to assist kiln operations (operating temperature is approximately 1600 °C) concerns regarding consistent waste supply requirements to warrant the effort of further investigation. Adelaide Brighton Cement, Angaston, SA Cement kiln – three kilns 250,000 tpa Currently treats < 20% woodchip derived fuel, carbon powder, waste fuel and some miscellaneous waste streams. Predominantly SA region The facility can treat additional volumes of existing waste streams and additional wastes that may require adaptation of feed and handling systems. Modifications can be made to the facility regarding the feed process into the kiln and waste handling/storage facilities/procedures. Having three kilns potentially provides some flexibility of feed types. Adelaide Brighton would need to work with licensing authorities in SA to evaluate options and undertake feasibility. The company expressed concerns regarding consistent waste supply to warrant the effort of further investigation. Further evaluation of suitable problem waste streams should be considered and feasibility of the Angaston facility to be modified to take additional volumes. This will also need to include evaluation of air emission impacts.
Cement Australia*, Gladstone, QLD Cement kiln 1.7 million tpa Currently the facility treats between 15,000-20,000 tpa of hazardous waste in part prepared by Geocycle in Victoria. Most waste streams from Australia’s east coast. The facility can potentially treat a significant increase in the volume of hazardous waste and has identified SPL, hazardous soils, pharmaceuticals, fuel products, solvent-based waste and AQIS waste as potential waste streams. Other hazardous waste streams may be potentially treated in this facility. Current thermal energy replacement from waste is about 12%. Cement Australia has indicated similar plants in Europe are processing thermal The facility can treat significant additional quantities of hazardous waste with minimal modifications. Modifications are likely to be in feed systems and waste handling and review/ evaluation of thermal displacement on kiln performance and air emissions. Licensing changes are also likely to be required. Depending on the scale and feasibility of changes, this could be undertaken in relatively short time frames. Cement Australia has expressed interest in optimising facilities to take significant additional volumes of hazardous waste that meet the kiln operating requirements. Further evaluation of waste streams and feasibility of modifications should be considered. 80%
displacement from waste sources. Cement Australia*, Railton, TAS Cement kiln 1 million tpa Currently the facility treats between about 25,000 tonnes per annum of hazardous waste in part prepared by Geocycle in Victoria. Mostly Tasmania and waste streams from Australia’s east coast. The facility can potentially a significant increase in the volume of hazardous waste and has identified SPL, hazardous soils, pharmaceuticals, fuel products, solvent-based waste and AQIS waste as potential waste streams. Other hazardous waste streams may be potentially treated in this facility. Current thermal energy replacement from waste is about 12%. Cement Australia has indicated similar The facility can treat significant additional quantities of hazardous waste with minimal modifications. Modifications are likely to be in feed systems and waste handling and review/ evaluation of thermal displacement on kiln performance and air emissions. Licensing changes are also likely to be required. Depending on the scale and feasibility of changes, this could be undertaken in relatively short time frames. Cement Australia has expressed interest in optimising facilities to take significant additional volumes of hazardous waste that meet the kiln operating requirements. Further evaluation of waste streams and feasibility of modifications should be considered.
plants in Europe are processing thermal displacement from waste sources. Renewed Metal Technologies, Bomen, NSW Rotary kiln and rotary furnace 42,000 tpa from four processes. Lead acid batteries, Australia wide Mostly running at full capacity. Can potentially treat other waste streams if an expansion is undertaken. Each new furnace is approximately 45,000 tonnes and the waste treatment demand and volume would need to support the cost of an expansion. Evaluating options for expansion with NSW Government. is the potential to expand the facility for the treatment of lead acid batteries and potentially other hazardous waste streams. The existing facility/operation is able to increase the volume of waste for thermal treatment, thereby avoiding the requirements for a greenfield site in NSW. Regain Services Spent Pot Lining Reprocessing Facility – Tomago, NSW and Point Henry, VIC Rotary kiln operating at 600-700 °C. 45,000 – 50,000 tpa Spent pot lining (SPL) from host facilities. Host plants include Tomago, NSW and Point Henry, Victoria. Both facilities have capacity for approximately an additional tpa. Expansion or modification may be challenging as facilities operate on host sites under host licence. Potential to explore other waste streams including additional volumes of SPL and other streams suitable for the process that do not require any significant handling/storage constraints. opportunity for treatment of similar industrial waste streams at the two sites. Changes required to licence would generally be avoided. There is potential to treat SPL from other aluminium smelting sites that would involve interstate transport. 80%
Weston Aluminium, Kurri Kurri, NSW Rotary furnace. 8,000 tpa Quarantine, medical waste and paints. Local Hunter and other NSW regions. Can treat additional volumes and additional waste streams without modifications. Capacity to additional hazardous waste volumes would require an additional rotary kiln to be accommodated within the existing baghouse system capacity. Significant challenges in achieving cooperation with NSW EPA and or Cessnock Council. Attempting to build an industrial ecology park to promote waste treatment and industrial resource recovery. The facility has potential to treat a broad range of additional waste streams and types. Weston Aluminium is motivated to explore doing this but have had major challenges educating or achieving cooperation from state or local government authorities. * - Geocycle Pty Ltd is wholly subsidiary of Cement Australia in the business of processing of flammable and hazardous waste into alternative fuel and raw materials, for use in cement kilns, such as: paints; resins; solvents; oils and greases; tars and fats. Other technologies Table 7 describes other technologies for hazardous waste treatment. Table Description of other treatment technologies for hazardous waste Facility Description Total Treatment Capacity Waste type and source Capacity to accept other waste Potential for upgrade or expansion Summary
Toxfree, – Narangba, QLD and Laverton, VIC Plasma Arc Furnaces – 10,000 °C. Not available Dedicated industrial waste from host sites – PCB and organochlorines. Could potentially treat other wastes but the operating cost is high. Recently have explored the potential treatment of fluorinated refrigerant gasses and firefighting foam. Not being considered at this time. Price point for treatment of waste is the most significant issue. The Narangba and Laverton facilities are currently operating on host sites and there is limited appeal to expand or take additional waste if not commercially viable. Toxfree would explore options, if appropriate waste streams were required for special treatment. Veolia Autoclave & Liquid Treatment Plant, Berrimah, NT Autoclave facility. Not available Quarantine waste (Darwin Port incinerator is closed). Darwin region. Can also take medical waste but is not cost competitive with the deep burial option being used at the local landfill. Not proposed at this time due to limited waste volumes. In addition to quarantine the facility should be taking appropriate medical waste to avoid landfilling. Mobile and packaged waste treatment plants Table 8 describes the mobile and packaged waste treatment plants currently available in Australia. A mobile plant is usually defined as a facility that is readily relocatable and only requires the connection of services to become operational. A packaged plant is usually defined as a plant that consists of discrete operational components that can be readily assembled. Minimal commissioning is required to make the plant operational.
Potential treatment capacity Facilities with potential additional treatment capacity 9 shows the facilities listed in Table 3 to Table 7 and their potential additional waste treatment capacity, including the certainty associated with the additional capacity estimates. Table Potential additional capacity of waste treatment facilities Facility Additional potential capacity estimates for hazardous treatment Certainty (%) Veolia Thermal Desorption Plant, Brooklyn, VIC 6,500 tpa 50% Ace Waste Incinerator, Dandenong, VIC 8,000 tpa Ace Waste Incinerator, Willawong, QLD 3,600 tpa Renex, Dandenong, VIC 70,000 tpa 90% Veolia Incinerator, Dry Creek, SA 2,000 tpa 80% Korea Zinc Smelter, Townsville, QLD 30,000 tpa 40% Adelaide Brighton Cement Kiln, Birkenhead, SA 60,000 tpa 40% Adelaide Brighton Cement, Angaston, SA 20,000 tpa 40% Cement Australia*, Gladstone, QLD 70,000 tpa 60% Cement Australia*, Railton, TAS 62,500 tpa 60% Renewed Metal Technologies, Bomen, NSW 45,000 tpa 80% Regain Services Spent Pot Lining Reprocessing Facility – Tomago, NSW and Point Henry, VIC 30,000 tpa 80% Weston Aluminium, Kurri Kurri, NSW 25,000 tpa 50% Toxfree, – Narangba, QLD and Laverton, VIC Not Considered – gate fee too high 90%