Industrial expertise at the service of the environment and the energy performance of waste-to-energy plants
What is a waste-to-energy incinerator?
A waste-to-energy incinerator is an industrial facility designed to burn solid waste while recovering the energy generated by the combustion process. This energy can be transformed into electricity, heat or steam, which can be used for a variety of industrial, commercial or domestic applications.
Incinerators in France
While almost 70% of modern incinerators worldwide incorporate energy recovery systems, in France almost all incineration plants are equipped with them (90%).
This is due to strict regulations and a national policy of encouraging waste management and renewable energy production. The French Law on Energy Transition for Green Growth (LTECV) strongly encourages energy recovery. Local authorities and private operators are investing in advanced technologies to meet these regulatory requirements.
The challenges facing this market
There are many issues at stake in this waste incineration market:
- Environmental
- Reducing the volume of waste sent to landfill, thereby helping to reduce soil and groundwater pollution.
- Reduction of greenhouse gas emissions by reducing the anaerobic decomposition of landfill waste.
- Energy
- Production of renewable energy from non-recyclable waste, contributing to the diversification of energy sources.
- Improving overall energy efficiency by using waste heat for district heating or industrial processes.
- Social and economic :
- Job creation in plant construction, operation and maintenance.
- Social acceptance and local opposition to incinerators due to concerns about emissions and impact on public health.
How is this heat used?
The energy produced by modern incinerators is most often used in the form of heat. This heat is redistributed and sent to different sites: within the plant, to homes in the city, to third-party structures such as hospitals, offices etc…
It can also be converted into electricity to supply local networks and thus contribute to the diversification of energy sources.
What do waste incineration plants need?
In order to optimize energy recovery and thus reduce emissions, these processes are constantly innovating, incorporating advanced control systems.
- SCADA control and supervision systems to monitor and control the plant’s various systems in real time
- Sensors, actuators and PLCs to automate actions, increase efficiency and implement a predictive maintenance policy.
- Electrical generators and distribution devices to convert thermal energy into electricity and feed it into the local grid
- Energy management systems (EMS) to optimize energy consumption
- Standardized systems and fault protection devices to ensure the safety of installations and operators
En instrumentation
- Sensors of various types (temperature, pressure, flow, levels, etc.) to monitor and control a number of indicators required for the proper operation of the process.
- Emissions measurement instruments (CO2, Nox, etc.) to ensure compliance with environmental standards
Our expertise at the service of our customers
We are recognized by the automation community for our advanced hardware and software expertise. Thanks to our production and integration capabilities, our proven working methods and the international mobility of our teams, we take charge of programming PLCs, supervisory systems and man-machine interfaces, as well as creating and improving our customers’ programming standards.
On the industrial electricity side, we have over 20 years of proven expertise. Surveys, design and schematics, installation studies, equipment manufacturing – the list of our services is long! These services can be offered either as contract drawings or as custom-built projects.
Whether in waste or wastewater treatment, or in the control of smoke and gas emissions, we have been able to evolve over the decades, making IESA a recognized player in this type of installation in the service of the environment.
We work with numerous waste incineration plants, either directly or via integrators. We are mainly involved in 2 plant processes.
1/ Flue gas treatment
2/ The boiler
We can also offer :
1/ Maintenance contracts
3/ Enhancement of their HMI views by integrating 3D views
Here are a few examples of our work
Monaco waste-to-energy plant
The waste-to-energy plant, managed by SMA, comprises two boiler furnaces and two flue gas treatment lines. It operates continuously throughout the year and recovers energy from combustion in two forms
The plant is equipped with all the modern equipment needed to operate in compliance with European flue gas emission standards.
IESA has been present at the site since 2006 to modernize and automate combustion and flue gas treatment.
Since 2008, we have set up a maintenance contract to carry out all operating checks once or twice a year.
- Supervision update
- Program modification
- CR on parts stock to compensate for obsolescence
- Backup of program and supervision to create a back-up
In 2009, our teams implemented an automation architecture to ensure the plant’s safety.
In 2019, the plant operators contacted us to renovate the plant’s complete command and control system. After carrying out an in-depth site survey, we assessed the interventions required to begin the implementation phase of the work.
SMA, a pioneer in the continuous improvement of operational control, contacted IESA to rethink the HMI views by integrating 3D, and collaborated with IESA to implement new dynamic and voice-activated TEO screens.
The 3D graphical display on a giant screen provides a clearer overview of the plant, and enables a number of process indicators to be visualized: temperatures, fluids, pollutant emissions, and the operating status of the plant’s 2 lines to be quickly identified.
A waste-to-energy plant in northeastern France
This waste-to-energy plant recovers around 70,000 tonnes of waste a year. It incinerates residual household waste from 89 communes. These communes belong to the Syndicat Intercommunal de Traitement des déchets.
When we had to comply with stricter European pollution standards, we modernized the plant’s furnaces by improving the combustion systems. To achieve this, we optimized the Schneider PLC program as well as the Level 2 program. We also produced the electrical diagrams, manufactured the cabinets and managed the entire electrical contract.
During the same improvement phase, we had the opportunity to improve the plant’s flue gas treatment system by developing the process PLC program managing the storage and distribution of activated carbon and dolomite.
In a second phase, we improved the process by adding a lime injection system and eliminating the filtration system bypass.
We are currently in the process of converting Schneider’s TSX premium PLC programs to M580 as part of the plant’s obsolescence management. After identifying the changes to be made, we proceeded with the conversion to a new platform, replacing all the elements that no longer existed or functioned.
A waste incinerator in the Paris region
This waste sorting and processing center handles household waste, selective collection, green waste, bulky waste and residual waste.
Incineration takes place in several stages
- Waste recovery
- Waste combustion
- Recovery of bottom ash and scrap metal
- Heat recovery from flue gases
- Flue gas treatment
- Control of atmospheric emissions
In a first contract, in 2019, we were involved in modifying the plant’s flue gas treatment from wet to dry in order to bring it into compliance.
We took over all the PLC programs, then rewrote the entire functional analysis of the flue gas treatment.
We proceeded to dismantle the parts of the plant no longer in use following compliance.
Our technical teams managed the installation of the new electrical cabinets and equipment.
On-site commissioning was also carried out by our automation specialists and electricians.
At the same time as the first chapter, but via different batches, we proceeded to replace the supervision system as part of the plant’s obsolescence management. First of all, we retrieved the various existing applications in order to draw inspiration from the current views, so as to be able to recreate all the visuals on the new platform without unduly disrupting the plant’s operators.
We also worked on the heat recovery process, participating in the addition of a waste heat recovery system. A water-to-water exchanger was integrated to heat the water and supply the district heating network and the WTE offices with heating.
For the automation part, the technical scope included the creation of retro-engineering programs, the writing of the functional analysis, and testing on a simulated test platform using the IESA Plug’n Test simulator.
On the industrial electricity side, we added the electrical equipment, drew up the electrical diagrams, manufactured the new cabinets and tested the I/Os with the panel builder.
Evna, the Schweighouse-sur-Moder household waste-to-energy plant
Built in 1990, smitom’s waste-to-energy plant is the residual household waste treatment center for an area of over 400,000 inhabitants.
Operated by SUEZunder a public service delegation agreement, the plant was modernized in 2018 to boost energy performance.
Since then, the energy efficiency rate is approaching 100%. Modernized and with a more efficient process, the plant has been given a new name: EVNA, Energie et Valorisation Nord Alsace.
At this plant, we took part in the project to change the filtration system. In order to comply with pollution standards, the bag filter was replaced, and a heat recovery system and pneumatic ash transport system were added to the process.
The technical scope included various parts, all of which were included in a single turnkey package. On the automation side, we were responsible for drafting the functional analysis, PLC and Level 2 programming, and integration into the existing system. On the industrial electricity side, we carried out the studies and schematics, dismantled, manufactured and installed the power and control cabinets and local boxes on site, fitted out the electrical room, and carried out the cable pulling, cabling and routing work. All installations were tested and commissioned on site, ensuring optimal operation.
An incineration plant in England
This biomass-fired cogeneration plant in England has been operated by VEOLIA since 2011.
Each year, between 115,000 and 120,000 tonnes of wood are consumed by the plant to produce electricity, enough to supply up to 20,000 homes via the national grid. The plant has the distinction of being one of the first in the UK to use domestic wood waste to supply electricity to the national grid, rather than to an industrial site. It is the first project in a series of similar plants that Dalkia plans to deploy across the UK.
As part of the project to comply with European standards, our team was involved in adding a flue gas treatment system to an existing installation equipped with an electrostatic precipitator. The aim of this project was to improve discharge quality by integrating a dry filtration system (hot + activated carbon). The scope of our intervention covered several aspects: on the automation side, we carried out the functional analysis, programmed the HMI and PLC interfaces, and ensured communication with the existing DCS. On the electrical side, we carried out the technical studies, designed the schematics and manufactured the cabinets as well as a fully equipped electrical shelter. Finally, commissioning on site enabled the new system to be integrated into the existing infrastructure, ensuring efficient, regulatory-compliant flue gas treatment.
La Rochelle waste-to-energy plant
The La Rochelle Energy-from-Waste Plant (EfW) treats waste from local authorities and industry, transforming it into thermal and electrical energy.
Treatment methods :
- Suction of stale air from the pit for use as primary air
- Reduction of nitrogen oxides through injection of ammoniacal water and a catalyst
- Gas cooling via a water-tube boiler
- Acid neutralization using lime
- Capture of heavy metals and furan dioxins by activated carbon
- Fume filtration through bag filters
- Flue gas analysis at the chimney outlet
In this way, 75,000 MWh of recovered heat are used to supply the district heating network in the Mireuil and Port-Neuf districts, as well as the nearby Rhodia plant.
The unit processes household waste, as well as non-inert, non-hazardous industrial waste from industrial and non-industrial companies, such as scrap metal, paper and cardboard, glass, textiles, wood, etc.
As part of an improvement and profitability project aimed at optimizing the overall operation of the La Rochelle incineration plant, a technical project was launched to integrate a new section into the existing infrastructure. The main objective was to meet current environmental standards, by improving the flue gas filtration system and reducing the annual amount of energy discharged by Aero condensation due to lack of demand, by adding a turbine and a condenser for urban heat.
The project included the addition of a catalytic treatment device to enhance the efficiency of the existing filtration system, as well as increased heat recovery to improve combustion. Thanks to the heat recovery process, the air entering the furnaces is now warmer and drier. Pneumatic conveying of the residues from the bag filters (a mixture of lime, activated carbon and dolomite) has also been installed, with a lime reactivation system using steam injection. In addition, a system for injecting lime, activated carbon and dolomite has been integrated into the flue gas treatment process to ensure optimum compliance with standards.
The addition of a 3 megawatt 2.2 turbine enables the production of electricity for self-consumption as well as production for the EDF grid, and a heat recovery unit now enables energy to be recovered by producing heat to supply the district heating network.
The project covered industrial automation and electrical work. For automation, this included functional analysis, PLC programming and development of the supervision system, all integrated into the Schneider Electric infrastructure already in place. On the electrical side, the teams carried out the HV and LV studies, designed the electrical diagrams, manufactured the cabinets, and carried out the cable pulling, wiring and routing work. All the installations were tested and commissioned on site, ensuring optimal operation of these new devices. We also installed, connected and commissioned a new HV substation with DEIE and a 2.5 megawatt 6.6/15KV step-up transformer.
SHMVD – Haute Marne waste-to-energy plant
The SHMVD Waste-to-Energy Plant (WTE), located in Chaumont in the Haute-Marne region of France, has been operating since 1998, applying an advanced model of waste management and ecological industrial synergies. Thanks to its certifications and the technical training received by its teams, the WTE has all the necessary tools to guarantee safety, operational efficiency and the prevention of environmental risks.
Treatment methods :
- Reception and control of incoming waste
- Incineration process
- Flue gas treatment
- Continuous monitoring of atmospheric emissions
- Refiom management in a specialized hazardous waste center
- Pre-treatment and maturation of bottom ash on site, followed by recycling
- Recovery and valorization of ferrous and non-ferrous metals
- Combined production of electricity and heat.
The unit processes household waste, bulky items and residual waste.
As part of the modernization of the Haute Marne Waste-to-Energy Unit (WTE), a technical project was carried out in collaboration with KANADEVIA INOVA AG to improve energy recovery and ensure compliance with environmental standards. The project focused in particular on flue gas treatment and the optimization of energy recovery.
A technical shutdown of the plant took place in order to carry out the necessary work, which included the installation of a new control system for heat recovery and its interfacing with the entire plant operating system managed by VEOLIA France. The project also included the integration of safety-compliant equipment, with adapted Siemens Safety devices, including equipment installed in ATEX zones.
The scope of work included both automation and electrical systems. On the automation side, programming was carried out in compliance with IESA standards dedicated to WTEs, using a Siemens Safety SIMATIC 1512 SPF PLC, with an HMI TP1500 supervision screen integrated into the front of the cabinet. A FAT test was carried out, followed by commissioning on site, with adaptations to suit local conditions. On the electrical side, three inverter-driven steam circulation pumps were installed, along with six pilot-operated three-way valves and a pressure-maintaining unit. The major challenge of the project lay in the restricted space available, requiring a creative design of the electrical cabinets, divided into several small interconnected modules to optimize the integration of control and command equipment.
This project exemplifies how incinerators can evolve to meet environmental challenges while maximizing energy recovery.
Mo’UVE, Montauban’s energy recovery unit
Mo’UVE, an acronym for « Montauban Unité de Valorisation Énergétique », stands for the waste treatment plant managed by Sirtomad (Syndicat de traitement des déchets du Grand Montauban et de Terres des Confluences), located on avenue de Gasseras in Montauban. Built in 1985, this household waste recovery facility has been operated by Séché Environnement under a Délégation de Service Public since January 1, 2021. Within the framework of this DSP, Séché has developed a major program of works from 2021 to 2023. This involved the construction of a complete new treatment line, featuring high energy and environmental performance, while keeping the old facility in operation.
The new equipment has been designed to maximize the recovery of thermal energy from waste treatment. Once commissioned at the end of 2023, the MoVE will triple its energy production, achieving near 100% efficiency.
The plant supplies an urban heating network (40 GWh of heat delivered/year), is self-sufficient in terms of electricity and injects nearly 15GWh of electricity annually into the public grid.
As a result, the region benefits from a highly efficient energy recovery unit, both in environmental and energy terms. This new local energy source, 50% of which will be classified as “green”, is in line with the region’s environmental strategy, contributing to its decarbonization and air quality objectives.
The main interventions on this modernization project included the complete replacement of the incineration line by Leroux & Lotz Technologies, with a new installation capable of processing up to 5 tons per hour. At the same time, the flue gas treatment system was completely overhauled, along with the associated auxiliary equipment. Part of the existing process and facilities were also dismantled to make way for the new installations.
The tasks involved in this project were numerous. They included PID analysis, risk assessment, and consideration of technical specifications. On the electrical side, complete CFO/CFA studies were carried out, covering single-line diagrams, calculation notes, detailed diagrams of power and control cabinets, thermal studies, as well as cable and IO lists, with particular attention to ATEX zones.
The installation study included equipment layout planning, cable tray sizing and layout, and the design of lighting systems and outlet boxes. The manufacture of electrical cabinets and boxes was followed by the installation and connection of equipment, including motors, instrumentation, fire detection systems and IT infrastructure. Finally, full commissioning support for the electrical and automation systems was provided to ensure the smooth operation of the entire modernized process.
We are delighted to support our customers, who call on us for our expertise in industrial automation and industrial electricity, as well as our in-depth knowledge of the specifics of the Waste-to-Energy plant (WTE) market. Thanks to our skills, we are able to help Waste-to-Energy plants modernize their infrastructures, integrating advanced solutions to optimize energy production and guarantee compliance with environmental standards. Energy recovery, at the heart of our projects, offers significant benefits in terms of waste reduction and diversification of energy sources, thus contributing to more sustainable and efficient resource management.
