SIST CR 13686:2002
(Main)Packaging - Optimization of energy recovery from packaging waste
Packaging - Optimization of energy recovery from packaging waste
The objective of this report is to identify and define properties of packaging and packaging waste to allow optimization of energy recovery.
This report takes a wide approach to the process of energy recovery in order to identify the items to be standardised according to the Directive and the Mandate.
Embalaža - Optimizacija energijske predelave odpadne embalaže
General Information
Standards Content (Sample)
SLOVENSKI STANDARD
SIST CR 13686:2002
01-januar-2002
Embalaža - Optimizacija energijske predelave odpadne embalaže
Packaging - Optimization of energy recovery from packaging waste
Ta slovenski standard je istoveten z: CR 13686:2001
ICS:
13.030.99 Drugi standardi v zvezi z Other standards related to
odpadki wastes
55.020 Pakiranje in distribucija blaga Packaging and distribution of
na splošno goods in general
SIST CR 13686:2002 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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SIST CR 13686:2002
CEN REPORT
CR 13686
RAPPORT CEN
CEN BERICHT
April 2001
ICS
English version
Packaging - Optimization of energy recovery from packaging
waste
Emballage - Optimisation de la valorisation énergétique des Verpackung - Optimierung der energetischen Verwertung
déchets d'emballages von Verpackungsabfällen
This CEN Report was approved by CEN on 2 June 1999. It has been drawn up by the Technical Committee CEN/TC 261.
CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,
Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: rue de Stassart, 36 B-1050 Brussels
© 2001 CEN All rights of exploitation in any form and by any means reserved Ref. No. CR 13686:2001 E
worldwide for CEN national Members.
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Contents
Foreword.3
Introduction .4
1 Scope .5
2 Terminology.5
3 Packaging and packaging waste.5
4 Optimization of energy recovery.6
5 Requirements for packaging recoverable in the form of energy.8
6 Theoretical determination of calorific gain .9
7 Identification of the minimum inferior calorific value .10
8 Theoretical and practical implementation.10
9 Determination of calorific gain .14
10 Conclusions.15
Annex A (normative) The Calorific Gain and Method of Calculation.17
Bibliography .25
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Foreword
This document has been prepared by CEN /TC 261, "Emballage".
This document is actually submitted to the publication.
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Introduction
The Directive on Packaging and Packaging Waste, Annex II, 3(b) states that Packaging waste processed for the
purpose of energy recovery shall have a minimum inferior calorific value to allow optimization of energy recovery
(Ref. 1).
The Commission’s Mandate M 200 Rev. 3 asks CEN to propose a standard on Requirements for packaging
recoverable in the form of energy recovery, including specification of minimum inferior calorific value
(EN 13 431).
Energy recovery is defined in Article 3.8 of the Directive : ‘energy recovery’ shall mean the use of combustible
packaging waste as a means to generate energy through direct incineration with or without other waste but with
recovery of the heat.
EN 13431 shall apply to packaging placed on the market in order to allow optimization of energy recovery of
packaging waste by specifying minimum inferior calorific value and other supplementary requirements. It cannot
and does not consider conditions or contaminants of packaging waste at arrival to furnace at the energy recovery
plant.
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1 Scope
The objective of this report is to identify and define properties of packaging and packaging waste to allow
optimization of energy recovery.
This report takes a wide approach to the process of energy recovery in order to identify the items to be
standardised according to the Directive and the Mandate.
2 Terminology
Net calorific value (inferior calorific value), Q : defined in ISO 1928 :1995 (Ref. 3).
net
Required energy H : energy necessary to adiabatically heat the post combustion substances of a material and
a
excess air from ambient temperature to the specified final temperature.
Calorific gain : the positive difference between the energy released on combustion of a material (the net calorific
value) and H .
a
Available calorific gain : recovered heat providing useful energy.
3 Packaging and packaging waste
The statement in Annex II of the Directive quoted above refers to packaging waste, whereas the Mandate wording
refers to packaging. Packaging waste can be used for energy recovery, but it is the packaging placed on the
market that has to meet the specific requirements for energy recovery and therefore is subject to meeting the
standard. The link between the Directive and the Mandate can be described in the following manner :
PACKAGING
recoverable
in the form of
no
energy
?
yes
PACKAGING WASTE has a minimum
inferior calorific value to allow
optimization of energy recovery
Figure 1
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As shown in Figure 2, packaging materials, packaging, used packaging and packaging waste form a sequence
from production and consumption to waste, without intrinsic change of the chemical material properties which are
essential for energy recovery.
Packaging
“Specification of Minimum Inferior Calorific Value” (Mandate M 200)
Material
Packaging
“Packaging Waste processed for Energy Recovery shall
Re-Use have a Minimum Inferior Calorific Value in order
Used
to allow optimization of Energy Recovery “ (Directive)
Packaging
Packaging
Waste
Incineration of waste
Collected with MSW ~ Power
with Energy Recovery
Boiler
Net
Separately
Calorific
Furnace
Collected
Prepara-
Gain
Storage
tion
Heat
Recovery as
Other
Other Fuel
Specified Fuel
Combustibles
Co-combustion of fuel
for
Energy Conversion
Preparation Handling Firing Calorific Gain
Collection Heat and Power Utilisation
“Optimization of Energy Recovery”
Figure 2 - The Overall System of Optimization of Energy Recovery
4 Optimization of energy recovery
The objective of this report is to identify and define properties of packaging and packaging waste to allow
optimization of energy recovery. Optimization of Energy Recovery from packaging waste involves the overall
system including properties of packaging, waste collection systems, preparation, storage and energy conversion to
provide net calorific gain as shown in Figure 2. Some steps included in the overall system are not related to the
packaging itself, and therefore not considered influential to the requirements of the packaging. Combustion plants,
for example, are subject to specific regulation and the use of produced energy depends on local circumstances.
Figure 3 shows the relationship between packaging, packaging waste and their relevant requirement in the
framework of the overall system of optimization of recovery in the form of energy. These issues are discussed in
detail in the following.
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Packaging
Packaging
Material
Material
Criteria for Packaging Performance
- Suitability for use
- Content of Mercury, Cadmium,
Packaging
Article 11
Packaging
Lead and Hexavalent Chromium
Requirements for Recovery
Annex II, § 3(b)
- Provision of Calorific Gain
Criteria for Energy Recovery
~
- Allow optimization of Energy Recovery
.
Packaging .
Boiler
Power
- Obtain Calorific Gain in technically and
Packaging
Waste
environmentally adequate technology Furnace
Waste
- Safe disposal of residues Annex II, § 1 indent 2 and 3
Heat
Figure 3 - Relevant Issues of Directive of Packaging and Packaging Waste and Mandate M 200 Rev. 3
Collection system and preparation
In order to optimize energy recovery from used packaging, the waste collection system should be designed and
managed so that the energy content and other fuel properties of used combustible packaging are preserved. The
extent of preparation necessary to transform packaging waste into a fuel, depends on the requirements of the
actual energy conversion plant.
Today, two different methods of collection and preparation or pre-treatment are prevailing (Figure 2) :
1) packaging waste is collected with other Municipal Solid Waste (MSW) for direct incineration in MSW
incinerators. This type of incinerator is efficient, proven and requires little pre-treatment of the mixed waste ;
2) separation of combustible waste gives a combustible fraction, known as Refuse-Derived Fuel, RDF. Source
separation and preparation of combustible packaging waste allows for the production of an energy-rich solid
fuel with specific properties (Packaging-Derived Fuel, PDF).
These derived fuels can be used as a single fuel or used in co-combustion with other fuels in existing solid fuel
fired combustion systems.In all these processes, combustible packaging waste substitutes primary fuels.
Energy conversion and generation of net calorific gain
Energy conversion of chemically bound energy to generate net calorific gain consists of three main process steps :
- combustion of a fuel in a combustion chamber, resulting in hot flue gases and solid residues, such as ashes
and slag ;
- utilization of the heat content of the hot gases in a heat recovery system ;
- conversion of the recovered heat to provide end-use energy in the form of electricity and/or heat.
Combustion
Combustion efficiency is related to the degree of completeness of combustion. It is mainly affected by fuel particle
size, fuel-to-air ratio, temperature, residence time and turbulence (mixing of fuel and air) in the furnace. Products of
incomplete combustion are carbon monoxide, volatile organic compounds and soot particles in flue gas and
unburnt carbon in ashes and slag. In the combustion process, organic substances are decomposed and
transformed into gaseous components. Depending on the combustion conditions, inorganic compounds are either
unaffected or transformed into insoluble oxides, sulphides, or water-soluble chlorides and sulphates. High
combustion efficiency therefore means minimisation of these pollutants.
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In grate fired mass burn systems the dominant part of ash leaves the furnace in the form of bottom ash (slag). The
amount of organic carbon in bottom ash is low, and the slag may be used for construction applications. High
temperature and the presence of acid components volatilise certain heavy metals, e.g. cadmium and zinc, from the
bottom ash to fly ash and filter residues. This can be seen as a positive clean-up effect of the slag (Ref. 4). Fly ash
and filter residues always contain high concentrations of fuel pollutants and require special treatment. In
accordance with current regulations, modern Waste-to-Energy plants are well equipped to deal with these
pollutants in an environmentally sound way (Ref. 5).
Utilization of the heat content of combustion gases
The heat content of combustion gases is recovered in the boiler as steam or hot water. The heat exchange
efficiency is proportional to the temperature difference between the hot and cold sides of the system. General
aspects on generating net calorific gain are :
- the facility is designed for a specified type, quality and range of fuel. A fuel that is unsuitable for the actual
equipment may affect the energy recovery process negatively and cause fouling, slagging and corrosion in the
boiler. As a result, frequent soot blowing and shut downs for mechanical clean-up and repair work will be
necessary. This reduces the plant availability ;
- the internal energy consumption of blowers, pumps, extensive flue gas cleaning equipment etc. reduces
overall efficiency and the net calorific gain.
Overall efficiency and net calorific gain are optimized by minimising thermal losses, e.g. by :
- extensive cooling of the hot flue gases in the boiler ;
- utilization of the remaining heat in the flue gases after the boiler for drying and preheating of the fuel, or for
other process steps.
Conversion of thermal energy to electricity and/or useful heat
The efficiency of energy conversion to electricity and/or heat depends on temperature and pressure of generated
steam.
Combined generation of electricity and steam or hot water for heating purposes gives overall energy utilization of
more than 70 %. This combination is favourable to the optimization of energy recovery. Condensation of water
vapour in the flue gases may further increase energy utilization.
5 Requirements for packaging recoverable in the form of energy
Calorific Gain
The principal requirement for packaging to be recoverable in the form of energy is that it is combustible under
ordinary conditions (Ref. 6). and, in order to allow optimization, capable of providing calorific gain. This means that
the net heat of combustion, Q , of the packaging shall exceed the energy required, H , to raise the temperature of
net a
its combustion products, residues and excess air to the required temperature, as given in Ref. 5. This is evaluated
in Chapter 6 and is true for all organic materials and most multi-material light-weight packaging containing a major
amount of organic material.
Ash content
The energy recovery process gives a substantial total reduction of the volume of waste and provides slag that may
be recycled. Average combustible packaging has an ash content lower than MSW or coal. The requirement for
calorific gain, by implication, limits the total ash content. The limit varies according to the packaging composition
(see Table 1 and examples in Chapter 9). Efficient combustion limits the content of unburnt organic matter in ash,
and as a result only little energy is lost in slag and ash residues. The ash content of packaging is therefore not an
important issue with respect to optimization of, or suitability for energy recovery.
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Other supplementary requirements
Other supplementary requirements could be on acid forming substances, heavy metals and other hazardous
substances in combustible packaging. These subjects are covered in Ref. 6. The following can be stated :
- the content of acid forming substances, i.e. sulphur, nitrogen and chlorine, in the fuel feed to an energy
conversion plant is determined by the design and regulated emission limits of the plant. MSW incineration
plants are equipped to deal with average packaging waste. The final disposal of residues from incineration is
also subject to regulation ;
- the fate of heavy metals in incineration is thoroughly described in Refs. 4, 7 and 8. The emission of these is
regulated. Heavy metals do not normally play a major functional role in combustible packaging materials, since
a major part of which is used for food application. Mercury, cadmium, lead and hexavalent chromium are
regulated in Article 11 of the Directive (Ref. 1) ;
- any other hazardous components, that may be present in packaging waste, will be decomposed by the high
temperature of the combustion process.
6 Theoretical determination of calorific gain
According to the definition in Ref. 6, a combustible material is defined as capable of releasing energy by burning.
By standard thermodynamic procedure, its characteristics as an energy generator can be calculated. In order to
allow optimization of energy recovery the released energy must be high enough to provide calorific gain in the
combustion process.
The net heat of combustion (net calorific value), Q , of a material is the amount of heat released when it burns
net
and when all water remains in the gas phase. It depends on chemical composition of the material. The rate of heat
release also depends on the physical properties of the material. In order to provide calorific gain, Q , of a material
net
shall exceed the amount of energy required, H , to adiabatically raise the temperature of the post-combustion
a
substances (including excess air) from ambient temperature to the specified final temperature. A calorific gain is
obtained when Equation (1) is fulfilled :
QH0 (1)
net a
The net calorific value of a packaging consisting of different constituents can be calculated according to Equation
(2) :
n
Qf Q
(2)
neti net,i
i1
where
net calorific value of the packaging ;
Q
net
f fraction of constituent i in the packaging ;
i
Q net calorific value of constituent i of the packaging.
net,i
Combustible packaging may contain non-combustible materials, of inert or reactive nature, that may have a
negative effect on the calorific gain. H for a packaging material may be calculated according to Equation (3) :
a
m
Hg C .(TT ) (3)
aj p, j a o
j1
where
energy required to adiabatically heat combustion products, residues and excess air from T to T ;
H o a
a
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ratio of combustion products and residues (flue gases and ashes) and excess air ;
g
j
C specific heat capacity of post combustion product j at constant pressure ;
p, j
T the final combustion temperature ;
a
the ambient temperature.
T
o
Equation (3) is valid for an adiabatic situation. For the purpose of the EN Standard on Requirements for packaging
recoverable in the form of energy (Ref. 9) this equation is used to estimate calorific gain of packaging.
H of a packaging consisting of different constituents can be calculated according to Equation (4) :
a
n
Hf H (4)
a i a,i
i1
where
H T
energy required to adiabatically heat the combustion products, residues and excess air from to
a o
T
;
a
f fraction of constituent i in the packaging ;
i
H energy required to adiabatically heat the combustion products, residues and excess air from T to
a,i o
T of constituent i of the packaging.
a
For a more elaborated explanation on calorific gain and methods of calculation, see standard textbooks on
thermodynamics and Annex A.
7 Identification of the minimum inferior calorific value
The minimum inferior calorific value, Q , is identified as H , i.e. :
net,min, a
QH (5)
net,min a
The minimum inferior calorific value is material specific and depends on combustion conditions. Thus there is no
universal minimum inferior calorific value. For the EN Standard on Requirements for Packaging Recoverable in the
Form of Energy Recovery (Ref. 9), the conditions required in Ref. 5 are used.
8 Theoretical and practical implementation
When Equation (1) is fulfilled, the Q of a combustible material is sufficient to provide calorific gain in a given
net
combustion system.
Ref. 10 reports the energy required to achieve different combustion temperatures for MSW of different composition.
The curve in Figure 4 shows typical H values for different temperatures. Q of MSW, being usually in the range
a net
o
8-12 MJ/kg, is sufficient for reaching combustion temperatures of 1200 C, which is well above the minimum
o
combustion temperature of 850 C as specified in Ref. 5.
In order to maintain optimum operation of existing Waste-to-Energy plants it is important to keep the net calorific
value of the mixed feed within the design range of the incinerator, i.e. 8 - 12 MJ/kg. This can be achieved by
leaving the high calorific, combustible packaging waste from households in MSW.
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.
.
.
.
.
.
.
o( C)
Figure 4 - The curve shows typical H values for MSW of different compositions incinerated in an MSW
a
incinerator at different temperatures. Data obtained from practical experiences (Ref. 10)
In Figure 5 a, the relevant energy values for different combustible packaging materials and fuels are compared. For
all materials and fuels shown, the values of Q exceeds that of H , and Equation (1) is fulfilled. Furthermore,
net a
H exceeds the total losses in typical waste incinerators. The available calorific gain as obtained in practice is in
a
reality higher than the theoretically calculated calorific gain (Figure 5.b). This demonstrates that the requirement for
packaging recoverable in the form of energy as defined in Chapter 5, i. e. providing calorific gain, is a conservative
approach.
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Comparison of net calorific values (Qnet)
and energy content of materials
50
Ha (850°C : O2-excess = 6 Vol.%)
+
MJ/kg material
Total energy losses Qnet
45
Calorific gain
Available calorific gain
+
40
35
30
25
20
15
10
5
0
0 5 10 15 20 25 30 35 40 45 50
MJ/kg material
Net calorific value (Qnet)
Figure 5 a- Comparison of net calorific values ( Q ) with the energy content (Ha) of their flue gases at
net
850°C and 6 % excess oxygen for some packaging materials and fuels and with the heat losses
Energy content
Wood, 60% H2O
Brown Coal, 59% H20
Cellulose
PVC
Wood, dry
Peat, dry
2
Brown Coal, 10% H O
Coal, 10% H2O
Al < 50 μm
PS
PE
PP
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Real system
Adiabatic system
- heat generation, no losses - heat recovery, losses
Figure 5 b - Calorific gain and available calorific gain at a specified temperature and oxygen
content of the flue gas
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9 Determination of calorific gain
Q is material specific and may be determined by standard methods, e.g. by calorimetry (Ref. 3). Data for most
net
materials are available in the literature (e.g. Ref. 11).
H for an assumed final temperature and amount of excess air, is material specific and may be obtained by
a
Equation (3). The Council Directive on Incineration of waste Plants (Ref. 5) provides that combustion temperature
o
must be at least 850 C and excess oxygen higher than 6 %. These minimum conditions are used for the
calculation of calorific gain of packaging materials.
o
Table 1 shows Q and H at 850 C and 6 % excess oxygen in the flue gas for some packaging materials, inert
net a
materials and moisture.
Table 1 - Typical Q , H and differences calculated for an ambient temperature of 25 C and a final
net a
specified temperature of 850 C at 6 % O , of some packaging materials and constituents. In case of a
2
positive difference there is a calorific gain.
Constituent
Q H Q - H
net a net a
(MJ/kg) (MJ/kg) (MJ/kg)
Paper constituents :
- cellulose 16 8 8
- lignin 26 12 14
Plastics :
- polyethylene, PE 43 21 22
- polypropylene, PP 44 20 24
- polystyrene, PS 40 18 22
- polyvinyl chloride, PVC 17 8 9
- polyethylene terephthalate, PET 22 10 12
a
Aluminium (combustible) 31 6 25
b
Aluminium (inert) 01 -1
Steel (inert) 0 0,4 -0,4
Other inert material (ceramic, glass etc) 0 1 -1
c
Calcium Carbonate -2 1 - 3
Water (as moisture) -2 2 - 4
a
Thin gauge aluminium up to 50 μm is calculated as combustible.
b
Aluminium over 50 μm is calculated as not combustible.
C
During the combustion process, calcium carbonate forms calcium oxide and carbon dioxide
endothermatically.
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For packaging made of multi-materials, Eq :s 1-4 can be used to determine whether it provides calorific gain or not.
Some examples of calculation of typical calorific gain for multi-material packaging :
EXAMPLE 1 Composition : Cardboard (66 % cellulose, 23% lignin) with 11% inert coating
Calorific gain : 0,66 x 8 + 0,23 x 14 + 0,11 x (-1) = 8 MJ/kg
Ash content : 11 % (inert coating)
EXAMPLE 2 Composition:PP with 50 % carbonate filler
Calorific gain : 0,5 x 24 + 0,5 x (-3) = 10,5 MJ/kg
Ash content : 30 % (CaO from CaCO )
3
EXAMPLE 3 Composition : PS with 2 % TiO
2
Calorific gain : 0,98 x 22 + 0,02 x (-1) = 22 MJ/kg
Ash content : 2 % (TiO )
2
EXAMPLE 4 Composition : Laminate of 71 % PE, 12 % Al and 17 % PET
Calorific gain : 0,71 x 22 + 0,12 x 25 + 0,17 x 12 = 21 MJ/kg
Ash content : 23 % (Aluminium oxide)
EXAMPLE 5 Composition : Laminate of 49 % PE, 22 % Al and 29 % PET
Calorific gain : 0,49 x 22 + 0,22 x 25 + 0,29 x 12 = 20 MJ/kg
Ash content : 41 % (Aluminium oxide)
10 Conclusions
I Optimization of Energy Recovery from packaging waste in the wide sense means that process equipment
and overall management are optimized to utilise the energy content of combustible packaging waste to provide net
calorific gain. This includes properties of packaging, collection system, preparation, storage and energy conversion
to useful energy for a specific need.
Some steps included in the overall system, but not directly related to the packaging itself, i.e. collection and
preparation systems, utilization of the heat content, conversion of the energy into useful heat and/or power are not
considered influential on the requirements for packaging.
In order to maintain optimum operation of existing Waste-to-Energy plants it is important to keep the net calorific
value of the mixed feed within the design range of the incinerator, i.e. 8 - 12 MJ/kg. This may be achieved by
leaving the high calorific, combustible household packaging waste in MSW.
II The minimum inferior calorific value of a packaging is identified to be the amount of energy, H , sufficient to
a
adiabatically heat up its gaseous combustion products, residues and excess air from ambient temperature to the
final temperature. This value can be calculated for given conditions, e.g. as specified in Ref. 5. It is material specific
and depends on the chemical composition of the packaging. There is no universal value.
III Packaging made of organic material has a net calorific value, Q , that exceeds the minimum inferior calorific
net
value and is capable of providing calorific gain. It is therefore recoverable in the form of energy and suitable for
optimization of energy recovery. The suitability for energy recovery of packaging made of multi-materials,
including both organic and inorganic materials, can be verified by calculation.
IV The net calorific value
of a packaging can be measured by standard methods (Ref. 3 or equivalent) or
calculated by Equation (2).
V
The energy recovery process gives a substantial total reduction of the volume of waste and provides slag for
recycling. The requirement for calorific gain, by implication, limits the ash content of packaging recoverable in the
form of energy. The limit varies according to the packaging composition. The ash content is not an important issue
with respect to optimization of, or suitability for energy recovery. Only little energy is lost in slag and ash residues
and the requirements for a calorific gain takes due account of it. Average combustible packaging has an ash
content lower than MSW or coal.
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VI The content of acid forming substances, i.e. sulphur, nitrogen and chlorine, in the fuel feed to an energy
conversion plant is determined by the design and regulated emission limits of the plant. MSW incineration plants
are equipped to deal with average packaging waste. The final disposal of residues from incineration is also subject
to regulation. Therefore, a supplementary requirement for acid forming substances for packaging recoverable in the
form of energy recovery is unnecessary.
VII Heavy metals do not normally play a major functional role in combustible packaging materials. The Packaging
Directive regulates the content of mercury, lead, cadmium and hexavalent chromium in packaging.
VIII
Any other hazardous constituents, that may be present in packaging waste, will be decomposed by the high
temperature of the combustion process.
IX Energy conversion plants have to comply with regulations with respect to the quality of combustion and to
flue gas treatment. A high calorific value contributes to the quality of combustion. Particles, acid forming
constituents and other pollutants, i.e. heavy metals, originating from the fuel, have to be effectively removed from
the exhaust gases and be safely dispos
...
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