Value from Waste. Amsterdam s Vision on the 4 th -generation Waste-2-Energy. Ir. M.A.J. (Marcel) van Berlo

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ISWA

Ir. M.A.J. (Marcel) van Berlo

Waste & Energy Company City of Amsterdam

info@afvalenergiebedrijf.nl

Value from Waste

Amsterdam’s Vision on

the 4

th

-generation Waste-2-Energy

ISWA congress 2007

Plant Visit at Afvalenergiebedrijf

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ISWA

1. INTRODUCTION

1. Introduction

2. Scenarios for Recovery

3. Amsterdam

4. New generation of waste incineration

5. Conclusion

1. Introduction

2. Scenarios for Recovery

3. Amsterdam

4. New generation of waste incineration

5. Conclusion

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Afval Energie Bedrijf

Society

Raw materials

Air

Water

Waste

Water

Waste

Exhaust

Society

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Closing the loop

Waste

Energy

Air

Water

Waste

Water

Exhaust gas

Society

WFPP

Raw materials

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Desert

• Scarcity • Survival • Self supporting • Deterrence • Robustness • Long live cycle

• Economical (=Zuinig)

• Waste prevention • Residues remain

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Tropical rain

forest:

Tropical rain

forest:

• Abundance • Growth • Competition • Complexity • Redundancy • Short life-cycle • Wasteful (=Verspillend) • Massive disposal • Massive recycling: 1. Eat-and-be-eaten =

use the proteins

2. Down cycle =

Molecular decomposition

3. Production =

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Grades of recycling

Society

Reuse: “as-is or repair”

Disassemble: “components”

Fragment: “materials”

Decompose: “Molecules”

Convert: “Atoms and energy”

Second hand car

Dismantling the car

Shredder

Fermentation, Pyrolysis

Burn

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Waste is a RENEWABLE !

l

100% Sustainable

Energy from an endless

flow of waste

l

50% Renewable

CO₂-free energy

from biomass

l

100% Sustainable

Energy from an endless flow of waste

l

50% Renewable

CO₂-free energy

from biomass

l

Richer than most RAW MATERIALS

high concentration of

valuable METALS

l

Richer than most RAW MATERIALS

high concentration of

valuable METALS

Waste Fired Power Plant

Renewable

ENERGY 50% of waste is BIOMASS

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2. Dutch scenario 2012

0 10 20 30 40 50 60 70 Not Combustible Combustible Reuse 0 10 20 30 40 50 60 70 Not Combustible Combustible Reuse

Total Waste Production

0 2 4 6 8 10 12 2002 2012 Landfill

Other waste incineration R1 Hazardous waste R1 Sludges D10 Incineration D10 0 2 4 6 8 10 12 2002 2012 Landfill

Other waste incineration R1 Hazardous waste R1 Sludges D10 Incineration D10

Combustible Waste

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Dutch Results of policy

0

10

20

30

40

50

60

70

19

85

19

88

19

91

19

94

19

97

20

00

20

03 M

ton/

y

ear

Reuse/Recycling

Incineration

Discharge

Landfill

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ISWA

Dutch waste policy

Instruments for steering waste management:

Regulations on landfill (1980-90)

Legislation

- stringent emission limits incineration(1990) - directives and covenants (glass, paper, CFK)

Ban on landfill and

landfill tax

for combustible waste (1995)

Financial incentives (REB 1997, MEP 2005)

Preference order:

1. Prevention

2. Reuse and Recycling

3. Incineration/energy production

4. Landfill

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ISWA

Cost ranges for Waste Management options

20 50 30 150 30 200 110 80 0 50 100 150 200

Landfill Incineration Reuse/recycling

€ / ton MSW

Landfill Tax

Maximum cost range Minimum cost

Price competition versus Preference order

Cheap landfill beats every other option

Landfill tax (or landfill ban) is needed to give reuse/recycling a fair chance

WtE (as alternative for land filling) is needed to implement landfill taxes

Prices of incineration are within range of reuse/recycling options

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2. SCENARIOS: “Integral chain efficiency”

Paper

Glass

Household

Energy

30%

WFPP

30%

Separation

(mechanical)

Energy

28%

Overall efficiency Conversion efficiency 30% Percent of Mass

RDF

40%

25%

Landfill

Energy

2%

25% 20% Digestion 5% recovery

_Material

Source

Paper

Glass

Landfill 1,5%

Materials

SAI

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The NEW Generation WtE

Third generation (1985-now) is

“designed to be CLEAN”

Fourth generation (now--> ….) is

“designed for RECOVERY”

of ENERGY and MATERIALS

Third generation (1985-now) is

“designed to be CLEAN”

Fourth generation (now--> ….) is

“designed for RECOVERY”

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2. PERFORMANCE INDICATORS for WtE

Energy _LCA, GHG-emission/ avoidance, LCC Mass Dust, NO_x, CO, HCl, SO₂, C_xH_y dioxin, HM, CO₂ Deviation rate R1/D10, Exergy, Primary-resources

Output

Quantity

Effect

Evaluation

Acidity, Toxicity, CO₂-equiv Waste WtE Electricity Exhaust gas Residues Heat Materials

Input

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RECOVERY is the new RULE !

It was

WI

Waste incineration

It is

WTE

Waste To Energy

It will be

WFPP Waste Fired

Power Plant

It was

WI

Waste incineration

It is

WTE

Waste To Energy

It will be

WFPP

Waste Fired

Power Plant

ca.

15%

Æ

30%

ca.

15%

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Electrical Efficiency of Power Plants

Depends on

fuel quality

:

l

Natural Gas

55 %

l

Oil

50 %

l

Coal

45 %

l

Lignite

40 %

l

Biomass

35 %

l

Waste 15…22 %....30%

Depends on

fuel quality

:

l

Natural Gas

55 %

l

Oil

50 %

l

Coal

45 %

l

Lignite

40 %

l

Biomass

35 %

l

Waste 15…22 %....30%

Current: State-of-the-Art Current: State-of-the-Art New:

Best Available Technology

New:

Best Available Technology

Current Average

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EXergy Production

0,0% 5,0% 10,0% 15,0% 20,0% 25,0% 30,0% 35,0% 40,0% 45,0% 50,0% Exergy equ. Recovered metals Exergy efficiency

Exergy equ. Recovered metals 0,0% 0,0% 4,5% 7,0% 10,8% 7,0% 10,8% 4,5% Exergy efficiency 0,0% 2,0% 14,6% 19,8% 30,0% 24,5% 33,1% 14,6% DUMPSITE LANDFILL+ biogas engines WtE Average NL WtE Convention al WtE Optimised WtE Conv.+CHP WtE Optim.+CH P WtE heat only

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R1 / D10

(with proposed limits)

R1 / D10

(with proposed limits)

0 0,05 0,84 0,63 0,5 0,91 0,88 1,11

0,6

0,65

0 0,2

0,4

0,6

0,8

1 1,2

DUM P S IT E L ANDF IL L Wt E A ver ag e Wt E Co n v . Wt E O p tim . Wt E Co n v .+ CHP Wt E O p tim .+CHP W tE h eat onl y

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3. Amsterdam:

Waste & Energy Enterprise

3. Amsterdam:

Waste & Energy Enterprise

l

Owned by Local government

l

Long term contracts

l

Commercial operation: 70 €/ton of waste

l

Capital intensive

l

Industrial scale

l

Mission:

Maximise the use of waste

l

Ambitious targets

-

Best environmental performance

-

Lowest cost

l

Owned by Local government

l

Long term contracts

l

Commercial operation: 70 €/ton of waste

l

Capital intensive

l

Industrial scale

l

Mission:

Maximise the use of waste

l

Ambitious targets

-

Best environmental performance

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Generations in Waste incineration

Generation Capacity [ton/year] Operational paradigm

1885

-

Open air incineration

1

st

1917

150.000 Hygiene

2

nd

₁₉₆₉

_500.000

_{Flue gas de-dusting}

3

rd

1993

800.000 Chemical

cleaning

4

th

₂₀₀₆

₊

_500.000

_RECOVERY

of ENERGY and MATERIALS

Generation Capacity [ton/year] Operational paradigm

1885

-

Open air incineration

1

st

1917

150.000 Hygiene

2

nd

1969

500.000 Flue gas de-dusting

3

rd

₁₉₉₃

_{800.000 Chemical}

_cleaning

4

th

2006

+

500.000 RECOVERY

of ENERGY and MATERIALS

Start collection

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1 st

Incineration 1919-1969

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AVI-Noord 1969-1993

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Aerial picture (overview)

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Construction of WFPP in Amsterdam

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ISWA

Generations Waste to Energy in Amsterdam

0 200.000 400.000 600.000 800.000 1.000.000 1.200.000 1.400.000 1.600.000 1.800.000 2.000.000 19 15 19 20 19 25 19 30 19 35 19 40 19 45 19 50 19 55 19 60 19 65 19 70 19 75 19 80 19 85 19 90 19 95 20 00 20 05 Waste [Tons/Year] 0 100.000 200.000 300.000 400.000 500.000 600.000 700.000 800.000 900.000 1.000.000 Elektricity [MWh/Year] HR-AEC AEC - slib AEC - afval AVI-Noord2 AVI-Noord1 E-productie 4e 1e 2e 3e 4e 3e 2e 1e

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SIZE MATTERS

Investment in relation to the capacity of 4 Dutch AVI’s

SIZE MATTERS

Investment in relation to the capacity of 4 Dutch AVI’s

0 500 1000 1500 2000 100 200 300 400 500 600 700 800 900

Capacity in 1000 ton / year 0 500 1000 1500 2000 100 200 300 400 500 600 700 800 900

Capacity in 1000 ton / year

AVI Amsterdam AVI Amsterdam Investment Investment in in €€ perper ton / ton / yearyear

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4. New generation in Waste incineration

Historical waste incineration “generations”:

l

0 Open air incineration

l

1

st

1900

oven

l

2

nd

1960

dust removal

from flue gas

l

3

rd

1985

chemical cleaning of flue gas

In this presentation we outline a new step:

l

4

th

2006

RECOVERY

of energy and materials

Historical waste incineration “generations”:

l

0 Open air incineration

l

1

st

1900

oven

l

2

nd

1960

dust removal

from flue gas

l

3

rd

1985

chemical cleaning

of flue gas

In this presentation we outline a new step:

l

4

th

2006

RECOVERY

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Why new generation ?

RECOVERY is the

“next logical step”.

RECOVERY is the

“next logical step”

.

Historical development of public awareness:

A newly identified need leads to

a new technical concept.

A newly identified need

leads to

a new technical concept.

The adapted installations will have

additional lifetime because of

social acceptability

The adapted installations will have

additional lifetime

because of

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4th-generation Incineration

l

Cost must go down

l

Reliable, proven technology

l

Energy Optimisation

to the max !!

Leap from 22%

to >30%

l

Material reuse

to the max !!

Fe, Al, Cu, Gypsum, CaCl2,

Washed bottom ash = N1 quality building material

Washed fly ash = inert

l

Cost must go down

l

Reliable, proven technology

l

Energy Optimisation

to the max !!

Leap from 22%

to >30%

l

Material reuse

to the max !!

Fe, Al, Cu, Gypsum, CaCl2,

Washed bottom ash = N1 quality building material

Washed fly ash = inert

=

WFPP

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CONCEPT for RECOVERY

Incineration Fluegass cleaning Chemicals 10 kg Chemicals 10 kg Fluegass Fluegass Municipal Municipal Solid Solid Waste Waste

850

kWh/tonkWh/ton = =

30

30 %

%

of energy in wasteof energy in waste

Salt 7 kg Gypsum 5 kg Fly-ash 10 kg Residue Residue 55 kgkg Non Ferro 5 kg Iron 25 kg Sand 100 kg Granulate 100 kg Fines Fines 2020 kgkg SAI Output per Output per ton of waste: ton of waste:

Energy utilisation rate = 0,84

EU discussion on R1/D10

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Sorting After Incineration

Sort Bottom Bottom ash ash Cyclone 6 6--40mm40mm 2 2--6mm6mm <2mm <2mm Clean sand

Dewatering _{Sludge cake}_{Sludge cake}

Magnet Eddy current

Density separation Magnet

Iron

Non-Fe metals Coarse granulate Fine granulate Washing water Washing water

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ISWA

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HR-AVI project

l

Systematic approach to optimise recovery

l

Using proven technologies in new combination

l

Electrical efficiency >30%

l

New logistic concept

l

Budget:

400 M€

l

Construction start:

Begin 2004

l

Completion:

End 2006

l

Systematic approach to optimise recovery

l

Using proven technologies in new combination

l

Electrical efficiency >30%

l

New logistic concept

l

Budget:

400 M€

l

Construction start:

Begin 2004

l

Completion:

End 2006

=

WFPP

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- Large 1st draw: Height >20m,

Flue-gas velocity < 3m/s - Large 2nd and 3rd-draw

- Super-heater: Flue-gas velocity < 2,5 m/s - Second Economiser after fabric filter

- Flue-gas recirculation

(primary and secondary air) 3e 2e 1e Evaporator Superheater Economiser

2 _{3 4}

terti secu terti secu Prim 1st 2nd 850°C 3rd 650°C SSH 1 180°C

1

4th α Ketelas 1 Ketelas 2 Bodemas SSH 2 SSH 3 SSH 4 ECO 1 ECO 2 ECO 3

Sketch boiler design

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Superheated steam 440-480°C

Steam pressure 125-130 bar

Steam reheating after HP-turbine

Extra economiser

Drum

Boiler

Reheater

25°C 0,03 bar

Superheater

x

1 2

x

320°C 13 bar 190°C 14 bar 480°C 130 bar 335°C 135 bar

Turbine

Sketch steam reheating

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ISWA Generator Generator

Reheater (2x)

Condensor Condensor Cooling water Cooling water HP-Turbine

HP-Turbine LP-TurbineLP-Turbine

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Boiler WFPP

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ISWA

Flue-gas cleaning WFPP

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Energy-potential in Waste

Waste

in EU

:

182 MTon/year x 10 MJ/kg x 30%

Electricity:

= 550 PJ / year

= 150 TWh / year

= 17.300 MW-continuous

=

8 %

of total EU-production

Avoided CO

₂

= 200 million tons per year

Waste

in EU

:

182 MTon/year x 10 MJ/kg x 30%

Electricity:

= 550 PJ / year

= 150 TWh / year

= 17.300 MW-continuous

=

8 %

of total EU-production

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ISWA

Efficiency breakdown

0% 20% 40% 60% 80% 100% Conventional Boiler losses (stack) Cooling = Loss 20% el 0% 20% 40% 60% 80% 100% WFPP Boiler losses (stack) Cooling = Loss 30% el 20% el 0% 20% 40% 60% 80% 100% Conv+ heat

Boiler losses (stack)

Cooling = Loss Heat 20% el Derating of electricity by heat delivery 0% 20% 40% 60% 80% 100% WFPP+ heat Boiler losses (stack) Cooling = Loss Heat 30% el 20% el Derating of electricity by heat delivery

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Greenhouse effect overall

Greenhouse effect overall

976 328 81 -15 -219 -173 -349 -153 -400 -200 0 200 400 600 800 1.000 DUM PS ITE LAN DFI LL+ biog as e ngine s WtE Aver age N L WtE Conv entio nal WtE Op timis ed WtE Conv .+C HP WtE Opt im.+C HP WtE heat on ly kg CO2/ton Waste Landfill Electricity Heat

Combined heat and power

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Greenhouse gas balance

-1500 -1250 -1000 -750 -500 -250 0 250 500 750 1000 1250 1500 [kg CO2 / ton Waste]

Avoided CO2 by Heat delivery 0 0 -25 0 0 -241 -210 -563

Avoided CO2 by Electricity production 0 -33 -234 -332 -495 -248 -416 59

Avoided CO2 by metal recovery 0 0 -44 -65 -98 -65 -98 -44

Methane (CO2-equiv.) 1.251 693 15 15 15 15 15 15

CO2 emission Fos.orig. 0 0 383 381 374 381 374 394

CO2 emission Bio.orig. 208 151 468 468 468 468 468 468

CO2 used for biomass -483 -483 -483 -483 -483 -483 -483 -483

DUMPSIT

E LANDFILL

WtE

Average WtE Conv.

WtE Optim. WtE Conv.+CH P WtE Optim.+CH P WtE heat only

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ISWA

WFPP

®

is the most cost-effective

renewable option…

Sources: EZ, Regeling subsidiebedragen milieukwaliteit elektriciteitsproductie; VROM, personal communication; ECN, 2002, Duurzame Energie en Ruimte, M. Menkveld; analysis Deloitte

€

Cost per avoided ton CO₂

0 20 40 60 80 100 120 140 Waste-2-Energy WFPP® Wind on land

Biomass Wind on sea Photo-voltaic

1033

€

Cost per avoided ton CO₂

0 20 40 60 80 100 120 140 Waste-2-Energy WFPP® Wind on land

Biomass Wind on sea Photo-voltaic

1033 € / av oid e d ton of C O 2 € / av oid e d ton of C O 2

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Optimal Electrical efficiency

OPTIMISATION:

•Local conditions •Cooling water •Type of waste •Size of installation •Electricity price •Depreciation time •Subsidies •Environmental profile •Permit conditions

OPTIMISATION:

•Local conditions •Cooling water •Type of waste •Size of installation •Electricity price •Depreciation time •Subsidies •Environmental profile •Permit conditions Source: W+G 0 5 10 15 20 25 30 35 20 40 60 80 Electricity price [€/MWh] Small installation Big installation % %

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ISWA

Income from waste and energy

110

0

10

20

30

40

50

60 -10 -5 0

5 10 15 20 25 30 35 40 45 50

Year (

before/after scheduled startup)

M € / year Extra lifetime 4th-generation Gain on permiting HE Green Fee Aditional Electricity Electricity Waste 2 1 3 ₄

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ISWA

2 1

3 4

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ISWA

Incineration

SYNERGY

Waste

Water

Waste

Biogas Engines

Electricity

Water

Electricity Sewage Sludge Biogas Heat Exhaust

Sewage

Treatment

Plant

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ISWA

Patents for licensing

with support for implementation

Flue gas Cleaning

1. Dioxin removal in wet flue gas cleaning with detergents

2. Mercury removal in wet flue gas cleaning

3. Combining waste incineration and sewage treatment plant

Energy Recovery

4. High Efficiency - Waste Fired Power Plant

5. Flue gas recirculation to primary air

6. Steam super heater construction with screen pipes

7. Steam super heater with unround pipes

Material recovery

8. Salt fabrication from flue gas cleaning residue

9. Recovery of fine Non-Ferrous metals from bottom ash

10. Gravity Separation of Non-Ferrous metals from bottom ash Flue gas Cleaning

Flue gas Cleaning

1.

1. Dioxin removal in wet flue gas cleaning with detergentsDioxin removal in wet flue gas cleaning with detergents 2.

2. Mercury removal in wet flue gas cleaningMercury removal in wet flue gas cleaning 3.

3. Combining waste incineration and sewage treatment plantCombining waste incineration and sewage treatment plant

Energy Recovery

4.

4. High Efficiency High Efficiency -- Waste Fired Power PlantWaste Fired Power Plant 5.

5. Flue gas recirculation to primary airFlue gas recirculation to primary air 6.

6. Steam super heater construction with screen pipesSteam super heater construction with screen pipes 7.

7. Steam super heater with Steam super heater with unroundunround pipespipes

Material recovery

8.

8. Salt fabrication from flue gas cleaning residueSalt fabrication from flue gas cleaning residue 9.

9. Recovery of fine NonRecovery of fine Non--Ferrous metals from bottom ashFerrous metals from bottom ash 10.

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6. CONCLUSION

COST can/must go DOWN

SIMPLE process do it OPTIMAL

Environmental efficiency use all SYNERGY

Electrical Efficiency

> 30%

COST can/must go DOWN

SIMPLE process do it OPTIMAL

Environmental efficiency use all SYNERGY

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ISWA

Conclusion:

Waste is the directly available raw

material for clean renewable energy

and high quality building materials

Let’s explore together world’s most

valuable mineral

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Nothing is waste!

info@afvalenergiebedrijf.nl

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Tropical rain forest

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AEB Amsterdam