Firing Up a WtE Plant: Case Studies from Australia and ...

Firing Up a WtE Plant: Case Studies from Australia and Beyond

Dr. Marc R. Stammbach

Waste Expo Australia

23 to 24 Oct Melbourne VIC

Firing Up A WtE Plant 1

Firing Up a WtE Plant: Case Studies from Australia and Beyond

We shall check-in, fire up the engine room, and check-out with local and overseas examples why WtE is credible,

sustainable, possible, and how it can and will roll out in Australia.

Short History of WtE in Australia

The Millerhill RERC EfW Plant in seven chapters

Roll out in Australia

2Firing Up A WtE Plant

A Short History of WtE in Australia


Several large and many small incinerators in Australia in last century:

No incineration made it into this millennium

Waterloo Incinerator closed in 1997 due to public

protest over lack of flue gas treatment

SWERF autoclave / pyrolysis / gasification debacle,

which cost EDL a write-down of $136.7 million in 2003

4


Construction underway for Australia’s first thermal waste-to-energy facility

Site progress: September 2019 3D-Model of Avertas Energy

5


Current Projects in Australia with an approval or in construction

Project Size Promoters Permit Financial Close

Avertas Energy 400,000 tpy Macquarie/DIF April 2016 Oct 2018

East Rockingham RRF 300,000 tpy HZI / NEC / TRIBE

(NEC till 2016)

July 2019 EfW

(Jan 2015 Gasification)

Maryvale EfW 650,000 tpy Australian Paper /

SUEZ

Nov 2018

Port Hedland MRF &

Gasification

50,000 tpy New Energy

Corporation

May 2013

… and many more projects talked about, but without a permit


The Millerhill RERC EfW Plant


Introduction to FCC

FCC is one of the UK’s leading recycling and waste management companies

FCC is part of a leading group in environmental services and infrastructure development, FCC SA, based in Spain.

FCC employs over 2,400 people across the UK and operate a wide range of waste management sites

FCC minimizes waste that ends up in landfill by transforming it into valuable resources:

Recycling 1.6m tonnes of waste and

Over 102 MW of renewable energy (electrical)

FCC operates in five key areas:

Green energy

Municipal services

Recycling and composting

Waste processing

Business waste solutions


Introduction to FCC

Green Energy operates 6 EfW facilities across the UK

Allington (Kent)

Eastcroft (Nottingham)

North Hykeham (Lincolnshire)

Greatmoor (Buckinghamshire) – built by HZI

Hartlebury (Herefordshire and Worcestershire) – built by HZI

Millerhill (Edinburgh & Midlothian) – built by HZI


Firing Up A WtE Plant

Millerhill Project Outline

10

Towards Zero Waste


One of the biggest waste partnerships in Scotland between City of Edinburgh Council

and Midlothian Council

Project formally initiated in 2009

The partnership sought delivery of two dedicated facilities for treatment of food waste

and residual waste

Separate procurements: AD and EfW

Site acquired by the councils and outline planning was achieved

Ultimate aim to deliver infrastructure which would help achieve “towards zero waste”

Millerhill Zero Waste Park – 5 years from procurement to construction start

Procurement process formally commenced with issue of OJEU notice – December 2011

Return of pre-qualification questionnaires – February 2012

Submission of detailed tenders – July 2013

Submission of final tenders – October 2014

Appointment of FCC as preferred bidder – December 2014

Detailed planning permission granted – October 2015

Confirmation of HZI as preferred partner – December 2015

SEPA environmental permit granted – December 2015

Financial close and contract award – October 2016


Location Map for Millerhill RERC close to Edinburgh, Scotland


Aerial View, January 2015


Millerhill Zero Waste Park Site

Part of former Millerhill marshalling yards was acquired by the partner councils and offered to the bidders for the

Zero Waste projects

Site risk contractually covered by HZI

Shortly after construction commencement, a major live drain was identified on site, which cut right across

the location of the bunker!

The total process took around 6 months and required close cooperation between the parties to ensure that there

was no impact on the delivery of the scheme


What Did the Contracts Require?

Treatment of up to 135,000 tonnes per year of residual waste from the City of Edinburgh Council and Midlothian

Council areas for 25 years

20,000 tpa plant capacity will be used for other municipal contracts or commercial & industrial waste

Designed with the option to export heat in future

155,000 tonnes per year energy-from-waste plant

Front-end mechanical pre-treatment facility capable of removal of recyclable metals

CV capability range 7 to 12 MJ/kg (design point 9.4 MJ/kg)

Designed with the option to export heat in future


Millerhill Low Carbon District Heating Project

In Scotland, SEPA (Scottish Environment Protection Agency) requires that within 6 years of operation an EfW

must have found a solution for heat offtake

Up to 20MWth available for the plant

Edinburgh and Midlothian are developing a district heating scheme for the “new town” development that will

surround Millerhill to the south and west

This will be the largest district heating scheme in Scotland, fully supplied by the heat generated at Millerhill



The Millerhill Project

18

The Project – the 3D Vision


The Project – Main technical data for EfW plant (the «main» facility)

Number of processing lines 1

Thermal capacity: 50 MW per line

Nominal waste throughput: 19.35 t/h per line; 155,000 tpa

Grate: Air-cooled grate firing

Energy recovery: Superheated steam boiler, 6-pass, 400°C / 60 bar(a)

Energy use: Electricity production, CHP-enabled

Gross/net electricity output 14.245 MW / 12.49 MW

Flue gas treatment: SNCR and XeroSorp Dry System

Cost: £142M or A$268 at FX: £0.53 = A$



General Plant Arrangement

21

ERF Longitudinal View: Chute to Stack


RECEPTION

HALL

BUNKER BOILER

HALL

FGT AREA TURBINE

HALL

ACC

22

Mechanical Pre-Treatment Plant


BUNKER MECHANICAL PRE-TREATMENT

PLANT

WATER

MANAGEMENT

23

Progress Summary


Progress Phases

Phase 1: Culvert diversion works 1.5 month

Phase 2: Main civil works allowing M&E to start 9 months

Phase 3: M&E installation including preassembly 12 month

Phase 4: Commissioning and testing (including reliability test) 8 months


NTP06.10.16

2017 2018 2019

Start M&E Erection07.08.17

End M&E Erection31.08.18

Start Commissioning07.08.18

Start Civil14.11.18

End Civil24.08./12.09.18

Erection: 12 months Commissioning: 8.0 monthsCivil: 9.0 months

PAC17.04.19

Planned PAC06.05.19

NTP to December 2016

Site established

Temporary facilities & culvert diversions

Bulk earth works

Waste bunker foundation: completed


June 2017

Major concrete works completed

Roads being installed providing clean access


November 2017

M&E construction well under way

Boiler parts being installed

Steel structure reaching the top

Clean & tidy site


February 2018

Boiler pressure test completed

Turbine and FGT ongoing

Cladding being installed

Admin building installed


August 2018

Start commissioning

M&E erection practically completed

Cladding works progressing

Steam blow started end of August


October to First Fire on 9 November 2018

Hot commissioning ongoing

1st waste delivery 23 Oct 2018

1st waste fire 9 Nov 2018

Civil substantially completed

Landscaping works started


April 2019

Project completed and handed over

Service commencement 17 Apr 2019



New Ways in Execution

33

Fire Strategy


FCC developed fire strategy using in-house experience and local

experts

Full coordination on fire strategy with two insurers and building

control

Managed to satisfy the expectations of all involved, enabling FCC

to find best value insurer for the plant

Quote from Graham Jukes, CHUBB:

“[…] The approach to risk management in respect of the

Chubb insured risks on the project was amongst the best I

have seen […]”

34

Boiler Design and Manufacturing

Boiler design by HZI with assistance of external design

partners

Boiler manufactured globally in various manufacturers’

workshops in Europe and Asia

Installed using one experienced installation company

Fully commissioned by HZI’s own personnel

Confirmed by notified body


Detail

Design

Manufacturer 1

Manufacturer 2

Manufacturer 3

Manufacturer 4

Manufacturer 5

InstallationCommissioning

& TestingSpecification

Hitachi Zosen Inova: Boiler Manufacturing

35

Steel Structure Supply and Installation

Civil and process steel structures have different

requirements in terms of design

However, the installation process is similar

Design and procurement of the civil and process civil

were done seperately

Installation was undertaken by one company under the

direction and supervision of HZI

HZI erection concepts could be easily implemented,

e.g. bunker roof modules

Clear advantages in day-to-day site management,

including optimisation of crane usage

Ability to absorb equipment delivery delays


Site Infrastructure

Traditionally managed by civil contractor

Now undertaken by HZI, including a site facilities

manager

Provides flexibility

Provides high-quality accommodation for the

workforce, enhancing productivity


Site Infrastructure

Fantastic Considerate Constructor Scheme Score

44/50 points Exceptional

Quote from Crystal MacLoed (BREEAM Assessor):

“This is the best CCS score I have ever seen”


HZI Projects Compared – Progress at NTP + 14 Months

Hartlebury (Herefordshire and Worcestershire) Millerhill (Edinburgh & Midlothian)


P-3266 Edinburgh

Health & Safety (HSE)

1'150'000 hTotal manhours

Worked

100 hTotal lost time

Lost Time due to Accidents

Total manhours Worked Total lost time



Innovations

41

Technical Innovations

XeroSorp

Efficient design

Size

Reduced residues

Reduced consumables

Boiler efficiency

Cost-effective

Ready for the future


XeroSorp – Size comparison dry versus semi-dry


XeroSorp inside the Millerhill RERC


Flue gas treatment

Xerosorp lime reactor

Fabric filter

Residue recirculation

ID fan

Stack

Millerhill Recycling and Energy

Recovery Centre (RERC)

XeroSorp – Key Data


XeroSorp - Performance

General performance of the system:

Simple design ensures

- High availability

- Low maintenance costs

- Low operation costs

Reduction in residue costs and additive amount

due to residue circulation

Significant reduction of water consumption

Higher boiler efficiency and control possible

Specific performance results:

The emission limit values can be safely complied

with

The system can be operated with elevated

concentrations of calcium chloride in the residues.

As a result, very low stoichiometric ratios are

achieved (low consumption of lime)

Outlook: review results and tests with regard to

new BREF emission values



Conclusions Millerhiller RERC

47

Conclusions for a partnership with FCC


Working in a partnership approach is key to a successful project

HZI’s set-up changes were successful

Full control throughout to complete project

HZI provides best value for customers’ projects

Future improvements for HZI:

Earlier involvement of HZI will further optimise the project for the customer

Improvements have been identified in HZI’s set-up to the benefit of all new projects

48

3D Model to Reality – it worked!


Roll-out in Australia


WtE – Kickstarting a nascent industry…

…. capable of adding 2 GW baseload capacity and 2,000 jobs

East Rockingham RRF

AUSTRALIA’S WASTE

OPPORTUNITY…

600kt CO2Savings p.a. through

landfill reduction and

avoided methane

emissions

$450mPioneering best-in-class

technology, a first for

Australia, utilising HZI,

the world leader

28MWBaseload renewable

power at a capacity factor

of more than 95%

22 million tpaResidual solid waste going to

landfill across Australia

50+ plantsCould be developed to

handle existing and future

residual waste demand

2,000MWBaseload power capacity

additions nationally with

50%+ renewable

eligibility

287ktpaMSW diverted from

landfill each year through

pioneering Energy-from-

Waste technology in

Australia


Waste is our Energy.Engineering is our Business.Sustainable Solutions are our Mission.

Check our References.


References

Some current Projects in financial close or execution


Client Dubai Municipality

Start-up December 2021

Technology

Furnace Grate furnace (air-cooled)

Energy Recovery 4-pass vertical boiler, turbine

Flue gas treatment SemiDry with SNCR

Technical Data

Fuel Municipal and industrial waste

Waste capacity 1’500’000 t/a (4 x 46 t/h)

Net calorific value 7 – 14 MJ/kg

l The largest Resource Recovery Facility worldwide

l Build, Operate and Transfer project for 30 years Operation

Joint venture formed by Hitachi Zosen Inova (Switzerland) and BESIX (Belgium), a

truly unique partnership, to implement a first class Energy from Waste plant for the

Emirate of Dubai

The facility will convert approximately 1’500’000 tonnes of waste per year into

baseload renewable energy, producing 137MW of electricity at full capacity

Dubai, UAE


Client RT-Invest

Start-up 2022

Technology




Technical Data


Waste capacity 700,000 t/a (3 x 30 t/h)

Net calorific value 7.5 – 12.5 MJ/kg

l EPC turnkey contract for complete plant incl. civil works

l Pilot project for a total of five planned energy-from-waste plants in Moscow and

Kazan

l Plant contributes to Russia’s energy strategy according to which by 2020, 4.5% of

energy must be from renewable energy sources

Moscow, Russia


Client Istanbul Metropolitan

Municipality (IMM)

Start-up 2020

Technology




Technical Data


Waste capacity 1,000,000 t/a in 3 lines

Thermal capacity 3 * 87 MW

l EPC turnkey contract for complete plant incl. civil works and O&M for one year

l Largest energy-from-waste plant for municipal solid waste in Europe

l With 1 Mio t/a largest turnkey project ever awarded in Europe

l The project will be executed by a consortium of Hitachi Zosen Inova and its Turkish

partner Makyol

l Besides electricity the plant provides economical value for the region: One fifth of all

components will be produced locally and construction work will be executed by local

work forces only

Istanbul, Turkey


Ferrybridge 2, UK

l EPC turnkey contract for complete plant

l Multi-fuel facility for RDF and waste wood

l Fuel delivery by road and train

l The plant will be producing enough energy to power around 170,000 homes

l High efficient process with direct driven turbine and flue gas recirculation

l Built adjacent to the existing Ferrybridge C and Ferrybridge Multifuel 1 sites

Client Ferrybridge Mutlifuel Energy 2 Ltd

Start-up 2019

Technology


Energy recovery 5-pass boiler, hanging

Flue gas treatment SemiDry and Wet scrubber, with SNCR DeNOx

Technical Data

Fuel RDF and waste wood

Waste capacity 2 x 35.5 t/h @ nominal

2 x 42.2 t/h @ max

566’000 t/a

Net calorific value 12 MJ/kg at LPN (8.5 – 16.5 is the full range)

Thermal capacity 2 x 117.7 MW

Steam 2 x 145.1 t/h (73 bar, 430°C)


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