© 2009 UNIVERSITY OF ROSTOCK | FACULTY OF AGRICULTURAL AND ENVIRONMENTAL SCIENCES

“Municipal Solid Waste Treatment Modeling to be SRF for Cement Industry”

Case Study, PT Indocement CitereupIndonesia

7/15/2019

Angga Kusuma

Universität Rostock Agrar- und Umweltwissenschaftliche Fakultät

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Indocement Location

PT Indocement Tunggal Prakarsa Tbk. (Indocement)operated since August 1975 and under subsidiary of HeidelbergCementLocated in Indonesia, South East of Asia

CiteureupPlants

TarjunPlant

Citeureup, Bogor, Wes Java: 10 Plants(15 M. Ton Cements/year)

Research Location

BACKGROUND :

Population Growth

Indonesia:

2018 : 266 Million

2050 : 321 Million

(World Population Clock, 2019)

Urban Activities

Municipal solid waste such as waste, paper,

cardboard, plastic, textile, wood, glass, etc

MSW Used to Alternative Energy

Process MSW to RDF.

Heating value of RDF can reach 15 MJ/ kg or more, moisture content below

20%

Process MSW to SRF

equipped with the right processing unit and

affordable costs.

Problem statement

Moisture = 62%LHV = 3 MJ/Kg

SRFMoisture = 20%LHV = 14 MJ/Kg2D Size < 5 cmCost = 15 €/ton

Raw Municipal Solid Waste Treatment Facility Alternative Fuel Cement Plant

Non Combustible Raw MSW No Treatment Facility Yet in Indonesia

SRF Quality Specs & Cost

Fuel Cost €/ton MJ/Kg €/JFine Coal 70.0 23 3.0 SRF 15.6 14 1.1

Fuel Cost Comparison

Indocement willingness to pay

Problem Statement

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• To design Waste Treatment Modelling that has SRF output with <25% Moisture, < 5cm 2D Size and 14 MJ/kg Calorific Value

Quality

• To design 300 tpd (100,000 tpa) input Waste Treatment ModellingSupply

• To design Waste Treatment Modelling that offers SRF costs of 15 euros / ton Financial

Objectives

Objectives

EN 148991 published by the European Committee for Standardization• Random sampling can be used to get solid waste samples that represent all solid waste

European Commission (2004)• Sampling from external containers outside the house on the roadside

UNI 10802: 2013 (Wastes – Manual Sampling and Preparation of Sample and Analysis of Eluates)• To determining the sampling plan, the technique used in sampling, and the procedures for packing, storing, and

transporting samplesNT ENVIR 001: 1995 (Solid Waste, Municipal: Sampling and Characterisation)

• Coning and Quartering method to get the required sample sizeLeachate Sampling (Environment Agency, 2013)

• 2 kg samples with particle size of sample <10 mmBio-drying

• Box Bio-drying, 1.52% Moisture loss/dayCost

• Tipping Fee and SRF Cost by Interview• Treatment cost by calculation and get from suppliers

Methods

Service Area

MSW Treatment Facility

The treatment facility of 300 tpd MSW is planned to be located 1 KM from

Indocement to collect waste from Citeureup

regency

Existing Area, 10 ha

MSW Quality & Treatment Flows

70 Temporary MSW Storage,

300 tpd or 100,000 tpa

MSW Treatment Facility

Pre-processing

Box Bio-drying

Post Processing

IndocementPlant

5 unit Compactor truck 25m3

Collection at 21.00 – 05.00 WIB to avoid traffic jam

3 unit Compactor truck 25m3

Paper/Cardboard; 7,31%

Textiles; 7,66%

Wood; 4,03%

Plastic; 20,90%

Rubber; 1,76%

Inerts; 1,00%

Ferrous; 0,31%Alumunium; 

0,25%

Organic Coarse; 56,72%

Fines < 2 mm; 0,00%

Others; 0,06%

MSW Quality :

Moisture62.27%

Heat Content3.1 MJ/Kg

Sulfur0.02%

Chlorine 0.13%

Treatment Flows

Raw MSW

Pre-processing

Bio-drying

Post-Processing

SRF Product

100,000 tpaMoisture = 62%LHV = 3 MJ/Kg

97,088.48 tpa to Bio-dryingRecyclable Plastics = 965.68 tpa

Bag Opening

200 mm screening

Manual Sorting

100 mm Shredding

17 Box-drying3,912.65 tpa Leachate

46,083.84 tpa Air48,091.99 tpa Dried MSW

Collected from 70 MSW Temporary Storage

20 mm Screening

Air & Magnetic Separator

Optical Sortir& Eddy Current

50 mm Shredding

236.1 tpa Fe168.8 tpa Al

15,900.0 tpa Landfill

Sale to Cement Plant32,383.4 tpa SRFMoisture = 22.5%LHV = 13.6 MJ/Kg

Treatment Process

No Material Quantity (Tpa) Yield (%) MC (%) Cl (%) S (%) LHV (MJ/kg)

1 MSW Input 100,000.0 100.0% 62.3% 0.33% 0.02% 18.52 Output2.1Leachate 2,912.7 2.9% 100.0% 0.00% 0.00% 0.02.2Evaporated Water 46,083.8 46.1% 100.0% 0.00% 0.00% 0.02.3Moisture Loss due to Mechanical 

Friction1,349.6 1.3% 100.0%

2.3SRF 32,383.4 32.4% 22.5% 0.67% 0.05% 13.62.4Recyclable Plastics 965.7 1.0% 0.1% 0.87% 0.02% 35.12.5Recyclable Fe 236.1 0.2%2.6Recyclable Al 168.8 0.2%2.7Landfill 15,900.0 15.9% 31.2% 0.66% 0.05% 11.5

Total 100,000.0 100.0%

Summary Mass Flows

Bio-drying Dimensioning

Input FeedstockMatrices % Waste In Qty (tpy) Density (t/m3) Volume (m3) MC (%)

Biodrying Material Input 97.09% 97,088.48  0.5 194,177  62.87%

Bio‐drying (Biotunnel) Data

Heap Length (m) Width (m) Height (m) Heap Volume (m3) Heap Mass (t)

24 10 3.5 840 420Design Results

Output Biodried Material (tpa) MC Bio‐dried (%)

Retention Time + Filling time 

(dd)

Annual Bio‐drying cycles

No. of Biotunnel Required

Blower Min. Power (kwh) Area (m2)

48092 26.9% 26 13.8 17  7.5 20,000.00 

3.5 m

10.0 m

10.0 m

24.0 m

1. CAPEX €Mechanical and Electrical Equipments 2,215,242.21 Operational Vehicles 1,035,481.85 Civil Work 821,718.75 Land 1,340,625.00 Installation for mechanical and electrical work 257,750.00 Investment Cost Total 5,670,817.81

-Project Management Cost (2,0%) 113,416.36 Value Added Tax (10,0%) 567,081.78 Import With-holding Tax (2,5%) 355,908.29 Working Capital 83,661.52 Initial Funding Requirement 6,790,885.76 Difference 5.17 Rounding - Financing Principle 6,790,937.50 Capitalized Interest 332,755.94 Total Initial Investment 7,123,693.44

2. OPEX €/YearFuel 185,032.68 Support 173,875.00 Mechanical electrical 31,133.16 Vehicle Maintenance 51,774.09 Heavy Equipment 2,589.78 Building 8,217.19 Unit Processing 112,912.88 Total OPEX 165,301.68

3. Human Resources €/Year

Director 26,250.00 SHE Inspector 5,250.00 Manager 9,000.00 Secretary 3,000.00 Finance 5,250.00 HRGA 5,250.00

Security 12,000.00 House Keeping 2,250.00 Receptionist 3,000.00 Maintenance Staff 5,250.00 Marketing Chief 5,250.00 Laboratory Chief 5,250.00 Laboratory Staff 3,750.00 Processs Chief 5,250.00 Admin Process Staff 3,000.00 Unloading and Loading Staff 3,000.00 RDF Staff 3,750.00 Recycling Staff 3,750.00 Bio-Drying Staff 3,750.00 Truck Driver 15,000.00 Heavy Equipment Driver 7,500.00 Sub Total 135,750.00

Cost Structure

Cost Structure Value Service Years Unit Cost for MSW 100,000 tpa (€/ton)CAPEX (€) 7,123,693.44 10 7.1Depreciation (10%/year) 7,123,693.44 10 7.1OPEX (€/Year) 165,301.68 1.7Human Resource (€/Year) 135,750.00 1.4Total 17.3

No Material Quantity (Tpa) Unit Cost (€/ton) Total Cost (€/Year)

Remarks

1 MSW Input 100,000.0 17.3 1,725,790.37 1.1Tipping Fee From Local Gov. 100,000.0 -14.1 (1,406,250.00) Local Gov pay for Waste

treatment service2 Material Output

2.1SRF 32,383.4 -15.6 (505,990.53) SRF Sales to Indocement

2.2Recyclable Plastics 965.7 -93.8 (90,532.94) 3R material sales2.3Recyclable Fe 236.1 -112.5 (26,557.31)2.4Recyclable Al 168.8 -112.5 (18,992.81)2.5Landfill 15,900.0 7.8 124,218.64 Landfill Cost

Total (Margin) -2.0 (198,314.59) 11.5% from Unit Cost

Unit Cost

Business Model

Treatment Facility

100,000 TPA MSW

14.1 €/Ton Tipping Fee

17.3 €/Ton Treatment Cost

Cement Plant

15.6 €/Ton SRF Sales

3R Party93.8 €/Ton

Plastics, 112.5 €/Ton Fe & AL Sales

Net Margin 2 €/Ton MSW

€198,314.59/Year

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• To design Waste Treatment Modelling that has SRF output with <22.5% Moisture, < 5cm 2D Size and 14 MJ/kg LHV. Treatment process takes 26 days.

Quality

• 100,000 tpa or 300 tpd MSW can be converted to 32,383.39 tpa or 98 tpdSRF

Supply

• Unit cost for MSW Processing is 17.3 €/Ton MSW.

• Income: Tipping Fee = 14.1 €/Ton, SRF Sales = 15.6 €/Ton and 3R Plastic and Metals

• Treatment Facility get 2 €/Ton MSW or €198,314.59/Year net margin

Financial

Conclusion

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Next Step

1. SRF Supply is expected to Reach 500 tpd to get significant Coal Replacement in Cement Production. So that further research can be done by multiplying 5 of these treatment designs

2. Modeling for waste originating from Commercial waste. This waste is thought to be drier than MSW so the treatment costs are expected to be lower.

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Thank YOU!!!

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