Feasibility Study for Organic Waste Diversion & SLCP

Feasibility Study for Organic Waste Diversion & SLCP

Avoidance in Penang, Malaysia

Final Report

31 March 2017

KANSO Co., Ltd.

For Global Environment Centre(GEC)

Supported by:

Contents

Ⅰ．Contents of the project ........................................................................................................................... 1

1. Project name ........................................................................................................................................... 1

2. Objectives................................................................................................................................................... 1

3. Scope of works ........................................................................................................................................... 1

3.1 Activity 1 – Feasibility study for Material Recovery Facilities (MRF) and Bio-Digester at the Pulau Burong

landfill site .................................................................................................................................................. 1

4. Risk assessment .......................................................................................................................................... 2

5. Dispatch landfill concessionaire/operator for Technology training in Japan and presentation in the stakeholders’

workshop ....................................................................................................................................................... 2

6. Study period ............................................................................................................................................... 3

Ⅱ. Study results ............................................................................................................................................ 4

Activity 1 – Feasibility study for Material Recovery Facilities (MRF) and Bio-Digester at the Pulau Burong landfill

site ................................................................................................................................................................. 4

1. Characterization of wastes ........................................................................................................................... 5

2. Obtained values in the study for FS ............................................................................................................ 18

3. Material recovery facility (MRF) and biodigester ......................................................................................... 19

4. Estimation of CH4 reduction and SLCPs reduction converted to CO2 ............................................................ 21

5. Building and proposing appropriate business model ..................................................................................... 22

6. Facilities for better recycling ...................................................................................................................... 27

7 Realistic scale ............................................................................................................................................ 29

8. Rough estimate of construction cost ............................................................................................................ 31

10. Comparison of methane recovery installation cost with incineration ............................................................ 44

11. Available technologies developed by Japanese manufacturer regarding methane recovery ............................. 45

Ⅲ. Others .................................................................................................................................................... 45

1. Risk assessment ....................................................................................................................................... 45

2. Dispatch presenter for technology training in Japan and presentation in the stakeholder’s workshop ..... 48

2.1 CCAC-3 Technology Training in Japan ................................................................................................. 48

2.2 Workshop in Penang ............................................................................................................................ 49

3. Conclusions ............................................................................................................................................. 50

4. References; .............................................................................................................................................. 50

5. Attachments ............................................................................................................................................ 51

1

Ⅰ．Contents of the project

1. Project name

Feasibility Study (FS) for Organic Waste Diversion & SLCP Avoidance in Penang, Malaysia regarding CCAC

Stage III of the “Organic Waste Diversion from Landfill and Avoidance of Short-lived Climate Pollutants

(SLCPs)” Under the Municipal Solid Waste Initiative (MSWI) of the Climate and Clean Air Coalition (CCAC)

to Reduce SLCPs, in Penang, Malaysia.

2. Objectives

This FS is a part of the program to reduce Short-Lived Climate Pollutants (SLCPs) by Climate and Clean Air

Coalition (CCAC) to implement Municipal Solid Waste Initiative (MSWI) with the objectives of enhancing

waste management practices while reducing methane and black carbon emissions.

For Phase I and II of the initiative, GEC supported CCAC by assisting UNEP IETC conduct a “City

Assessment” for Penang, Malaysia in the Stage 1 and prepare a report on Waste and SLCPs with analysis (2012-

2013). In the Stage 2 of the City of Penang, the state government of Penang developed an “Organic Waste

Management Plan” and “Best Practices paper on organic waste management” (2014-2015). GEC was selected

as an implementer of the Stage 3 activities, part of Phase III of the initiative, because its experiences and strong

partnership with Penang developed through waste management projects since 2004.

KANSO has worked on potential to reduce SLCPs（mainly methane）through methane recovery and selected

best practice/technologies to induce sustainable effects.

3. Scope of works

3.1 Activity 1 – Feasibility study for Material Recovery Facilities (MRF) and Bio-Digester at the Pulau Burong

landfill site

3.1.1 Waste Characterization study

The study was implemented at landfill to determine the type and quantity of discards for 5 calendar days. This

waste characterization study was done with MSW samples collected for a period of 5 calendar days from both

Penang Island and Sebarang Perai. Furthermore, MSW samples were also sampled from 13 parliamentary

constituencies. Collected samples were sorted out into the different categories; weighed and recorded e.g.

2

recyclables consisting of paper products, plastics, ferrous metals, non-ferrous metals, organic waste and

residuals for final disposal etc.

3.1.2 Feasibility Study of appropriate MRF and bio-digester technologies

With the aim of providing flexibility for future expansion and upgrading with new MRF technology, the

following matters were studied in this FS.

1) Appropriate MRF technologies for inorganic wastes

2) Bio-digester technology for organic waste, and carry out the

3) Estimation of reducing emissions of methane gas as CO2 by producing biogas (mainly methane gas).

3.1.3 Building and proposal of appropriate business model

The feasibility of bio-digester technology for organic waste will be identified with a possible business model

including design of an appropriate MRF, bio-digester in Pulau Burong landfill.

4. Risk assessment

Major risks including stakeholder participation and the process in the identification of the appropriate

technology and affordability associate with the project activities and the likelihood of their occurrence, were

assessed.

5. Dispatch landfill concessionaire/operator for Technology training in Japan and presentation in the

stakeholders’ workshop

The landfill concessionaire/operator was sent for the technology training organized by GEC. The training

was held on December 2016 to support the landfill operators and governmental officer assisting in learning

technology operation and maintenance, including environmental impact, engineering design and business

models in Japan.

The stakeholders’ collaborated workshop was organized by GEC and the Penang state government. The

stakeholders’ workshop review the Stage 3 activities being implement under this agreement and pending

activities. The next steps and how to replicate to other cities and countries are also discussed at the workshop.

3

6. Study period

Start date 1 July 2016

End date 31 March 2017

4

Separation Recovery Methane

Fermentation Efficient Use

Landfill Disposal / Drainage treatment

Ⅰ Ⅱ Ⅲ

Ⅱ. Study results

Activity 1 – Feasibility study for Material Recovery Facilities (MRF) and Bio-Digester at the Pulau Burong

landfill site

This FS aims at reducing amounts of municipal solid wastes (MSW) and short-lived climate pollutants,

(SLCPs) in Pulau Burong landfill where is the place of the final waste disposal sites of Penang, Malaysia. Figure

2-1 indicates the outline of this FS.

Ⅰ：Material Recovery Facility (Separation and recovery)

Ⅱ：Methane Fermentation

Municipal solid waste Ⅲ：Efficient Use(Electricity, thermal recycle and so on)

Remark: Red dashed square indicates the scope of this study.

Ⅰ・Ⅱ ⇒ Material recovery facility (MRF) and biodigester

Ⅲ ⇒ Efficient Use

Figure 2-1 Schematic diagram of this study

At the Pulau Burong landfill site (Figure 2-2), potential of introducing Material Recovery Facilities (MRF)

and biogas recovery facilities from separated wastes (mainly organic wastes) were investigated.

Organic Waste

Methane

Residue / Waste water Residue

Electricity / Thermal recycle

5

Figure 2-2 Study locations（cited from Google map）

1. Characterization of wastes

For collected and transported wastes into the study landfill, the type and amount were analyzed and evaluated

according to the procedure shown in Figure 2-3.

1.1 Type and amount of wastes in the landfill

In order to evaluate a feasibility of biogas recovery, 500 kg of wastes brought into the landfill were studied

(Figure 2-3). Wastes were separated into 12 types (Figure 2-4) and measured its weight. Moisture percentage as

well as ash content were measured by the AOAC 923.03-1923, ash of flour direct method (Figure 2-5).

Pulau Burong landfill

Ampang Jajar Waste

Transfer Station

6

Figure 2-3 Outline of waste characterization study

Organic waste Non-organic waste

Weight ○ ○ ○ ○ ○

Moisture* ○ ☓ ☓ ☓ ☓

Moisture* - Drying by the oven

Paper (OCC, ONP) Ferrous/N

on-ferrousPlastic Others

PP

PE

PET

HDPE

HP

Organic Green waste

Clipboard

All samples brought in the landfill by 500kg will be the

samples for separation test.

500kg of sample will be separated into the next

types.

7

Ⅰ．Waste separation

Before separation During separation

1. Organic Waste 2. Paper (OCC)

n.d

3. Paper (ONP) 4. GW + Woody C&D

Figure 2-4 (1) 12 types of separated wastes

8

5. Ferrous 6. Non Ferrous

7. Plastic (PP) 8. Plastic (PE)

9. Plastic (PET) 10. Plastic (HDPE)


9

11. Plastic (HP) 12. Others (Unrecyclable)


Ⅱ．Water & Ash Percentage

[Before Drying] [After Drying]

Figure 2-5 Moisture percentage measurement

10

Table 2-1 Results of waste composition study

Island (MBPP) Study date

8/25 8/26 8/29 8/30 8/31 average

Organic Waste 45.1 68.1 39.5 44.9 68.3 52.3

Moisture

(average)

53.0 59.0 - - -

Paper (OCC) 2.2 6.8 8.0 1.4 - 3.4

Paper (ONP) - 1.4 - - 4.8 1.0

GW+Woody C&D 6.5 7.6 - 2.2 - 4.1

Ferrous 1.3 0.5 1.4 0.9 0.2 0.9

Non-Ferrous 0.1 0.1 0.2 0.0 0.0 0.1

Plastic (PP) 0.8 1.8 2.0 0.80 0.3 1.1

Plastic (PE) 8.8 11.1 11.9 9.0 7.9 9.6

Plastic (PET) 0.3 0.6 0.8 0.6 0.5 0.5

Plastic (HDPE) 0.1 0.7 0.1 0.3 - 0.2

Plastic (HP) 0.1 - - 0.7 - 0.2

Others 34.6 1.3 36.2 39.1 18.0 26.6

Waste net weight

[tonne]

609.69 662.37 622.18 709.22 592.43

Mainland (MPSP) Study date

8/25 8/26 8/29 8/30 8/31 average

Organic Waste 52.4 44.4 34.3 41.2 38.2 43.9

Moisture

(average)

68.6 57.2 - - -

Paper (OCC) 1.6 1.6 6.1 5.7 3.9 3.4

Paper (ONP) - 0.8 - - 0.4 0.2

GW+Woody C&D 5.0 6.7 0.4 - - 3.0

Ferrous 0.8 0.4 1.2 0.8 1.1 0.9

Non-Ferrous 0.1 0.1 0.2 0.1 0.1 0.1

Plastic (PP) 0.6 1.0 1.3 0.5 0.5 0.8

Plastic (PE) 9.1 6.7 7.5 8.3 10.2 8.4

Plastic (PET) 0.5 0.2 1.2 0.3 0.5 0.5

Plastic (HDPE) 0.2 0.2 0.6 0.2 0.5 0.3

Plastic (HP) 0.1 - 0.1 - 1.4 0.3

Others 29.6 37.9 47.2 42.9 43.3 38.3

Waste net weight

[tonne]

1,217.11 1,260.96 1,481.59 1,384.21 854.16

Source：Penang Waste Characterisation Study 2016, Infitech Machinery Sdn. Bhd.

11

Table 2-2 Summary of waste composition study

In 5 days of waste composition survey, % of organic waste was the highest (Figure 2-6) and almost invariable

during 5 days measurement (Figure 2-7). % of organic waste composition was higher in MBPP (52.3 %)

comparing to that of MPSP (43.9 %), reflecting different level of industrial development and economic

condition between two regions. Among non-organic wastes, nearly 10 % is plastic in which PE occupies the

largest proportion.

[%] Stdev [%] Stdev

Organic Waste 52.3 13.9 43.9 6.9

Paper (4.4) (3.6)

OCC 3.4 3.3 3.4 2.1

ONP 1.0 2.5 0.2 0.3

GW + Woody C&D 4.1 2.9 3.0 3.3

Ferrous 0.9 0.5 0.9 0.3

Non-Ferrous 0.1 0.1 0.1 0.04

Plastics (11.6) (10.3)

PP 1.1 0.8 0.8 0.4

PE 9.6 1.7 8.4 1.4

PET 0.5 0.2 0.5 0.4

HDPE 0.2 0.3 0.3 0.2

HP 0.2 0.4 0.3 0.7

Others (Non-recyclables) 26.6 16.0 38.3 6.8

Total 100.0 100.0

Organic

Non-Organic

MBPP MPSP

12

Figure 2-6 Waste composition in 5 days study

Table 2-3 Comparison of waste composition between different years and with KL

When compared the results of this study with other similar studies, organic waste % was as high as those of

2003 waste composition study conducted by UNDP and those of 2011 Japanese government study in Kuala

Source; *Satang for UNDP SWN Study Report 2007, **Min. of Environment,

Japan government. FY 2011 Programme to support feasibility studies for overseas

promotion of venous industries

-10.0 0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0

Others

Plastics

Non-ferrous

Ferrous

GW+Woody

Paper

Organic waste

Composition ratio (%)

MPSP MBPP

Kuala Lumpur

This study 2003* 2011

[%] [%] [%]

Organic Waste 48.1 41.9 42.6

Plastics 10.9 15.9 18.1

Paper 4.0 16.5 13.3

Green waste 3.5 11.0 4.1

Ferrous 0.9 4.2 2.2

Others 32.5 10.5 0.5

Penang

13

Lumpur (Table 2-3). Omran et al. (2009) reported that food waste was the largest among MSW in Penang state

in the studies conducted in 1996, 1997, 2003 and 2004. The tendency that organic waste is the largest component

of the waste stream by weight has still be the same in Penang and which suggests a potential of recovering

methane from organic rich MSW.

% of plastics, paper, green waste and ferrous was lower than those of 2003 study and of Kuala Lumpur which

would be due to intensive recyclable activities. % of paper was only 4 % which drastically decreased from

16.5% in 2003. Most of paper and paper products are sold to newspaper vendors in Malaysia (Omran et al.

2009). Furthermore green waste has been increasingly utilized for tips and other biomass uses (NEDO 2015).

These would have attributed to a significant decrease of these wastes.

Comparing to the composition data of 2003, organic wastes increased in MBPP but decreased in MPSP.

Organic waste composition during 5 days survey has changed daily showing that % of organic waste was lesser

amount but invariable in MPSP. A high fluctuation of organic waste % in MBPP may indicate that MBPP

comprises a higher % of commercial sectors.

Figure 2-7 Daily change of organic waste % in 5 days study

14

Figure 2-8 Water and ash contents in organic wastes

A moisture content of organic waste was relatively high exceeding over 55% both in MBPP and MPSP

(Figure 2-8). Since a high moisture content of MSW affects a transportation cost, many of municipalities place

an effort in reducing moisture content. To reduce moisture content, it would be indispensable to have

cooperation from households since which is the major source of organic waste. Considering that organic wastes

from households normally contains a few % of ash, a high ash content in organic wastes (Figure 2-8) indicates

organic wastes contain not only garbage trash but also rubber, leather, clothes.

Chemical constituents of organic waste were not analyzed in this FS but more detailed chemical analysis

will be necessary when implementation design for methane recovery is needed.

15

Source：Penang Waste Characterisation Study 2016, Infitech Machinery Sdn. Bhd.

Figure 2-9 Locations of the waste separation study in Penang (Plau Burong landfill, 13 parliamentary areas)

13 parliamentary

area

October 2016

16

Waste composition was studied at Penang, 13 parliamentary areas on October 2016 (Figure 2-9). Table 2-4

indicates the results of waste composition study conducted in October 2016 at 13 parliamentary areas of Penang.

Values in the table are indicated as the mean values of the weekday and weekend, respectively. Although some

areas such as Tanjong showed relatively low percentage of organic waste, % of organic waste was almost

identical among areas (Table 2-4). A difference of % of organic waste can be influenced a degree of urbanization.

For example, Tanjong is less populated with lower degree of urbanization, therefore generates less amount of

organic waste.

Table 2-4 Results of waste separation study conducted at MPSP and MBPP

Seberang Perai (MPSP)

Kepala Batas

Tasek Gelugor

Bagan Permatang

Pauh Bukit

Mertajam Batu

Kawan Nibong Tebal

Organic Waste 52.8 54.9 59.6 45.9 48.5 39.1 35.7

Paper (OCC) 1.8 2.8 3.2 3.7 3.4 5.4 5.5

Paper (ONP) - - - - - - -

GW+Woody C&D 0.7 0.3 0.4 - 0.4 - -

Ferrous 1.2 0.7 0.7 1.4 2.0 0.4 0.5

Non-Ferrous 0.7 0.2 0.3 0.1 0.1 0.2 0.3

Plastic(PP) 1.6 1.4 1.3 1.3 0.8 0.9 1.0

Plastic(PE) 6.6 5.6 5.4 4.7 7.9 6.4 8.1

Plastic(PET) 1.0 1.4 0.9 1.0 1.9 0.6 1.0

Plastic(HDPE) 0.4 0.6 0.5 0.4 0.8 0.3 0.3

Plastic(HP) - 0.2 - - - - 0.1

Others 33.2 32.1 27.9 41.6 34.0 46.7 47.5

Total 100.0 100.0 100.0 100.0 100.0 100.0 100.0

Penang Island (MBPP)

Bukit Bendera

Tanjong Jelutong Bukit

Gelugor Bayan Baru

Balik Pulau

Organic Waste 48.7 31.8 38.8 42.4 43.9 44.9

Paper (OCC) 3.8 5.0 1.7 1.0 6.0 0.8

Paper (ONP) - - 0.2 - - 0.2

GW+Woody C&D - 0.2 0.2 0.5 0.4 0.2

Ferrous 0.9 1.7 0.6 0.5 0.8 1.9

Non-Ferrous 0.2 0.2 0.3 - 0.2 0.1

Plastic (PP) 0.8 1.3 1.6 1.3 1.1 1.5

Plastic (PE) 8.3 8.6 5.7 6.4 17.0 6.5

Plastic (PET) 1.1 0.8 1.1 0.9 1.1 0.7

Plastic (HDPE) 0.4 0.5 0.5 0.3 0.1 0.4

Plastic (HP) 0.4 0.3 0.8 - 0.1 -

Others 35.4 49.7 48.6 46.7 29.2 42.9

Waste net weight

[tonne]

100.0 100.0 100.0 100.0 100.0 100.0

Source：Penang waste characterization study repot 2016

17

Based on the data of Table 2-4, mapping for different composition of MSW was made. Organic waste was

more generated in the north regions of MPSP (Figure 2-10) and ferrous in the west part of island and the middle

of mainland. Paper and plastic were likely to be higher at the urban areas.

Figure 2-10 The composition of generated wastes according to the region

18

2. Obtained values in the study for FS

Waste composition study provided necessary values for conducting feasibility study to evaluate potential of

methane recovery in the Pulau Burong landfill. Hereinafter values shown in Table 2-5 are used for examining

recycle in the landfill and for estimating methane recovery in the landfill.

Table 2-5 (1) Used values for estimating methane recovery in the landfill

(Actual condition)

Item Value Remarks

Amounts of wastes brought into the

landfill

1,800t/day

Based on oral interviews and literature

Separated wastes 250t/day Based on oral interviews

Ratio of organic waste 48.1% From Table 2-1

Water content of organic waste 60% ditto

Solid ratio of organic waste 40% ditto

Sorting work force 10 persons/shift Based on hearing, 3 shifts

Table 2-5 (2) Used values for estimating methane recovery in the landfill

(Expectation)

Item Value Remarks

Amounts of wastes brought into the

landfill

2,450t/day Based on official population statistics

Effective % among all collected

organic wastes for methane recovery

10% Based on past experience

Organic matter solids for methane

recovery

20t/day

19

3. Material recovery facility (MRF) and biodigester

3.1 Sorting facilities for non-organic wastes

MRF, crushing sorting machine which has been used in Nantan Clean Center, Hyogo, Japan can be considered

as adequate model and to be introduced in the landfill. In this Center, 6 different procedures are integrated to

collect waste materials which are 1) separation unit, 2) rotary crusher, 3) magnetic collection machine, 4)

particle size sorting machine, 5) aluminum sorting machine, and 6) hand sorting conveyor (Figure 2-11, 2-12).

Among which 1) separation unit has original crushing procedures composed of two different crushing steps.

The first step is the crushing by the biaxial crusher and followed by the crusher as the second step. If this

machine is installed ahead of belt-conveyer in the study landfill, sorting efficiency will be improved. The

manufacturer of this machine is Matsumoto Iron Works Inc. Nominal treatment capacity is 38t/d and there is no

bigger capacity than this. This company currently doesn’t sell this machine to overseas, however Moki Co., Ltd

which is introduced in page 35 has same technology and can provide in Malaysia

Figure 2-11 A high efficient crushing and sorting machines in Nantan Clean Centre, Hyogo, Japan

Shaft for

Blade Hammer

Blade

Hammer Casing

Blade Hammer

Screen

Drive Axis

Latter Screen Former Screen

Running

Stopping

Organic Waste

Crushed Waste

(From two-axial crusher)

Residue

Methane

Fermentation

20

1.Rotary crusher 2. Magnetic cobbing machine

3. Particle size sorting machine 4. Aluminum sorting machine

5. Hand sorting conveyor

Figure 2-12 The facilities in the Recycle Centre of Nantan Clean Centre, Hyogo, Japan

21

4. Estimation of CH4 reduction and SLCPs reduction converted to CO2

In order to assess Greenhouse Gas (GHGs) and Short Lived Climate Pollutants (SLCPs) (such as black

carbon) from waste management and then to identify suitable alternative solutions in order to develop climate

friendly waste management systems, the CCAC MSWI emission quantification tool was used. This tool was

developed by the Institute for Global Environmental Strategies (IGES) for the Waste Initiative.. Using this tool,

CH4 and SLCPs reduction due to methane recovery were estimated (Figure 2-13)

Figure 2-13 Amounts of material at each operation at business as usual (BAU) and methane recovery

4.1 CH4 reduction

Two different scenarios were considered in this tool, one is the case for using 20 ton/day organic waste in

methane recovery and another is 40 ton/day. At present methane emission level is 931,111 kg/month since all

organic wastes disposed in the landfill emit methane continuously. If 20 ton/day organic waste is used for

methane recovery, net climate impact of GHGs are 112 tons of CO2-eq/month and which increased to 228 tons

of CO2-eq/month if organic wastes to use for methane recovery increases from 20 to 40 ton/day (Table 2-5).

4.2 SLCPs reduction

Figure 2-14 indicates impact of GHGs (CO2 equivalent) by methane recovery. 40 ton/day (Scenario 2) was

almost double than 20 ton/day (Scenario 1) in terms of GHGs reduction. CO2 reduction by different level of

recycling was estimated (Table 2-7). Currently, not all of plastics are recycled, around 80% of PE and HDPE

are possibly collected. If all of these PE and HDPE are recycled (Scenario 1), 2159.6 ton CO2-eq/month can be

reduced. And if all types of plastics are recycled, 3515 ton CO2-eq/month will be reduced.

Business as Usual (BAU)

Collected waste(807,455 ton/year)

Treatment of separated waste

Treatment of remaining mixed

waste

Composting(0 ton/year)

Anaerobic digestion(0 ton/year)

Recycling(179,789 ton/year)

MBT(0 ton/year)

Incineration(0 ton/year)

Landfilling(714,461 ton/year)

Collected waste(807,455 ton/year)

Treatment of separated waste

Treatment of remaining mixed

waste

Composting(0 ton/year)

Anaerobic digestion(7,300 ton/year)

Recycling(179,789 ton/year)

MBT(0 ton/year)

Incineration(0 ton/year)

Landfilling(707,162 ton/year)

Methane recovery (20t/day organic waste)

22

Figure 2-14 Net climate impact of GHGs (CO2 equivalent) by methane recovery

Table 2-6 Estimation of CH4 reduction and SLCPs reduction using the emissions quantification tool

Table 2-7 Estimation of CO2 reduction by different level of recycling

5. Building and proposing appropriate business model

In order to design appropriate facilities for methane recovery, current operation in Plau Burong landfill shall be

understood because it can only clarify which factors are important to enhance organic wastes recovery rate.

5.1 Current situation

According to the statistics for Penang, population has increased around 13% in 6 years from 2010 to 2016,

exceeding 1.8 million. Assuming that amount of waste is correlated with population, amount of daily waste in

2016 would be 2,450 ton (Table 2-8).

Moreover, 49-months record from July 2012 to July 2016 (Source; PLB, 2016) showed the mean daily waste as

1,753 ton (1,518 – 1,969 ton) which is almost stable with ±13% without seasonal fluctuation. A mean daily

waste as of October 2016 was 1,800 ton/day (from hearing by KANSO mission team).

Nevertheless there are different figures, we adopted a daily waste amount, 2,450 ton/day in this FS.

-250.00

-200.00

-150.00

-100.00

-50.00

0.00

50.00

BAU Scenario

1

Scenario

2

Scenario

3

Scenario

4

Net

cli

mat

e im

pac

t (T

onnes

/m

on

th)

Net climate impact from AD

Net BC emissions (tonnes of BC/month)

Net climate impact of GHGs (tonne of CO2-eq/month)

Scenario 1 Scenario 2 Unit

SLCPs CH4 Emissions CH4 biogenic-Direct (unavoidable leakages) 16,800 33,600 kg/month

CH4 fossil-Direct (fuel consumption) 5 5

Other CO2 Emissions Direct (fossil fuel consumption) 4,525 4,525

GHGs Avoided Through electricity production 133,381 266,762

Net impact Net climate impact of GHGs -112.0 -228.6 tonne of CO2-eq/month

Case Conditions

Businesss as usual 80% of PE and HDPE are recycled

Scenario 1 All of PE and HDPE are recycled

Scenario 2 Plastics are all recycled

2159.6

3515.0

Recycled amount

[t/month]

CO2 reduction

(t-CO2-eq/month)

7,925

9,950

11,102

-

23

Table 2-8 Statistical Data of Penang state (2010/16)

MBPP MPSP Total Unit

2010

Population 741,300 868,500 1,609,800

Annual waste 261,599 528,275 789,874

Waste per capita 0.97 1.47 kg/capita/day

Daily amount 716.7 1,447.3 2,164 ton/day

2016

Population increase

rate (%)

1.9 2.2

Population increase

(%) between 2010 and

2016

11.9 13.9

Population 829,500 989,200 1,818,700

Annual waste 292,729 601,392 894,121 ton

Waste per capita 0.97 1.47 kg/capita/day

Daily amount 802.0 1,647.6 2450 ton/day

5.2 Estimated organic waste amount

5.2.1 Ratio of organic waste among total MSW

Organic waste composition which was measured for 5 days during 25 – 31 August 2016, was 48.1％. Applying

this ratio, the following daily amount of organic waste was obtained,

2,450 × 0.481＝1,178 t (1)

This amount is expressed as wet basis meaning that there still contains a high percentage of water. In addition,

it contains inconvenient materials such as chips, coconut shell which are highly resistant to methanogen

digestion.

Population in MBPP and MPSP as of 2016 was 829,500 and 989,200, respectively which totaled up to around

1,820,000. With the daily amount of MSW, MSW per capita is calculated as

2,450,000 kg ÷ 1,820,000 people＝1,347g/person day

24

Daily amount of organic waste per capita is estimated from the ratio of organic waste, 48.1 %.

1,347 g × 0.481＝ 648 g/capita, day (2)

In the outline survey for MSW in Japan (Min of the Environment, Gov of Japan 2011), the daily amount of

MSW per capita is regarded as 1,000 g/person day and that of food waste as 500 g/person day. In 500 g, 40 %

are considered as inadequate materials for fermentation.

5.2.2 Effective amount for fermentation

Fluidity influences fermentation intensity in a tank. It is difficult to remove organic wastes from wastes having

a high moisture content, therefore 10 % of organic wastes are presumably used as effective amount for

fermentation.

1,178 t which are classified as organic waste, contains 60% of water content (from actual measurement done

in this FS), thus solid content is

1,178 t × 0.40 = 471.2 t (3)

As effective part for fermentation is considered to be about 40％,

471.2 t × 0.40＝188.5 t (4)

Around 10% is the amount which is able to collect after all mixed organic wastes pass through classifier.

188.5 t × 0.1 = 18.9 t ≑ 20 t (5)

As a consequence, 20 t was used for facility design in this FS.

5.2.3 Estimation of methane gas generation

20 t of dry organic waste is regarded as 100 t of wet organic waste if moisture content is 80%. Amount of

biogas generation varies depending on composition of fermented materials. Then sampling test to check gas

generation and fermentation is normally performed using known waste composition in a real plant design. In

this FS, most of extracted organic waste are assumed to be from household origin. According to several reports,

organic wastes derived from household normally produce 110. 3 Nm3/t of biogas.

110.3 Nm3/t × 100 t =11,030 Nm3 (6)

25

5.2.4 Estimation of electricity generation

Calorific value of methane is 9.95kWh/Nm3. Assuming that 60% methane and 30% generation efficiency, one

ton of organic waste produce the following amount of electricity

110.3 Nm3/t × 0.6 × 9.95 kWh/Nm3 × 0.3 ＝197.5 kWh/t (7)

100 t of wet organic waste could generate the following amount of electricity

197.5 kWh/t ×100 t = 19,750 kWh (8)

Therefore, generation capacity is

19,750 kWh/24h＝823 kW (9)

As a result, power generation equipment would be 1,000kVA～1,500kVA

Above procedures for calculating generation capacity of electricity were summarized in Table 2-9 and Table

2-10.

Table 2-9 Values used for electricity generation by methane recovery（measured values）

Item Value Remarks

Amounts of wastes

brought into the landfill

2,500 t/day

According to statistics

Ratio of organic waste 48.1 % From this waste separation study

Water content of organic

waste

60 % From this study

Solid ratio of organic

waste

40 % in-situ measurement

26

Table 2-10 Values used for electricity generation by methane recovery（predicted values）

Item Value Remarks

Effective part for methane

fermentation

40% According to Japanese fact

% of organic waste to be

separated for fermentation

10% According to the previous slide

Organic matter solids for

methane recovery

20 t/day

(dry base)

calculated from predicted available amount of

organic waste (10%)

Biogas generation 11,030 Nm

3 110.3 Nm

3 x 100 t (wet base of 20 t/day)

Amounts of electricity 19,750 kWh Calorific value of methane; 9.95 kWh/Nm

3 , 60%

of methane content, 30% of generation

efficiency

Generation capacity 823 kWh 19,750 kWh/24h

5.3 Scale of the expected facilities

When track records are compared, nominal receiving amount of each facility is expressed as facility capacity.

However, this capacity doesn’t necessarily define exact facility capacity and scale of facility.

Normally nominal receiving amount is calculated from loaded values indicated at collection vehicle regardless

of what kind of waste are collected. Waste composition made from unspoken agreement is used for this

calculation. Consideration is made individually for moisture content of target waste. MSW are composed of all

kinds of wastes. As was measured in this FS, 60 % is the typical moisture content, and upon which dry solid

weight and ash content are measured. Moisture content is fixed for particular food waste, animal manure, sewage.

They are transported by special container so then their moisture content is normally higher than MSW.

Facility design was made based on 280 days. 280 days makes possible to maintain treatment capacity. Annual

value therefore would be 130 % of calculated value (≑ 365/280). Scale of attached facilities like recycling

facility will be decided base on this concept.

5.4 Basic calculation

5.4.1 Dry type and Wet type

Methane recovery has two types, “Dry” and “Wet”. Dry type promotes fermentation under low moisture

content (80%) while Wet type with higher liquidity above 90% of moisture content. Both type has different

27

characteristics and main difference is the stirring power. 5 – 10 higher capacity in Dry type leads to bigger scale

of mechanical and electrical facilities. Wet type demands a larger amount of water to reduce solid waste

concentration, consequently generates larger amount of fermentation liquid. Historically, Dry type has been

developed by heavy industry company while Wet type by water treatment company.

Maximum receiving capacity is 50 t/day in Dry type and 100 t/day in Wet type. Considering track records for

the project facility, Wet type would be better for this project.

5.4.2 Volume of fermentation tank

95% water content is for the design.

Adding water for 20 t organic waste to make 95% water content, one day capacity is 400 m3. Since fermentation

period is ranged from 20 to 30 days, total capacity of fermentation tank is

400 m3 × 20 = 8,000 m3 (10)

Initial scale of fermentation tank is better to be larger than 8,000 m3, then

8000 m3 ×1.3 = 10,400 m3 (11)

Considering workability and stirring efficiency, 2,600 m3 × 4 unit can be recommended.

5.4.3 Capacity of gas holder

Amount of gas storage differs is determined by applied method and gas consumption. Size of gas holder

becomes smaller in case of continuous use. Minimum 1 day capacity shall be secured for the capacity of gas

holder in order to cope with fluctuation of user demand and to keep minimum required pressure. As the inner

pressure is around 20 kPa, 4 holders with 500 m3 of one each can be installed.

5.4.4 Size of the tank

Spiral-type steel tank has an advantage in terms of workability and cost. This type has maximum capacity of

10,000 m3 but its diameter becomes bigger than 25 m to reinforce a strength against pressure given from the

lower parts when liquid is filled in. 25 m is inadequate for fermentation tank in terms of reinforcement of the

ceiling strength and efficient flowing of waste materials in the tank.

Considering track records on the tank, a size of tank would be 16 m of diameter, 15 m of height with 3,000 m3

of the volume. Initial number of tank will be 4 and which can be increased in a response to future demand.

6. Facilities for better recycling

Recycle system shall be designed comprehensively. From counter-measure against waste generation till

recycling of wastes, overall system shall be made in well-balanced and maintained to avoid generation of extra

28

cost and to prevent interference on system construction. First step shall be placed on waste separation at waste

source since separation at waste source enables to collect and transport waste individually. In addition, a high

level separation makes possible to establish collection station for respective type of wastes.

A large number of trials for enhancing waste separation at source has been made worldwide. Since local

condition varies a lot depending on the country and the region, universal method must haven’t exist. However,

separation system should be constructed so as to provide easy method to people. Abiko city, Chiba prefecture,

Japan has been providing the trash bag specified by each category of recyclable wastes, and succeeded in saving

a tax through proper waste separation (Ozawa, 2012). Nakano ward, Tokyo, Japan conducted questionnaire

survey towards inhabitants of the ward and squeezed out particular age group who is not keen on separating

wastes (Nakano ward, 2007). Nakano ward then made specific measures towards that group by designating

waste collection day and time which are convenient for them.

Moreover if recycling is perceived as beneficial by people, separation will be accelerated. In several

municipalities, gained money from recycling has been used for civic life like development of a park. Household

garbage in Abiko city is composed of 38 % of paper/cloth in recyclable wastes (Ozawa, 2012). Implementation

of fee-charging on household garbage ensured waste separation due to economic incentives.

6.1 Receiving at treatment station

Together with individual separation, collection, receiving at a treatment station shall be done along the same

separation line. Separation varies its difficulties depends on waste type. PET and PE are relatively easy to

separate even at a disposal stage. Therefore, many countries commence first separation from these to process

recyclable resin.

A high moisture content of organic wastes frequently becomes problem in separation. Organic wastes are

collected together with other type of wastes in current practice so that a significant amount of organic waste

adhere into others and become inseparable. If complete separation of organic waste from others is achieved,

methane recovery will be significantly improved. However complete separation/collection of organic waste is

quite rare and not many cases in the world.

6.2 Improvement of separation

Problem lies in no complete breaking of plastic bags in the landfill. Normally bag breaking facility is allocated

before Trommel separation machine to remove all wastes from bags immediately after waste disposal.

Incomplete breaking of plastic bags reduce efficiency of mechanical separation and unbroken bags reach to the

stage of hand separation. Allocating bag breaking machine at most beginning stage of separation and adjustment

of mesh size of Trommel separation machine may improve separation efficiency nevertheless all together

collection has always a certain limitation for improvement.

Currently around 10 % of total organic wastes is considered to be effective amount for fermentation but 10 %

29

will increase to 20 % by an improvement of separation capacity.

188.5 t × 0.2 = 37.7 t ≑ 40 t (if separation capacity is improved) (12)

7 Realistic scale

Collected amount would be 20 t which is 10% of total organic wastes, as judged by current level of separation

in the site. For this amount, 2 units of fermentation tank (or 4 units for the case of 5% materials) are ideal for

methane recovery. If collected amount increases by improvement of separation capacity, it will increase to 4

units at 10% to the upper limit.

7.1 Outline of separation and methane recovery facility installation

The area nearby passageway to the landfill is designated as separation yard. 10 separation conveyer with the

same scale as the current one are allocated at the lower part of each conveyer for accumulation of wastes in the

hopper. Separation will be conducted both by Trommel and hand separation which is the same as the current

practice. Consideration should be paid to organize vehicles on separation yard where carry-in and -out vehicles

are moving. Organic wastes are directly loaded into wet type tank by conveyer at adjacent methane fermentation

facilities.

7.2 Separation yard

7.2.1 Separation process

Recyclables are gathered in the hopper nearby passageway and taken out outside the landfill. Among

recyclables, only plastics are processed to make pellets in the station. Organic wastes are gathered in the hopper

nearby methane fermentation yard and brought into methane recovery process. Wastes are collected by the

categories which are organic waste, ferrous, non-ferrous, HDPE, LDPE, PET, PP and paper. Remaining from

these are gathered in the hopper and disposed in the landfill. Individual separation line will be utilized once

recycling process for each category is established. Laborers for separation will work on the platform installed

alongside the conveyer. Height of the platform will be 2 m and conveyer by category is operated. Basic design

of the line is not so different from the current line. Important is to improve efficiency of Trommel through

complete breakage of bags achieved by breaking bag machines. If an introduction of breaking bag machines

doesn’t improve efficiency of Trommel, use of Trommel shall be re-considered.

30

7.3 Breakage and crushing separation machine

This machine installed in Nantan Clean Center is manufactured by Matsumoto Iron Inc. Moki Co., Ltd. has

been producing the breakage and crushing separation machine as same capacity as, or more than that of

Matsumoto Iron Inc. Their products have a high separation performance with 99.9 % of the precision level.

There are a number of models having different waste treatment capacities ranged from 200 kg/hour to 8 ton/hour.

7.4 Fermentation yard

7.4.1 Mixed water

Supernatant water in the lagoon is basically used for fermentation with a premise that affected substances for

fermentation are not included in water. 200 m3～400 m3 of mixed water are necessary per day. It is expected to

store water of one week volume for settling down sediments. 2,000 m3 of water are induced from lagoon into

the receiving tank. At the flowing tank, water will be mixed with organic wastes and adjusted to concentration

(initially 90% of moisture content) at mixture tank (3,000 m3) after removal of solid from bags. Storing water

of 10 days volume will homogenize irregularity of mixture ratio occurring at onset of mixing.

7.4.2 Fermentation tank and peripheral equipment

Install 4 units of fermentation tank with each of 2,600 m3（16 mφ×15 mH）. Try first with 2 units when

moisture content is 90% to check how it goes. If inclusion of solid material is significant, regular cleaning is

necessary but if not, continuous operation for a couple of years is possible.

Sludge of brewery factory is normally used as seed sludge however manure (ex. Pig manure) can be replaced

for it.

Fermentation gas is stored in gas holder after passing through desulfurization equipment. Size of gas holder can

be decided depending on a size of generator and operation frequency. Recommended gas holder is seal, bilayer

type equipped with surplus gas combustion device which can respond an increased inner pressure caused by

surplus storage.

7.4.3 Heating boiler

Heating boiler will be installed to keep stable mesophilic fermentation (35℃) and which can be operated when

necessary. Fuel type would be heavy oil, light oil, purified waste oil, biogas, or their mixture.

31

7.5 Power generation facility

20,000 kWh can be generated from organic wastes. As there is no grid in the project site, sale of electricity

through grid connection is not feasible. The fact that a sale of electricity into the grid requires stable supply is

another reason for infeasibility. Instead self-consumption within the facilities makes it possible to establish a

maximum hourly power consumption according to a duration of separating operation and to operational status

of recycling facilities. For the case facility is only operated at daytime, it would be 3 units of 1,000 kVA gas

power generation and 1 unit of diesel generation.

7.6 Digestion liquid

Digestion liquid generated in fermentation tank shall be treated periodically. Theoretically, same amount as

fermenting raw material (≒200 – 400 m3) is necessary to be treated. If there is a demand for agricultural use,

digestion liquid can be used as fertilizer liquid. However, such a demand is not expected in the project site, thus

water treatment will not be conducted to discharge outside of the landfill. A digestion liquid is transported by

either tank truck or pumping with pipeline and discharged in the landfill.

Discharge method influences how much digestion liquid is stored within the plant. Storage facility to keep

digestion liquid would be over one month volume (≒6,000 m3). If possible to transport continuously and/or

frequently, small tank would be sufficient. If a demand for fertilizer liquid occurs in the future, large tank will

be necessary.

8. Rough estimate of construction cost

Calculation of overall construction cost is rather difficult. One reason is that most of Japanese manufacturer

cannot provide a service for export so that cost estimation only can be made in domestic basis. Unit construction

cost differs between Japan and Malaysia. Costs of construction materials fluctuates and access to construction

site, ground condition also influence overall cost. Hereinafter, construction cost is estimated as the case in Japan.

8.1 Cost estimation by each step

1st step

Utilize the current line and install breaking bag machine at the most upper part of flowing line in order to

32

improve efficiency of organic waste collection

2nd step

Add new separation line including breaking bag machine at new area.

3rd step

Add collection conveyer line at each category of wastes and install hopper at the end of the line.

4th step

Construction of methane recovery facilities which are mix water facility, methane fermentation tank,

desulfurization tower, power generator, discharge facility of digestion liquid.

Table 2-11 (1) Cost estimation according to the step

STEP Outline

Rough

estimation

［million yen］

Remarks

1 Basically the existing line is used

and add newly breaking bag

machine at the most upper part of

the line

40 Installation of bag breaking machine

including hopper and conveyer

2 Add 1 new separation line

including breaking bag machine at

new area

70 Separated waste by category is

collected in bag. Platform as working

place is included.

3 Install the collection conveyer

lines for each categorized waste

and the hopper at the end of the

line

300 9 conveyer and hopper by category.

Organic wastes are conveyed into the

inlet of methane fermentation facility

4 Construction of methane recovery

facilities including mix water

facility, fermentation tank,

desulfurization tower, power

generation facility and digestion

liquid discharge facility

6,000 Overall methane fermentation facility

including maintenance room

33

Table 2-11 (2) Electricity expense and labor costs

Electricity expense

USD（RM）

Source

Electricity

expense (Grid）

USD 0.08/kWh

（RM0.33/kWh）

Tenaga Nasional Berhad 2013 （ Overseas electricity

statistics 2015）

JAPAN ELECTRIC POWER INFORMATION CENTER

" ; JEPIC

Labor cost USD317/person, month The Bank of Tokyo-Mitsubishi UFJ, Ltd (BTMU) Global

Business Insight Area Report 432

USD1.00＝RM4.0495（As of 30 August 2016）

Table 2-11 (1) shows rough cost at each step. Electricity consumption will be increased coupled with

installation of facilities. Electricity expense and labor costs are indicated in the Table 2-11 (2).

［1st step］

To the existing line, add newly breaking bag machine at the most upper part of the line and biaxial crusher.

And changes on collection efficiency of organic waste will be monitored. Introduction of these facilities is

likely to improve recycle rate of polybags and to reduce labor costs and landfilling costs (Figure 2-15) while

depreciation costs and operation/maintenance costs will increase due to these installations.

Existing line

New breaking bag machine

Figure 2-15 Installation of new breaking bag machine makes in 1st step

34

Although the breaking bag machine is already installed in Pulau Burong landfill, wastes are not properly

separated due to incomplete breakage of plastic bag (Figure 2-16). According to the waste separation study,

approximately 23 t/day of PE at maximum can be recycled. However much less amount of PE have been

recycled due to insufficient collection. Installation of appropriated breaking bag machine could enhance

amounts of recycled materials as well as those of organic waste which relate with methane recovery.

Figure 2-16 Incomplete breakage of plastic bags

9. Introduction of breaking bag and crushing & sorting machines

A number of breaking bag and crushing & sorting machines has been manufactured by companies. The

crushing method varies among machines depending on a type of target material. Table 2-12 demonstrates those

machines manufactured in Japan.

Table 2-12 Breaking bag and Crushing & Sorting machines made in Japan

Type Name Manufacturer

Breaking bag machine PB12-16 Pioneer Gisetsu Co., Ltd.

HTP-15S Osaka NED machinery Co., Ltd.

Crushing and sorting machine MK2208 Moki Co., Ltd.

1) Pioneer Gisetsu Co. Ltd. (http://pioneer-gisetsu.co.jp/)

This is efficient breaking bag machine (Figure 2-17) which can

enhance collection rate of PE bag by installing before the existing

conveyer. Specification is indicated in the Table 2-13.

Figure 2-17 PB12-16

Incomplete breakage of plastic bags

http://pioneer-gisetsu.co.jp/

35

Table 2-13 Specification of PB12-16

Type Size[mm] Motor[kW] Speed[t/h] Price[RM]

PB12-16 7500 x 1700 7.5 10(max) 0.6mil.※

※Price at hand-over at factory

Figure 2-18 Principle of breaking bag, PB12-16

2) Osaka NED machinery Co., Ltd.

This breaking bag machine (Figure 2-19) can increase collection rate of PE bag by installing before the

existing conveyer.

The machine repeats rotation of blade forward and reverse and enhance ability of breaking bags (Figure 2-

20). Furthermore wrapping is prevented by this repeated rotation.

Figure 2-19 Outlook of the machine Figure 2-20 Principle of crushing

Table 2-14 Specification of the machine

Type Size[mm] Motor[kW] Speed[m3/h] Price[RM]

HTP-15S 2100 x 3381 x 3300 11 120(max) 0.6mil.※


Air cylinder

Direction of flow

From Hopper Direction of flow

Air cylinder

36

3) Moki Co., Ltd.

MK2208 type produced by Moki Co., Ltd has the

specification indicated in the Table 2-13. This machine can be

used together with other company’s machine, enabling to break

and separate organic wastes at the same time. Washing is also

possible when cleaned plastic is required for recycling.

Figure 2-21 MK2208


Type Size[mm] Motor[kW] Speed[m3/h] Price[RM]

MK2208 1450 x 4835 x2275 22 16(max) 1.6mil.

Figure 2-22 Principle of the machine

Input Organic waste Plastic (PE etc.)

37

［2nd step］

Add one new line to 1st step. Recycle rate of polybag will significantly increase and subsequently reduce

landfill cost. However, depreciation costs and operation/maintenance costs will increase due to these

installations.

Table 2-16 Specification of recommended machines and its cost

Pre-treatment Methane Fermentation

Type of

Machine

Breaking bag

machine

Conveyer Crushing &

Sorting machine

Fermentation

Tank

Gas tank Liquefied and

usage of

methane

Manufacturer Osaka NED

Co., Ltd.

Existing Moki Co., Ltd. Swing Co., Ltd.

Initial cost

[RM]

0.6mil. - 1.6mil. 24～28 mil.

Maintenance

cost [RM]

0.1mil.

（3% of initial cost）

0.7～0.8mil.

（3% of initial cost）

Electricity use

[kWh]

132 318 528 4.8 －

Water use

[t/day]

－－ 60 8 －－

Labor 10 person/shift × 3 shift/day (no additional labor for the new machines)

※Operators are not needed for normal operation in breaking machine and fermentation tank. If necessary, labors in conveyer can attend

38

Figure 2-23 (1) The proposed flow for better waste separation (STEP 2)

Conveyer

PE, HDPE（Recycled in Pulau Burong Landfill）

( 250t/day×0.093=23.25t/day )

－Maximum amount, according to this study －

Organic:120.25 t/day

⇒ 5.0t/hour

(Dry base:48.1t/day)

Crushing and sorting machine

MK2208 (Moki Co., Ltd.)

RM 1.6mil.

Breaking bag machine

PB12-16(Pioneer Gisetsu Co., Ltd.) Osaka NED machinery Co.,

Ltd.

Methane fermentation tank

Nantan Yagi Bioecology Centre

To Landfill

0.25t/day 2.25t/day

Ⅰ

Input：250t/day（≒10t/h）

In questioning

Each RM 0.6mil. (Price of hand-

over at the factory)

Pioneer Gisetsu Co., Ltd. Osaka NED machinery Co., Ltd

Moki Co., Ltd.

Magnet

Sold to other company

Aluminum

Hand Sorting

Steel

PE, HDPE

Others

2 t/day (Dry base)

(10t/day in 80% water)

PE, HDPE

Hand Sorting

Residue

1.25t/day

PET

81.25t/day

23.25 t/day

Proposed Equipments

Proposed Flow

Existing Flow


39

Methane fermentation tank

Nantan Yagi Bioecology

Centre

24～28 mil. RM

Electricity generation

Gas station for the use of forklift, truck

Figure 2-23 (2) The proposed flow for methane fermentation (STEP 2)

Ⅱ Ⅲ

RM 1.3 mil.

Electricity use：4.8kWh

1.3 mil. RM

RM 2 mil.

[Methane gas]

1,103 Nm3/day

Methane

Gas holder

Gas station

[Electricity]

1,975 kWh/day

0.3 %

Purification Compress Storage

Kanpo Recycle Plaza

Kanpo Recycle Plaza


TOYOTA L&F

40

Examples of methane fermentation tanks and methane utilization

[Methane fermentation tanks]

Quantity, quality of organic wastes and applied

microbes for fermentation are decisive to determine

fermentation intensity. Considering amounts and type

of organic waste, volume of fermentation tank was set

as 10,040 Nm3.

Figure 2-24 Methane fermentation (Vietnam, cassava powder）

Assuming that fermentation period is 20 day, 8,000 m3 of tank is at least necessary (Figure 2-25). 400 m3 of

organic waste which comes from 20 ton dry base weight is stocked every day. At the day 21, amounts of

materials in the tank reach 8,000 m3.

Figure 2-25 Expected volume of methane fermentation tank

[Methane utilization]

In order to operate sustainably, H2S and NH4 shall be removed from fermentation gas nevertheless its content

is minor. For the use of vehicles such as automobile and forklift, compression machine, gas station besides

purification equipment are necessary. The following is the case of Kanpo recycling center in Japan where the

mission from Penang visited in 2016.

・Purification, gas station

Figure 2-26 shows the outline of methane gas facilities equipped at Kanpo recycling center.

41

Figure 2-26 Methane gas station (Kanpo recycle plaza)

・Forklift run by methane gas

TOYOTA produces the forklift run by methane gas (Figure 2-27).


Type Length [mm] Rated capacity

[kg]

Total emission

[cc]

Price [RM]

02-8FG25 3,690 2,500 2,237 0.16mil.※


Figure 2-27 Forklift manufactured by TOYOTA L&F

Biogas

CH4+CO2

Desulfurization

equipment

Gas folder Burning equipment for excess gas

Generator

Gas station

Forklift

42

・Generator run by methane gas

Number of manufacturers has been selling generator run by methane gas. Next two companies are the

examples for it.

1) Yanmar Co., Ltd.

This company has top sharing in Japanese generator market and plenty of sale tract.


Type Size [mm] Generation

[kWh/Nm3]

Electricity Price [RM]

Filius 404b BG 3040 x 980 x 1698 4.98 (Hi) 400V/50Ha ？

2) 2G Co., Ltd.

2G is German company which has long experience in generator engineering. This machine can be stored in

container and monitored its operation status in real time.

Figure 2-28 Generator manufactured by 2G


Type Size [mm] Generation

[kWh/Nm3]

Electricity Price [RM]

Filius 404b BG 3040 x 980 x 1698 4.98 (Hi) 400V/50Ha 1.3 mil.

43

［3rd step］

In this 3rd step, new conveyer line will be added to the 2nd step. With this addition, Recycle rates will

significantly increase and subsequently reduce landfill cost. However, depreciation costs and

operation/maintenance costs brought by newly installed facilities will increase significantly. Labor cost also

will be increased because of additional separation work.

1.2 MR will be necessary to introduce new conveyer if Japanese made conveyer is installed. Cost can be

reduced if other cheaper type of conveyer is installed.

［4th step］

Methane recovery and its maintenance facility will be added. By which both methane recovery from organic

wastes and electricity generation can be made. Generated electricity will be used within the facilities in the

landfill, which could reduce diesel consumption. If the project site is connected with the grid, sale of electricity

is also expected. However, depreciation costs and operation/maintenance costs due to newly installed facilities

will increase significantly. Labor cost also will be increased because of an increased separation work.

Figure 2-29 shows the layout map for the 4th step. All necessary facilities are allocated in the proper positions.

This layout map will be modified according to the results which will be obtained from 1st to 3rd steps.

Profitability is greatly affected by initial capital investment, so then public fund would be necessary.

Figure 2-29 Layout map for the 4th step

Water Treatment PlantPower

Generation Operation Center Adminisration Office

Digestive Water Tank400m3×2

Gas Holder 500m3×2+(1)

Water Tank 1000m3

Organic Waste Receiver

Solid Remover

Apprx. 80m

Apprx. 200m

Desuifurization Equipment

Fermentation Tank 2600m3×4+(2) Mixing Tank 3000m3

Excess Gas Burner

Fermentation & Power Generation Site

Section A

44

Figure 2-30 Layout map image for the 4th step

10. Comparison of methane recovery installation cost with incineration

Table 2-20 shows possible cost for installation of biodigester facility and incinerator plant in Japan (Ministry

of Japan, Study on Promotion to Utilize Waste Biomass, 2013). Initial cost is the amount if a half is covered by

a government subsidy. Initial cost of the incineration plants with the capacity of 100 ton/day is much bigger

than that of biodigester plant with the capacity of 25 ton/day. Running cost is also much higher in incinerator

plant. As FIT price is set to a higher price in Japan, income from gas sale at biodigester facility is relatively

high.

45

3 Catastrophic 3 6 9

2 Moderate 2 4 6

1 Negligible 1 2 3

Negligible Moderate Catastrophic

1 2 3

Pro

bab

ilit

y

Impact

Table 2-20 Comparison of annual cost between biodigester technology and incineration in Japan

Source; Min of the Environment, Gov of Japan, 2013

11. Available technologies developed by Japanese manufacturer regarding methane recovery

Technologies of recycling, crushing and methane fermentation have been developed by Japanese

manufacturer. The following is the examples of which and currently available in Japanese market. These

information was taken from the database of Ministry of Environment, Japan

(http://www.env.go.jp/recycle/circul/venous_industry/index_en.html)

Ⅲ. Others

1. Risk assessment

Risk may arise regarding Activity 1 in terms of social, economy and environmental aspects. Thereby,

expected risks are extracted and evaluated according to degree of impact and occurrence frequency. Moreover,

possible protective and reductive methods for these risks are examined.

Figure 3-1 Risk Profile Matrix

UnitBiodigester technology

(25ton/day)

Incinerator plant

(100ton/day)

Initial cost*

Facilities expense and thousand USD 3,500 65,200

base maintenance expense

Running cost

Depreciation cost thousand USD 175 3,260

Electricity cost thousand USD 77 2,777

Fuel cost thousand USD 7.2 156

Water supply cost thousand USD 6.2 130

Sewer cost thousand USD 0 0

Chemical cost thousand USD 50 1,486

Final disposal costs thousand USD 0 2,112

Maitenance cost thousand USD 292 6,519

Total 607.4 16,440

Income

Electricity thousand USD 3,300

Gas thousand USD 1,200

Initial cost* - Half of the initial cost is covered by a government subsidy

http://www.env.go.jp/recycle/circul/venous_industry/index_en.html

46

【Landfill】

Category Item Impact Probability Way of Countermeasure and Mitigation

Environment Occupational Accident 3 2 Installation of protective cover

Setting of no entry area

Safety and Health Education

Creating a work manual

Dust 2 2 Installation of defense cover

Installation of local exhaust equipment

Wear masks

Reduction of dust generation by watering

Noise and Vibration 2 2 Installation of soundproof wall

Use of ear plugs

Installation of anti-vibration equipment

Economy A high Cost for Introduction 3 2 Use of public fund

Use of lease contract

Examination of partial introduction

A high Running Cost 3 2 Adoption of energy conservatin type facilities

Use of house power generation

A high Maintainance Cost 3 2 Use of maintenance contract

Procurement of parts

Decreased sales profit from recyclable

valuables3 2

Quality improvement of recyclable valuable materials

Diversification of buyers

Decrease of amounts recyclable

valuables3 2

Increase of recyclable valuables due to an installation of

breasing & crushing machines

Increase of recyclable valuables due to an increased number

of employees

Increase of recyclable valuables due to employees education

Society Reduction of labour by installing

facilities2 2

Consultation between employers and employees

Impact on labors due to a change of

working time2 1

Consultation between employers and employees


Environment Lignition of methane 3 1 Attachment of fire-prevention equipment

Allocation of fire ban area


Fire safety training


Occupational Accident 3 2 Installation of protective cover




Economy A high installation cost 3 2 Use of public fund



A high power cost 3 2 Adoption of energy conservatin type facilities


A high maintenance cost 3 2 Use of maintenance contract


Reduction of the recyclable organic waste 3 2 Quality improvement of recyclable valuable materials

Society Protest Activities by NGOs 3 3 Public relations

Briefing to stakeholders

Waste Separation Equipment

Methane Fermentation Equipment

Table 3-1 (1) Risk Assessment

47


Environment Noise and Vibration 2 2 Installation of soundproof wall

Use of ear plugs

Installation of anti-vibration equipment

Occupational Accident (Electrification) 3 2 Installation of protective cover




Economy A high installation cost 3 2 Use of public fund



A high power cost 3 2 Adoption of energy conservatin type facilities


A high maintenance cost 3 2 Use of maintenance contract


Reduction of methane 3 2 Quality improvement of recyclable valuable materials

Society Protest Activities by NGOs 3 3 Public relations

Briefing to stakeholders

Electricity Generator

Table 3-1 (2) Risk Assessment

48

2. Dispatch presenter for technology training in Japan and presentation in the stakeholder’s workshop

CCAC-3 Technology Training in Japan was conducted in Osaka, Japan.

Table 3-2 Presentation in Japan and Penang

No. Date Content Location

1 6 December 2016 CCAC-3 Technology Training in Japan

Technology training given by Mr. Taniuchi

KANSO, Osaka, Japan

2 16 March 2017

2.1 CCAC-3 Technology Training in Japan

Date：6 December 2016, 9:00～12:00

Location：Conference room at Kanso headquarter office, Osaka, Japn

Participants：［Penang］Mr. Syamshuar Bin Husin, Ms. Yeap Cyndy, Mr. Khor Hung

［GEC］ Mr. Hirata, Ms. Doi, Mr. Shimizu

［Kanso］ Mr. Takahashi, Mr. Fukuda

This training was held by the lecturer, Mr. Taniuchi who has experience in the field of waste management

over 40 years. Mr. Taniuchi insisted an importance of waste separation when they are generated which is highly

recommendable rather than separation in the later stage. In the training, the fact that collection of separated

valuable wastes and social environment also will affect so much was explained. Training materials are shown

in the attachment 5.

Figure 3-2 Opening remark by Mr. Hirata Figure 3-3 Lecturing by Mr. Taniuchi

49

2.2 Workshop in Penang

Date：16 March 2017

Location：PLB Terang Sdn. Bhd.

Participants：［Penang］YB Phee, Mr. Syamshuar Bin Husin, Ms. Yeap Cyndy, Mr. Khor Hung

[GEC］Ms. Doi, ［KANSO］Mr. Matsui, Mr. Fukuda

Ms. Doi, GEC explained first about CCAC3 Stage3 project for Penang and the progress results of FS were

reported by Kanso. Future plan and business model were discussed. And in which breaking bag machine

and crushing machine which are manufactured in Japan, were introduced using the video.

Figure 3-4

Workshop held in Penang (16 March 2017)

50

3. Conclusions

・ Organic waste is the largest component of the waste stream by weight

・ 20～40 t/day will be available for methane recovery according to waste separation study, and which will

lead to 1,000kVA～1,500kVA of electricity generation

・ Plastic bags are not sufficiently broken and organic wastes are mixed with other non-fermentable when they

come to the landfill. These lower methane recovery rate.

・ Enforcement of waste separation lines and installation of efficient breaking bag machine/crushing machine

are effective to increase rate of organic waste collection

・ Improvement of separation efficiency not only in the landfill also in the source will be effective for enhancing

rates of methane recovery and recycling of other valuable wastes

4. References;

Institute for Global Environmental Strategies (IGES), Climate and Clean Air Coalition (CCAC), (2016) User’s

Manual; A Tool for Quantification of Short Lived Climate Pollutants (SLCPs) and Other Greenhouse Gas

(GHG) Emissions from Waste Sector

Min of the Environment, Gov of Japan (2011) Report on the emission of municipal waste and treatment in

Japan. http://www.env.go.jp/press/press.php?serial=16503 (in Japanese)

Min of the Environment, Gov of Japan (2013) Study on Promotion to Utilize Waste Biomass

http://www.env.go.jp/recycle/circul/venous_industry/index_en.html (in Japanese)

Nakano ward, (2007) Recycling enhancement program. Report of Nakano ward council for waste reduction

promotion (in Japanese)

NEDO (2015) FS report on the project for low-carbon city development through the introduction of package-

style woody biomass power generation in Penang State, Malaysia (in Japanese)

Omran Abdelnaser, El-Amrouni Abdelsalam O, Suliman Larifa K, Pakir, Abdul Hamid, Ramli Mahyuddin,

Aziz Hamidi Abdul. (2009) Soild waste management practices in Penang state: A review of current practices

and the way forward. Environmental Engineering and Management Journal 8 (1): 97-106

Ozawa Asumi (2012) Achievements and challenges of waste reduction and recycling in Abiko City 49; 311-

http://www.env.go.jp/press/press.php?serial=16503

http://www.env.go.jp/recycle/circul/venous_industry/index_en.html

51

327 Toyo University repository for academic resources. http://id.nii.ac.jp/1060/00007265/ (in Japanese with

English abstract)

Tenaga Nasional Berhad 2013（Overseas electricity statistics 2015）Japan Electric Power Information Center

" ; JEPIC

Company profile; Pioneer Gisetsu Co. Ltd. (In Japanese)

Osaka NED machinery Co., Ltd. (In Japanese)

Moki Co., Ltd. (In Japanese)

The Bank of Tokyo-Mitsubishi UFJ, Ltd (BTMU) Global Business Insight Area Report 432

Product Brochure; TOYOTA L&F (In Japanese)

Yanmar Co., Ltd. (In Japanese)

2G Co., Ltd.

5. Attachments

1. Penang waste characterization study 2016

2. Penang waste characterization study 2016: By parliament areas

3. Municipal waste control (6th December 2016 Lecture)

4. Activity 3: Penang CCAC Stage 3 Technology Training in Japan Report (5-8 December 2016)

5. Presentation file on “Waste characterization study” (2 March 2016 meeting)

6. Presentation file on “MRF and biodigester study” (16 March 2016 final meeting)

http://id.nii.ac.jp/1060/00007265/

Documents

Feasibility Study for Organic Waste Diversion & SLCP