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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
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
Firing Up A WtE Plant 4
Construction underway for Australia’s first thermal waste-to-energy facility
Site progress: September 2019 3D-Model of Avertas Energy
5
Firing Up A WtE Plant 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
Firing Up A WtE Plant 6
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
Firing Up A WtE Plant 8
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
9Firing Up A WtE Plant
Towards Zero Waste
11Firing Up A WtE Plant
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
Firing Up A WtE Plant 12
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
Firing Up A WtE Plant 15
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
16Firing Up A WtE Plant
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
Firing Up A WtE Plant 17
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$268 at FX: £0.53 = A$
20Firing Up A WtE Plant
ERF Longitudinal View: Chute to Stack
Firing Up A WtE Plant
RECEPTION
HALL
BUNKER BOILER
HALL
FGT AREA TURBINE
HALL
ACC
22
Mechanical Pre-Treatment Plant
Firing Up A WtE Plant
BUNKER MECHANICAL PRE-TREATMENT
PLANT
WATER
MANAGEMENT
23
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
25Firing Up A WtE Plant
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
26Firing Up A WtE Plant
June 2017
Major concrete works completed
Roads being installed providing clean access
27Firing Up A WtE Plant
November 2017
M&E construction well under way
Boiler parts being installed
Steel structure reaching the top
Clean & tidy site
28Firing Up A WtE Plant
February 2018
Boiler pressure test completed
Turbine and FGT ongoing
Cladding being installed
Admin building installed
29Firing Up A WtE Plant
August 2018
Start commissioning
M&E erection practically completed
Cladding works progressing
Steam blow started end of August
30Firing Up A WtE Plant
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
31Firing Up A WtE Plant
April 2019
Project completed and handed over
Service commencement 17 Apr 2019
32Firing Up A WtE Plant
Fire Strategy
Firing Up A WtE Plant
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
Firing Up A WtE Plant
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
36Firing Up A WtE Plant
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
37Firing Up A WtE Plant
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”
Firing Up A WtE Plant 38
HZI Projects Compared – Progress at NTP + 14 Months
Hartlebury (Herefordshire and Worcestershire) Millerhill (Edinburgh & Midlothian)
39Firing Up A WtE Plant
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
Firing Up A WtE Plant 40
Technical Innovations
XeroSorp
Efficient design
Size
Reduced residues
Reduced consumables
Boiler efficiency
Cost-effective
Ready for the future
42Firing Up A WtE Plant
XeroSorp inside the Millerhill RERC
44Firing Up A WtE Plant
Flue gas treatment
Xerosorp lime reactor
Fabric filter
Residue recirculation
ID fan
Stack
Millerhill Recycling and Energy
Recovery Centre (RERC)
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
46Firing Up A WtE Plant
Conclusions for a partnership with FCC
Firing Up A WtE Plant
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
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
Firing Up A WtE Plant 51
Waste is our Energy.Engineering is our Business.Sustainable Solutions are our Mission.
Check our References.
52Firing Up A WtE Plant
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
54Firing Up A WtE Plant
Client RT-Invest
Start-up 2022
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 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
55Firing Up A WtE Plant
Client Istanbul Metropolitan
Municipality (IMM)
Start-up 2020
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 1,000,000 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
56Firing Up A WtE Plant
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
Furnace Grate furnace (air-cooled)
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)
57Firing Up A WtE Plant