Supporting Statement Application for R1 recovery status by

Supporting Statement – Application for R1 recovery status by Bulwell Energy Ltd (An application based on design data)

Former allotments

Blenheim Lane

Bulwell

Nottingham

NG6 8UR

January 2017

Introduction

This document has been prepared by support of an application for R1 recovery operation status (An application based on design data) for an

Energy from Waste (EfW) installation (‘the installation’) on Blenheim Lane, Bulwell in Nottingham.

This installation currently has an environmental permit ‐ Environmental Permit reference EPR/LP3239NX and an application to vary this permit

is to be submitted.

The varied scheme (for which this R1 recovery operation application is being made) will utilize two Chinook Sciences’ patented RODECS

gasifiers in order to produce a syngas from 160,000 tonnes per year of residual Commercial and Industrial Wastes (C&I) and with the capability

to process Municipal Solid Wastes (MSW). Each gasifier will process ½ (80,000 tonnes per year) of the total throughput of 160,000 tonnes per

year of waste. The syngas from each gasifier is directly combusted in a combustion chamber (each gasifier has its own combustion chamber),

from which the exhaust gases pass to a waste heat recovery boiler stage to generate steam (each gasifier has its own waste heat boiler). Energy

can then be recovered from the steam produced and electricity generated via a steam turbine (the steam turbine is common to both gasification

lines i.e. receives steam from waste heat boilers).

Background

Chinook Sciences (the technology provider), part of the Chinook Sciences group of companies, based in Cranford, New Jersey, was founded in

1998 and is a leading manufacturer and operator of advanced gasification technology. Its RODECS® gasification system is now in its ninth

design generation and is capable of processing a wide range of waste streams. It has been installed in 17 locations throughout the world since

2002 where it gasifies organic material without incineration and fully recovers metals in its patented ACTIVE PYRO® process.

Innovative Environmental Solutions (IES), a joint venture between global leaders in recycling European Metal Recycling Ltd (EMR) Ltd and

Chinook Sciences Ltd, are currently commissioning a waste disposal and energy recovery facility in Oldbury, West Midlands – this has been

issued with an Environmental Permit (EPR/GP3739VR). This is capable of processing up to 180,000 tonne/year of Automobile Shredder Residue

(ASR) to produce some 40 MWe of electricity. Furthermore, in 2014 Chinook Sciences secured a contract with UAE waste management,

recycling and environmental services firm, Bee'ah to build the world’s largest waste to energy gasification facility in the Emirate of Sharjah.

This will be capable of processing up to 400,000 tonnes/year of MSW.

In 2015 (19/08/15), the EA issued a variation (EPR/CP373737CV/V003) to an existing permit (EPR/CP373737CV) for a two processing line EfW

facility in Dagenham – each line processing 90,000 tonnes per year of waste and comprising a single RODECS® gasifier, combustion chamber,

waste heat boiler stage, steam turbine, APC and an emission flue i.e. similar to the scheme here for which this R1 recovery operation application

is being made.

Process Overview

The installation will process waste in order to recover energy using the gasification process patented by Chinook Sciences. The waste will be

sourced from a variety of waste operators. 160,000 tonnes / year of waste, which otherwise would be expected to go to landfill, will be

processed.

The gasification process operates using a batch gasification system as shown in Figure 1 below (two of these identical gasification lines are to

be utilised at this facility). Each system comprises a RODECS® processing unit & a heating chamber which gasifies the waste material to produce

a syngas. The syngas is then directly combusted in a combustion chamber, from which the exhaust gases pass to a waste heat recovery boiler

stage to generate steam with energy being recovered from the steam produced and electricity generated via a steam turbine (common to both

lines). The flue gases from each boiler pass through their own Air Pollution Control (APC) system prior to discharge via their own flue (i.e. a dual

flue stack).

Figure 1: Process Schematic (EACH LINE)

Heat and Mass Balance

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The following is the heat and mass balance for the process, arranged in the following order –

Schematic 1 – Mass balance per tonne of waste processed;

Schematic 2 – Energy balance per tonne of waste processed;

Schematic 3 – Energy balance per RODECS per hour;

Schematic 4 – Energy balance for the complete plant per hour.

PLUS

R1 Calculation Sheet

070 BulwellMASS Balance per Tonne of waste processed

NaturalGas

3.0 Kg

Natural Waste Burners Waste Burners Make ‐ up CondensateGas Oil Air Oil Air Water Return

3.0 Kg 83.5 Kg 1624.8 Kg 34.0 Kg 760.9 Kg 49.75 Kg 4978.1 KgSteamFlow

Feedstock CV 4978.1 Kg5,805 Btu/lb13.5 MJ/Kg

MSW Hot GasesFeedstock 16466 Kg1000.0 Kg

Metal Dust / Ash Recirculated Blow ExhaustRecovered Inerts Gases Down to Stack29.0 Kg 100.0 Kg 7687.5 Kg 49.75 Kg 8778.9 Kg

CombustionAir

5302.6 Kg

Waste Heat Boiler

Environmental System (APC)

RODECS

December 24, 2016

Steam Turbineand Condenser SystemHeating Chamber Combustion Chamber

RODECS System Power Island: Boiler and Combustion Chamber Power Island: Steam Cycle Environmental

070 BulwellEnergy Balance Per Tonne of Waste

Waste Natural Waste NaturalOil Gas Oil Gas

0.93 MW 0.03 MW 0.38 MW 0.03 MWHeat to

Steam CycleFeedstock CV 4.30 MW5,805 Btu/lb13.5 MJ/Kg

Electricity1.36 MWe

MSW Hot GasesFeedstock 4.98 MW3.75 MW

Metal Heat Heat Recirculated Heat Exhaust HeatRecovered Loss Loss Gases Loss to Ambient /Stack0.19 MW 0.14 MW 0.12 MW 0.30 MW 0.05 MW 0.33 MW

RODECS System Power Island: Boiler and Combustion Chamber Environmental Power Island: Steam Cycle

RODECS Heating Chamber Combustion Chamber Waste Heat BoilerSteam Turbine

and Condenser System


2.94 MW

LossesMech & Thermal

070 BulwellEnergy Balance Per RODECS per hour


9.89 MW 0.37 MW 4.03 MW 0.37 MWHeat to


Electricity14.55 MWe


Metal Heat Heat Recirculated Heat Exhaust HeatRecovered Loss Loss Gases Loss to Ambient /Stack2.01 MW 1.51 MW 1.26 MW 3.23 MW 0.54 MW 3.47 MW

RODECS Heating Chamber Combustion Chamber Waste Heat Boiler


RODECS System Power Island: Boiler and Combustion Chamber Environmental

Steam Turbineand Condenser System


31.33 MW

Power Island: Steam Cycle

070 BulwellEnergy Balance Per Plant per hour


19.78 MW 0.73 MW 8.06 MW 0.73 MWHeat to


Electricity29.10 MWe


Metal Heat Heat Recirculated Heat Exhaust HeatRecovered Loss Loss Gases Loss to Ambient /Stack4.02 MW 3.02 MW 2.51 MW 6.46 MW 1.08 MW 6.95 MW 62.66 MW

2 x RODECS Heating Chamber Combustion Chamber Waste Heat BoilerSteam Turbine

and Condenser System



Power Island: Steam CycleRODECS System Power Island: Boiler and Combustion Chamber Environmental

NOTTM ‐ BULWELL PROJECT ‐ CHINOOK SCIENCES GASIFICATION TECHNOLOGY ‐ R1 METHODOLOGY V17 ‐ 06/01/2017

INCLUDING WASTE OIL HEATING ‐ WITH HIGHER EFFICIENCY STEAM TURBINE GENERATOR ‐ 95% WASTE OIL 5% NG RATIO

NATURAL GAS 2.5 MMBtu/hr 0.7328 MWt NG

Efactual 47.5 MMBtu/hr 13.922 MWt Waste Oil

WASTE OIL 13.922 MWt 13.922 MWt

Assume Waste Oil CV 39.97 MJ/kg Ef1 Ef2 65 BarG, 480 DegC Steam Conditions

30% Re‐cycle Boiler Feed WaterWaste Oil Consumption 0.35 kg/sec NG WASTE OIL NG WASTE OIL STEAMWaste Oil Consumption 1,254 kg/hr

SYNGASIN TRANSIT

BOILER FEED WATER

FLUE GASFLUE GAS

MSW T= 600 DegCT= 150 DegC

EWT= 915 DegC

HEATING CHAMBER COMBUSTION CHAMBER

GASIFICATION ISLAND POWER ISLANDTO EXHAUST STACK

BULWELL ‐ ENERGY INPUTS ‐ SINGLE RODECS SYSTEM BULWELL ‐ TWO RODECS SYSTEM ‐ R1 CALCULATION

Determination of Ew Bulwell ‐ R1 Formula Calculation R1 = (Ep ‐ (Ef + Ei)) / (0.97 x (Ew + Ef))

Feedstock MSW MWt 40.0247.5 MM Btu/hr Waste Oil MWt 13.92Ew (including Waste Oil) MWt 53.94 MW MWhrs/yr GJ/yr Factor Final Number

Ep ‐ (Electrical) 29.12 218,400 786,240 2.6 2,044,224Determination of Ep Ep ‐ (Thermal) 0 0 1.1 0

Ep ‐ Total 2,044,224Stated Design Power Output MWe 14.56

Ef ‐ (Natural gas input) 1.48 11,100 39,960 1 39,960Determination of Ef

Ei ‐ (Electrical) 6.02 1,155 4,158 2.6 10,8102.5 MM Btu/hr NG MWt 0.740 (with waste oil) Ei ‐ (Natural gas input) 1.48 284 1,023 1 1,023

Ei ‐ Total 11,833

Ew 107.88 809,130 2,912,868 1 2,912,868

Waste Oil Consumption kg/hr 1254 Per RODECS system R1 Energy Efficiency ‐ by the calculation method 0.696

Waste Oil Consumption 2,508 kg/hr

WASTE HEAT BOILER

STEAM TURBINE AND CONDENSER SYSTEM

RODECS

APC

In accordance with the Environment Agency’s own guidance ‘Waste incinerator plant: apply for R1’ (4 October 2016) ‐

https://www.gov.uk/guidance/waste‐incinerator‐plant‐apply‐for‐ri‐status, it is possible to use the EA’s own R1 efficiency formula spread‐sheet

OR ‘alternative calculation method agreed with the Environment Agency…’. A previous R1 application was made in January 2016

(EPR/LP3239NX/V002 withdrawn 6th September 2016) and through detailed discussions/meeting with the EA – it was established that the EA’s

own spread‐sheet could not be used for this type of process and an alternative calculation was established which is used in the application

presented here. This has yielded a figure of 0.696 i.e. above the performance threshold of 0.65 for MWI (as per Waste Framework Directive

2008/98/EC).

We request that the Environment Agency consider our application based on the information provided – the above guidance stating ‘Once the

plant design is known you can submit an application based on design data. You can apply before the plant has been commissioned including

before you seek planning approval or apply for an environmental permit’. As above, this installation does have an environmental permit ‐

Environmental Permit reference EPR/LP3239NX although an application to vary this permit in accordance with the design described here is to

be submitted. The installation also has planning approval (issued by Nottingham City Council) ‐ 16/01055/PVAR3 s73 Variation of S1 of

13/03051/PMFUL3 dated 22/07/16 – which is based on the design described here.

Documents

Supporting Statement Application for R1 recovery status by