Proposed Development of a Waste to Energy Plant for Jeddah Municipality, KSA

A PRESENTATION TO Gulf Environment Forum (7-9 March 2010) By Prof. Dr Mamdouh F. Abdel-Sabour Head of Environmental Studies Department Saudi ASMA Environmental Solution (SAES)

S T R I C T L Y P R I V A T E & C O N F I D E N T I A L

In Collaboration

Ministry of Municipal and Rural Affairs

Municipality of Jeddah Province

Project Background Project Milestones

25 May 2005. Green Energy & Technology Middle East (GETME) and Octagon Consolidated Berhad (Octagon) has submitted the proposal for a waste to energy project (Project) which is able to process 2,000 tons/day of municipal solid waste (MSW) and up to 400 tons/day of industrial hazardous waste (IHW).

11 Nov 2007. The Municipality agreed in principal for the development of the Project.

11 Jan 2008. The Municipality request for an independent validation study be conducted for the Project.

7 June 2008. GETME/Octagon and the Ministry of Municipal and Rural Affairs (“Ministry”) signed an agreement for GETME/Octagon to undertake independent validation study comprise the followings:

Technology Validation Study – Stopford Projects Limited (UK), Fides International Consultants Luxemburg and Russian Academy of Sciences, Institute for Electro-Physics and Electric Power

MSW and IHW Waste Study – SAES, Jeddah

Preliminary Environment Assessment – SAES, Jeddah

Financial Feasibility – Ernst & Young Consulting Limited, Jeddah

31 Dec 2008. The Study was submitted to the Municipality and presented on 17 Jan 2009.

22 March 2009. A letter and report submitted to ECRA to consider the power tariff of SAR0.35 kWH for the Project.

Improve the environmental and health standards in the city of and its suburbs through hygienic treatment of MSW.

The project will convert untreated MSW and IHW into renewable energy. This will reduce methane (a potent greenhouse gas) generation from landfills, odour, health hazards and leachate contamination of ground water that are currently being caused as a result of disposal of MSW and IHW.

The project is consistent with government objectives in promoting an environmentally beneficial project that will significantly improve waste management, promote renewable energy generation and reduce the emissions of green house gases.

Reduce requirement of landfill area for dumping of MSW and IHW, thereby freeing up land resources for other socially beneficial usage.

Expand the range of energy generation sources by promoting the development of renewable energy projects to meet a part of the energy requirements.

Promote private sector participation and investment in clean and renewable energy projects.

Project Benefits

Source : Juniper Consultancy Ltd., UK. “Progress Towards Commercialising Waste Gasification” A World Wide Status Report :

Presentation to the Gasification Technology Conference : San Francisco USA 2003 and secondary market information

≤ 5,000c

≤ 1,250c

≤ 1,200c

≤ 700c

-

Advanced Thermal Process System

Fixed or Fluidised Bed Gasification

Incineration

Burning (Furnace)

Landfill

Waste Destruction Energy Generation

Waste Destruction Energy Generation

Waste Destruction Landfill

Waste Disposal Landfill

Waste Disposal

- Dump Site Waste

Disposal

No GHG “Zero” Landfill

No GHG Landfill/Ashes

GHG, Dioxin/Furan Landfill/Ashes

GHG, Dioxin/Furan Ashes

GHG Leachate

GHG Leachate

Temp. Technology Selection Outcome Environmental

Issues

Te

ch

no

log

y E

vo

luti

on

Technology Application Progress of Technology for Waste Destruction

Technology improvement naturally draws increased capital cost but … the improvements minimize or mitigate adverse environmental and health impacts

Dumping Landfill Sanitary

Landfill

Incinerator Gasification Advanced Thermal Process System

Water source

contamination

Air pollution

impacts

Overall

environmental

costs

Various waste

disposal

technologies

Uncontrolled leachate: high risk

of water contamination Moderate risk of water

contamination

Controlled leachate:

Minimised water contamination

Moderate to high risk of air

pollution from methane

Moderate risk of air

pollution from methane

Risk of air pollution from

furans & dioxins presents

No risk of

air pollution

Prospect for

energy

recovery

No prospect of recovery of

energy waste

Minimal prospect of recovery

of energy from waste

HIGH

High prospect of recovery of energy waste

(energy recovery is maximised)

MODERATE LOW NEGLIGLIBLE

Tipping Fees

per Ton

Technology Application Progress of Technology for Waste Destruction

Higher awareness of environmental, safety and health impacts

More stringent requirement for compliance with emission standards

Land scarcity

Drawing the most efficient recovery of energy from wastes

Not least, escalating fuel prices which makes fossil fuel more expensive for power generation

Competitive cost of technology over time

Waste disposal technology improves over time as a result of, inter-alia :-

Technology Application Progress of Technology for Waste Destruction

Plasma Torch

GreenTech Advanced Thermal Process Reactor Configuration

SYNGAS EXIT

WASTE FEED

PORTS

CO ENHANCEMENT

THERMAL ENERGY

SYSTEM

MOLTEN SLAG

TAPPING PORT

ATPR - Operating Temperature Profile

SYNGAS EXIT

1200 – 1400OC

GASIFICATION

3000 – 1400OC

SYNGAS RETENTION

3000 – 1400OC

CARBON BED

5000 – 3000OC

THERMAL ENERGY INPUT

8000 – 3000OC

1. Recycle and RDF Processing

Stage Integrated Process

1. GASIFICATION OF THE WASTE 2. FILTERATION AND GAS CLEANING

3. GAS COMPRESSION & CONDITIONING 4. COMBINE CYCLE POWER GENERATION

THE BASIC STAGES OF

GREENTECH WASTE TO ENERGY PLANT

LP SYNGAS

COMPRESSOR

ESD VALVE

EMERGENCY FLARE

BLOWER

LP CONDENSATE

KNOCK-OUT

DRUM

CONDENSATE

PUMP

HP CONDENSATE

KNOCK-OUT

DRUM

HP SYNGAS

COMPRESSOR

CONDENSATE

PUMP

TO EMERGENCY

FLARE

SYNGAS TO

QUENCH

FROM GAS

CLEAN-UP

RECUPERATOR

CONDENSATE

PUMP

CONDITIONED GAS TO

POWER GENERATION

FC on pH

LC

SATURATOR

BAG FILTER

INDUCED

DRAFT

BLOWER

HCl

ABSORBER

COLUMN

QUENCH

SOLUTION

DRUM

QUENCH FEED PUMP

RE-CYCLE PUMP

RE-CYCLE HEAT-X

FCV

FCV

FCV

SOLIDS COLLECTION

CONVEYOR

NAOH MAKEUP SOLUTION

SYNGAS WASTE HEAT

STEAM GENERATOR

SYNGAS FROM

QUENCH VESSEL

HP STEAM

ATOMIZED

SYNGAS

RE-CYCLED

WATER

VITIRFIED SLAG

FOR RE-USE

THERMAL

REACTOR

VESSEL

SLAG QUENCH CONVEYOR

QUENCH

VESSEL

PARTICULATE STORAGE

PARTICULATE TO

GASIFIER FOR

RECYCLE

COKE SUPPLY

SYSTEM

WASTE &

LIME FEED

SYSTEM

SYNGAS TO

GAS

CLEANING

QUENCH

FLUID

CO Enhancement

System

WASTE &

LIME FEED

SYSTEMTorch Air

Compressor

1st Stage Heat Recovery

HP

SteamDe-min

Water

Steam condensing loop

Liquid Waste

Feed Port

DE-MIN WATER MAKER &

MAKE-UP SYSTEM

FC

FCV

AIR COOLED STEAM

CONDENSER

EMISSIONS

CONTROL

SYSTEM

PCV

START-UP &

EMERGENCY FUEL

SUPPLY

4

KNOCK-OUT

DRUM

HEAT RECOVERY

STEAM GENERATOR

STGAC

GENERATOR

FCDV

CONDITIONED GAS

FROM RECUPERATOR

CTGAC

GENERATOR

H P STEAM FROM

1st

STAGE HEAT

RECOVERY SYSTEM

& WASTE HEAT

STEAM GENERATOR

WATER TO WASTE

HEAT STEAM

GENERATOR

2. Gasification of the Waste

VITIRFIED SLAG

FOR RE-USE

Thermal

Reactor

Vessel

SLAG QUENCH CONVEYOR

QUENCH

VESSEL

PARTICULATE STORAGE

PARTICULATE TO

GASIFIER FOR

RECYCLE

COKE SUPPLY

SYSTEM

WASTE &

LIME FEED

SYSTEM

SYNGAS TO

GAS

CLEANING

QUENCH

FLUID

CO Enhancement

System

WASTE &

LIME FEED

SYSTEMAir

Compressor

1st Stage Heat Recovery

HP

SteamDe-min

Water

Steam condensing loop

Liquid Waste

Feed Port

Stage Integrated Process

FC on pH

LC

SATURATOR

BAG FILTER

INDUCED

DRAFT

BLOWER

HCl

ABSORBER

COLUMN

QUENCH

SOLUTION

DRUM

QUENCH FEED PUMP

RE-CYCLE PUMP

RE-CYCLE HEAT-X

FCV

FCV

FCV

SOLIDS COLLECTION

CONVEYOR

NAOH MAKEUP SOLUTION

SYNGAS WASTE HEAT

STEAM GENERATOR

SYNGAS FROM

QUENCH VESSEL

HP STEAM

ATOMIZED

SYNGAS

RE-CYCLED

WATER

3a. Cooling – Filtration - HCl Absorption

Stage Integrated Process

SYNGAS FROM HCl ABSORBER

CONDENSATE TO

SLAG CONVEYOR

SOUR GAS

(LP) COMPRESSOR

TO EMERGENCY

FLARE

ESD VALVE

EMERGENCY FLARE

BLOWER

CONDENSATE

KNOCK-OUT DRUM

FLUSH WATER

SLURRY PUMPAIR BLOWER

VENT TO SAFE AREA

SYNGAS TO HP COMPRESSOR

H2S CONTACTOR

REMOVAL VESSEL

H2S REGENERATION

DEGASSER VESSEL

H2S REGENERATION

SURGE SETTLER

VESSEL

SULPHER CAKE

FILTER

SULPHER CAKE

COLLECTION

REGEN FEED PUMP

H2S CONTACTOR

RE-CYCLE PUMP

H2S CONTACTOR

SOLUTION MAKE-UP

28

CONDENSATE

PUMP

M

ATOMIZED SYNGAS TO

QUENCH VESSEL

3b. 1st Stage Compression - H2S Removal

Stage Integrated Process

HP CONDENSATE

KNOCK-OUT

DRUM

HP SYNGAS

COMPRESSOR

RECUPERATOR

CONDENSATE

PUMP

CONDITIONED GAS TO

POWER GENERATION

LP SYNGAS

COMPRESSOR

ESD VALVE

EMERGENCY FLARE

BLOWER

LP CONDENSATE

KNOCK-OUT DRUM

CONDENSATE

PUMP

CONDENSATE

PUMP

SYNGAS TO

QUENCH

FROM GAS

CLEAN-UP

5/6-Stage Integrated Process

4. Gas Compression and Conditioning

5. Combine Cycle Power Generation

5/6 - Stage Integrated Process

DE-MIN WATER MAKER &

MAKE-UP SYSTEM

FC

FCV

AIR COOLED STEAM

CONDENSER

EMISSIONS

CONTROL

SYSTEM

PCV

START-UP &

EMERGENCY FUEL

SUPPLY

4

KNOCK-OUT

DRUM

HEAT RECOVERY

STEAM GENERATOR

STGAC

GENERATOR

FCDV

CONDITIONED GAS

FROM RECUPERATOR

CTGAC

GENERATOR

H P STEAM FROM

1st

STAGE HEAT

RECOVERY SYSTEM

& WASTE HEAT

STEAM GENERATOR

WATER TO WASTE

HEAT STEAM

GENERATOR

DCS & System Monitoring

Z Z Z Z Z

V A Hz

HV/LV Switch Room

VSA Oxygen

Generation

Plant start-up

& Emergency

Power System PSA Nitrogen

Generation

Water Treatment

& Storage

Diesel Day Tank

Water

Storage

Firewater

Storage

Fire & Gas Detection

& Safety Systems

Water Cooling & Re-cycling

Safety Support and Utility System

Higher Energy Recovery No Chemical Treatment or Solidification for Slag Eliminating requirements for ash and residual materials land filling (zero landfill) Final and Permanent solution Significantly Greater Volume Reduction Smaller Overall Plant Footprint Greater Flexibility of Waste Streams being Processed for the same given Plant Significantly lower emissions – No SVOCs Lower cost and shorter construction time

The Waste to Energy Process Flow Advanced Thermal Process System Vs Incineration Burning

Green solutions for Environmental Dilemma !!

Toyohashi, Japan Mitsui R1 2002 120,000 TPY

Kawaguchi, Japan Ebara 2002 125,000 TPY

Kazusa, Japan Nippon Steel 2002 60,000 TPY

Aomori, Japan Ebara 2001 135,000 TPY

Technology Track Record Independent Validation and Experience

WTE Plants produce electricity “with less environmental impact than almost any other source

of electricity” – US EPA

22

Technology Track Record Independent Validation and Experience

Russian Academy of Sciences, Institute for Electro-Physics and Electric Power. “Calculations and experiments prove that plasma methods of waste and coal treatment are economically beneficial and ecologically friendly. Plasma generators operating on water vapour are the most promising for treatment of organic-containing waste for syngas production”.

Concept Engineering Design validated by Simon Carves Limited, UK.

Front End Engineering Design undertaken by Stopford Projects Limited, UK (completed)

Detailed engineering design undertaken by Stopford Projects Limited, UK (work in progress)

Gasification Vessel Design and CO Enhancement validated by Stopford Projects Limited and PSE, UK.

Individual process is proven technologies undertaken by companies with strong track record including: Fairport, UK (Waste Receiving, Sorting and RDF Production), Europlasma, FR (Plasma Torches and Reactor Design), La Gas Integral, FR (Gas Processing), Peter Brotherhood, UK (Gas Compression), General Electric, USA (MV Power Generation), Caterpillar, USA (LV Power Generation), EPCC contractors in KSA (Civil and Utilities)

Technology Suitability

Multiple feedstock capability

Capable of receiving, handling, processing and disposing, different types of wastes (e.g., MSW, IHW) concurrently.

Complete destruction of wastes

Plasma gasification process is a NO BURN process hence, it does produce residuals, i.e., fly & bottom ashes as typically found with incinerators.

Fly & bottom ashes are harmful, may contain heavy metals and require secure landfilling. Since plasma gasification does not produced ash, landfilling will no longer be a requirement.

Maximum energy recovery from wastes

Plasma gasification process is designed and engineered to ensure efficient energy recovery from wastes.

Environmentally friendly

Operating at temperature range of about 3,000oC in the Gasification Zone in an oxygen starved environment, are realised in the plasma reactor therefore, plasma gasification process presents no opportunity for formation of hazardous flue gases, e.g., dioxin & furans, SOx and Nox.

Clean Development Mechanism under Kyoto Protocol

Capable for qualification as CDM project, i.e., reduction of emission of methane typically from landfills and reduction of CO2 emission from avoidance of use of fossil fuels for power generation.

Project Feasibility Technology Suitability

25 May 2005. Project Proposal

11 Nov 2007. Agreement in Principal by the Municipality

11 Jan 2008. Request for GETME/Octagon to undertake Independent Validation Study (Study)

7 June 2008. Agreement between GETME/Octagon and the Ministry of Municipal and Rural Affairs (“Ministry”) for the Study

31 Dec 2008. The Study submitted to Municipality and presented on 17 Jan 2009.

22 March 2009. Report submitted to ECRA to consider power tariff of SAR0.35 kWH

19 April 2009. Request Approval-in-Principal for Feed in Power Tariff subject to further approvals from the relevant authorities

May – Dec 2009. Municipality Award Process and Engineering Work

Jan 2010. Execute Concession Agreement for MSW/IHW and Power Purchase Agreement

March 2010. Commence Project Construction

March 2012. Construction Completed

June 2012. Plant Commissioning

Moving Forward Request to ECRA

Thank You