MSW BASED POWER PLANT AVANT GARDE ENGINEERS AND

MSW BASED POWER PLANT AVANT - GARDE ENGINEERS AND CONSULTANTS (P) LTD

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Group Avant-Garde Engineers and Consultants (P) Ltd Consultancy and Detailed Engineering Services Avant-Garde Systems and Controls (P) Ltd Supply of Power Plant Equipment, Site Services, O&M, Plant Revamping Avant-Garde Projects and Infra (P) Ltd Avant-Garde Engineers & Consultants FZC, Sharjah Infra Projects Consultancy and Detailed Engineering Services for Overseas Projects

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Staffing Mechanical 45 Software Development Civil & Structural 40 35 30 Administration & Accounts Material Handling 25 20 15 10 Business Development Thermal Design 5 0 Site Services Piping Quality / Inspection Project Management 200+ Workforce Electrical & Instrumentation Process Engineering 40, 320 Engg Man-hours / Month 7, 000 Manhours / Month - Job shopping

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Domain Strength Power Plants IPP, CPP, Biomass, Co-Gen, MSW, WHRSG, DG, GTG Sugar Plants Raw Sugar, Plantation White, Refined Sugar Distillery/Ethanol Plants Solar Plants Molasses, Grain Sweet Sorghum PV, CSP Co-Generation Plants Bagasse, Coal, SLOP Fired Boiler Design Grate Boiler, AFBC, WHRSG

Overall Power Projects S. No Description Completed Under Implementation Nos Capacity 1 Captive Power Plants 82 2238. 00 MW 24 691. 50 MW 2 Cogeneration Plants 102 2246. 61 MW 55 1626. 00 MW 3 Biomass / MSW based Power Plants 49 464. 10 MW 7 89. 50 MW 4 Steel / Sponge Iron Captive Power Plants 22 428. 50 MW 34 1003. 50 MW 5 Solar Power Plants 96 850. 00 MW 10 375. 00 MW

Waste to Energy Projects - Completed • Two (2) projects have been commissioned to a cumulative capacity of 30 MW – Shriram Energy Systems Limited – 6 MW in A. P – Delhi MSW Solutions Limited – 1200 TPD / 24 MW MSW based Power Plant • Detailed Project Report (DPR) has been completed for eleven (11) projects

Wt. E – Detailed Project Reports S. No Project / Job No. 1 RDF Power Projects Limited, Nalgonda 2 Timarpur-Okhla Waste Managmenet Co. Pvt. Ltd, New Delhi (C/o. IL & FS, New Delhi)MSW and Biomethanisation Plant 3 East Delhi Waste Processing Co. Pvt. Ltd. , Ghaziapur – for IL & FS 4 Delhi MSW Solutions Ltd, (Group of Ramky Energy, Delhi) 5 Hi MSW Ltd, (Group of Ramky Energy, Hyderabad) Capacity (TPD) 1200 1 X 1300 Power Plant In MW 11 16 & 100 1 x 1300 2 X 600 10 24 24

Wt. E – Detailed Project Reports S. No 6 Project / Job No. Guwahati Waste Management Company Pvt. Ltd, (Group of Ramky), Guwahati Capacity (TPD) 1 X 600 Power Plant In MW 10 7 Ramky Energy & Environment Ltd, Bangalore 1 X 600 10 8 Ramky Enviro Engineers Ltd, Pimpri 1 X 600 10 9 IL&FS Energy Development Company Limited, Gurgaon (Puducherry Project) 1 X 600 06 10 Pune Bio-Energy Systems Private Limited, Pune 2 X 375 13 11 Rewa MSW Holding Limited, Rewa 1 x 310 06

Current Waste to Energy Projects • Pallavapuram Tambaram MSW Pvt. Limited – 300 TPD / 5 MW RDF based Wt. E Project in Chennai • Hyderabad Integrated MSW Limted – 1200 TPD / 24 MW Wt. E Project at Jawahar Nagar, Hyderabad • Rewa Wt. E Project Limited – 340 TPD / 6 MW Wt. E Project in M. P • Pune Bio-Energy Systems Private Limited – 750 TPD / 12 MW Wt. E Project in Pune

WASTE TO ENERGY (DIRECT MASS INCINERATION) Presented By: J. Gladstone Evans (HOD – Thermal Department) AVANT-GARDE ENGINEERS AND CONSULTANTS (P) LTD

INTRODUCTION WASTE TO ENERGY TECHNOLOGY AVANT-GARDE

WASTE TO ENERGY (WTE) • Waste To Energy (WTE) is Process / Technology to obtain useful energy from waste (MSW / RDF), in the form of Heat (or) Electricity (or) Fuel for further conversion. • There are various Process / Technology available in WTE – Biological Processing Technology (Composting, aerobic digestion, Biomethanization, etc) – Thermal Conversion technology INCINERATION GASIFICATION PYROLYSIS Heat Fuel Gas Fuel gas / Oil • Steam Generation • Electricity • Heat • Steam / Hot water • Electricity AVANT-GARDE PELLETIZATION RDF

WTE - INCINERATION • Incineration Technology is a well developed technology followed in many countries from past few decades. In India also recently, few plant are in continuous operation with this technology. • Incineration is the Engineered process of controlled burning / combustion of solid waste at a high temperature, in the presence of oxygen. • Incineration of Municipal Solid Waste (MSW / RDF) is divided in to two broad categories – Burning “as received” waste. – Burning “pretreated” waste. • Burning of the “as received” waste requires little or no pretreatment (RDF – 1 & 2). This is termed as Direct Mass Incineration (DMI). Burning of pretreated waste (RDF – 3, 4 & 5), requires considerable amount of treatment process. AVANT-GARDE

WASTE TO ENERGY Flexibility in the system due to wide change in the MSW quality Proven Technology & In house availability RISK’S TO BE ANALYSED Expertise in Operation & Maintenance IN Meeting the Environmental Pollution Norms Meeting Contractual Targets Energy Recovery & Over all Economics AVANT-GARDE TECHNOLOGY SELECTION

INCINERATION - ADVANTAGES • It address two sets of environmental issues in one stroke – Land use and pollution issues & Environmental impacts of fossil power plants • Volume and weight reduction (approx. 85 to 90% in volume and 75% in weight) • Waste Reduction & Destruction is immediate, no long term wait is required • No foul smell and infections to the public • Incineration is carried out at generation site • Air discharges can be well controlled to the permissible norms • Ash residue is usually do not protrude, they are sterile & inert • Small disposal area required • Investment cost can be offset by heat recovery / sale of energy AVANT-GARDE

WASTE TO ENERGY INCINERATION TECHNOLOGY AVANT-GARDE

INCINERATION - TECHNOLOGY SELECTION Moving Grate - Pretreatment of MSW is not required - High capacity efficiency - Drying and carbonization takes place in the first zone, followed by ignition and combustion in the second and complete burnout and cooling of the slag in the third. AVANT-GARDE and thermal Fluidized Boiler - RDF, Sludge, co-firing , etc - Requires extensive treatment of MSW - - Rotary kiln - For Hazardous and hospital waste. - Cannot be used for burning MSW. - Burning at a very high temperature with a long residence time and requires support fuel. pre- Waste is introduced into a sand bed which is fluidized via blowing air through a nozzle floor Very sensitive towards the RDF size and its density

MOVING (STEP) GRATE - WTE BOILER Heat Recovery System 2 Ash & Leachate Disposal System 4 MSW Receipt, Storage, Preprocessing & Feeding System 1 AVANT-GARDE Incineration System 2 Flue gas cleaning & Safe disposal System 3

MSW HANDLING – SOURCE TO BOILER -Proximity to generation the waste -Traffic & Transport -Approach Road to the Plant MSW Receipt, Storage, Pre-processing & Feeding System Weigh Bridge MSW Receiving Platform MSW Pit Grab Crane with its control system Fuel feed hopper AVANT-GARDE

PRE-PROCESSING IN MSW PIT Function of MSW pit • • To reduce Surface Moisture To Homogenize the incoming MSW To remove the large debris/ inerts To create a buffer & to reduce fluctuations With above features, the output from the pit will qualify under RDF 1 of ASTM classification AVANT-GARDE

IMPROVEMENT IN CALORIFIC VALUE OF MSW IN PIT 1600 79 1416 1337 1400 1258 78 77. 8 LCV, 1100 77. 5 1000 77. 1 800 76. 4 76. 5 76 600 400 77 Boiler Eff, 75. 5 75 200 Leachate collection quantity, Greatly depends on The numbers of storage days, Storage height, Surface moisture in the MSW, Compaction in the pit, etc. AVANT-GARDE 74. 5 0 74 0% MR 5% MR 10% MR 15% MR 20% MR Moisture Reduction (MR) in the Pit (%) Boiler Efficiency (% LCV basis) LCV of MSW in the pit (kcal/kg) 1200 1180 78. 5 78. 3

WASTE TO ENERGY PLANT • The various important systems in the WTE plant is listed below: – MSW handling, Pre-processing (If required) and feeding system. – Incineration System (MSW Firing & combustion system) – Heat Recovery System from the flue gas & Power Generation System. – Gas cleaning & Disposal system – Ash Collection, Handling, Storage & Disposal system AVANT-GARDE

FIRING AND COMBUSTION SYSTEM • It is the most critical part in the WTE Boiler. Major components of the combustion system is 4 5 – – – 1. Ram feeder 2. Pusher Grate 3. Hot air to grate 4. Furnace / Combustor 5. Over fir air system 6. SCAP AVANT-GARDE 1 2 3 6

1400 1200 1000 800 600 400 200 0 LCV of MSW Vs Furnace Temperature 00 10 LCV OF MSW AVANT-GARDE • Furnace and firing Grate Construction & its Arrangement • Refractory in the combustion chamber and its material selection. kc 11 al/k 00 g kc 12 al/k 00 g kc 13 al/k 00 g kc 14 al/k 00 g kc 15 al/k 00 g kc 16 al/k 00 g kc 17 al/k 00 g kc al /k g Furnace Temperature (Deg. C) FIRING & COMBUSTION SYSTEM • Operating Excess Air levels in various zones in the grate & furnace • OFA system arrangement and its effectiveness.

WASTE TO ENERGY PLANT • The various important systems in the WTE plant is listed below: – MSW handling, Pre-processing (If required) and feeding system. – Incineration System (MSW Firing & combustion system) – Heat Recovery System from the flue gas & Power Generation System. – Gas cleaning & Disposal system – Ash Collection, Handling, Storage & Disposal system AVANT-GARDE

ENERGY RECOVERY SYSTEM • Process – 1: Water to steam in Steam generator ( 2 – 3) Steam Generator 2 • Process – 2: Steam is expanded in steam turbine (3 4) 3 Turbo Generator • Process – 3: Steam is condensed in a condenser (4 – 1) • Process – 4: Condensate is circulated / Pumped back to the boiler (1 – 2) AVANT-GARDE 1 Boiler Feed Water Pump 4 Condenser

SELECTION BASIS FOR POWER CYCLE PARAMETER • • • Capacity of Power Plant Type of Power Plant Characteristics of Fuels and ash Operation with the existing Facility Initial Investment Limitation in the technology AVANT-GARDE

HISTROY OF STEAM CYCLE PRESSURE 87 ata 110 ata 67 ata • There is a gradual increase in the power cycle parameters across the globe 45 ata 300 250 215 235 260 275 285 200 150 • Today there are many small capacity power plants operating at 87 ata and 110 ata. 100 50 110 ata & 540°C 87 ata & 515°C 67 ata & 485°C 45 ata & 440°C 0 35 ata & 380°C Power Output (k. W)/TPH of steam (Under full condensing mode) 35 ata • However, WTE power plants normally operate a power cycle levels of 45 ata & 400°C. The data furnished above is preliminary in nature. Contact AVANT-GARDE for precise / more detail AVANT-GARDE

STEAM AND POWER OUTPUT FROM 1. 0 TPH OF MSW AT PIT (At a steam pressure of 45 ATA & 400°C, with a feed water temperature of 130°C) 2500 2300 500 450 1650 1400 1500 400 350 365 300 315 250 270 1000 200 150 500 100 50 0 0 1000 kcal/kg 1100 kcal/kg 1200 kcal/kg 1300 kcal/kg 1400 kcal/kg 1500 kcal/kg 1600 kcal/kg 1700 kcal/kg MSW LCV Steam Generation (TPH) Power Output(k. W) The data furnished above is preliminary in nature. Contact AVANT-GARDE for precise / more detail AVANT-GARDE Power Output (k. W) Steam Output in kg/h 445 1900 2000

TYPICAL HEAT AND MASS BALANCE OF A 750 TPD WTE PLANT The data furnished above is preliminary in nature. Contact AVANT-GARDE for precise / more detail AVANT-GARDE

WASTE TO ENERGY PLANT • The various important systems in the WTE plant is listed below: – MSW handling, Pre-processing (If required) and feeding system. – Firing and combustion system. – Energy recovery system from the flue gas. – Gas cleaning & Disposal system – Ash Collection, Handling, Storage & Disposal system AVANT-GARDE

EMISSION STANDARD - SWM 2000 & 2016 RULES From Boiler SWM 2000 Rules* SWM 2016 Rules** Particulate Matter (mg/Nm³) 150 50 300 to 400 HCL (mg/Nm³) 50 50 400 to 600 SO 2 (mg/Nm³) NS 200 10 to 50 CO (mg/Nm³) NS 100 10 to 40 Total organic carbon (mg/Nm³) NS 20 10 to 15 HF (mg/Nm³) NS 4 300 to 500 Nox (mg/Nm³) 450 400 1 to 5 Total dioxins and furans (ng. TEQ/Nm 3) NS 0. 1 to 0. 5 Cd + Th + their compounds (mg/Nm³) NS 0. 05 0. 1 to 0. 15 Hg and its compounds (mg/Nm³) NS 0. 05 Sb+As+Pb+Cr+Co+Cu+Mn+Ni+V+their compounds (mg/Nm³) NS 0. 5 2000 to 3000 1 to 20 Parameter * - @12% CO 2 correction AVANT-GARDE ** - @11% O 2 correction on dry basis

GAS CLEANING & DISPOSAL SYSTEM 1 FURNACE – RESI TIME & TEMPERATURE GAS CLEANING SYSTEM EQUIPMENTS (As per SWM 2016) 3 FGD SYSTEM 4 5 AVANT-GARDE 2 SNCR / SCR SYSTEM ACTIVATED CARBON INJECTION SYSTEM DE DUSTING SYSTEM

GAS CLEANING SYSTEM – SEMI DRY SYSTEM Chimney Height will be around 60 mts AVANT-GARDE

WASTE TO ENERGY PLANT • The various important systems in the WTE plant is listed below: – MSW handling, Pre-processing (If required) and feeding system. – Firing and combustion system. – Energy recovery system from the flue gas. – Gas cleaning & Disposal system – Ash Collection, Handling, Storage & Disposal system AVANT-GARDE

ASH SYSTEM • Bottom Ash (Slag) – From combustion chamber / Grate outlet (Course Ash) • Fly Ash – Heat Recovery Ash – Collected in the heat recovery sections (Boiler, Superheater, Economizer, & Air heater ) – (Combination of course & Fine ash) – Dust collector Ash – Particulate matter removed from dust collection equipments (ESP / Bag Filter) – (Fine Ash) AVANT-GARDE

ASH COLLECTION POINTS IN THE WTE BOILER Grate Ash - Slag AVANT-GARDE Fly Ash - Heat Recovery Ash Fly Ash – From Dust Collector Ash

ASH REUSE OPTIONS • Construction fill • Road Construction • Pavement Blocks & Kerb stones • Landfill Daily Cover • Cement Block Production AVANT-GARDE

LEACHATE SYSTEM • • • Leachate drainage system. Leachate storage and discharge system. Leachate treatment system. • RO based treatment system. • Biological treatment followed by RO system. (Further Energy recovery from the Leachate to an extent of 10 to 15 k. W/m³/hr is possible) AVANT-GARDE

WTE PLANT • Land Requirement – 10 to 20 Acres • Water consumption will be around 225 to 250 kl/day in case of ACC & 1300 to 1400 kl/day in case of WCC (Typical values for a 750 TPD WTE Plant) • In house power consumption will be around 17 to 20% • Plant Availability - 60% for 1 st Year, 70 – 75+% from 2 nd Year Onwards • Load factor - 80 – 90% • Manpower - Approx 60 - 100 • Project Schedule - 20 to 24 Months from Boiler & TG ordering. • Cost of the WTE plant will be around 12 to 15 Cr / MW AVANT-GARDE

POWER GENERATION FROM WTE PLANT WTE plant standard capacity (TPD) 300 Power plant Capacity (MW) 4. 0 to 6. 0 450 6. 0 to 8. 0 600 8. 0 to 12. 0 750 10. 0 to 13. 0 AVANT-GARDE

AVANT-GARDE’S EXPERIENCE IN MSW BASED WTE PROJECTS • Two MSW / RDF based WTE projects commissioned with a cumulative capacity of 30 MW. • DPR has been completed for about 11. 0 MSW based WTE projects • Four MSW / RDF based WTE projects are under execution with a cumulative capacity of around 70 MW. AVANT-GARDE

INDIAN EXPERIENCE IN DMI • Jindal Power Project 1350 TPD @ Okhla (3 x 450 TPD with 21 MW PP – Operating in the range of 17 to 21 MW) • Delhi MSW 1200 TPD Plant @ Delhi (2 x 600 TPD with 24 MW PP – Operating in a range of 15 to 22 MW) • Essel Infra Pvt. Limited – 600 TPD @ Jawalphur. (1 x 600 TPD with 11. 5 MW PP – Operating in a range of 6 to 11 MW) • IL&FS – 550 TPD of RDF @ Gazipur. (1 x 550 TPD with 12 MW PP – Operating in a range of 2 to 3 MW) AVANT-GARDE • Hi-MSW 2400 TPD (4 x 600 TPD) Plant @ Hyderabad with 48 MW PP • Pune Bio Energy Limited 1 x 750 TPD Plant @ PUNE with 13 MW PP • Ramky @ Rewa Plant – 1 x 300 TPD plant with 6. 0 MW PP • Essel Infra, Chennai – 1 x 300 TPD with 4. 0 MW PP

SUMMARY (MSW - A new beginning for an old source) • DMI with Energy Recovery is one of the best WTE technology suitable for wide varying fuel like MSW, for effective disposal of waste. There are more than 1000 WTE plant with DMI technology in operation world wide. In India, around four (4) plants are is successful operation and few plant are under construction stage. • In the incineration technology, there is a volume reduction to an extent of 90% and the gasses are let out from the chimney, satisfying the pollution norms. Most of the ash from the WTE plant can used. • There is a power generation potential from the MSW in the order of 270 to 445 k. W / TPH of MSW depending on the LCV. • With Tipping Fees, Capital Subsidiary from the Government & Export power cost above 7. 0 Rs / unit, the DMI based WTE project becomes viable with a pay back less than 5. 0 years. AVANT-GARDE

AVANT-GARDE

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