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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).
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
Environmental System (APC)
2.94 MW
LossesMech & Thermal
070 BulwellEnergy Balance Per RODECS per hour
Waste Natural Waste NaturalOil Gas Oil Gas
9.89 MW 0.37 MW 4.03 MW 0.37 MWHeat to
Steam CycleFeedstock CV 45.88 MW5,805 Btu/lb13.5 MJ/Kg
Electricity14.55 MWe
MSW Hot GasesFeedstock 53.12 MW40.02 MW
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
Environmental System (APC)
RODECS System Power Island: Boiler and Combustion Chamber Environmental
Steam Turbineand Condenser System
LossesMech & Thermal
31.33 MW
Power Island: Steam Cycle
070 BulwellEnergy Balance Per Plant per hour
Waste Natural Waste NaturalOil Gas Oil Gas
19.78 MW 0.73 MW 8.06 MW 0.73 MWHeat to
Steam CycleFeedstock CV 91.76 MW5,805 Btu/lb13.5 MJ/Kg
Electricity29.10 MWe
MSW Hot GasesFeedstock 106.25 MW80.03 MW
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
Environmental System (APC)
LossesMech & Thermal
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.