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Modern waste management concept
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Modern Waste Management Concept
Alzey, 2012
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Contents
Company
Team
Technology1. Faber Ambra® System
2. Waste To Energy
Strategic Options
Cost Efficiency
Business Models
Contact
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eFaber Ambra and its subsidiaries have been
managing waste projects since 1992
Company snapshot
� Founded: 1992
� Subsidiaries in Thailand, Mexico, Guadeloupe
� Owner of proprietary waste treatment technology Faber-Ambra® system
� 11 waste projects implemented worldwide since inception
� 4 projects ongoing in Mexico, Thailand, Indonesia and St. Martin
� Since 2010: strategic partnership with VM Press to market extruder presses in selected markets
Key strengths
Technological partnerships
BiogasWaste water treatmentDrinking water protectionWaste to EnergyWaste to WaterCDMRDF
International network
Governmental agenciesIndependent universitiesNGO‘sTÜV-certified companies
Competence in MSW
treatment
More than 15 years of experience in treating municipal solid waste (MSW)
References in the waste
treatment industry
Municipalities in Asia, Europe, Latin America and the CaribbeanCement industry (RDF)
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eHistorically, Faber Ambra has offered a
proprietary technology for MSW treatment
The original Faber Ambra® system steps
After delivery of MSW, large items (wood, batteries, etc.) are removed and the remainder is loaded into homogenization drums; here, the waste is opened and mixed with water (mechanical treatment)
After mechanical treatment, the waste is stacked into specified windrows and covered with a bio-filter; this stage of biological treatment lasts between 6 to 9 months
As a final step, the treated material can either be landfilled or further processed (compost, RDF); the treated material has a much higher density than untreated MSW and is biologically inert
History
� Faber Ambra was founded in 1992 with the goal to monetize a MSW treatment system that was developed at the University of Braunschweig (Germany)
� The technology requires minimal capital investment and is aimed at developing country communities
� The technology was piloted and subsequently operated at 11 projects in 9 countries
Evaluation of original technology
� Low capital investment
� Low maintenance/operating cost
� Improvement of environmental situation for most developing country communities
� Significant space requirement
� Need for landfilling/further treatment
� No direct usage of energy – not a waste-to-energy option
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Goals for the client
The customer will become a benchmark in environmental politics through:
1. Sustainable waste management (Faber Ambra®)
2. Waste to energy (Biogas, RDF)
3. Waste to water (Biogas)
4. Usage of secondary raw material
5. Environmental friendliness
6. Saving of space
7. Different options also in compost and anaerobe technology
Benefit: Creating new jobs locally with advanced, forward-looking technologies
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1
2
3
6
4
5
7
8
9
10
11
1) Mexico, Atlacomulco
2) Brazil, Blumenau
3) Luxemburg, Diekirch
4) Thailand, Phitsanulok
5) Brazil, São Sebastião
6) Brazil, Rio de Janeiro
7) Germany, Meisenheim
8) Saint Martin, Culde Sac
9) Turkey, Osmaniye
10) Chile, Villa Alemana
11) Indonesia, Semarang
More than EUR 13.5 m
of consulting fees
since 1992
Track record of 11 waste projects in mostly developing
countries with 4 projects currently ongoing
x
x
Iongoing project
Icompleted project
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Contents
Company
Team
Technology1. Faber Ambra® System
2. Waste To Energy
Strategic Options
Cost Efficiency
Business Models
Contact
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Background – Wolfgang Tönges, CEO
Wolfgang Tönges ( * 1957)
� Until 1984: In parts executive position with Sparkasse and Volksbanken
� 1984 – 1992: Cooperative audit association Frankfurt
� 1992 – 2011: Executive positions with the Faber Grouppe Alzey
� from 2000: MD & CFO for all companies of the group globaly. TheFaber group (infrastructure / building construction, environmentalengineering, quarries/ gravel pits, asphalt mixing plants, ready-mixedconcrete facilities, sewer renovation, temporary employment, cardealership) generated a yearly revenue of EUR 150 million with ~1,200 employees
� 2007- 2009: Prepare sale of the construction and raw material businessof Faber group to Eiffage, France (screening for potential buyers, vendor due dilligence, lead sales process and negotiations)
� From June 2011: Management Buyout of Faber Ambra GmbH as part of thesuccession planning process; International business with focus on wasteand water management, waste and waste-water to energy and renewableenergy
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Background – Hardy Ehrhardt, COO
Hardy Ehrhardt ( * 1965)
� Study of mining at the Technical University “Bergakademie Freiberg“, academic degree as graduate engineer
� 1992 – 2001: COO in quarries, gravel quarries, asphalt plants, concrete plants and landfill sites in Germany and Hungary
� 2001 – 2004: Responsible project manager of Faber Ambra for international projects in the field of waste management (construction of landfill sites, removal of old landfills, MBT, compost) at national and international sites
� 2003 – 2004: COO at the MBT-landfill in Atlacomulco, Mexico
� 2005: Preparation of a CDM (Clean Development Mechanism) certification
� Since 2006: Project management and monitoring of several projects using the Faber Ambra technology
� Since 2011: CEO of MBS Business Consultants GmbH
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Contents
Company
Team
Technology
1. Faber Ambra® System
2. Waste To Energy
Strategic Options
Cost Efficiency
Business Models
Contact
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Mechanical treatment of fresh municipal waste
homogenization
Biological treatment
packaging of compost
aerobic rotting windrow
Technical process
Faber Ambra® system > composting
structuralmaterial M
IXING
recycling as structural material or disposal of the residues
effluent gas
freshair
freshair
residues frombiogas production
(must be dried)
sieving of compost
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Loading of the homogenization drum before the mechanical
waste treatment
Finished rotting windrow for the biological waste
treatment
Final disposal of the remaining material after
the mechanical and biological treatment
Pictures of the Faber-Ambra® process
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eTemperature pattern –
Pilot project Rio de Janeiro
Temperature of the Windrow
0
10
20
30
40
50
60
70
80
90
1 2 3 4 5 6 7 8 9 10Months
T1
T2
T3
TEMP.AMB.
Temperature (°C)
Source: Analyses by UFRJ
outside temp.
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Pilot project FABER-AMBRA in Rio de Janeiro
Process water analyses
55654
28116
13200
19033128239847395443
4224
747 235549675852,3819,3
33310
0
10000
20000
30000
40000
50000
60000
17.10.99 06.12.99 25.01.00 15.03.00 04.05.00 23.06.00 12.08.00 01.10.00 20.11.00
Date
Concentration [mg/l]
CSB
BSB5
TOC
NH4-N
Source: Analyses by UFRJ Time
Process water analysis –
Pilot project Rio de Janeiro
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Landfill with MBT
versus
Landfill without MBT
Landfill with MBT
versus
Landfill without MBT0
2000
4000
6000
8000
10000
12000
14000
16000
18000
mg/L
DQO DBO
Tradicional IPT FABER-AMBRA (UFRJ)Traditional landfill FABER AMBRA landfill
Source: Analyses by UFRJ
CSB BSB5
Organic leachate contamination analysis -
Pilot project Rio de Janeiro
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Durability of the landfill
Durability of the landfill
0
100
200
300
400
500
600
700
800
900
1.000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Period of exploitation [a]
verfügbare
s D
eponie
volu
men [m
³]
traditionelle Deponierung
Deponierung mit MBA-Material
Landfill capacity: 1 million m³
Daily waste amount: 150 t
Available landfill capacity [1000 m³] Traditional landfill
Landfill with MBT material
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Advantages of the Faber-Ambra® system
No methane gas emission
No noteworthy leachate contamination (reduction of the contamination potential of up to 98 %)
Duplication of the utilization time of the landfill or reduction of the required landfill area by 50 %
No rodents, birds, dogs and microbes due to the high temperature generated during the biological process
Option to dispose of possibly existing sewage sludge (affordable preparation within the biological process)
Reduction of the post-operative maintenance from 20 to 2 until max. 5 years after closing of the landfill
Approved and tested in different climatic zones
High degree of result transparency – process supervision by independent institutions
Reduction of exposure
Possible certification in the context of the contract of Kyoto (additional revenues)
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Disadvantages of the Faber-Ambra® system
Additional area required for the mechanical-biological waste treatment
Increased operating costs at short-term compared to the traditional disposal without treatment
No need of high-tech-equipment
No visible spectacular effect
Recruitment of local human resources - manpower requirements
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Contents
Company
Team
Technology
1. Faber Ambra® System
2. Waste To Energy
Strategic Options
Cost Efficiency
Business Models
Contact
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eTechnical process
Fresh household waste
Delivery of fresh waste
Biogas plant is used to
produce biogas
Electricity
Feeding into extruder
presses
OPTION
O
P
T
I
O
N
Wet/organic fraction
Dry/solid fraction
Addition of
sewage
Liquid fertilizer Heat Sale of RDF
fraction
Recycling
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Extruder press
from
wasteto
energy
Different sizes for different tonnages from 100 t/d up to 3,500 t/d
Modular construction allows extension
The heart of the process is the extruder press.
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eThe waste press / RDF equipment is sourced
from our exclusive partner
Process description – extruder press and RDF production
� Municipal solid waste is fed into the extruder press; the waste is pushed into the perforated cylindrical chamber of the extruder press and “squeezed” at a very high pressure. In this way, the wet fraction (containing 50-55% moisture) is separated from the dry one (18 – 22 % moisture)
� The pressure-extruded dry fraction is riddled in order to remove inert materials (crumbled by the extruder press) and then shredded using a hammer mill so as to obtain an homogeneous size
� The RDF obtained is in compliance with the laws in force and sent to energy exploitation plants.
Technical specifications – extruder press
� Output of 15 t/h
� Operating pressure 280 bar
� max. length 20,000 mm; max. width 12,000 mm; height 5.000 mm
Reference plants
� Plants currently operating with municipalities in Germany/Italy
� Reference cases / performance data available to Faber Ambra
CommentPresses / separation
Exclusive
distribution
agreement for
selected
markets
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eWe are employing proven 3rd party solutions/
equipment to minimize the technology risk
Solid fraction Separation /
press
Refuse Derived
Fuel (RDF)
Wet fraction Anaerobic
digestion
Biogas
(methane)
Municipal solid
waste
Waste press
The waste-to-energy process
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Press Feeding the press 1
Wet fraction Dry fraction
Feeding the press 2
Pictures of the extruder press system
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eThe biogas plant is sourced from a couple of
trusted turn-key providers
Process description – biogas production
� The wet fraction after the extruder press, which has 60% moisture (Total Solid TS=40%) is conveyed the anaerobic digestion plant.
� The matter is pumped from the mixing tanks onto the top of the digester where the anaerobic digestion process occurs.
� The digested matter which is extracted from the digester bottom cone and is not used for the inoculation is pressed to remove excess water and then sent to the aerobic stabilisation process.
� During the aerobic stabilisation the matter is left to rest in static biocells with air insufflation for 3-4 weeks and then matured under a canopy for 60 days; the stabilised matter obtained is used as covering soil in landfill sites
Reference plants – our partners
� Our partner is installing and operating biogas plants in e.g., Germany, Italy, Brazil and Croatia
� Cooperation of well known companies for biogas plants
� Reference cases / performance data available to Faber Ambra
CommentBiogas plant
Faber Ambra
maintains
relationships with
additional biogas
plant turnkey
providers
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Biogas plant (example)
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Biogas plant (example)
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Contents
Company
Team
Technology1. Faber Ambra® System
2. Waste To Energy
Strategic Options
Cost Efficiency
Business Models
Contact
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Strategic options
Option 1:
Producing compost(subject to analysis of the household waste)
Option 2:
Separating recycling material
Option 3:
Using RDF for incineration or for desalting plants and concreteplants
Option 4:
CDM
recycling
clean development
mechanism
desalting plant
compost
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Strategic options
Option 5:
Removal of the old landfill
Possible risks
! Renaturalizing the old landfill body is not without risk, because nobody knows exactlywhat the landfill body contains.
! Danger such as methane bubbles and leachate exists. An accurate working isnecessary so that no explosions or an issue of leachate happens.
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Contents
Company
Team
Technology1. Faber Ambra® System
2. Waste To Energy
Strategic Options
Cost Efficiency
Business Models
Contact
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Profitability of the treatment plant
For the calculation of the profitability the decisive factors are:
The gate fee
The market price per kWh (purchase price and sale price)
Recycling (market price of the respective recycled material –paper, cardboard, metal, non-ferrous metal, glass, plastics)
Demand for and price of agricultural fertilizer
Saving of costs for the treatment of sewage (liquid and dry)
The market price of RDF material
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Profitability - Waste Management
The market price per KWh and the price per ton of compost play a decisiverole for the calculation of the profitability.
Refinancing possibilities based on CDM, use of biogas to produceelectricity, recycling, sale of RDF material and use of liquid fertilizer.
In order to obtain an external finance based on international standards, it isimportant to have a calculation and an investment hedging.
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eCost estimation
Extruder press and biogas plant (example)
Cost estimation example, based on the treatment of 500 tons a day:
Investment for biogas:
Approximately 8 million euros
Investment for the extruder presses
Approximately 4 million euros
Cost estimation does not include:
Infrastructure on the landfill
Eventual new properties
The calculation depends on many factors and must therefore be adapted as a project arises.
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RDF-Material
Average calorific level > 15,000 kJ/kg *
The caloric value depends on thecomposition of the input material
Fertilizer
Liquid with ca. 15 - 20% solid material *
Option: Recycling
* Estimation, must be analyzed and calculated locally
Utilization potential
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Saving potential
Reduction of the volume of the landfill
Reduction of the costs for the landfill
Reduction of follow-up costs for the landfill
Reduction of follow-up costs for ground water
Reduction of climate gas (CH4)
Reduction of the amount of polluted leachate
CDM is possible
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Contents
Company
Team
Technology1. Faber Ambra® System
2. Waste To Energy
Strategic Options
Cost Efficiency
Business Models
Contact
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Option 1: Turn-key
Investment by municipality
Faber Ambra and partners are subcontractors and provide
Planning
Delivery
Implementation
Education
Quality control
Faber Ambra® system > Composting
Licence contract
Contract period: 15 years
Subcontracting model
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Option 2: Build – Own – Operate (BOO)
Must be calculated after the MOU and the letter of exclusivity
Contract period: at the minimum 15 years
To ensure the quality of the final product
Faber Ambra takes on
the investment risk
the technological risk
the operational risk
Precondition for the BOO model are securities, garanties, etc.
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Initially Faber Ambra plans to purely operate the plants to
gain an operational track record and ultimately move to a
BOT model
� Faber Ambra designs and installs the waste-to-energy process according to the municipality’s requirements
� The municipality provides the necessary CAPEX and owns the facilities / equipment
� Faber Ambra enters a long-term contract with themunicipality to operate & maintain the process
Description
Municipality
Faber Ambra
(BOT)
� Faber Ambra designs and installs the waste-to-energy process according to the municipality’s requirements
� Faber Ambra provides financing for the necessary CAPEX and transfers the ownership of the facilities / equipment to the municipality after a defined period of time
� Faber Ambra enters a long-term contract with themunicipality to operate & maintain the process
Upside limited;
preferred model to
gain operational
track record with
the initial plants
More attractive
returns; requires
access to finance
at reasonable
conditions
Hybrid models
possible
Source of
Financing
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Contents
Company
Team
Technology1. Faber Ambra® System
2. Waste To Energy
Strategic Options
Cost Efficiency
Business Models
Contact
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Faber Ambra GmbH
Klosterstr. 3
D-55232 Alzey
GERMANY
Tel. +49 (0) 6731 548898 10
Fax +49 (0) 6731 548898 99
Contact
Wolfgang Tönges, CEO
