Conceptual_Design_Report_Bac_Ninh_WtE_Project

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REPORT 115002070 June 16, 2019 CONCEPTUAL DESIGN REPORT Bac Ninh WtE Project 115002070 Bac Ninh WtE Conceptual Design Report i Copyright © Pưyry Switzerland Ltd All rights are reserved This document or any part thereof may not be copied or reproduced without permission in writing from Pöyry Switzerland Ltd Copyright © Pöyry Switzerland Ltd 115002070 Bac Ninh WtE Conceptual Design Report ii Internal document control Client Thang Long Energy and Environment Joint Stock Company Conceptual Design Report Bac Ninh WtE Project Title Project Phase Project No 115002070 Classification Drawing/Reg./Serial No File name File location System Conceptual Design Report 115002070_clean.docx Microsoft Word 16.0 External distribution Internal distribution Contribution Responsible BU Revisions: Original Date of document Author/position/signature Date of control Checked by/position/signature A Date of document Author/position/signature Date of control Checked by/position/signature B Date of document Author/position/signature Date of control Checked by/position/signature Change at last revision Copyright © Pưyry Switzerland Ltd 14/06/2019 Ilkka Lassila, et al / WtE/process specialist 15/06/2019 J de Beer / Proj Manager 115002070 Bac Ninh WtE Conceptual Design Report iii Preface Contact: Jacques De Beer Pöyry Switzerland Ltd Hanoi Representative Office 5A Floor BIDV Tower 194 Tran Quang Khai street, Hoan Kiem district, Hanoi, Vietnam Tel +84 (24) 3974 8388 Fax +84 (24) 3974 1199 E-mail: jacques.debeer@poyry.com Copyright © Pưyry Switzerland Ltd 115002070 Bac Ninh WtE Conceptual Design Report iv Preface Contents INTRODUCTION BASIC CONCEPT DESIGN BASIS 3.1 3.2 3.3 3.3.1 3.3.2 3.3.3 3.4 3.5 3.5.1 3.5.2 3.5.3 Site Location Site Layout and Equipment Arrangement Site Conditions Soil Conditions Climatic Conditions Seismic Conditions Reference Design Conditions Fuel Municipal Solid Waste (MSW) Pollutants Concentration Fuel Oil Analysis 3 4 4 6 BOILER PLANT CONCEPT 4.1 4.2 4.3 4.4 4.5 4.6 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.6.6 General Steam Generation Fuel Oil Firing System Draft Plant Boiler Pressure Part Emissions Emissions Limits NOx Emissions Acid Gaseous Emissions Particulate Emissions Dioxin and Furans Emissions Heavy Metal Emissions 10 10 11 11 13 13 15 15 15 15 15 TURBINE GENERATOR PLANT 16 5.1 5.2 Condensing Extraction Turbine Condensing Plant 16 16 BALANCE OF PLANT 17 6.1 6.2 6.3 6.4 6.5 6.6 Waste Storage Requirements and Volumes Waste Handling Ash Collection and Removal Ash Disposal Considerations Water Supply Water Treatment 17 19 20 20 21 22 Copyright © Pưyry Switzerland Ltd 115002070 Bac Ninh WtE Conceptual Design Report v 6.7 6.8 6.9 6.9.1 6.9.2 6.9.3 6.9.4 6.10 6.10.1 6.10.2 6.10.3 6.10.4 6.10.5 6.10.6 6.10.7 Demineralization Plant Waste Water Treatment Electrical Works 22kV MV Substation 11kV STG Power Generation System 690V Power Distribution System 400V Power Distribution System Instrumentation and Control Distributed Control System (DCS) Programmable Logic Controllers (PLC) Steam Turbine Governing, Protection and Supervision Boiler Safety Related System (SRS) Emissions Monitoring System RDF Plant General Field Instrumentation 22 23 23 23 23 23 24 24 24 24 25 25 26 26 26 CIVIL AND STRUCTURAL WORKS 27 HEAT AND MASS BALANCE 28 WATER BALANCE 29 10 EPC COST ESTIMATE 30 11 O&M COSTS 30 11.1 11.2 Fixed costs Variable costs 30 31 12 PRELIMINARY TIME SCHEDULES 32 Annexes Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix Appendix 10 Appendix 11 Process Flow Diagram Plant Layout Climatic Conditions Preliminary Soil Investigation Report Fuel Analysis Raw Water Quality Overall Single Line Diagram Heat Mass Balance Diagram Water Balance Diagram Preliminary Project Time Schedule Comparison of grab cranes versus front end wheel loaders Copyright © Pưyry Switzerland Ltd 115002070 Bac Ninh WtE Conceptual Design Report vi List of Tables Table 3-1 Fuel Analysis Hanoi Table 3-2 Fuel Sample Calorific Value Table 3-3 Valmet requirement Table 3-4 BMH Waste Specification Table 3-5 Fuel Oil Quality Table 4-1 Emission Limits# 13 Table 6-1 Water Demand 21 Table 8-1 Heat Balance Analysis 28 Table 9-1 Water Balance Analysis 29 Table 10-1 EPC Cost Estimates 30 List of Figures Figure 3-1 Project Location Figure 3-2 Map of strong earthquake originated zones and maximum shake zoning Figure 3-3 Seicmic Zone and Maximum seismic intensity zone of Vietnam (TCVN 9386-2012) Copyright © Pưyry Switzerland Ltd 115002070 Bac Ninh WtE Conceptual Design Report vii Abbreviations HBD IW MSW RDF WBD Heat Balance Diagram Industrial Waste Municipal Solid Waste Refuse Derived Fuel Water Balance Diagram Copyright © Pöyry Switzerland Ltd 115002070 Bac Ninh WtE Conceptual Design Report 1 INTRODUCTION Thang Long Energy and Environment Joint Stock Company is developing a Waste to Energy (WtE) plant capable to process 500 tons per day of Municipal Solid Waste (MSW) and an additional 100 tons per day of Industrial Waste (IW) located in Que Vo district of Bac Ninh Province, approximately 55 km from Hanoi, and producing around 10 MW net electricity exports to the EVN distribution system The objectives are to: (a) Develop a WtE Plant having a dependable capacity of about 10 MW net power output and an incineration capacity of 500 t/d municipal waste disposal and 100 t/d industrial waste disposal The project will also include, –among others, the design and construction of the fresh water supply system for the WtE Plant from a nearby river, and the construction of overhead power lines to evacuate the power to the adjacent EVN 22kV transmission line; (b) Place a turnkey fixed lump sum price EPC contract with a qualified contractor; and (c) Own and operate the WtE Plant from the Commercial Operation Date Copyright © Pưyry Switzerland Ltd 115002070 Bac Ninh WtE Conceptual Design Report 2 BASIC CONCEPT The concept of the project is to develop a WtE Plant of about 10 MW net power output and an incineration capacity of 500 t/d MSW and 100 t/d IW The WtE Plant shall have one Circulating Fluidized Bed (CFB) boiler and Refuse Derived Fuel (RDF) preparation plant with the associated waste receiving and storing system CFB boilers combined with adequate flue gas treatment have been selected to fulfil the Vietnamese regulatory requirements for stack emission limits as stated in greater detail later in this document The boilers shall be designed to burn RDF produced from MSW and IW only The WtE Plant will be connected to the EVN 22kV power grid Raw fresh water shall be drawn from a river adjacent to the site The preliminary process flow diagram is shown in Appendix [Process Flow Diagram] Copyright © Pưyry Switzerland Ltd 115002070 Bac Ninh WtE Conceptual Design Report 90 Appendix – Fuel Analysis Copyright © Pưyry Switzerland Ltd KẾT QUẢ PHÂN TÍCH RÁC Ngày: 6.10.17 FINAS Finnish Accereditation Service T104 ( EN ISO/IEC 17025 ) Mẫu rác: Hà Nội, Bãi rác Bắc Ninh Mẫu lấy bởi: Khách hàng Đặc tính mẫu rác: Rác tươi Ngày phân tích: 29.09,2017 Số mẫu: 2017-02062-01 Ngày nhận mẫu phòng thí nghiệm: 29.09.2017 Tiêu chí Criteria Độ ẩm mẫu rác/ Humidity Tổng nhiệt trị cho mẫu rác khô Total caloric value of dry waste sample Tổng nhiệt trị sở nhận Total caloric value received Nhiệt trị thực mẫu rác khô ( MJ/KG ) Actual caloric value of dry waste sample Nhiệt trị thực mẫu rác khô (MWh/t ) Actual caloric value of dry waste sample Nhiệt trị thực sở nhận (MJ/kg ) Actual caloric value received Nhiệt trị thực sở nhận (MWh/t ) Actual caloric value received Kết Result 58,2 20,06 Đơn vị Unit % MJ/kg Hệ thống tiêu chuẩn Standard system CEN/TS 15414-2:2010 * SFS-EN 15400:2011 8,39 MJ/kg *SFS-EN 15400:2011 18,47(1) MJ/Kg *SFS-EN 15400:2011 5,13(1) MWh/t *SFS-EN 15296:2011 6,30(1) MJ/kg *SFS-EN 15400:2011 1,75(1) MWh/t *SFS-EN 15296:2011 *Phương pháp kiểm định cơng nhận Kết luận khơng nằm ngồi phạm vi cơng nhậ (1) Gía trị dự tính 115002070 Bac Ninh WtE Conceptual Design Report 92 Appendix – Raw Water Quality Copyright © Pưyry Switzerland Ltd Bac Ninh WtE Raw Water Quality The sampling points are below NM02, NM03 and NM04 are in the Cau river which is the river closest to the site 115002070 Bac Ninh WtE Conceptual Design Report 94 Appendix – Overall Single Line Diagram Copyright © Pưyry Switzerland Ltd Project Title : Owner : Consultant : Pöyry Energy Ltd 1126/2 Vanit Building II 22 nd Floor, Room No.2202-2204 New petchburi Road, Makkasan Rajchthewi, Bangkok Thailand 10400 Document Title : Main Contractor : 115002070 Bac Ninh WtE Conceptual Design Report 96 Appendix Heat and Mass Balance Diagram Copyright © Pưyry Switzerland Ltd NOTE : PRELIMINARY Project Title : Document No : 115002070-M-030-001 BAC NINH WASTE POWER PLANT Document Title : A A BCC Poyry Rev.No FOR PROPOSAL Description - Prepd - Chkd Appd Authd HEAT BALANCE DIAGRAM Project No : 115002070 Page No : OF A Scale : File Name: A3 115002070 Bac Ninh WtE Conceptual Design Report 98 Appendix – Water Balance Diagram Copyright © Pưyry Switzerland Ltd 50 River Water 3.8 tph tph Drift & evaporation 37 tph 5.0 Cycles of concentration 46 tph Blowdown Cooling Towers 10 tph tph Quench Water (Could possibly be replaced with some of the waste waters) 0.5 tph Raw Water Pretreatment Filter Backwash 0.5 tph Total 1.0 0.4 3.3 tph tph 700 214 m3 hours 1.4 1.0 tph Service water & Fire Water Tank(s) Demin Plant 0.2 tph 0.1 tph tph 0.4 tph 60 26 m3 hours Discharge to River tph (Could be also pumped to the cooling tower basin) 0.8 tph Blow Down Pit Boiler Blowdown 2.3 tph Neutralization Basin Aux Steam Losses Chemical Dosing Demin Water Tanks 0.2 tph tph 0.4 1.0 0.1 Waste Water Holding Pond tph m3 hours 0.1 tph 0.1 tph Quench Water 1.4 To Atmosphere tph 30 31 0.5 tph 12 tph Soot Blowing Sampling System 1.1 tph 0.1 tph CCCW Make-up tph 1.1 Other Service Water tph pH Adjustment Flocculation Tank Clarifier Oil Separator Sewage Treatment Plant Treatment of Potable Water 0.4 tph Potable Water Field of planning - Dwg No: Document No: 0.0 tph Fire Fighting Losses Client / Project: Indonesia Power Bali Waste to Energy Feasibility Study Contents of drawing: Preliminary Water Balance Diagram Sea Water Cooling Towers Notes: All flows are averages during full load operation based on a plant output of 12 MW Possible waste bunker run-off is assumed to be injected into the furnace and a closed bottom ash cooling system is assumed without significant consumption Drawn by: PH Date designed: Date: 11 June 2019 Date Approved: Job No: 115002070 Bac Ninh WtE Conceptual Design Report 100 Appendix 10 – Preliminary Project Time Schedule Copyright © Pöyry Switzerland Ltd 115002070 - Bac Ninh WtE Project Preliminary Project Time Schedule No Description I Unit Duration Commencement II Engineering Mth 10 III Procurement & Delivery Mth 16 IV Construction & Erection Mth 17 V Test and Commissioning Mth VI COD M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15 M16 M17 M18 M19 M20 M21 M22 M23 M24 115002070 Bac Ninh WtE Conceptual Design Report 102 Appendix 11 – Comparison of wheel loader versus grab crane Copyright © Pưyry Switzerland Ltd Simple Comparison of Materials Handling from RDF Storage Yard to Boiler Fuel Hopper Fuel data Density (figures per BMH) MSW RDF (average) Delivery (figures per Owner) MSW 400 250 500 tpd 1,250 m /day RDF production (based on assumed boiler capacity) RDF (total) 450 RDF to boiler RDF kg/m kg/m3 tpd 1,800 m /day 75.00 m /hr Medium sized Front End Loader Bucket size Trips / hour Fuel consumption Fuel consumption (8,300 h/a) Fuel cost 15 41 338,308 0.76 l/h l/a USD/l Capital cost O&M (4% of Capex) Fuel cost 180,000 7,200 257,114 USD USD/a USD/a Grab crane Power consumption Power costs Capital cost O&M (4% of Capex) Power costs (8,300 h/a) m3 100 kW 0.09563 c/kWh 1,650,000 66,000 79,376 USD USD/a USD/a Comparison Loader annual O&M Crane annual O&M Difference annual O&M Difference in capital cost Payback period 264,314 145,376 118,938 1,470,000 12.4 $/y $/y $/y $ years In this type of application, however, maintenance costs for a front end loader will be much higher than the typical 4% of capital costs used here and the useful life of the machine could be as low as years, as opposed to the more frequently used 10 year figure This would mean a "top to bottom" rebuild every years, in addition to the annual maintenance costs, at a cost of typically 70% of the costs of a new machine or replacing the machine with a new machine Conclusion From a cost point of view the crane is a better option than the front end loader There are some issues to be considered with the crane: - Redundancy has to be considered given a small boiler hopper with a capacity of only 15 minutes, meaning that crane maintenance has to be a priority - Maintenance for the crane has to be a priority, but with two outages on the RDF plant per year, this should be manageable - Cycle time will have to be carefully considered when sizing the crane considering the small capacity of the boiler hopper, but with careful design of the RDF bunker and selection of the crane, this should not be a problem - Operation will take place on a 24/7 basis, but given that automation is an option, having operational staff available is not a critical issue There are similarly some issues which need to be considered if front end loaders are selected as the preferred materials handling option in the RDF storage yard: - - Cycle time for the front end loader will also have to be carefully considered when selecting a machine for the application Materials handling operations will run on a 24/7 basis as long as the boiler is in operation and this means that the front end loader will need to have operators available on a 24/7 basis Refueling of the machine has to be considered carefully as the machine will operate on a 24/7 basis and any refueling operation will have to be factored into the cycle time or operational strategy On balance a materials handling solution using grab cranes is likely to yield a more reliable, efficient and cost effective solution