Waste to Energy

An Indian Case Study

30.11.2018

THE LAST 2 MONTHS

Sardar Patel’s Statue of Unity

CONFIDENTIAL 3

• TCE was appointed as the Proof Consultant in Joint Venture with EGIS India

• TCE scrutinised, vetted technical studies related to wind tunnel test, seismic studies and documents relating to the 182 meter tall statue of unity and made recommendation for the architectural, civil, structural engineering components of the Statue foundation, Statue Base, Statue Structure (concrete and steel), Bronze Cladding

TCE MD

Mr. Amit Sharma

CONFIDENTIAL 4

Sardar Patel’s Statue of Unity

Oct 2018 Offsite – Inauguration of IIOT Lab in Airoli

CONFIDENTIAL 5

Day 2

Sat 27 Oct 2018

TATA CONSULTING ENGINEERS

Tata Group and TCE

CONFIDENTIAL 7

Engineering a Better Tomorrow

8

56

2800

7500

Years

Engineers

Projects

of Technical

Excellence

on rolls across

domains

Delivered Globally

Infrastructure

Energy

Process

• Water / Waste Water, Sewage, Environment

• Built Environment

• Buildings, Facilities, Master Plans,

Architecture, Industrial Facilities, Urban

Development

• Port & Harbour

• Transportation

• Power Generation (Fossil Fuel, Hydro & Renewable)

Transmission & Distribution

• Nuclear Energy Fuel fabrication, Waste Mgmt.

• Chemical Oil & Gas, Petrochemicals & Refineries, Food and

Pharma, Specialty Chemicals

• Steel, Metal and Mining Ferrous & Non-Ferrous Metals, Geology & Mining,

Benefaction, Material Handling

Design & Engineering

Project Management

Procurement Management Services

Construction Management & Safety

Advanced Technologies & Simulation

SERVICES

Ownership – Wholly owned subsidiary of Tata Sons Ltd.

$35 B of projects under

management

CONFIDENTIAL

INDUSTRIES

Service Offerings - from concept to commissioning

Lender Services

Owners / Developers

EPC / OEM

• Pre-Feasibility Studies

• Feasibility Studies

• Detailed Project Reports

• Project Management Consultancy

• Basic Engg. + FEED + Procurement Assistance

• Tendering & Construction Mgmt.

• OPEX services + Commissioning Support

• Pre-bid and detailed Engineering

• Procurement Assistance

• Commissioning Support

• Construction Mgmt. & Supervision

Service Offerings Details

Engineering Studies Project Concept Development, Pre-feasibility & Feasibility

Reports, Detailed Project Reports, Environmental Study

Reports, System Studies

Design Engineering

Services

Basic Engg., Pre-bid engineering (RFQ stage),

Procurement Support for vendor selection, vendor

drawings & document review, Detailed Engineering

including 3D modelling as per requirement, Inspection

Services, Assistance to Commissioning and Contract

Closure

Constr. Supr. & Proj.

Mgmt. Cons.

Services

Project management, including construction monitoring

and control, site supervision

OPEX Engineering related to Sustenance, Improvement, Value

Engg., Asset Digitisation / Management, etc. for Owners,

OEMs, Utility Majors, DECs, mostly funded from Client

OPEX budgets

CONFIDENTIAL 9

ENERGY BUSINESS

Steam Power Plants Gas Turbine Power Plants Hydro Power Plants

Renewable Energy Transmission & Distribution

Power Solutions

Opex & Industry 4.0

11

India’s Nuclear Power Reactors & TCE

12

Narora 1 & 2 (1991-92) 220 MWe PHWR

Kalpakkam 1 & 2 (1984-86) 220 MWe PHWR

Kakrapar 1 & 2 (1993-95) 220 MWe PHWR

Tarapur 1 & 2 (1969) 150 MWe BWR

Tarapur 4 & 3 (2005-06) 540 MWe PHWR

Rawatbhata 5 & 6 (2008) 220 MWe PHWR

Kalpakkam PFBR (2012) 500 MWe FBR

Kudankulam 1 & 2 (2012) 1000 MWe PWR (VVER)

Installed capacity : 4780MWe Under Construction : 6700 MWe

Legend: Kaiga 4 (2011) - 220 MWe PHWR

Kaiga 3 (2007) 220 MWe PHWR

TCE involvement TCE not involved Completed Under Construction

Rawatbhata 7 & 8 (2016-17) 700 MWe PHWR

Kakrapar 3 & 4 (2015,16) 700 MWe PHWR

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Gorakhpur 1&2 (2017-18) 700 MWe PHWR

Rawatbhata 1 & 2 (1973 & 1981) 100 / 220 MWe PHWR Rawatbhata 3 & 4 (2000) 220 Mwe PHWR

Kaiga 1&2 (1999) 220 MWe PHWR

Renewable – Areas of Operation

Solar WtE

Wind

Small-hydro

Geothermal

13 CONFIDENTIAL

WASTE TO ENERGY

Services – Waste to Energy

Site Specific Client Specific Other Services

• Site Selection • Techno-Economic

Feasibility Studies • Geotechnical

Study/Investigation • Financial Analysis • Power System Studies • Site Surveys • Site Specific Studies • Environmental Impact

Assessment • Waste Collection &

Management Studies

• IPP Bid Solicitation & Selection

• EPC Bid Solicitation & Selection

• Pre-tender Support to EPC Bidders

• Owner’s Engineer Services to Utilities & IPPs

• O & M Contractor Bid Solicitation & Selection

• Commissioning & Supervision

• AE Services to Utilities & IPPs

• Post-award Detailed Engineering services to EPC Contractors

• Technical Due Diligence

CONFIDENTIAL 15

Experience Snapshot

16 CONFIDENTIAL

WtE

Cli

en

t

Private & Government Players

TC

E ‘

s S

co

pe

Concept to Commissioning

• Detailed Project Report/ Feasibility

Report

• Owner’s Engineering Services

• Detailed Engineering Services

• Inspection Services

• Site Supervision

• Site Specific Studies

• MSW based

• RDF based

• Biomass based

• Industrial waste based

Key Highlights

Associated with Urban Local Bodies, State Government in the range of 250kWe to 25MWe projects of WtE plants (DBO, DBFOT, PPP projects)

Experience in gasification, combustion, and incineration for energy conversion from waste materials

Experience in gas engine, gas turbine, steam turbine route for power generation

CONFIDENTIAL 17

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Zonta Infratech Pvt. Ltd

Project Description: o Essel Infraprojects Ltd. is setting up a Refuse Derived Fuel

(RDF) based WtE plant at Kancheepuram district in Tamil Nadu.

o Zonta Infratech Pvt. Ltd., and Michaelis GmbH have jointly undertaken detailed engineering.

o Zonta has engaged TCE for providing detailed engineering services.

Project Start: Aug 2016, Project End: On going

Present Engineering Progress : Basic engg. completed,

specifications issued, site preliminary works under progress, Incinerator and HRSG ordered and STG bid review under progress.

Technology : Incinerator type, Power: 5MW

TCE Scope Of Services: o Basic engineering including DBRs for Balance of plant

systems. o Preparation of the specifications o Bid evaluation o Vendor engineering review

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GJECO Power Pvt. Ltd.

Project Description: o An international competitive tender was published by Kochi

Municipal Corporation for the treatment and disposal of 300 TPD unsegregated MSW at Brahmapuram. The project was on a Public Private Partnership [PPP] basis.

o A SPV, GJ Eco Power Pvt Ltd, has been set up in India with Biomass Power (technology provider), GJ Nature Care& Energy Pvt Ltd and London Investments Consultancy (financial partner).

o Power generation : 10MW

Project Start: Oct 2016, Engagement Completion: Dec

2016

Present Engineering Progress: Land handed over to SPV

Technology: Gasifier using RDF prepared from MSW

TCE Scope Of Services: o Review the detailed project report prepared by GJ Eco

Power Pvt. Ltd.

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20

Swachha Andhra Corporation (SAC)

Project Description: o SAC is setting up a MSW based WtE plant at Visakhapatnam

in Andhra Pradesh under DBFOT scheme under PPP. o Lead ULB: Greater Visakhapatnam Municipal Corporation

(GVMC) o Concessionaire: Jindal Urban Waste Management

(Visakhapatnam) Limited (JUWMVL) o SAC has engaged TCE for providing Owners Engineer

services. o Waste processing capacity: 1200TPD o Power generation : 15MW

Project Start: April 2017, Project End: On going

Present Engineering Progress: Civll works under progress.

Technology: Incineration technology using MSW

TCE Scope Of Services: o Independent engineer services

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21

Swachha Andhra Corporation (SAC)

Project Description: o SAC is setting up a MSW based WtE plant at Nellore in

Andhra Pradesh under DBFOT scheme under PPP.

o Lead ULB: Municipal Corporation Nellore

o Concessionaire: Envikare Green Energy Private Limited

o SAC has engaged TCE for providing Owners Engineer services.

o Waste processing capacity: 300TPD o Power generation : 5MW

Project Start: Oct 2018, Project End: Ongoing Present Engineering Progress: Civll works under progress

Technology: Incineration technology using MSW

TCE Scope Of Services: o Independent engineer services

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AN INDIAN CASE STUDY

1

Key Challenges in WtE Projects in India

• Collection of Waste

• Quantity of Waste

• Quality of Waste

• Segregation of Waste

• Odour

• Leachet Management

• Flue Gas (Dioxins and Furons)

• Ash Disposal

• Incinerator – Redundancy …?

• Performance Guarantees

• O & M Contracts

1

Key Considerations

• Changes expected in the quality and quantity of waste due to enforcement of MSW rules – i.e. • segregation of waste at source • treatment of biodegradable waste near source • enhanced recovery of recyclables (inclusive of high CV plastic, etc.).

• This is expected to reduce overall quantum of waste available for WtE and need for realistic assessment of CV • Seasonal variations in waste (Monsoon, festive seasons) – variation in moisture, CV • Availability of suitable land for WtE facility in urban territory is a constraint. Land also required for ash disposal.

Leads to use land of existing dump sites calling for excessive costs for foundation/ ground treatment. Approach for removal of legacy waste, recovery and reuse. Need for ash reuse facility – bricks etc.

• Emission issues – due to variation in waste composition and variation in operating conditions (burning temperatures). Need for stringent control technologies for emission compliances.

• Technologies for wet waste treatment are very sensitive to waste composition. • Efficiencies of incineration plant for heating are high but low for power generation. • Challenge of storage of waste during major plant maintenance – need for modularised approach. • Approaches for maximising power generation at minimum plant capacity –

• Preprocessing • Storing RDF (high CV waste) after preprocessing of waste for supplementing during monsoon

1

Project Overview

Item Detail Remarks

Type of project Waste to Energy Processing of waste and generation of electric power

Waste handling 3000TPD

With calorific value of 1500 kCal/ kg at 50% moisture

Waste Processing is part of project

Waste would be available at the doorstep of WtE plant free of cost

Expected Power

Generation 25-30 MWe Gross Power Generation

Land 14Ha Land development is the part of project scope including removal of legacy

waste

Water 4.5MLD Treated water is available and is to be conveyed by a 3km long pipeline

Laying of pipeline and associated infrastructure are part of the project scope

Design Life 25 years

Project Cost confidential Inclusive of land development cost

Statutory Clearances Env., AAI etc. Major clearances by customer and other clearances to be taken by operator at

later stage

1

Project Objectives and Benefits

Objectives

• Provide environmentally safe and sustainable solution to implement affordable system and technology for WtE that is easy to maintain and is in line with global standards

• Reduce Municipal Solid Waste (MSW) burden on landfill and generate electric power

• Compliant to SWM Rules 2016

• Process 3000 TPD mixed waste and improve environmental conditions

Benefits

• Reduced burden on Landfill and reduction of area requirement

• Control of emissions from fire of the dumpsite and other fugitive emissions

• Better hygiene and health benefits

• Minimizing surface and ground pollution

• Reduction in bird menace, particularly in view of dumping site is in flying zone

• Reduction in Green House Gas (GHG) emissions

4

Site Characteristics

• The dumping ground extends over 120 hectares

• The dumping ground receives 5500 TPD of waste and 600TPD of silt (March to June)

• Site is 60~70% saturated and has limited space for future waste

• Dumping ground has caused health issues for the residents

• Partial closure is carried out in some sections of the site

• Waste is dumped indiscriminately on fairly even ground with maximum waste height of about 37m (above ground surface)

• Encroachments by industrial / residential settlements

• Puddles of leachate at few locations

• No impervious barrier laid at the bottom and no cover at the top except soil cover in partial closure area

4

Waste Characteristics

• Waste Characterization is carried out previously by others

• High moisture content of 60~80%

• Calorific value of 530~1200 kCal / kg – huge seasonal variation

• Mix of MSW and non-combustibles

• Pre-processing needed to reduce moisture content and enhance calorific value

4

Technology Options for MSW Treatment

4

Technology Options – Incinerator Option

4

Typical WtE Flow Diagram

4

Power Plant Capacity

4

Power Plant Capacity

Parameter Unit Range of Values

Pre-Monsoon Monsoon Post Monsoon

Calorific value of MSW*1 on as received basis

kcal/kg 820 – 1380 220 – 670 410 – 940

Moisture content*1 % 65 – 79 83 – 89 77 – 85

Total combustibles*1 TPD 504 – 866 270 – 406 395 – 845

Gross plant efficiency expected*2 % 18.5 15.7 17.0

Gross Power Generation expected MW 18 – 31 3 – 13 9 – 25

*1 The above values indicate the range for each of the MSW quality parameters. However, lowest/ highest values are not coincident for any particular sample

MSW quality as per earlier study report by others 50% moisture is considered in feed stock. Excess moisture to be removed in pre-processing unit *2 Gross plant efficiency variation is due to part load operation of the plant

4

Estimated Annual Net Power Generation

MSW quality as per earlier study report by others.

Weighted average quality of MSW considered is equal to arithmetic average of MSW quality in that season.

Total number of hours in a year 8,760 Hrs

Hours in different seasons

Pre-monsoon 2,920 hrs

Monsoon 2,920 hrs

Post-Monsoon 2,920 hrs

Gross power generation range 87000 – 215,000 MWh

Average Gross Power generation expected (*) 135,000 MWh

Auxiliary Power Consumption 15 %

Average net Power generation expected 115,000 MWh Say 115 million units

4

Regulatory Framework and Clearances

Sr. No. Project Stage Compliances/ Requirements Agency

1 . Project Dev Stage Environmental Clearance (EC) by MoEF: Environment Protection Act 1986, EIA 2006 SEAC/ SEIAA

2. Pre Construction Consent to Establish (CTE) from State PCB under Water Act 1974 & Air Act 1981 SPCB

3. Construction Reg. under The Contract Labour (Regulation & Abolition) Act, 1970 as Principal Employer State Labour Dept

4. Pre Construction Central Ground Water Board NOC for ground water extraction CGWB

5. Pre Construction Airport Authority of India (AAI) Clearance/NOC AAI

6. Pre Construction Building Plan Approval from ULB ULB

7. Pre Construction Other Site/ Location Specific Clearances: Forest Dept. Clearance SEAC/ SEIAA

8. Pre Construction/

Operational Phase

Consent to Operate from State Pollution Control Board under Water Act 1974 & Air Act

1981

SPCB

9. Pre Construction Authorization under MSW (M&H) Rules 2016 (State Pollution Control Board) SPCB

10. Operational Phase Value Added Tax (VAT & CST) Registration

11. Operational Phase GST Registration GST Council

12. Operational Phase Registration under Employees Provident Fund Act

13 . Operational Phase Registration under Employees State Insurance Act

Note: SWM Rules 2016 for Air, Water, Leachate Disposal; Noise limits as per SPCB

4

Factors Impacting Technology Selection, Plant Design and Project Viability

• Assessment of Land availability and requirement

• Assessment of Water availability and requirement

• Assessment of Power availability and requirement

• Demarcation of land on the proposed site

• Layout Planning

• Site preparation

• MSW Pre-processing plant

• Waste to Energy Plant

• Power generation and evacuation system

• Auxiliary Power Supply System

• Process water conveyance system

• Raw Water Treatment Plant

• Management of Rejects – Inert material, Glass & Metals, Bottom ash and fly ash etc.

• Leachate, Effluent and Sewage Management

• Emission Control and Monitoring

• Green Belt

• Provision of required allied infrastructure

4

Design Components

• MSW Processing Plant • Power House • Common Infrastructure

• MSW Pre-Processing Unit • Weighbridge • Internal / Service Roads • Storm Water Drainage System • Boundary Wall • Process Water Conveyance Pipeline • Leachate Collection & Mgmt System • Reject Management System • Landscape Works / Greenbelt • Adm Office, Canteen, Security, Workers

MSW Pre-Processing Plant • Screens, Magnetic Separators, Eddy

Current Separators & Shredders • Storage Shed & Drying Area • Feedstock Feeder System • Feedstock

Incinerator / Steam Generator / Plant Systems • Moving Grate / Fluidized Bed / Rotary

Kiln • Steam Turbine Generator & Auxiliaries • Condensor, CEP, BFP, Deaerator, Fuel Oil • Water System, Raw Water Supply,

Storage & Treatment, RWPH, CW System, CW Pumps, CWPH, IDCT, Valves & Spclty, Blowdown, Makeup Water, Chlorination, ACW, WTP, DM Plant, Service & Potable WS, Fire Protection, Chemical Lab, Effluent Disposal System

• Electricals, Generator, Gen Transformer, Aux / Service Transformers, Emergency Power, UPS, Cabling, Lighting, Earthing, Lightning Protection, Communication

• Power Evacuation, Auxiliary Power

• Supply, Metering & Protection • Control Philosophy, DCS, PLC, CCR, SWAS,

CEMS, AAQMS, VMS, Fire Fighting, Emission Controls

• FGD • Ash Collection & Management, Fly Ash,

Bottom Ash, Handling, Collection and Disposal, ETP, STP

• Plant Buildings & Structures, Ground Improvement, Chimney, Ground Improvement, Foundations

• Design Codes & Standards • Quantity & Cost Estimates • Environment & Social Analysis, EMP • Risk Assessments • Tariff Calculations • Financial Models

4

Financial Model and Risks

Criterion PPP DBO

Financial Procedures

• SPV formation is required . • For raising capital land lease is essential. • VGF may be required from Customer • Less clarity on tariff at bidding stage . • Legal complications and will need significant time period.

• Customer is in a position to fund the capital cost, hence can expedite the project.

• Customer can use the power generated for it’s own purpose, hence project is not dependent on tariff finalization.

Maximizing Revenue

There is incentive to the Developer to maximize revenue. (Operator may compromise on compliances or use supplementary fuel)

The model can include sharing of benefits of the additional power generated beyond guaranteed power to the Contractor. Customer has adequate control over the plant operation.

Financial Risk

In case the contractor gets bankrupt then project may get shelved. The project objective of waste processing gets jeopardized.

Customer owns assets, hence can exercise alternate strategies to mitigate financial risk, in case of stressed financial situation of the contractor.

Cash flow

Any issues in arranging finance timely can impact project execution. Only financially strong parties can bid, and may limit the role of technology partner.

Assured Cash flow for the Bidder enables timely completion of the project also is considered to be attractive proposition for reputed parties.

4

Financial Model and Risks

Criterion PPP DBO

Incoming waste Financial viability significantly depends on Waste characteristics and quantity. Any downside variation can lead to legal issues/ non performance.

Financial risk/ benefit is with Customer, so variations in the Waste can be accommodated.

Functional Risk Redundancies for critical equipments may or may not be provided, thus may not ensure continuous processing of waste.

Redundancy can be specified for critical equipments for ensuring continuous processing of waste.

Technology Risk In case of non performance of the plant the project revival is relatively difficult.

In case of non performance of the plant the remedial measures are relatively easier

• Based on the Financial and Project Implementation risk, DBO Model is recommended with Operation service period

• Risks: Legal, Environmental, Social, Design Basis, Technological, Fire & Explosion, Disaster, Financial, Non-Compliance, Non-Performance (contractor)

57

• The proposed project is to be implemented on Design, Built and Operate basis

• Project period is for 25 years

• Operator to develop the project and provide operation services

Project Implementation Strategy

58

Project Milestones

CONFIDENTIAL 42

Rajashekhar Malur, Ph D Chief Technology Officer Tata Consulting Engineers rmalur@tce.co.in +91 80 6622 6485 www.tce.co.in