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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).
Figure 1: Process Schematic (EACH LINE)
Heat and Mass Balance
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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