“Municipal Solid Waste Treatment Modeling to be SRF for ... · 7/15/2019 2 Indocement Location PT...
Transcript of “Municipal Solid Waste Treatment Modeling to be SRF for ... · 7/15/2019 2 Indocement Location PT...
© 2009 UNIVERSITY OF ROSTOCK | FACULTY OF AGRICULTURAL AND ENVIRONMENTAL SCIENCES
“Municipal Solid Waste Treatment Modeling to be SRF for Cement Industry”
Case Study, PT Indocement CitereupIndonesia
7/15/2019
Angga Kusuma
Universität Rostock Agrar- und Umweltwissenschaftliche Fakultät
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Indocement Location
PT Indocement Tunggal Prakarsa Tbk. (Indocement)operated since August 1975 and under subsidiary of HeidelbergCementLocated in Indonesia, South East of Asia
CiteureupPlants
TarjunPlant
Citeureup, Bogor, Wes Java: 10 Plants(15 M. Ton Cements/year)
Research Location
BACKGROUND :
Population Growth
Indonesia:
2018 : 266 Million
2050 : 321 Million
(World Population Clock, 2019)
Urban Activities
Municipal solid waste such as waste, paper,
cardboard, plastic, textile, wood, glass, etc
MSW Used to Alternative Energy
Process MSW to RDF.
Heating value of RDF can reach 15 MJ/ kg or more, moisture content below
20%
Process MSW to SRF
equipped with the right processing unit and
affordable costs.
Problem statement
Moisture = 62%LHV = 3 MJ/Kg
SRFMoisture = 20%LHV = 14 MJ/Kg2D Size < 5 cmCost = 15 €/ton
Raw Municipal Solid Waste Treatment Facility Alternative Fuel Cement Plant
Non Combustible Raw MSW No Treatment Facility Yet in Indonesia
SRF Quality Specs & Cost
Fuel Cost €/ton MJ/Kg €/JFine Coal 70.0 23 3.0 SRF 15.6 14 1.1
Fuel Cost Comparison
Indocement willingness to pay
Problem Statement
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• To design Waste Treatment Modelling that has SRF output with <25% Moisture, < 5cm 2D Size and 14 MJ/kg Calorific Value
Quality
• To design 300 tpd (100,000 tpa) input Waste Treatment ModellingSupply
• To design Waste Treatment Modelling that offers SRF costs of 15 euros / ton Financial
Objectives
Objectives
EN 148991 published by the European Committee for Standardization• Random sampling can be used to get solid waste samples that represent all solid waste
European Commission (2004)• Sampling from external containers outside the house on the roadside
UNI 10802: 2013 (Wastes – Manual Sampling and Preparation of Sample and Analysis of Eluates)• To determining the sampling plan, the technique used in sampling, and the procedures for packing, storing, and
transporting samplesNT ENVIR 001: 1995 (Solid Waste, Municipal: Sampling and Characterisation)
• Coning and Quartering method to get the required sample sizeLeachate Sampling (Environment Agency, 2013)
• 2 kg samples with particle size of sample <10 mmBio-drying
• Box Bio-drying, 1.52% Moisture loss/dayCost
• Tipping Fee and SRF Cost by Interview• Treatment cost by calculation and get from suppliers
Methods
Service Area
MSW Treatment Facility
The treatment facility of 300 tpd MSW is planned to be located 1 KM from
Indocement to collect waste from Citeureup
regency
Existing Area, 10 ha
MSW Quality & Treatment Flows
70 Temporary MSW Storage,
300 tpd or 100,000 tpa
MSW Treatment Facility
Pre-processing
Box Bio-drying
Post Processing
IndocementPlant
5 unit Compactor truck 25m3
Collection at 21.00 – 05.00 WIB to avoid traffic jam
3 unit Compactor truck 25m3
Paper/Cardboard; 7,31%
Textiles; 7,66%
Wood; 4,03%
Plastic; 20,90%
Rubber; 1,76%
Inerts; 1,00%
Ferrous; 0,31%Alumunium;
0,25%
Organic Coarse; 56,72%
Fines < 2 mm; 0,00%
Others; 0,06%
MSW Quality :
Moisture62.27%
Heat Content3.1 MJ/Kg
Sulfur0.02%
Chlorine 0.13%
Treatment Flows
Raw MSW
Pre-processing
Bio-drying
Post-Processing
SRF Product
100,000 tpaMoisture = 62%LHV = 3 MJ/Kg
97,088.48 tpa to Bio-dryingRecyclable Plastics = 965.68 tpa
Bag Opening
200 mm screening
Manual Sorting
100 mm Shredding
17 Box-drying3,912.65 tpa Leachate
46,083.84 tpa Air48,091.99 tpa Dried MSW
Collected from 70 MSW Temporary Storage
20 mm Screening
Air & Magnetic Separator
Optical Sortir& Eddy Current
50 mm Shredding
236.1 tpa Fe168.8 tpa Al
15,900.0 tpa Landfill
Sale to Cement Plant32,383.4 tpa SRFMoisture = 22.5%LHV = 13.6 MJ/Kg
Treatment Process
No Material Quantity (Tpa) Yield (%) MC (%) Cl (%) S (%) LHV (MJ/kg)
1 MSW Input 100,000.0 100.0% 62.3% 0.33% 0.02% 18.52 Output2.1Leachate 2,912.7 2.9% 100.0% 0.00% 0.00% 0.02.2Evaporated Water 46,083.8 46.1% 100.0% 0.00% 0.00% 0.02.3Moisture Loss due to Mechanical
Friction1,349.6 1.3% 100.0%
2.3SRF 32,383.4 32.4% 22.5% 0.67% 0.05% 13.62.4Recyclable Plastics 965.7 1.0% 0.1% 0.87% 0.02% 35.12.5Recyclable Fe 236.1 0.2%2.6Recyclable Al 168.8 0.2%2.7Landfill 15,900.0 15.9% 31.2% 0.66% 0.05% 11.5
Total 100,000.0 100.0%
Summary Mass Flows
Bio-drying Dimensioning
Input FeedstockMatrices % Waste In Qty (tpy) Density (t/m3) Volume (m3) MC (%)
Biodrying Material Input 97.09% 97,088.48 0.5 194,177 62.87%
Bio‐drying (Biotunnel) Data
Heap Length (m) Width (m) Height (m) Heap Volume (m3) Heap Mass (t)
24 10 3.5 840 420Design Results
Output Biodried Material (tpa) MC Bio‐dried (%)
Retention Time + Filling time
(dd)
Annual Bio‐drying cycles
No. of Biotunnel Required
Blower Min. Power (kwh) Area (m2)
48092 26.9% 26 13.8 17 7.5 20,000.00
3.5 m
10.0 m
10.0 m
24.0 m
1. CAPEX €Mechanical and Electrical Equipments 2,215,242.21 Operational Vehicles 1,035,481.85 Civil Work 821,718.75 Land 1,340,625.00 Installation for mechanical and electrical work 257,750.00 Investment Cost Total 5,670,817.81
-Project Management Cost (2,0%) 113,416.36 Value Added Tax (10,0%) 567,081.78 Import With-holding Tax (2,5%) 355,908.29 Working Capital 83,661.52 Initial Funding Requirement 6,790,885.76 Difference 5.17 Rounding - Financing Principle 6,790,937.50 Capitalized Interest 332,755.94 Total Initial Investment 7,123,693.44
2. OPEX €/YearFuel 185,032.68 Support 173,875.00 Mechanical electrical 31,133.16 Vehicle Maintenance 51,774.09 Heavy Equipment 2,589.78 Building 8,217.19 Unit Processing 112,912.88 Total OPEX 165,301.68
3. Human Resources €/Year
Director 26,250.00 SHE Inspector 5,250.00 Manager 9,000.00 Secretary 3,000.00 Finance 5,250.00 HRGA 5,250.00
Security 12,000.00 House Keeping 2,250.00 Receptionist 3,000.00 Maintenance Staff 5,250.00 Marketing Chief 5,250.00 Laboratory Chief 5,250.00 Laboratory Staff 3,750.00 Processs Chief 5,250.00 Admin Process Staff 3,000.00 Unloading and Loading Staff 3,000.00 RDF Staff 3,750.00 Recycling Staff 3,750.00 Bio-Drying Staff 3,750.00 Truck Driver 15,000.00 Heavy Equipment Driver 7,500.00 Sub Total 135,750.00
Cost Structure
Cost Structure Value Service Years Unit Cost for MSW 100,000 tpa (€/ton)CAPEX (€) 7,123,693.44 10 7.1Depreciation (10%/year) 7,123,693.44 10 7.1OPEX (€/Year) 165,301.68 1.7Human Resource (€/Year) 135,750.00 1.4Total 17.3
No Material Quantity (Tpa) Unit Cost (€/ton) Total Cost (€/Year)
Remarks
1 MSW Input 100,000.0 17.3 1,725,790.37 1.1Tipping Fee From Local Gov. 100,000.0 -14.1 (1,406,250.00) Local Gov pay for Waste
treatment service2 Material Output
2.1SRF 32,383.4 -15.6 (505,990.53) SRF Sales to Indocement
2.2Recyclable Plastics 965.7 -93.8 (90,532.94) 3R material sales2.3Recyclable Fe 236.1 -112.5 (26,557.31)2.4Recyclable Al 168.8 -112.5 (18,992.81)2.5Landfill 15,900.0 7.8 124,218.64 Landfill Cost
Total (Margin) -2.0 (198,314.59) 11.5% from Unit Cost
Unit Cost
Business Model
Treatment Facility
100,000 TPA MSW
14.1 €/Ton Tipping Fee
17.3 €/Ton Treatment Cost
Cement Plant
15.6 €/Ton SRF Sales
3R Party93.8 €/Ton
Plastics, 112.5 €/Ton Fe & AL Sales
Net Margin 2 €/Ton MSW
€198,314.59/Year
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• To design Waste Treatment Modelling that has SRF output with <22.5% Moisture, < 5cm 2D Size and 14 MJ/kg LHV. Treatment process takes 26 days.
Quality
• 100,000 tpa or 300 tpd MSW can be converted to 32,383.39 tpa or 98 tpdSRF
Supply
• Unit cost for MSW Processing is 17.3 €/Ton MSW.
• Income: Tipping Fee = 14.1 €/Ton, SRF Sales = 15.6 €/Ton and 3R Plastic and Metals
• Treatment Facility get 2 €/Ton MSW or €198,314.59/Year net margin
Financial
Conclusion
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Next Step
1. SRF Supply is expected to Reach 500 tpd to get significant Coal Replacement in Cement Production. So that further research can be done by multiplying 5 of these treatment designs
2. Modeling for waste originating from Commercial waste. This waste is thought to be drier than MSW so the treatment costs are expected to be lower.
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Thank YOU!!!
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