Finlay: woodchips to energy

Veolia’s recent moves in the waste-to-energy market has seen them team up with specialist equipment supplier Finlay.

Populations are growing and, as a result, so too is waste generation. Conversely, landfill capacity is declining as urban areas become increasingly dense.

While the waste hierarchy privileges avoidance, reuse and recycling, interest in waste-to-energy as a solution for material that falls through the cracks is growing. Capturing this potential was the driving force behind Veolia’s decision to open a new facility in Horsley Park, New South Wales.

According to site manager Stephen Bernhart, the new resource recovery facility handles wood waste material, which it then processes into a wood chip product.

“After running multiple equipment trials in 2018, we have recently kicked into operation,” Stephen says.

He adds that the wood chip product will be provided to a customer where it will be used as a substitute for coal within a cement kiln.

Veolia’s facility processes a significant amount of wood waste, such as pallets, offcuts and plywood which need to be shredded, and has the capacity to receive 430,000 tonnes of general solid non-putrescible waste per year.

“We have detailed specifications we need to meet to supply our waste-to-energy customer, and a big part of that is ensuring we achieved a material size sub 50 millimetres,” he says.

“It’s quite a challenging task because it’s such a small grade, so we decided to invite multiple suppliers out to the site to run tests and demonstrate their equipment.”

Stephen says Finlay Screening, Crushing and Recycling Systems, a supplier of screening and processing equipment for the waste and recycling industry, stood out during the trials.

“Finlay were heads and shoulders above the rest in demonstrating not just what their equipment could achieve, but how it could achieve it consistently,” he explains.   

Finlay initially trialed a medium speed shredder, however, the resulting material didn’t quite meet specifications. Three weeks later they were back, with a Terex Finlay 693+ Super Track Screening Plant that, according to Stephen, worked extremely well.

“During the second trial there was a large lump of steel which had passed through the primary shredder into the secondary shredder,” Stephen says.

“The TDSV20 shredder shut down as intended, and Finlay representatives opened it up to remove the steel. The machine was back up and running in approximately three minutes – I was very impressed with how the equipment handled it.”

According to Stephen, Finlay also demonstrated how the shredding equipment could maintain the required tonnage throughput in spite of the small material specifications.

In addition to the screening plant, Stephen purchased a Terex Finlay TDS 820 Slow Speed Shredder and a Terex Finlay TDS V20 Mid Speed Shredder and Finlay 5032HD wheeled conveyor.

Built to process bulky, solid waste, the TDS 820 has a two-metre shaft manufactured with a fully welded tooth configuration. Stephen explains that the length allows for significant throughput and size reduction of material.

“The machine’s independent gearboxes enable each shaft to be run separately, which reduces material wrappage and facilitates viable shredding,” he adds.

The Terex Mid Speed Shredder has a twin-shaft, allowing it to perform both primary and secondary shredding. The TDS V20 also has the ability to self-protect against uncrushable material like steel, making it well suited to shredding waste wood materials.

“We have had no trouble meeting specifications after procuring the equipment, all three machines have been running very well.”

According to Stephen, there has been very little down time at the Horsley Park facility.

“There were one or two minor teething issues initially, but Finlay were able to handle them quickly and without fuss,” he says.

Finlay representatives also assisted on-site equipment training when the facility was commissioned.

“They are very forthcoming with their information and we were able to get local contractors trained up on how to run and maintain the shredders and screening plant as well,” he says.

“We are at a really exciting stage in our capability with an eye for expansion, so it’s crucial to have equipment that’s both reliable and efficient.”

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WMRR holds EfW conference

The Waste Management and Resource Recovery Association of Australia (WMRR) has held the first Energy from Waste (EfW) Conference in Canberra.

Attendees heard from a host of international and local speakers, who tracked the success of EfW facilities globally and the current gaps, challenges and opportunities to drive the technology in Australia.

According to WMRR CEO Gayle Sloan, there are currently more than 2000 EfW plants operating safely around the world.

“EfW technologies have been proven overseas, and at this conference, attendees heard from our international keynotes about the success of EfW working as part of an integrated waste management and resource recovery system,” Ms Sloan said.

“Industry is not touting EfW as the be all and end all of waste management, rather it is a recovery solution above disposal when we are unable to recycle. EfW assists in driving positive diversion and recovery outcomes.”

Ms Sloan said harmonisation was another topic of conversation at the conference.

“At the Around the States panel, comprising senior government officers from QLD, SA, NSW, ACT, WA, and VIC, industry reiterated the need for all jurisdictions to come together, led by the Federal Government, to develop a nationally consistent policy and regulatory framework,” Ms Sloan said.

“That would go a long way in creating certainty for industry and all other stakeholders.”

Ms Sloan said attendees had numerous opportunities to discuss the various presentations.

“At an interactive session led by Arup, attendees were called upon to share their thoughts on what they believed were the gaps that needed to be closed, the opportunities that could be captured and the barriers that stood in the way of EfW development in Australia,” Ms Sloan said.

“From the feedback received at this session, Arup will now develop an industry roadmap to develop and establish EfW within a successful waste management and resource recovery system. WMRR will soon release this roadmap.”

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Contract awarded for East Rockingham WtE facility

A construction contract for the East Rockingham Resource Recovery Facility’s new waste-to-energy (WtE) plant has been awarded to ACCIONA.

The Engineering, Procurement and Construction (EPC) contract was awarded by the facility’s development consortium, which consists of the New Energy Corporation, Tribe Infrastructure Group and Hitachi Zosen INOVA.

Under the EPC contract, ACCIONA will deliver the project in partnership with Hitachi Zosen INOVA.

According to a consortium statement, the project encompasses the design, construction, financing and operation of a greenfield WtE facility in the Rockingham Industry Zone south of Perth.

“The new facility will recover resources from approximately 300,000 tonnes of residual waste from municipal, commercial and industrial sources per year, and up to 30,000 tonnes of biosolids,” the statement reads.

“The WtE facility will generate approximately 29 megawatts of reliable renewable energy, enough to power over 36,000 homes.”

ACCIONA Geotech Managing Directer Bede Noonan said the facility was a landmark project for Australia.

“WtE is gaining traction quickly, and it’s great to see New Energy, Tribe and our EPC partners HZI developing the second large-scale plant here,” Mr Noonan said.

“Not only will we be able to build on the capabilities harnessed for our first project in Perth, but also get the opportunity to work with industry leader HZI to bring the best available technology to Australia for the first time.”

New Energy Chairman Enzo Gullotti said awarding the contract was the final piece of the project puzzle, with construction expected to commence in the coming months.

“This project is well aligned with WA’s recently released Waste Strategy, supporting kerbside organics separation and helping make aggressive landfill diversion targets possible for the Perth region,” Mr Gullotti said.

“We also look forward to rewarding the bold leadership of Perth’s Local Government Authorities, namely the EMRC and the City of Cockburn.”

Australian Paper and SUEZ partner on WtE project

Australian Paper has partnered with SUEZ to develop the $600 million Maryvale Mill waste to energy (WtE) project following the successful completion of its feasibility study.

The $7.5 million study was co-funded with the Federal and Victorian Governments.

Australian Paper will now partner with SUEZ  to secure the long-term access to waste required to power the facility.

Australian Paper’s study examined the technical, social, environmental, and commercial feasibility of establishing an WtE facility at Maryvale.

The 18 month study found the facility would operate at a high efficiency of 58 per cent due to the mill’s need for baseload steam and electricity all year round. It would also divert approximately 650,000 tonnes of residual waste from Melbourne and Gippsland landfill, saving 543,000 tonnes of carbon emissions per annum. The new facility would allow the return of up to four Petajoules of natural gas per annum and 30 megawatt-hour per hour of electricity to Victoria’s retail energy market.

Australian Paper Chief Operating Officer Peter Williams said the company is committed to its mission of sustainable growth for the next generation.

“As the largest industrial user of natural gas in Victoria and a significant energy consumer, we must develop alternative baseload energy sources to maintain our future competitiveness,” Mr Williams said.

“Creating energy from waste is a perfect fit with our operations, because in addition to electricity we require significant quantities of thermal energy to generate steam. A WtE facility at Maryvale would secure ongoing investment at the site, support employment growth in the Latrobe Valley and also provide the missing link in Victoria’s waste management infrastructure,” Mr Williams said.

A recent economic impact study from Western Research Institute has confirmed that the WtE facility would support an average of 1046 Victorian jobs per annum during the three year construction period and more than 900 when operational.

Australian Paper and SUEZ will seek to finalise waste supply arrangements for the project by 2020. Construction of the WtE facility is planned to begin soon after with completion expected in 2024.

Environment Protection Authority Victoria granted Australian Paper a works approval to develop a large-scale, WtE facility in Victoria at the end of 2018. The facility is proposed to be co-located within the boundaries of the Australian Paper site in Maryvale, Latrobe Valley and process residual municipal solid waste, and industrial and commercial waste.

East Rockingham first waste-to-energy project for SUEZ

WA’s East Rockingham Resource Recovery Facility has awarded waste management giant SUEZ a 20-year minimum contract as waste management partner.

SUEZ has partnered with a consortium of four companies running the facility – Hitachi Sozen INOVA (HZI), Tribe Infrastructure Group and New Energy Corporation, which won a series of competitive tenders for long-term contracts in the Perth metropolitan area before securing the East Rockingham partnership.

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The facility encompasses the design, construction, financing and operation of a greenfield waste-to-energy facility, 40 kilometres south of the Perth CBD.

The project aims to treat approximately 300,000 tonnes of waste per year from municipal, commercial and industrial sources including up to 30,000 tonnes per year of biosolids.

Energy generation targets are expected to reach 29 megawatts of renewable energy, enough to supply 36,000 homes following the start of construction slated for 2019.

SUEZ will provide 65,000 tonnes per year of commercial and industrial waste, maintenance services, removal of non-processable waste at its Bibra Lake and North Bannister facilities and the purchase of renewable electricity generated for its Perth operations.

This is the second waste-to-energy plant planned for the Rockingham-Kwinana industrial region.

WA EPA recommends approval for East Rockingham WtE

The WA EPA has recommended conditional approval of New Energy Corporation’s change in technology from gasification to combustion for its proposed East Rockingham waste to energy (WtE) facility.

New Energy Corporation proposed using Hitachi Zosen Inova (HZI) Grate Combustion technology, which the EPA found did not bring any further risks to the surrounding environment or communities.

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The technology allows for a greater waste throughput at the facility, increasing the amount of waste it can process from 225,000 tonnes per year to 300,000, leading to increased electricity generation.

The EPA has also recommended strict new conditions for the proposal to ensure only residual waste is accepted at the WtE facility to be consistent with the state’s waste hierarchy.

The EPA has defined residual waste as “waste that remains after the application of a best practice source separation process and recycling systems, consistent with the waste hierarchy”.

Under the new conditions, WtE proponents will need to develop a Waste Acceptance System Plan and a Waste Acceptance Monitoring and Management Plan to identify the suppliers of waste and describe the types of waste, waste loads and quantities accepted.

WA currently has four approved WtE facilities, however none are in operation.

EPA Chair Tom Hatton said the HZI technology is used widely around the world, having been tried and tested in more than 500 plants.

“While the gasification technology originally proposed for the facility was also deemed to be acceptable by the EPA, the combustion technology has been used in a number of facilities of a similar scale, and we have determined it does not pose any additional risks to the surrounding environment and community,” Dr Hatton said.

Environment Minister Stephen Dawson will make the final decision for the proposed change. The EPA’s report is also open for a public appeal period which closes Monday 5 November.

Community consultation open for Canberra WtE

The ACT Government has begun community consultation on waste to energy (WtE) to help develop policy and provide information for stakeholders.

It follows the results of the ACT’s Waste Feasibility Study which found Canberra was unlikely to achieve a recovery rate of more than 80 per cent without some form of WtE leaving 200,000 to be sent to landfill.

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The ACT Government has launched a survey to gather community feedback and provide information on the different types of WtE to clearly outline the territory’s position on energy recovery. It has also launched an information paper to outline the challenges and opportunities for the technology in the ACT’s context.

The consultation will inform the ACT Government’s consideration of WtE in the territory.

Currently the ACT has a target to divert 90 per cent of waste from landfill by 2025 and has implemented a container deposit scheme to also improve the territory’s waste diversion rates.

WtE processing facilities are already in use in the ACT with methane gas captured at the Mugga Lane and West Belconnen landfill facilities used to power around 3000 homes.

The ACT has also set a range of targets to 2020 for secure and affordable energy which involves using clean energy technology.

City Services Minister Chris Steel said in the information paper that a serious conversation about what to do to reach the ACT’s landfill diversion targets is needed and should explore whether WtE is part of the solution.

“WtE technologies sit on a spectrum – not all of these involve burning or heating and some technologies are already in use in the ACT, for example through landfill gas capture at our Mugga Landfill site,” Mr Steel said.

“One of the key recommendations of the Waste Feasibility Study was the development of a WtE policy in the ACT to provide certainty to industry and the community about whether WtE has a role in the nation’s capital.

“As the Minister for City Services I want our community and industry to be partners in co-designing a long-term, informed and evidence-based policy vision for WtE in the ACT.”

The community consultation period will close on 29 November 2018.

Veolia signs 25 year deal to operate WA WtE facility

Veolia has signed a $450 million 25-year operations and maintenance service agreement on a large-scale waste to energy facility in Kwinana, WA, capable of producing 36 megawatts of electricity – enough to power 50,000 homes.

The Clean Energy Finance Corporation (CEFC) will commit up to $90 million towards towards the $688 million and will be able to process 400,000 tonnes of household, commercial and industrial residual waste per year.

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Operations and maintenance of the facility will commence in 2021. Veolia operates 61 thermal waste to energy facilities around the world.

Macquarie Capital and Phoenix Energy Australia are co-developing the Kwinana plant, with co-investment by the Dutch Infrastructure Fund (DIF). Infrastructure company Acciona has been appointed to design and construct the facility. The project has been approved by the WA Environmental Protection Authority.

It is expected to produce cost-competitive base load power by processing household waste from local councils and contribute to grid stability in WA’s South West Interconnected System.

Technology that has been previously used in Europe will be implemented in the plant, which is expected to reduce carbon dioxide emissions by 400,000 tonnes per year – the equivalent of taking 85,000 cars off the road.

The plant will use the Keppel Seghers grate technology, which has seen use in more than 100 waste to energy plants across 18 countries. Metals recovered in the process are then able to be recycled, with the facility producing an ash byproduct that is commonly used as road base or for construction.

CEFC’s funding is part of a $400 million debt syndicate that includes SMBC, Investec, Siemens, IFM Investors and Metrics Credit Partners. The Australian Renewable Energy Agency (ARENA) is contributing a further $23 million in grant funding.

Veolia Australia and New Zealand Managing Director and CEO Danny Conlon said the project is an exciting development for Veolia in Australia.

“Adding to Veolia’s existing infrastructure in NSW and QLD, where we generate enough electricity to power 35,000 homes per year from waste, the Kwinana Project is another example where we will extract value from waste materials, delivering a clean energy source,” Mr Conlon said.

At a time when Australian businesses and households are seeing energy shortages and rising costs, Veolia is proud to be working with innovative partners to help deliver new, environmentally sustainable energy from waste”.

ARENA CEO Darren Miller said the project provides a renewable energy solution for reducing waste going to landfill.

“The use of combustion grate technology is well established in Europe and North America but has not yet been deployed in Australia,” Mr Miller said.

“More than 23 million tonnes of municipal solid waste is produced annually in Australia and this project could help to divert non-recyclable waste from landfill and recover energy in the process.”

CEFC CEO Ian Learmonth said the landmark project was the CEFC’s largest investment in WA to date.

“Creating energy from waste is an exciting and practical way to reduce the amount of waste going to landfill, while also delivering cleaner low carbon electricity,” Mr Learmonth said.

“The average red lid wheelie bin contains enough waste to produce up to 14 per cent of a household’s weekly power needs. This investment is about harnessing that energy potential, while safely diverting waste from landfill.

“We are pleased to be working alongside Phoenix Energy Australia, Macquarie Capital and DIF in bringing this state-of-the art technology to Australia. We congratulate the Western Australian government and the participating councils in embracing this 21st century approach to waste management,” he said.

Macquarie Capital Executive Director Chris Voyce said the Kwinana plant is expected to employ around 800 workers, including apprentices, during its three-year construction phase, and some 60 operations staff on an ongoing basis.

“Macquarie Capital is pleased to be contributing to the supply of sustainable and secure renewable power to Australia’s overall energy mix,” Mr Voyce said.

“As an adviser to, investor in and developer of renewable energy projects around the world, we see waste-to-energy as an effective example of adaptive reuse: reducing the pressures on landfill by diverting it toward the generation of clean energy,” he said.

Pictured: Henry Anning

CEFC Energy from Waste lead Henry Anning said the CEFC is pleased to play a role in demonstrating the business case for large-scale waste to energy investments in Australia in the future.

“Australians produce almost three tonnes of waste per person per year. While the priority is always a strong focus on recycling and organic waste management, there is still a considerable amount of household waste from red-lidded bins ending up as landfill, where it produces a large amount of emissions,” Mr Anning said.

“Energy from waste investments such as the Kwinana plant are about creating new clean energy opportunities for Australia, while offering councils and households a practical and innovative way to manage waste. Just as importantly, they can significantly cut methane emissions produced by landfill.”

With the addition of the Kwinana facility, the CEFC has now made six large scale investments to reduce waste-related emissions.

 

Community comments called for Australian Paper WtE facility

EPA Victoria has called for further community consultation on Australian Paper’s proposal to develop a large-scale waste to energy facility.

The company has provided the EPA with a health impact assessment to support its application to develop the facility within the boundaries of its site in Maryvale, Latrobe Valley.

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The proposed plant would generate both steam and electricity which can be directly in the paper mill or exported to the grid. It would replace two gas-fired boilers and would produce around 30 megawatts of electricity and 150 tonnes of steam per hour.

The EPA’s assessment of the applications will consider issues such as best practice technology, energy efficiency and greenhouse gas emissions, waste fuel composition, compliance with waste hierarchy, potential risks to human health and the environment from air, noise, disposal of fly ash, wastewater treatment and operational contingencies.

It follows a community public meeting held earlier in July, which found there was significant support for the proposals, with many submitters commenting the technology is already operating safely overseas, there are environmental benefits of less waste going to landfill and economic benefits of local job creation.

EPA Development Assessments Director Tim Faragher said the works approval application was originally open for public comment in June and EPA received 115 submissions.

“EPA also ran a community conference in July to hear concerns from those that made submissions. This further consultation period allows interested community members to make further comments on the new information that Australian Paper has submitted,” Mr Faragher said.

When making a final determination, the EPA will also consider all public submissions and the outcomes of the community conference.