VIRIDOR BEDDINGTON ERF SUPPORTING INFORMATION

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1 VIRIDOR BEDDINGTON ERF SUPPORTING INFORMATION 25/08/2011 Beddington ERF - Supporting Information Page i

2 VIRIDOR BEDDINGTON ERF SUPPORTING INFORMATION Document Production & Approval Record ISSUE NO. 3 NAME SIGNATURE POSITION DATE Prepared by: James Sturman Consultant 23 rd July 2012 Checked by: Stephen Othen Technical Director 23 rd July 2012 Document Revision Record ISSUE NO. DATE DETAILS OF REVISIONS 1 28 th May 2012 Draft for client review 2 29 th June 2012 Final draft for client approval 3 23 rd July 2012 Final for issue Fichtner Consulting Engineers. All rights reserved. This report and its accompanying documents contain information which is confidential and is intended only for the use of Viridor. If you are not one of the intended recipients any disclosure, copying, distribution or action taken in reliance on the contents of the information is strictly prohibited. Unless expressly agreed, any reproduction of material from this report must be requested and authorised in writing from Fichtner Consulting Engineers. Authorised reproduction of material must include all copyright and proprietary notices in the same form and manner as the original, and must not be modified in any way. Acknowledgement of the source of the material must also be included in all references. 25/08/2011 Beddington ERF - Supporting Information Page ii

3 TABLE OF CONTENTS TABLE OF CONTENTS... III 1 Introduction The Applicant The Site Listed Activities Waste Operations The Stationary Technical Unit Raw Materials Combustion Process Energy Recovery Gas Cleaning Ancillary Operations Bottom Ash Processing Liquid Effluent and Site Drainage Emissions Monitoring Other Information for Application Form Raw materials Types and amounts of raw materials Reagent Storage Raw Materials Selection Reagent selection Auxiliary Fuel Incoming Waste Management Waste to be Burned Waste Handling Waste Minimisation Audit (Minimising the Use of Raw Materials) Feedstock Homogeneity Furnace Conditions Flue Gas Treatment Control Waste Management Water Use Overview Potable and Amenity Water ERF Process Water Emissions Point Source Emissions to Air Odour Emissions to Water & Sewer Contaminated Water /08/2011 Beddington ERF - Supporting Information Page iii

4 2.3 Monitoring Methods Emissions Monitoring Monitoring Emissions to Air Monitoring Emissions to Land Monitoring of Process Variables Technology Selection Combustion Technology NO x Reduction System Flue Gas Recirculation (FGR) Conclusion Acid Gas Abatement System Particulate Matter Cooling System Selection Specific Information required by the Waste Incineration Directive Furnace Requirements Validation of Combustion Conditions Measuring Oxygen Levels Combustion System Waste Charging Bag Filter Operation Unavoidable Stoppages Energy Efficiency General Basic Energy Requirements Operating and Maintenance Procedures Energy Efficiency Measures Further Energy Efficiency Requirements Waste Recovery and Disposal Introduction Bottom Ash Air Pollution Control Residues Management Introduction Business Management System Integrated Management Systems Developing, Implementing and Improving the BMS Developing Implementing Improving Reporting Structures and Communication Communication /08/2011 Beddington ERF - Supporting Information Page iv

5 2.10 Commissioning Closure Introduction General Site Closure Plan General Requirements Specific Details Disposal Routes Pre-operational Conditions and Improvement Programme Pre-operational Conditions Commissioning Develop Site Closure Plan Waste Incineration Questions /08/2011 Beddington ERF - Supporting Information Page v

6 1 INTRODUCTION The Beddington Energy Recovery Facility (ERF) will generate 26.1 MW of electricity using residual Municipal Solid Waste from South London, plus some commercial and industrial (C&I) waste, as the fuel. With an annual availability of 7,800 hours, the plant will process 275,000 tonnes of waste per annum. In addition, there is a Waste Transfer Station and dry recyclates transfer facility which will be developed within the site. The environmental permit application for the Waste Transfer Station and dry recyclates transfer facility is being submitted separately. This document and its annexes contain the supporting information for the application for the Environmental Permit (EP). They should be read in conjunction with the formal application form. In this section 1, we have provided an overview of the proposed installation. In section 2, we have provided further information in response to specific questions in the application form. In section 3, we have responded to the specific questions designed to demonstrate that the proposed installation would comply with the requirements of the Waste Incineration Directive. The requirements of Sector Guidance Notes (SGNs) EPR 5.01, S5.06 and the sector BREF Waste Incineration Industries - have been addressed throughout this document. 1.1 The Applicant Viridor Waste Management Limited is one of the UK s leading recycling, renewable energy and waste management companies. The company works with more than 90 local authorities and thousands of private customers across the country. Viridor s aim is to protect human health and the environment by safely, responsibly and efficiently managing waste and maximising recycling and resource generation opportunities. Viridor offer a wide range of services to its customers from recycling and waste collections, skips and bins through to fully integrated contracts. To do this and keep up with the huge number of developments in the waste industry, Viridor invest heavily in treatment and processing equipment to ensure that the technology used is state-of-the-art. Viridor is refocusing its business away from simply disposing of society s wastes towards far higher levels of resource efficiency via the recovery of energy and materials. As a market leader in recycling and reuse of waste, Viridor partners local councils, helping them to meet waste prevention, recycling and landfill diversion targets. Viridor also provide the private sector with integrated recycling, waste management and specialist solutions. Viridor currently operate a range of sites including 3 Energy from Waste plants, 25 Materials Recycling Facilities and 21 Landfills, as well as offering services from waste collection, composting and logistics to skip and bin hire. Viridor provides the full range of recycling and waste services including advanced materials recycling, glass and plastics reprocessing, composting, mechanical & biological treatment, waste to energy, transport, collection, and safe and efficient landfill disposal. Each year the company recycles c. 2 million tonnes of materials, has the capacity to generate over megawatts of renewable energy and handled over 8 million tonnes of waste material. Viridor is owned by Pennon Group, a FTSE 250 British based plc focused on the water and waste management industries. 25/08/2011 Beddington ERF - Supporting Information Page 1

7 1.2 The Site The site is located at Beddington Farmlands, which is located south of Mitcham Common and north of Beddington Park, within the London Borough of Sutton. The site lies 500m metres to the south of the London Borough of Merton and 600m to the west of the boundary of the London Borough of Croydon. The area identified for the Beddington ERF is fairly flat, and is currently in use as a dry recyclate and waste transfer facility, a skip waste recycling compound, part of an in-vessel composting facility and associated vehicle circulation areas and hardstanding. The application site has historically been used for treatment and processing of waste and waste water and minerals extraction. Prior to this the area was in agricultural use. The site is bounded to the east by sludge beds (part of Thames Water s waste water treatment works) and Beddington Lane beyond, to the west by the railway, to the north by sludge beds and to the south by Beddington Park. Access to the site will be gained from a new access road linking into the Coomber Way roundabout on Beddington Lane. This is presented in Annex 1 (Phase 8: Restoration Plan). 1.3 Listed Activities The principal activity will consist of a combination of Schedule 1 installation activities (as defined in the Environmental Permitting Regulations) and directly associated activities: Table 1.1: Environmental Permit Activities Type of Activity Schedule Activity Description of Activity Incineration Line Part A (1) c) Incineration Line 1 and 2 the incineration of residual wastes with a combined nominal operating capacity of tonnes per hour Directly Associated Activities Directly Associated Activities Directly Associated Activities Directly Associated Activities Directly Associated Activities Acceptance of waste to the installation. Dewatering of gulley waste The abatement of emissions to air from the installation. The export of heat and electricity from the installation. A drawing which identifies the installation boundary is presented in Annex 1 (Ref: : Site Plan). 1.4 Waste Operations To the south of the main ERF building there will be a facility for recyclable wastes and waste unsuitable for combustion. There is not technical connection between the two facilities. The application will be applied for separately to this submission. 25/08/2011 Beddington ERF - Supporting Information Page 2

8 1.5 The Stationary Technical Unit The Stationary Technical Unit (installation) covers the ERF includes the two waste incineration lines, waste reception, waste storage, water, fuel gas and air supply systems, boilers, facilities for the treatment of exhaust gases, on-site facilities for treatment or storage of residues and waste water, flues, stack, devices and systems for controlling incineration operations, recording and monitoring conditions. The plant will be configured as a Combined Heat and Power (CHP) Plant and will have capacity to export heat to local users and power to the National Grid. The turbine has been designed to deliver up to 20 MW of thermal energy to the CHP plant, which could deliver approximately 150,000 MWh of thermal energy per year. The nominal operating capacity of each incineration line will be approximately tonnes per hour of waste, with an estimated calorific value of 9.8 MJ/kg. The plant will have an estimated availability of around 7,800 hours. Therefore the ERF will have a nominal design capacity of approximately 275,000 tpa. The maximum waste throughput which can be processed continually at 100% MCR (with a lower CV 8.7 MJ/kg) will be tonnes per hour. Therefore the installation has the potential to be able to incinerate up to approximately 302,500 tonnes per annum assuming an annual availability of 7,800 hours. A firing diagram demonstrating the range of capacities for the installation is presented in Annex 7. This demonstrates that the facility will maintain the power output during fluctuations in fuel mix and with wastes that have lower calorific values. The other factor which will affect total fuel input capacity will be the hours of operation. In some years, the plant may not need to be shut down for as long a period, consequently the fuel input capacity will increase. The process is illustrated in the diagram below. A larger copy is also included in Annex 1. 25/08/2011 Beddington ERF - Supporting Information Page 3

9 1.5.1 Raw Materials Waste will be delivered to the plant in road vehicles. Waste deliveries will typically be during weekdays between 07:00 and 18:00 hours, and on Saturdays between 07:00 and 18:00 hours, although daily waste deliveries will be completed by 1700 hours. Road deliveries will be weighed at the entrance of the site, before being directed to the tipping hall. The tipping hall will be a fully enclosed building, maintained under slight negative pressure to ensure that no odours, dust or litter can escape the building. The vehicles will tip into a waste storage pit from where a grab transfers waste to the feed hoppers on the combustion lines. The grab will also be used to homogenise the waste and to identify and remove any unsuitable or non-combustible items. Bulky items will be passed through a shredder so that they are suitable for incineration. Hydrated lime is used to react with the acid gases in the flue gas cleaning process. Lime will be stored in silos. The lime will be delivered by tanker and offloaded pneumatically by means of the on board truck compressor into the silo. The displaced air will be vented to atmosphere through a fabric filter located on the top of the silo. Powdered activated carbon (PAC) used for the absorption of volatile heavy metals and organic components is added with the lime. PAC will be stored in silos. PAC is pneumatically transferred from the delivery truck by means of an on board compressor. As with the lime, the exhaust air is de-dusted using a fabric filter located on the top of the silo. Urea is used for the NOx reduction using SNCR. Urea will be delivered to the site in dry form, and stored in a designated area in a silo. Demineralised water is supplied from an onsite demineralisation plant. It is used to supply the steam cycle. Various maintenance materials (oils, greases, insulants, antifreezes, welding and fire fighting gases etc.) will be stored in an appropriate manner Combustion Process The combustion chamber uses a reverse acting grate which agitates the fuel bed to promote a good burnout of the material and a uniform heat release. The residence time of the fuel on the grate is expected to be approximately minutes. Primary combustion air is drawn from the tipping hall to minimise odour issues from stored waste in the bunker and fed into the combustion chamber beneath the grate. Secondary combustion air injected into the flame body above the grate to facilitate the oxidation of unburned gasified material released from the fuel. Further up the flue, above the combustion zone, dry urea is injected through sprays. The urea reacts with the oxides of nitrogen formed in the combustion process forming water, carbon dioxide and nitrogen. By controlling the flow rate of urea introduced into the gas stream the concentration of NOx is reduced to meet required limits. The combustion chamber is provided with auxiliary burners that use fuel oil. Their purpose is to ignite the refuse at start-up and to raise the combustion chamber temperature to the required 850 C. There will be interlocks preventing the charging of waste until the temperature within the combustion chamber has reached 850 C. During normal operation, if the temperature falls below 850 C the burners are again initiated to maintain the temperature above this minimum. Air flow for combustion is controlled by measuring excess oxygen content in the flue gas. This is set to maximise the efficiency of the heat recovery process while maintaining the combustion efficiency. 25/08/2011 Beddington ERF - Supporting Information Page 4

10 Bottom ash falls from the grate into the discharger which comprises a water bath followed by a chute inclined upwards that forms a water seal preventing uncontrolled air ingress to the combustion chamber from the boiler house. The water serves as a quench and makes it possible to remove the bottom ash without dust or odour issues. The ash is pushed upwards and out of the water bath by hydraulically driven rams. The ash will pass over a vibrating bar screen. After this, the ash is conveyed to a storage area. There will be regular collections of IBA from the storage area for transfer off-site to a suitably licensed waste facility. Ferrous scrap from the vibrating bar screen is stored in a dedicated part of the ash bunker. The material will be stored on site until a sufficient quantity has been accumulated, at which point it will be transported to a suitably licensed waste facility Energy Recovery Heat is recovered from the flue gases by means of a water tube boiler integral with the furnace. Heat is transferred through a series of heat exchangers. The hot gases from the furnace first pass through evaporators that raise the steam. The hot flue gases then pass into the boiler. The boiler consists of 4 passes containing evaporators, superheaters and economisers. At the boiler outlet the flue gases pass through an external economiser which controls the flue gas temperature to 140 C. The boiler economisers are used to pre-heat the evaporator feedwater supply. The cooling medium in the external economiser is condensate from the air cooled condenser. The flue gas temperature is reduced quickly through the critical range where dioxin reformation can occur. Superheated steam at 60 bar-g and 400 C is supplied to a high efficiency turbine which through a connecting shaft turns a generator to produce electricity. The turbine has a series of extractions at different pressure that are used for preheating air and water in the steam cycle. The remainder of the steam passes out of the final low pressure condensing stage. To generate the pressure drop to drive the turbine the steam must be condensed back to water. A fraction will condense at the exhaust of the turbine in the form of wet steam. The majority is condensed in the air cooled condenser (ACC) following the turbine at a pressure well below atmospheric. A flange will be provided on the medium pressure bleed of the steam turbine in order to allow a future connection to provide additional steam extraction as required. As potential heat users become available, the provision of a heat supply will be possible without modification to the installed system Gas Cleaning The abatement of oxides of nitrogen (NO x ) will be achieved by selective non-catalytic reduction (SNCR). NO x is formed in the boiler at high temperature from nitrogen in the fuel and in the combustion air. Urea will be injected at the combustion chamber through a bank of nozzles installed at different places to provide flexibility of dosing, directly into the hot flue gases above the flame. NO x is chemically reduced to nitrogen, carbon dioxide and water by the urea. After the heat recovery stages the flue gas passes to the flue gas treatment (FGT) plant. The method chosen is known as dry FGT and uses hydrated lime to reduce the concentrations of acid gases, such as SO x and HCl, in the flue gas stream. This abatement technology has the benefit that it does not produce a liquid effluent. Energy recovery is more efficient as additional heat in the boiler flue gas is not required to evaporate water as in a semi-dry or conditioned FGT process. 25/08/2011 Beddington ERF - Supporting Information Page 5

11 Powdered activated carbon (PAC) is used as an adsorbent to remove volatile metals, dioxins and furans. Both PAC and lime are held in dedicated storage silos and transported pneumatically and mixed in line and introduced to the flue gas stream through a common injection point. The flue gases containing the reagents pass through a reaction loop and into a bag filter arrangement where reaction products and un-reacted solids are removed from the stream. The residues cake the outside of the filter bags with the units periodically cleaned by a reverse jet of air displacing the filtered solids into chutes beneath. Residues collected by the bag filters are held in a silo from where it is recycled back into the flue gas stream at the top of the reaction loop. The lime flow rate is controlled by the upstream acid gas pollutant concentration measurements and proportioned to the volumetric flow rate of the flue gases. As fresh reagents are added an equivalent amount of residues collected from the bag filters are removed. There will be online monitoring of pressure drop within bag filter compartments to identify when there has been bag filter failure. If a pressure drop is identified, bag filter compartments will be isolated to prevent uncontrolled emissions and repaired before being brought back on-line. The cleaned gas is monitored for pollutants and discharged to atmosphere through two 85m stacks Ancillary Operations The plant includes a demineralised water plant to treat towns water or collected and cleaned harvested rainwater so that it is suitable for use as top up for the process requirements. The treated water will be used to initially fill up the boilers and the water network and replace blowdown losses. Steam losses from the steam/water cycle would cause a build-up of solids in the system as concentrations of impurities in the water gradually increase. Water addition and blowdown prevent this from occurring. The demineralised water system has a buffer tank to ensure demineralised water is always available. Blowdown and waste process water is directed to a settlement pit that will remove suspended solids. Through a buffer tank the water is supplied to the bottom ash quench system. Excess wastewater in the settlement pit will be discharged to sewer following ph correction. During normal operation, the plant is expected to be zero discharge to water. Water for fire fighting will be supplied by the potable water supplier, and will be stored in a dedicated firewater tank Bottom Ash Processing The ERF facility is expected to produce approximately 69,000 tonnes per annum of bottom ash which will be transferred off-site to a suitably licensed waste facility. Small volumes of boiler ash will be combined with the bottom ash as part of the process. Bottom ash from the grate will have oversized components removed by a vibrating bar screen and then be conveyed to the ash bunker. Grate riddling and boiler cleaning residues will be collected with the bottom ash through the ash dischargers Liquid Effluent and Site Drainage During normal operation the ERF is designed to have zero discharges to water. Surface run-off from the main access road will be diverted to swales running alongside it, which will be designed to have the water flow an attenuation pond. Rainwater will be collected from buildings and used for grey water harvesting for domestic uses. 25/08/2011 Beddington ERF - Supporting Information Page 6

12 The Beddington Lane site has direct connections available to the adjacent Thames Water sewage works. Discharges from sanitary and kitchen sources within the facility, including from the administration building, control room, workshop area, tipping hall, and the weighbridge office, will be discharged to sewer. All process water within the ERF will be reused within the waste water collection system. Blowdown and waste process water is directed to a settlement pit that will remove suspended solids. Through a buffer tank the water is supplied to the bottom ash quench system. Excess wastewater in the settlement pit will be discharged to sewer following ph correction if necessary. This is only expected to be required during periods of abnormal operation Emissions Monitoring Reporting on emissions monitoring is integrated into the continuous emissions monitoring system (CEMS). There will be one CEMS per line. The following measurements will be continuously monitored and recorded: Particulates (PM 10 ); HCl (Hydrogen chloride); CO (Carbon monoxide); SO 2 (Sulphur dioxide); NO x (Nitrogen oxides, NO & NO 2 expressed as NO 2 ); NH 3 (Ammonia); VOC (Volatile Organic Compounds); oxygen (O 2 ); water vapour (H 2 O); pressure; temperature; and volume flow. As allowed by WID Article 11(4), continuous HF emission monitoring will be replaced by relying on continuous HCl monitoring. This is because the lime system used for the abatement of hydrogen chloride is effective for the abatement of hydrogen fluoride and is operated with an excess of lime. As hydrogen fluoride is more reactive than hydrogen chloride, by controlling hydrogen chloride below the Emissions Limit Value (ELV), the hydrogen fluoride level is maintained below the relevant ELV. Periodic monitoring will be used to verify this is the case. A spare CEMS unit is available and will be set-up as a stand-by. It will be signalled to be switched on in case of a failure of either one of the main units. 25/08/2011 Beddington ERF - Supporting Information Page 7

13 2 OTHER INFORMATION FOR APPLICATION FORM 2.1 Raw materials Types and amounts of raw materials Question 3c in application form B3 requires information on the types and amounts of raw materials which will be used. The information requested is shown in Table 2.1 below. In addition, information on the potential environmental impact of these raw materials, as required by Getting the Basics Right, is included in Table 2.2. Table 2.1: Types and Amounts of Raw Materials and consumption rate at design load Schedule 1 Activity Material Maximum Amount (m 3 ) Annual Throughput (tonnes per annum) Description including any hazard code ERF Fuel oil Low sulphur fuel oil Urea Prills Hydrated lime 160 3,500 Dry, hydrated Activated carbon Boiler treatment chemicals Powdered < 5 < 50 Corrosion inhibitor, scale inhibitor, biocide, ion exchange resins 25/08/2011 Beddington ERF - Supporting Information Page 8

14 Fuel oil Product Chemical Composition Mixture of aliphatic and aromatic hydrocarbons. Low sulphur (<0.1%) Table 2.2 Raw materials and their affect on the environment Environmental Medium Typical Quantity Units Air Land Water Impact Potential 2000 tonnes / year Low impact Lime Ca(OH) 2 >95% 3,500 tonnes / year Low impact Activated Carbon C 100 tonnes / year Low impact Urea CO(NH 2 ) tonnes / year Low impact Water H 2 O 33,000 m 3 / year Low impact Water Treatment Chemicals Corrosion inhibitor, scale inhibitor, biocide, ion exchange resins Comments Fuel for start-up and shutdown of the ERF, and site vehicles. Injected lime is removed with the APC residues at the bag filter and disposed of as hazardous waste at a suitable licensed facility. Injected carbon is removed with the APC residues at the bag filter and disposed of as hazardous waste at a suitable licensed facility. Reacts with nitrogen oxides to form nitrogen, carbon dioxide and water vapour. Any unreacted ammonia (a chemical intermediate) is released to atmosphere at low concentrations. Water is used for various uses, including: Demineralised water make-up; Cleaning water; Ash quench. < 50 tonnes / year Corrosion inhibitor, scale inhibitor, biocide, ion exchange resins will be used for the treatment of boiler feedwater. 31/07/2012 Beddington ERF - Supporting Information Page 9

15 Various other materials will be required for the operation and maintenance of the plant, including: a) Hydraulic oils and silicone based oils; b) Electrical switchgear; c) Gas supply equipment; d) Refrigerant gases for the air conditioning plant; e) Oxyacetylene, TIG, MIG welding gases; f) CO2 / fire fighting foam agents; g) Test and calibration gases. These will be supplied to standard specifications offered by main suppliers. All chemicals will be handled in accordance with COSHH Regulations as part of the quality assurance procedures and full product data sheets will be available on site. Periodic reviews of all materials used will be made in the light of new products and developments. Any significant change of material, where it may have an impact on the environment, will not be made without firstly assessing the impact and seeking approval from the Environment Agency. The Operator will maintain a detailed inventory of raw materials used on site and have procedures for the regular review of new developments in raw materials Reagent Storage In order to minimise contamination risk of process or surface water, all liquid chemicals will be stored on site in accordance with the Environment Agency Pollution Prevention Guidelines. In the event of a spillage and/or a leak they will be retained in these areas and treated locally. High-level sensors, relief valves, and discharge air filters will be installed on all silos to prevent over-pressurisation and release of consumables to atmosphere. Hydrated lime,, activated carbon and urea prills will be delivered to the plant for storage in silos. Both the lime and the activated carbon will be transported pneumatically from the delivery vehicle to the correct storage silo. Control is achieved through high level control and alarm. The top of all silos will be equipped with a vent fitted with a fabric filter. Cleaning of the filter is done automatically with compressed air after the filling operation. The filter will be inspected regularly for leaks Raw Materials Selection Reagent selection Acid Gas Abatement There are several reagents available for acid gas abatement. Sodium Hydroxide (NaOH) or hydrated lime (Ca(OH) 2 ) can be used in a wet FGT system. Quicklime (CaO) can be used in a semidry FGT system. Sodium bicarbonate (NaHCO 3 ) or hydrated lime can be used in a dry FGT process. The reagents for wet scrubbing and semi-dry abatement are not considered, since these abatement techniques have been eliminated by the BAT assessment in Annex 4 section 1. The two alternative reagents for a dry system lime and sodium bicarbonate have therefore been assessed further. 25/08/2011 Beddington ERF - Supporting Information Page 10

16 The level of abatement that can be achieved by both reagents is similar. However, the level of reagent use and therefore residue generation and disposal is different and requires a full assessment following the methodology in Horizontal Guidance Note H1. The assessment is detailed in Annex 4 section 3 and is summarised in the table below. Table 2.3 Acid Gas Abatement BAT Data Item Unit NaHCO 3 Ca(OH) 2 Mass of reagent required kg/h Mass of residue generated kg/h Cost of reagent /tonne Cost of residue disposal /tonne Overall Cost /op.hr/kmol 1,200, ,000 Ratio of costs Note: Data based on abatement of one kmol of Hydrogen Chloride In summary, there is a small environmental benefit for using sodium bicarbonate, in that the mass of residues produced is smaller. However, there are a number of significant disadvantages: The sodium bicarbonate residue has a higher leaching ability than lime-based residue, and therefore may require additional treatment prior to disposal, making it more expensive to dispose of; The reaction temperature for sodium bicarbonate doesn t match as well with the optimum adsorption temperature for activated carbon, which will be dosed at the same time as the acid gas reagent; and The costs of sodium hydroxide are approximately 30% higher than using a lime system. Thus, the use of lime is considered to represent BAT for this installation. NO x Abatement A detailed BAT Assessment for the assessment of technologies for the abatement of NOx has been presented in section The SNCR system can be operated with dry urea, urea solution or aqueous ammonia solution. There are advantages and disadvantages with all of these options: Urea is easier to handle than ammonia; the handling and storage of ammonia can introduce an additional risk. Dry urea needs big-bags handling whereas urea solution can be stored in silos and delivered in tankers. Ammonia tends to give rise to lower nitrous oxide formation than urea. Nitrous oxide is a potent greenhouse gas. Ammonia emissions (or slip ) can occur with both reagents, but good control will limit this. The Sector Guidance on Waste Incineration considers all options as suitable for NO x abatement. It is proposed to use urea for the SNCR system. The climate change impacts of urea are considered to be significantly less significant than the handling and storage issues associated with ammonia solution. The use of urea in the SNCR system is therefore regarded as representing BAT. 25/08/2011 Beddington ERF - Supporting Information Page 11

17 Auxiliary Fuel The auxiliary fuel for the ERF will be fuel oil. This will be brought in by tanker, loaded/unloaded via a sealed pipe system, and stored in an above ground bunded storage tank. As stated in Article 6 (1) of the Waste Incineration Directive: During start-up and shutdown or when the temperature of the combustion gas falls below 850 o C, the auxiliary burner should not be fed with fuels which can cause higher emissions than those resulting from the burning of gasoil as defined in Article 1 (1) of Council Directive 75/716/EEC, liquefied gas or natural gas. Therefore as identified by the requirements of WID the only available fuels that can be used for auxiliary firing are: (1) Natural gas; (2) Liquefied gas (LPG); or (3) Gasoil. Auxiliary burner firing on a well managed waste combustion plant is only required intermittently, i.e. during start-up, shutdown and when the temperature in the combustion chamber falls to 850 o C. Natural gas can be used for auxiliary firing and is safer to handle than LPG. As stated previously, auxiliary firing will only be required intermittently. When firing this requires large volumes of gas, which would be need to be supplied from a highpressure gas main. The installation of a high-pressure gas main to supply gas for auxiliary firing to the Beddington ERF would be very expensive. LPG is a flammable mixture of hydrocarbon gases. It is a readily available product, and can be used for auxiliary firing. As LPG turns gaseous under ambient temperature and pressure, it is required to be stored in purpose built pressure vessels. If there was a fire within the site, there would be a significant explosion risk from the combustion of flammable gases stored under pressure. A fuel oil tank can be easily installed at the Beddington ERF. Whilst it is acknowledged that fuel oil is classed as flammable, it does not pose the same type of safety risks as those associated with the storage of LPG. The combustion of fuel oil will lead to emissions of sulphur dioxide, but these emissions will be minimised as far as reasonably practicable through the use of low sulphur fuel oil. Therefore, low sulphur light fuel oil will be used for auxiliary firing Incoming Waste Management Waste to be Burned The proposed plant will be used to recover energy from MSW and Commercial and Industrial waste, with European Waste Catalogue Codes as shown in the table below. 25/08/2011 Beddington ERF - Supporting Information Page 12

18 Table 2.4 EWC Code List for Installation EWC Code Description of Waste WASTES FROM AGRICULTURE, HORTICULTURE, AQUACULTURE, FORESTRY, HUNTING AND FISHING, FOOD PREPARATION AND PROCESSING wastes from agriculture, horticulture, aquaculture, forestry, hunting and fishing animal-tissue waste plant-tissue waste waste plastics (except packaging) wastes from forestry agrochemical waste other than those mentioned in wastes from fruit, vegetables, cereals, edible oils, cocoa, coffee, tea and tobacco preparation and processing; conserve production; yeast and yeast extract production, molasses preparation and fermentation materials unsuitable for consumption or processing wastes from the dairy products industry materials unsuitable for consumption or processing wastes from the baking and confectionery industry materials unsuitable for consumption or processing wastes from preserving agents WASTES FROM WOOD PROCESSING AND THE PRODUCTION OF PANELS AND FURNITURE, PULP, PAPER AND CARDBOARD wastes from wood processing and the production of panels and furniture waste bark and wood sawdust, shavings, cuttings, wood, particle board and veneer other than those mentioned in WASTES FROM ORGANIC CHEMICAL PROCESSES wastes from the MFSU of plastics, synthetic rubber and man-made fibres waste plastic WASTE FROM WOOD PROCESSING AND THE PRODUCTION OF PANELS AND FURNITURE, PULP, PAPER AND CARDBOARD Wastes from pulp, paper and cardboard production and processing Waste bark and wood Mechanically separated rejects and pulping of waste paper and cardboard Waste from sorting of paper and cardboard destined for recycling WASTES FROM THE LEATHER, FUR AND TEXTILES INDUSTRIES Wastes from the textiles industry Wastes from composite materials, (impregnated textile, elastomer, plastomer) Organic matter from natural products (for example grease, wax) 25/08/2011 Beddington ERF - Supporting Information Page 13

19 Table 2.4 EWC Code List for Installation EWC Code Description of Waste Wastes from unprocessed fibres Wastes from processed fibres WASTES FROM ORGANIC CHEMICAL PROCESSES wastes from the MFSU of plastics, synthetic rubber and man-made fibres waste plastic WASTES FROM THE PHOTOGRAPHIC INDUSTRY wastes from the photographic industry photographic film and paper containing silver or silver compounds photographic film and paper free of silver or silver compounds single-use cameras without batteries WASTES FROM SHAPING AND PHYSICAL AND MECHANICAL SURFACE TREATMENT OF METALS AND PLASTICS wastes from shaping and physical and mechanical surface treatment of metals and plastics plastics shavings and turnings WASTE PACKAGING; ABSORBENTS, WIPING CLOTHS, FILTER MATERIALS AND PROTECTIVE CLOTHING NOT OTHERWISE SPECIFIED Packaging (excluding separately collected municipal packaging waste) Paper and cardboard packaging Plastic packaging (which is contaminated) Wooden packaging Composite packaging Mixed packaging Textile packaging Absorbents, filter materials, wiping cloths and protective clothing Absorbents, filter materials, wiping cloths and protective clothing other than those mentioned in WASTES NOT OTHERWISE SPECIFIED IN THE LIST End-of-life vehicles from different means of transport (including off-road machinery) and wastes from dismantling of end-of-life vehicles and vehicle maintenance (except 13, 14, and 16 08) plastic CONSTRUCTION AND DEMOLITION WASTES (INCLUDING EXCAVATED SOIL FROM CONTAMINATED SITES) Wood, glass and plastic Wood Plastic 25/08/2011 Beddington ERF - Supporting Information Page 14

20 Table 2.4 EWC Code List for Installation EWC Code Description of Waste Mixed construction and demolition wastes other than those mentioned in , and WASTES FROM HUMAN OR ANIMAL HEALTH CARE AND/OR RELATED RESEARCH (except kitchen and restaurant wastes not arising from immediate health care) wastes from natal care, diagnosis, treatment or prevention of disease in humans wastes whose collection and disposal is not subject to special requirements in order to prevent infection(for example dressings, plaster casts, linen, disposable clothing, diapers) chemicals other than those mentioned in medicines other than those mentioned in wastes from research, diagnosis, treatment or prevention of disease involving animals wastes whose collection and disposal is not subject to special requirements in order to prevent infection chemicals other than those mentioned in medicines other than those mentioned in WASTES FROM WASTE MANAGEMENT FACILITIES, OFF-SITE WASTE WATER TREATMENT PLANTS AND THE PREPARATION OF WATER INTENDED FOR HUMAN CONSUMPTION AND WATER FOR INDUSTRIAL USE wastes from physico/chemical treatments of waste (including dechromatation, decyanidation, neutralisation) Premixed wastes composed only of non-hazardous waste Combustible wastes other than those mentioned in and stabilised/solidified wastes stabilised wastes other than those mentioned in solidified wastes other than those mentioned in Wastes from aerobic treatment of solid waste Non-composted fraction of municipal and similar wastes Non-composted fraction of animal and vegetable waste Off specification compost wastes from anaerobic treatment of waste digestate from anaerobic treatment of municipal waste digestate from anaerobic treatment of animal and vegetable waste wastes from waste water treatment plants not otherwise specified screenings wastes from shredding of metal-containing wastes fluff-light fraction and dust other than those mentioned in Wastes from waste water treatment plants not otherwise specified 25/08/2011 Beddington ERF - Supporting Information Page 15

21 Table 2.4 EWC Code List for Installation EWC Code Description of Waste Sludges from other treatment of industrial waste water other than those mentioned in Wastes from the mechanical treatment of waste (for example sorting, crushing, compacting, pelletising) not otherwise specified Paper and cardboard (which is contaminated) Plastic and rubber (which is contaminated) Wood other than that mentioned in Textiles Combustible waste (refuse derived fuel) Other wastes (including mixtures of materials from mechanical treatment of wastes other than those mentioned in ) MSWS (HOUSEHOLD WASTE AND SIMILAR COMMERCIAL, INDUSTRIAL AND INSTITUTIONAL WASTES) INCLUDING SEPARATELY COLLECTED FRACTIONS Separately collected factions (except 15 01) Paper and cardboard (which is contaminated) Biodegradable kitchen and canteen waste Clothes Textiles Edible oil and fat Paints, inks, adhesives and resins other than those mentioned in Detergents other than those mentioned in Medicines other than those mentioned in Discarded electrical and electronic equipment other than those mentioned in , and Wood other than that mentioned in Plastics Garden and park wastes (including cemetery waste) Biodegradable waste other non-biodegradable wastes Other MSWs Mixed MSW Waste from markets Street cleaning residues waste from sewage cleaning Bulky waste MSWs not otherwise specified 25/08/2011 Beddington ERF - Supporting Information Page 16

22 The nominal operating capacity of each incineration line will be approximately tonnes per hour of waste, with an estimated net calorific value of 9.8 MJ/kg. The plant will have an estimated availability of around 7,800 hours. Therefore the ERF will have a nominal design capacity of approximately 275,000 tpa. The maximum waste throughput which can be processed continually at 100% MCR (with a lower NCV of 8.7 MJ/kg) will be tonnes per hour. Therefore the installation has the potential to be able to incinerate up to approximately 302,500 tonnes per annum assuming an annual availability of 7,800 hours. This would maintain the power output during fluctuations in fuel mix and with wastes that have lower calorific values. The other factor which will affect total fuel input capacity will be the hours of operation. In some years, the plant may not need to be shutdown for as long a period, so that the fuel input capacity will increase. Checks will be made on the paperwork accompanying each delivery to ensure that only waste for which the plant has been designed will be accepted. Where possible, the weighbridge operator will undertake a visual inspection of waste to confirm it complies with the specifications of the waste transfer note (WTN). For waste delivered in Refuse Collection Vehicles (RCVs), it will not be practical to inspect this waste before it is tipped into the bunker, since it is compressed in the vehicles/storage vessels. The waste will be observed by the tipping hall operator as it is tipped and by the crane driver and control room operator as it is mixed. Unacceptable waste will be removed from the bunker for further inspection and quarantine, prior to transfer off-site to a suitable disposal/recovery facility. The bunker design will incorporate a back-loading facility to enable the contents to be emptied into vehicles for removal from site in the event of unplanned periods of prolonged shut-down. This will comprise a feed chute, to be loaded by one of the waste feed cranes, and discharging into an articulated vehicle. This facility can also be used for the removal of oversized items or non-combustible items identified within the bunker. Any unacceptable waste will be rejected and stored in a designated area in the tipping hall. The Environmental Management System (EMS) will include procedures to control the inspection, storage and onward disposal of unacceptable waste. Certain wastes will require specific action for safe storage and handling. The EMS will also contain procedures for controlling the blending of waste types to avoid mixing of incompatible wastes. Unsuitable wastes could include items which are considered to be non-combustible, large/bulky items or items of hazardous waste. Large/bulky items will be shredded prior to transfer to the waste bunker. All other unsuitable wastes will be loaded into a bulker or other appropriate vehicle for transfer off-site either to the producer of the waste or to a suitably licensed waste management facility. Gulley waste will be delivered to the Gulley Waste facility for processing. The SRF produced from from the Gulley Waste facility will be transferred to the waste bunker Waste Handling At the start of operation, the installation will have documented procedures which will comply with the BAT requirements in the Sector Guidance Note, including: A high standard of housekeeping will be maintained in all areas and suitable equipment to clean up spilled materials will be provided and maintained. Vehicles will be loaded and unloaded in designated areas provided with impermeable hard standing. These areas will have appropriate falls to the process water drainage system. 25/08/2011 Beddington ERF - Supporting Information Page 17

23 Fire fighting measures will be designed by consultation with the Local Fire Officers, with particular attention paid to the waste bunker. Delivery and reception of waste will be controlled by a management system that will identify all risks associated with the reception of waste and shall comply with all legislative requirements, including statutory documentation. Incoming Municipal and Commercial and Industrial waste will be: in covered vehicles or containers; and unloaded into the enclosed reception bunker. Gulley wastes will be delivered to site in enclosed vehicles and unloaded into the Gulley Waste facility for processing. Design of equipment, buildings and handling procedures will ensure there is no dispersal of litter. Waste crane operating procedures will ensure the waste is well mixed in the bunker to maximise the homogeneity of waste fed to the ERF Facility. Inspection procedures will be employed to ensure that any wastes which would prevent the ERF Facility from operating in compliance with its permit are segregated and placed in a designated storage area pending removal. Further inspection will take place by the crane operator during vehicle tipping and waste mixing Waste Minimisation Audit (Minimising the Use of Raw Materials) A number of specific techniques are employed to minimise the production of residues. All of these techniques meet the Indicative BAT requirements from the Sector Guidance Note on Waste Incineration Feedstock Homogeneity Improving feedstock homogeneity can improve the operational stability of the plant, leading to reduced reagent use and reduced residue production. The process of tipping waste into the storage bunker and subsequent mixing by the grab will serve to improve the homogeneity of waste from different deliveries Furnace Conditions Furnace conditions will be optimised in order to minimise the quantity of residues arising for further disposal. Burnout in the furnace will reduce the TOC content of the bottom ash to less than 3% by optimising waste feed rate and combustion air flows Flue Gas Treatment Control Close control of the flue gas treatment system will minimise the use of reagents and hence minimise the residues produced. SNCR reagent dosing is optimised to prevent ammonia slip. In particular, Computational Fluid Dynamic modelling will be used to optimise the injection locations of the urea SNCR system to achieve good dispersion. 25/08/2011 Beddington ERF - Supporting Information Page 18

24 Lime usage will be minimized by trimming reagent dosing to accurately match the acid load using fast response upstream HCl monitoring. Variable speed screw feeders will ensure the lime dosing rate can be rapidly and precisely varied to match the acid load. The plant preventative maintenance regime will include regular checks and calibration of the lime dosing system to ensure optimum operation. Back-up feed systems will be provided to ensure no interruption in lime dosing. The bag filter is designed to build up a filter cake of unreacted lime, which acts as a buffer during any minor interruptions in dosing. There will be separate controls for the dosing rate for lime and activated carbon Waste Management Water Use Details of waste management procedures can be found in Section 2.7. In particular, bottom ash and residues from the flue gas treatment system will be stored and removed from site separately Overview The following key points should be noted: The water system has been designed with the key objective of minimal consumption of potable water. Surface water run-off from the roofs of the main ERF process buildings will be collected and used within the ERF to supplement the use of potable water. Most of the steam produced will be recycled as condensate. The remainder will be lost as blowdown to prevent build-up of sludge and chemicals, through sootblowing and through continuously flowing sample points. Lost condensate will be replaced with demineralised water. During normal operation waste water from the process will be re-used in the bottom ash quench system. A Process Water Mass Balance drawing is presented on the next page. A larger version is included within Annex 1. 25/08/2011 Beddington ERF - Supporting Information Page 19

25 25/08/2011 Beddington ERF - Supporting Information Page 20

26 Potable and Amenity Water Water for supplies for the offices facilities will come from a potable water supply. The quantity of this water is expected to be small compared to the other water uses on site. Waste water from showers, toilets and other mess facilities will be discharged to sewer ERF Process Water It is anticipated that the facility will use approximately 100 m 3 /hr of water. This water will consist of harvested rainwater, potable mains water and demineralised water. Demineralised water will be supplied to the Beddington ERF from an onsite water treatment plant. Process waste water will be collected and treated in the settlement pit and then used in the bottom ash quenching system. Under normal operating conditions, waste water is generated from the following: Process effluent collected in the site drainage system (e.g. boiler blowdown); Effluent generated through washing and maintenance procedures; Leachate from the waste reception areas. The settlement pit allows reuse of the water in the ash quench. Sludge tankers will periodically remove the settled material and boiler blowdown sludge from the pit for offsite disposal. During normal operation there will be no water discharge from the waste water pit or process water system; all water from the ERF plant will be reused within the building. In the event of overflow from tanks and equipment within the process, the water will be directed via the process water drains to the waste water pit for reuse in the ash quench system. The settlement pit will be provided to maximise the reuse of process water. 2.2 Emissions Point Source Emissions to Air The full list of proposed emission limits for atmospheric emissions is shown in Table 2.4. Emissions to air from the ERF will be discharged to atmosphere via a 85m high stack. The stack will contain two flues. The emission points from the ERF facility stack will be A1 and A2. Details regarding the location of the stack are presented in Annex 5 - Air Quality Assessment. In addition, there will be emission points from the back-up generators. Due to the capacity (3MW) of these units, and they are only used infrequently it is not considered suitable to propose emission limits for these emission points. There will be two point source emission points for emissions to air from the installation. These are presented in the table below: 25/08/2011 Beddington ERF - Supporting Information Page 21

27 Table 2.5 Proposed Emission Points Emission Point Reference Source A1 Incineration Line 1 A2 Incineration Line 2 The full list of proposed emission limits for atmospheric emissions is shown in the table below. This includes the information requested in Table 2 of Application Form Part B3. The limits are based on the emission limits required by the Waste Incineration Directive with the following exception: The Waste Incineration Directive allows the omission of continuous monitoring of HF if treatment stages for HCl are used which ensure that the emission limit for HF is not being exceeded. Table 2.6 Proposed Emission Limits Values (ELV s) Parameter Units Half Hour Average Emission Points A1 and A2 Daily Average Periodic Limit Particulate matter mg/nm VOCs as expressed as Total Organic Carbon (TOC) mg/nm Hydrogen chloride mg/nm Carbon monoxide mg/nm Sulphur dioxide mg/nm Oxides of nitrogen (NO and NO₂ expressed as NO₂) mg/nm Odour Hydrogen fluoride mg/nm 3 2 Cadmium & thallium compounds (total) and their mg/nm Mercury and its compounds mg/nm Sb, As, Pb, Cr, Co, Cu, Mn, Ni and V and their compounds (total) mg/nm Dioxins & furans ITEQ ng/nm All expressed at 11% oxygen in dry flue gas at 0 C and 1 bar-a. The storage and handling of waste is considered to have potential to give rise to odour. The facility will be designed in accordance with the requirements of Environment Agency Guidance Note H4: Odour. The facility will include a number of controls which are deemed to represent appropriate measures to minimise odour from the installation during normal and abnormal operation. 25/08/2011 Beddington ERF - Supporting Information Page 22

28 Tipping Hall and Waste Bunker The tipping hall will be within a fully enclosed building, to contain odours, dust or litter within the building. The ERF will be a two stream facility, and will include a waste bunker which will be maintained under a slight negative pressure. During normal operation this will ensure that no odours are able to escape the building. The negative pressure will be created by drawing combustion air from within the ERF building. During periods of planned maintenance for the incineration plant, there will only be one stream shutdown at a time. This will ensure that the building is maintained at negative pressure during maintenance periods. During periods of short term unplanned outage when the ERF is not available, misting sprays may be used to reduce odour from the waste storage areas. Management Controls The installation will include the following appropriate management controls for odour: Olfactory monitoring for odour will be undertaken at the site boundary. Waste will be stored within contained structures maintained at negative pressure to prevent odour release. During shutdown, doors will limit odour spread while still allowing vehicle access. Misting sprays may be used to reduce odour from the waste storage area. The main doors used for the waste delivery vehicles will be kept closed, except during waste delivery periods.. Waste storage management procedures and good mixing will avoid the development of anaerobic conditions within the waste bunker. The plant will employ bunker management procedures (mixing and periodic emptying and cleaning) to avoid the development of anaerobic conditions. Wastes will be removed from the bunker on a first in, first out basis. Procedures will be in place to divert waste away from the site during lengthy shut downs. Self-closing doors will be provided for any potentially odorous indoor areas Emissions to Water & Sewer A schematic identifying the Drainage Systems Principle from the installation is presented below: 25/08/2011 Beddington ERF - Supporting Information Page 23

29 A full Retention Class 1 separator will provide containment of any spillages or leaks of oil into the drainage system, and prevent potential contamination of local watercourses. Therefore the only discharges to water from the installation will be of uncontaminated rainwater. During normal operation the ERF is designed to have zero discharges to water. Surface run-off from the main access road will be diverted to swales running alongside it, which will be designed to have the water flow an attenuation pond. Rainwater will be collected from buildings and used for grey water harvesting for domestic uses. The Beddington Lane site has direct connections available to the adjacent Thames Water sewage works. Discharges from welfare facilities, including from the administration building, control room, workshop area, tipping hall, and the weighbridge office, will be discharged to sewer. All process water within the ERF will be reused within the waste water collection system. Blowdown and waste process water is directed to a settlement pit that will remove suspended solids. Through a buffer tank the water is supplied to the bottom ash quench system. Excess wastewater in the settlement pit will be discharged to sewer following ph correction where required. This is only expected to be required during periods of abnormal operation. 25/08/2011 Beddington ERF - Supporting Information Page 24

30 2.2.4 Contaminated Water All chemicals will be stored in an appropriate manner incorporating the use of bunding and other measures (such as acid and alkali resistant coatings) to ensure appropriate containment. The potential for accidents, and associated environmental impacts, is therefore limited. Concrete structures used for the storage of waste will be designed in accordance with with BS EN :2006 Design of Concrete Structures Part 3: Liquid retaining and containment structures standard. Preventative maintenance systems will include inspection and maintenance of containment systems. Adequate quantities of spillage absorbent materials will be made available onsite, at an easily accessible location(s), where liquids are stored. A site drainage plan, including the locations of foul and surface water drains and interceptors will be made available onsite, where practicable. This will be available following detailed design of drainage systems. Vehicles operating within the ERF will refuel at the on-site refuelling station located in a lay-by on the eastern side of the ERF building. This will comprise a 90,000 litre fuel oil tank and associated pumps. This tank will also be used to supply fuel to the ERF auxiliary burners. A Full Retention Class 1 Separator is included within the carriageway drainage system. No additional provision is required for the containment of fuel oil from spills/leaks. Any spillage, no matter how minor, will be reported to the Plant Manager and recorded on the Inspection Checklist in accordance with site inspection, audit and reporting procedures. Relevant authorities (EA/ Health and Safety Executive) will be informed if spillages are over a certain volume threshold, as specified in the procedures. The effectiveness of the Emergency Response Procedures for spillages is subject to Management Review and may be reviewed following any major spillages and revised as appropriate. In the event of a spillage, the following steps are proposed, and these will be developed into specific procedures for the facility: (1) Minor spills: a) Cover the absorbent granules and leave to work for effect as per instructions on the container. (2) Major spills, leakage, or run-off: a) Contained within bunds, oil absorbent granules, sand, or booms to prevent spill reaching drains and watercourses; b) If spillage has the potential to reach drains, drain outlets to be bunged; c) If there is a risk of fire, the Fire Brigade is to be contacted; d) Inform supervisor/area manager, who will notify the Environment Agency; and e) Arrange for a specialist contractor to clear up. In the event of a fire, potentially contaminated water resulting from fire-fighting operations will be contained on site by two means. (1) Any fire water collected within the building will be collected in the internal drainage, which will drain to the waste bunker. The capacity of the waste bunker is 5,500m 3. (2) Fire in external areas will be contained in the external drainage network. This will include an automatic control valve to shut-off the surface water drainage system. This water will be transferred off-site to a suitably licensed facility. All firewater would be sampled and tested prior to discharge/transfer off-site. 25/08/2011 Beddington ERF - Supporting Information Page 25

31 2.3 Monitoring Methods Emissions Monitoring Sampling and analysis of all pollutants including dioxins and furans will be carried out to CEN or equivalent standards (e.g. ISO, national, or international standards). This ensures the provision of data of an equivalent scientific quality. The plant will be equipped with modern monitoring and data logging devices to enable checks to be made of process efficiency. The purpose of monitoring has three main objectives. (1) To provide the information necessary for efficient and safe plant operation; (2) To warn the operator if any emissions deviate from predefined ranges; (3) To provide records of emissions and events for the purposes of demonstrating regulatory compliance Monitoring Emissions to Air The following parameters at the stack will be monitored and recorded continuously using a Continuous Emissions Monitoring System (CEMS): Oxygen; Carbon Monoxide; Hydrogen Chloride; Sulphur dioxide; Nitrogen oxides; Ammonia; VOCs; and Particulates; In addition, the water vapour content, temperature and pressure of the flue gases will be monitored so that the emission concentrations can be reported at the reference conditions required by the Waste Incineration Directive. The continuously monitored emissions concentrations will also be checked by an independent testing company at frequencies agreed with the Environment Agency. The following parameters will also be monitored by means of spot sampling at frequencies agreed with the Environment Agency: Hydrogen Fluoride Heavy Metals; Organic Compounds; Dioxins and furans. The methods and standards used for emissions monitoring will be in compliance with guidance note S5.01 and the Waste Incineration Directive. In particular, the CEMS equipment will be certified to the MCERTS standard and will have certified ranges which are no greater than 1.5 times the relevant daily average emission limit. The CEMS incorporates an approach to limit alarm in order to provide warning of any potential problem. Should the alarm be triggered, the system will inhibit the feeding of waste until the reason for the alarm has been fully investigated and the cause determined and rectified. It is anticipated that: 25/08/2011 Beddington ERF - Supporting Information Page 26

32 HCl, CO, SO 2, NO x (NO+NO 2 )and NH 3 will be measured by an FTIR type multigas analyser; VOC will be measured by a FID type analyser; Particulate matter will be measured by an opacimeter; and O 2 will be monitored by a zirconium probe The frequency of periodic measurements will comply with the Waste Incineration Directive as a minimum. The flue gas sampling techniques and the sampling platform will comply with Environment Agency Technical Guidance Notes M1 and M2. Reliability WID article 11 allows a valid daily average to be obtained only if no more than 5 halfhourly averages during the day are discarded due to malfunction or maintenance of the continuous measurement system. The WID also requires that no more than 10 daily averages are discarded per year. These reliability requirements will be met primarily by selecting MCERTS certified equipment. Calibration will be carried out at regular intervals as recommended by the manufacturer and by the requirements of BS EN Regular servicing and maintenance will be carried out under a service contract with the equipment supplier. The CEMS will be supplied with remote access to allow service engineers to provide remote diagnostics. There will be one duty CEMS per line and a stand-by CEMS. The standby CEMS will be permanently installed and ready to be switched on, if there is a failure of the duty CEMS. This will ensure that there is continuous monitoring data available even if there is a problem with the duty CEMS system. If this is not possible, then the plant must be shut down within 4 hours. Start-up and Shut-down The emission limit values under the Waste Incineration Directive do not apply during start-up and shut-down when the plant is incinerating waste. Therefore, a signal would be sent from the main plant control system to the CEMS package to indicate when the plant is operational and burning waste. The averages would only be calculated when this signal was sent, but raw monitoring data would be retained for inspection. Start-up ends when all the following conditions are met: The feed chute damper is open and the feeder ram, grate, ash extractors and flue gas treatment systems are all running; The temperature within the combustion chamber is greater than 850 o C; Exhaust gas oxygen is less than 15% (wet measurement); and The combustion grate is fully covered with waste. Shutdown begins when all the following conditions are met The feed chute damper is closed; The waste on the grate is burn out; The flue gas treatment systems are running; The shutdown burner is in service; and 25/08/2011 Beddington ERF - Supporting Information Page 27

33 Monitoring Emissions to Land Disposal of residues to land will comply with all relevant legislation. In particular the bottom ash will comply with the WID criterion of Total Organic Carbon less than 3% or Loss on Ignition less than 5%. Compliance with the TOC criterion will be demonstrated during commissioning and checked at periodic intervals agreed with the Environment Agency throughout the life of the plant. Testing for TOC will be conducted by an independent laboratory Monitoring of Process Variables The following process variables have particular potential to influence emissions. Waste throughput will be recorded to enable comparison with the design throughput. As a minimum, daily and annual throughput will be recorded. Combustion temperature will be monitored at a suitable position to demonstrate compliance with the requirement for a residence time of 2 seconds at a temperature of at least 850 C. The oxygen concentration will be measured at the outlet from the boiler. The differential pressure across the bag filters will be measured, in order to optimise the performance of the cleaning system. The concentration of HCl in the flue gases upstream of the flue gas treatment system will be measured in order to optimise the performance of the emissions abatement equipment. Additionally, water use will be monitored and recorded regularly at various points throughout the process to help highlight any abnormal usage. This will be achieved by monitoring the water consumption within the installation. 2.4 Technology Selection Combustion Technology It is proposed that the combustion technology for the plant will be a moving grate furnace. This is the leading technology in the UK and Europe for the combustion of untreated MSW. The moving grate comprises of inclined fixed and moving bars (or rollers) that will move the waste from the feed inlet to the residue discharge. The grate movement turns and mixes the waste along the surface of the grate to ensure that all waste is exposed to the combustion process. The Incinerator Sector Guidance Note discusses a number of alternative technologies for the combustion of waste. (1) Moving Grate Furnaces As stated in the Sector Guidance Note, these are designed to handle large volumes of waste. (2) Fixed Hearth These are not considered suitable for large volumes of waste. They are best suited to low volumes of consistent waste. 25/08/2011 Beddington ERF - Supporting Information Page 28

34 (3) Pulsed Hearth Pulsed hearth technology has been used for municipal waste in the past, as well as other solid wastes. However, there have been difficulties in achieving reliable and effective burnout of waste and it is considered that the burnout criteria required by WID would be difficult to achieve. (4) Rotary Kiln Rotary Kilns have achieved good results with clinical waste, but they have not been used in the UK for municipal waste. The energy conversion efficiency of a rotary kiln is lower than that of a moving grate due to the large areas of refractory lined combustion chamber. An oscillating kiln is used for municipal waste at one site in England and some sites in France. The energy conversion efficiency is lower than that of a moving grate for the same reasons as for a rotary kiln. (5) Pyrolysis/Gasification Various suppliers are developing pyrolysis and gasification systems for the disposal of municipal waste. However, it is not considered that any of these technologies can be considered to be proven. While pyrolysis and gasification systems which generate a syngas can theoretically take advantage of gas engines or gas turbines, which are more efficient that a standard steam turbine cycle, the losses associated with making the syngas and the additional electricity consumption of the site mean that the overall efficiency is no higher than for a combustion plant and is generally lower. This means that a combustion plant will have a more beneficial effect on climate change. These systems are modular and are only available for small-scale facilities. The Beddington ERF plant would need at least three modules in order to achieve the required capacity. This significantly increases the capital cost of the plant, meaning that it is not viable in this configuration. Pyrolysis and gasification are therefore not considered to be suitable technologies for the proposed volume of waste. (6) Fluidised Bed Fluidised beds are designed for the combustion of relatively homogeneous waste. For residual MSW and commercial and industrial (C&I) waste, the waste would need to be pre-treated before feeding to the fluidised bed, which would lead to additional energy consumption and a larger building. The pre-treatment can lead to higher quantities of rejected material. Where MSW is treated at a material recycling facility, the residues from the MRF may already be suitable for feeding to the fluidised bed. This does not apply to residues from kerbside collection schemes, such as that proposed for the Beddington ERF, which would need some pretreatment, including shredding and metals removal as a minimum, before feeding to the fluidised bed. While fluidised bed combustion can lead to slightly lower NOx generation, the injection of ammonia or urea is still required to achieve the emission limits specified in WID. Fixed hearth, pulsed hearth and pyrolysis/gasification are not considered suitable, but moving grate, rotary / oscillating kiln and fluidised bed technologies are considered in more detail in Annex 4 section 4 following the Horizontal Guidance Note EPR-H1. The conclusions are summarised below. 25/08/2011 Beddington ERF - Supporting Information Page 29

35 Table 2.7 Comparison, Combustion Options Grate Fluidised Bed Kiln Reduction in GWP t CO2 p.a. 104,100 94,900 85,000 Urea t/a Residues 78,100 Less bottom ash, more fly ash 78,100 Operating Cost p.a. 2,580,000 7,460,000 4,440,000 Grate vs Fluidised Bed The benefit of reduced urea consumption for a fluidised bed is outweighed by the higher parasitic load and the higher operating costs. In addition the fluidised bed technology processing residual MSW has a record of poor reliability. Experience in the UK of fluidised bed combustion of MSW has been limited. Two plants are operational, but both have had significant operational problems. Viridor do not consider that they can be considered a reliable technology for MSW at this stage. Grate vs Kiln The kiln system has a lower combustion efficiency resulting in a greater fraction of uncombusted material in the ash stream. This has a significant impact on the global warming potential and the operating costs. In addition, the capital cost is likely to be higher for a kiln since more streams are required. Therefore, the moving grate is considered to be BAT for this installation NO x Reduction System Burners used for auxiliary firing will be of low NOx design. NOx levels will primarily be controlled by monitoring the combustion air. Selective noncatalytic NOx reduction (SNCR) methods will also be installed, using urea as the reagent. The use of Selective Catalytic Reduction (SCR) has also been considered. In this technique, the urea is injected into the flue gases immediately upstream of a reactor vessel containing layers of catalyst. The reaction is most efficient in the temperature range 200 to 350 C. The catalyst is expensive and to achieve a reasonable working life, it is necessary to install the SCR downstream of the flue gas treatment plant. This is because the flue gas treatment plant removes dust and SO 3 which would otherwise cause deterioration of the catalyst. Since the other flue gas cleaning reactions take place at an optimum temperature of around 140 C, the flue gases have to be reheated before entering the SCR. This requires some thermal energy which would otherwise be converted to electrical power output, reducing the overall energy recovery efficiency of the facility. The catalytic reactor also creates additional pressure losses to be compensated by a bigger exhaust fan, reducing further the overall energy efficiency Flue Gas Recirculation (FGR) The proposed installation will not employ flue gas recirculation. 25/08/2011 Beddington ERF - Supporting Information Page 30

36 It is important to understand that FGR is not a bolt-on abatement technique. The recirculation of a proportion of the flue gases into the combustion chamber to replace some of the secondary air changes the operation of the plant in various ways, by changing the temperature balance and increasing turbulence. This requires the boiler to be redesigned to ensure that the air distribution remains even. Some suppliers of grates have designed their combustion systems to operate with FGR and these suppliers can gain benefits of reduced NO x generation from the use of FGR. Other suppliers of grates have focussed on reducing NO x generation through the control of primary and secondary air and the grate design, and these suppliers gain little if any benefit from the use of FGR. It is also important to emphasise that, even where FGR does improve the performance of a combustion system, it does not reduce NOx emissions to the levels required by WID and so it would not alleviate the need for further abatement. The proposed technology has been demonstrated on other sites to meet the required emission limits for NO x by using SNCR. A BAT assessment of both SNCR and SCR has been carried out in Annex 6 section 2 with an additional assessment of FGR plus SNCR. The conclusions are summarised below Conclusion Table 2.8 Comparison Table, NOx Abatement Options SNCR SCR FGR+SNCR Capital Cost 740,000 5,910,000 2,120,000 NOx abated t p.a Photochemical Ozone -10,700-4,200-10,700 Creation Potential (POCP) Global Warming Potential t CO2 p.a. 1,400 4,800 1,900 Urea t p.a Annualised Cost 295,000 1,160, ,000 SNCR vs. FGR+SNCR Some suppliers of grates have designed their combustion systems to operate with FGR, and these suppliers can gain benefits of reduced NOx generation from the use of FGR. Other suppliers of grates have focussed on reducing NOx generation through the control of primary and secondary air and the grate design. Both grate designs operate at the same NOx emission level. Therefore, suppliers which have designed their systems to reduce NOx through controlling air supplies gain no benefit from the use of FGR. Introducing FGR increases the annualised costs by 55%, or approximately 167,000, whilst reducing the consumption of urea by 390 tonnes per annum and abating an additional 110 tonnes per annum of NOx. FGR has no effect on the direct environmental impact of the plant, but it increases that impact on climate change by 500 tonnes per annum of CO 2. Therefore the effective cost of FGR is approximately 1,500 per additional tonne of NOx abated. However, this is based on the assumption that FGR reduces the furnace s NOx generation. As discussed in section above, this is not necessarily the case for all furnace manufacturers. Some designs can achieve lower levels of NOx without FGR. 25/08/2011 Beddington ERF - Supporting Information Page 31

37 SNCR vs. SCR Using SCR increases the annualised costs by 865,000 and the global warming potential by 3,400 tonnes of CO 2, while reducing urea consumption by 330 tonnes and abating an additional 100 tonnes of NOx. This gives an effective cost of approximately 5,400 per additional tonne of NOx abated. When taken with the additional contribution to climate change, this is not considered to represent BAT. It is possible to achieve lower levels of NOx than 70 mg/m 3 with SCR, although this increases the urea consumption. However, this would not change the conclusion of this assessment. The cost per tonne of NOx abated would remain high, and the impact on climate change combined with the extra cost is considered to outweigh the reduction in NOx emissions. SNCR is considered to represent BAT for the Beddington ERF. FGR is considered to be BAT if it improves the performance of the furnace, but this will be dependent on the selected furnace manufacturer/supplier, as discussed in section above Acid Gas Abatement System There are currently three technologies widely available for acid gas treatment on municipal waste incineration plants in the UK: (1) Wet scrubbing, involving the mixing of the flue gases with an alkaline solution of sodium hydroxide or hydrated lime. This has a good abatement performance, but it consumes large quantities of water, produces large quantities of liquid effluent which require treatment and has high capital and operating costs. It is mainly used in the UK for hazardous waste incineration plants where high and varying levels of acid gases in the flue gases require the buffering capacity and additional abatement performance of a wet scrubbing system. (2) Semi-dry, involving the injection of lime as a slurry into the flue gases in the form of a spray of fine droplets. The acid gases are absorbed into the aqueous phase on the surface of the droplets and react with the lime. The fine droplets evaporate as the flue gases pass through the system, cooling the gas. This means that less energy can be extracted from the flue gases in the boiler, making the steam cycle less efficient. The lime and reaction products are collected on a bag filter, where further reaction can take place. (3) Dry, involving the injection of solid lime into the flue gases as a powder. The lime is collected on a bag filter to form a cake and most of the reaction between the acid gases and the lime takes place as the flue gases pass through the filter cake. In its basic form, the dry system consumes more lime than the semi-dry system. However, this can be improved by recirculating the flue gas treatment residues, which contain some unreacted lime and reinjecting this into the flue gases. Wet scrubbing is not considered to be suitable, due to the production of a large volume of hazardous liquid effluent and a reduction in the power generating efficiency of the plant. The dry and semi-dry systems can easily achieve the emission limits required by the Waste Incineration Directive and both systems are in operation on plants throughout Europe. Both can be considered to represent BAT by Sector Guidance Note S5.01. The advantages and disadvantages of each technique are varied which makes assessment complex, therefore the assessment methodology described in Horizontal Guidance Note H1 has been used and is detailed in Annex 6 section 1. 25/08/2011 Beddington ERF - Supporting Information Page 32

38 The table below compares the options for acid gas treatment. Table 2.9 Comparison Table, Acid Abatement Options Dry Semi-Dry SO2 abated t p.a POCP tonnes ethylene eq Global Warming Potential t CO2 p.a. 5,000 8,100 Raw Materials More lime, less water Less lime, more water APC Residues t p.a. 9,100 9,100 Waste water No No Annualised Cost p.a. 4,540,000 4,720,000 The performance of the options is very similar. The semi-dry system has a greater global warming potential and greater annualised operating costs that the dry system. The dry system will use less water than the semi-dry system. In addition, reagent consumption can be reduced by recycling within the flue gas treatment plant. The two systems produce the same quantity of residues, however, in a semi-dry system it will not be possible to recycle reagent within the flue gas treatment plant. Due to the lower global warming potential and opportunities for recycling reagent within the flue gas systems, the dry acid gas control system is considered to represent BAT for the Beddington ERF. The dry system will include recirculation of APCr residues back into the flue gas treatment plant Particulate Matter The proposed plant will use a multi-compartment fabric filter for the control of particulates. There are a number of alternative technologies available, but none offer the performance of the fabric filter. Fabric filters represent BAT for this type of MSW combusting installation for the following reasons: (1) Fabric filters are a proven technology and used in a wide range of applications. The use of fabric filters with multiple compartments, allows individual bag filters to be isolated in case of individual bag filter failure. (2) Wet scrubbers are not capable of meeting the same emission limits as fabric filters. (3) Electrostatic precipitators are also not capable of abating particulates to the same level as fabric filters. They could be used to reduce the particulate loading on the fabric filters and so increase the acid gas reaction efficiency and reduce lime residue production, but the benefit is marginal and would not justify the additional expenditure, the consequent increase in power consumption and significant increase in the foot-print of the facility. (4) Ceramic Filters have not been proven for this type of MSW combustion plant, and are regarded as being more suited to high temperature filtration. Fabric filters are considered to represent BAT for the removal of particulates for this installation. 25/08/2011 Beddington ERF - Supporting Information Page 33

39 2.5 Cooling System Selection There are three potential BAT solutions considered in Sector Guidance Note EPR 5.01 as representing indicative BAT for the installation, which are: Air Cooled Condenser (ACC); Once though Cooling; and, Evaporative Condenser. The plant will operate an ACC to condense the steam output from the turbine to allow return of the condensate to the boiler. The advantages of using ACC are that it does not require large volumes of water and does not generate a discharge. There is no visual impact of the ACC, as required for evaporative cooling. The ACC will be designed and guaranteed by the technology supplier with enough additional capacity to maintain turbine efficiency during the summer. Once through cooling systems require significant quantities of water. As there is no readily available supply of water once through cooling systems are not regarded as appropriate for this installation. Evaporative condenser systems also require large volumes of water. There is no local abstraction point so this would lead to significant potable water use. Chemical additives are also needed which means there would be a significant effluent flow to water or sewer. Additionally, evaporative condensers have a significant potential for release of water vapour plumes. Air cooled condensing is considered to represent BAT for this installation. 2.6 Specific Information required by the Waste Incineration Directive This section contains information on how the plant will be designed, equipped and run to make sure it meets the requirements of Council Directive 2000/76/EC Furnace Requirements Legislative Obligations Waste Incineration Directive (2000/76/EC) (1) The design of the combustors will ensure that all gases resulting from the combustion of waste are maintained at or above 850ºC for at least 2 seconds; (2) Sufficient oxygen levels will be maintained to ensure good combustion. (3) Auxiliary burners, fired with gas oil are used to automatically maintain furnace conditions, again controlled by the combustion control system; (4) Measures will be included to minimise the amount and harmfulness of residues formed from the combustion process. The bottom ash from the combustion process will not exceed Total Organic Carbon 3% or Loss on Ignition 5%. (5) Urea powder will be injected into the combustion chamber to reduce NO x emissions. Moving Grate Operation and Combustion Air The waste will be transferred onto the moving grate from the feeding chutes by hydraulic power feeding units. Waste charging requirements are detailed in section Fixed and moving sections on the inclined grate will move the waste from the feed inlet to the residue discharge. The grate movements mix the waste along the surface of the grate to ensure that all waste is exposed to the combustion process. 25/08/2011 Beddington ERF - Supporting Information Page 34

40 Primary air for combustion will be fed to the underside of the grates by fans. Secondary air will also be admitted above the grates to create turbulence and ensure complete combustion with minimum levels of oxides of nitrogen (NOx). Multiple air injection points will be provided in groups in both primary and secondary air systems and the proportion of combustion air sent to each group will be adjustable by the operator. The volume of both primary and secondary air will be regulated by a combustion control system. The combustion chamber and associated outlet gas ducts will be designed to be as airtight as possible and will be maintained under a slight negative pressure to prevent releases into the atmosphere. During operation the temperature in the combustion chamber will be continuously monitored and recorded to demonstrate the compliance with the Waste Incineration Directive. Temperature sensors installed within the boiler will identify if the temperature within the first pass falls below 860 C. The combustion control system will automatically start the auxiliary burners when the temperature drops to this level. The combustion control system will be an automated fully adjustable system, including the monitoring of combustion and temperature conditions of the grate, modification of the waste feed rate and the control of primary and secondary air. The control system will automatically control combustion to avoid excessive temperatures or uneven temperature profiles that would lead to increased NOx formation. Boiler Design The boiler will include the following design features to minimise the potential for reformation of dioxins within the de-novo synthesis range: The steam/metal heat transfer surface temperature will be a minimum where the flue gas in the de novo synthesis temperature range. CFD will be used to confirm that there are no pockets of stagnant or low velocity gas. Boiler passes will be progressively decreased in volume so that the gas velocity increases through the boiler, and Boiler surfaces have been designed to minimise boundary layers of slow moving gas. In addition, the boiler will include control for preventing the build up of deposits in the boiler. Supplementary Burners and Fuels Supplementary burners will be provided for start-up and shut-down and to maintain the combustion chamber temperatures above the legislative requirements of 850ºC during operation. They will be automatically initiated by the combustion control systems Validation of Combustion Conditions The plant will be designed to provide a residence time, after the last injection of combustion air, of more than two seconds at a temperature of at least 850 C. This criterion will be demonstrated using Computational Fluid Dynamic (CFD) modelling during the design stage and will be approved by the EA by way of a Pre-operational Condition. It will also be demonstrated during commissioning that the Plant can achieve complete combustion by measuring concentrations of carbon monoxide, volatile organic compounds and dioxins in the flue gases and TOC of the bottom ash. 25/08/2011 Beddington ERF - Supporting Information Page 35

41 During the operational phase, the temperature at the 2 seconds residence time point will be monitored to ensure that it remains above 850 o C. The location of the temperature probes will be selected using the results of the CFD model. If it is not possible to locate the temperature probes at precisely the 2 seconds residence time point then a correction factor will be applied to the measured temperature. Urea will be injected into the combustion gases at a temperature of between 850 and 1000 C. This narrow temperature range is needed to reduce NOx successfully and avoid unwanted secondary reactions, meaning that at least two levels of injection points are needed in the radiation zone of the furnace. Sufficient nozzles will be provided at each level to distribute the urea correctly across the entire cross section of the radiation zone. Advanced CFD modelling will be used to define the appropriate location and number of injection levels as well as number of nozzles to make sure the SNCR system achieves the required reduction efficiency for the whole range of operating conditions while maintaining the ammonia (NH 3 ) slip below the required emission level. The CFD modelling will also be used to optimise the location of the secondary air inputs to the combustion chamber Measuring Oxygen Levels The oxygen concentration at the boiler exit will be monitored and controlled to ensure that there will always be adequate oxygen for complete combustion of combustible gases. Oxygen concentration will be controlled by regulating combustion airflows and waste feed rate Combustion System The ERF will be controlled from the Central Control Room. A modern control system, incorporating the latest advances in control and instrumentation technology, will be used to control operations, optimising the process relative to efficient heat release, good burn-out and minimum particle carry-over. The combustion control system will include an infra-red camera to identify cold spots on the grate, and redistribute waste accordingly to maximise energy release. The system will control and/or monitor the main features of the plant operation including, but not limited to the following: primary air; secondary air; waste feed rate; SNCR system; flue gas oxygen concentration at the boiler exit; flue gas composition at the stack; combustion process; boiler feed pumps and feedwater control; steam flow at the boiler outlet; steam outlet temperature; boiler drum level control; flue gas control; power generation; 25/08/2011 Beddington ERF - Supporting Information Page 36

42 steam turbine exhaust pressure. The response times for instrumentation and control devices will be designed to be fast enough to ensure efficient control Waste Charging The ERF will meet the indicative BAT requirements outlined in the Incinerator Sector Guidance Note for waste charging and the specific requirements of WID: The combustion control and feeding system will be fully in line with the requirements of WID. The conditions within the furnace will be continually monitored to ensure that optimal conditions are maintained and that the mandatory WID emission limits are not exceeded. Temperature sensors installed within the boiler will identify if the temperature falls below 860 C. The combustion control system will automatically start the auxiliary burners when the temperature drops to this level. The waste charging and feeding systems will be interlocked to prevent waste charging when the furnace temperature is below 850ºC, both during start-up and if the temperature falls below 850 C during operation; The waste charging and feeding systems will also be interlocked to prevent waste charging if the emissions to atmosphere are in excess of an emission limit value; Following loading into the feeding chutes by the grab, the waste will be transferred onto the grates by hydraulic powered feeding units; The backward flow of combustion gases and the premature ignition of wastes will be prevented by keeping the chute full of waste and by keeping the furnace under negative pressure; A level detector will monitor the amount of waste in the feed chute and an alarm will be sounded if the waste falls below the safe minimum level. Secondary air will be injected from nozzles in the wall of the furnace to control flame height and the direction of air and flame flow. The feed rate to the furnace will be controlled by the combustion control system Bag Filter Operation The bag filter will not require a flue gas bypass station Unavoidable Stoppages The table below lists unavoidable stoppages, disturbances and failures of the abatement plant or continuous emission monitoring system during which plant operation will continue. The table also shows the maximum anticipated frequency of these events. It is highly unlikely that all of these events would occur at their maximum anticipated frequencies. Table 2.10 Unavoidable Stoppages Event Mitigation Action Required Incident Duration Anticipated Maximum Frequency 25/08/2011 Beddington ERF - Supporting Information Page 37

43 Table 2.10 Unavoidable Stoppages Event Mitigation Action Required Incident Duration Anticipated Maximum Frequency Combustion air fan(s) failure Filter bag leak (not exceeding particulate ELV s) Failure of lime hydrate dosing system Failure of SNCR reagent dosing system Failure of activated carbon dosing system Loss of electricity generation Failure of emission monitoring equipment Burner not starting as needed when 2 second temperature drops below 850C Maintenance Maintenance Stand-by reagent blower; filter cake on bag filter acting as buffer Stand-by dosing pump Stand-by reagent blower / detection by flow indicator Emergency supply from back-up diesel generators Redundant equipment is installed; maintenance Maintenance of burner Weekly test of burner Failure of ID Fan Maintenance ; bearings vibration monitoring Emergency shutdown initiated Isolation of filter compartment Bag replacement Start stand by blower Start stand by pump Start stand by blower If emergency supply fails, emergency shutdown initiated Start stand by CEMS Emergency shutdown initiated Emergency shutdown initiated 10 min until combustion stopped 30 min until filter compartment isolated Once every 3 years Once a year - Twice a year - Twice a year - Twice a year 10 min until combustion stopped Once every 10 years - Twice a year 10 min until combustion stopped 10 min until combustion stopped Once every 10 years once every 5 years Should the grid connection fail, the turbine generator will switch automatically to island mode to allow for continued operation, although without electrical export to the grid. Should the grid connection fail while the plant is running in import mode, then a standby diesel generator will start automatically to restore power to those high-priority circuits required to permit safe plant shut-down. The standby generator will not be used as a source of power for normal operations. In addition, an uninterruptible power supply (UPS) will be installed to provide power to sensitive items of electrical equipment that could be damaged by the loss of power, or cause operational difficulties due to the loss or corruption of data. The UPS will be capable of at least 30 minutes of continuous operation to provide time for the standby diesel generator to run and synchronise so as to re-supply the equipment. 25/08/2011 Beddington ERF - Supporting Information Page 38

44 2.7 Energy Efficiency General The ERF will utilise a waste fired steam boiler. The generated steam will supply a steam turbine generator to generate electricity. The facility will supply electricity to the local electricity grid via a power transformer which increases the voltage to the appropriate level. The plant will be configured as a Combined Heat and Power (CHP) Plant and will have capacity to export heat to local users In case of failure of the electricity supply, an emergency supply from diesel back-up generators will be provided to safely shut down the plant. In considering the energy efficiency of the facility, due account has been taken of the requirements of the Environment Agency s Horizontal Guidance Note H2 on Energy Efficiency Basic Energy Requirements The ERF will be capable of generating 26.1 MWe with no steam export. About 3.9 MWe of this electricity will be used within the facility as a parasitic load with the remaining 22.2 MWe available for export to the National Grid. An indicative Sankey Diagram for the proposed design, assuming no heat export, is presented below: 25/08/2011 Beddington ERF - Supporting Information Page 39

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