Philippines: Proposed Loan for Energy Efficiency Project

Transcription

1 Philippines: Proposed Loan for Energy Efficiency Project Program Design Document Program A.4: Lamp Waste Management I. Background Rationale Safe disposal of spent fluorescent lighting is a critical issue from a public health perspective and the current policies and practices of Lamp Waste Management (LWM) in the Philippines do not adequately address this issue. With the promotion of Energy Efficient Lighting Systems (EELs) the use of fluorescent lighting is expected to increase significantly. Mercury is known for its high toxicity and its significant adverse impacts on human health throughout the world are well documented. Exposure to high levels of mercury can cause permanent brain damage, central nervous system disorders, memory loss, heart disease, liver damage, loss of vision, loss of sensation and tremors. In view of the enormous impact of mercury containing wastes on public health there is a need to strengthen current strategies and policies on LWM. The current facilities that recover, treat and dispose lamp wastes need to be upgraded to ensure minimum environmental impacts. The policy study on LWM conducted under PELMATP considered various options for market based models for disposal and recycling. A more detailed techno-economic study was recommended for LWM including the option of a Recycling Facility which would have the least environmental impact compared to treatment/disposal options. Objectives Conduct a detailed techno-economic assessment on the feasibility of establishing a Lamp Waste Recycling Facility and the establishment of a pilot facility on a business model to attract a private operator. Program Description Safe disposal of spent fluorescent lighting is a critical issue from a public health perspective. A T12 lamp contains between 7 to 40 mg of mercury and a spent lamp contains around 1 mg of Hg vapor which is emitted upon lamp breakage. The Policy study on LWM conducted under PELMATP estimates the current annual spent FTLs in the Philippines to be 24.8 Million (equivalent to 499 kg of Mercury per year). With the promotion of Energy Efficient Lighting Systems (EELs) the use of fluorescent lighting (FTLs and CFLs) is expected to increase significantly. The Philippines has two major policies addressing mercury containing lamp wastes Chemicals and Hazardous Waste Management under RA 6969 and Solid Waste Management through RA Currently, there are 95 Hazardous Waste Management Operators in the Philippines (77 in Luzon, 13 in Visayas and 5 in Mindanao). The recycling of spent FTLs offers a total solution compared to the current practice of storage, treatment and disposal, with a residual limit of 0.2 ppm of mercury. There are no FTL recycling facilities currently in the Philippines primarily due to limited volumes of spent FTLs due to inadequate collection. Nearly, 88% of the residential FTLs are A.4: Lamp Waste Management Program 1

2 disposed with ordinary household wastes. A survey conducted in Business establishments revealed 77% of the respondents disposed the FTLs with garbage and only 3% sent the spent lamps to a waste-treater. This program aims to establish a pilot recycling facility and a procedure for efficient collection of spent FTLs and operate the facility on a business model to facilitate the transfer of the facility to a private operator after a specified period. The project will be based on the Policy study on Lamp Waste Management conducted for DOE (PELMATP) by Innogy Solutions Inc., in August II. Impacts and Outcome Impacts Human exposure to mercury is through inhalation, absorption, ingestion and skin/eye contact. The Permissible limit set by the Occupational Safety and Health Administration is 0.1 mg/m 3. This program will address the health issues through proper awareness, collection and recycling of spent FTLs. The recycling of spent FTLs will offer a total solution for recovery of residual mercury. Outcome The techno-economic assessment will determine the feasibility of establishing a LW Recycling Facility, followed by a Memorandum of Agreement (MOA) with a private WM Operator for locating and operation of the facility. The assessment will provide the overall specifications for a pilot recycling facility including the appropriate feedstock (FTLs, CFLs, clinical thermometers etc), method of collection, facility location, appropriate markets and business model for operation. The procurement of the facility will be based on a similar facility operating in Thailand. Following initial evaluation of the performance of the facility the operation will be transferred to the WM operator. Outputs The program aims to procure a spent FTL (and CFLs) recycling facility that would offer a total solution for the recovery of mercury. The capacity of the pilot recycling facility will be based on a techno-economic assessment, which will consider other mercury containing wastes (batteries and clinical thermometers, etc.), in addition to spent fluorescent lamps. The economic assessment will consider the market for the products it is estimated that for every 1 million lamps, it is possible to recover 900,000 intact glass tubes, 2.2 tons of aluminum, 120 kg of tin, 944 kg of copper and 360 kg of chloride salts, in addition to 10 kg of mercury. The aim is to test a profitable business model that will facilitate the transfer of the facility to a private operator. III. Program Design Target Market Segments The segments targeted for collection of spent fluorescents lamps include Households, Institutions and Business Establishments. The health sector will be included if medical wastes are also considered. A.4: Lamp Waste Management Program 2

3 Program Tasks The program includes the following key tasks: 1. Project Preparation 2. Detailed Techno-Economic Assessment 3. Establishment of Pilot Recycling Facility 4. Evaluation Program Activities Task 1: Project Preparation Review of PELMATP LWM study this study will be the basis for the program and will consider the recommendations made for the program options including interventions to address policy, legal and regulatory gaps. Consultation with stakeholders this would include consultations with organizations that could coordinate waste lamp collection and WM operators to determine a host for the pilot facility. Task 2: Techno-Economic Assessment Prepare TOR for study the scope of the study will include a detailed review of existing facilities in Asia (especially Thailand), assessment of lamp collection options, review of market for products, assessment of the economic viability of the operation and the determination of a sustainable business model. Conduct and Review of Study Results based on the study results this activity will include the preparation of an implementation plan for the procurement and operation of a recycling facility. Task 3: Establishment of Pilot facility Finalize Site for facility this activity will include consultations with WM operators to finalize a suitable site for the facility. A contract between DOE and the host site will be executed prior to procurement. Prepare tender documentation for Pilot facility the scope would be for a turnkey facility including supply, shipping, installation, commissioning, operator training and regular maintenance. Establishment and Operation of facility following installation the responsibility for the operation will be with the host site. The project will provide assistance in the initial operation cost which would include lamp collection. The collection procedures will be established based on the recommendations of the technoeconomic assessment. Task 4: Evaluation Evaluate performance and viability of Facility the evaluation will focus on the commercial viability of the facility based on the throughputs and market for the end-products. The initial evaluation will consider options for increasing the viability of the facility by processing other products (e.g. batteries, clinical thermometers etc). Facilitate transfer of facility to private operator this would include the formal transfer of the facility to the WM operator after a specified period based on the contract between DOE and the operator. A.4: Lamp Waste Management Program 3

4 Program Management The overall program management should be with DOE and hence, it is recommended that a Working Group is established comprising of DOE (Chair) and a representative from key stakeholders (DNER, LGUs, NGOs, private sector WM operators). The functions of the Working Group include: Overall Program Administration Preparation of tender documentation and contracting for Recycling Facility Coordination of implementation Coordination of Monitoring & Verification Progress reporting to DOE management. Procurement The procurement of professional services for techno-economic assessment and design and construction of the Recycling Facility will conform to the procurement procedures of the project Implementing Agency (DOE). The procurement of the recycling facility will be undertaken by the Working Group. IV. Program Costs The cost of the pilot recycling facility is based on a similar plant currently in operation in Thailand. The turnkey plant with an average throughput of 6 million FTLs cost around 1.35 Million US$. The estimated recycling cost is 1.34PHP per lamp. Note that the facility will generate revenues from the sale of the recycled products. It is expected that this would at least cover the operating costs. A budget quotation was obtained from MRT Systems (Sweden) who supplied the Thailand facility. Details of the quotation and plant specification are given in the Appendix. A summary of the estimated program costs are: Item Description Cost ($) Equipment Turnkey Procurement of facility 1,350,000 Program Costs Administration 100,000 Techno-Economic Assessment 50,000 Operating cost (2 years) 350,000 Other 50,000 Contingency 100,000 Total 2,000,000 Please note that the facility will generate revenues from the sale of the recycled products. It is expected that this would at least cover the operating costs. A.4: Lamp Waste Management Program 4

5 V. Environmental Impacts The recycling of spent FTLs will offer a total solution for recovery of residual mercury. VI. Relevant International Experience There are several lamp recycling commercial operations in the United States, Canada and Europe. In Asia, there are operations in Japan, Korea and Taiwan. Thailand has initiated a Fluorescent Lamp Partnership Program with the objective of enhancing recycling and proper waste management of t lighting products. The program is in cooperation with the Government of Japan through its Green Partnership Program. Under the program a recycling facility was established in Thailand and hosted in the site of one major lighting supplier. The next stage of the program is for a large-scale recycling program by establishing a partnership with related agencies, local administrators, recyclers and waste processors. A.4: Lamp Waste Management Program 5

6 Appendices Details of Proposed Lamp Waste Recycling Facility Item Description Cost (Euro) 1 Compact Crush and Separation Plant with CFL pretreatment (CCS/CS) 420,000 2 Superior Distiller (HGV5) 250,000 3 Set of ware parts / spare parts for each machine 4,883 4 Shipping to the Philippines 5,000 5 Installation, Commissioning and Training 20,000 Total 699,663 6 After sales service Annual maintenance under service contract 20,000 Plant specifications are given in the following pages. A.4: Lamp Waste Management Program 6

7 COMPACT CRUSH AND SEPARATION PLANT (CCS) built into a 20ft container The CCS is designed for processing fluorescent tubes of various length and shapes. The machine crushes separates the material into a glass fraction, a metal end (end cap) fraction and a fluorescent powder fraction. The manual feeding for tubes is located at the long side of the container adjacent to the electrical control panel. The glass discharge is likewise placed at the front long side while end-cap fractions are collected in barrels, easy to reach inside the container. The fluorescent powder is collected in barrels beneath the cyclones and the filter system. A level sensor for the cyclone indicates to the operator when the barrels need to be replaced. Capacity: Max 300 kg of tube material per hour, equal to approx tubes per hour (1200 mm long, diameter 25.5 mm). The material to be processed should be dry, without dirt, and of such kind and condition as is intended and expected for the application of the equipment. Media: Electrical connection: 400V, 50 Hz Electrical consumption: Max. 25 kw Compressed air: Maximum 500l/min. Supply pressure: 6 bar dry oil free (dew point 3 C.) Connection pipe 0.5 inch, thread. Operational temp range: +10 C - +35ºC Measurements: Length: 6800 mm Height: 2600 mm Width: 2450 mm A.4: Lamp Waste Management Program 7

8 Hg emission in the atmosphere: Inside the room: max mg/m 3. The room has to be ventilated by fresh air at least 3 exchanges/h. The Hg concentration is mainly depending on how waste is handled in the room and how maintenance work on the equipment is executed. The CCS itself generates only negligible amounts of mercury concentration in the room during operation. Exhaust: Exhaust max 0.025mg/m 3 Exhaust flow max 1500m 3 /h. Exhaust duct: Ø 200mm The process air is discharged through two series connected carbon filters. Hg exhaust to be confirmed by using Jerome 431-X instrument in stationary air. Residual values: Glass fraction: Hg: max 0.1mg/l (leachate) Hg content values have to be confirmed by using Leachate procedure in accordance with DIN The conditions for that the above presented Hg values are kept within the guaranteed max values, are that the fluorescent tubes are dry and have been stored indoors prior to the process and that the MRT instructions for the operation of the plant always are followed. The purchase will include the following components: 1 pc conveyor belt 1 pc hammer mill, first stage crushing 3 pc material air transporting device 1 pc vibration sieve 1 pc conveyor for glass and metals 1 pc magnetic separator 1 pc secondary stage crusher for metals 1 pc secondary stage crusher for glass 1 pc glass conveyor 1 pc rotary drum feeder for glass 1 pc discharge conveyor for glass 1 pc metal separator 1 pc soft ware and control panel 1 pc complete ventilation system consisting of: 1 pc cyclone 2 pc dust filter 8 pc carbon filters 1 pc fan A.4: Lamp Waste Management Program 8

9 CCS with CFL PRE TREATMENT The CFL Pre treatment is a small crush and sieve unit which remove the e-base/socket from CFL -and energy saving lamps before further treatment in the CCS unit. The CFL pre treatment will be attached to the CCS as a separate feeding point. CFLs will be fed with a manually bin turning device. The equipment can also handle pre crushed material. Capacity: Max 300kg/hour The material to be processed should be dry, without dirt, and of such kind and condition as is intended and expected for the application of the equipment. Media: Electrical connection: Electrical consumption: Compressed air: Supply pressure: 50Hz 400V Max. 15 kw Maximum 500l/min. 6 bar dry oil free (dew point 3 C.) Connection pipe 0.5 inch, thread. Operational temp range: +10 C - +35ºC Measurements: Length: 6644 mm Height: 2600 mm Width: 1338 mm Hg emission in the atmosphere: Inside the room: max mg/m 3. A.4: Lamp Waste Management Program 9

10 The room has to be ventilated by fresh air at least 3 exchanges/h. The Hg concentration is mainly depending on how waste is handled in the room and how maintenance work on the equipment is executed. The CCS itself generates only negligible amounts of mercury concentration in the room during operation. Residual values: Glass fraction: Hg: max 0.1mg/l (leachate) Hg content values have to be confirmed by using Leachate procedure in accordance with DIN Exhaust: Via CCS The purchase will include the following components: 1 pc crusher screw 1 pc hopper 1 pc drum sieve 1 pc vibration feeder 1 pc diverter 1 pc manual bin turning device. EEC Conformity - the equipment is made in accordance with; EN ISO Safety of machinery basic concept for design. Part: 1 Basic terminology, methodology. EN ISO Safety of machinery. Part: 2 Technical principles. EN 294 Safety of machinery- safety distances to prevent danger zones. EN 418 Safety of machinery - Emergency stops equipment, functional aspects - Principles for design. EN 1070 Safety of machinery - Terminology. In particular with the EEC normative EEC Directive on machinery (89/392/EEC) and subsequent (91/368/EEC). A.4: Lamp Waste Management Program 10

11 BATCH DISTILLER For recovery of mercury from fluorescent powder, tube ends from fluorescent tubes, arc tubes from high pressure mercury vapour lamps, mercury button cell batteries, thermometers, electrical switches and rectifiers, dental amalgam, etc. Capacity: 4x25l/batch, equivalent to approx. 140l fluorescent powder or 400kg button cell batteries Process time: 120 l/batch of crushed lamps and tube ends. Process time: approx. 10 hours. 100 l/batch of fluorescent powder Process time: approx hours. 100 l/batch of arc tubes from high pressure mercury vapour lamps. Process time: approx. 12 hours. 100 l/batch of button cell batteries. Process time: approx hours. Process time varies depending on material composition and dampness. Media: Electrical connection: 400V, 50Hz Electrical consumption: Max. 35 kw A.4: Lamp Waste Management Program 11

12 Compressed air: Supply pressure: Maximum 300 m 3 per batch. 6 bar dry (dew point +3 C) oil free Maximum flow 500l/minute Connection pipe 0.5 inch hose nipple or ¼ inch thread. Oxygen: Supply pressure: 10-15m 3 per batch 5 bar ± 5 % dry. Maximum flow 2000 Nl/h Connection pipe 6mm hose nipple or ¼ inch thread. Nitrogen: Supply pressure: 7-10m 3 per batch 5 bar ± 5 %. Dry. Maximum flow 4000 Nl/h Connection pipe Outer diameter 10 mm. Measurements: Length: 2990 mm Height: 3800 mm Width: 1580 mm Operational temp range: +10 C - +35ºC Hg emission in the atmosphere: Inside the room max mg/m 3 The room has to be ventilated by fresh air at least 3 exchanges/h. The Hg concentration is mainly depending on how waste is handled in the room and how maintenance work on the equipment is executed. The distiller itself generates only negligible amounts of mercury concentration in the room during operation. Exhaust: Exhaust: Max mg/m 3 Exhaust flow max.500 m 3 /h Exhaust duct: 125 mm The process air is discharged through two series connected carbon filters. Hg exhaust to be confirmed by using Jerome 431-X instrument in stationary air. Nl = normal litre at atmosphere pressure A.4: Lamp Waste Management Program 12

13 Hg content after distillation Hg concentration: max. 0,1mg/l Hg content values have to be confirmed by using Leachate procedure in accordance with DIN The purchase will include the following components: 1pc dome 1pc post combustion chamber 1pc condenser 1 pc vacuum system 1 pc fan 2 pc carbon filters 1 pc electrical cabinet 1 pc PLC 1 pc crane pillar and telpher. 1 pc cooling unit 8 pc distiller barrels (30 l). EEC Conformity - the equipment is made in accordance with; EN ISO Safety of machinery basic concept for design. Part: 1 Basic terminology, methodology. EN ISO Safety of machinery. Part: 2 Technical principles. EN 294 Safety of machinery- safety distances to prevent danger zones. EN 418 Safety of machinery - Emergency stops equipment, functional aspects - Principles for design. EN 1070 Safety of machinery - Terminology. In particular with the EEC normative EEC Directive on machinery (89/392/EEC) and subsequent (91/368/EEC). A.4: Lamp Waste Management Program 13