Process flow diagram Keppel Seghers

Keppel Seghers is a leading provider of

comprehensive environmental solutions,
and provides consultancy, design and
Stack engineering, technology development,
construction, operation and maintenance
Greater
Manchester
Cooling towers Turbine building
of plants and facilities, as well as investments
Steam export in large-scale environmental projects.
To INEOS Chlor

Keppel Seghers’ advanced technology solutions

Energy-from-
Selective
Power
supply
Activated
Carbon Lime
address a wide spectrum of environmental
issues for both solid waste and water.
Waste Plant
Non-Catalytic Superheated Steam
Reduction
Providing a Waste Management
To date, Keppel Seghers has executed more Solution for Greater Manchester
Secondary air Boiler than 100 waste-to-energy projects and more
Residue Continuous
Digestate Bunker storage Emission than 350 water and wastewater projects in
Monitoring more than 25 countries worldwide.
System

Keppel Seghers is a wholly-owned subsidiary

of the Keppel Infrastructure group, which is
a division of Keppel Corporation Limited, a
leading company listed on the Singapore Exchange.
Residue Dry Flue Gas Dry Flue ID-Fan
discharge Treatment Gas
RDF Bunker Combustion Primary Ash Stage 1 Treatment
grate air bunker Stage 2

General information
Client Phase I: Ineos Runcorn TPS

Phase II: Viridor Waste Management - Ineos Chlor

Scope Design & Build; EPC-turnkey

Process Combined Heat & Power

Project specific info Phase I is part of the GMWDA PFI Scheme

Waste delivered by road and rail

TECHNICAL DATA PHASE I (LINES 1 AND 2) PHASE II (LINES 3 AND 4)

Capacity 375 ktpa (mechanically designed 375 ktpa (mechanically designed

for 425 ktpa) for 425 ktpa)

Calorific value 11.5 MJ/kg design & 13 MJ/kg @ 11.5 MJ/kg design & 13 MJ/kg @
nominal operation point nominal operation point

Combustion grates Water-cooled (2 X 9.9 m width) Water-cooled (2 X 9.9 m width)

Keppel Seghers Pte Ltd Keppel Seghers Belgium NV
Boiler 2 X 100 Tph 52 barg, 2 X 100 Tph 52 barg,
400°C superheated steam 400°C superheated steam 1 HarbourFront Avenue Hoofd 1
Flue gas treatment capacity 2 X 170,000 Nm3/h 2 X 170,000 Nm3/h
#05-05 Keppel Bay Tower 2830 Willebroek - Belgium
Singapore 098632 Tel: +32(0) 3880 7700
Thermal power 2 X 87 MWth 2 X 87 MWth
Tel: +65 6278 1800 Fax: +32(0) 3880 7749
Steam export 51.2 MWth (70t/h @ 16 barg) NA Fax: +65 6278 07771 Email: info_belgium@keppelseghers.com
Electrical power 34.7 MWel 47.5 MWel Email: info_singapore@keppelseghers.com
Website: www.keppelseghers.com

GCC06.2015
Waste management
solution for the future
Across the globe, growing volumes of waste,
shortfalls of landfill areas and soaring energy
prices are making Energy-from-Waste (EfW)
a leading solution for a cleaner future.
EfW plants not only help in landfill diversion
through as much as 90% reduction in the volume
of waste disposed; using proven technology, the
plant releases the energy embedded in materials
such as plastics, paper, wood scraps and food
scraps, and uses that energy to generate
electricity and steam, thereby replacing
substantial amounts of fossil fuel.
Compared to landfills, EfW plants are also a
“greener” way of waste disposal, as they reduce
the production and emission of the greenhouse
gas, methane, produced during waste
Waste is delivered by rail to the Greater Manchester EfW plant and transferred to trucks for tipping
EfW plants help
battle climate
change by reducing
greenhouse gas
emissions by landfills
decomposition from organic matter in landfills.
With a well-regulated flue gas treatment system,
emissions from EfW plants do not pose a threat
to public health and the environment.
The plant can divert more than 75% of Greater Manchester’s waste from landfill
Preferred EPC partner
Keppel Seghers, the environmental engineering
arm of Keppel Infrastructure, is the preferred
partner for the Engineering, Procurement and
Construction (EPC) of the Greater Manchester
EfW Combined Heat and Power (CHP) Plant.
Keppel Seghers secured the contracts for
Phase I and Phase II of the integrated EfW
project, worth about GBP 390 million in total,
in 2009 and 2010 respectively.
Phase I is built primarily as part of the Greater
Manchester Waste Private Finance Initiative (PFI)
project to manage 1.3 million tonnes of municipal
waste handled by the Greater Manchester Waste
Disposal Authority (GMWDA) each year. The plant
can divert more than 75% of Greater
Manchester’s waste from landfill.
The plant will be built for Ineos Runcorn TPS,
a special purpose vehicle set up by Viridor Waste
Management (Viridor), John Laing and Ineos Chlor
for the procurement, operation and maintenance
of the plant. The plant will produce around 20%
of the total energy needs of Ineos Chlor’s
Runcorn manufacturing site.
Phase II is built for Viridor EFW (Runcorn) Ltd.
and will be available for the market generally,
as steeply rising landfill tax drives residual waste
disposal away from landfill towards EfW.
The first-of-its-kind combined plant will be one
of the largest and most efficient in Europe when
completed, with a total capacity to treat 750 ktpa
of solid recovered fuel (SRF) and to produce
83 MW of electricity and 51.2 MW of heat by
steam export per year. The entire project is
expected to be completed by 2014/15.
Built to Keppel Seghers’ proprietary EfW
technology, the plant will use Keppel Seghers’
Water-Cooled Grates, its horizontal boiler
design integrated with its Prism technology
for enhanced heat recovery and its double
dry flue gas cleaning system.
Proven technologies for
sustainable solutions
Keppel Seghers’ EfW installations and
technologies effectively convert waste into
valuable energy and remove pollutants from
emissions. In-house technologies by Keppel
Seghers that can be found in the Greater
Manchester EfW plant include the:
• Keppel Seghers Water-cooled Multi-Stage
Grate which can withstand high temperature
abrasion, as well as ensure thorough mixing
and even burning of the waste Keppel Seghers’ proprietary EfW technologies integrated
into the plant
• Boiler with Keppel Seghers Prism Technology
which provides an optimal secondary air
injection, thereby increasing plant availability
and prolonging operation times between
planned maintenance
• Double Dry Flue Gas Treatment System which
effectively removes harmful and acidic gases,
dust and particulates so that only clean air,
compliant with the EU standards, is emitted
Keppel Seghers Water-cooled Multi-Stage Grate with
Keppel Seghers Prism technology
Stringent air pollution controls
Modern EfW plants that are well managed and - A scrubber sprays a mixture of dry hydrated
regulated do not pose any threat to public health. lime and active carbon into the hot exhaust
At the Greater Manchester EfW Plant, special gases to neutralise acidic gases
attention is given to flue gas cleaning through the
application of a dual ‘all dry’ scrubbing system. - A carbon injection system blows powdered
carbon into the exhaust gas to absorb mercury.
Typically, an EfW plant uses the following Carbon injection also reduces emissions of
methods to remove pollutants from its emissions: trace organics such as dioxins
- A selective non-catalytic reduction process - A baghouse works like a giant vacuum cleaner
converts nitrogen oxides and water to harmless with hundreds of fabric filter bags that clean
nitrogen by spraying ammonia or urea into the the air of soot, smoke and metal
hot furnace