CHAPTER 5 Project Description

CHAPTER 5

Project Description

ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPOSED NEW INSTALLATION OF THERMAL TREATMENT FACILITY FOR CENTRE OF HEALTHCARE WASTE TREATMENT PLANT FOR MEDIVEST SDN BHD AT LOT 6939, 6940, 6947 & 6948, MUKIM TANJUNG MINYAK, DAERAH MELAKA TENGAH, MELAKA

CHAPTER 5 – PROJECT DESCRIPTION

Chapter

5 PROJECT DESCRIPTION

5.1 Introduction

This chapter describes the Project location, components and layout as well as the Project activities. The Project management structure and implementation schedule are also presented.

5.2 Project Location

As mentioned in Section 1.2 in Chapter 1, the Project is located within the existing MSB’s centre of healthcare waste treatment plant located at Kawasan Perindustrian Bukit Rambai, Fasa 4C, Mukim Tanjung Minyak, Melaka. The Project location map is as shown in Figure 1.2.1. Approximate coordinates of the Project area are tabulated in Table 1.2.1.

5.3 Project Components and Layout

The Project involves planning, construction, installation and operation of a counter-current rotary kiln type incinerator with a capacity to treat 20 MT/day of healthcare waste. This counter-current rotary kiln type incinerator is developed by BIC Systems Asia Pacific Pte Ltd. Generally, the main components of the thermal treatment facility include waste reception and storage, waste combustion, gas cooling, air pollution control and ash receiving and storage system, truck and bin washing system and temporary waste water storage tank.

Figure 5.3.1(a) illustrates the current setting of the centre of healthcare waste treatment plant which include the existing components. Meanwhile Figure 5.3.2(b) illustrates the layout of the new thermal treatment facility. The Project components are elaborated in the following sub-sections.

5.3.1 Former Incinerator Plant

The existing centre of healthcare waste treatment plant commenced its operation in 1997 using stepped hearth incineration system. During the operation of the former incinerator plant, there were two incinerator lines equipped with respective air pollution control systems. Both incinerators, were stepped hearth system, have the same exact specifications and treatment capacity of 7.2 MT/day (300 kg/hr).

MSB has ceased the incinerator operation in March 2016. Abandonment Management Plan was submitted to DOE Negeri Melaka in May 2017 (see Appendix 5.3.1). It was approved on 6 June 2017. Dismantling and removal works were completed on 28 November 2017.

Chemsain Konsultant Sdn Bhd Page | C5-1 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

5.3.2 Existing Components

5.3.2.1 Healthcare Waste Reception Area

This area is allocated to house the unloading and weighing of received healthcare waste. It is for temporary storage before further feeding process in the system.

5.3.2.2 Healthcare Waste Storage (Cold Room)

At the end of the day, untreated healthcare wastes will be stored in the cold storage area before being processed the following day. There are six existing cold room stores with a capacity of 15 MT each (total capacity of 90 MT), temperature of below 6 °C and 8 holding days. The current practice at the plant is the healthcare wastes bins will be managed based on first in first out order.

5.3.2.3 Microwave Machines

There are two microwave machines available at the Project site. Details of the machines are summarised as follows: i. Model AMB Ecosteryl 250

This microwave machine is from Belgium and has a capacity of 6 MT/day. License for operation was obtained in 2016. This microwave machine is currently operating as the main clinical waste treatment facility at the Project site. ii. Model MDS 2481

This microwave machine is from the US. It has a capacity of 9 MT/day or 270 MT/month. License for operation was obtained in May 2018.

5.3.2.4 Infrastructures and Utilities

5.3.2.4.1 Water Supply

Water supply requirement for ancillary facilities is estimated at 250m3/month (average). Since the Project site is an existing healthcare waste treatment facility, water supply distribution pipe, water pump house and storm water drainage system are already available on-site. Oil sumps, septic tank, holding tank and sewerline are also already installed at site.

5.3.2.4.2 Electricity

Electricity supply requirement for the incinerator is estimated about 50 kWh. Meanwhile for the ancillary facilities the electricity requirement is 80 kWh (average).

5.3.2.4.3 Internet Network

The Project site requires internet speed of 4Mbps for computer networking.

Chemsain Konsultant Sdn Bhd Page | C5-2 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

Figure 5.3.1(a) Figure 5.3.1(b) ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPOSED NEW INSTALLATION OF THERMAL TREATMENT FACILITY FOR CENTRE OF HEALTHCARE WASTE TREATMENT PLANT FOR MEDIVEST SDN BHD AT LOT 6939, 6940, 6947 & 6948, MUKIM TANJUNG MINYAK, DAERAH MELAKA TENGAH, MELAKA

CHAPTER 5 – PROJECT DESCRIPTION

5.3.2.4.4 Storm Water Drainage System

There is an existing storm water drainage system around the Project boundary. Storm water within the Project area will be channelled to existing perimeter drainage system and it will be discharged off- site to the existing drainage system available within the Kawasan Perindustrian Bukit Rambai, Fasa 4C.

5.3.2.4.5 Other Facilities

Other facilities available at the Project site include main office, scheduled waste store, general room and staff room.

5.3.3 Upcoming Components

5.3.3.1 Incinerator Plant

An opened but roofed pad area will accommodate for combustion / incineration process block. Components of the incinerator plant are summarised below:

5.3.3.1.1 Waste Feeding System

Automated with minimum manual intervention. Skip hoist system comprises of:

a) A hydraulically operated automatic skip hoist mechanism Working pressure hydraulics: 100 barG Hydraulic oil: ARO ISO 46 Max lifting weight (net): 250 Kg

b) A hydraulically operated automatic skip tilting mechanism Working pressure hydraulics: 100 barG Hydraulic oil: ARO ISO 46 Max tilting weight (net): 250 kg A bin holding structure: For standard 850 l or 240 l Euro bins

c) A weighing unit Maximum load: 1000 kg Precision: 1 kg

Chemsain Konsultant Sdn Bhd Page | C5-3 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

Plate 5.3.2: Skip Tilting Mechanism

Plate 5.3.3: Bin Weighing Unit

Plate 5.3.1: Skip Hoist Mechanism

5.3.3.1.2 Primary Combustion – Feeding Ram System

Features of the feeding ram system:

. Feed hopper height is 5 meters, from where the waste is introduced. . Suitable level indication/switches are incorporated. . Suitable weight monitoring system is incorporated. . The bottom of the hopper that feeds to the incinerator has interlocks to protect the hopper from the high temperature in the incinerator. . The bottom of the hopper is designed sufficiently strong to receive impact from the waste dropping and not bend over time. . Dumping the waste from the feed hopper to the incinerator is monitored by the interlock system, so that the incinerator is not overloaded or running without feed. . Feeding ram design is trouble free and very versatile. . A scraper will be installed to prevent waste from adhering onto the ram. . The ram has improved stiffeners to prevent it from bending over time. . Cooling water injection is foreseen in the feeding area.

Chemsain Konsultant Sdn Bhd Page | C5-4 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

The primary combustion comprises of:

Pneumatic cylinder working pressure: 8 barG a) A Feed Hopper: Power supply: 24VDC Length: 1500 mm Width: 1500 mm Height: 2000 mm Mild steel thickness: 10 mm

Working pressure: 100 barG b) A Hydraulic Ram: Length: 1250 mm Width: 1000 mm Height: 500 mm Mild steel thickness: 16 mm

Working pressure pneumatic cylinder: 8 barG c) A Guillotine Door: Grease type door tracks: graphite or copper powder based Insulation: refractory lined with concrete Mild steel: 6 - 10 mm Length: 250 mm Width: 1500 mm Height: 2100 mm Refractory steel back plate: Included

Plate 5.3.4: Feeding Hopper

Plate 5.3.5: Hydraulic Ram Plate 5.3.6: Guillotine Door

Chemsain Konsultant Sdn Bhd Page | C5-5 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

5.3.3.1.3 Primary Combustion – Incinerator

Features of the incinerator:

. The incinerator is equipped with a diesel oil burner, which will start automatically when the temperature in the kiln drops below a preset value. . There is a robust and foolproof ash collection system for the incinerator. No ash/ partially burned waste shall be dropped from any part of the incinerator. . A liquid injection system for the liquid waste is included.

The incinerator comprises: a) A Stationary Part

A stationary part that links the feed system to the rotary kiln and serving as a flue gas collector between the kiln and the post combustion chamber (mild steel sheet of 6 - 8 mm and is lined with an 85 % alumina containing refractory concrete). The improved version includes the modification of the voute above the feeding mouth and the addition of a liquid waste injection system.

Plate 5.3.7: Stationary Part b) A Counter Current Rotary Kiln

The rotary kiln, which is a cylindrical combustion chamber in 10 mm mild steel sheet lined with 200 mm of refractory concrete containing 85 % alumina. The refractory lined ash extraction flights at the rear of the kiln have been redesigned. Refractory lining made of high alumina (85%) high density castable materials. The kiln now has a VSD motor control with integrated management of motor parameters. This way, automatic action can be taken in case of increased kiln friction. The specification kiln’s specification is provided in Table 5.3.1.

Table 5.3.1: Counter Current Rotary Kiln Specification

Type BIR 375 External diameter 2000 mm Internal diameter 1600 mm Length 4650 mm Volume 12 m3 Thermal capacity 3,75 Gcal/Hr Design CV of waste 2000 - 10.000 kcal/kg (8372 - 41860 kJ/kg) Residual organic carbon content of bottom ash 2 % maximum Operating temperature 900 °C to 1000 °C Rotary speed 1.5 rev/min (max.) Source: BIC Systems Asia Pacific Pte Ltd. (2018)

Chemsain Konsultant Sdn Bhd Page | C5-6 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

Plate 5.3.9: Rotary Motor Plate 5.3.8: Rotary Kiln

c) Kiln rotation CW/CCW Power: 2x2.2 Kw Tension: 3 x 400/50Hz + N Rotational speed outgoing shaft: 1.5 rpm Control: by VSD

d) A Cylindrical Section With Reduced Diameter For Ash Evacuation

Refractory lining made of high alumina (85%) high density castable materials. Refractory steel (AISI 310) flame deflector for the burner flame will be installed. External diameter: 1100 mm Internal diameter: 900 mm Length: 850 mm

3 Volume: 0.7 m Plate 5.3.10: Reduced Cylindrical Section for Ash Evacuation

e) A Supporting Frame

Comprises of four supporting wheels and one trust wheel on self- lubricating bearing and a motor redactor.

Plate 5.3.11: Supporting Frame

Chemsain Konsultant Sdn Bhd Page | C5-7 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

f) A Burner

Burner with thermal power rating of 90 kW and requires 3 x 400/50Hz + N power supply.

Plate 5.3.12: Burner g) A De-Ashing Chamber

Features of the de-ashing system:

The bottom ash bin replacement system is manually done for optimum reliability. The bins for ash collection cannot be equipped with level sensors because of the presence of the burner flame. A timer system is also not reliable to monitor the levels. These principles also apply to the de-ashing system for the fly ash.

5.3.3.1.4 Secondary Combustion (Post Combustion)

Features of post combustion chamber:

. Fuel/Air ratio is on auto-control . Fuel flow is measured and recorded . Lo, Lo-Lo, Hi and Hi-Hi temperature alarms are included . High temperature and low temperature trips are incorporated. . For the post combustion chamber, burner flame failure signal will trip the incinerator

The post combustion zone comprises of: a) The upper part of the Stationary Zone

Plate 5.3.13: Post Combustion – Upper Part of Stationary

Chemsain Konsultant Sdn Bhd Page | C5-8 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

b) Two vertical cylindrical chambers

Specifications of the two vertical cylindrical chambers are listed in Table 5.3.2.

Table 5.3.2: Two Vertical Cylindrical Chambers Specification

Type BIR 375 Length 6000 mm Width 1500 mm Height - Steel mild steel sheet 6 mm Insulation lined with 150 mm refractory concrete 85 % alumina content Inspection Inspection doors at bottom and top Source: BIC Systems Asia Pacific Pte Ltd. (2018) c) A Retractable Burner

The retracting mechanism is actuated by one single horizontal compressed air cylinder, protected from radiant heat. The specifications of the retractable burner is provided in Table 5.3.3. Table 5.3.3: Retractable Burner Specification

Type BIR 375 Thermal power rating 90 Kw Power supply 3 x 400/50Hz + N Working pressure pneumatic cylinder 8 barG Source: BIC Systems Asia Pacific Pte Ltd. (2018)

Plate 5.3.14: Post Combustion – Retractable Burner

5.3.3.1.5 Flue Gas Pre-Cooling

A flue gas pre-cooling system consists of a flue gas inlet flange fitted with a butterfly valve operated by a servo motor. Purpose is to reduce the temperature at the heat exchanger inlet below fusion point of the particulates to avoid slagging. This system is to prevent any risk of corrosion. The specifications of the flue gas pre-cooling system are provided in Table 5.3.4.

Chemsain Konsultant Sdn Bhd Page | C5-9 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

Table 5.3.4: Flue Gas Pre-Cooling System Specification

Type BIR 375 Maximum inlet temperature 1200 °C

Exit temperature 800 °C Maximum flow rate 8000 Nm3/h Source: BIC Systems Asia Pacific Pte Ltd. (2018)

Plate 5.3.15: Flue Gas Pre-Cooling System

5.3.3.1.5.1 A Flue Gas to Thermal Oil Heat Exchanger

Features of the flue gas heat exchanger:

. The heat exchanger is designed to be trouble-free . Online back blowing facility by ultrasonic soot blowers are foreseen to blow off accumulated soot and dust . Vertical dual pass water (thermal fluid) tube heat exchanger has been designed for easy access and maintenance. Large inspection doors at the inlet, as well as at the outlet of the exchanger allow easy and quick access to the pipe bundles and allow quick cleaning by means of a vacuum cleaner . Automatic evacuation of fly ash by rotary valve into a removable steel bin with quick couplings

The specifications of the exchanger are provided in Table 5.3.5. Table 5.3.5: Flue Gas to Thermal Oil Heat Exchanger Specification

Type BIR 375 Design inlet temperature 850 °C Exit temperature 200 °C Maximum flue gas flow rate 11000 Nm3/h Source: BIC Systems Asia Pacific Pte Ltd. (2018)

Chemsain Konsultant Sdn Bhd Page | C5-10 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

Plate 5.3.16: Thermal Oil Heat Exchanger

5.3.3.1.5.2 A Thermal Oil Pump Skid

The new thermal oil system is designed for full automation. The system mainly features two identical circulation pumps, one main and one back-up with auto switch-over with their respective shut off valves. Low oil flow will trigger the stand by pump. Oil return Hi-Hi temperature will trigger incinerator trip. Specification of the thermal oil pump skid is listed in Table 5.3.6. Table 5.3.6: Thermal Oil Pump Skid

Type BIR 375 Electrical supply 3 x 400 V/ 50Hz + N Pressure 2.0 bar Flow rate 80 m3/h Source: BIC Systems Asia Pacific Pte Ltd. (2018)

The system features a thermal filling pump and filling shut-off valves. Each pump can be separately drained into a closed-loop drain system for spill-free and safe maintenance. The system also includes a 3-way control valve for temperature control and a safety by-pass valve.

Plate 5.3.17: Thermal Oil Pump Skid

Chemsain Konsultant Sdn Bhd Page | C5-11 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

5.3.3.1.6 Sodium Bicarbonate (NaHCO3) Storing and Injection by Loss-in-Weight

Features of chemical dosing system:

. Dosing chemical flow with feed rate adjustable according to the quantity and quality of flue gas . Dosing chemical flow indication by loss-in-weight feed back . No/Low sensors give alarm to warn operators . The dosing system is designed to prevent clogging of bicarbonate powder . Replacement of bags is done at floor level . FIBC’s are attached to an easy to handle and easy to install solid steel frame

The system has maximum mass flowrate of 25 kg/h and requires 3 x 400 V/ 50Hz + N of electricity supply.

The advantage of using Bicarbonate instead of lime, is that the neutralising reaction time is much (five times) shorter and the reaction itself nearly stoichiometric. This results in using less reactant and a more complete reaction and a nearly null emission of acids to the atmosphere. Further, using less reactant, means less fly ashes to be evacuated.

Plate 5.3.18: Sodium Bicarbonate Storing Plate 5.3.19: Activated Carbon Storing and and Injection Injection

5.3.3.1.7 Activated Carbon Storing and Injection by Loss-in-Weight

Features of chemical dosing system (similar to the above):

. Dosing chemical flow with feed rate adjustable according to the quantity and quality of flue gas . Dosing chemical flow indication by loss-in-weight feed back . No/Low sensors give alarm to warn operators . The dosing system shall be designed to prevent clogging of bicarbonate powder The system has maximum mass flowrate of 3.5 kg/h and requires 3 x 400 V/ 50Hz + N of electricity supply.

Chemsain Konsultant Sdn Bhd Page | C5-12 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

5.3.3.1.8 Bag House Filter

Features of bag filter house/system include:

. Auto back blow system on timer basis and on differential pressure basis, whichever triggers first . Manual back blow facility, which will override the auto settings . Bag filter, comes along with maintenance platform . Fly ash is collected at the bottom of the hoppers and is evacuated automatically by rotary air locks into sealed container with automatic lid

The bag house filter specifications are provided in Table 5.3.7. Table 5.3.7: Bag House Filter Specifications

Type BIR 375 Tension electrical supply 3 x 400 V/ 50Hz + N Maximum air pressure 6 barG Flow rate 30,000 m3/h Design inlet temperature 200 °C No. of sleeves 432 Material for sleeves Teflon needle felt Removal of fly-ash By Rotary air locks Efficiency 99.9% Source: BIC Systems Asia Pacific Pte Ltd. (2018)

Plate 5.3.20: Bag House Filter

Chemsain Konsultant Sdn Bhd Page | C5-13 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

5.3.3.1.9 Exhaust Fan

Features of flue gas treatment system, in terms of emissions:

. The flue gas treatment system is able to treat the flue gas to meet the emission standards . The exhaust fan speed is controlled by the negative pressure in the kiln

Table 5.3.8: Exhaust Fan Specifications

Type BIR 375 Tension electrical supply 3 x 400 V/ 50Hz + N Power rating 110 kW Maximum inlet temperature 250 °C Maximum gas flow rate 600 m3/min Maximum rotation speed 1500 rpm Source: BIC Systems Asia Pacific Pte Ltd. (2018)

Plate 5.3.21: Exhaust Fan

5.3.3.1.10 Emission Monitoring Equipment

Highlighted features of emission monitoring equipment:

. The emission monitoring equipment includes continuous recording and online monitoring system for all the gas elements, as specified by the incinerator emission standards stipulated by the Department of Environment Malaysia . Alarms are activated to notify the plant operator when the pre-set values are exceeded. If the emission further crosses the limits, then incinerator will be tripped Table 5.3.9: Emission Monitoring Equipment

Equipment Principle / Manufacturer

Extractive CO, CO2, SO2 Principle of measurement: NDIR analyser Extractive NOx, O2 analyser Principle of measurement: CLD / Zirconia HCL / HF analyser In-situ

Chemsain Konsultant Sdn Bhd Page | C5-14 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

Equipment Principle / Manufacturer Dust monitoring In-situ SCADA The data of the monitoring system will be connected to and integrated with the plant PLC/PC. Process interlocks will not be implemented from the start but can be added easily at a later stage if required. The plant supervision PC will show and log all emission monitoring data continuously. CAL gases The system has provisions for connection of the necessary CAL gas bottles. Enclosure Weather-proof analyser system, cabinet construction based on 2.0 mm thickness galvanised plate with powder coated equipped with air condition unit and heating. Equipped with power distribution panel, lighting, switch and plug C/W cylinder rack. Source: BIC Systems Asia Pacific Pte Ltd. (2018)

5.3.3.1.11 Peripherals a) A hydraulic pack Working pressure: 100 barG Volume of oil tank: 250 l Hydraulic oil: ARO ISO 46 Power electric motor: 11 kW Tension electrical supply: 3 x 400 VAC/50Hz + N

Plate 5.3.22: Hydraulic Pack b) A chimney

The chimney is equipped with the necessary sampling ports and access platform. The chimney is self- supporting and of mild steel. Table 5.3.10 provides the specifications of the chimney

Chemsain Konsultant Sdn Bhd Page | C5-15 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

Table 5.3.10: Specification of Chimney

Type BIR 375 External diameter 1350 mm Height 21 m Flow volume of flue gas 5.1 m3/s Exit velocity of flue gas 12 m/s Temperature of flue gas at inlet 473.15 K Source: BIC Systems Asia Pacific Pte Ltd. (2018)

Plate 5.3.23: Chimney Stack c) An air compressor assembly

Features of air compressor assembly:

. Careful location of the unit (dust-free) and preventive, regular maintenance will render it trouble- free Maximum working pressure: 8 barG Flow rate: 2.85 m3/min

Plate 5.3.24: Air Compressor Assembly

Chemsain Konsultant Sdn Bhd Page | C5-16 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION d) Emergency by-pass

Features of emergency by-pass:

. Emergency bypass system for the bag house filter is fully automated . The bypass is a failsafe design (gravity opened) and is interlocked with the process . When the bypass valve is open, the incinerator is tripped . The bypass valve manual control is not allowed by law

The emergency by-pass consists of an automatic lid on top of the emergency dump stack at the top of the post combustion. A guillotine-type shut-off valve to isolate the process downstream.

Plate 5.3.25: Emergency By-pass e) Fly ash evacuation system

A fly ash evacuation system comprises two dust hoppers, two rotary air locks and two easily replaceable dust containers with semi-automatic lid.

Plate 5.3.26: Dust Hopper and Container

Chemsain Konsultant Sdn Bhd Page | C5-17 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

f) Liquids Injection Systems

The system consists of a volumetric injection pump (temperature controlled) and a compressed air assisted injection nozzle. The flow rate is 500 l/h meanwhile the maximum pressure is 8 barG.

Plate 5.3.27: Liquid Injection System g) Safety valve (Diluting air inlet)

The safety valve consists of an automatic control valve for controlled air ingress after the heat exchanger (set point 200 °C).

Plate 5.3.28: Safety Valve h) A Plant Automation System

Highlighted features of plant automation system

. The plant is fully automatic, safe and user-friendly in all circumstances . Motor Control Center (MCC) and Programmable Logic Controls (PLC) are housed in a control room

All components are designed for the fail-safe conditions.

Chemsain Konsultant Sdn Bhd Page | C5-18 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

The plant automation system comprises of: i. An MCC Power Switchboard - The switchboard houses all motor starters, variable speed drives (VSD) and thermal overloads. ii. A PLC Switchboard - The switchboard houses PLC and Ethernet modules.

Plate 5.3.29: MCC Power Switch Plate 5.3.30: PLC Switch Board

iii. A Pulpit Supervisory Control and Data Acquisition (SCADA) PC for User Interfacing - The pulpit is equipped with a desktop PC with the LCD screen behind a protective window. A back-up PC runs in parallel in a control room/rack room to render the system fail safe.

Plate 5.3.31: Control Panel Plate 5.3.32: PC Screen (Sample)

5.3.3.2 Truck and Bin Washing Bay

Washing bay will be provided near the weighing area for truck/ bin washing and cleansing upon tipping of waste and prior to leaving the centre. Based on the Industrial Effluent Characteristic Study done, volume of waste water generated from both activities is 0.633 m3 per day. Waste water from the washing bay will be channelled to temporary waste water storage tanks prior being injected to the counter current rotary kiln for incineration.

Chemsain Konsultant Sdn Bhd Page | C5-19 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

5.3.3.3 Temporary Waste Water Storage Tank

The incineration processes using the counter current rotary kiln does not generate any effluent. Sources of waste water are from healthcare waste wheel bins and trucks washing activities. Waste water from the washing activities are considered to have potential infection risk as the wheel bins and trucks are likely to be exposed to the healthcare wastes. The waste water will be channelled to temporary waste water storage tanks that will be installed within the Project site.

There will be two temporary waste water storage tanks. The first tank is the underground waste water storage tank with a capacity of 8 m3. The second tank will be on the ground with a capacity of 28 m3. Total storage capacity is 36 m3 which is capable to store the waste water for 56 days. The first tank will be connected to the second tank via a piping system.

The second waste water tank will be equipped with strainer, pump system and piping connection, which is designed to pump the waste water from the tank to the incinerator with rate of 1.0 m3 per hour, at 3.0 bar pressure.

Injection of waste water to the counter current rotary kiln will be of closed system. Regular inspection of the piping system for any leakage will be carried out to avoid any spillage of the waste water.

5.4 Design Criteria of the Thermal Treatment Facility

5.4.1 Key Design Parameters

The thermal treatment facility is designed according to European Union (EU) standards. The key design aims to fulfil typical regulatory requirements to date, with the key parameters being Destruction Efficiency (DRE %) of 99.9999%, minimum residence time of minimum two seconds at 1,100 °C in the post combustion. The Operating Standards are listed in Table 5.4.1. Table 5.4.1: Incinerator Operating Standards Item Specifications Destruction efficiency (DRE) 99.9999 % Primary Combustion Chamber Temperature 850 °C minimum / 1,000 °C maximum

Secondary Combustion Chamber Temperature 1,100 °C minimum / 1,200 °C maximum

Residence Time Minimum 2 seconds Minimum Oxygen Content 12%-13% Air / Fuel Ratio 2.5 Source: BIC Systems Asia Pacific Pte Ltd. (2018)

Chemsain Konsultant Sdn Bhd Page | C5-20 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

The other key parameter is the conformance to emission standards in Malaysia. The limits are in Table 5.4.2. The EU standard, which is the design standard used by BIC Systems Asia Pacific Pte Ltd is equally or more stringent than Malaysian standard.

Table 5.4.2: Emission Standards –European Union and Malaysia Parameter EU (Daily) EU (Hourly) EU ( 4- Hour) EU Summary Malaysia*

mg/m3 Ash / Particulates 5 10 - 5 100 HF - - - - 1 HCl 5 10 - 5 40 CO 50 100 - 50 50 NOx 100 200 - 100 200 SOx 25 50 - 25 50 Cd - - 0.05 0.05 0.05 Hg - - 0.05 0.05 0.05 Pb - - - - - Heavy Metals - - - - 0.5 Dioxin / Furan - - 0.10 ng/m3 0.10 ng/m3 0.10 ng/m3 Total Organics 5 10 - 5 10 Note: Environmental Quality (Clean Air) Regulations 2015 (3rd Schedule Regulation 13, Item K: Waste Incinerator in All Sizes. Source: BIC Systems Asia Pacific Pte Ltd. (2018)

The design also considers the typical chemical composition of healthcare waste as shown in Table 5.4.3.

Table 5.4.3: Typical Healthcare Waste Chemical Composition

Element Mass % Mol/kg C 74.80 0.062 H 7.00 0.070 N 1.00 0.001 S 1.000 0.000 Hg 0.00 0.000 Pb 0.000 0.000 Zn 0.000 0.000 0.000 0.000 0.000 Cl 1.00 0.000 F 0.10 0.000 Br 0.10 0.000

Chemsain Konsultant Sdn Bhd Page | C5-21 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

Element Mass % Mol/kg O 5.00 0.003 Ash 10.000 - Total 100.00 - Source: BIC Systems Asia Pacific Pte Ltd. (2018)

Summary of design and operational particulars of the thermal treatment facility are as listed in Table 5.4.4. The plant is designed to operate at a capacity of 833 kg/hr where 20 MT/day of healthcare wastes are expected to be treated. Table 5.4.4: Summary of General Technical Characteristic of the Thermal Treatment Facility

Thermal Capacity 3,750,000 Kcal/hr (15,750 MJ/hr) Throughput 833 kg/hr (20 MT/day) (Based on the average calorific value of waste of 4500 kcal/kg (20 MJ/kg) Design Life Span 20 years

Process Line 1 Operating Hours 24 hours per day, 7 days per week Waste storage capacity 90 MT Incinerator System Counter Current Rotary Kiln Destruction efficiency (DRE) 99.9999 % Feeding Loading Skip hoist system Start-up Duration 8 hours to automatically heat up to operating temperature (depending on atmospheric conditions) Burn period 8 hours Burn Cycle 8 cycles (160 kg per loading) Residential time 2 – 3 seconds Cool Down Period 24 hours Auxiliary Fuel Diesel - 50 l/hr (for start-up only) Air Pollution Control System Heat Removal Heat exchanger: flue gas to thermal oil Dioxin and Furan Control Continuous operation creating steady state conditions, ensuring complete combustion leading to complete destruction of dioxins and furans (dioxins can completely be eliminated with a residence time of 2 seconds at 1000°C and oxygen level of min 10% is thoroughly distributed) Dosing of Activated Carbon to remove any remaining dioxin and furan Acidic Gas Neutralizer Dosing of Sodium Bicarbonate Dust Filtration Baghouse: 432 Teflon Felt bags Parameter of CEMS Conformity with EC and Malaysian emission regulations Ash Removal Daily

Chemsain Konsultant Sdn Bhd Page | C5-22 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

Utilities Power supply 50 kW/hr (average) Estimated waste Fly ash 85 kg/hr Bottom ash 62 kg/hr

5.5 Process Description

5.5.1 Handling of Healthcare Wastes at Source (On-Site Handling)

SW 403, SW 404, SW 409, SW410, SW 429 and SW 430 will be collected and transported from the respective hospitals and laboratory to the Project site using dedicated trucks. Healthcare wastes characteristics are listed in Table 5.5.1. Clinical wastes analysis are listed in Table 5.5.2 and Table 5.5.3. Table 5.5.1: Healthcare Wastes Characteristics

Material Percentage P.V.C 3% Pathological 5% Plastic other than P.V.C 33% Paper including waxed paper 30% Hospital dressing, swab, etc. 10% Non-combustible including glass, metal, etc. 10% Obsolete laboratories chemical 5% Miscellaneous (including flowers, rags, etc.) 5% Source: Medivest Sdn Bhd. (2018)

Table 5.5.2: Proximate Analysis of Clinical Waste

Analysis Range (%) Average (%) Moisture ontent 16.9 - 28 21 Ash Content 1.6 - 4.7 3.1 Volatile matter 66.1 - 77.2 72.2 Fixed Carbon 1.2 - 4.3 3.2 Adapted from: Radicare (M) Sdn Bhd. (2012)

Chemsain Konsultant Sdn Bhd Page | C5-23 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

Table 5.5.3: Ultimate Analysis of Clinical Waste

Component Weight Percentage (%) Carbon 51.83 Hydrogen 8.63 Oxygen 35.53 Nitrogen 0.17 Sulphur 0.10 Chlorine 0.64 Ash 3.1 Adapted from: Radicare (M) Sdn Bhd. (2012)

Collection and storage of healthcare wastes in Clinical Wastes Management Services (CWMS) is one of MSB’s responsibilities as the Concession Company. As such, relevant products (i.e. receptacles, plastic bags and on-site containers) are to be supplied to the hospitals or establishments to contain healthcare wastes.

Segregation of the healthcare wastes is done by MOH’s staff in accordance to Management of Clinical and Related Wastes in Hospital and Health Care Establishments (1993) and Project Operations Guidelines on Clinical Wastes Management Services (2009) released by the MOH.

Healthcare wastes that have been segregated are stored in dedicated containers/ plastic bags before being sealed and labelled. Once the plastic bags or sharp containers are sealed, it is strictly prohibited to break the seal. They are handled with care to prevent accidental tears or breaks until the incineration process, as it may cause health and environmental hazards.

Table 5.5.4 presents types of products approved by the MOH to be used for containment of CW generated at source.

Plastic bags and sharp containers are then transported in wheeled bins to the hospital’s central storage for collection by MSB staff. Collection of healthcare wastes shall be done daily or as frequently as circumstances demand. Authorised representative of the MOH and MSB staff weight the healthcare wastes and record the quantities and weights. During the collection of the wheeled bins containing healthcare wastes, MSB staff shall provide adequate supply of plastic bags, sharp containers and cleaned receptacles for the collection and on-site storage. Consignment notes are completed for each collection. Both the MOH’s staff and MSB staff are well-trained and equipped with personal protective equipment (PPE) during the handling process.

Chemsain Konsultant Sdn Bhd Page | C5-24 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

Table 5.5.4: Approved Products Used for CWMS

Purpose Products Used Segregation of sharps and Yellow-coloured triple-lock syringes container (20L, 10L, 5L and 2.5L)

Segregation of non-sharps Yellow-coloured plastic clinical wastes bags

Holding of non-sharps clinical Bag Holder (Size 18L & wastes 35L)

Sealing and tagging of plastic One-way bags during collection plastic seal

For collection and Yellow-coloured wheeled transportation of clinical waste bin (240L)

Chemsain Konsultant Sdn Bhd Page | C5-25 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

This Project will accommodate healthcare wastes generated from government hospitals and laboratory in Negeri Sembilan, Melaka and Johor. Estimated quantities of healthcare wastes to be collected and treated at the Project site are listed in Table 5.5.5. As mentioned in Chapter 1, in future, the Project Proponent may also consider collection of healthcare waste from private sectors, however information about the waste generators from private sectors and estimated amount of healthcare wastes to be collected are yet to be developed at the moment.

Table 5.5.5: Healthcare Wastes Collection from Waste Generators

Source Estimated Load, 2018 (kg/month)

SW 404 SW 403 SW 429 SW 430 SW 409 SW 410

Hospital Tuanku Ja'afar 45,731 0 0 0 0 15 Seremban, Negeri Sembilan Hospital Melaka 63,435 0 0 51,189 0 15

Hospital Sultanah Aminah, 52,485 0 0 0 0 20 Johor Bahru, Johor Hospital Jelebu, Kuala 3,552 0 0 6,383 0 0 Klawang, Negeri Sembilan

Hospital Alor Gajah, Melaka 4,983 0 0 0 0 0

Hospital Enche' Besar Hajjah 20,444 0 0 0 0 5 Kalsom, Kluang, Johor Hospital Tuanku Ampuan 20,426 0 0 77 0 0 Najihah, Kuala Pilah, Negeri Sembilan Hospital Sultanah Nora 24,818 0 0 0 0 5 Ismail, Batu Pahat, Johor Hospital Kota Tinggi, Kota 7,033 0 0 0 0 0 Tinggi, Johor Hospital Port Dickson, 5,803 0 0 0 0 0 Negeri Sembilan Hospital Jasin, Melaka 4,044 66 0 3,484 0 0

Hospital Temenggong Seri 4,984 0 0 0 0 0 Maharaja Tun Ibrahim, Kulai, Johor Hospital Tampin, Negeri 3,570 364 0 0 0 0 Sembilan Hospital Pakar Sultanah 22,061 0 5,072 0 0 5 Fatimah, Muar, Johor Hospital Mersing, Johor 3,001 0 0 0 0 0

Hospital Segamat, Johor 12,915 0 0 0 0 0

Chemsain Konsultant Sdn Bhd Page | C5-26 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

Source Estimated Load, 2018 (kg/month)

SW 404 SW 403 SW 429 SW 430 SW 409 SW 410

Hospital Pontian, Johor 4,530 0 0 0 0 0

Hospital Tangkak, Johor 2,391 0 0 0 0 0

Hospital Permai, Johor 7,044 0 0 0 0 0 Bahru, Johor Makmal Kesihatan Awam 630 0 0 0 20 20 Johor Bahru, Tampoi, Johor Bahru Hospital Sultan Ismail, Johor 38,998 0 0 0 0 15 Bahru, Johor Hospital Jempol, Negeri 2,979 31 0 28 0 0 Sembilan Total 355,857 461 5,702 61,161 20 100

Source: Medivest Sdn Bhd. (2018)

5.5.2 Transportation of Healthcare Wastes to Project Site

Six dedicated trucks are allocated for transportation of the healthcare wastes. One of the truck has a capacity of 16 MT meanwhile the remaining five trucks have a capacity of 18 MT each. It is estimated that there will be one trip of delivery daily for each truck. Truck details are listed in Table 5.5.6.

Table 5.5.6: Details of Transportation

No. Truck Registration No. Brand Capacity 1 MBC 288 Nissan 16 Tonne 2 MCG 3259 Nissan 18 Tonne 3 MCN 6259 Hino 18 Tan 4 MCN 9252 Hino 18 Tonne 5 MCS 3722 Hino 18 Tonne 6 MCS 3726 Hino 18 Tonne Source: Medivest Sdn Bhd. (2018)

Transportation and collection of the healthcare wastes are daily and divided by five routes as follows:

i. Route 1: Plant – Hospital Pontian – Hospital Sultanah Aminah – Makmal Kesihatan Johor – Hospital Kulai – Plant.

ii. Route 2: Plant – Hospital Kluang – Hospital Kota Tinggi – Hospital Sultan Ismail – Hospital Permai – Plant.

iii. Route 3: Plant – Hospital Mersing – Hospital Batu Pahat – Hospital Muar- Plant.

Chemsain Konsultant Sdn Bhd Page | C5-27 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

iv. Route 4: Plant – Hospital Port Dickson – Hospital Tampin – Hospital Alor Gajah – Hospital Tangkak – Hospital Jasin – Hospital Segamat – Plant.

v. Route 5: Plant – Hospital Seremban – Hospital Jelebu – Hospital Jempol – Hospital Kuala Pilah –Hospital Melaka – Plant.

5.5.3 Handling of Healthcare Wastes at Project Site (Off-site Handling)

Healthcare wastes received at the Project site will be weighed before further handling and treatment.

5.5.4 Incineration Process

Block diagram for the overall processes proposed to be undertaken at the thermal treatment facility (incinerator plant) is shown in Figure 5.5.1.

The healthcare wastes contained in standard 660 L or 240 L plastic waste bins is fed into the system with a skip hoist system. The feeding process is automated with minimum manual intervention. In exception of placing bins in position, the rest of the process including lifting, tilting, as well as lowering the bins are fully automated.

The primary combustion train comprises a feeding hopper, a hydraulic ram that pushes the waste and a guillotine (fire) door that opens only when waste is pushed into combustion chamber. The dumping of the waste from the feeding hopper to the incinerator is monitored by interlock system, to eliminate the possibility of overloading or under-loading of waste. The hydraulic ram will be scraped by guillotine door so that no adhering of waste onto the feeding ram. Meanwhile, cooling air will be aspired through the feeding area, to cool it down.

A stationary part links the feed system to the rotary kiln and serves as a solid hearth bed to start and to preheat the freshly introduced waste. After being partly burnt, the solid waste enters a counter current rotary kiln for further complete combustion. The cylindrical rotary kiln rotates clockwise or counter-clockwise at a controllable speed, to ensure thorough and speedy combustion. A cylindrical section at the rear end of the kiln serves as an ash evacuation portion. The entire rotary kiln is supported by four supporting wheels and one trust wheel on self-lubricating bearings.

To raise the temperature at start-up, the incinerator is equipped with a diesel burner. The burner will start firing automatically when the temperature inside the kiln drops below a pre-set value. There will be a robust and fool proof ash collection system for the incinerator. The new design can ensure that no ash nor partially burnt waste shall drops from any part of the incinerator. In addition, replacement of the bottom ash bin will be manually done for optimum reliability.

The secondary combustion, also known as post combustion chamber, starts at the upper part of the stationary part, followed by an extension chamber equipped with and retractable burner.

Chemsain Konsultant Sdn Bhd Page | C5-28 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

Refractory lined

Source: BIC Systems Asia Pacific Pte Ltd. (2018)

Figure 5.5.1: Process Flow Block Diagram

Chemsain Konsultant Sdn Bhd Page | C5-29 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

5.5.4.1 Gas Cooling

After combustion, the flue gas will first enter a flue gas cooling system. The flue gas will be directed in to a Flue Gas Thermal Oil (FGTO) heat exchanger. The vertical thermal heat exchanger enables easy access and maintenance. The trouble-free design of the vertical FGTO heat exchanger is equipped with ultrasonic soot blowers, in order to blow off accumulated fly-ash and soot. The newly designed thermal oil system, fully automatically triggers the stand-by pump in case of low oil flow, where Hi-Hi temperature will trigger plant trip (emergency by-pass).

5.5.4.2 Incinerator Plant Control System

The entire incinerator plant is automatically controlled by a PLC (Programmable Logic Controller). All required instrumentation for the incineration system, the waste feed system, the rotary kiln, the post combustion chamber, the flue gas treatment and scrubbing system, the fan controls and emergency by-pass system are included. The incinerator controls include temperature controls, pressure controls, excess air controls, all burner safeties and the necessary alarms/alert and data logging equipment.

5.5.4.3 Healthcare Waste Storage

In the event that healthcare wastes could not be incinerated within 24 hours of reception, they will be stored in a dedicated storage container/ refrigerator at temperature of between below 6˚C (cold storage). There are six storage containers available at the Project site. Total holding capacity is 90 MT.

5.5.4.4 Cleansing and Disinfection of Wheeled Bins and Trucks

Upon unloading of healthcare wastes at the reception area, the emptied wheeled bins will be transferred to the washing bay area. Wheeled bins will be washed, sprayed with biodegradable disinfectant solution and rinsed before being transferred to clean bin storage area. Trucks will also be cleaned and disinfected before the next collection trip or usage. Clean wheeled bins will be returned to the healthcare wastes generators (hospitals).

5.5.4.5 Thermal Treatment Facility’s Mass Balance

The thermal treatment facility’s mass balance is shown in Figure 5.5.2.

5.6 Air Pollution Control System and Waste Management

5.6.1 Air Pollution Control

The Air Pollution Control (APC) that will be installed at the thermal treatment facility includes a dry scrubber (with sodium bicarbonate (NaHCO3) and activated carbon storing and injection systems) and a bag house filter. Features and specifications of these APCs are provided in Section 5.3.3.1.6, Section 5.3.3.1.7 and Section 5.3.3.1.8.

Sodium Bicarbonate will be used for acidic gas neutralizer. The advantage of using Sodium Bicarbonate instead of lime, is that the neutralising reaction time is much (five times) shorter and the

Chemsain Konsultant Sdn Bhd Page | C5-30 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION reaction itself nearly stoichiometric. Activated carbon will be used to remove any remaining of Dioxin and Furan in the flue gases.

Sodium bicarbonate and activated carbon are stored and injected according to loss-in-weight. The new chemical dosing design is such that it will dose the chemical flow with adjustable feeding rate according to the quantity and quality of the flue gas. The dosing of chemical flow is by loss-in-weight feedback. The operators will be notified by the No/Low sensor together with alarms. Moreover, the dosing system is designed to prevent clogging of bicarbonate powder.

The flue gas then will enter the bag house filter to remove particulates and dust. A pulsating compressed air system will blow-off the filtered dust from the filter bags and be triggered by differential pressure across the bags. A large maintenance platform is installed at the top of the baghouse. Rotary air locks will collect the fly-ash and the collected fly-ash drops by gravity into sealed containers with automatic lid. The exhaust fan speed is controlled by the negative pressure in the kiln. The flue gas treatment system is able to treat the flue gas to meet the emission standards.

5.6.1.1 Air Emission Limit

Air emission from the Project shall comply with emission limits based on Activity K: Waste Incinerators in All Sizes under the Third Schedule of Environmental Quality (Clean Air) Regulations 2014 as listed in Table 5.6.1.

Table 5.6.1: Air Emission Limit- Activity K-CAR 2014

Activity K Parameter Limit Values Monitoring

3 Total PM 100 mg/m Continuous 3 NMVOC as total organic carbon 10 mg/m Continuous 3 Hydrogen Chloride (HCl) 40 mg/m Continuous 3 Hydrogen Fluoride (HF) 1 mg/m Continuous 3 Sum of SO2 and SO3 expressed as SO2 50 mg/m Continuous 3 Sum of NO and NO2 200 mg/m Continuous 3 Carbon Monoxide (CO) 50 mg/m Continuous Cadmium and its compounds, expressed as Cadmium (Cd) Total 3 Periodic Thalium and its compounds, expressed as Thalium 0.05 mg/m (TI) Mercury and its compounds, expressed as Mercury 3 Periodic (Hg) 0.05 mg/m Antimony (Sb), Arsenic (As), Lead (Pb), Chromium (Cr), Cobalt (Co), Copper (Cu), Manganese (Mn), Total 3 Periodic Nickel (Ni), Vanadium (V) and their compounds 0.05 mg/m expressed as the element 3 PCDD / PCDF 0.1 ng TEQ /m Periodic Note: TEQ: Toxicity Equivalent Quantity; 11% O2 Reference

Chemsain Konsultant Sdn Bhd Page | C5-31 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

5.6.2 Water Pollution Control

5.6.2.1 Storm Water

Storm water within the Project area will be channelled to the existing perimeter drainage system and it will be discharged off-site to the existing drainage system available within the industrial area before entering Sg Ayer Salak that traverses further northwest to south from the project site (about 1.4 km) before joining Sg Melaka and entering the Selat Melaka.

5.6.2.2 Waste water from Washing Activities

The thermal treatment facility does not generate any effluent from the incinerator processes. Sources of waste water are from healthcare waste wheel bins and trucks washing activities. Waste water from the washing activities are considered to have potential infection risk as the wheel bins and trucks are likely to be exposed to the healthcare wastes. Figure 5.6.2 illustrates the waste water management at the Project site.

Volume of the waste water generated from the washing activities is 0.633 m3 per day. Waste waters from the bin washing bay and truck washing bay are immediately channelled to temporary waste water storage tanks through piping system. No waste water will be stored at the washing bays.

The second waste water tank will be equipped with pump system and piping connection, which is designed to pump the waste water from the tank to the incinerator with rate of 1.0 m3 per hour, at 3.0 bar pressure.

High pressure waste water will be injected into the high temperature combustion chamber in the thermal treatment facility with injection rate of 0.15 m3 per hour. The injections are continuous but depending on the temperature of the combustion chamber, which the injection only activate at high temperature and stop when the temperature is low. On daily basis, the thermal treatment facility only require 4 hours injection to incinerate daily waste water.

Chemsain Konsultant Sdn Bhd Page | C5-32 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

Waste water generated from bin and truck washing activity

The waste water flow out from the washing bays to temporary waste water storage tanks

Temporary storage of the waste water

Pumping out the waste water from

the temporary waste water storage

Disposal of the waste water in the incinerator

Figure 5.6.2: Process Flow of Waste Water Management

5.6.3 Solid and Scheduled Wastes Management

5.6.3.1 Domestic Solid Wastes

Domestic wastes will comprise general refuse (such as paper, cardboard, stationery, packaging materials and plastics). These wastes will be disposed of at the nearest municipal landfill approved by Majlis Bandaraya Melaka Bersejarah.

5.6.3.2 Scheduled Wastes

Key scheduled wastes that will be generated by the Project are bottom ash (SW 406), fly ash (SW 406) and fluff (SW 501).

Bottom ash will be generated 8% from the waste fed into the incinerator which is approximately 62 kg/hr. Bottom ash will be temporary stored inside first and second compartment of Scheduled Waste Storage Area before being sent to Kualiti Alam for disposal at a secured landfill with frequency of three times a month.

Meanwhile, it is estimated about 85 kg/hr of fly ash will be generated. Fly ash will be temporary stored at the Scheduled Waste Storage Area and sent to Kualiti Alam Sdn Bhd for disposal twice a month. Collection of both type of ashes will done by Kualiti Alam personnel.

During incinerator shutdown events, healthcare wastes at the Project site will be treated using the two microwave machines available on-site. SW 501 which consist of fluff will be generated as residues

Chemsain Konsultant Sdn Bhd Page | C5-33 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION from the activity. Based on the current Jadual Pematuhan for the microwave operation, SW 501 shall be sent for disposal at a secured landfill e.g. Kualiti Alam, within 24 hours or may be required to be treated by incineration process. However, since the microwaves machines will only be in operation during incinerator shut down events, SW 501 will not be able to be treated via incineration process at the Project site as the fluff need to be treated within 24 hours. Furthermore, MSB is not able to store the residue for long period i.e., during the incinerator shutdown. MSB will arrange transportation to deliver the residue to a licensed premise, within 24 hours.

Other scheduled wastes such as spent lubrication oil (SW 305), spent hydraulic oil (SW 306), disposed containers, bags or equipment contaminated with chemicals, pesticides, mineral oil or schedule wastes (SW409), rags or filters contaminated with scheduled waste (SW410) used during maintenance activities will be handled and disposed off according to Environmental Quality (Scheduled Wastes) Regulations 2005.

5.7 Environmental Performance Status of Existing Healthcare Waste Treatment Plant

Reference was made to the Environmental Compliance Audit Report (RYSS/AUDIT/0218/1592) produced in February 2018 by RY Smart Solutions and Environmental Compliance Audit Report (AS 50/013/901/023/01/2017) produced in September 2017 by SFE Consultant Sdn Bhd (See Appendix 5.7.1). The main findings of the two audits showed that, MSB complied with most of the terms and conditions stipulated in the licensed approval conditions.

Among the documents reviewed during the documents verification include:

. DOE Site Visit Report . EIA records . Monitoring Reports . Notification and E-Swis record . Site layout plan and schedule waste storage area plan

During the February 2018 audit, there were four good practices identified, no non-compliances recorded and only one observation were identified.

Meanwhile during the September 2017 audit, there were four good practices identified, one non- compliance recorded and only one observation were identified.

Several non-compliances throughout the operation of the existing healthcare waste treatment plant are summarised in Table 5.7.1.

Chemsain Konsultant Sdn Bhd Page | C5-34 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

Table 5.7.1: Non-compliances during Operation of the Existing Healthcare Waste Treatment Plant

No Issue Action Done

1. Written Notice from DOE Melaka (Ref. No. . Perkhidmatan Arah (M) Sdn Bhd has ASMK(B)50/013/901/001 Jld 27 (15) dated 27 stopped the activity and the premise has January 2016 been closed in 2018 . Issue on bin washing activity . After the incident, bin washing are . at non licensed premise conducted at Kualiti Alam

2. Written Order from DOE Melaka (Ref. No.

ASMK(B)50/013/901/001 Jld 26 (28) dated 26

August 2016

. Issue on information required for update . The necessary information has been of Conditions under Written Notification provide to DOE Melaka

. Requirement to submit Written . The Project Proponent has decided not to Notification for IETS install IETS, therefore Written Notification was not submitted

. Requirement to submit Abandonment . Abandonment Management Plan was Plan for Incinerator submitted to DOE Negeri Melaka in May 2017 (see Appendix 5.3.1)

. MSB has replied with a letter (MSB- 3. Written Notice from DOE Melaka (Ref. No. WTP/ADM/JASMLK/PP/012018-003). ASMK(B)50/013/901/001 Jld 29 (08) dated 9

January 2018 Actions taken: . Operation of treatment plant over licensed 1. Treat clinical waste with licensed capacity in August, September, October capacity and November 2017 2. Send excessive clinical waste to Kualiti Alam for treatment or store in Cold Room available at site. 3. Request DOE to expedite in processing the Written Notification application the second microwave machine.

Chemsain Konsultant Sdn Bhd Page | C5-35 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

5.8 Project Activities

Development of the Project will involve the following activities:

. Pre-Construction Stage . Construction Stage . Operation and Maintenance Stage

5.8.1 Pre-Construction Stage

Pre-construction stage will include the appointment of consultants and surveyors. The activities during this stage include project planning and environmental assessment.

It is anticipated that the environmental risks range from no impact to low degree of significant impact during this pre-construction stage.

5.8.2 Construction Stage

The construction and installation stage is expected to have the following activities:

Mobilisation of Workers and Machineries

Mobilisation of Workforce [Project Manager – 1, Project Supervisor –1, General Worker (local and foreigner) – 15], Machineries and Construction Materials

Accessibility

The Project site is accessible via Lebuh AMJ/Route 19 – Lebuh SPA/ Route 33 – Jalan M9 – Jalan PBR 37.

Foundation Works

Some soil and foundation improvement works are anticipated especially at areas to be loaded with plant’s component. Earthwork will be very minimal since the site is a ready site. Typical foundation work includes piling. Most of these works apply typical construction methodologies.

Civil and Structure Works

Civil and structural works involve preparation of thermal treatment plant floor piling and slab, thermal treatment plant component delivery and installation of thermal treatment plant. Most of these works apply typical construction methodologies.

Mechanical and Electrical Works

Mechanical works, equipment installations and electrical works are necessary during the installation of all the plant equipment and components. These will include the necessary piping, electricity, material

Chemsain Konsultant Sdn Bhd Page | C5-36 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION and water supply connection with external sources. The environmental impacts from these activities are not significant although it is necessary to assess the occupational related hazards.

Testing and Commissioning

Components of the plant will be commissioned as they are completed. Various load tests and performance tests will be conducted once all the associated plant’s components are commissioned. During this testing and commissioning period, the operation mode will be fine-tuned and optimised where necessary.

Tests that will be carried out during testing and commissioning include:

. Start-up Inspection & Cold Test Run . Refractory Lining Curing Burn Run . Waste Feeding Test Run . Burn Test Run . Performance Testing under Full Load . Operation Training . Emission & Performance Test . Continuous Run Performance Monitoring . Operation Running Monitoring

Demobilisation of workers and temporary facilities.

On completion of the development of the Project, all temporary facilities holding will be removed from site and these shall also include any excess of construction materials and wastes.

5.8.3 Operation Stage

On commercial operation date, the Project will be operated by the existing operational team as follows:

. Senior Manager -1 . Plant Manager – 1 . Engineer – 2 . Technical Officer – 3 . Technician (Shift Leader) – 3 . Operator - 3

The organisation chart is shown as Figure 5.8.1.

Chemsain Konsultant Sdn Bhd Page | C5-37 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

Figure 5.8.1: Existing Operation Team-Organisation Chart

Operation of the Project is largely automated and control via process control system. Other important activity during the operation stage is transportation of healthcare wastes. Maintenance activities will be carried out as per schedule. The maintenance activities are:

Regular Maintenance

The Regular Maintenance is essential to ensure that the plant continuously operates at optimum level. This generally involves the following:

. Cleaning of the various parts of the plant (pumps, air compressor, pneumatic cylinders, etc.) . Greasing of various components (wheels, ram, guillotine doors, etc.) . Filling up oil for the various pneumatic systems . Various other checks for potential issues

Chemsain Konsultant Sdn Bhd Page | C5-38 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019

CHAPTER 5 – PROJECT DESCRIPTION

Scheduled Maintenance

Every year (even two years depending on how the plant has been maintained), there will be need for a major shutdown (Scheduled Maintenance). Amongst the key areas are the patching / repairs of refractory, checks and servicing of the burners and cleaning up the heat exchanger.

5.8.4 Abandonment Stage

Abandonment can occur at any stage of a Project. There are various possible causes of Project abandonment. Abandonment during planning stage will not result in any significant financial losses other than the costs incurred for the undertaking of various studies and planning. Abandonment during the construction or the operation stages requires the Project Proponent to consider plans for removal and/or disposal of temporary structures and facilities. In addition, restoration plans and works for the Project area after the cessation of the Project will have to be undertaken. However, for this development, Project abandonment is very unlikely in view of the market demands as well as the Project Proponent’s sound management and financial background.

5.9 Project Implementation Schedule

Upon completion of the detailed engineering design, and subjected to relevant Government authorities (including the approval of this EIA study by DOE), construction would then commence. The thermal treatment plant is scheduled to operate in 2021. The project implementation schedule and key milestone are appended in Appendix 5.9.1.

Chemsain Konsultant Sdn Bhd Page | C5-39 Revision No. : 0 CK/EV803/8026/18 Revision Date : July 2019