Final Report

Feasibility Study for Organic Waste Diversion & SLCP

Avoidance in Penang, Malaysia

Final Report

31 March 2017

KANSO Co., Ltd.

For Global Environment Centre(GEC)

Supported by:

Contents

Ⅰ．Contents of the project ...... 1

1. Project name ...... 1

2. Objectives...... 1

3. Scope of works ...... 1

3.1 Activity 1 – Feasibility study for Material Recovery Facilities (MRF) and Bio-Digester at the Pulau Burong landfill site ...... 1

4. Risk assessment ...... 2

5. Dispatch landfill concessionaire/operator for Technology training in Japan and presentation in the stakeholders’ workshop ...... 2

6. Study period ...... 3

Ⅱ. Study results ...... 4

Activity 1 – Feasibility study for Material Recovery Facilities (MRF) and Bio-Digester at the Pulau Burong landfill site ...... 4

1. Characterization of wastes ...... 5

2. Obtained values in the study for FS ...... 18

3. Material recovery facility (MRF) and biodigester ...... 19

4. Estimation of CH4 reduction and SLCPs reduction converted to CO2 ...... 21

5. Building and proposing appropriate business model ...... 22

6. Facilities for better recycling ...... 27

7 Realistic scale ...... 29

8. Rough estimate of construction cost ...... 31

10. Comparison of methane recovery installation cost with incineration ...... 44

11. Available technologies developed by Japanese manufacturer regarding methane recovery ...... 45

Ⅲ. Others ...... 45

1. Risk assessment ...... 45

2. Dispatch presenter for technology training in Japan and presentation in the stakeholder’s workshop ..... 48

2.1 CCAC-3 Technology Training in Japan ...... 48

2.2 Workshop in Penang ...... 49

3. Conclusions ...... 50

4. References; ...... 50

5. Attachments ...... 51

Ⅰ．Contents of the project

1. Project name

Feasibility Study (FS) for Organic Waste Diversion & SLCP Avoidance in Penang, Malaysia regarding CCAC Stage III of the “Organic Waste Diversion from Landfill and Avoidance of Short-lived Climate Pollutants (SLCPs)” Under the Municipal Solid Waste Initiative (MSWI) of the Climate and Clean Air Coalition (CCAC) to Reduce SLCPs, in Penang, Malaysia.

2. Objectives

This FS is a part of the program to reduce Short-Lived Climate Pollutants (SLCPs) by Climate and Clean Air Coalition (CCAC) to implement Municipal Solid Waste Initiative (MSWI) with the objectives of enhancing waste management practices while reducing methane and black carbon emissions.

For Phase I and II of the initiative, GEC supported CCAC by assisting UNEP IETC conduct a “City Assessment” for Penang, Malaysia in the Stage 1 and prepare a report on Waste and SLCPs with analysis (2012- 2013). In the Stage 2 of the City of Penang, the state government of Penang developed an “Organic Waste Management Plan” and “Best Practices paper on organic waste management” (2014-2015). GEC was selected as an implementer of the Stage 3 activities, part of Phase III of the initiative, because its experiences and strong partnership with Penang developed through waste management projects since 2004.

KANSO has worked on potential to reduce SLCPs（mainly methane）through methane recovery and selected best practice/technologies to induce sustainable effects.

3. Scope of works

3.1 Activity 1 – Feasibility study for Material Recovery Facilities (MRF) and Bio-Digester at the Pulau Burong landfill site

3.1.1 Waste Characterization study

The study was implemented at landfill to determine the type and quantity of discards for 5 calendar days. This waste characterization study was done with MSW samples collected for a period of 5 calendar days from both Penang Island and Sebarang Perai. Furthermore, MSW samples were also sampled from 13 parliamentary constituencies. Collected samples were sorted out into the different categories; weighed and recorded e.g.

recyclables consisting of paper products, plastics, ferrous metals, non-ferrous metals, organic waste and residuals for final disposal etc.

3.1.2 Feasibility Study of appropriate MRF and bio-digester technologies

With the aim of providing flexibility for future expansion and upgrading with new MRF technology, the following matters were studied in this FS.

1) Appropriate MRF technologies for inorganic wastes

2) Bio-digester technology for organic waste, and carry out the

3) Estimation of reducing emissions of methane gas as CO2 by producing biogas (mainly methane gas).

3.1.3 Building and proposal of appropriate business model

The feasibility of bio-digester technology for organic waste will be identified with a possible business model including design of an appropriate MRF, bio-digester in Pulau Burong landfill.

4. Risk assessment

Major risks including stakeholder participation and the process in the identification of the appropriate technology and affordability associate with the project activities and the likelihood of their occurrence, were assessed.

5. Dispatch landfill concessionaire/operator for Technology training in Japan and presentation in the stakeholders’ workshop

The landfill concessionaire/operator was sent for the technology training organized by GEC. The training was held on December 2016 to support the landfill operators and governmental officer assisting in learning technology operation and maintenance, including environmental impact, engineering design and business models in Japan.

The stakeholders’ collaborated workshop was organized by GEC and the Penang state government. The stakeholders’ workshop review the Stage 3 activities being implement under this agreement and pending activities. The next steps and how to replicate to other cities and countries are also discussed at the workshop.

6. Study period

Start date 1 July 2016

End date 31 March 2017

Ⅱ. Study results

Activity 1 – Feasibility study for Material Recovery Facilities (MRF) and Bio-Digester at the Pulau Burong landfill site

This FS aims at reducing amounts of municipal solid wastes (MSW) and short-lived climate pollutants, (SLCPs) in Pulau Burong landfill where is the place of the final waste disposal sites of Penang, Malaysia. Figure 2-1 indicates the outline of this FS.

Ⅰ：Material Recovery Facility (Separation and recovery) Ⅱ：Methane Fermentation Municipal solid waste Ⅲ：Efficient Use(Electricity, thermal recycle and so on)

Electricity / Thermal recycle Ⅱ Ⅲ Ⅰ

Methane Separation Recovery Efficient Use Fermentation Organic Waste Methane

Residue Residue / Waste water

Landfill Disposal / Drainage treatment

Remark: Red dashed square indicates the scope of this study.

Ⅰ・Ⅱ ⇒ Material recovery facility (MRF) and biodigester Ⅲ ⇒ Efficient Use

Figure 2-1 Schematic diagram of this study

At the Pulau Burong landfill site (Figure 2-2), potential of introducing Material Recovery Facilities (MRF) and biogas recovery facilities from separated wastes (mainly organic wastes) were investigated.

Ampang Jajar Waste

Transfer Station

Pulau Burong landfill

Figure 2-2 Study locations（cited from Google map）

1. Characterization of wastes

For collected and transported wastes into the study landfill, the type and amount were analyzed and evaluated according to the procedure shown in Figure 2-3.

1.1 Type and amount of wastes in the landfill

In order to evaluate a feasibility of biogas recovery, 500 kg of wastes brought into the landfill were studied (Figure 2-3). Wastes were separated into 12 types (Figure 2-4) and measured its weight. Moisture percentage as well as ash content were measured by the AOAC 923.03-1923, ash of flour direct method (Figure 2-5).

All samples brought in the landfill by 500kg will be the samples for separation test.

500kg of sample will be separated into the next

types.

Organic waste Non-organic waste

Organic Paper (OCC, ONP) Green waste Ferrous/N Plastic Others Clipboard on-ferrous PP PE PET HDPE HP

Weight ○ ○ ○ ○ ○ Moisture* ○ ☓ ☓ ☓ ☓

Moisture* - Drying by the oven

Figure 2-3 Outline of waste characterization study

Ⅰ．Waste separation

Before separation During separation

1. Organic Waste 2. Paper (OCC)

n.d

3. Paper (ONP) 4. GW + Woody C&D

Figure 2-4 (1) 12 types of separated wastes 7

5. Ferrous 6. Non Ferrous

7. Plastic (PP) 8. Plastic (PE)

9. Plastic (PET) 10. Plastic (HDPE)

Figure 2-4 (2) 12 types of separated wastes 8

11. Plastic (HP) 12. Others (Unrecyclable)

Figure 2-4 (3) 12 types of separated wastes

Ⅱ．Water & Ash Percentage

[Before Drying] [After Drying]

Figure 2-5 Moisture percentage measurement

Table 2-1 Results of waste composition study

Study date Island (MBPP) 8/25 8/26 8/29 8/30 8/31 average Organic Waste 45.1 68.1 39.5 44.9 68.3 52.3 Moisture 53.0 59.0 - - - (average) Paper (OCC) 2.2 6.8 8.0 1.4 - 3.4 Paper (ONP) - 1.4 - - 4.8 1.0 GW+Woody C&D 6.5 7.6 - 2.2 - 4.1 Ferrous 1.3 0.5 1.4 0.9 0.2 0.9 Non-Ferrous 0.1 0.1 0.2 0.0 0.0 0.1 Plastic (PP) 0.8 1.8 2.0 0.80 0.3 1.1 Plastic (PE) 8.8 11.1 11.9 9.0 7.9 9.6 Plastic (PET) 0.3 0.6 0.8 0.6 0.5 0.5 Plastic (HDPE) 0.1 0.7 0.1 0.3 - 0.2 Plastic (HP) 0.1 - - 0.7 - 0.2 Others 34.6 1.3 36.2 39.1 18.0 26.6 Waste net weight 609.69 662.37 622.18 709.22 592.43 [tonne]

Study date Mainland (MPSP) 8/25 8/26 8/29 8/30 8/31 average Organic Waste 52.4 44.4 34.3 41.2 38.2 43.9 Moisture 68.6 57.2 - - - (average) Paper (OCC) 1.6 1.6 6.1 5.7 3.9 3.4 Paper (ONP) - 0.8 - - 0.4 0.2 GW+Woody C&D 5.0 6.7 0.4 - - 3.0 Ferrous 0.8 0.4 1.2 0.8 1.1 0.9 Non-Ferrous 0.1 0.1 0.2 0.1 0.1 0.1 Plastic (PP) 0.6 1.0 1.3 0.5 0.5 0.8 Plastic (PE) 9.1 6.7 7.5 8.3 10.2 8.4 Plastic (PET) 0.5 0.2 1.2 0.3 0.5 0.5 Plastic (HDPE) 0.2 0.2 0.6 0.2 0.5 0.3 Plastic (HP) 0.1 - 0.1 - 1.4 0.3 Others 29.6 37.9 47.2 42.9 43.3 38.3 Waste net weight 1,217.11 1,260.96 1,481.59 1,384.21 854.16 [tonne] Source：Penang Waste Characterisation Study 2016, Infitech Machinery Sdn. Bhd. 10

Table 2-2 Summary of waste composition study

MBPP MPSP [%] Stdev [%] Stdev Organic Waste 52.3 13.9 43.9 6.9 Paper (4.4) (3.6) Organic OCC 3.4 3.3 3.4 2.1 ONP 1.0 2.5 0.2 0.3 GW + Woody C&D 4.1 2.9 3.0 3.3 Ferrous 0.9 0.5 0.9 0.3 Non-Ferrous 0.1 0.1 0.1 0.04 Plastics (11.6) (10.3) PP 1.1 0.8 0.8 0.4

Non-Organic PE 9.6 1.7 8.4 1.4 PET 0.2 0.4 0.5 0.5 HDPE 0.2 0.3 0.3 0.2 HP 0.2 0.4 0.3 0.7 Others (Non-recyclables) 26.6 16.0 38.3 6.8 Total 100.0 100.0

In 5 days of waste composition survey, % of organic waste was the highest (Figure 2-6) and almost invariable during 5 days measurement (Figure 2-7). % of organic waste composition was higher in MBPP (52.3 %) comparing to that of MPSP (43.9 %), reflecting different level of industrial development and economic condition between two regions. Among non-organic wastes, nearly 10 % is plastic in which PE occupies the largest proportion.

Organic waste

Paper

GW+Woody

Ferrous MPSP MBPP

Non-ferrous

Plastics

Others

-10.0 0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 Composition ratio (%)

Figure 2-6 Waste composition in 5 days study

Table 2-3 Comparison of waste composition between different years and with KL

Penang Kuala Lumpur This study 2003* 2011

[%] [%] [%] Organic Waste 48.1 41.9 42.6 Plastics 10.9 15.9 18.1

Paper 4.0 16.5 13.3 Green waste 3.5 11.0 4.1 Ferrous 0.9 4.2 2.2

Others 32.5 10.5 0.5

Source; *Satang for UNDP SWN Study Report 2007, **Min. of Environment, Japan government. FY 2011 Programme to support feasibility studies for overseas promotion of venous industries

When compared the results of this study with other similar studies, organic waste % was as high as those of 2003 waste composition study conducted by UNDP and those of 2011 Japanese government study in Kuala

Lumpur (Table 2-3). Omran et al. (2009) reported that food waste was the largest among MSW in Penang state in the studies conducted in 1996, 1997, 2003 and 2004. The tendency that organic waste is the largest component of the waste stream by weight has still be the same in Penang and which suggests a potential of recovering methane from organic rich MSW.

% of plastics, paper, green waste and ferrous was lower than those of 2003 study and of Kuala Lumpur which would be due to intensive recyclable activities. % of paper was only 4 % which drastically decreased from 16.5% in 2003. Most of paper and paper products are sold to newspaper vendors in Malaysia (Omran et al. 2009). Furthermore green waste has been increasingly utilized for tips and other biomass uses (NEDO 2015). These would have attributed to a significant decrease of these wastes.

Comparing to the composition data of 2003, organic wastes increased in MBPP but decreased in MPSP. Organic waste composition during 5 days survey has changed daily showing that % of organic waste was lesser amount but invariable in MPSP. A high fluctuation of organic waste % in MBPP may indicate that MBPP comprises a higher % of commercial sectors.

Figure 2-7 Daily change of organic waste % in 5 days study

Figure 2-8 Water and ash contents in organic wastes

A moisture content of organic waste was relatively high exceeding over 55% both in MBPP and MPSP (Figure 2-8). Since a high moisture content of MSW affects a transportation cost, many of municipalities place an effort in reducing moisture content. To reduce moisture content, it would be indispensable to have cooperation from households since which is the major source of organic waste. Considering that organic wastes from households normally contains a few % of ash, a high ash content in organic wastes (Figure 2-8) indicates organic wastes contain not only garbage trash but also rubber, leather, clothes.

Chemical constituents of organic waste were not analyzed in this FS but more detailed chemical analysis will be necessary when implementation design for methane recovery is needed.

13 parliamentary

area

October 2016

Source：Penang Waste Characterisation Study 2016, Infitech Machinery Sdn. Bhd.

Figure 2-9 Locations of the waste separation study in Penang (Plau Burong landfill, 13 parliamentary areas)

Waste composition was studied at Penang, 13 parliamentary areas on October 2016 (Figure 2-9). Table 2-4 indicates the results of waste composition study conducted in October 2016 at 13 parliamentary areas of Penang. Values in the table are indicated as the mean values of the weekday and weekend, respectively. Although some areas such as Tanjong showed relatively low percentage of organic waste, % of organic waste was almost identical among areas (Table 2-4). A difference of % of organic waste can be influenced a degree of urbanization. For example, Tanjong is less populated with lower degree of urbanization, therefore generates less amount of organic waste.

Table 2-4 Results of waste separation study conducted at MPSP and MBPP

Seberang Perai (MPSP) Kepala Tasek Permatang Bukit Batu Nibong Bagan Batas Gelugor Pauh Mertajam Kawan Tebal Organic Waste 52.8 54.9 59.6 45.9 48.5 39.1 35.7 Paper (OCC) 1.8 2.8 3.2 3.7 3.4 5.4 5.5 Paper (ONP) ------GW+Woody C&D 0.7 0.3 0.4 - 0.4 - - Ferrous 1.2 0.7 0.7 1.4 2.0 0.4 0.5 Non-Ferrous 0.7 0.2 0.3 0.1 0.1 0.2 0.3 Plastic(PP) 1.6 1.4 1.3 1.3 0.8 0.9 1.0 Plastic(PE) 6.6 5.6 5.4 4.7 7.9 6.4 8.1 Plastic(PET) 1.0 1.4 0.9 1.0 1.9 0.6 1.0 Plastic(HDPE) 0.4 0.6 0.5 0.4 0.8 0.3 0.3 Plastic(HP) - 0.2 - - - - 0.1 Others 33.2 32.1 27.9 41.6 34.0 46.7 47.5 Total 100.0 100.0 100.0 100.0 100.0 100.0 100.0

Penang Island (MBPP) Bukit Bukit Bayan Balik Tanjong Jelutong Bendera Gelugor Baru Pulau Organic Waste 48.7 31.8 38.8 42.4 43.9 44.9 Paper (OCC) 3.8 5.0 1.7 1.0 6.0 0.8 Paper (ONP) - - 0.2 - - 0.2 GW+Woody C&D - 0.2 0.2 0.5 0.4 0.2 Ferrous 0.9 1.7 0.6 0.5 0.8 1.9 Non-Ferrous 0.2 0.2 0.3 - 0.2 0.1 Plastic (PP) 0.8 1.3 1.6 1.3 1.1 1.5 Plastic (PE) 8.3 8.6 5.7 6.4 17.0 6.5 Plastic (PET) 1.1 0.8 1.1 0.9 1.1 0.7 Plastic (HDPE) 0.4 0.5 0.5 0.3 0.1 0.4 Plastic (HP) 0.4 0.3 0.8 - 0.1 - Others 35.4 49.7 48.6 46.7 29.2 42.9 Waste net weight 100.0 100.0 100.0 100.0 100.0 100.0 [tonne] Source：Penang waste characterization study repot 2016 16

Based on the data of Table 2-4, mapping for different composition of MSW was made. Organic waste was more generated in the north regions of MPSP (Figure 2-10) and ferrous in the west part of island and the middle of mainland. Paper and plastic were likely to be higher at the urban areas.

Figure 2-10 The composition of generated wastes according to the region

2. Obtained values in the study for FS

Waste composition study provided necessary values for conducting feasibility study to evaluate potential of methane recovery in the Pulau Burong landfill. Hereinafter values shown in Table 2-5 are used for examining recycle in the landfill and for estimating methane recovery in the landfill.

Table 2-5 (1) Used values for estimating methane recovery in the landfill

(Actual condition)

Item Value Remarks Amounts of wastes brought into the 1,800t/day Based on oral interviews and literature landfill Separated wastes 250t/day Based on oral interviews Ratio of organic waste 48.1% From Table 2-1 Water content of organic waste 60% ditto Solid ratio of organic waste 40% ditto Sorting work force 10 persons/shift Based on hearing, 3 shifts

Table 2-5 (2) Used values for estimating methane recovery in the landfill

(Expectation)

Item Value Remarks Amounts of wastes brought into the 2,450t/day Based on official population statistics landfill Effective % among all collected 10% Based on past experience organic wastes for methane recovery Organic matter solids for methane 20t/day recovery

3. Material recovery facility (MRF) and biodigester

3.1 Sorting facilities for non-organic wastes

MRF, crushing sorting machine which has been used in Nantan Clean Center, Hyogo, Japan can be considered as adequate model and to be introduced in the landfill. In this Center, 6 different procedures are integrated to collect waste materials which are 1) separation unit, 2) rotary crusher, 3) magnetic collection machine, 4) particle size sorting machine, 5) aluminum sorting machine, and 6) hand sorting conveyor (Figure 2-11, 2-12). Among which 1) separation unit has original crushing procedures composed of two different crushing steps. The first step is the crushing by the biaxial crusher and followed by the crusher as the second step. If this machine is installed ahead of belt-conveyer in the study landfill, sorting efficiency will be improved. The manufacturer of this machine is Matsumoto Iron Works Inc. Nominal treatment capacity is 38t/d and there is no bigger capacity than this. This company currently doesn’t sell this machine to overseas, however Moki Co., Ltd which is introduced in page 35 has same technology and can provide in Malaysia

Shaft for Blade Casing Blade Hammer Hammer Crushed Waste

(From two-axial crusher)

Residue

Blade Hammer

Running Drive Axis Former Screen Latter Screen Organic Waste

Stopping

Methane

Fermentation

Screen

Figure 2-11 A high efficient crushing and sorting machines in Nantan Clean Centre, Hyogo, Japan

1.Rotary crusher 2. Magnetic cobbing machine

3. Particle size sorting machine 4. Aluminum sorting machine

5. Hand sorting conveyor

Figure 2-12 The facilities in the Recycle Centre of Nantan Clean Centre, Hyogo, Japan

4. Estimation of CH4 reduction and SLCPs reduction converted to CO2

In order to assess Greenhouse Gas (GHGs) and Short Lived Climate Pollutants (SLCPs) (such as black carbon) from waste management and then to identify suitable alternative solutions in order to develop climate friendly waste management systems, the CCAC MSWI emission quantification tool was used. This tool was developed by the Institute for Global Environmental Strategies (IGES) for the Waste Initiative.. Using this tool,

CH4 and SLCPs reduction due to methane recovery were estimated (Figure 2-13)

Business as Usual (BAU) Methane recovery (20t/day organic waste)

Collected waste Collected waste (807,455 ton/year) (807,455 ton/year) Composting Composting (0 ton/year) (0 ton/year)

Anaerobic digestion Anaerobic digestion Treatment of (0 ton/year) Treatment of (7,300 ton/year) separated waste separated waste Recycling Recycling (179,789 ton/year) (179,789 ton/year)

MBT MBT (0 ton/year) (0 ton/year)

Treatment of Treatment of Incineration Incineration remaining mixed remaining mixed (0 ton/year) (0 ton/year) waste waste

Landfilling Landfilling (714,461 ton/year) (707,162 ton/year)

Figure 2-13 Amounts of material at each operation at business as usual (BAU) and methane recovery

4.1 CH4 reduction

Two different scenarios were considered in this tool, one is the case for using 20 ton/day organic waste in methane recovery and another is 40 ton/day. At present methane emission level is 931,111 kg/month since all organic wastes disposed in the landfill emit methane continuously. If 20 ton/day organic waste is used for methane recovery, net climate impact of GHGs are 112 tons of CO2-eq/month and which increased to 228 tons of CO2-eq/month if organic wastes to use for methane recovery increases from 20 to 40 ton/day (Table 2-5).

4.2 SLCPs reduction

Figure 2-14 indicates impact of GHGs (CO2 equivalent) by methane recovery. 40 ton/day (Scenario 2) was almost double than 20 ton/day (Scenario 1) in terms of GHGs reduction. CO2 reduction by different level of recycling was estimated (Table 2-7). Currently, not all of plastics are recycled, around 80% of PE and HDPE are possibly collected. If all of these PE and HDPE are recycled (Scenario 1), 2159.6 ton CO2-eq/month can be reduced. And if all types of plastics are recycled, 3515 ton CO2-eq/month will be reduced.

Net climate impact from AD 50.00

0.00 BAU Scenario Scenario Scenario Scenario -50.00 1 2 3 4

/month) -100.00

-150.00

Net climate impact (Tonnes (Tonnes impact climate Net Net BC emissions (tonnes of BC/month) -200.00 Net climate impact of GHGs (tonne of CO2-eq/month)

-250.00

Figure 2-14 Net climate impact of GHGs (CO2 equivalent) by methane recovery

Table 2-6 Estimation of CH4 reduction and SLCPs reduction using the emissions quantification tool Scenario 1 Scenario 2 Unit

SLCPs CH4 Emissions CH4 biogenic-Direct (unavoidable leakages) 16,800 33,600 kg/month

CH4 fossil-Direct (fuel consumption) 5 5

Other CO2 Emissions Direct (fossil fuel consumption) 4,525 4,525 GHGs Avoided Through electricity production 133,381 266,762 Net impact Net climate impact of GHGs -112.0 -228.6 tonne of CO2-eq/month

Table 2-7 Estimation of CO2 reduction by different level of recycling Recycled amount CO2 reduction Case Conditions [t/month] (t-CO2-eq/month) Businesss as usual 80% of PE and HDPE are recycled 7,925 - Scenario 1 All of PE and HDPE are recycled 9,950 2159.6 Scenario 2 Plastics are all recycled 11,102 3515.0

5. Building and proposing appropriate business model

In order to design appropriate facilities for methane recovery, current operation in Plau Burong landfill shall be understood because it can only clarify which factors are important to enhance organic wastes recovery rate. 5.1 Current situation According to the statistics for Penang, population has increased around 13% in 6 years from 2010 to 2016, exceeding 1.8 million. Assuming that amount of waste is correlated with population, amount of daily waste in 2016 would be 2,450 ton (Table 2-8). Moreover, 49-months record from July 2012 to July 2016 (Source; PLB, 2016) showed the mean daily waste as 1,753 ton (1,518 – 1,969 ton) which is almost stable with ±13% without seasonal fluctuation. A mean daily waste as of October 2016 was 1,800 ton/day (from hearing by KANSO mission team). Nevertheless there are different figures, we adopted a daily waste amount, 2,450 ton/day in this FS. 22

Table 2-8 Statistical Data of Penang state (2010/16) MBPP MPSP Total Unit 2010 Population 741,300 868,500 1,609,800 Annual waste 261,599 528,275 789,874

Waste per capita 0.97 1.47 kg/capita/day Daily amount 716.7 1,447.3 2,164 ton/day

2016 Population increase 1.9 2.2 rate (%) Population increase (%) between 2010 and 11.9 13.9 2016 Population 829,500 989,200 1,818,700 Annual waste 292,729 601,392 894,121 ton Waste per capita 0.97 1.47 kg/capita/day Daily amount 802.0 1,647.6 2450 ton/day

5.2 Estimated organic waste amount 5.2.1 Ratio of organic waste among total MSW Organic waste composition which was measured for 5 days during 25 – 31 August 2016, was 48.1％. Applying this ratio, the following daily amount of organic waste was obtained,

2,450 × 0.481＝1,178 t (1)

This amount is expressed as wet basis meaning that there still contains a high percentage of water. In addition, it contains inconvenient materials such as chips, coconut shell which are highly resistant to methanogen digestion.

Population in MBPP and MPSP as of 2016 was 829,500 and 989,200, respectively which totaled up to around 1,820,000. With the daily amount of MSW, MSW per capita is calculated as

2,450,000 kg ÷ 1,820,000 people＝1,347g/person day

Daily amount of organic waste per capita is estimated from the ratio of organic waste, 48.1 %.

1,347 g × 0.481＝ 648 g/capita, day (2)

In the outline survey for MSW in Japan (Min of the Environment, Gov of Japan 2011), the daily amount of MSW per capita is regarded as 1,000 g/person day and that of food waste as 500 g/person day. In 500 g, 40 % are considered as inadequate materials for fermentation.

5.2.2 Effective amount for fermentation Fluidity influences fermentation intensity in a tank. It is difficult to remove organic wastes from wastes having a high moisture content, therefore 10 % of organic wastes are presumably used as effective amount for fermentation. 1,178 t which are classified as organic waste, contains 60% of water content (from actual measurement done in this FS), thus solid content is

1,178 t × 0.40 = 471.2 t (3)

As effective part for fermentation is considered to be about 40％,

471.2 t × 0.40＝188.5 t (4)

Around 10% is the amount which is able to collect after all mixed organic wastes pass through classifier.

188.5 t × 0.1 = 18.9 t ≑ 20 t (5)

As a consequence, 20 t was used for facility design in this FS.

5.2.3 Estimation of methane gas generation 20 t of dry organic waste is regarded as 100 t of wet organic waste if moisture content is 80%. Amount of biogas generation varies depending on composition of fermented materials. Then sampling test to check gas generation and fermentation is normally performed using known waste composition in a real plant design. In this FS, most of extracted organic waste are assumed to be from household origin. According to several reports, organic wastes derived from household normally produce 110. 3 Nm3/t of biogas.

110.3 Nm3/t × 100 t =11,030 Nm3 (6)

5.2.4 Estimation of electricity generation Calorific value of methane is 9.95kWh/Nm3. Assuming that 60% methane and 30% generation efficiency, one ton of organic waste produce the following amount of electricity

110.3 Nm3/t × 0.6 × 9.95 kWh/Nm3 × 0.3 ＝197.5 kWh/t (7)

100 t of wet organic waste could generate the following amount of electricity

197.5 kWh/t ×100 t = 19,750 kWh (8)

Therefore, generation capacity is

19,750 kWh/24h＝823 kW (9)

As a result, power generation equipment would be 1,000kVA～1,500kVA

Above procedures for calculating generation capacity of electricity were summarized in Table 2-9 and Table 2-10.

Table 2-9 Values used for electricity generation by methane recovery（measured values） Item Value Remarks Amounts of wastes 2,500 t/day According to statistics brought into the landfill Ratio of organic waste 48.1 % From this waste separation study Water content of organic 60 % From this study waste Solid ratio of organic 40 % in-situ measurement waste

Table 2-10 Values used for electricity generation by methane recovery（predicted values） Item Value Remarks

Effective part for methane 40% According to Japanese fact fermentation % of organic waste to be 10% According to the previous slide separated for fermentation Organic matter solids for 20 t/day calculated from predicted available amount of methane recovery (dry base) organic waste (10%)

Biogas generation 3 3 11,030 Nm 110.3 Nm x 100 t (wet base of 20 t/day)

Amounts of electricity 19,750 kWh 3 Calorific value of methane; 9.95 kWh/Nm , 60%

of methane content, 30% of generation efficiency Generation capacity 823 kWh 19,750 kWh/24h

5.3 Scale of the expected facilities When track records are compared, nominal receiving amount of each facility is expressed as facility capacity. However, this capacity doesn’t necessarily define exact facility capacity and scale of facility. Normally nominal receiving amount is calculated from loaded values indicated at collection vehicle regardless of what kind of waste are collected. Waste composition made from unspoken agreement is used for this calculation. Consideration is made individually for moisture content of target waste. MSW are composed of all kinds of wastes. As was measured in this FS, 60 % is the typical moisture content, and upon which dry solid weight and ash content are measured. Moisture content is fixed for particular food waste, animal manure, sewage. They are transported by special container so then their moisture content is normally higher than MSW. Facility design was made based on 280 days. 280 days makes possible to maintain treatment capacity. Annual value therefore would be 130 % of calculated value (≑ 365/280). Scale of attached facilities like recycling facility will be decided base on this concept.

5.4 Basic calculation 5.4.1 Dry type and Wet type Methane recovery has two types, “Dry” and “Wet”. Dry type promotes fermentation under low moisture content (80%) while Wet type with higher liquidity above 90% of moisture content. Both type has different

characteristics and main difference is the stirring power. 5 – 10 higher capacity in Dry type leads to bigger scale of mechanical and electrical facilities. Wet type demands a larger amount of water to reduce solid waste concentration, consequently generates larger amount of fermentation liquid. Historically, Dry type has been developed by heavy industry company while Wet type by water treatment company. Maximum receiving capacity is 50 t/day in Dry type and 100 t/day in Wet type. Considering track records for the project facility, Wet type would be better for this project.

5.4.2 Volume of fermentation tank 95% water content is for the design. Adding water for 20 t organic waste to make 95% water content, one day capacity is 400 m3. Since fermentation period is ranged from 20 to 30 days, total capacity of fermentation tank is

400 m3 × 20 = 8,000 m3 (10)

Initial scale of fermentation tank is better to be larger than 8,000 m3, then

8000 m3 ×1.3 = 10,400 m3 (11)

Considering workability and stirring efficiency, 2,600 m3 × 4 unit can be recommended.

5.4.3 Capacity of gas holder Amount of gas storage differs is determined by applied method and gas consumption. Size of gas holder becomes smaller in case of continuous use. Minimum 1 day capacity shall be secured for the capacity of gas holder in order to cope with fluctuation of user demand and to keep minimum required pressure. As the inner pressure is around 20 kPa, 4 holders with 500 m3 of one each can be installed.

5.4.4 Size of the tank Spiral-type steel tank has an advantage in terms of workability and cost. This type has maximum capacity of 10,000 m3 but its diameter becomes bigger than 25 m to reinforce a strength against pressure given from the lower parts when liquid is filled in. 25 m is inadequate for fermentation tank in terms of reinforcement of the ceiling strength and efficient flowing of waste materials in the tank. Considering track records on the tank, a size of tank would be 16 m of diameter, 15 m of height with 3,000 m3 of the volume. Initial number of tank will be 4 and which can be increased in a response to future demand.

6. Facilities for better recycling

Recycle system shall be designed comprehensively. From counter-measure against waste generation till recycling of wastes, overall system shall be made in well-balanced and maintained to avoid generation of extra 27

cost and to prevent interference on system construction. First step shall be placed on waste separation at waste source since separation at waste source enables to collect and transport waste individually. In addition, a high level separation makes possible to establish collection station for respective type of wastes. A large number of trials for enhancing waste separation at source has been made worldwide. Since local condition varies a lot depending on the country and the region, universal method must haven’t exist. However, separation system should be constructed so as to provide easy method to people. Abiko city, Chiba prefecture, Japan has been providing the trash bag specified by each category of recyclable wastes, and succeeded in saving a tax through proper waste separation (Ozawa, 2012). Nakano ward, Tokyo, Japan conducted questionnaire survey towards inhabitants of the ward and squeezed out particular age group who is not keen on separating wastes (Nakano ward, 2007). Nakano ward then made specific measures towards that group by designating waste collection day and time which are convenient for them. Moreover if recycling is perceived as beneficial by people, separation will be accelerated. In several municipalities, gained money from recycling has been used for civic life like development of a park. Household garbage in Abiko city is composed of 38 % of paper/cloth in recyclable wastes (Ozawa, 2012). Implementation of fee-charging on household garbage ensured waste separation due to economic incentives.

6.1 Receiving at treatment station Together with individual separation, collection, receiving at a treatment station shall be done along the same separation line. Separation varies its difficulties depends on waste type. PET and PE are relatively easy to separate even at a disposal stage. Therefore, many countries commence first separation from these to process recyclable resin. A high moisture content of organic wastes frequently becomes problem in separation. Organic wastes are collected together with other type of wastes in current practice so that a significant amount of organic waste adhere into others and become inseparable. If complete separation of organic waste from others is achieved, methane recovery will be significantly improved. However complete separation/collection of organic waste is quite rare and not many cases in the world.

6.2 Improvement of separation

Problem lies in no complete breaking of plastic bags in the landfill. Normally bag breaking facility is allocated before Trommel separation machine to remove all wastes from bags immediately after waste disposal. Incomplete breaking of plastic bags reduce efficiency of mechanical separation and unbroken bags reach to the stage of hand separation. Allocating bag breaking machine at most beginning stage of separation and adjustment of mesh size of Trommel separation machine may improve separation efficiency nevertheless all together collection has always a certain limitation for improvement.

Currently around 10 % of total organic wastes is considered to be effective amount for fermentation but 10 %

will increase to 20 % by an improvement of separation capacity.

188.5 t × 0.2 = 37.7 t ≑ 40 t (if separation capacity is improved) (12)

7 Realistic scale

Collected amount would be 20 t which is 10% of total organic wastes, as judged by current level of separation in the site. For this amount, 2 units of fermentation tank (or 4 units for the case of 5% materials) are ideal for methane recovery. If collected amount increases by improvement of separation capacity, it will increase to 4 units at 10% to the upper limit.

7.1 Outline of separation and methane recovery facility installation

The area nearby passageway to the landfill is designated as separation yard. 10 separation conveyer with the same scale as the current one are allocated at the lower part of each conveyer for accumulation of wastes in the hopper. Separation will be conducted both by Trommel and hand separation which is the same as the current practice. Consideration should be paid to organize vehicles on separation yard where carry-in and -out vehicles are moving. Organic wastes are directly loaded into wet type tank by conveyer at adjacent methane fermentation facilities.

7.2 Separation yard

7.2.1 Separation process

Recyclables are gathered in the hopper nearby passageway and taken out outside the landfill. Among recyclables, only plastics are processed to make pellets in the station. Organic wastes are gathered in the hopper nearby methane fermentation yard and brought into methane recovery process. Wastes are collected by the categories which are organic waste, ferrous, non-ferrous, HDPE, LDPE, PET, PP and paper. Remaining from these are gathered in the hopper and disposed in the landfill. Individual separation line will be utilized once recycling process for each category is established. Laborers for separation will work on the platform installed alongside the conveyer. Height of the platform will be 2 m and conveyer by category is operated. Basic design of the line is not so different from the current line. Important is to improve efficiency of Trommel through complete breakage of bags achieved by breaking bag machines. If an introduction of breaking bag machines doesn’t improve efficiency of Trommel, use of Trommel shall be re-considered.

7.3 Breakage and crushing separation machine

This machine installed in Nantan Clean Center is manufactured by Matsumoto Iron Inc. Moki Co., Ltd. has been producing the breakage and crushing separation machine as same capacity as, or more than that of Matsumoto Iron Inc. Their products have a high separation performance with 99.9 % of the precision level. There are a number of models having different waste treatment capacities ranged from 200 kg/hour to 8 ton/hour.

7.4 Fermentation yard

7.4.1 Mixed water

Supernatant water in the lagoon is basically used for fermentation with a premise that affected substances for fermentation are not included in water. 200 m3～400 m3 of mixed water are necessary per day. It is expected to store water of one week volume for settling down sediments. 2,000 m3 of water are induced from lagoon into the receiving tank. At the flowing tank, water will be mixed with organic wastes and adjusted to concentration (initially 90% of moisture content) at mixture tank (3,000 m3) after removal of solid from bags. Storing water of 10 days volume will homogenize irregularity of mixture ratio occurring at onset of mixing.

7.4.2 Fermentation tank and peripheral equipment

Install 4 units of fermentation tank with each of 2,600 m3（16 mφ×15 mH）. Try first with 2 units when moisture content is 90% to check how it goes. If inclusion of solid material is significant, regular cleaning is necessary but if not, continuous operation for a couple of years is possible.

Sludge of brewery factory is normally used as seed sludge however manure (ex. Pig manure) can be replaced for it.

Fermentation gas is stored in gas holder after passing through desulfurization equipment. Size of gas holder can be decided depending on a size of generator and operation frequency. Recommended gas holder is seal, bilayer type equipped with surplus gas combustion device which can respond an increased inner pressure caused by surplus storage.

7.4.3 Heating boiler

Heating boiler will be installed to keep stable mesophilic fermentation (35℃) and which can be operated when necessary. Fuel type would be heavy oil, light oil, purified waste oil, biogas, or their mixture.

7.5 Power generation facility

20,000 kWh can be generated from organic wastes. As there is no grid in the project site, sale of electricity through grid connection is not feasible. The fact that a sale of electricity into the grid requires stable supply is another reason for infeasibility. Instead self-consumption within the facilities makes it possible to establish a maximum hourly power consumption according to a duration of separating operation and to operational status of recycling facilities. For the case facility is only operated at daytime, it would be 3 units of 1,000 kVA gas power generation and 1 unit of diesel generation.

7.6 Digestion liquid

Digestion liquid generated in fermentation tank shall be treated periodically. Theoretically, same amount as fermenting raw material (≒200 – 400 m3) is necessary to be treated. If there is a demand for agricultural use, digestion liquid can be used as fertilizer liquid. However, such a demand is not expected in the project site, thus water treatment will not be conducted to discharge outside of the landfill. A digestion liquid is transported by either tank truck or pumping with pipeline and discharged in the landfill.

Discharge method influences how much digestion liquid is stored within the plant. Storage facility to keep digestion liquid would be over one month volume (≒6,000 m3). If possible to transport continuously and/or frequently, small tank would be sufficient. If a demand for fertilizer liquid occurs in the future, large tank will be necessary.

8. Rough estimate of construction cost

Calculation of overall construction cost is rather difficult. One reason is that most of Japanese manufacturer cannot provide a service for export so that cost estimation only can be made in domestic basis. Unit construction cost differs between Japan and Malaysia. Costs of construction materials fluctuates and access to construction site, ground condition also influence overall cost. Hereinafter, construction cost is estimated as the case in Japan.

8.1 Cost estimation by each step

1st step

Utilize the current line and install breaking bag machine at the most upper part of flowing line in order to

improve efficiency of organic waste collection

2nd step

Add new separation line including breaking bag machine at new area.

3rd step

Add collection conveyer line at each category of wastes and install hopper at the end of the line.

4th step

Construction of methane recovery facilities which are mix water facility, methane fermentation tank, desulfurization tower, power generator, discharge facility of digestion liquid.

Table 2-11 (1) Cost estimation according to the step

Rough STEP Outline estimation Remarks ［million yen］ 1 Basically the existing line is used 40 Installation of bag breaking machine and add newly breaking bag including hopper and conveyer machine at the most upper part of the line 2 Add 1 new separation line 70 Separated waste by category is including breaking bag machine at collected in bag. Platform as working new area place is included.

3 Install the collection conveyer 300 9 conveyer and hopper by category. lines for each categorized waste Organic wastes are conveyed into the and the hopper at the end of the inlet of methane fermentation facility line 4 Construction of methane recovery 6,000 Overall methane fermentation facility facilities including mix water including maintenance room facility, fermentation tank, desulfurization tower, power generation facility and digestion liquid discharge facility

Table 2-11 (2) Electricity expense and labor costs

Electricity expense Source USD（RM） Electricity USD 0.08/kWh Tenaga Nasional Berhad 2013 （ Overseas electricity expense (Grid）（RM0.33/kWh） statistics 2015） JAPAN ELECTRIC POWER INFORMATION CENTER " ; JEPIC Labor cost USD317/person, month The Bank of Tokyo-Mitsubishi UFJ, Ltd (BTMU) Global Business Insight Area Report 432 USD1.00＝RM4.0495（As of 30 August 2016）

Table 2-11 (1) shows rough cost at each step. Electricity consumption will be increased coupled with installation of facilities. Electricity expense and labor costs are indicated in the Table 2-11 (2).

［1st step］ To the existing line, add newly breaking bag machine at the most upper part of the line and biaxial crusher. And changes on collection efficiency of organic waste will be monitored. Introduction of these facilities is likely to improve recycle rate of polybags and to reduce labor costs and landfilling costs (Figure 2-15) while depreciation costs and operation/maintenance costs will increase due to these installations.

Existing line

New breaking bag machine

Figure 2-15 Installation of new breaking bag machine makes in 1st step

Although the breaking bag machine is already installed in Pulau Burong landfill, wastes are not properly separated due to incomplete breakage of plastic bag (Figure 2-16). According to the waste separation study, approximately 23 t/day of PE at maximum can be recycled. However much less amount of PE have been recycled due to insufficient collection. Installation of appropriated breaking bag machine could enhance amounts of recycled materials as well as those of organic waste which relate with methane recovery.

Incomplete breakage of plastic bags

Figure 2-16 Incomplete breakage of plastic bags

9. Introduction of breaking bag and crushing & sorting machines A number of breaking bag and crushing & sorting machines has been manufactured by companies. The crushing method varies among machines depending on a type of target material. Table 2-12 demonstrates those machines manufactured in Japan.

Table 2-12 Breaking bag and Crushing & Sorting machines made in Japan Type Name Manufacturer Breaking bag machine PB12-16 Pioneer Gisetsu Co., Ltd. HTP-15S Osaka NED machinery Co., Ltd. Crushing and sorting machine MK2208 Moki Co., Ltd.

1) Pioneer Gisetsu Co. Ltd. (http://pioneer-gisetsu.co.jp/) This is efficient breaking bag machine (Figure 2-17) which can enhance collection rate of PE bag by installing before the existing conveyer. Specification is indicated in the Table 2-13.

Figure 2-17 PB12-16

Table 2-13 Specification of PB12-16 Type Size[mm] Motor[kW] Speed[t/h] Price[RM] PB12-16 7500 x 1700 7.5 10(max) 0.6mil.※ ※Price at hand-over at factory

From Hopper DirectionDirection of of flow flow

Air cylinder

Figure 2-18 Principle of breaking bag, PB12-16

2) Osaka NED machinery Co., Ltd. This breaking bag machine (Figure 2-19) can increase collection rate of PE bag by installing before the existing conveyer. The machine repeats rotation of blade forward and reverse and enhance ability of breaking bags (Figure 2- 20). Furthermore wrapping is prevented by this repeated rotation.

Figure 2-19 Outlook of the machine Figure 2-20 Principle of crushing

Table 2-14 Specification of the machine Type Size[mm] Motor[kW] Speed[m3/h] Price[RM] HTP-15S 2100 x 3381 x 3300 11 120(max) 0.6mil.※ ※Price at hand-over at factory

3) Moki Co., Ltd. MK2208 type produced by Moki Co., Ltd has the specification indicated in the Table 2-13. This machine can be used together with other company’s machine, enabling to break and separate organic wastes at the same time. Washing is also possible when cleaned plastic is required for recycling.

Figure 2-21 MK2208

Table 2-15 Specification of the machine Type Size[mm] Motor[kW] Speed[m3/h] Price[RM] MK2208 1450 x 4835 x2275 22 16(max) 1.6mil.

Input Organic waste Plastic (PE etc.)

Figure 2-22 Principle of the machine

［2nd step］

Add one new line to 1st step. Recycle rate of polybag will significantly increase and subsequently reduce landfill cost. However, depreciation costs and operation/maintenance costs will increase due to these installations.

Table 2-16 Specification of recommended machines and its cost Pre-treatment Methane Fermentation

Type of Breaking bag Conveyer Crushing & Fermentation Gas tank Liquefied and Machine machine Sorting machine Tank usage of methane Manufacturer Osaka NED Existing Moki Co., Ltd. Swing Co., Ltd. Co., Ltd. Initial cost 0.6mil. - 1.6mil. 24～28 mil. [RM] Maintenance 0.1mil. 0.7～0.8mil. cost [RM] （3% of initial cost）（3% of initial cost） Electricity use 132 318 528 4.8 － [kWh]

Water use －－ 60 8 －－ [t/day] Labor 10 person/shift × 3 shift/day (no additional labor for the new machines)

※Operators are not needed for normal operation in breaking machine and fermentation tank. If necessary, labors in conveyer can attend

PE, HDPE（Recycled in Pulau Burong Landfill）

Breaking bag machine ( 250t/day×0.093=23.25t/day ) 23.25 t/day

－Maximum amount, according to this study －

PE, HDPE

Pioneer Gisetsu Co., Ltd. Osaka NED machinery Co., Ltd

Each RM 0.6mil. (Price of hand-

over at the factory)

PB12-16(Pioneer Gisetsu Co., Ltd.) Osaka NED machinery Co., Hand Sorting PE, HDPE Ltd. Organic:120.25 t/day 2 t/day (Dry base) Conveyer Crushing and sorting machine Methane fermentation tank

⇒ 5.0t/hour (10t/day in 80% water)

(Dry base:48.1t/day)

In questioning Nantan Yagi Bioecology Centre Moki Co., Ltd. Input：250t/day（≒10t/h）

RM 1.6mil. Magnet Hand Sorting

Nantan Yagi Bioecology Centre Steel Aluminum PET MK2208 (Moki Co., Ltd.) To Landfill

2.25t/day 0.25t/day 1.25t/day

Sold to other company Proposed Equipments

Residue Others Proposed Flow 81.25t/day Existing Flow Ⅰ

Figure 2-23 (1) The proposed flow for better waste separation (STEP 2) 38

Electricity generation

[Electricity]

1,975 kWh/day

[Methane gas]

3 1,103 Nm /day 0.3 %

Methane Methane fermentation tank

Gas holder RM 1.3 mil.

Gas station for the use of forklift, truck Nantan Yagi Bioecology Centre Kanpo Recycle Plaza

Electricity use：4.8kWh

Nantan Yagi Bioecology

Centre

Purification Compress Storage TOYOTA L&F Gas station 1.3 mil. RM

Kanpo Recycle Plaza

RM 2 mil.

24～28 mil. RM Ⅱ Ⅲ

Figure 2-23 (2) The proposed flow for methane fermentation (STEP 2) 39

Examples of methane fermentation tanks and methane utilization [Methane fermentation tanks] Quantity, quality of organic wastes and applied microbes for fermentation are decisive to determine fermentation intensity. Considering amounts and type of organic waste, volume of fermentation tank was set as 10,040 Nm3.

Figure 2-24 Methane fermentation (Vietnam, cassava powder）

Assuming that fermentation period is 20 day, 8,000 m3 of tank is at least necessary (Figure 2-25). 400 m3 of organic waste which comes from 20 ton dry base weight is stocked every day. At the day 21, amounts of materials in the tank reach 8,000 m3.

Figure 2-25 Expected volume of methane fermentation tank

[Methane utilization]

In order to operate sustainably, H2S and NH4 shall be removed from fermentation gas nevertheless its content is minor. For the use of vehicles such as automobile and forklift, compression machine, gas station besides purification equipment are necessary. The following is the case of Kanpo recycling center in Japan where the mission from Penang visited in 2016.

・Purification, gas station Figure 2-26 shows the outline of methane gas facilities equipped at Kanpo recycling center.

Forklift

Gas folder Burning equipment for excess gas

Desulfurization Generator equipment

Biogas

CH4+CO2

Gas station Figure 2-26 Methane gas station (Kanpo recycle plaza)

・Forklift run by methane gas TOYOTA produces the forklift run by methane gas (Figure 2-27).

Table 2-17 Specification of the machine Type Length [mm] Rated capacity Total emission Price [RM] [kg] [cc] 02-8FG25 3,690 2,500 2,237 0.16mil.※ ※Price at hand-over at factory

Figure 2-27 Forklift manufactured by TOYOTA L&F

・Generator run by methane gas Number of manufacturers has been selling generator run by methane gas. Next two companies are the examples for it.

1) Yanmar Co., Ltd. This company has top sharing in Japanese generator market and plenty of sale tract.

Table 2-18 Specification of the machine Type Size [mm] Generation Electricity Price [RM] [kWh/Nm3] Filius 404b BG 3040 x 980 x 1698 4.98 (Hi) 400V/50Ha ？

2) 2G Co., Ltd. 2G is German company which has long experience in generator engineering. This machine can be stored in container and monitored its operation status in real time.

Figure 2-28 Generator manufactured by 2G

Table 2-19 Specification of the machine Type Size [mm] Generation Electricity Price [RM] [kWh/Nm3] Filius 404b BG 3040 x 980 x 1698 4.98 (Hi) 400V/50Ha 1.3 mil.

［3rd step］ In this 3rd step, new conveyer line will be added to the 2nd step. With this addition, Recycle rates will significantly increase and subsequently reduce landfill cost. However, depreciation costs and operation/maintenance costs brought by newly installed facilities will increase significantly. Labor cost also will be increased because of additional separation work. 1.2 MR will be necessary to introduce new conveyer if Japanese made conveyer is installed. Cost can be reduced if other cheaper type of conveyer is installed.

［4th step］ Methane recovery and its maintenance facility will be added. By which both methane recovery from organic wastes and electricity generation can be made. Generated electricity will be used within the facilities in the landfill, which could reduce diesel consumption. If the project site is connected with the grid, sale of electricity is also expected. However, depreciation costs and operation/maintenance costs due to newly installed facilities will increase significantly. Labor cost also will be increased because of an increased separation work. Figure 2-29 shows the layout map for the 4th step. All necessary facilities are allocated in the proper positions. This layout map will be modified according to the results which will be obtained from 1st to 3rd steps. Profitability is greatly affected by initial capital investment, so then public fund would be necessary.

Section A Apprx. 200m

Fermentation Tank 2600m3×4+(2) Mixing Tank 3000m3

Water Tank 1000m3

Desuifurization Equipment Gas Holder 500m3×2+(1) Organic Waste Receiver Solid Remover

Digestive Water Tank400m3×2 Excess Gas Burner Apprx. 80m

Power Operation Center Water Treatment Plant Generation Adminisration Office

Fermentation & Power Generation Site

Figure 2-29 Layout map for the 4th step

Figure 2-30 Layout map image for the 4th step

10. Comparison of methane recovery installation cost with incineration

Table 2-20 shows possible cost for installation of biodigester facility and incinerator plant in Japan (Ministry of Japan, Study on Promotion to Utilize Waste Biomass, 2013). Initial cost is the amount if a half is covered by a government subsidy. Initial cost of the incineration plants with the capacity of 100 ton/day is much bigger than that of biodigester plant with the capacity of 25 ton/day. Running cost is also much higher in incinerator plant. As FIT price is set to a higher price in Japan, income from gas sale at biodigester facility is relatively high.

Table 2-20 Comparison of annual cost between biodigester technology and incineration in Japan Biodigester technology Incinerator plant Unit (25ton/day) (100ton/day) Initial cost* Facilities expense and thousand USD 3,500 65,200 base maintenance expense

Running cost Depreciation cost thousand USD 175 3,260 Electricity cost thousand USD 77 2,777 Fuel cost thousand USD 7.2 156 Water supply cost thousand USD 6.2 130 Sewer cost thousand USD 0 0 Chemical cost thousand USD 50 1,486 Final disposal costs thousand USD 0 2,112 Maitenance cost thousand USD 292 6,519 Total 607.4 16,440

Income Electricity thousand USD 3,300 Gas thousand USD 1,200 Initial cost* - Half of the initial cost is covered by a government subsidy Source; Min of the Environment, Gov of Japan, 2013

11. Available technologies developed by Japanese manufacturer regarding methane recovery

Technologies of recycling, crushing and methane fermentation have been developed by Japanese manufacturer. The following is the examples of which and currently available in Japanese market. These information was taken from the database of Ministry of Environment, Japan (http://www.env.go.jp/recycle/circul/venous_industry/index_en.html)

Ⅲ. Others

1. Risk assessment Risk may arise regarding Activity 1 in terms of social, economy and environmental aspects. Thereby, expected risks are extracted and evaluated according to degree of impact and occurrence frequency. Moreover, possible protective and reductive methods for these risks are examined.

3 Catastrophic 3 6 9 2 Moderate 2 4 6

Probability 1 Negligible 1 2 3 Negligible Moderate Catastrophic 1 2 3 Impact Figure 3-1 Risk Profile Matrix

Table 3-1 (1) Risk Assessment

【Landfill】 Waste Separation Equipment Category Item Impact Probability Way of Countermeasure and Mitigation Environment Occupational Accident 3 2 Installation of protective cover Setting of no entry area Safety and Health Education Creating a work manual Dust 2 2 Installation of defense cover Installation of local exhaust equipment Wear masks Reduction of dust generation by watering Noise and Vibration 2 2 Installation of soundproof wall Use of ear plugs Installation of anti-vibration equipment Economy A high Cost for Introduction 3 2 Use of public fund Use of lease contract Examination of partial introduction A high Running Cost 3 2 Adoption of energy conservatin type facilities Use of house power generation A high Maintainance Cost 3 2 Use of maintenance contract Procurement of parts Decreased sales profit from recyclable Quality improvement of recyclable valuable materials 3 2 valuables Diversification of buyers Decrease of amounts recyclable Increase of recyclable valuables due to an installation of 3 2 valuables breasing & crushing machines Increase of recyclable valuables due to an increased number of employees Increase of recyclable valuables due to employees education Society Reduction of labour by installing Consultation between employers and employees 2 2 facilities Impact on labors due to a change of Consultation between employers and employees 2 1 working time

Methane Fermentation Equipment Category Item Impact Probability Way of Countermeasure and Mitigation Environment Lignition of methane 3 1 Attachment of fire-prevention equipment Allocation of fire ban area Safety and Health Education Fire safety training Creating a work manual Occupational Accident 3 2 Installation of protective cover Setting of no entry area Safety and Health Education Creating a work manual Economy A high installation cost 3 2 Use of public fund Use of lease contract Examination of partial introduction A high power cost 3 2 Adoption of energy conservatin type facilities Use of house power generation A high maintenance cost 3 2 Use of maintenance contract Procurement of parts Reduction of the recyclable organic waste 3 2 Quality improvement of recyclable valuable materials Society Protest Activities by NGOs 3 3 Public relations Briefing to stakeholders 46

Table 3-1 (2) Risk Assessment Electricity Generator Category Item Impact Probability Way of Countermeasure and Mitigation

Environment Noise and Vibration 2 2 Installation of soundproof wall Use of ear plugs Installation of anti-vibration equipment

Occupational Accident (Electrification) 3 2 Installation of protective cover Setting of no entry area Safety and Health Education

Creating a work manual Economy A high installation cost 3 2 Use of public fund Use of lease contract

Examination of partial introduction A high power cost 3 2 Adoption of energy conservatin type facilities Use of house power generation

A high maintenance cost 3 2 Use of maintenance contract Procurement of parts Reduction of methane 3 2 Quality improvement of recyclable valuable materials

Society Protest Activities by NGOs 3 3 Public relations Briefing to stakeholders

2. Dispatch presenter for technology training in Japan and presentation in the stakeholder’s workshop CCAC-3 Technology Training in Japan was conducted in Osaka, Japan.

Table 3-2 Presentation in Japan and Penang No. Date Content Location 1 6 December 2016 CCAC-3 Technology Training in Japan KANSO, Osaka, Japan Technology training given by Mr. Taniuchi 2 16 March 2017

2.1 CCAC-3 Technology Training in Japan Date：6 December 2016, 9:00～12:00 Location：Conference room at Kanso headquarter office, Osaka, Japn Participants：［ Penang］Mr. Syamshuar Bin Husin, Ms. Yeap Cyndy, Mr. Khor Hung ［GEC］ Mr. Hirata, Ms. Doi, Mr. Shimizu ［Kanso］ Mr. Takahashi, Mr. Fukuda

This training was held by the lecturer, Mr. Taniuchi who has experience in the field of waste management over 40 years. Mr. Taniuchi insisted an importance of waste separation when they are generated which is highly recommendable rather than separation in the later stage. In the training, the fact that collection of separated valuable wastes and social environment also will affect so much was explained. Training materials are shown in the attachment 5.

Figure 3-2 Opening remark by Mr. Hirata Figure 3-3 Lecturing by Mr. Taniuchi

2.2 Workshop in Penang Date：16 March 2017 Location：PLB Terang Sdn. Bhd. Participants：［ Penang］YB Phee, Mr. Syamshuar Bin Husin, Ms. Yeap Cyndy, Mr. Khor Hung [GEC］Ms. Doi, ［KANSO］Mr. Matsui, Mr. Fukuda

Ms. Doi, GEC explained first about CCAC3 Stage3 project for Penang and the progress results of FS were reported by Kanso. Future plan and business model were discussed. And in which breaking bag machine and crushing machine which are manufactured in Japan, were introduced using the video.

Figure 3-4 Workshop held in Penang (16 March 2017)

3. Conclusions

・ Organic waste is the largest component of the waste stream by weight ・ 20～40 t/day will be available for methane recovery according to waste separation study, and which will lead to 1,000kVA～1,500kVA of electricity generation ・ Plastic bags are not sufficiently broken and organic wastes are mixed with other non-fermentable when they come to the landfill. These lower methane recovery rate. ・ Enforcement of waste separation lines and installation of efficient breaking bag machine/crushing machine are effective to increase rate of organic waste collection ・ Improvement of separation efficiency not only in the landfill also in the source will be effective for enhancing rates of methane recovery and recycling of other valuable wastes

4. References;

Institute for Global Environmental Strategies (IGES), Climate and Clean Air Coalition (CCAC), (2016) User’s Manual; A Tool for Quantification of Short Lived Climate Pollutants (SLCPs) and Other Greenhouse Gas (GHG) Emissions from Waste Sector

Min of the Environment, Gov of Japan (2011) Report on the emission of municipal waste and treatment in Japan. http://www.env.go.jp/press/press.php?serial=16503 (in Japanese)

Min of the Environment, Gov of Japan (2013) Study on Promotion to Utilize Waste Biomass http://www.env.go.jp/recycle/circul/venous_industry/index_en.html (in Japanese)

Nakano ward, (2007) Recycling enhancement program. Report of Nakano ward council for waste reduction promotion (in Japanese)

NEDO (2015) FS report on the project for low-carbon city development through the introduction of package- style woody biomass power generation in Penang State, Malaysia (in Japanese)

Omran Abdelnaser, El-Amrouni Abdelsalam O, Suliman Larifa K, Pakir, Abdul Hamid, Ramli Mahyuddin, Aziz Hamidi Abdul. (2009) Soild waste management practices in Penang state: A review of current practices and the way forward. Environmental Engineering and Management Journal 8 (1): 97-106

Ozawa Asumi (2012) Achievements and challenges of waste reduction and recycling in Abiko City 49; 311- 50

327 Toyo University repository for academic resources. http://id.nii.ac.jp/1060/00007265/ (in Japanese with English abstract)

Tenaga Nasional Berhad 2013（Overseas electricity statistics 2015）Japan Electric Power Information Center " ; JEPIC

Company profile; Pioneer Gisetsu Co. Ltd. (In Japanese)

Osaka NED machinery Co., Ltd. (In Japanese)

Moki Co., Ltd. (In Japanese)

The Bank of Tokyo-Mitsubishi UFJ, Ltd (BTMU) Global Business Insight Area Report 432

Product Brochure; TOYOTA L&F (In Japanese)

Yanmar Co., Ltd. (In Japanese)

2G Co., Ltd.

5. Attachments

1. Penang waste characterization study 2016 2. Penang waste characterization study 2016: By parliament areas 3. Municipal waste control (6th December 2016 Lecture) 4. Activity 3: Penang CCAC Stage 3 Technology Training in Japan Report (5-8 December 2016) 5. Presentation file on “Waste characterization study” (2 March 2016 meeting) 6. Presentation file on “MRF and biodigester study” (16 March 2016 final meeting)