FCC Environment (Lincolnshire) Limited Annual Performance Report
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Annual Performance Report 2019 Permit EPR/FP3739FS Lincolnshire Energy from Waste Facility FCC Environment (Lincolnshire) Limited Year: 2019 Address: Paving Way, North Hykeham, Lincoln, LN6 3QW Tel: 01522 814315 Email: Prepared by: Michael Day Position: Environment Manager Approved by: Juergen Schaper Position: General Manager Version: 1 Issue Date: 24/1/2020 Annual Performance Report 2019 Lincolnshire Energy from Waste Facility Contents Section Subject Page Facility Information 3 Operational Data 4 Operational Summary 5 Performance Form 1 6 Energy Form 1 7 Permit Compliance 8 Improvements 9 Public Liaison 10 Residue Quality 11 Emissions to Water 12 Emissions to Air (periodically monitored) 13 Emissions to Air (continuously monitored) 14 Hydrogen Chloride emissions 15 Sulphur Dioxide emissions 16 Oxides of Nitrogen emissions 17 Total Organic Carbon emissions 18 Particulate Matter emissions 19 Carbon Monoxide emissions 20 Ammonia emissions 21 Version Control Section Information Date 1 First release 24/1/2020 Distribution Copy Name, Role No. This report is required under the Industrial Emissions Directive’s Article 55(2) requirements on reporting and public information on waste incineration plants and co-incineration plants, which require the operator to produce an annual report on the functioning and monitoring of the plant and make it available to the public. Page 2 Annual Performance Report 2019 Lincolnshire Energy from Waste Facility Plant Description and Design The EFW facility has a total capacity of approximately 49.7 MW (thermal input) and is capable of generating up to 13.1 MWe of electrical power, the majority of which is exported to the National Grid. Provision has been made to supply additional heat in the form of up to 10 MWth when a commercial scheme becomes available to take the heat. The facility consists of one incinerator line with a total annual permitted capacity of 190,000 tonnes per year. Summary of Operational Processes and Procedures Waste material burned at the facility is residual municipal solid waste (i.e. waste that has had recyclable and re- usable materials source segregated) and commercial and industrial (C&I) waste derived from residential, commercial and industrial sources. All waste material for processing received at the facility is non-hazardous with the exception within 2019 where the site accepted some wastes from the NHS where a critical shortage of capacity for clinical waste ('orange bag') was experienced. Waste material arrives by road and is weighed before proceeding into the tipping hall where it is tipped into the waste bunker of sufficient capacity to hold several days waste inputs. Moving grate technology is used for burning the waste material. The furnace design ensures that a temperature of at least 850°C for a period of at least two seconds is achieved in the combustion chamber. To ensure that the temperature does not fall below 850°C auxiliary burners firing fuel oil are automatically triggered by online process monitoring equipment. Hot gases from the furnace pass into a boiler. Steam raised in the boiler is passed to a turbine to generate electricity. Combustion gases are cleaned before they are released to atmosphere. There are four components to the gas cleaning abatement technique; - Selective Non-Catalytic Reduction (SNCR) involving the injection of ammonia into the combustion chamber above the flame providing for the abatement of nitrogen oxides. - Dry hydrated lime re-agent injected to neutralise acid gas compounds. - Activated carbon injected to absorb heavy metals, dioxins and furans. - Bag filtration to remove fine particulates. The residues of the bag filters are collected and directed to a residues silo. Part of the residues are recycled to the reagent injection points to ensure maximum usage of the lime content. Cleaned flue gases exiting the abatement system of the incinerator line are discharged through the 75m tall stack. Gases are continuously monitored for particulate matter, oxides of nitrogen, sulphur dioxide, carbon monoxide, total organic carbon, hydrogen chloride and ammonia. Monitoring for heavy metals, dioxins, nitrous oxide and hydrogen fluoride is carried out periodically. Under normal circumstances there are no liquid effluent emissions from the incinerator. Water arising from boiler blowdown and water treatment backwash is recycled to the Incinerator Bottom Ash (IBA) quench. Water surplus to the requirements of quenching is discharged to the sewerage system. All plant areas are surfaced to the appropriate standards for the activities within those areas. All liquid tanks and drums whose emissions to water or land could cause pollution, are contained in adequate bunding constructed in line with industry best practice standards and sized to contain 110% of the contents of the largest tank or 25% of the total tonnage within the bund; whichever is the larger. Materials used for surfacing of process areas and bunds are resistant to the materials they may come into contact with. There are no direct discharges to groundwater from the facility. The solid residues produced by the EFW facility are Incinerator Bottom Ash (IBA) and Air Pollution Control (APC) residues. APC residues are hazardous and sent for treatment before landfill disposal. IBA is sent for separation and recycling of the metal content; with the remaining ash being used as a substitute aggregate. Page 3 Annual Performance Report 2019 Lincolnshire Energy from Waste Facility Operational Data Plant Size 190,000 tonnes pa 49.7 MWth 13.1 MWe No. of combustion lines 1 No. of Turbines: 1 Waste types received Unit Q1 Q2 Q3 Q4 Year Total % Household / Local Authority 46,378 43,734 41,027 38,042 169,181 95.3% Commercial & Industrial 1,020 1,125 696 3,452 6,293 3.5% Hazardous 916 830 326 2,072 1.2% Clinical - - Waste wood (biomass) - - Refuse derived fuel - - tonnes Solid recovered fuel - - Total waste received 48,314 45,689 42,049 41,494 177,546 100.0% Rejected Waste - - Waste transferred out - - Energy Usage / Export Unit Q1 Q2 Q3 Q4 Year Total KWh/te Power Generated 28,811 29,168 25,575 22,763 106,317 599 Power Exported 26,848 27,033 23,617 21,012 98,510 555 Power Used on site MWh 2,883 3,192 1,949 526 8,550 48 Power Imported 308 175 1,190 2,255 3,928 22 Parasitic Load % 7.8% 7.9% 11.8% 16.0% 10.6% Thermal Energy Produced - - Thermal Energy Exported GWh - - R1 value 0.7 Operational Waste Disposal & Recovery Unit Q1 Q2 Q3 Q4 Year Total % inputs APC Residues - produced 1,054 1,080 962 968 4,064 2.3% IBA - produced 10,101 10,751 9,486 7,939 38,277 21.6% Metals recycling tonnes - 2 3 6 11 0.0% Raw Material Usage Unit Q1 Q2 Q3 Q4 Year Total kg or Ltr /te Mains Water m3 3,727 3,708 3,976 4,859 16,270 0.09 Other Water m3 - - - - - - Ammonia kgs 98,731 111,963 106,513 90,392 407,599 2.30 Activated Carbon kgs 11,455 11,704 10,596 9,619 43,374 0.24 Lime / hydrated lime kgs 436,724 407,617 371,053 360,321 1,575,715 8.87 Fuel oil ltrs 23,819 8,868 52,192 73,969 158,848 0.89 Gas cf - - - - - - Other - - - - - - Summary of Hours Line/Unit Q1 Q2 Q3 Q4 Year Total Hours of waste combustion, total 1 2,127 2,176 1,998 1,770 8,071 92.1% Hours of heat / steam export n/a n/a n/a n/a - n/a Abnormal Events qty. none none none none - no Abnormal operation hours none none none none - 0.00% Permit Breaches qty. none none none none - no Page 4 Annual Performance Report 2019 Lincolnshire Energy from Waste Facility Summary of Plant Operations and Maintenance during the reporting year During 2019 due to a critical shortage in the available capacity for healthcare generated waste disposal the site was approached to accept waste from hospitals (Orange bag waste with potential for low infection risk). This is recorded within the operational dataset previously as hazardous waste. Following extensive consultation and audit with the Environment Agency the site accepted wastes classified as hazardous (limited to orange bag medical wastes from the NHS), initially under a Local Enforcement Position issued by the Environment Agency and then latterly through a Regulatory Position Statement. Additional procedures, monitoring and auditing was undertaken to demonstrate this would have no detrimental affect to the environment, health or to the operation of the facility. The acceptance ceased in August 2019 and is unlikely to be required in the future as healthcare waste disposal capacity has now been developed. The site otherwise concentrated on steady operations, operating for 92.1% of the year with 177,546 tonnes incinerated against a permit limit of 190,000 tonnes with full compliance to all limits set within the permit. The site had a planned annual outage within October 2019 where routine maintenance that cannot be done while the plant is online was undertaken. Works began on refurbishment to bag cell hoppers within the flue gas cleaning section of the facility along with replacement of filter bags within the cells. This will continue through 2020 in order to maintain the low particulate levels the plant continues to operate to. An additional compressor has also been added to site to increase energy efficiency and add further redundancy for the supply of plant air. Further optimisation of the dosing systems for efficient use of the reagents such as lime will continue with the replacement of filter bags and the site is preparing for the new emission limits following the publishing of the revised Waste Incineration BREF in late 2019. Summary of Residue Handling for the reporting year Incinerator Bottom Ash (IBA) is sampled 4 times per year for permit compliance purposes, in particular for Total Organic Content where the permit has a limit of 3%.