CHAPTER 5

Project Description

ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPOSED CLINICAL WASTE TREATMENT PLANT AT INDUSTRIAL ESTATE, KEMAMAN, FOR RADICARE (M) SDN BHD 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

The Proposed Project site is located at PT 9653, Telok Kalong Industrial Estate (TKIE), Kemaman, Terengganu. The site covers an area of 21,000 m2 (about 5.2 ha) approximately 169 km southeast from township and about 6 km from town. The Proposed site is a vacant land surrounded by industries mainly related to chemical and petrochemical industries. 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 15 MT/day x 2 lines of clinical waste per unit of incinerator. The project shall include 2 units of incinerator which will be developed in 2 phases. This counter-current rotary kiln type incinerator is developed by BIC Systems Asia Pacific Pte Ltd. Generally, the main components of the incinerator plant facility include waste reception and storage, waste combustion, gas cooling, air pollution control and ash receiving and storage system, truck and bin washing system. Also included is the industrial effluent treatment system (IETS) to treat the wastewater from the bin and truck washing.

Figure 5.3.1(a) shows the layout of the Project components that consist of proposed incinerator area, storage areas (for clinical waste, chemicals and ash), administration building, bin washing/ disinfection area and the IETS area. The Project components are elaborated in the following sub-sections.

5.3.1 Clinical Waste Reception Area

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

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BHA1315 _ 1101 D:\DESKTOP\bha1315\BHA1806_Clinwaste_TelukKalong_DD00_181106.rvt ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPOSED CLINICAL WASTE TREATMENT PLANT AT TELUK KALONG INDUSTRIAL ESTATE, KEMAMAN, TERENGGANU FOR RADICARE (M) SDN BHD CHAPTER 5 – PROJECT DESCRIPTION

5.3.2 Clinical Waste Storage (Cold Room)

In a normal operation, the CW received will be immediately treated via the proposed incinerator. As a safety measure, a cold room shall be provided to accommodate abnormal operation events such as plant shut down, maintenance and over generation of CW, probably from disease outbreak etc. At the end of the day, untreated CW will be stored in the cold storage area before being processed during the following day. There will be cold room stores which can accommodate 250 tonnes per month and able to store untreated wastes up to 16 days, temperature of below 6 °C.

5.3.3 Infrastructures and Utilities

5.3.3.1.1 Water Supply

Water supply requirement for ancillary facilities is estimated at 250m3/month (average). Among relevant components are water supply distribution pipe, water pump house and storm water drainage.

5.3.3.1.2 Electricity

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

5.3.3.1.3 Internet Network

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

5.3.3.1.4 Storm Water Drainage System

Storm water drainage system shall be prepared around the Project boundary. Storm water within the Project area will be channelled to perimeter drainage system and it will be discharged to the existing drainage system available within the Telok Kalong Industrial Estate.

5.3.3.1.5 Other Facilities

Sewerage treatment plant shall be provided with compliance to Standard B of the Environmental Quality (Sewerage) Regulation 2009.The STP shall cater for about 30 personnel. The discharged from the septic tank shall be to the nearest existing drain. Detail for the intended types of sewage treatment system is attached in Appendix 5.3.3.

Other facilities to be included are main office, workshop, scheduled waste store, general room and staff room.

5.3.4 Incinerator Plant

The incinerator plant will be divided in 2 phases, Phase 1 and Phase 2. For each phase the proposed incinerator system is for an operation capacity of 15 MT/day (625 kg/hr) utilising rotary kiln type with Flue Gas Thermal Oil (FGTO) heat exchanger. However, the design capacity is higher, at 18 MT/day (750 kg/hr). Designed plant life is 20 years with thermal capacity 3,750,000 Kcal/hr or 15,750 MJ/hr. An opened but roofed pad area will accommodate for combustion / incineration process block. Components of the incinerator plant are summarised in the following subsection. Figure 5.3.1(a) shows the layout of the Project components that consist of incinerator area, storage area (for clinical waste, chemicals and ash), administration building and bin washing/ disinfection area.

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ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPOSED CLINICAL WASTE TREATMENT PLANT AT TELUK KALONG INDUSTRIAL ESTATE, KEMAMAN, TERENGGANU FOR RADICARE (M) SDN BHD CHAPTER 5 – PROJECT DESCRIPTION

5.3.4.1 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

Plate 5.3.2: Skip Tilting Mechanism

Plate 5.3.1: Skip Hoist Mechanism Plate 5.3.3: Bin Weighing Unit

5.3.4.1.1 Primary Combustion – Feeding Ram System

Features of the feeding ram system:

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. 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.

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

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Plate 5.3.4: Feeding Hopper

Plate 5.3.6: Hydraulic Ram Plate 5.3.5: Guillotine Door

5.3.4.1.2 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.

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

Plate 5.3.7: Stationary Part

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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)

Plate 5.3.8: Rotary Kiln Plate 5.3.9: Rotary Motor

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

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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 Volume: 0.7 m3 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 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.

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5.3.4.1.3 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

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)

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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

5.3.4.1.4 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.

Table 5.3.4: Flue Gas Pre-Cooling System Specification

Type BIR 375 Maximum inlet 1200 °C temperature 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

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5.3.4.1.4.1 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)

Plate 5.3.16: Thermal Oil Heat Exchanger

5.3.4.1.4.2 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)

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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

5.3.4.1.5 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.

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

5.3.4.1.6 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 25 kg/h and requires 3 x 400 V/ 50Hz + N of electricity supply.

5.3.4.1.7 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

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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

5.3.4.1.8 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)

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Plate 5.3.21: Exhaust Fan

5.3.4.1.9 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 . 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 analyser Principle of measurement: NDIR Extractive NOx, O2 analyser Principle of measurement: CLD / Zirconia HCL / HF analyser In-situ 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)

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5.3.4.1.10 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.

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 473.15 K at inlet Source: BIC Systems Asia Pacific Pte Ltd. (2018)

Plate 5.3.23: Chimney Stack

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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 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 Plate 5.3.25: Emergency By-pass process downstream. 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

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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.

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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)

5.3.4.2 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. Estimated 3.0 m3 of waste water generated from this washing activity. Waste water from the washing bay will be channelled to the proposed Industrial Effluent Treatment System (IETS) for treatment prior discharge.

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5.3.5 Industrial Effluent Treatment System

The incinerator does not produce any waste water from the incinerator processes. Sources of waste water are from wheel bins and trucks washing activities. Wheel bins are used for CW collection in clinical facilities and trucks are used as to transport the collected CW (inside the bins) from clinical facilities to the Project site. 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 CW. The amount of waste water is estimated about 3 m3/day with capacity of 5m3/day. The waste water will be channelled to Industrial Effluent Treatment System (IETS) that will be installed within the Project site. The IETS capacity is 5m3/day. Chemical treatment to be applied and effluent shall comply with Standard B of the Environmental Quality (Industrial Effluent) Regulations, 2009

The wastewater generated from bin wash will be piped to the IETS for treatment prior discharge to the receiving body. The process flow block diagram of the wastewater treatment loading is as presented in Figure 5.3.5.1, which is based on maximum capacity of 5m3/day.

The treatment processes for the wastewater are described as follows:- a) Raw Wastewater

Wastewater from bin and truck washing area will be gravity flow to Collection Sump. From Collection Sump, wastewater will be pumped to Equalization Tank. In the Equalization Tank, the wastewater will be equalized via perforated air pipe which these pipes are connected to air compressor to provide sufficient mixing and prevent the anaerobic condition of the raw wastewater. At a pre-determined level, the homogenized wastewater will be pumped to Reaction Tank. b) Physical-Chemical Treatment i. Chemical Dosing

The physical-chemical treatment consists of Reaction Tank and primary Clarifier. Caustic will be dosed to Reaction Tank automatically by a dosing pump to adjust the wastewater pH to optimum level for chemical treatment. Coagulant will be dosed to coagulate non-biodegradable colloidal matter and suspended solid. Polymer will be dosed automatically by a dosing pump to settle-off the flocs (Sludge).

ii. Primary Clarifier

The wastewater will be fed to center cone of Primary Clarifier to undergo solid – liquid separation process. Flocculated sludge will be settled at the bottom of the tank which the tank is designed to cone base to ease of sludge withdrawal for further dewatering. However, supernatant will be moved upward to water surface and through baffle plates & v-notch weir overflow out from Primary Clarifier as clear water. c) Filtration System

The clarified water will be pumped to Sand Filter and Carbon Filter from Buffer Tank which act as temporary storage. Sand Filter, the filtration medium has multiple layer of sand, where each layer with a variety of size and different specific gravity. Activated Carbon Filter, the filtration medium has multiple layers of sand, where each layer with a variety of size and different specific gravity and a layer of activated carbon. Water is passed through these 2 filters to reduce the presence of suspended solids, odour and colour in the water. The filters need to be periodically cleaned (backwash) for 15-20 minutes

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4. Sludge Management

Settled sludge from Primary Clarifier will be transferred via air diaphragm pump into Sludge Tank for storage before collected by tanker. The IETS is to be designed to treat wastewater from the facility with the influent characteristic as shown in Table 5.3.11. to be compare with design value in compliance to Standard B of Environmental Quality (Industrial Effluent) Regulations 2009.

Table 5.3.11 : Characteristic of Raw Wastewater to the Wastewater Treatment Plant Design Value

Characteristic of the raw Design value to comply Parameter wastewater from bin washing* to Standard B pH 7.5 - 10.4 5.5 - 9.0 BOD (mg/L) ≤46 ≤ 50 COD (mg/L) ≤145 ≤ 200 Suspended Solids (mg/L) ≤32 ≤100 Oil and grease (mg/l) ≤5 ≤10 Cadmium (mg/l) ≤0.352 ≤0.02 Lead (mg/l) ≤5.79 ≤0.5

*The characteristic of the raw wastewater is derived from Radicare’s Teluk Panglima Garang wastewater sampled.

The removal efficiency of these operation scenario is 95% for cadmium and 92% for lead. The detailed calculation for the IETS mass balance is shown in Appendix 5.3.5.

Process Flow Diagram of the IETS Treatment Process incorporation the treatment of wastewater is shown in Figure 5.3.5.2.

5.3.6 Sewage Treatment

Sewage treatment shall be provided with compliance to Environmental Quality (Sewerage) Regulation 2009. It shall cater for about 30 personnel. Treated discharges from the septic tank shall be diverted to the nearest existing drain. The estimated P.E. for the site is PE 9.

The proposed septic tank for the site is the KOSSAN FRP Septic Tank approved by SPAN for serving PE 12. Details on the selected treatment plant system of Standard B of Environmental Quality (Sewage) Regulation 2009 is attached in the Appendix 5.3.3.

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BLOCK DIAGRAM AND MASS BALANCE

(+)74'C CHEMSAIN KONSULTANT SDN. BHD.

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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)

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)

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

Table 5.4.3: Typical Clinical 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 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 per line of 625 kg/hr where 15 MT/day of clinical wastes are expected to be treated. With the implementation of Phase 2, a total of 30 MT/day if wastes shall 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 625 kg/hr (15 MT/day) x 2 units (Based on the average calorific value of waste of 4500 kcal/kg (20 MJ/kg) Design Life Span 20 years

Process Line 2 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

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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 Utilities Power supply 50 kW/hr (average) Estimated waste Fly ash 16 kg/hr (PM) and 72 kg/hr (Salts) Bottom ash 64.28 kg/hr

5.5 Process Description

5.5.1 Handling of Clinical 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. Composition of clinical waste received at Teluk Panglima Garang Plant 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: Composition of Clinical Waste Received at Teluk Panglima Garang Plant

Material Percentage Mixed papers 14.13 Plastics 39.21 Diapers 7.32 Surgical garments 11.11 Gloves 15.6 Absorbent 12.63 Total 100 Source: TPG’S Radicare Sdn Bhd. (2009)

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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) 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 clinical wastes in Clinical Wastes Management Services (CWMS) is one of Radicare’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 clinical wastes.

Segregation of the clinical 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.

Clinical 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 Radicare staff. Collection of clinical wastes shall be done daily or as frequently as circumstances demand. Authorised representative of the MOH and Radicare staff weight the clinical wastes and record the quantities and weights. During the collection of the wheeled bins containing clinical wastes, Radicare 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 Radicare staff are well-trained and equipped with personal protective equipment (PPE) during the handling process.

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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)

This Project will accommodate clinical wastes generated from government hospitals and laboratory in East Coast Peninsular Malaysia namely Pahang, Terengganu and Kelantan. Estimated quantities of clinical wastes to be collected and treated at the Project site are listed in Table 5.5.5. and Figure 5.5.1.1 shows the Handling of Clinical Waste at Source (On-Site Handling)-by MOH staffs.

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Table 5.5.5: Clinical Wastes Collection from Waste Generators

LIST OF GOVERNMENT HOSPITALS LIST OF PRIVATE CLINICS AND CLINICAL CENTRES

Name MT/Yr Name MT/Yr Name

Pahang Kelantan Pahang

Hospital Besar Kuantan 450.24 Hospital Kota Bharu 437 Wasco Coating Malaysia Sdn Bhd Hospital Pekan 39 Hospital Kuala Krai 79 Unit Hemodialisis PDRM Hospital Bentong 48 Hospital Machang 34.4 RP Chemicals (M) Sdn Bhd Hospital Kuala Lipis 84.1 Hospital Pasir Mas 40.3 Hospital Pakar PRKMUIP Sdn Bhd Hospital Raub 34 Hospital Pasir Putih 33.5 Saznoor Industries Sdn Bhd Hospital Jerantut 34.4 Hospital Tanah Merah 101.1 Pusat Dialisis NKF-Sang Riang, Triang Hospital Jengka 43.5 Hospital Tumpat 33 Pusat Dialisis NKF-Tun Abdul Razak Hospital Rompin 7.2 Hospital Gua Musang 29.5 Hospital Muadzam Shah 31.2 Hospital Jeli 22 Terengganu Hospital Cameron Highland* 7.5 Universiti Teknologi Mara, Terengganu Hospital Temerloh 348.5 Pusat Kesihatan Pelajar, Universiti Malaysia Terengganu

Fakulti Perubaatan Sains Kesihatan

Pusat Dialisis NKF-Kuala Terengganu

Pusat Dialisis NKF-Yayasan Buah Pinggang Kemaman

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Table 5.5.5: Clinical Wastes Collection from Waste Generators (Cont.)

LIST OF GOVERNMENT HOSPITALS LIST OF PRIVATE CLINICS AND CLINICAL CENTRES

Terengganu MT/Year Kelantan

Hospital Kuala Terengganu 412.8 Fakulti Industri Asas Tani Hospital Dungun 42 Fakulti Perubatan Veteriner Pusat Dialisis NKF Hospital Hulu Terengganu 34.6 HUSM Hospital Besut 51.5 Hospital Kemaman 110.3

Hospital Setiu 23.4

*CW will be collected by other concession company.

Source: Radicare (M) Sdn Bhd. (2018)

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Collection, segregation, storage in dedicated Put in wheeled bin containers/ plastic bags

Weight and record quantities and weights Stored at hospitals Preparation of central storage Consignment note

Transportation to Radicare’s Plant via designated routes

FIGURE 5.5.1.1 : Handling of Clinical Waste at Source (On-Site Handling)-by MOH staffs ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPOSED CLINICAL WASTE TREATMENT PLANT AT TELUK KALONG INDUSTRIAL ESTATE, KEMAMAN, TERENGGANU FOR RADICARE (M) SDN BHD CHAPTER 5 – PROJECT DESCRIPTION

5.5.2 Transportation of Clinical Wastes to Project Site

Transportation of wheeled bins from the hospitals to the Proposed Project shall be via dedicated transportation route by means of five units of licensed trucks owned by Radicare with a capacity of 11 tonnes each. In the wheel bin, plastic bags containers are properly sealed and secured for easy transportation as well as to ensure no leakage or odour emitted during the transportation process. It is estimated that there will be one trip of delivery daily for each truck where the truck shall collect CW from respective hospitals and health facilities to the Proposed Project site located in Teluk Kalong Industrial Estate shown in Table 5.5.6. The flow diagram for the waste transportation shown in Figure 5.5.2.1.

Table 5.5.6: Transportation and collection of the CW are daily and divided by 4 routes

Area of CW Collection Route Kuantan, Hulu Terengganu, Kuala Terengganu, Kuala Terengganu-Kemaman-Lebuhraya Jabor- Dungun, Kemaman -Hulu Terengganu-Jalan Pantai- Dungun-Kemaman-Kuantan Muadzam Shah-Pekan-Temerloh Kuantan-Pekan-Muadzam Shah-Temerloh- LebuhRaya Pantai Timur-Kemaman-Kuantan Jengka-Jerantut-Temerloh Kuantan-Jengka-Jerantut-Temerloh-Lebuhraya Pantai Timur-Kemaman-Kuantan Tumpat, Pasir Mas, Tanah Merah, Machang, Jeli, Kota Bharu-Tumpat-Pasir Mas-Tanah Merah- Kuala Krai, Gua Musang, Kota Bharu, HUSM, Jeli-Machang-HUSM-Pasir Putih-Besut-Setiu- Pasir Putih, Besut, Setiu Gua Musang-Kuala Krai-Kota Bharu

Source : Radicare (M) Sdn. Bhd. 2018

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

Clinical 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 5.5.4.1.

The clinical 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.

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Collection of Clinical Waste from Hospital and Laboratory Designated Designated Routes Routes

Transporting Delivery of Clean Clinical Waste from Wheel Bin to Hospital to Hospital Incinerator Plant

Treatment Plant

Treatment Inside Arrival of Trucks Thermal Treatment Containing Plant Collected CW

Generation of bottom ash and fly ash SW406

Disposal of SW406 to Kualiti Alam

FIGURE 5.5.2.1 Flow Diagram Waste Transportation ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPOSED CLINICAL WASTE TREATMENT PLANT AT TELUK KALONG INDUSTRIAL ESTATE, KEMAMAN, TERENGGANU FOR RADICARE (M) SDN BHD CHAPTER 5 – PROJECT DESCRIPTION

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.

The air inlet at the Heat Exchanger is to limit its inlet temperature to 900°C to prevent clogging of the pipe bundles in the Heat Exchanger (Flue gas at the exit of SCC is at around 1000°C and it contains particulates - Fly Ash, which melt above 900°C). By reducing the temperature to 900°C, the particulates remain solid and therefore do not stick to the pipe bundles of the Heat Exchanger. Hence no clogging of the Heat Exchanger by Fly Ash.

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.

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Refractory lined

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

Figure 5.5.4.1: Process Flow Block Diagram

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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).

The air inlet at the Heat Exchanger is to limit its inlet temperature to 900°C to prevent clogging of the pipe bundles in the Heat Exchanger (Flue gas at the exit of SCC is at around 1000°C and it contains particulates - Fly Ash, which melt above 900°C). By reducing the temperature to 900°C, the particulates remain solid and therefore do not stick to the pipe bundles of the Heat Exchanger. Thus no clogging of the Heat Exchanger by Fly Ash is expected.

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 Clinical Waste Storage

In the event that clinical 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 250 MT.

5.5.4.4 Cleansing and Disinfection of Wheeled Bins and Trucks

Upon unloading of clinical 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 clinical wastes generators (hospitals).

5.5.4.5 Thermal Treatment Facility’s Mass Balance

The thermal treatment facility’s mass balance is shown in Figure 5.6.1a and Figure 5.6.1b

5.6 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.

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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 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 bag-house. 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 Emission Monitoring

Emission monitoring equipment installed at the incinerator will comprise of in-situ CO, CO2, SO2 analysers which adopt NDIR measurement principle; extractive NOx, O2 analysers which adopt CLD / Zirconia measurement Principle; in situ HCL/HF analysers and in-situ dust monitoring system. With SCADA, the data of the monitoring system will be connected and integrated with the plant PLC/PC. The plant supervision PC will show and log all emission monitoring data continuously. The compact emission monitoring system is enclosed with a weather proof analyser cabinet, equipped with air condition unit, power distribution panel, lighting, switch and plug C/W rack.

The emission monitoring equipment can continuously record and online monitor all gas components that are specified by the Malaysian Authorities. Alarms are activated to notify when the present value are exceeded. If the pre-set values are further exceeded, the incinerator will trip. The emission monitoring enclosure will be installed on the ground floor level, at the chimney base. The trial burn results from the Teluk Panglima Garang incinerator shall be made as references for the prediction of emitted pollutants explained in Chapter 6.

5.6.1.2 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

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Activity K Parameter Limit Values Monitoring

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

5.6.1.3 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.

5.6.1.4 Incinerator Plant Maintenance a) 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 b) 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.

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ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPOSED CLINICAL WASTE TREATMENT PLANT AT TELUK KALONG INDUSTRIAL ESTATE, KEMA

5.6.2 Management of Bottom Ash and Fly Ash (SW 406)

Bottom ash will be generated approximately 64.28 kg/H while fly ash estimated at 88 kg/H. These ashes will be temporary stored inside waste storage area before being sent to Kualiti Alam for disposal at a secured landfill with frequency of weekly basis. Collection will be done by Kualiti Alam personnel. The ash storage capacity is 16 tonnes which able to accommodate up to 30 days of ash generated. The ash will be properly stored as required by DOE regulations on Scheduled Wastes, not exceeding 20 tonnes or 180 days whenever comes first, at any one time.

5.6.3 CW Storage

In the event that CW could not be incinerated within 24 hours of reception, it will be stored in a dedicated storage container/ refrigerator at temperature of between below 6°C (cold storage). The storage container has a holding capacity of 250 tonnes capacity of cold water.

5.6.3.1 Cleansing and Disinfection of Wheeled Bins and Trucks

Upon unloading of clinical 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 CW generators (hospitals).

5.6.4 Incinerator Plant Balances

The incinerator plant’s mass balance is shown in Figure 5.6.1a and Figure 5.6.1b .

5.6.5 Water Pollution Control

5.6.5.1 Waste water from Washing Activities

The thermal treatment facility does not generate any effluent from the incinerator processes. Sources of waste water are from clinical 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 clinical wastes. Figure 5.6.5.1 illustrates the waste water management at the Project site.

Anticipated volume of the waste water generated from the washing activities 3.0 m3 per day with maximum capacity of 5.0m3. Waste waters from the bin washing bay and truck washing bay are immediately channelled to Industrial Effluent Treatment System through piping system.

The wastewater generated from bin wash will be piped to the IETS for treatment prior discharge to the receiving body. The general concept of the wastewater treatment loading is as presented in Figure 5.3.5.1. and the detailed IETS Treatment System in Section 5.3.5.

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CHEMSAIN KONSULTANT SDN. BHD.

MASS BALANCE

(+)74'Ä K CHEMSAIN KONSULTANT SDN. BHD.

MASS BALANCE

(+)74'Ä KK Wastewater generated from bin and truck washing activity

The wastewater from the washing bays shall be channel to IETS The clean bin shall be sent back to respective hospitals

The wastewater from the washing bin and truck will be treated in IETS

The effluent discharge shall comply to Standard B

FIGURE 5.6.5.1 : Process Flow of Wastewater Management

ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPOSED CLINICAL WASTE TREATMENT PLANT AT TELUK KALONG INDUSTRIAL ESTATE, KEMA

5.6.5.2 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 Perbandaran Kemaman.

5.7 Project Activities

Development of the Project will involve the following activities:

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

5.7.1 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.

5.7.2 Construction Stage

The construction and installation stage are 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 Proposed Project site is accessible from Kuantan via Federal Route 2 – Federal Route 3. The Project site is also accessible from Kuala Terengganu via Federal Route 3 – Federal Route 145. Meanwhile access to Project site from Kuala Lumpur is via Kuala via Kuala Lumpur Expressway – – Federal Route 3 – Route 145.

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. Foundation work includes piling. Most of these works apply typical construction methodologies.

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ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPOSED CLINICAL WASTE TREATMENT PLANT AT TELUK KALONG INDUSTRIAL ESTATE, KEMA

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 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.

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ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPOSED CLINICAL WASTE TREATMENT PLANT AT TELUK KALONG INDUSTRIAL ESTATE, KEMA

5.7.3 Operation Stage

On commercial operation date, the Project will be operated by the proposed estimated numbers of operational team as follows:

. Senior Manager -3 . Plant Manager – 1 . Engineer – 2 . Technical Officer – 3 . Technician (Shift Leader) – 3 . Boilerman – 1 . Chargeman – 1 . Supervisor – 1 . Fitter -1 . Plant Operator – 10 . Administrative-4

The proposed plant organisation chart is shown as Figure 5.8.1.

Operation of the Project is largely automated and control via process control system. Other important activity during the operation stage is transportation of clinical 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

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.

Management of waste

1. Normal operation – Clinical waste to be send to Teluk Kalong Incinerator.

2. Contingency operation in the event of planned and unplanned shut down of incinerator (Planned shutdown of incinerator shall occur during maintenance works.) – All wastes shall be sent to Teluk Panglima Garang for treatment.

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ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPOSED CLINICAL WASTE TREATMENT PLANT AT TELUK KALONG INDUSTRIAL ESTATE, KEMAMAN, TERENGGANU FOR RADICARE (M) SDN BHD CHAPTER 5 – PROJECT DESCRIPTION

Figure 5.8.1: Proposed Operation Organisation Chart

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ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPOSED CLINICAL WASTE TREATMENT PLANT AT TELUK KALONG INDUSTRIAL ESTATE, KEMAMAN, TERENGGANU FOR RADICARE (M) SDN BHD CHAPTER 5 – PROJECT DESCRIPTION

5.7.4 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.

5.8 Environmental Performance Status of Radicare’s Thermal Plant in Teluk Panglima Garang

Reference was made to the Environmental Compliance Audit Report (DOE tracking No. B (B) 63/200/900/006) produced in March 2015 as reported in EIA Teluk Panglima Garang. The main findings of the audit showed that, Radicare 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 March 2015 audit, there were five good practices identified, no non-compliances recorded and only four observation were identified.

All the NCRs have been closed out by Radicare on 14th April 2015. The other ECA findings are listed below:

Best Practices

i. Environmental monitoring (air quality, water quality, stack monitoring) was conducted regularly as follow the Supplementary Environmental Impact Assessment (SEIA) approval conditions. ii. Scheduled wastes were handled by the competent person and was managed properly according with the Environmental Quality (Scheduled Wastes) Regulations 2005. iii. Operation of bag filter was maintained by certified person. iv. Emergency Response Plan (ERP) was established at the premise for any accidental during the operational phase. v. Scrap metal was being kept in a proper temporary bin

Observation

i. At the ash storage and oil storage, cracked bund was noted. ii. Oil trap was not installed at the oil storage area.

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ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPOSED CLINICAL WASTE TREATMENT PLANT AT TELUK KALONG INDUSTRIAL ESTATE, KEMAMAN, TERENGGANU FOR RADICARE (M) SDN BHD CHAPTER 5 – PROJECT DESCRIPTION

iii. Certification of SAMM (Sijil Akreditasi Makmal Malaysia) from the laboratory was not available. iv. ERP training (fire drill) was not carried out since 2014 until up to this audit was conducted. v. No Environmental Management Plan (EMP) was prepared since the DEIA was approved by Department of Environment (DOE).

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.

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ENVIRONMENTAL IMPACT ASSESSMENT FOR PROPOSED CLINICAL WASTE TREATMENT PLANT AT TELUK KALONG INDUSTRIAL ESTATE, KEMAMAN, TERENGGANU FOR RADICARE (M) SDN BHD CHAPTER 5 – PROJECT DESCRIPTION

Table of Contents PROJECT DESCRIPTION ...... 1 5.1 INTRODUCTION ...... 1 5.2 PROJECT LOCATION ...... 1 5.3 PROJECT COMPONENTS AND LAYOUT ...... 1 5.3.1 Clinical Waste Reception Area ...... 1 5.3.2 Clinical Waste Storage (Cold Room) ...... 2 5.3.3 Infrastructures and Utilities ...... 2 5.3.4 Incinerator Plant ...... 2 5.3.5 Industrial Effluent Treatment System ...... 19 5.3.6 Sewage Treatment ...... 20 5.4 DESIGN CRITERIA OF THE THERMAL TREATMENT FACILITY ...... 21 5.4.1 Key Design Parameters ...... 21 5.5 PROCESS DESCRIPTION ...... 23 5.5.1 Handling of Clinical Wastes at Source (On-Site Handling) ...... 23 5.5.2 Transportation of Clinical Wastes to Project Site ...... 28 5.5.3 Handling of Clinical Wastes at Project Site (Off-site Handling) ...... 28 5.5.4 Incineration Process ...... 28 5.6 POLLUTION CONTROL SYSTEM AND WASTE MANAGEMENT ...... 31 5.6.1 Air Pollution Control ...... 31 5.6.2 Management of Bottom Ash and Fly Ash (SW 406) ...... 34 5.6.3 CW Storage ...... 34 5.6.4 Incinerator Plant Balances ...... 34 5.6.5 Water Pollution Control ...... 34 5.7 PROJECT ACTIVITIES ...... 35 5.7.1 Pre-Construction Stage ...... 35 5.7.2 Construction Stage ...... 35 5.7.3 Operation Stage ...... 37 5.7.4 Abandonment Stage ...... 39 5.8 ENVIRONMENTAL PERFORMANCE STATUS OF RADICARE’S THERMAL PLANT IN TELUK PANGLIMA GARANG ...... 39 5.9 PROJECT IMPLEMENTATION SCHEDULE ...... 40

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