Buckinghamshire Residual Waste Performance Report 2019/2020

Contents

1.0 Introduction 2 5.0 Integrated Management System 13 5.1 Internal auditing in this contract year 13 2.0 Waste management 3 6.0 Maintenance management 14 3.0 High Heavens Waste Transfer Station 4 6.1 Maintenance issues 14 3.1 Background 4 3.2 Waste inputs 5 7.0 Community liaison 15 3.3 Waste outputs 5 7.1 Greatmoor EfW Visitor Centre 16 3.4 Waste transfer 6 7.2 Outreach visits 17 3.5 Transport fleet 7 7.3 Other highlights 17 3.6 Environmental management 7 7.4 Summary of visitor feedback 17 3.7 Complaints 7 7.5 Local employment 18 7.6 Liaison Group meetings 18 4.0 Greatmoor EfW 8 4.1 Background 8 8.0 Conclusion 18 4.2 Waste inputs 9 4.3 Waste outputs 9 9.0 Glossary 19 4.4 Environmental management 10 4.5 Complaints 13

Buckinghamshire Residual Waste Performance Report 2019/2020 Page 1 1.0 Introduction

In 2013, Buckinghamshire County Council (BCC) This waste transfer station is designed to bulk up waste awarded FCC Buckinghamshire Limited (FCC from Chiltern, Wycombe and South Bucks District Environment) a 30 year contract for the management Councils delivered to the facility by Refuse Collection and treatment of household residual waste. Vehicles (RCV).

To manage and treat this residual waste, FCC Waste from Household Recycling Centres (HRCs) is also Environment constructed and now operate and delivered either directly to Greatmoor EfW or to High maintain the Greatmoor Energy from Waste (EfW) Heavens WTS. Bulking up waste into large articulated facility, which is located to the north of Buckinghamshire vehicles is an efficient method for reducing delivery County. This Energy from Waste facility is used to miles. Residual waste from Aylesbury Vale District dispose of residual waste that was otherwise destined Council (AVDC) and HRC sites in the north of the county for landfill, whilst recovering energy from the waste to is directly delivered into Greatmoor EfW due to the close generate electricity. The facility generates enough proximity to the facility. electricity to power over 40,000 homes. The contract entered operation in June 2016, following To facilitate transporting residual waste from Southern the construction and commissioning of both facilities. Buckinghamshire to Greatmoor EfW, FCC Environment This is the Fourth Annual Service Report, which provides constructed and now operate and maintain High details of FCC Environment’s contract performance from Heavens Waste Transfer Station (WTS). April 2019 to March 2020.

Map 1 – Location of FCC facilities and district councils

Greatmoor EFW Aylesbury Vale District

Aylesbury

Wycombe District Chiltern District

High Wycombe

High Heavens

South Bucks District

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 2 During the fourth contract year:

transport miles tonnes homes saed

of residual waste were of electrical power is Our electricity output through the operation of processed for energy recovery, generated from the residual was the equivalent to High Heavens Waste Transfer with 104,013 tonnes of waste waste energy recovery at that needed to power Station to feed contract waste processed directly from BCC. Greatmoor EfW. 40,000 homes. to Greatmoor EfW.

school pupils isitors compliant

engaged with during to Greatmoor over with the of electrical power 21 educational 166 community Environmental Permit was exported to the outreach sessions. engagement tours. at both facilities. National Grid system

2.0 Waste management

Total waste volumes handled

Table 1 – Summary of waste inputs processed at High Heavens During this contract year, WTS and Greatmoor EfW in this contract year by supplier FCC Environment have processed 304,952 tonnes of residual waste Waste inputs Tonnes across both facilities. Aylesbury Vale District Council 32,917

BCC Contract Waste was delivered by all the Chiltern & Wycombe District Councils 44,511 Buckinghamshire District Councils and also from South Bucks District Council 10,666 Household Recycling Centres (HRC). Bulky waste from the District Councils, as well as HRCs, is Household Recycling Centre Residual (BCC) 10,301 shredded and delivered to Greatmoor EfW via High Shredded Bulky Waste (BCC) 5,618 Heavens WTS, reducing waste that would otherwise be sent to landfill. In addition to BCC Contract Waste, Total Contract Waste Handled 104,013 Greatmoor EfW also receives Third Party Residual Third Party Residual Waste 200,939 waste. A full summary of the total waste inputs across both facilities is featured in Table 1. Total inputs to Greatmoor EfW 304,952

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 3 3.0 High Heavens Waste Transfer Station

3.1 Background

High Heavens WTS is situated at transfer to Greatmoor EfW, reducing the number of the High Heavens Waste Treatment transport miles required. This central delivery point provides efficient waste transfer, compared with RCVs Complex in High Wycombe, located delivering directly to the EfW facility. As well as to the south of the county. significantly reducing waste transport miles, this also reduces the time, costs and associated environmental This BCC waste treatment complex contains several impacts of the service, allowing the waste services to waste operations and the WTS was developed operate more efficiently in the areas that are needed. As a specifically for residual waste. condition of planning permission, there is a designated transport route (45.3 miles) between High Heavens WTS High Heavens WTS was constructed and commissioned and Greatmoor EfW, which maximises the use of major by FCC Environment and entered into commercial roads and motorways whilst reducing the use of minor operations in November 2015, in advance of the original roads that are not suitable for larger vehicles. June 2016 handover. High Heavens WTS is used as the local delivery point by the Southern District Councils to transfer residual waste to be processed at Greatmoor EfW. The waste is loaded onto articulated vehicles to

Map 2 – High Heavens WTS and Greatmoor EfW, location of council districts and transport route across Buckinghamshire.

Greatmoor EFW A41 Aylesbury Vale District

Aylesbury

Wycombe District Chiltern M40 District

High Wycombe

High Heavens

South Bucks District

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 4 Page 5

3.2 Waste inputs 3.3 Waste outputs

During this contract year, High Heavens The majority of waste from High Heavens WTS processed over 67,691 tonnes of WTS is bulked residual waste destined for residual waste, demonstrating the Greatmoor EfW. benefits of bulking waste from a highly Bulky waste is unsuitable for processing at populated region. Greatmoor EfW and is removed for shredding at the neighbouring treatment facility before returning the Figure 1 identifies the percentage breakdown of waste back into the delivery stream. Oversize waste waste delivered to High Heavens WTS by supplier is undesirable for Greatmoor EfW as it directly affects and Table 2 identifies the amount of waste delivered. combustion efficiency and energy recovery; and can cause significant blockages within the plant. The Figure 1 – High Heavens WTS waste inputs during the contract year (% by supplier) major benefit to shredding oversize waste is that it can still be processed at the EfW facility that would otherwise be sent to landfill. Additional benefits are

8.2% Chiltern and Wycombe non-conforming waste can be separated, disposed District Councils or recycled prior to delivery. 10.2% South Bucks District Council No ad-hoc waste was delivered into High Heavens Household Recycling 15.8% Centre Residual (BCC) in the contract year.

65.8% Shredded bulky waste (BCC)

Table 2 – Tonnes of waste delivered into High Heavens WTS during the contract year by supplier

Waste inputs Tonnes

Chiltern and Wycombe District Councils* 44,511

South Bucks District Council 10,666

Household Recycling Centre Residual (BCC) 6,936

Shredded bulky waste (BCC) 5,578

Total 67,691

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 5 3.4 Waste transfer Transport mileage savings

Transport savings through bulk transfer of waste from High Heavens WTS

Bulking operations of BCC Contracted Waste at on district council collections. That’s more than four times High Heavens WTS successfully reduced transportation around the world. miles by 125,336 miles during this contract year. The miles saed breakdown of this is shown in Table 3.

The transportation saving is calculated by analysing the delivery tonnes and mileage travelled from each location and adding the bulking transfer mileage to Greatmoor EfW. The transportation mileage saving takes into account a predetermined route (45.3 Miles) from High Heavens WTS to Greatmoor EfW, as defined on residual waste from Household Recycling Centres, in the planning permission. We have used the the equivalent of a return trip theoretical vehicle mileage for direct deliveries into from London to Shanghai. Greatmoor EfW, rather than the actual mileage to miles saed High Heavens WTS.

Since year 3 of the contract (April 2018 to March 2019), the average residual waste payload collected from High Heavens WTS improved by 2%, from 23.93t to 24.49t per collection. The improved payload is part of High Heavens WTS commitment to continual improvement on Shredded bulky waste. in the area of transport savings by reducing the That’s the same as a round trip number of deliveries required throughout the year. from London to Ho Chi Minh. miles saed Table 3 – Summary of vehicle movements and associated miles saved due to bulk waste transfer from High Heavens WTS

Waste transferred Vehicle Miles saved due movements to bulk transfer of saved waste from High Heavens WTS

BCC Residual 10,063 107,396

Household Recycling Centre 701 11,544 Residual (BCC)

Shredded bulky 141 6,397 waste (BCC)

Total 10,905 125,337

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 6 3.5 Transport fleet 3.6 Environmental

On 1 June 2016, FCC Environment management awarded a residual waste haulage High Heavens WTS operates under contract to Fred Sherwood and Sons a Pollution Prevention and Control Limited to transport waste between permit (PPC number XP3091ER) issued HH WTS and Greatmoor EfW, and by the Environment Agency. has continued to develop a strong partnership and a successful service. There were no PPC permit breaches and the Environment Agency did not conduct a site The haulage contract includes service performance inspection during this contract year. guarantees to ensure the availability of a sufficient number of delivery vehicles to ensure High Heavens Full details of the Environmental Permit WTS remains in operation. (XP3091ER) can be found here

Branded haulage trailers are in service promoting the partnership between BCC, FCC Environment and the Greatmoor EfW brand. 3.7 Complaints Greatmoor trailers During the contract year, one complaint was raised at High Heavens WTS.

The complaint related to a member of the FCC Environment team using inappropriate language to a Serco delivery driver (C0025). The complaint was investigated and the FCC Environment employee was reprimanded.

The site received no litter complaints during this contract year, which reflects the continued hard work by site staff to keep the site in good order. The continued reduction in complaints demonstrates FCC Environment’s commitment to improving service delivery and site reputation.

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 7 4.0 Greatmoor EfW

4.1 Background

FCC Environment operate and maintain boiler to produce high pressure, high temperature the Greatmoor EfW facility that is located steam. This steam is used to drive a Steam Turbine Generator to generate enough electricity to power to the north of Buckinghamshire County over 40,000 homes. and adjacent to the FCC Environment Calvert Landfill site. The EfW process generates by-products (residues), such as ash and combustion exhaust gases. The Construction of the EfW plant commenced in September Incinerator Bottom Ash (IBA) is removed after the 2013 and the plant became fully operational in June 2016. combustion stage and is continually inspected, with all non-combustible materials separated and The location of the Greatmoor EfW was selected due to recycled, with the remaining ash used as landfill the existing waste transport infrastructure to the aggregate. The Air Pollution Control residues (APCr Calvert Landfill site and the suitability of deliveries from or Fly Ash) produced are removed from the across Buckinghamshire County. Greatmoor EfW also combustion exhaust gases and sent to a facility to be benefits from a rail siding at the landfill site providing neutralised before being landfilled. Combustion options to transport waste via train to the facility from exhaust gases are treated through a complex Flue other locations outside of Buckinghamshire. Gas Treatment (FGT) process that removes harmful emissions before being released to the atmosphere. Greatmoor EfW processes non-recyclable household All emissions to the atmosphere are rigorously residual waste that would have previously been sent controlled and managed by the onsite team and to landfill for disposal. The process involves incinerating continually monitored by the Environment Agency. the waste to recover energy, which then heats a

The process of producing Energy from Waste

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 8 4.2 Waste inputs 4.3 Waste outputs

A total of 304,871 tonnes of household Power generation residual waste were delivered and The Steam Turbine Generator is designed processed at Greatmoor EfW during this to generate up to 32 megawatts (MW) of contract year. electrical power. The breakdown of waste inputs is shown in The facility house load is up to 6 MW and the Figure 2 and Table 4. resultant 26 MW of power is exported to the National Grid system. All of the residual waste received at High Heavens WTS was bulked to Greatmoor EfW. Greatmoor EfW The contract base case exports 23 MW of electrical has been able to process a large amount of Third power and the measurement of how many MW Party waste due to plant efficiencies that allowed the are generated over the specified amount of time site to handle more waste than originally estimated. is referred to as Megawatt hours (MWh). In this contract year Greatmoor EfW exported 190,888 MWh Figure 2 – Breakdown of waste inputs at Greatmoor EfW during of electrical generation. the contract year (% by supplier)

As highlighted in Figure 3, the amount of electricity generated varied over the contract year. The 10.8% Aylesbury Vale District Council reduction in the amount of power exported in May Household Recycling was due to the planned annual outage and the Centre Residual (BCC) reduction in export power in September, October 65.9% 22.2% High Heavens Waste Transfer Station and November were due to plant breakdowns. Third Party Residual waste Figure 3 – Monthly electricity exported from Greatmoor EfW throughout the contract year

25,000

20,000 Table 4 – Tonnes of waste delivered into Greatmoor EfW during the contract year by supplier 15,000

10,000 MWh Waste inputs Tonnes

5,000 Aylesbury Vale District Council 32,917

0 Household Recycling Centre Residual (BCC) 3,365 Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar 2019 2019 2019 2019 2019 2019 2019 2019 2019 2020 2020 2020 High Heavens Waste Transfer Station 67,610 Actual MWh Shredded bulky waste (BCC) 40 Base Case MWh

Total BCC inputs 103,932

Third Party Residual waste 200,939

Total inputs to Greatmoor EfW 304,871

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 9 Residual outputs 4.4 Environmental From the 304,871 tonnes of residual waste treated at management Greatmoor EfW, 62,742 tonnes of ash and residues were removed from the process, representing approximately Greatmoor EFW is regulated by the 20% of all waste handled sent for landfill disposal. In addition, 3,068.86 tonnes of metal was separated out Environment Agency under the Pollution from the IBA and recycled. Table 5 provides a Prevention and Control Permit (PPC) that breakdown of residual waste outputs from Greatmoor is issued to the facility. EfW during the contract year. The PPC integrates specific UK and European Table 5 – Residual waste outputs from Greatmoor EfW Environment and Waste Management directives to ensure the operator acts responsibly to prevent a Waste outputs Tonnes failure to comply with these regulations.

APCr (Before treatment) 11,414.18 A significant environmental risk for all EfW plants is the emissions to atmosphere. Greatmoor EfW has IBA (Before separation) 51,277.95 Continuous Emissions Monitoring (CEMS) equipment installed in the exhaust gas system to constantly Non-conforming waste 49.90 monitor for harmful emissions. This real time data is

Total outputs 62,742.03 recorded and presented to the Environment Agency as evidence that the facility complies with the PPC emissions limits. The Greatmoor EfW operations staff Non-conforming waste materials are unsuitable continually analyse the CEMS emissions data to for the EfW process and are removed during the ensure the plant is operated with PPC regulations. If pre-sorting and inspection stages. These materials are there is any approach to these limits, the operator will removed from the waste source to prevent impacting take action to prevent an environmental incident on the plant’s combustion efficiency and emissions ensuring the requirements of the Environmental control. As highlighted above, the volume of non- Permit are maintained. conforming waste material received at Greatmoor EfW is low and FCC Environment have waste inspection IBA and APCr residues are periodically inspected and procedures to ensure the amount of non-conforming tested by an independent UKAS accredited laboratory waste from Buckinghamshire County Council and Third to ensure the residue characterisation has not changed Party suppliers remains low. and is being appropriately managed.

Waste inspection procedures The PPC Permit UP3734HT requires FCC Environment to prepare and submit quarterly and annual reports detailing FCC Environment operates waste inspection the facilities environmental performance. Regardless of procedures at both High Heavens WTS and this requirement, FCC Environment pro-actively manages Greatmoor EfW facilities to ensure the incineration the facility’s environmental performance with the of non-conforming waste is minimised as far as Environment Agency in real time. As demonstrated in reasonably practicable. The removal of non-conforming the following section, there were no Permit breaches at waste minimises the potential impacts to the operation Greatmoor EfW during the contract year. of plant and any subsequent harmful emissions to the atmosphere. Random inspection activities are scheduled daily throughout the operation of both Full details of the Environmental Permit facilities and any removed waste will be managed (UP3734HT) can be found here appropriately and returned back to their original supplier were practicable.

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 10 Permit monitoring requirements Emissions limits The emission monitoring requirements are set out in The PPC Permit specifies Emission Limit Values (ELV) Schedule 3 of the PPC Permit. There are two types of for all emission substance monitoring. The plant substance emissions monitoring, continuous (all the emissions must not exceed these limits to ensure time) and periodic (quarterly). PPC compliance. In the event of plant abnormal operation affecting the emissions to atmosphere Continuously monitored emissions are measured using above the ELVs the Environment Agency shall be CEMs technology. Exhaust gas sample probes extract formally notified. During this contract year no ELVs concentration samples that analyse and measure each were exceeded. emission parameter. This information automatically updates on the plant control system and is recorded in The ELVs specified in the PPC Permit refers to half a dedicated read only data acquisition system. The hourly and a 24 hour averages displayed in table 7. facility operations team constantly monitor this CEMS data against the plant performance. Table 7 – Half hourly average and daily average Emission Limit Values (ELV) by Substance Periodic extractive sampling is carried out twice a year by a competent UKAS accredited specialist contractor. Extractive exhaust gas samples are Substance Half hour average Daily average (mg/m³) (mg/m³) removed independently from the CEMS equipment and analysed in laboratory conditions. Particulates 30 10

Hydrogen chloride 60 10 Table 6 – Emission monitoring requirements Nitrogen oxides 400 200 Substance Continuously Periodically Sulphur dioxide 200 50 Particulates a Total organic carbon 20 10 Total organic carbon a Substance 10 min average Daily average Hydrogen chloride a (mg/m³) (mg/m³) Carbon monoxide a Carbon monoxide 150 50 Sulphur dioxide a Nitrogen oxides a Ammonia a Nitrous oxide a Hydrogen fluoride a Cadmium & Thallium a Mercury a Heavy metals a Dioxins and furans a

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 11 Continuous monitoring limits Figure 5 depicts the maximum concentration percentage levels of Dioxins and Furans for the period Figure 4 depicts the maximum concentration of April 2019 to March 2020. The graph shows that at no percentage half hourly and full daily emission for the point during the contract year did the facility produce period of April 2019 to March 2020. The graph shows Dioxins and Furans that approached or exceeded the that at no point during the contract year did the facility ELVs. N.B. these are instantaneous values and not emissions approach or exceed the ELVs. N.B these are average percentage values. instantaneous values and not average percentage values. Therefore, each limit was 100% compliant during Figure 6 depicts the maximum concentration this contract year, as shown in the compliance percentage levels of Cadmium & Thallium, Heavy summary Table 8. Metals, Mercury and Hydrogen Fluoride for the period of April 2019 to March 2020. The graph shows that at no Figure 4 – Maximum percentage of emission value point during the contract year did the facility produce during contract year

100% Figure 5 – Bi-annual emission values for Dioxins

90% and Furans during the contract year

80% 20% 70%

60% 15%

50% 10% 40%

30% 5%

20%

Percentage of Emission Percentage Limit Value 0% Percentage of Emission Limit Value Percentage 10% Apr 2019 Oct 2019

0% Carbon Particulate Hydrogen Nitrogen Sulphur Total monoxide chloride oxides dioxide organic harmful emissions that approached or exceeded the carbon Max value ½ hourly as a % of ELV ELVs. N.B these are instantaneous values and not Max value daily as a % of ELV average percentage values.

Table 8 – Summary of Emission Limit Value Compliance Figure 6 – Bi-annual emission values for Cadmium & Thallium, during contract year Heavy Metals, Mercury and Hydrogen fluoride during the contract year Monitoring Element Compliance

Particulates 100% 20% Carbon monoxide 100%

Total organic carbon 100% 15% Hydrogen chloride 100%

Sulphur dioxide 100% 10%

Nitrogen oxides 100% 5%

0% Periodic monitoring of Emission Percentage Limit Value Apr 2019 Oct 2019

A requirement of the PPC Permit is to complete Cadmium & Thallium Mercury independent stack emission testing for Dioxins, Furans, Heavy metals Hydrogen fluoride Cadmium and Thallium, Heavy Metals, Mercury and Hydrogen Fluoride.

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 12 Summary of Plant compliance 4.5 Complaints In addition to monitoring and reporting emissions to air, FCC Environment has a responsibility to monitor the Greatmoor EfW, received two complaints quality of IBA produced by the facility to ensure the in this contract year as detailed below. characterisation remains non-hazardous. All data taken and analysed by a UKAS accredited research facility The first complaint was received in October 2019, as an showed that the IBA remains non-hazardous; ensuring Aylesbury Vale District Council delivery vehicle driver the waste fuel and combustion system is as per design. was reported as driving to close to a visitor’s car on the access road leaving site. The driver was reported to Greatmoor EfW’s environmental performance has BCC. The incident was investigated and it was consistently achieved the PPC Permit ELV levels determined that no further action was required. throughout the contract year. Both continuous and periodic monitoring indicates that the EfW facility The second complaint was received in February 2020, operates well below Environment Agency regulations. raised by a member of the public stating a delivery vehicle had waste escaping from the top of the vehicle. The haulage company was requested to investigate the complaint and all drivers were reminded to ensure their vehicles are adequately covered.

5.0 Integrated Management System

FCC Environment operates an Integrated NCR ID: 665309 Management System (IMS) to achieve and Facility: High Heavens maintain ISO 9001, ISO 14001, ISO 45001 Description: Air spectrum service 25/6/20189 permit to work. and ISO 50001 accreditations. Pre-start meeting and hazards ID sheet are consistent with the RAMS. Permit to work is complete. No plant Greatmoor EfW and High Heavens WTS are operated safety check for the hired (by FCC) MEWP for the and managed under the IMS requirements that have contractor to use. successfully achieved the British Standards Institution accreditations. Date complete: 05/07/2019

NCR ID: 665308 5.1 Internal auditing in Facility: High Heavens Description: this contract year SWP 005 and also checked 10. 005 use of diesel, lists very few of the control measures listed in the risk High Heavens WTS successfully achieved assessment for use of diesel. Checked control a 97.07% IMS audit score in July 2019. measures for the Removal of gas bottles, handling and storage. Referred to the former gas cylinder document Greatmoor EfW IMS audit was scheduled for the in the old IMS. New IMS guidance for gas bottles in 17th March 2020, however due to Covid-19 this IMS-UG- 019. The control measures in the SWPs need audit was deferred to later in the year. to be checked against current working practices and the risk assessment when they are reviewed. A summary of the NCRs (Non Conformance Reports) received during internal IMS audits that were closed Date complete: 05/07/2019 out during this contract year are provided below.

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 13 6.0 Maintenance management

Maintenance management ensures IBA Extractor Forced Conveyor Repairs the EfW plant remains reliable, safe to FCC Environment took the opportunity to undertake operate and demonstrates compliance essential repairs to the Bottom Ash Extractor, 2/3 boiler with statutory legislation. pass conveyor blockage removal and primary air heat exchanger cleaning. The outage was originally planned Greatmoor EfW utilises AX Dynamics for the for one day. The 2/3 pass boiler ash conveyor work maintenance management system. This software delayed the return to service as it required a full boiler package allows for detailed maintenance activity entry, with cool down and ash hang up inspection. scheduling, tracking and recording of plant history to Once the boiler was authorised the rope access team ensure successful maintenance management. cleaned the entry free from ash hanging up on the During the contract year, all maintenance activities walls, roof and cleared the conveyor blockage. were carried out in the determined periodicity. IBA Extractor and Generator Greatmoor EfW carries out an annual shutdown to Rotor Earth Fault undertake lifecycle maintenance and overhaul to maintain plant performance, reliability and safe The plant was removed from service due to a operation. During this year, the annual shutdown Bottom Ash Extractor fault. The failure was caused by a was carried out in May. combination of factors, which included excess volumes of waste on the conveyor, causing it to trip, and had to be removed once the conveyor and boiler were isolated. The conveyor had a seized slat (conveyor belt) hinge pin 6.1 Maintenance issues that required a number of slats to be replaced as they were contributing to the conveyor tripping on high load. Plant Breakdowns A fist sized hole was found in a slat that had allowed ash On occasion the EfW plant will breakdown due to to enter the drive mechanism and a significant number mechanical and electrical faults, resulting in a full of RHS conveyor flights were bent back affecting the plant shut down. Table 10 identifies breakdown operation of conveying waste from the loading point failures and downtime hours, with more details on underneath the furnace grate. each breakdown provided in the following section. However, during the short shut down the 2nd/3rd pass

Table 10 – Summary of major availability losses shower cleaning system leaked water from a stuck open during contract year solenoid, which had resulted from the auxiliary power changeover. Water leaking into the 2nd/3rd pass was

Returned to Hours lost identified and actioned on the second day of the Date Breakdown service date per month shutdown as water was running from the ash conveyor. The water was isolated and the 2nd/3rd pass ash Primary Air 20/08/19 Same Day 6 conveyor was checked, cleaned and managed for Fan trip blockages and defects throughout the shutdown. IBA Extractor During start up, agglomerated ash, that was most likely 24/09/19 forced conveyor 29/09/19 118 attached to the walls, was liberated and blocked the ash repairs conveyor. The team endeavoured to clear the blockage IBA Extractor as normal, however it was evident that the blockage was 21/10/19 and Generator 27/10/19 178 Rotor Earth sufficient to prevent a full start-up and hence the start-up was abandoned and we went into another ID Fan VSD 16/11/19 19/11/19 70 shutdown to clear the blockage internally. To reduce the trip and repair likelihood of this failure in the future, the operations IBA Extractor 29/12/19 30/12/19 27 team will re-write the operations shower cleaning blockage procedure to ensure the water system is isolated after 399 hours each operation rather than during a shutdown only. Total loss (hours) (16.6 days)

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 14 The operations team received a ‘Generator Rotor restoring the power supply to the AVR (Automatic Earth Fault Alarm’ on the steam turbine control Voltage Regulator), the device controls the rotor system, this generator high risk fault can lead to a excitation system that produces power. catastrophic failure of the generator rotor. The machine was removed from service in line with the ID Fan VSD Trip and Repair industries best practice. During the root cause investigation a fault was found with the alarm rotor The ID fan Variable Speed Drive (VSD) tripped causing measuring circuit, however the OEM (ELIN) an immediate full plant shutdown. Danfoss, the OEM recommended carrying out rotor insulation and for the VSD, were called out to repair the drive in line resistance checks to ensure the Generator Rotor was with the maintenance Service Level Agreement. The free from Earth and prove the generator was not in VSD drive tripped due to a catastrophic failure of the danger. To carry out this check required the generator DC smoothing capacitors and the IGBT cards. It is not excitation system located at the end of the machine understood what component failed first. The drive to be stripped down, tested and rebuilt. The testing was repaired with a combination of onsite spares and proved the rotor was free from earth and was not in suppler spares. danger. During start up the generator rotor failed to excite and power could not be produced. Following IBA Extractor Blockage further investigation, the control system had tripped to manual voltage control and field current controller The plant was taken off-line due to unburned during the rotor strip down. The reason for this control waste blocking the ash extractor and hopper, operations trip is unknown as both systems cannot be when investigated the blockage had been cleared. changed over or influenced by the operator. The The opportunity was taken to replace two leaking control functions were switched back to automatic grate rams and the re-circulation duct pneumatic voltage control and voltage controller by removing/ actuator positioner.

7.0 Community liaison

FCC Environment employs a dedicated with views of waste tipping into the bunker, and Waste Awareness and Education loading the system by the large grab crane. Visitors Manager with the aim to raise public can also look inside the furnace inspection hatch to see waste being burnt. awareness of waste issues, including waste prevention, reuse and recycling As well as hosting on-site tours, FCC Environment through educational initiatives. also carry out outreach visits to schools and other organisations within the county. The Waste Awareness Greatmoor EfW has an on-site visitor centre that hosts and Education Manager attends school classes and site tours of the facility for local community groups assemblies to educate and raise awareness about and schools. Tours include showing visitors the control recycling and waste management. room to demonstrate how the plant is operated, along

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 15 7.1 Greatmoor EfW Figure 7 – Breakdown of visitors by sector 2019-2020 Visitor Centre

The headline figures for 2019–20: Bucks Community Schools & Higher Ed • 1,724 visitors 45% BCC & District members/officers • 166 tours FCC Visitors 45% Non Bucks Community Groups • 1,241 attended Outreach Events

• Further increase of % of visitors from schools and colleges, including trebling of % from secondary schools

• 97.17% Excellent or Very Good feedback across six key questions Figure 8 – Breakdown of visitors by sector 2018-2019

On 9th March 2020, in response to the UK Government’s advice regarding the Coronavirus outbreak, the decision 6% was made to postpone visits and outreach work until Bucks Community the Government advice changed. Schools & Higher Ed BCC & District members/officers This resulted in the cancellation of visits from 10 55% 33% FCC Visitors community groups, 5 school visits, 1 open day and the Non Bucks Community Groups Drawing Greatmoor art course before the end of March.

Table 11 – Number of Visitors over the contract year

When the types of visitors are analysed, it shows a large 1st April 2019 – 1st July 2018 – increase in visitors from schools and higher educational 31st March 2020 31st March 2019 facilities. As highlighted in Figures 7 and 8, this year Adult Visitors 1,151 1,058 45% of visitors were from educational facilities, compared with 33% for 2018/19. For the first time the number of Under 16s 573 450 visitors from the education sector has been roughly Total Visitors 1,724 1,508 comparable with the number of community visits.

No of Tours 166 155 There has been a slight drop in visitors from Primary Schools, but a large increase in Secondary School visits Three outreach visits to schools were also cancelled. (up to 4.8% of total visitors from 0.9% in previous year). Estimated attendee figures for the visits to Greatmoor Many of the Secondary School visits were organised totalled 323, which would have taken the visitor figures through Action4Youth, as part of their Inspiration to more than 2000 in the year, for the first time. Programme. There was also a rise in visitors from higher education facilities and other educational organisations, including adults with special educational needs and home-schooling groups.

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 16 7.2 Outreach visits 7.4 Summary of

During the contract year, 21 outreach visitor feedback visits were undertaken to raise awareness FCC Environment encourages feedback from those on waste prevention, reuse and recycling; visiting Greatmoor EfW by providing feedback forms together with the operations at Greatmoor after tours to highlight positive feedback and also identify areas for improvement to continuously focus EfW. A total of 1,241 people attended the on delivering the best service possible. outreach visits. Feedback from visitors has been excellent, which Table 12 – Detail of outreach visits included comments on the structure of the visits and the suitable levels of detail for the audience, providing attendees with a classroom overview to gain an initial understanding followed by seeing the plant in action. Visitor feedback has also shown commitment to change behaviours towards recycling, reuse and

Type of visit Number of visits Number of under 16s Number of adults Number of assemblies/ presentations Number of activity sessions waste minimisation.

Primary 9 525 38 3 14 Schools Table 13 – Feedback summary

Secondary 1 118 8 0 7 Schools % Excellent % Excellent or Very Good or Very Good Bucks 2 148 94 0 0 Tour Section 2019-2020 previous year Skills Show Introduction 100 97 Community 9 14 296 8 1 Group Guided Tour 100 95 Total 21 805 436 11 22 Visitor Centre 94 98 Facilities

Visitor 99 98 7.3 Other highlights Centre Staff

Information 1,000,000 tonnes and provided 99 88 5,000th Visitor Celebration before visit

On 6th September 2019, FCC Environment celebrated Greatmoor website 91 84 the twin milestones of 1,000,000 tonnes of waste processed along with 5,000 local visitors at the facility.

Greatmoor EfW sponsored one million bees for the county of Buckinghamshire. The first bees and hives were welcomed at Greatmoor EfW by Bill Chapple OBE, Cabinet Member for Planning and Environment at BCC and Steve Brown, Operations Director GE+ at FCC Environment. Also attending were representatives from TherapBEE, the Armed Forces charities SSFA and Veterans Association UK, as well as the Mid Buckinghamshire’s Beekeepers Association, the British Beekeepers Association, and Westcott Venture Park, where the hives are located.

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 17 7.5 Local employment 7.6 Liaison Group meetings

There are a total of 48 full time members Since April 2019, there have been three of staff working on the Contract, 41 at Greatmoor Community Liaison Group Greatmoor EfW and 7 at High Heavens (CLG) meetings. Waste Transfer Station. The meetings occur regularly and from Service Of this number, 48% of the staff employed live within Commencement have been held in conjunction with the Buckinghamshire itself, with others from the local Calvert Landfill CLG. These sessions are attended by local surrounding areas of Oxfordshire, Northamptonshire residents, parish councillors, interest groups, and Berkshire. There is only a small number of staff that Environment Agency officers, Buckinghamshire travel from outside of the local vicinity, demonstrating councillors and FCC Environment employees. The good levels of local employment. Greatmoor EfW CLG is an opportunity for members to ask questions in relation to the EfW operations and raise any issues or concerns.

High Heavens also has a Joint High Heavens CLG attended by similar groups as detailed above. As the site is a shared residual waste treatment facility, other operators, and representatives are also in attendance to provide a collaborative approach to the meeting discussion.

8.0 Conclusion

The fourth contract year has been There has been no Environment PPC Permit breaches, successful for both BCC and FCC at either facility, during the contract year. This success Environment at Greatmoor EfW. demonstrates FCC Environment’s credibility as a responsible operator dedicated to operating plant The contract has performed well and built on the within national regulations and guidelines. NO Lost success of previous contract years. The contract time Accidents occurred at Greatmoor EfW or High demonstrates year on year improvements based on Heavens WTS for either FCC Environment employees or both facilities operational success. their contractors in this contract year. FCC Environment are committed to protecting their staff, contractors and FCC Environment has continued to operate and site visitors. maintain the Greatmoor EfW and High Heavens WTS facilities safely and with the utmost respect for the environment. The facilities continue to outperform For more information about FCC Greatmoor, expectations. The EfW plant has been optimised please visit www.greatmoor.co.uk successfully and experiences an increase in the amount For more information about FCC Environment, of waste incinerated. The plant’s thermal efficiency has please visit www.fccenvironment.co.uk been improved increasing the amount of electrical power being exported to the National Grid System and For more information about Energy from Waste subsequently powering more homes and businesses. from Buckinghamshire County Council, please visit www.buckscc.gov.uk/services/waste-and- recycling/energy-from-waste/

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 18 9.0 Glossary

Air Pollution Control residue (APCr) Community Liaison Group (CLG) By products of the flue gas cleaning process and An organised group involving local community typically include ash, carbon and lime due to fly ash representatives, residents and other interest groups materials emitted from the combustion process and to facilitate communication, share information and injection of neutralising agents to clean the gases encourage engagement for those who may be before being released to the atmosphere. These affected by the operation of the waste management materials are hazardous and are removed and disposed facilities. These sessions are hosted by the council of by authorised licence holders for appropriate and operators to provide a transparent platform for collection and disposal. attendees to ask questions.

Automatic Number Plate Continuous Emissions Monitoring Recognition (ANPR) systems (CEMs) Automatic Number Plate Recognition (ANPR) is a Continuous Emissions Monitoring system (CEMs) technology that uses optical character recognition technologies are used to constantly monitor emissions on images to read vehicle registration plates to create from the Energy from Waste process against the vehicle location data. It can use existing closed-circuit emission limit values specified within the Environmental television, road-rule enforcement cameras, or cameras Permit. Gas samples are extracted using a sample specifically designed for the task. probe and analysers are used to measure concentrations of each parameter. Aylesbury Vale District Council (AVDC) Aylesbury Vale District Council (AVDC) is one of four Contract waste local government districts in the non-metropolitan Waste materials that are included in the residual waste county of Buckinghamshire and act as the Waste treatment contract between FCC and BCC. This Collection Authority for this district responsible for includes all residual household waste collected across the collection of residual waste. AVDC is located to the the county by the district councils and residual wastes north of the county. disposed of at the Household Recycling Centres.

Buckinghamshire County Council (BCC) Dioxins and Furans BCC is the administrative body governing the county Dioxins (polychlorinated dibenzodioxin, PCDD) and of Buckinghamshire who are responsible for the Furans (polychlorinated dibenzofuran, PCDF) are disposal of the county’s residual waste and therefore families of complex chemicals containing chlorine. act as the Waste Disposal Authority. BCC are in a 30 There are several hundred dioxin substances. They are year contract with FCC for the treatment of this waste crystalline solids which dissolve in organic (carbon- for energy recovery as a more sustainable alternative containing) solvents, fats and oils – but not in water. than landfill disposal. District Council Carbon monoxide (CO) The District Councils within Buckinghamshire act as Carbon monoxide is a common naturally occurring the Waste Collection Authority and are responsible for chemical but can also be produced from human the collection of household waste and delivery to the activity. It is a colourless, odourless, poisonous gas. facilities on the contract.

Chiltern District Council (CDC) Chiltern District Council (CDC) is one of four local government districts in the non-metropolitan county of Buckinghamshire and act as the Waste Collection Authority for this district responsible for the collection of residual waste. CDC is located to the south-east of the county.

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 19 Emission Limit Value (ELV) Heavy metals Emission Limit Values (ELV) are specified limits for A metal of relatively high density, or of high relative various pollutant emissions from the Energy from atomic weight and includes Arsenic, Antimony, Waste process and are set out as conditions of the Cadmium, Chromium, Cobalt, Copper, Lead, Environmental Permit. Emissions must be monitored Manganese, Mercury, Nickel, Thallium, Vanadium. against the ELV for each pollutant and reported to the Environment Agency. Emissions must remain within Household Recycling Centre (HRC) the specified limits to maintain compliance with the A facility where members of the public can reuse, Environmental Permit. recycle and dispose of their household waste.

Energy from Waste (EfW) Hydrogen chloride (HCl) Incineration process in which residual waste is Hydrogen chloride is a naturally occurring chemical, converted into thermal energy to generate steam that but can also occur in manufacturing processes. It is a drives turbines for electricity production. Energy from colourless, reactive gas with a strong, pungent odour. waste is a method of recovery and therefore preferable In solution with water it forms hydrochloric acid. over landfill disposal. Hydrogen fluoride (HF) Environment Agency (EA) Under normal conditions, Hydrogen fluoride will be The Environment Agency (EA) is a non-departmental a colourless gas, which has a sharp, pungent smell. public body sponsored by the United Kingdom It is highly toxic and irritating, but non-flammable. government’s Department for Environment, Food and Hydrogen fluoride is however usually found as a strong Rural Affairs (DEFRA), with responsibilities relating to solution in water, whereby it is Hydrofluoric acid. the protection and enhancement of the environment. Hydrofluoric acid is an extremely strong acid. It will severely corrode metals, glass, minerals and many Environmental Permit organic (carbon-containing) substances – and will The Environmental Permitting (England and Wales) release highly flammable hydrogen in the process. Regulations 2016 requires waste management facilities to obtain an environmental permit before Incinerator Bottom Ash (IBA) they are allowed to operate. Both Greatmoor EfW Incinerator Bottom Ash (IBA) is a form of ash produced and High Heavens WTS are operated under as a residue from the incineration of Environmental Permits, which are regulated by waste in Energy from Waste (EfW) facilities. This the Environment Agency. material is discharged during combustion and is often processed to recover ferrous metals prior to onward FCC treatment or disposal of the ash products. FCC Environment is one of the UK’s leading waste and resource management companies who has been Integrated Management Systems (IMS) contracted by BCC for the treatment of the county’s An Integrated Management System (IMS) combines residual waste. related management systems of a business into one system for easier management and operations. Quality, Flue Gas Treatment (FGT) Environmental, and Safety management systems are FGT is the cleaning process to remove pollutants from often combined and managed as an IMS through flue gasses emitted during combustion. The treatment combined policies and procedures for more efficient includes a series of chemical processes and filters to and robust management processes. neutralise gasses and remove particulates before releasing to the atmosphere.

Buckinghamshire Residual Waste Performance Report 2019/2020 CONTENTS Page 20 Landfill disposal South Bucks District Council (SBDC) A disposal site where residual waste is buried, spread South Bucks District Council (SBDC) is one of four into layers and compacted. Modern landfills are local government districts in the non-metropolitan engineered to prevent any pollutants from leaking county of Buckinghamshire and act as the Waste into the surrounding soil and water courses. Landfill Collection Authority for this district responsible for the is considered the least sustainable method of waste collection of residual waste. SBDC is located to the disposal and therefore other methods of recycling south of the county. and energy recovery are sought before landfill.

Sulphur dioxide (SO2) Megawatt (MW) Sulphur dioxide is man-made and naturally occurring A unit of electricity equal to 1 million watts, or 1,000 colourless gas with a penetrating odour. It dissolves in Kilowatts. This unit of electricity is the constant used water to form an acidic solution. Sulphur dioxide gas is to represent the power generated from energy from one of the main chemicals that causes acid rain, which waste recovery. Greatmoor EfW is designed to can damage crops and forests and acidify sensitive soils generate 22MW of electricity which is sufficient to and water bodies. power 36,000 homes. Third Party waste Nitrogen oxides (NOx) Residual waste that is not included in the residual The term ‘nitrogen oxides’ (NOx) usually covers two waste treatment contract between FCC and BCC. Third gases - nitric oxide (NO), which is a colourless, odourless party waste includes other municipal waste contracts gas and nitrogen dioxide (N2O), which is a reddish- that FCC have with nearby local authorities. Third party brown gas with a pungent odour. These contribute waste is processed at Greatmoor to fill the capacity of to acid rain, depletion of the ozone layer and have the plant, increase landfill diversion and maximise detrimental effects on health. They are also electricity generation for Buckinghamshire. greenhouse gases. Total Organic Carbon (TOC) Particulates Total Organic Carbon is a measurement of Volatile Particulates is the term used to describe tiny Organic Compounds (VOC). VOC is a term used particles in the air, made up of a complex mixture of to classify a large group of liquids and gases soot, organic and inorganic materials with a particle (containing carbon) that are gaseous or easily size less than or equal to 10 microns diameter (10 vaporize at room temperature. microns is equal to one hundredth part of a mm). Waste transfer station Refuse Collection Vehicle (RCV) A waste transfer station is a building used for the A vehicle commonly referred to as a dustcart bulking of residual waste prior to onward transfer of specially designed to collect waste and/or recycling, waste to a treatment or disposal facility. The transfer and transport the collected materials to an onwards station operating on the residual waste contract is High waste treatment facility. Heavens located in High Wycombe in the South of the County. This site services the southern district councils Residual waste whose RCVs tip residual waste on site prior to bulk waste transfer to Greatmoor EfW. Waste tonnages that remain after reuse, recycling and composting activities have taken place. This typically refers to everything that is disposed of in household Wycombe District Council (WDC) black bin bags. Wycombe District Council (WDC) is one of four local government districts in the non-metropolitan county of Buckinghamshire and act as the Waste Collection Authority for this district responsible for the collection of residual waste. WDC is located to the south-west of the county.

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