WASTE TO ENERGY IN THE AGE OF THE CIRCULAR ECONOMY COMPENDIUM OF CASE STUDIES AND EMERGING TECHNOLOGIES NOVEMBER 2020 ASIAN DEVELOPMENT BANK WASTE TO ENERGY IN THE AGE OF THE CIRCULAR ECONOMY COMPENDIUM OF CASE STUDIES AND EMERGING TECHNOLOGIES NOVEMBER 2020 ASIAN DEVELOPMENT BANK Creative Commons Attribution 3.0 IGO license (CC BY 3.0 IGO) © 2020 Asian Development Bank 6 ADB Avenue, Mandaluyong City, 1550 Metro Manila, Philippines Tel +63 2 8632 4444; Fax +63 2 8636 2444 www.adb.org Some rights reserved. Published in 2020. ISBN: 978-92-9262-483-5 (print); 978-92-9262-484-2 (electronic); 978-92-9262-485-9 (ebook) Publication Stock No. TIM200332-2 DOI: http://dx.doi.org/10.22617/TIM200332-2 The views expressed in this publication are those of the authors and do not necessarily reflect the views and policies of the Asian Development Bank (ADB) or its Board of Governors or the governments they represent. 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On the cover: Municipal garbage truck brings about 3,500 tons of garbage daily from a waste transfer station to a waste-to-energy plant in the People’s Republic of China (photos by Lu Guang, 12 February 2014). Waste-to-energy plant in the People’s Republic of China. (photos by Lu Guang, 12 February 2014). CONTENTS Tables and Figures iv Abbreviations and Units and Measures vi Executive Summary viii 1 Overview of Waste-to-Energy Case Studies 1 1.1 Baku Waste-to-Energy Plant 4 1.2 Pilot Project Waste to Energy with Bio-Drying 12 1.3 Decentralized Plastic Pyrolysis 19 1.4 Plastic-to-Liquid Fuel 27 1.5 Ankur Waste-to-Energy Project 34 1.6 HighCrest Corporation 42 1.7 Decentralized Waste Management Model 51 1.8 Carbon Masters Koramangala Plant 60 1.9 Combined Heat and Power Facility 68 1.10 150-Kilowatt Electrical Power Generation in Dual Fuel Mode 72 1.11 Australian Bio Fert Small-Scale Biological Fertilizer Demonstration and Product 75 1.12 CBE—Clean Energy Community 82 1.13 ID Gasifiers Coconut Shell-Fueled Module—Coconut Technology Centre Development 88 1.14 Sumilao Farm Waste to Energy 96 1.15 Waste to Energy Siang Phong Biogas 101 1.16 Kitroongruang Compressed Biomethane Gas Project 110 1.17 Rainbarrow Farm Poundbury 116 1.18 Yitong Distributed Waste-to-Energy Project 123 2 Emerging Technologies 131 2.1 EcoFuel Technologies 134 2.2 Pragmatec & Pyro-Kat Environmental Technologies GmbH 136 2.3 InEnTec 138 2.4 Enerkem (Canada) 140 2.5 Fulcrum BioEnergy 142 2.6 Cogent Energy Systems 144 2.7 Orsted (formerly DONG Energy) 146 2.8 Oak Ridge National Laboratory 147 2.9 Sekisui Chemical/LanzaTech 149 2.10 Walbruze Waste Energy Management 151 2.11 Ecalox 152 References 153 TABLES AND FIGURES Tables 1 Summary of Project Examples 2 2 Performance Indicators of Baku Waste-to-Energy Project 10 3 Energy Balance 23 4 Mass Balance 23 5 Result Specification 23 6 Associated Costs in Processing Vegetable Market Waste in Virudhunagar 24 7 Emissions of Ankur Gasification Technology 38 8 Indicative Assumptions for Economic Analysis of Gasification Technology 39 9 Mass Balance 45 10 Energy Balance 45 11 Economic Analysis of the Biogas Project 47 12 Revenue and Costs of Saahas Zero Waste Three Verticals 56 13 Financials of Zero Waste Program 57 14 Biogas Composition 61 15 Costs and Revenue of Carbon Masters Waste-to-Energy Facility 64 16 Amount of Waste Collected, Useful Products Generated, and Carbon Dioxide Saved 65 17 Estimated Energy Requirements for a 64,000-Ton Fertilizer Plant 79 18 Extract from 2017 Merrijig Pasture Trials 80 19 Financial Scenarios for Cassava Starch Factory Owner (Simplified) 105 20 General Estimation of Cost and Performance Metric for Biogas 120 21 Input of Waste 129 22 Capital Cost of Demonstration Project 129 23 Revenue on Demonstration Project 130 24 Summary of Featured Emerging Technologies 133 Figures 1 Location of the Baku Waste-to-Energy Project 5 2 Principle Diagram of Baku Waste-to-Energy Plant 8 3 Baku Waste-to-Energy Plant Water Loop System 9 4 CONVAERO Membrane-Covered System 13 5 Complete Process 15 6 Summary of Results 16 7 Waste Management Supply Chain 20 8 Waste Management Processes 20 9 Major Impacts of the Decentralized Plastic Pyrolysis Project 25 10 Process in Converting Plastic-to-Liquid Fuel 28 11 Distribution of Normal Alkanes in Diesel Samples 31 12 Distribution of Components in Diesel Sample Based on Carbon Number 31 13 Ankur Gasification Process 36 Tables and Figures v 14 Gasification Process 37 15 Biogas Flowchart 44 16 Plant Layout 44 17 Key Parameters in Design 45 18 Saahas Zero Waste from Linear to Circular Principle 52 19 Three Verticals of Saahas Zero Waste Services 53 20 Carbonlites Cylinders—Process Flow 62 21 Carbonlites Business Model Illustration 64 22 Process Flow of Pepsi Rosario Biomass Power Plant 70 23 Process of Generating Ultra Clean Gas 73 24 Simple Diagram of Nutrient Recovery and Recycling Process and Production 76 of Organics-Based Fertilizer 25 Manufacturing Process Diagram 77 26 Computer Image of Small-Scale Biological Fertilizer Demonstration 78 and Product Development Facility 27 CBE Combustion Process 84 28 Schematic Diagram of CBE Business Model 85 29 Financial Forecast for 20-Year Project Lifetime 86 30 Schematic IDG Process 91 31 Process Flow of Sumilao Biogas Plant 97 32 Native Starch Process 102 33 Biogas Production Process Using CIGAR Technology 104 34 Financing Structure 107 35 Impact of the Biogas Plant 108 36 Gas Desulfurization 118 37 Schematic Diagram of the Membrane System 118 38 Layout of the Yitong Factory 124 39 Yitong Waste Processing Flow 125 40 Heating and Electricity with Straws 126 41 Waste Sorting and Crushing and System 127 42 Anaerobic Fermentation Process 127 43 Aerobic Fermentation Process 128 44 Plastics Anaerobic Digestion Process 128 45 Technology Readiness Level 132 46 Type of Plastics 134 47 Schematic of Larger Ecofuel Units 135 48 Process Overview 140 49 Comparison of HelioStorm Operational Parameters 145 50 PFD of DRANCO Plant in Hengelo, The Netherlands 148 51 Sekisui Chemical and LanzaTech Technology 149 52 Ultimate Recycling System 150 53 Equipment and Production Process of the Wastrong Machine 151 ABBREVIATIONS AND UNITS AND MEASURES ADB – Asian Development Bank BOOT – build–own–operate–transfer CAPEX – capital expenditure CBE – Clean Energy Community CBG – compressed biomethane gas CHP – combined heat and power CIGAR – Covered-in-Ground Anaerobic Reactor CNG – compressed natural gas CNIM – Constructions Industrielles de la Méditerranée COD – chemical oxygen demand EFT – EcoFuel Technologies, Inc. EPR – extended producer responsibility GHG – greenhouse gas HDPE – high-density polyethylene HFO – heavy fuel oil IDG – ID Gasifiers Pty, Ltd. KPP – Kokonut Pacific Pty KPSI – Kokonut Pacific Solomon Islands LPG – liquified petroleum gas LSFO – low sulfur fuel oil MRF – material recovery facility MSW – municipal solid waste PAH – polycyclic aromatic hydrocarbon PCPPI – Pepsi Cola Products Philippines, Inc. PEA – Provincial Electricity Authority (Thailand) PEM – plasma enhanced melter PPA – power purchase agreement PRC – People’s Republic of China PTF – plastics to fuel RDF – refuse-derived fuel Abbreviations and Units and Measures vii SRF – solid recovered fuel SZW – Saahas Zero Waste TRL – technology readiness level UK – United Kingdom US – United States WtE – waste to energy ZWP – zero waste program Units and Measures GW – gigawatt kCal – kilocalorie kg – kilogram kJ – kilojoule kV – kilovolt kW – kilowatt kWe – kilowatt electrical kWh – kilowatt-hour m3 – cubic meter MJ – megajoules Mt – metric ton MW – megawatt MWe – megawatt electrical MWh – megawatt-hour MWt – megawatt thermal Nm3 – normal cubic meter T – tonne* TPD – tons per day tph – tons per hour wt% – weight percent * T is referred to as tonne (metric) which is equivalent to 1,000 kilograms. In the US, ton is used, which is equivalent to 0.907185 tonne or 907.185 kilograms. $1:€:0.756 as of 31 December 2012 (Source: https://forex.adb.org/fx_rate/getRates) EXECUTIVE SUMMARY his compendium to the Waste to Energy in the Age of the Circular Economy Handbook outlines waste-to-energy project implementations with background, technology, financing, operations, Tand lessons learned.