A Plant for Australian Conditions

The Concept

  • This plant features the most recent Grate technology and combustion control system developed by Martin GmbH – Germany. It is the culmination of 90 years ongoing development.
  • The Plant has three Reverse-Acting Vario Grate runs. Each longitudinal grate run is divided into 3 sections so that the reverse action speed can be adjusted at different point along the grate as part of the control process. This process achieves better than 99% burnout of combustibles and optimum efficiency in down line components of the plant - boiler, emission control and residue management, water and other consumable use.
  • Martin Engineers have studied Australian typical Calorific values of waste and other conditions. Their analysis has produced an Australian version that will target efficiency and economy that meets the most stringent emission standards – typically better than those required under the current Euro WID directive for WtE plants.

A Plant for Australian Conditions - The Concept

 

The Plant Footprint

  • Land-area requirement for a plant of 250,000 tonnes throughput capacity is 50,000 m2, which includes offices parking plant footprint and service maintenance workshop.
  • Additional area required for doubling plant capacity by installation of a second line of 250,000 tonnes capacity would be an additional 8000 m2. Plant design would provide for possible expansion.
 

Visual Presence

  • Architectural design – This is the client/community’s choice.
  • In Europe, some plants have become architectural icons, valued for their aesthetic as well as their utilitarian effect. At the extreme end, a plant now in construction in Northern Europe will have a built-in ski slope, rock climbing wall and coffee shop on the side and high up the emission stack.
  • Some plants have glass coverings reflecting light in the day and emitting it in attractive patterns and sequences at night. Emission stacks can have artistic shapes and colours – or can be hidden entirely.
  • Generally plants are welcomed in the landscape as reminders to communities of the contribution they make to provide heating and electricity in an environmentally friendly way, by disposing of residual waste as a better alternative to landfill.
 

Plant Throughput and Output

  • One line Martin Reverse-Acting Vario Grate, High-Efficiency Boiler and Steam Turbine.
  • 250,000 tonnes MSW per annum – 31 tonne per hour.
  • MSW calorific value per kg range from 8,000 – 16,000 mj.
  • Life expectancy of plant is 25 -30 years
  • Burn efficiency of carbon content of waste in a self-sustaining uptime of 90% – 7824 hrs (90%) per yr.
  • Plant outputs ideal is CHP steam use for industry and some electrical.
  • Waste does not need any pre-treatment. Crushing of very large items occur for large furniture items – e.g. linen cupboards or large mattresses, in order to allow entry to the furnace chute.
  • Dirty water can be taken into the plant and refined within the plant for use in boilers and steam turbines, minimising demand and cost for reticulated supply.
 

Plant Energy

  • Start up and shut down – fuel oil.
  • Normal plant operation requires just 3 MW electricity, supplied by plant output.
  • Staffing – approx. 45 people, based on 4 operational shifts per day. Staff numbers include Administration and Basic-Maintenance operational staff.
  • For double capacity – i.e. one more line 250K tonnes per annum added – 1 staff member per operational shift.
  • Electrical output net - 23 MW continuous at 26% efficiency.
  • Steam at 450 degrees 64 bar at 82 % efficiency.
 

Plant Emissions

  • Monitoring of emissions will occur on a continuous basis.
  • Emission performance will be available for report on the facility website monthly.
  • In addition to local monitoring, emission reporting as part of overall performance data will be available online for monitoring by Martin Corporation Engineers in Munich, Germany.
  • Australian authorities hare indicating that Euro standards will likely apply in licenses for Australian WtE plants and the proposed plant will meet all of the Euro WID standards. There are more than 400 operating Martin plants that conform, or improve upon Euro WID standards by more than 50% for many emission items including CO, NOx HCI, SO2 and VOCs.
 

Flexibility for the Future

  • The Reverse-Acting Vario Grate, under and overfire air controls, reburning of some flue gasses and infrared camera analysis of real time combustion feed a fuzzy logic control program to adjust plant operational settings on an ongoing basis. These controls (together with additional monitoring through all plant components) feeds adjustment decisions to base settings and components to maintain full operational capacity of the plant.
  • Plant designs now recognise that the character waste can change within a few years as materials change and therefore emphasise the best environmental and conservation outcome changes at different points in the waste hierarchy.
  • Also, while the plant operates as an integrated unit, the component parts can be replaced if necessary when technological improvements are available to improve efficiency, or to accommodate new functions.
  • Urban mining is one new function – now technically possible, but needing improvement for guaranteed financial viability. It allows extraction of precious metals (gold, silver, platinum etc) and rare earths from bottom ash in addition to ferrous metals, which are already easily extracted for sale and reuse.

A Plant for Australian Conditions - Flexibility for the Future

 

Plant Maintenance

  • This plant will follow the typical design and experience pattern of Martin Plants (i.e. > 90% uptime on a base of 365 days 24 hrs per day). This translates to 7824 hrs per year.
  • To achieve 90 % uptime, cleaning and maintenance is built into plant components, or by maintenance staff while the plant is operating.
  • Once per year the plant is closed down for major servicing and parts replacement if required. This shutdown period is 2-3 weeks only. Experience through years of operation with hundreds of Martin plants, plus ongoing monitoring results in individual plants, makes major maintenance functions routine operations with few possibilities for surprises.