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Process flow diagram Keppel Seghers

Keppel Seghers is a leading provider of

comprehensive environmental solutions,
and provides consultancy, design and
Stack engineering, technology development,
construction, operation and maintenance
Cooling towers Turbine building
of plants and facilities, as well as investments
Steam export in large-scale environmental projects.
To INEOS Chlor

Keppel Seghers’ advanced technology solutions

Carbon Lime
address a wide spectrum of environmental
issues for both solid waste and water.
Waste Plant
Non-Catalytic Superheated Steam
Providing a Waste Management
To date, Keppel Seghers has executed more Solution for Greater Manchester
Secondary air Boiler than 100 waste-to-energy projects and more
Residue Continuous
Digestate Bunker storage Emission than 350 water and wastewater projects in
Monitoring more than 25 countries worldwide.

Keppel Seghers is a wholly-owned subsidiary

of the Keppel Infrastructure group, which is
a division of Keppel Corporation Limited, a
leading company listed on the Singapore Exchange.
Residue Dry Flue Gas Dry Flue ID-Fan
discharge Treatment Gas
RDF Bunker Combustion Primary Ash Stage 1 Treatment
grate air bunker Stage 2

General information
Client Phase I: Ineos Runcorn TPS

Phase II: Viridor Waste Management - Ineos Chlor

Scope Design & Build; EPC-turnkey

Process Combined Heat & Power

Project specific info Phase I is part of the GMWDA PFI Scheme

Waste delivered by road and rail


Capacity 375 ktpa (mechanically designed 375 ktpa (mechanically designed

for 425 ktpa) for 425 ktpa)

Calorific value 11.5 MJ/kg design & 13 MJ/kg @ 11.5 MJ/kg design & 13 MJ/kg @
nominal operation point nominal operation point

Combustion grates Water-cooled (2 X 9.9 m width) Water-cooled (2 X 9.9 m width)

Keppel Seghers Pte Ltd Keppel Seghers Belgium NV
Boiler 2 X 100 Tph 52 barg, 2 X 100 Tph 52 barg,
400°C superheated steam 400°C superheated steam 1 HarbourFront Avenue Hoofd 1
Flue gas treatment capacity 2 X 170,000 Nm3/h 2 X 170,000 Nm3/h
#05-05 Keppel Bay Tower 2830 Willebroek - Belgium
Singapore 098632 Tel: +32(0) 3880 7700
Thermal power 2 X 87 MWth 2 X 87 MWth
Tel: +65 6278 1800 Fax: +32(0) 3880 7749
Steam export 51.2 MWth (70t/h @ 16 barg) NA Fax: +65 6278 07771 Email:
Electrical power 34.7 MWel 47.5 MWel Email:

Waste management Proven technologies for
solution for the future sustainable solutions
Across the globe, growing volumes of waste, EfW plants help Keppel Seghers’ EfW installations and
shortfalls of landfill areas and soaring energy technologies effectively convert waste into
prices are making Energy-from-Waste (EfW) battle climate valuable energy and remove pollutants from
a leading solution for a cleaner future. change by reducing emissions. In-house technologies by Keppel
Seghers that can be found in the Greater
EfW plants not only help in landfill diversion
greenhouse gas Manchester EfW plant include the:
through as much as 90% reduction in the volume emissions by landfills
of waste disposed; using proven technology, the • Keppel Seghers Water-cooled Multi-Stage
plant releases the energy embedded in materials Grate which can withstand high temperature
such as plastics, paper, wood scraps and food abrasion, as well as ensure thorough mixing
scraps, and uses that energy to generate and even burning of the waste Keppel Seghers’ proprietary EfW technologies integrated
electricity and steam, thereby replacing into the plant
substantial amounts of fossil fuel. • Boiler with Keppel Seghers Prism Technology
which provides an optimal secondary air
Compared to landfills, EfW plants are also a decomposition from organic matter in landfills. injection, thereby increasing plant availability
“greener” way of waste disposal, as they reduce With a well-regulated flue gas treatment system, The plant can divert more than 75% of Greater Manchester’s waste from landfill and prolonging operation times between
the production and emission of the greenhouse emissions from EfW plants do not pose a threat planned maintenance
gas, methane, produced during waste to public health and the environment.
• Double Dry Flue Gas Treatment System which
Preferred EPC partner effectively removes harmful and acidic gases,
dust and particulates so that only clean air,
compliant with the EU standards, is emitted
Keppel Seghers, the environmental engineering of the total energy needs of Ineos Chlor’s
Keppel Seghers Water-cooled Multi-Stage Grate with
arm of Keppel Infrastructure, is the preferred Runcorn manufacturing site. Keppel Seghers Prism technology
partner for the Engineering, Procurement and
Construction (EPC) of the Greater Manchester Phase II is built for Viridor EFW (Runcorn) Ltd.
EfW Combined Heat and Power (CHP) Plant. and will be available for the market generally,
Keppel Seghers secured the contracts for as steeply rising landfill tax drives residual waste
Phase I and Phase II of the integrated EfW disposal away from landfill towards EfW.
project, worth about GBP 390 million in total,
in 2009 and 2010 respectively. The first-of-its-kind combined plant will be one
Stringent air pollution controls
of the largest and most efficient in Europe when
Phase I is built primarily as part of the Greater completed, with a total capacity to treat 750 ktpa Modern EfW plants that are well managed and - A scrubber sprays a mixture of dry hydrated
Manchester Waste Private Finance Initiative (PFI) of solid recovered fuel (SRF) and to produce regulated do not pose any threat to public health. lime and active carbon into the hot exhaust
project to manage 1.3 million tonnes of municipal 83 MW of electricity and 51.2 MW of heat by At the Greater Manchester EfW Plant, special gases to neutralise acidic gases
waste handled by the Greater Manchester Waste steam export per year. The entire project is attention is given to flue gas cleaning through the
Disposal Authority (GMWDA) each year. The plant expected to be completed by 2014/15. application of a dual ‘all dry’ scrubbing system. - A carbon injection system blows powdered
can divert more than 75% of Greater carbon into the exhaust gas to absorb mercury.
Manchester’s waste from landfill. Built to Keppel Seghers’ proprietary EfW Typically, an EfW plant uses the following Carbon injection also reduces emissions of
technology, the plant will use Keppel Seghers’ methods to remove pollutants from its emissions: trace organics such as dioxins
The plant will be built for Ineos Runcorn TPS, Water-Cooled Grates, its horizontal boiler
a special purpose vehicle set up by Viridor Waste design integrated with its Prism technology - A selective non-catalytic reduction process - A baghouse works like a giant vacuum cleaner
Management (Viridor), John Laing and Ineos Chlor for enhanced heat recovery and its double converts nitrogen oxides and water to harmless with hundreds of fabric filter bags that clean
for the procurement, operation and maintenance dry flue gas cleaning system. nitrogen by spraying ammonia or urea into the the air of soot, smoke and metal
Waste is delivered by rail to the Greater Manchester EfW plant and transferred to trucks for tipping of the plant. The plant will produce around 20% hot furnace