WASTE TO ENEEGY

Solid waste generated at domestic level is the single largest component of all wastes
generated in our country. A number of research studies have shown that somewhere 300
to 600 gm of solid waste is generated per person per day in our country.

Eventually, Municipalities everywhere face the problems of waste collection, processing

and disposal or treatment of voluminous solid waste produced by the cities. Moreover,
the rains and humidity on the garbage promotes the bacterial multiplication and enhances
the spread of infectious diseases. Due to their rich organic contents , the solid waste can
be a good resource to produce manure & energy. It has been estimated that about 70 MW
equivalent power could be generated from urban & municipal waste alone. This potential
is likely to increase further with our economic growth.

Gujarat is a fast developing state and have huge gap in demand & supply of electricity
generated by conventional sources. To reduce the gap partly non- conventional energy
sources should be taped.

In order to recover energy from municipal solid waste (MSW) and liquid waste (MLW) ,
Gujarat Energy Development Agency (GEDA) Vadodara , had carried out the Pre-
feasibility Studies in total seven cities ( i.e. Ahmedabad , Bhavnagar , Vadodara , Rajkot
, Bhuj , Bharuch & Valsad ) under “National Programme on “Energy
Recovery From Urban, Municipal & Industrial Wastes” launched by
Ministry of Non Conventional Energy Sources (MNES) Govt. of India.

The Govt. of India has already announced a National policy of fiscal & financial
incentives to private as well as Public Sector entrepreneurs and investors interested in
setting up Urban & Industrial wastes based power projects on Build Own Operate &
Transfer (BOOT ) , Build Own & Operate (BOO) , Build Operate and Transfer (BOT)
and on Build Operate Lease & Transfer (BOLT) basis.

ELIGIBLE WASTE TREATMENT TECHNOLOGICAL OPTIONS :

• Bio-methanation • Gasification / Pyrolysis
• Pelletisation • Incineration
• Sanitary Land filling with gas recovery • Mix of above technologies

MINIMUM CAPACITY & TYPE OF FUEL /ENERGY RECOVERY

ELIGIBLITY :
• Waste to Energy (in the form of fuel 15 TPD
pellets) 300 Cu. m./hour
• Waste to Energy ( in the form of Bio-gas) 2.5 tons/hr. at min. pressure of 20 bars
• Waste to Energy ( in the form of steam) 25 KW
• Power generation from Waste to Energy ( in
the form of electricity)
Waste To Energy Recovery (WTE) Projects Implemented in Gujarat By GEDA

GEDA has implemented two project under MNES Waste to Energy (WTE) scheme
Energy “National policy on Energy Recovery from Urban , Municipal & industrial
Wastes” and one project has been recently sanctioned to SMC by MNES . The details of
respective projects is here as under :

1) 2.0 MW capacity Bio-gas based Power Generation Project at M/S

Kanoria Chemicals Industries Ltd. , Ankleshwar.
This project was commissioned during November (5.11.98 ) 1997-98 financial
year under MNES capital investment subsidy scheme on WTE projects.

The distillery having capacity of 55KLPD is generating about 675 M3/day spent
wash per day . this spent wash is being treated in 2no. Anaerobic Digesters for
Bio-methanation. Approximately 21000 to 24000 nm3 /day Bio-gas (containing
60 – 62 % Methane) is produced daily. The produced gas is further treated for
H2S removal and clean gas is supplied to 2MW Power Plant consisting of 2 no.
generators of 1.003 MW each. The Power plant is connected to existing
Electrical Power Supply System.

In order to have maximum benefits the Waste Heat Recovery System ( W.H.R.U.)
has also been installed and about 1700 Kg/hr (at 10Kg/Cm2 pressure ) steam
generation takes place daily.

Further , The biological sludge /slurry from distillery ETP is piped to ETP sludge
receiving tank and after de watering mixing with press mud is transformed into
Bio-Compost Windrows for 30-45 days to get Bio-Fertiliser.

The Power plant is working since on average 68.5 to 72.3 PLF having average
monthly generation of 1005000 units.

2) Industrial Waste based 4800nm3/day capacity Bio-methanation

Project at M/s Anil Starch Products Ltd., Ahmedabad.
An Up Flow Anaerobic Sludge Blanket technology reactor (UASB) having total
bio-gas generation capacity of 4800 nm3/day has been installed at M/s Anil
Starch Products Ltd. Under Waste to Energy project related interest subsidy
scheme of MNES for WTE projects during financial year 2000-2001.

The project was initially completed & commissioned in April’2001, however gas
generation was not up to the mark because of various teething problems , it
picked up during month of August’ 2001 when it reached to its design level .
 On average about 4300- 4400 nm3/day bio-gas generation is taking place
which is used in the boilers.

Having this bio-gas unit monthly savings of about Rs. 7.40 lacs ( earlier used to
be incurred on coal electricity & lime for starch waste treatment ) on average
is achieved by M/s ASPL .

3) Bio-gas based 0. 5 MW capacity Power Plant at Sewage

Treatment Plant – ANJANA site , Surat Municipal Corporation,
Surat.

MNES has sanctioned 0.5 MW capacity bio-gas based power generation Project
under UNDP/GEF assisted Project on “Development of High Rate Bio-
methanation Processes for Reducing Green House Gases Emmission” . The
project was sanctioned by MNES to SMC at the total outlay of Rs. 161.955 lacs
on 50% cost sharing basis by MNES. vide its sanctioned no. PMC/182-97/ SMC
dated 21st July, 2002.

To monitor the implementation of the project a Project Implementation

Committee (PIC) has been constituted comprising of representatives of SMC,
GEDA & MNES .

4) Industrial effluent based based 5500 nm3/day capacity Bio-

methanation Project at M/s Riddhi Siddhi Gluco Biols Ltd.,
Viramgam , Ahmedabad.

MNRE sanctioned a 5500 nm3 /day capacity bio-methanation project in year

2007-08. The project has been completed & commissioned in February’2008. The
UASB reactor designed for 5500 nm3 is working on 90 % efficieny. The COD
reduction is seen about more than 95%. On average 6100 nm3 gas is daily
generated and used in the coal fired boiler , resulting to coal saving /day about 5.0
Ton .

5) Bio-gas based 0. 975 MW capacity Power Plant at Ms. Sayaji

Industries , Maize Products , Ahemedabad.
About 14000 nm3/day biogas is generated in the Industry as result of Bio-
methanationo of Industrial waste through existing UASB reactors. Approx. 20-
25% biogas quantity was being used for running their drier for gluten product and
remaining biogas was flared. Based on surplus biogas (approx.12000nm3/day)
1MW capacity biogas based power plant was sanctioned by MNRE under its
Biogas to Power head. The project commissioned in June’2009.
6) Industrial effluent based based 12000 nm3/day capacity Bio-
methanation Project at M/s Riddhi Siddhi Gluco Biols Ltd.,
Viramgam , Ahmedabad.

The project has been sanctioned by MNRE under its programme on Energy
Recovery from Industrial & Commercial effluent /waste. Basic objective of
objective was to support their Coal based Co-gen power plant. The project has
been commissioned in Jan’2010 and approximately 700-720 Ton coal (worth of
Rs. 21.60 lacs) is saved monthly by means of biogas supply to coal fired boilers.
Power Generation Cost :

Cost of per MW power generation is dependent on the land availability , technology

adoption , qualitative & quantitative aspects of the waste material , handling / Eco-
friendly treatment technology adaptability , which needs a through detailing in the pre-
requisite DPR for setting up Power project .

TECHNOLOGY MSW LAND COST( RS. IN CRORE

QUANTITY (ACRE) PER MW ) +
(MT)
BIOMETHANATION 150 6 6-9
PELLETISATION 125 3 5.0
INCINERATION 100 2 5.0
* CELL RICH 150 7. 5 1. 5
(COMPOSTING) (Per 37. 5 Tones of manure
• There is no generation of Power.
• + Base year 1994 -95

Incentives available from Central Govt. (MNRE) for Energy Recovery

from Industrial & commercial wastes:

Scope: The incentive scheme provides CFA in the form of capital subsidy
and Grant –in – Aid in respect of following activities.

i) Industrial waste to biogas

ii) Power Generation from Biogas
iii) Power Generation from solid industrial waste
iv) Promotional activities
v) R&D , Resource assessment, technology upgradation and performance
evaluation, etc.

Eligibility Criteria:
a) Criteria based on type of wastes:
i) Projects based on any bio-waste from industrial / agro-
industrial sector (excluding rice husk & bagasse) that require
pre-processing before utilization for energy recovery.
ii) Projects for Co-generation/power generation from available
biogas.
iii) Mixing of other wastes of renewable nature, including rice
husk, bagasse, sewage, cow dung, other biomass and
industrial effluents, including distillery effluents, up to a
maximum of 25% will be permissible.
 iv) Projects based on distillery effluents for generation of biogas,
wastes from fossil fuels and waste heat (flue gases) shall not
be supported.

b) Criteria for Technologies :

i) Projects based on waste–to–energy conservation
technologies, namely bio-methanation , combustion, or a
combination thereof.
ii) Projects for generation of power from biogas through 100%
biogas engines or steam turbines with aminimum steam
pressure of 42 bar.

c) Criteria based on capacity:

There will no minimum / maximum limit of project capacity.

Details of Capital Subsidy to Promoters

Sr. Waste /process/Technologies Capital subsidy

No.
1. Industrial waste to biogas
i) Biomethanation of low energy density Rs. 1.0 crore / MWeq.
and difficult industrial wastes (i.e. dairy, (12000 Cu.m. per day)
tannery, slaughter house, sugar
(liquid),bagasse wash, textile (liquid),
paper (liquid), and pharmaceutical
industry)
ii) Bio-methanation of other industrial Rs. 0.50 crore / MWeq.
wastes (12000 Cu.m.per day)
2. Power Generation from Biogas

i) Boiler + Steam Turbine Configuration Rs. 0.20 crore / MW

ii) Biogas Engine + Turbine Configuration Rs. 1.00 crore / MW
3. Power Generation from solid Industrial Rs. 0.20 crore / MW
Waste (boiler + Steam Turbine
Configuration)
 WTE Potential in INDIA

Based on the structured data base prepared by using four- step Methodology :
1)Preparation of Preliminary Database
2) Data Classification
3) Identification of missing data
4) Creation of Structured Database and
Project specific web site ( www.indiawteplan.com), the potential in the Urban and
Industrial Sectoresis as mentione below

Urban sector :
Municipal Liquid waste (sewage) conversion to Energy Generation
Year Sewage Generation Power generation
(MLD)
2007 14151 264
2012 16523 308
2017 19542 365

The treatment of the urban liquid wastes is principally managed by local bodies and
supported financially to some extent by the MoEF through NRCD’s River Action Plans
for some identified River Basins. Since Waste to Energy projects are an integral part of
the overall waste water treatment, MNES has a limited role in the overall project being
executed with NRCD support or directly by the Municipality.

Out of these projects, only those, which use anaerobic systems, will be amendable to
energy generation. Also the amount of power generated by these plants is generally
sufficient to meet about 60% (in some cases 100%) of power needs of the plant itself thus
making it a “captive generation plant”.

Considering the above, although urban liquid waste has potential of conversion to energy
, the scope for MNES initiative is rather limited , for the projects approved by NRCDs.

Municipal Solid Waste

The potential of the MSW for conversion to energy is presented below :

Energy Generation Potential from MSW

Period MSW Generated (TPD) Power Generation (MW)
2007 130927 2266
2012 189986 3276
2017 265834 4566
Under the Municipal Solid Wastes (Management & Handling) Rules of December 2000,
all Class I cities have to provide proper treatment and disposal facility for MSW. This
translates to a very significant potential for Waste to Energy projects.

Based on the above it was decided that, in urban sector, focus of the NMP would be
primarily on MSW with emphasis on class I cities. The present policy for MLW however,
would be continued.

Industrial Sector
Energy Generation Potential in Identified Industrial Sectors.

Sectors Period
2007 2012 2017
Dairy 61 779966
Distillery 503 628 785
Maize Starch 105 132 164
Liquid waste 24 30 37
Solid waste 81 102 127
Tapoica Starch 24 30 37
Liquid waste 18 122 27
Solid waste 6 8 10
Poultry 65 81 102
Paper 58 72 90
Slaughterhouse 94 117 146
Sugar 363 453 567
Liquid waste 59 73 92
Solid waste 304 380 475
Tanneries 6 8 10
TOTAL 1279 1598 1997

The priority rating of various industrial sectors for waste to energy projects is based on
sector power potential , waste availability / collection , emerging clean technology and
technology status . The identified priority areas based on these criteria are shown below:

Prioritization of Industrial sector for WTE Projects

SECTOR GRADE / PRIORITY
Distillery , Paper, Sugar (Press mud) , A
Maize Starch
Dairy, Sugar (liquid), Poultry Farms, B
Slaughter house, Tapioca Starch
Tannery C
(Ref: Technical Memorandum on Shelf of viable Projects ,
August’2003)
The approach proposed for the industrial sector is that the focus should be on the priority
sectors, for sectors where individual units do not have a potential for energy generation
(e.g. Poultry, Cattle Farms etc.) clusters of units would have some potential, which can be
tapped. A mechanism similar to CETPs can be considered to harness the energy potential.

Evaluation of WTE Technologies

The most significant waste- to- energy technologies are based on the biological or
thermal methods. Biological method involves bio-methanation producing methane-
enriched bio-gas, which can be used as fuel. Whereas thermal method involves
combustion of organic wastes as fuel with the evolution of heat energy for recovery.
Advanced thermal conversion involves destructive heating of organic materials with a
limited supply of oxygen (gasification) or without any oxygen (pyrolysis) to produce a
combustible gaseous product consisting of simple hydrocarbons and hydrogen.

The above WTE technology options have been analyzed and ranked using a set of
evaluation criteria consisting of system configuration , system auxiliaries , environmental
aspects, resources recovery and commercial aspects ( Reference : Technical
Memorandum on Waste To Energy Technologies).

Urban Sector :
Ranking of Technologies
Technology Ranking
Biological methods
Bio-methanation 1
Landfill with Gas recovery* 2
Thermal Method
Gasification 3
Combustion 4
* Landfill with Gas recovery is excluded as a potential technology option in view of “The
Municipal Solid Waste (Management & Handling) Rules, 2000.Under unavoidable
circumstances or till installation of alternate facilities , landfill shall be done following
proper norms.

Industrial Sector
Identified Industrial WTE Technologies
Type of Waste Technology
Liquids Bio-methanation
Solids Gasification / Pyrolysis, Incineration / Combustion
Semi- solids Biomethanation, Gasification/ Pyrolysis, Incineration/
Combustion
 Desirable range of important waste parameters for technical viability of
Energy Recovery

Waste Treatment Basic Principle Important Waste parameters Desirable

Method range*
Thermo-chemical Description of • Moisture content < 45%
conversion organic matter by • Organic / Volatile matter > 50%
- Incineration action of heat • Fixed Carbon < 16 %
- Pyrolysis • Total Inert < 36 %
- Gasification • Calorific Value (NCV) >1200 kcal/kg.
Bio-chemical Decomposition of • Moisture Content > 60 %
conversion organic matter by
-Anaerobic Digestion / microbial action • Organic / Volatile matter > 40 %
Bio-methanation
• C/N Ratio 25 - 30
* Indicated values pertain to segregated / processed / mixed waste and do not necessarily
Correspond to wastes as received of the treatment facility.
 Power Generation through Renewable Energy Sources

Gujarat is a fast developing state and needs a huge amount of electricity for its high
profile growth. There is tremendous potential of power generation in the state through
non –conventional energy sources (i.e. wind, solar and bio-mass). The Bio-mass, urban
& industrial wastes could be the best sources in our state for power generation in
centralized as well as de-centralized manner.

The power generation projects may be basically categorized in to two

categories as follows:

1) Grid connected power generation projects.

2) Captive / de centralized power generation projects.

The type of waste/raw materials & wastes treatment technology options for Grid
connected & captive /de centralized power projects is defined here as under:

Sr. Power generation Grid connected Captive/ Technological

No. projects power projects De centralized treatment path
power projects
1. Biomass based power Crop residues Woody bio-mass Gasification /
generation combustion
2. Municipal solid waste Municipal solid waste Agro. food Combustion Bio-
based power projects, & distillery wastes processing methanation ,
Urban & Industrial industrial wastes Gasification,
waste based power canteen waste, Refused derived fuel
generation vegetable market technology,
yard waste, press pyrolysis &
mud , dairy waste gasification.
etc.
3. Bagasse based Bagasse - Combustion /
Co-generation pyrolysis
Projects
4. Animal Dung based - Cow dung Community &
electricity generation Institutional bio-gas
in villages gaushalas Technology
/ Panjrapoles .