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Treasure Legacy Sdn. Bhd. Page 1


INSTALLATION AND OPERATION OF
TREATMENT PLANT CONVERTING WASTE TO
DIESEL USING CLPD TECHNOLOGY
1. INTRODUCTION
The project involves the treatment of solid organic and inorganic waste into DIESEL.
The process is known as Catalytic Pressure-less Depolymerization (CLPD) and
henceforth will be referred to as CLPD Technology. Since its first inception in
Germany, more of this CLPD plants are already in operation in Germany, Italy, USA,
Bulgaria, Canada, Spain and Mexico. These plants practically run by itself, as the
diesel produced is use as fuel for the plants.
International Consulting Service (ICS), Abu Dhabi, who holds the marketing right
for the technology, provides the opportunity to Treasure Legacy Sdn. Bhd. (TL) to
lead the development of CLPD plant. Initially the focus will be in South East Asia,
starting with Malaysia. Now we are studying the possibility of introducing this
technology to other parts of Asia.
The estimate cost to build and install one plant in operation is RM132 Millions. The
first of this plant will be built in Tepoh, Terengganu as the State Government of
Terengganu had given a firm support for this project to be done in the state. The state
landfill is located is located in Tepoh.
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2. PROJECT BRIEF
The objective of this proposal is to provide a brief and general outline for the
implementation of a CLPD Plant, besides giving an in depth understanding of the
processes and how the plant works.
The salient points are as follows:
2.1 The CLPD Technology can virtually convert both organic and inorganic waste
to diesel.
2.2. The size of the plant varies according to volume of OUTPUTS ranging from
500 liter per hour to 10,000 liter per hour. The size and the number of the
plants to be built depend on the volume of waste available to process daily. In
the beginning CLPD5000 will be installed. This can be upgraded later should
the volume of waste inputs increases.
2.3 TL as the technology holder, will implement, manage and monitor all the
development and day-to-day operation of the plants. TL will be responsible to
provide the Diesel technology, operating and maintaining the Plants, as well
as responsible for the financing exercise. TL as the main partner will be
responsible to raise the funds and supervise the financial and accounting
aspect of the business.
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3. THE EXISTING WASTE TREATMENT TECHNOLOGIES
Before we go into the CLPD Technology proper, let us examine the
various forms of waste treatment technology presently available in the market,
namely:
3.1 Landfill
- Very common method of disposing of waste
3.2 Incineration
Waste to Energy, Energy to Waste
Converts waste into heat, gas steam and ash
3.3 Recycling Methods
- Items are usually composed of a single type of material making it
easy to recycle into new products e.g. plastic, used tire, paper, etc
3.4 Biological Reprocessing
- Composting process
- Biological composting and digesting processes to decompose
the organic matter, resulting organic material is then recycle as
compost and the gas emission is collected and used for
generating energy
3.5 Bio-chemical processing
- After biological fermentation, part of the biomasses are diverted
by various chemical methods in Bio-Ethonal process and Bio-
Diesel process
3.6 Energy Recovery
- Chemical methods using Pyrolysis, Gasification and Advanced
Plasma Treatment methods
3.7 Avoidance and Reduction Methods
- 3R-Solution by Reduce, Reuse and Recycle
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4. WHAT IS CLPD?
IT MEANS CATALYTIC PRESSURE-LESS DEPOLYMERIZATION (OILING)
New crystalline catalysts combined with a highly innovative process technology now
allow the competitive production of biologically regenerating raw materials!
The future way of economic all production of high quality synthetic Diesel fuel:
After years of intensive catalyst and process research the breakthrough of
reproducing the natural way of fossil oil production within a process duration
turned down from hundreds of millions of years to now only 3 (three) minutes
has finally becomes a reality.
This causes the synthetic Diesel fuel produced by this method to be fully
competitive.
With most of the input materials the quality of the synthetic fuel produced by
this new ground breaking method is even higher than that of regular Diesel fuel
available at gas stations.
Cost per litre of Diesel produced between USD 0.125 0.1375 without
Government subsidies.
Elimination of almost all environmental pollution through inorganic
transformation of harmful substances into salts and crystals, based on the ion
changing characteristics of our proprietary catalyst.
For the first time this method now allows active environmental protection as
well as optimized energy production from industrial residuals, waste and
biologically regenerating raw materials in perfect combination and free of any
conflicts.
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5. CLPD TECHNOLOGY IS A TRULY GREEN TECHNOLOGY
Our proposed waste treatment technology is using worldwide patented of de-
polymerization process that runs in relatively low temperature range up to 350
0
C and
operates with the inside system pressure in less than 1 atm.
5.1 The main function of CLPD waste treatment plant is to process any type of
organic waste and capable to reduce the size of the waste up to 97% from
the original based volume.
5.2 The side effect from the process is producing high quality renewable
synthetic diesel (not bio-diesel) with CETANE value of 60 as compared to
petroleum diesel with CETANE value of 52, (Super Diesel has CETANE
value of 56.
5.3 The synthetic diesel produced from the CLPD plant is different to the
Bio-fuel and B5 diesel. The Bio-fuel is produce from the Crude Palm Oil
(CPO) as input based material whereas B5 diesel is the blend of 95% of
petroleum diesel and 5% of CPO. On the other hand, our synthetic
diesel is produced from the plantation waste such as waste from the palm
tree, empty fruit bunches, palm kernel pressed cake and kernel endocarp
as input material.
5.4 A CLPD plant with a capacity of producing diesel in the rate of 5000 liter per
hour requires three hundred and ten (310) tons of organic waste per day in
twenty-two (22) hours of continuous operation. From the waste input, CLPD
plant can produces 110,000-liter diesel per day and 3,300,000-liter diesel per
month.
6. TYPES OF WASTE
Domestic and municipal waste landfills can receive only certain types of waste, and
cannot receive others, due to their potentially harmful effects on the environment and
negative impacts on the landfill itself.
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4.1 Types of waste that can be disposed of in these landfills include:
Domestic waste
Commercial waste
Non-scheduled solid industrial waste
Construction waste
Waste from drain and river cleansing
Waste from road cleansing
Garden and yard waste
Animal carcasses
Waste from sludge treatment plants
Any waste approved by the Department of Environment (DOE)
4.2 Waste types that cannot be disposed of at domestic waste landfills include:
Biomedical waste
Radioactive waste
Asbestos
Lead acid and other batteries
Used vehicle oil
Toxic / scheduled waste
4.3 Waste that can be processed by CLPD Plant by preference:
Oil Sludge from refinery or oil mills
Used vehicle and machine oils
Used Tyres
Waste from plants wood, leaves etc
Plastics
Paper
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100% domestic waste in Asia
47% organic
15% paper
14% plastic
4% metal
4% wood
3% textiles
3% glas
1% rubber/leather
9% others (e-waste a.o.)
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7. HOW A CLPD PLANT OPERATES
Basically each CLPD Plant has two main and distinct operations i.e. Preparation of
Waste Inputs and the Processing of Waste using the CLPD Technology. Each
operation has different works involved depending on the type of waste used as inputs,
as follows:
The CLPD Plant is designed as a highly efficient and closely controlled unit able to
provide all neccessary supplies to operate the CLPD facillity and consists of:
Main input bunkers of unsorted waste material
Waste sorting, separation and shredder system
Main fraction storages
Storages of catalysts and neutraliser
CLPD-Unit
Tanks for diesel and for water
Water treatment system for the bunker drainage water
C3i, administration and service &maintenace facillities
Infrastructure
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7. HOW A CLPD PLANT OPERATES
Basically each CLPD Plant has two main and distinct operations i.e. Preparation of
Waste Inputs and the Processing of Waste using the CLPD Technology. Each
operation has different works involved depending on the type of waste used as inputs,
as follows:
The CLPD Plant is designed as a highly efficient and closely controlled unit able to
provide all neccessary supplies to operate the CLPD facillity and consists of:
Main input bunkers of unsorted waste material
Waste sorting, separation and shredder system
Main fraction storages
Storages of catalysts and neutraliser
CLPD-Unit
Tanks for diesel and for water
Water treatment system for the bunker drainage water
C3i, administration and service &maintenace facillities
Infrastructure
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7. HOW A CLPD PLANT OPERATES
Basically each CLPD Plant has two main and distinct operations i.e. Preparation of
Waste Inputs and the Processing of Waste using the CLPD Technology. Each
operation has different works involved depending on the type of waste used as inputs,
as follows:
The CLPD Plant is designed as a highly efficient and closely controlled unit able to
provide all neccessary supplies to operate the CLPD facillity and consists of:
Main input bunkers of unsorted waste material
Waste sorting, separation and shredder system
Main fraction storages
Storages of catalysts and neutraliser
CLPD-Unit
Tanks for diesel and for water
Water treatment system for the bunker drainage water
C3i, administration and service &maintenace facillities
Infrastructure
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7.1 PREPARATION OF WASTE INPUTS
i. Household or Domestic Waste
Household or Domestic Waste (sometimes called Municipal Waste) normally
are brought by lorries to the plant site. The waste may come in various
components, sizes and quantity. As these waste are brought daily, a suitably large
area must be allotted from the very beginning to store these unsorted waste.
These waste are then carried by forklifts and deposited on a sorting platform,
where workers will sort out the waste according to type e.g. paper, plastics,
wood, stones, glass etc.
Sorting Platforms
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7.1 PREPARATION OF WASTE INPUTS
i. Household or Domestic Waste
Household or Domestic Waste (sometimes called Municipal Waste) normally
are brought by lorries to the plant site. The waste may come in various
components, sizes and quantity. As these waste are brought daily, a suitably large
area must be allotted from the very beginning to store these unsorted waste.
These waste are then carried by forklifts and deposited on a sorting platform,
where workers will sort out the waste according to type e.g. paper, plastics,
wood, stones, glass etc.
Sorting Platforms
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7.1 PREPARATION OF WASTE INPUTS
i. Household or Domestic Waste
Household or Domestic Waste (sometimes called Municipal Waste) normally
are brought by lorries to the plant site. The waste may come in various
components, sizes and quantity. As these waste are brought daily, a suitably large
area must be allotted from the very beginning to store these unsorted waste.
These waste are then carried by forklifts and deposited on a sorting platform,
where workers will sort out the waste according to type e.g. paper, plastics,
wood, stones, glass etc.
Sorting Platforms
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Using the sorting platforms, workers will sort the waste manually. They may
work in three daily shifts. The number of platforms to be build is based on the
volume of waste supplied daily and the consumption per day of the CLPD unit.
More or larger CLPD units may have to be installed if the volume of waste to be
processed is huge.
Paper waste can be pressed and formed into bales to reduce the water content
and for easier storage.
ii. Plants branches, wood etc
Wood and plant materials have to go into a shredding machine before they are
bundled and stored.
iii. Used Tyres
Used tyres are also shredded before they can be treated in the CLPD unit.
iv. Oil Sludge, Used Motor and Machine Oil
Sludge and used oils which are kept in tanks can be sent straight into the
CLPD unit for processing.
7.2 THE CLPD PROCESS AND STORAGE
The CLPD Plant is a self-sustaining energy production platform. It only uses up to 10%
of its own energy production to run the plant through a 230kw block-type total energy
plant (BHKW).
In the plants closed-process cycle, the input waste materials are mixed with the catalyst,
which initiates a catalytic reaction characterized by the following results:
Molecular de-polymerization at low temperatures (290 350
o
C) and virtually
pressure-free (about 0.1 bar below ambient pressure).
Hydrocarbon conversion rates not previously achievable of more than 80%
without the same magnitude of dangerous residual by-products.
Decontamination of dangerous residual by-products (halogens, etc) in a liquefied
process that yields salt.
High-quality Diesel Fuel or Jet-Fuel suitable for use in todays engines, and soon
also Gasoline for todays and tomorrows fleet of cars on the road.
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The catalytic process produces certain catalyst crystals (processed metal impurities that
originally appear in the input waste materials) that must be removed once the high-
quality Diesel fuel has been delivered to the production storage vessel. The technology of
the plant guarantees that the metals and metal connections in the residue of the catalytic
process (used up catalyst) are merged together and delivered to the plants exit waste
vessel. The final product Diesel fuel (which develops exclusively over the vapor phase),
is absolutely free from these materials.
Since the approved input waste materials are mixed completely into the reaction oil at a
temperature of over 300
o
C and no further separation possibility exists once in the
process, no protein molecules (thus no Prions) are present without exiting and reduction
to decomposition or into the product, in this case Diesel fuel.
ADVANTAGES
Quality of Product This plants final product is a high quality motor vehicle fuel
(Cetane > 56) or fuel oil to be used in less critical uses, and thus has excellent resale
value.
Efficiency The plants high efficiency (~80%) gives the entire catalytic process a
positive energy balance that is to a large extent emission-free and self-supporting from an
energy standpoint.
ADVANTAGES AND BENEFITS OF THE CLPD PLANT
It uses raw materials that have no cost waste and thrash
Eco-friendly there is no emission of toxic gas from the plant
Solves the countrys waste disposal problems
Waste are converted to high quality diesel
Provide jobs in the country
Export Revenue for the country through the export of diesel
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CLPD Unit
i. Basic Components of a CLPD Plant
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CLPD Unit
i. Basic Components of a CLPD Plant
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CLPD Unit
i. Basic Components of a CLPD Plant
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CAPACITIES OF VARIOUS CLPD PLANTS
Size of Plant DAY YEAR
in Waste in Diesel in Diesel in Waste in Diesel in Diesel in
Litres/hour Tons Litres Tons Tons Litres Tons
500 31 12,000 10.8 10,881 4,212,000 3,778.2
1,000 62 24,000 21.6 21,762 8,424,000 7,556.3
1,500 93 36,000 32.4 32,643 12,636,000 11,334.5
2,000 124 48,000 43.2 43,524 16,848,000 15,112.7
3,000 186 72,000 64.8 65,286 25,272,000 22,669.0
4,000 248 96,000 86.4 87,048 33,696,000 30,225.3
5,000 310 120,000 108.0 108,810 42,120,000 37,781.6
10,000 620 240,000 216.0 217,620 84,240,000 75,563.3
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8. FINANCIAL
8.1 Utilization of Fund (for 1 CLPD5000 Plant):
USD
Total Development Cost is RM132,000,000.00 30,000,000
EXPECTED COST BREAKDOWN:
RM
Plant and Machinery 88,500,000
Land Cost 19,600,000
Motor Vehicles 2,500,000
Import and Sales Taxes 7,500,000
Insurance 4,000,000
Consultants 5,000,000
Lenders Counsel Fees 5,000,000
Feasibility study 600,000
General Contingency 600,000
Working Capital 1,200,000
TOTAL DEVELOPMENT COST (1 plant) 132,000,000
8.2 Production For One CLPD5000 Plant (Operating Assumptions)
i. Plant Solid Waste Treatment Capacity 310 tons/day
ii Plant Diesel Production Capacity 5,000 liters/hour
iii Plant Operational Capacity 95%
iv Net Diesel Production 42,120,000 liters/year
v Plant Load Factor 87%
vi Plant Aux Load Consumption 10%
vii Construction Period 9 months
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8.3 Revenue
Expected Annual Sales of Diesel @RM 1.98/litre = RM83.4 million for 1 Plant.
8.4 Other Financial Consideration
i. Payback Period Year 8
ii. Breakeven Period Year 3
iii. IRR 26 %
9. CONCLUSION
Both from the viability and financial aspects, we believe that the Project can be
successful. Active participation from the government will ensure that all
requirements are taken care of. As such we appreciate if our proposal is given a
positive appraisal culminating in full financial and operational support.
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8.3 Revenue
Expected Annual Sales of Diesel @RM 1.98/litre = RM83.4 million for 1 Plant.
8.4 Other Financial Consideration
i. Payback Period Year 8
ii. Breakeven Period Year 3
iii. IRR 26 %
9. CONCLUSION
Both from the viability and financial aspects, we believe that the Project can be
successful. Active participation from the government will ensure that all
requirements are taken care of. As such we appreciate if our proposal is given a
positive appraisal culminating in full financial and operational support.
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8.3 Revenue
Expected Annual Sales of Diesel @RM 1.98/litre = RM83.4 million for 1 Plant.
8.4 Other Financial Consideration
i. Payback Period Year 8
ii. Breakeven Period Year 3
iii. IRR 26 %
9. CONCLUSION
Both from the viability and financial aspects, we believe that the Project can be
successful. Active participation from the government will ensure that all
requirements are taken care of. As such we appreciate if our proposal is given a
positive appraisal culminating in full financial and operational support.
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