A1 - COWS plant & process design
Screening for updated technology availability Preliminary Design of the modified plant Design of COWS prototype Tendering for detailed and execution project plans M - Design contract awarded M - Detailed Project Plan Ready Permit request Permits granted D1 - COWS preliminary design
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Contents
A1 - COWS plant & process design
Description and methods employed (what, how, where and when)
What
This preparatory action serves to create the essential conditions for implementation of the project, i.e. completion of the final design and obtaining of the necessary permits.
To achieve this result the following tasks will be performed:
- preliminary project of alterations to the current treatment cycle in order to implement the COWS process;
- COWS prototype project, which is the core of the system;
- assignment of final design operations, as foreseen by the authorizing regulations in force in Italy (pursuant to art. 208 of Legislative Decree no. 152/06);
- receipt of final project;
- forwarding of the application for the building permit on behalf of the company (Viareggio Patrimonio s.r.l.)
- forwarding of the application for extension of the existing permit
This action terminates with the issuance of all the permits and authorizations.
The work performed is outlined in greater detail here below.
How/Methods
The first task will be the screening for updated technology availability
The feasibility study already carried out has shown that the COWS process can be implemented successfully. The innovative COWS approach operates in two directions:
- processing;
- technology for treatment of the OFMSW.
The approach (co-digestion of the organic fractions of municipal solid waste well amalgamated with wastewater sludge) has by now satisfactorily completed the experimental stage and there are a number of sites in operation. The innovation introduced by the COWS process consists of furnishing suitable OFMSW (Organic Fraction of Municipal Solid Waste)with mechanical extrusion treatment, rather than going through costly and not always feasible selection processes.
A number of technologies are available for mechanical treatment (pulping devices, screw presses, extrusion presses). During the feasibility study, the extrusion press process was deemed the most suitable for the application, but also the most versatile in terms of repeatability and transferability of the solution.
Technological evolution in the sector is constant and rapid and the development of new, more efficient machinery with higher performance is to be expected as part of a normal trend. It is therefore reasonable and advisable to perform an update screening to ascertain that the solutions used for the COWS prototype are always the most updated.
This screening will focus on mechanical treatment of the OFMSW, although it will, of course, take account of all the elements in the process. The screening will be done by means of a documentary type study, through contacts with operators in the sector and visits to producers of the technologies examined.
The second stage is the preliminary design of the modified plant. This is the preliminary project of changes to the current treatment cycle, necessary to apply the COWS process. The new treatment cycle that will use the COWS process requires alterations to the existing installation in order to install the COWS prototype that will treat the OFMSW.
The preliminary project is based on feasibility studies already carried out, and specifies the alterations necessary for upgrading, so that the final executive design can be commissioned.
These alterations concern:
- Adaptation of the primary and secondary digesters, adaptation of the pre- and after-thickeners, gas meter, torch, and dewatering section
- Design and construction of an air exhaust and treatment plant
- Adaptation of the (pre- and after-thickeners), gas meter and torch, dewatering system with installation of a new centrifuge
- Construction of the new cogeneration plant
- Preparation of a small test laboratory
In this task, the project director, with the approval of the SEAAMB experts, who will perform the market surveys for the A2 action with the SEARIS experts, will present the guidelines for drafting the preliminary project, and organize the team’s work.
Preparation of the preliminary project will include the preparation of layout drawings indicating the characteristics of the main machinery to be installed, the characteristics of the measuring instruments, the routes that will have to be taken by the pipelines for sludge, gas and water, the positions of the electrical wiring raceways, and the dimensions of the different sections. Photographic documentation will be provided showing the current layout of the installation for every section of the works, and a technical report describing the works to be performed and the operation of the system will be provided.
The next task is the design of COWS prototype.
The mechanical treatment unit, which is represented by the COWS prototype part, is also the core of the COWS process. With its mechanical treatment, the OFMSW will yield the ‘puree’ to be mixed with the sludge. At the same time, the treatment unit will have to ensure the possibility of recovering the residual portion of the waste in a readily manageable way.
The choice of the treatment unit will be made on the basis of performance criteria and effective industrial availability, taking account of the results of prior investigations.
Early in this task a call for expression of interest will be issued to vendors in order to get a preliminary map of parties willing to contribute to the development of the COWS separator prototype subsystem.
The project will concern the entire subsystem and will include the design of the electrical and water systems, as well as conveyors for transport and movement.
Where
This action will mainly take place in Viareggio. Some trips will be necessary to visit technology providers' sites and reference installations.
When
01/06/2012-28/11/2013
Constraints and assumptions
- Constraints
- Permit for plant upgrading issued by the Municipality of Viareggio by 28/11/2013
- Permit for processing 15000 ton/year of OFMSW issued by the Province of Lucca by 28/11/2013
- Permit to produce 6500 cubic meters per diem of biogas to be used for electric energy production issued by the Province of Lucca by 28/11/2013
- Construction works for the building that will host the COWS prototype and the handling of OFMSW input will be awarded and paid by Viareggio Patrimonio Srl (the owner of the asset and conceding organism on behalf of the Municipality of Viareggio) on the basis of the project elaborated by SEARIS. Relevant costs are NOT included in the COWS project budget.
- Assumptions
- The environmental legal framework (relevant to MSW and sludge treatment) will continue to evolve following the current trend
- Works permits are a straightforward procedure because the owner of the asset and conceding organism has already obtained a deliberation of authorization by the municipality of Viareggio.
- No disrupting organizational change will occur in partner organizations
- Mandates and current PPP agreements of beneficiaries do not substantially change across project duration
- Turnover of key resources is low.
Beneficiary responsible for implementation
P1-SEARIS
Expected results
Key deliverable of Action A1 is D1 - COWS preliminary design. In addition this action brings about the outputs:
- Detailed project plan of plant upgrading
- Detailed project plan of the COWS mechanical treatment unit (prototype)
- Permit for plant upgrading
- Permit for processing 15000 ton/year of OFMSW
- Permit to produce 6500 cubic meters per diem of biogas to be used for electric energy production
Indicators of progress
- Schedule and effort variance;
- actual vs. planned start/duration of tasks (if lag time reserved for contingency is to be used then remediation actions must be triggered);
- actual vs. planned resource use (15% work overload and 5% budget variance are thresholds for triggering remediation actions)
- Performance
- Delivery of compliant outputs: preliminary project, tender documents, permits and detailed projects
- Quality of delivered outputs: completeness and appropriateness (assessed by the project management team and by users, e.g. tender documents used by bidders). The threshold is that no formal complaint is raised)
