Catalytic Pressure-less Depolymerization” (CLPD)

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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 BioDiesel 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: 

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 

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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 depolymerization 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

4.2

4.3

Types of waste that can be disposed of in these landfills include: 

Domestic waste

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Commercial waste

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Non-scheduled solid industrial waste

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Construction waste

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Waste from drain and river cleansing

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Waste from road cleansing

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Garden and yard waste

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Animal carcasses

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Waste from sludge treatment plants

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Any waste approved by the Department of Environment (DOE)

Waste types that cannot be disposed of at domestic waste landfills include: 

Biomedical waste

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Radioactive waste

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Asbestos

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Lead acid and other batteries

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Used vehicle oil

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Toxic / scheduled waste

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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7.1 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.

iii. iv.

Plants – branches, wood etc Wood and plant materials have to go into a shredding machine before they are bundled and stored. Used Tyres Used tyres are also shredded before they can be treated in the CLPD unit. 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 plant’s 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 – 350o 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 today’s engines, and soon also Gasoline for today’s and tomorrow’s 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 highquality 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 plant’s 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 300o 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 plant’s 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 plant’s 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

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Eco-friendly – there is no emission of toxic gas from the plant

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Solves the country’s waste disposal problems

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Waste are converted to high quality diesel

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Provide jobs in the country

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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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CAPACITIES OF VARIOUS CLPD PLANTS Size of Plant in Litres/hour

DAY Waste in Diesel in Diesel in Waste in Tons Litres Tons Tons

YEAR Diesel in Litres

Diesel in 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 30,000,000 Total Development Cost is RM132,000,000.00

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 Lender’s 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. ii iii iv v vi vii

Plant Solid Waste Treatment Capacity Plant Diesel Production Capacity Plant Operational Capacity Net Diesel Production Plant Load Factor Plant Aux Load Consumption Construction Period

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310 tons/day 5,000 liters/hour 95% 42,120,000 liters/year 87% 10% 9 months

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8.3

Revenue

Expected Annual Sales of Diesel @ RM 1.98/litre = RM 83.4 million for 1 Plant. 8.4

Other Financial Consideration i. ii. iii.

Payback Period Breakeven Period IRR

Year 8 Year 3 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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