Sarpsborg, Norway

A new ENERGOS designed energy from waste (EfW) plant in Sarpsborg is displacing 24,000 tonnes of heavy fuel oil each year at Borregaard Industries, a major supplier of wood-based chemicals.

The company owns and operates one of the world’s most advanced bio-refineries in Sarpsborg where it has demonstrated its commitment to sustainability by securing the supply of more renewable heat for its operations.

Borregaard has already been benefiting from the supply of low-cost renewable heat from an existing ENERGOS designed plant, which has been operating successfully on a commercial basis since 2002 and Borregaard recognised that additional energy cost savings and carbon reductions could be realised if a second plant was built to supply more renewable energy.

Working with one of Norway’s leading power suppliers, Hafslund Heat and Power AS, a contract was awarded to ENERGOS in February 2008. Work started soon and the plant was officially handed over in July 2010, ahead of schedule and within budget.

ENERGOS supplied, installed and commissioned the mechanical and electrical equipment.

The new plant will produce 32MW of renewable heat, delivered as high quality process steam to a number of nearby chemical process plants.  The gasification facility will treat 78,000tpa of locally sourced, non-recyclable, non-hazardous commercial and industrial waste recovering more than 80% of the energy contained.

The £45 million project generates up to 250GWh/annum of steam and will reduce carbon dioxide emissions by approximately 40,000 tpa which is equivalent to the environmental benefit of 4 million trees.

The new plant compliments the existing 27MW (thermal) ENERGOS facility that has been generating 185GWh/a of steam, bringing the total capacity for residual waste treatment to 156,000 tpa.

There are 7 existing ENERGOS designed plants featuring the same gasification technology and the company has used this experience to deliver the second Sarpsborg plant in record time.

At the beginning  of 2011 over 450,000 operating hours had been accumulated at existing plants so the technology is fully proven and bankable. 7 new planning consents for plants using the ENERGOS technology have been granted in the UK since 2008. All but one of these consents was granted within 12 months of the application date.

The ENERGOS technology is an advanced two-stage thermal treatment process that converts residual, non-recyclable waste into a gas by using the heat of partial combustion to liberate the hydrogen and carbon within the waste. The waste is fed into a gasification chamber, where it is used to produce a syngas.

This syngas is transferred to a secondary high temperature oxidation chamber where it is fully combusted under tightly controlled conditions which results in very low emissions.

The resulting heat energy is used to produce steam, which can be used to supply renewable heat and/or generate renewable electricity.

The design is very flexible and suitable to treat wastes with calorific values between 8 and 18 MJ/kg. The design is modular in the range of 40,000 tpa to 200,000 tpa. A plant can be delivered to meet current residual volumes and additional capacity can be added as and when it is needed in the future, reducing the likelihood of expensive redundant capacity.

A typical 80,000 tpa facility can generate sufficient renewable electricity to power 10,000 homes, which is the equivalent to the output of 15 large wind turbines. Most ENERGOS designed plants are located next to major energy consumers where heat recovery can be optimised, or in locations where hot water can be supplied to a district heating network.

The energy recovered from the biodegradable fraction of waste allows limited exemption from CO2 emissions under the EU Emissions Trading Scheme (EU ETS).