Carbon Emissions

The following information is indicative as the plant is not up and running at optimal input volumes.

Factory Consumption Estimation

At full load condition, i.e. 2.5 tonnes/hour PET flake and 1.5 tonne/hour HDPE flake, the estimated electricity consumption of the plant is 1,138 kWh per hour.

For other lighting and small power, water pumps, ventilation and air conditioning, the consumption would be around 185 kWh per hour.

For one working day of one shift (9 am to 6 pm), the consumption would be around (9 hours x 185 kW) + (8 hours x 1,138 kW)* = 10,769 kWh

(Note: *Allowed time to start up and shut down, hence 8 hours instead of 9 hours)

For one year of (365 days – 52 Sundays – 17 holidays) 296 working days, the consumption will be 3,187,624 kWh.

Full load capacity

for 1 year of 296 working days at full load condition

= 3,187,624 kWh/yr

PV System Generation
Estimation

installed and operational from April 2021

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PV System

Tomi Fuji’s estimation of annual generation

= 256,060 kWh / yr

Net Electrictity Taken
From The Grid

Total electricity usage.- PV system generation

  • Weights may vary considerably as there is no standard size bottle
Powergrid

Estimation of annual generation

= 2,931,564 kWh / yr

Heat Recovery From Air Compressors

NLP has two 75kw screw type air compressors installed, both with heat recovery features built in. Under full load conditions, about 75% of the power of the compressors can be recovered to generate hot water which could reach a temperature of 90oC. The hot water will be used in the HDPE wash line to increase the cleanness of the output flakes.
The estimated energy saving in using this heat arrangement instead of using electricity to heat up the water is calculated as:

= 2 x 75kW x 75% = 112.5 kW per hour

For a one shift operation, the saving will be 11,205 kW x8 hours
= 900kWh.

For a one year operation with 296 working days, the annual saving
= 266,400 kWh.

The corresponding annual emission savings would be:
= 0.37 kgCO2e/kWh x 266,400 kWh = 98.568 tCO2e.

Annual saving for 1 year operation with 296 working days

= 266,400 kWh/yr

Estimation of annual carbon savings

= 98.568 tCO2e

Total Average Emissions

1,085 tCO2e

The latest emission factor of CLP is 0.37 kgCO2e/kWh (Reference from CLP 2020 Sustainability Report (page 45). Based on the estimated net grid electricity, the total emissions NLP will emit each year = 2,931,564 kWh * 0.37 kgCO2e/kWh = 1,084,679 kgCO2e / 1,085 tCO2e.

Energy Management

When NLP is up and running at normal input volumes, we will engage an energy management specialist to see whether we can drive further energy reductions in the highest consuming operations of the recycling process – namely in the making of the compressed air and in the hot wash process.

Measurement management image thumb 01
Measurement management image thumb 01

Water Consumption

The following information is indicative as the plant is not up and running at optimal input volumes.

NLP Water Consumption Estimation

At full load conditions, i.e. 2.5 tonnes/hour PET flake and 1.5 tonne/hour HDPE flake, the estimated water consumption of the plant is 2.5 cbm per hour. Of this 1.3 cbm will be re-used, while 1.2 cbm will be treated by our wastewater treatment facility and returned to the municipal waste water.

For one working day of one shift (9 am to 6 pm), the consumption would be around 9.6 cbm. This includes a 30 minute start time and 30 minute shut down time. Hence, staff start at 9 am to prepare start -up of the plant; water flow only starts 30 minutes later; similarly water flow stops 30 minutes earlier; hence a total of 8 hours of water flow => 8 x (2.5 – 1.3) = 9.6 cbm for one working day.

For one year of (365 days – 52 Sundays – 17 holidays) 296 working days, the consumption will be 2,841.6 cbm while 2,841.6 cbm will be treated by our waste water treatment facility and returned to the municipal wastewater.

Below is a simplified water circuit of our plant.

Full load capacity (1)

= 2,841.6 cbm

for 1 year of 296 working days at full load condition, all of which will be treated and returned to the municipal wastewater

water cycle

Management & Measuring

NLP has an industrial water meter at the Water Services Dept (WSD) incoming pipe. This will record (but manually) the total water NLP will consume in the washing lines. Within the recycling equipment, NLP has a number of flow meters to capture the water flow rates at the different water paths including the two cutting mills, two hot washers (PET), one cold washer (HDPE), two decanters, etc. This will allow management and refinement of NLPs water usage. In the waste water treatment plant (WWTP), NLP also has a digital flow meters to monitor and record the outward flows.

Dunwell Wastewater Treatment Plant

Plant Waste

Information will be presented once operations begins