Saudi Arabia - Makkah Case Study

The primary mission of this facility was to efficiently manage the animal waste generated during the Hajj religious festival in Makkah, Saudi Arabia. Over four to five days during the festival, approximately 10,000 tonnes of such waste is produced. Traditionally handled via landfill methods, recent initiatives aim to eliminate these hazardous practices and reduce excessive transport movement. Underpinned by an investment project worth ￡30 million commissioned by The Ministry of Municipality and Rural Affairs, state-of-the-art mechanisms have been employed with remarkable efficiency; these comprise dedicated waste transfer systems, reception bunkers for incoming waste material alongside advanced machinery such as transfer cranes and crushers - all integrated into its meticulously designed infrastructure involving delivery conveyors leading up to high-capacity disposal incinerators.

Area of responsibility

Matthews Environmental Solutions is entrusted with the tasks encompassing design, construction, installation, and commissioning.

Operational Design

The system operates on a round-the-clock basis, functioning 24 hours per day and 7 days per week. This accumulates to a total of 312 days throughout the year. Given its annual operational time of approximately 7500 hours, this amounts to an impressive availability rate of 85.6%.

Scope of Supply

he key specifications of this system include two Rotary Primary Combustion Chambers which operate at an optimal rate of 2500 kg per hour, fueled by a diesel-fired Ignition burner. In tandem with the primary chambers exists an automated combustion air system aimed at enhancing operational efficiency.

Additionally, the unit incorporates a secondary chamber equipped with a diesel-fired secondary burner to ensure thorough combustion. An automated ash transfer conveyor manages waste residues efficiently while emergency bypass Systems assure safety in exceptional circumstances.

Other critical components include hot gas transfer ducts and heat-to-hot Water boilers capable of converting 5.9MW waste heat into heating solution.

The package also encompasses one set of hot water pipes along with an assortment array of fan-cooled heat pumps for efficient cooling operations.

In terms of emissions mitigation, the design includes cool gas transfer ducts and supplementary systems such as sodium bicarbonate storage and its delivery mechanisms that contribute towards neutralising acidity within flue gases.

Administering these intricate sections is a flue gas abatement filtration plant aiding emission control measures in conjunction with compressed air systems designed for varied functions within industrial settings.

Notably, the management aspect isn't compromised owing to the incorporation remote monitoring control system ensuring real-time oversight over the system's functionalities through means beyond physical presence. Completing the configuration are exhaust chimneys facilitating secure gas venting complying overall mission of environmentally responsible disposal procedures.

Project Management

Owing to the intricate dynamics of the entire project, rigorous supervision was indispensable to guarantee that the custom-made solution seamlessly merged with the comprehensive system. To fulfill time constraints, we adopted a continuous 24/7 operation with teams operating in shifts for deploying the installation phase of the project.

Solution

The advanced incineration system includes a pair of 60-tonne daily capacity incinerators, each comprising of an innovative cylindrical, rotary primary chamber. This dynamic design ensures optimal waste agitation and facilitates continuous operation.

Complementing the primary chamber is a two-stage vertical secondary compartment equipped with an automatic de-ashing process that uses a wet bath drag conveyor. For unabridged safety measures, there's an in-place pneumatically controlled emergency bypass system prone to fail-safe operations.

Each incinerator unit capable of managing 2500kg/hr has its exclusive flue gas treatment installation as part of its essential components, showcasing:

1. A highly efficient self-regulating heat dissipation circuit incorporated within a waste heat boiler.

2. Twin cyclone towers tasked with the removal of large particulates and integration of powdered reagent into the flue gas stream.

3. An adaptable five-pod modular bag house filter with hibernation mode deployed during periods when systems are offline for reduced wear on filter bags.

Working hand-in-hand with these features is our line-up of robust air blast coolers, forming a significant portion of the heat dissipation circuitry which incorporates duty/standby pump sets alongside proactive management capabilities including automated top-ups between operational stages and idle-mode protection mechanisms to safeguard system internals during non-operational intervals.

Our dedication towards round-the-clock function also extends to power supply continuity via an Uninterruptable Power Supply (UPS) switchover method geared to oversee safe equipment shutdown upon encountering unexpected interruptions in mains power availability.

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