The plant is designed to combust municipal and commercial solid waste (240 tons per day) using step hearth combustors, Zurn boilers, and an ABB Vax turbine generator. This is a highly efficient facility predicated on mass burn operations and designed to maximize power conversion. All plans, specifications and operations documents are included as well as comprehensive EPA air quality study and R.W. Beck re-commissioning study.
For further information please email or fax request to The Utility Warehouse, attention Matt Freeman.
Description of Equipment for Sale
1. (2) Zurn waste heat 24,000 lb/hr steam generators, single reheat, 650 psi, 570 deg F, with economizers. Includes insolation dampers, boiler fittings, soot blowers, sweetwater condensers, continuous and freeblow drain tanks, madeup feed preheater and sootblower air receiver.
2. (1) ASEA Stal VAX two cylinder reheat turbine generator geared to a Brush 6.9 MW 1800 rpm 4,160 volt generator. Includes Graham main condenser, switchgear and trubine controls, (4) condensate pumps, drain pump, steam heat air ejectors, inter and after condenser, hotwell tank and all turbine auxiliaries, i.e., lube oil and hydraulic pumps, gland exhaust and sump vent fans, coalescer and dual filters.
3. (1) Chicago Spray-Tray Deaerating Heater.
4. (1)Pacific multi-stage, diffuser, horizontal split case turbine driven feed pump.
5. (1) Pacific multi-stage, diffuser, horizontal spilt case motor driven feed pump.
6. (1) Gardner Denver reciprocating service air compressor Model MELEDD, size 10 1/2 - 6x5, with receiver.
7. (1) Gardner Denver reciprocation service ari compressor Model MELEDD, size 9 1/2 x 5.
8. (1) Pneumatec Model PE-150 electric air dryer.
9..(1) Graham Model 39"x 5' x 60 AFL bypass condenser.
10. (2) Enercon 120 ton per day mass burn solid waste combustors including reciprocating hearths, ALE hydraulic pack, controls, secondary and tertiary chambers, hydraulic loader and associated dampers and duction.
11. (1) Beaumont Birch heavy duty # 698 chain, 1' x 6" x 2' flight chain conveyor.
12. (2) Robinson 200 HP induced draft fans with variable speed drives.
13. (2) Robinson 150 HP recirculating flue gas fans with variable speed drives.
14. (2) New York Blower 50 HP fresh air fans.
15. (2) New York Blower 25 HP underfire air booster fans.
16. (2) Enercon primary burner systems.
17. (2) Enercon post boiler burner systems
18. (1)Baily Net 90 distributed control system including (3) OIU's, (3) PCU's and (1) work station.
19. (1) HDR uninterruptable power supply including battery chargers, inverters, and lead calcium batteries.
20. (1) Yale 10 ton, 25 foot lift, electric monorail crane with pendant controls.
21. (1) Lilie Hoffmann counter flow cooling tower with 60 HP Tuf-Lite fans and Amarillo angle drives.
22. (2) Ingersoll-Rand 100 HP, 5,000 GPM vertical centrifugal circulation pumps.
23. Hydro-max water treatment system including water softener, chlorine injection system and boiler water treatment system.
24. Substations including 45kV, 4,160 V and 480 V.
25. Motor control centers and switchgear.
26. (1) Ten thousand gallon stainless steel tank.
27. (1) Sixty-two hundred gallon FRP insulated tank.
28. (2) Anderson packed tower absorbers with circulation pumps.
29. (2) Belco 4 Field electrostatic precipitators with TR sets and controls
30. (1) Dynatron dilution extractive continuous emissions monitoring system for SXO, NOX and CO2.
31. (4) In situ CO monitors.
32. Office furniture
33. Miscellaneous pumps, tools chain falls and spares.
34. International Chimney FRP lined, dual flue, 165' freestanding steel stack.
COMBUSTION SYSTEM
The system used by VIWS is controlled air incineration, a technology proven in various installations for over 30 years and demonstrated when this plant operated in 1988.
In this process the combustible waste is fed into the furnaces after pre-processing to remove the recyclable and compostable materials, Loading of the incinerator hoppers is controlled by the front end loader operator at he direction of the control room operator and the automatic sequencing of the incinerator loading cycles. The waste enters the furnace by means of a hydraulic ram which pushes it into a primary combustion chamber. The burning waste travels through the furnace down a series of fixed refractory hearths or "steps" conveyed from step-to-step by hydraulic rams. The residue (ash) is dumped into a quench trough for cooling and is the conveyed by a drag chain conveyor to a rolloff container for transport to the landfill. The ash volume is less 10% of that which enters the facility.
The hot gases from the primary combustion chamber a secondary combustion chamber wherein combustion is completed, through a tertiary (mixing) chamber and then into the waste heat boilers. The temperature of the gas is controlled at a constant level by automatically adjusting the overfire and underfire combustion air and through mixing the recirculated flue gas. The gas is passed through the boilers, producing superheated process steam, and through an economizer which preheats boiler feedwater. Before being vented to the atmosphere the gas is passed through air pollution control devices to collect particulate matter, acid gases and other emissions. The system provides redundancy against power failures, and potential equipment and system shutdowns through its modular concept and duplex auxiliary system. Design and construction criteria assure continuous (24hour a day, 7 day a week) operation.
LOADER ASSEMBLY
A ram type long stroke (17ft.) loader of approximately (7) cu, yd. capacity is provided to accept waste and transfer it into the primary chamber. The ram is hydraulically driven. Alternative manual retraction of the ram is provided in event of jamming. The ram is water cooled to allow penetration into the primary chamber to advance refuse to the next lower hearth. A heavy duty semicompactor cover is provided with hydraulic cylinder actuation to level or crush the load within the loader hopper and provide fire flame protection. Waste in the loader is segregated from the interior of the primary chamber by an automatically actuated fire door. The fire door is hydraulically actuated and constructed of heavy gauge plate steel sufficiently braced and faced with refractory material to withstand the heat and corrosive atmosphere within the primary chamber.
PRIMARY CHAMBER
The primary chamber consists of the following:
1. ShellSECONDARY CHAMBER
Constructed of 1/4" plate steel with structural bracing. Air cooling is provided where necessary to maintain shell temperature within specified limits.
2. Refractory
Floor and sidewall areas in direct contact with waste - prefired brick units with a service temperature of 2600 degrees F.
Upper Wall and Roof Areas - These areas are covered with high alumina, cast refractory with a service temperature of 2800 degrees F. Refractory anchors are fastened to the steel shell for support of the cast refractory.
Block Insulation - Mineral fiber (13 lb./cu. ft. - 1800 degrees F service temperature.
3. Ash Transfer Rams
Five (5) transfer rams are located along the length of the primary chamber to advance waste and ash during combustion. The lower rams are used to discharge ash from the furnace to the continuous ash conveyor. All rams are hydraulically actuated. Ram cylinder force is 40,000 lb.. maximum. Rams are capable of manual retraction in event of shutdown. Rams are continuously cooled with recirculating water. All rams are easily removable and standardized for interchangability.
4. Step Floor Construction
Fabricated steel support system with cast insulation, brick, and precast nose blocks complete with underfire air distribution system.
5. Combustion Air Supply
Combustion air is drawn from the waste receiving area through a screened grill located above the tipping floor. Duct work distributes this air to the main combustion air blower. Discharge from the combustion air blower is directed through pneumatically controlled dampers for controlled underfire and overfire air. Overfire air is supplied through a series of incinerators. Air is introduced through air nozzles. Each hearth is supplied with controlled air through an underfire air system to insure uniform distribution and burning. The air plenums are of a propriety non-plugging design capable of being cleaned while in service.
The secondary chamber consists of the following:
1. ShellTERTIARY CHAMBER
Constructed of 1/4" plate steel, cylindrical construction. with structural bracing. The chamber is lined with 6" refractory and 3" of insulation block.
2. Refractory
The secondary chamber is lined with high alumina cast refractory (ASTM class"c" 401) with a temperature of 2600 degrees F. Heavy alloy anchors are fastened to the steel shell for support of the cast refractory.
The tertiary chamber consists of cylindrical 1/4" plate steel lined with 3" of insulating block and 6" of refractory. Heavy alloy anchors are fastened to the steel shelf for support of the cast refractory. The tertiary chamber serves to convey hot gases from the incinerators to the waste heat boilers. Mixing of recirculated flue gas for temperature stability is accomplished within the tertiary chamber.
ISOLATION GATE
Isolation gate type dampers are utilized to segregate incinerators and boilers form the process train. These high temperature gates are constructed of 304 stainless steel with refractory coating. The gates will operate within a sealed frame and be air cooled when exposed to high temperatures. Isolation gates can be controlled locally or from the central control room.
COOLING WATER
The incinerator cooling water system consists of all necessary distribution piping, a water storage reservoir with circulating pumps and heat exchangers. This cooling system serves to cool exposed steel, rams and rails within the incinerator. A water-to-water heat exchange system dissipates heat from incinerator cooling water and pre-heats combustion air. The incinerator cooling system is a closed loop incorporating an automatic make-up water control and an emergency water supply back-up in case of a system failure.
WASTE HEAT BOILERS
The boilers are Zurn three drum custom designed waste heat boilers, completely shop assembled. The design complies with the latest edition of the ASME Code in effect on the date of procurement for all pressure components as to design, material, and workmanship. The steam drums and mud drums are furnished with ASME standard heads as well as 12" and 16" manholes furnished with press steel manhole plates of the hinged type with dogs, bolts, and gaskets at both ends of the drums. Each unit is equipped with internal piping for feedwater distribution, continuous blowdown, level, steam gauge and chemical feed.
Also included are steam separator assemblies to produce a steam quality of 1 PPM of feed water solids. The boiler tubes are 2" O.D. with a wall thickness suitable for the design parameters. The walls are membrane construction. The side, front, and roof construction consists of 3" high temperature insulating block and a 10 lb. gauge gas tight carbon steel outer casing. Diamond "Air Puff" soot blowers, utilizing compressed air as soot blowing medium, are provided for each waste heat boiler. Ash hoppers are blowing sequences.
SUPERHEATERS
One stop assembled superheater is supplied with the waste heat boiler. The superheater consists of two external headers and elements. Each element consists 2" O.D. tubing with sufficient heating surface to provide the specified superheat.
WASTE HEAT ECONOMIZERS
Waste heat economizers are constructed to conform to ASME Boiler Codes. Each economizer has been fabricated in two identical sections, each with inlet and outlet headers, casings, and support subsection, are incorporated in the economizer. Ash hoppers will be provided to collect soot and blown down ash materials.
AUXILIARY FIRING SYSTEM
An auxiliary firing system is utilized for start-up and preheating, and it can also supplement steam generating capability if necessary. The primary chamber in each incinerator is equipped with a 10,000,000 BTU per hour #2 fuel oil burner. The oil burners are of the low pressure air atomizing nozzle type and are ignited by a spark gas pilot flame. A flame safeguard in programming control includes an infra red sensitive scanner and frequency discriminating electronic network that will shut down the burner in event of flame failure and prevent the burner from starting in the event of non- programmed flame.
The programming portion of this control provides a pre-purging period, proving of the pilot and main flame, and a period of continued blower operation to purge the system of unburned fuel vapor. Integral safety controls will shut down the burner under low water or excess steam pressure conditions. Burners may be operated from the local burner control system or from the central control room through the micro processor based burner management system.
FEEDWATER SYSTEM
All boiler feedwater is provided by the following equipment:
(1) Zeolite water softening systemThe packaged deaerator system is rated at 60,000 pounds per hour with a guaranteed oxygen removal of 0.005 cc per liter. The deaerator tank has a storage capacity of 3,000 gallons and operates at 30 psig.
(2) Make up water transfer pumps
(1) Deaerator
(2) Feedwater pumps
(1) Blowdown system
(3) Chemical feed systems
Two full capacity feedwater pumps are installed beneath the deaerator system. Each pump is capable of supplying all of the boiler requirements. One pump is electric motor driven for start up, shutdown, and standby service. A steam turbine drives the second pump.
BLOWDOWN SYSTEM
The boiler blowdown system for intermittent manual and automatic continuous blowdown is provided for additional heat recovery. Softened water extracts heat from the heat exchanger within the blowdown unit while cooling the waste water to the desired temperature. This cooled wastewater is then directed to the ash quench trough for makeup. Flash steam produced in the blowdown system is piped to the deaerator and utilized for feedwater heating. The blowdown heat recovery system consists of controls and valves which automatically proportion blowdown and makeup water, a 600 pound ASME coded heat exchanger with stainless steel tubes, a flash separator and all ancillary equipment.
FIELD WATER TREATMENT SYSTEM
The equipment consists of an automatic zeolite softener with regeneration initiated by a conductivity meter. The regeneration system utilizes day tanks and eductors. The conductivity meter is located in the control panel for both indication and control of the regeneration cycle. An alarm light and external alarm are provided to alert the operator that the unit is exhausted and needs regeneration.
CHEMICAL FEED SYSTEM
Three chemical feed systems are installed to provide all the necessary treatment for the deaerator and boilers. Each chemical feed system consists of the following:
1. Polyethylene tank and cover.COOLING WATER SYSTEM
2. Steel frame with agitator.
3. Metering pump and motor.
4. PVC strainer and suction pipe.
5. Stainless steel discharge piping and relief valve.
6. Level control system.
The cooling water system provides cooling water to the incinerators to keep the ash transfer rams and the underfire air rails cooled. The system consists of a storage tank for the treated water, a duplex pumping system, heat exchangers, piping, valves and appurtenances. The heated water exiting the incinerators is utilized for heating combustion air by passing it through a heat exchanger before returning it to the storage tank. the piping and valves are arranged to allow either incineration to be shut down while the other incinerator is in operation.
COMPRESSED AIR SYSTEMS
The compressed air system for the pneumatically operated controls and instrumentation consists of the following:
1. Two type 30 water cooled reciprocating compressors.The compressor system supplies 100% of plant instrument air requirements with one compressor operating and the second as standby. The alternator control panel will equalize compressor operating time and automatically maintains air supply in the event of equipment failure. Compressed air is stored in the 120 gallon receiver where moisture is automatically drained. Any additional moisture is removed by the regenerative dryer before the compressed air is finally purified with the in-line filter system. An independent instrument air distribution system is installed within the facility.
2. Water cooled aftercooler.
3. 120 gallon receiver with automatic condensate drain value.
4. Alternator control panel.
5. Automatic regenerative dryer.
6. In-line oil, dirt, and contaminant filters.
Air for the plant air system is supplied by one air compressor backed up by the instrument air compressor. Included in the plant air compressor system are the following:
1. Afercooler and separatorThe plant air compressor operates at 250 psig. Air from this system serves the boiler soot blowers and all other miscellaneous plant air requirements. Pressure reducing stations are provided for each application. Cross connections are installed between plant air and instrument air systems to ensure an uninterrupted supply of dried and filtered instrument air.
2. Air receiver
3. Control system
4. Protective unit control
5. Heavy duty inlet filter silencer
AIR HANDLING SYSTEMS
Ash Handling
The residue, is expected to be from 20-25 percent by weight of the raw refuse delivered to the plant, and is discharged form each furnace through a discharge chute into a water filled trough conveyed to containers for transfer to the landfill. Ash passing through the quench trough ensures there is no burning ash and that the ash is wetted to prevent dust emissions.
The residue conveyor rated capacity is in excess of the weight and volume discharged by both incinerators. The conveyor is designed for jog reversing service to handle wet ash residue at a rate of not less than 12.5 tons per hour at a speed not to exceed 6 feet per minute.
Water quenched ash will be transported to the inclined conveyor are for detention. Ash on the inclined conveyor will be dewatered until the incinerator discharge cycle is initiated and the conveyor restarts. Ash will then be deposited in residue containers for further dewatering, transpiration and disposal. Gravity dewatering will include but not be limited to the tilting of ash containers to ensure a continuous drain of the water out of the container and back into the quench trough through the use of floor drains.
The existing plant water balance and previous plant operating experience suggest and excess of quench water under certain operating conditions. These conditions include those that cause the plant to reduce output 48 hours or more. Due to the zero discharge status of the plant certain boiler blowdowns, scrubber blowdowns and other process water discharge accumulate. This occurs because at low loads the amount of ash discharged decreases, decreasing the amount of the quench water being absorbed without a proportional decrease in the discharges.
The management plan to handle this excess includes a system of treatment and storage. During times of decreased output excess water will be diverted to a holding tank with a capacity of at least 10,000 gallons. When the plant resumes full operation the stored water will be used as make-up to the ash quench system until consumed, at which point make-up from the city system will resume.
The conveyor trough is constructed of concrete. The trough bottom is fitted with a liner plate, angle guide, adjustable anchor plates, and removable chain guide wear plate. The incline trough is made of steel plates suitably stiffened with angles and made watertight by continuous welding of all joints.
Fly ash is collected in the hopper of the electrostatic precipitator. By the use of screw conveyors, fly ash is transported to the water trough, removed by the ash conveyor and disposed together with the residue.
Heavy duty containers 28 ft. long and 62 in. high with a 30-40 yd. capacity will be supplied for residue storage and disposal. these residue containers will be stored within the ash handling areas of the building. All ash containers will be water tight, leach. resistant, have covers and be approved by the Secretary of the Agency of Natural Resources. Each container will be marked with a 2 or 3 digit identification code so that it is possible to maintain records of the containers that are used for ash transport.
Ash Testing
VIWS will perform the US EPA Toxic Characteristic Leaching Procedure (TCLP) for targeted heavy metals on samples of RRRC residue. All TCLP testing will include the routine procedure using acid and an additional procedure using deionized water in accordance with EPA Method SW 924. Residue is defined as a composite of bottom residue and air pollution control device residue collected from the end of the ash conveyor. This testing will be performed in accordance with the following schedule:
During the first six (6) months of RRRC operation, a five (5) pound sample of RRRC residue shall be collected each week. These samples shall be composited according to standard procedures and every month a TCLP Toxicity analysis shall be performed on the composite sample for that month. The parameters to be analyzed for are: Conductivity (umhos/cm), Aluminum, Barium, Cadmium, Chromium, Iron, Lead, Manganese, Mercury, Nickel, Sodium, Zinc, Chlorides, Sulfates, and Chemical Oxygen Demand (COD).
The pH and alkalinity of the RRRC residue itself shall be determined in a settled solution of 10 grams per sample in 100 ml of deionized water; and
For the remainder of the certification period, a five (5) pound residue sample shall be collected each week during the months of January, April, August and November. Each week's sample shall be composited according to standard procedures to produce a representative sample for the month specified. A TCLP toxicity analysis shall be performed on each composited sample. The parameters to be analyzed for shall be the same as identified above.
Samples of RRRC residue, collected as described above shall be subject to the following physical analysis and schedule:
The percent of solids shall be determined on each weekly five (5) pound sample at an appropriate time so as to represent the residue's percent of solids when transported in containers to the certified disposal facility; and
The grain size distribution shall be determined on the composited monthly sample.
AIR POLLUTION CONTROL SYSTEM & STACK
Flue gases exiting the boiler economizers at a temperature of 400 degrees F pass through high temperature duct work into the electrostatic precipitator. The gases exiting the precipitator pass through the induced draft ( ID) fan and discharge to a low temperature economizer which condenses flue gas compounds. From the low temperature economizer, the gasses pass directly to a packed wet scrubber for acid gas neutralization and into the stack at a temperature of 130 degrees F and a velocity of 50 feet per second.
Additional information on the Air Pollution Control Systems is contained in the Air Quality Permit.
Induced Draft Fans. These fans are heavy duty industrial type, radial tip blade, minimum 600 degrees F construction, with heavy duty water cooled sleeve bearings, split housing , inspection door, drain, shaft seal, fan casing insulation and shaft guard. the fans are driven by 200 HP, TEFC motors ( 3/60/460Vd) mounted on a slide base. Variable frequency drive units control fan speed and total flow.
Stack. the stack ( 165' high) is a dual flue, fiberglass reinforced plastic and steel shelled stack with the following associated equipment:
Exterior safety climb ladder with 360 degree platform.CONTROL SYSTEMS
Lightning grounding system.
EPA 4" diameter test ports.
Process Control. Process Control is a digital microprocessor based control system with partial analog backup and manual override capabilities.
Under normal operating conditions, the computer system coordinates all incinerator, boiler, pollution control and miscellaneous signals initiated by the microprocessor unit. Sequence control and program changes will be initiated utilizing the keyboard and screen.
Setpoint process controllers can be utilized for automatic control during interim operating conditions, computer shutdown, reprogramming, or at any other time independent automatic control is desired. This analog system displays direct readings on process indicators in the computer automatic or manual modes. All systems are capable of manual override, utilizing the computer/manual/automatic selector switches. Failsafe manual controls are installed in the event of equipment failure to maintain critical systems and prevent equipment damage.
DATA RECORDING
Recorded data variables can be presented on the screen or in printout form, such as trend analyses, rates of change, maintenance logs, alarm logs, sensor failures, and sequence control. Demand or automatic printouts can be used to record and maintain permanently all pertinent data. Chart recorders are utilized for continuous recording functions completely independent of the microprocessor data system. In addition to chart recordings, totalizers and flow integrators provide that basis for all plant billings.
EMISSION MONITORING
Plant stack emissions are continuously monitored suing an opacity monitor and a comprehensive continuous emissions monitoring system. Additional waste gas monitoring will be accomplished with incinerator process control data and air pollution control device monitoring equipment. Plant operations parameters are set to conform with emission control requirements. (Please see the Air Pollution Control Permit for more detail.)
AUXILIARY SYSTEMS
All auxiliary systems are controlled form the centralized control room. Control room equipment, including centralized control panel, computer, automatic and manual control systems are served by an uninterrupted power supply. Annunciation of alarm conditions at a predetermined sequence as established by the operator.
During any annunciated alarm condition, the operator can recall the sequence control for the specific equipment involved for further alarm clarification or resolution through the computer system. Additionally, automatic or manual controls may be initiated to acknowledge the graphic annunciation. The graphic panel displays the overall process complex through the visual display of all systems. The graphic display panel illustrates all major process equipment with subsystem block diagrams and process flow schematics presented in a simple straight forward photographic approach.
ELECTRICAL SYSTEMS
The electrical system consists of a utility feeder with a two way transformers, primary switchgear, 7MW steam driven turbine generator, secondary switchgear, stepdown transformers, and distribution switchboards with motor control centers. During normal operation the steam driven turbine generator will deliver electricity to the Grid as well as supply all electrical power requirements for the resource recovery facility.
The steam driven turbine generator supplies electrical power at 4160 volts. Indoor stepdown transformers provide 480 volts for all plant processing equipment. Isolation and transfer switches segregate the transformer and turbine generating systems from the plant distribution system while the emergency generator is in use. A step up transformer will be provided for the 4160 volt to 46 kV utility interconnection.
Plant distribution consists of a 480 volt switchboard and motor control centers to service all plant electrical requirements. An uninterrupted power supply will supply power for the control room complex. All motor control centers are 480 volt Y/ 277 volt, 3 phase, 4 wire, type 1B wiring. Stepdown transformers providing 208 Y/120 volt, 3 phase power are installed adjacent to motor control centers to supply miscellaneous loads.
Unit assemblies consist of mechanisms, mechanical interlocks, panel lock switches, starters, overload relays, terminal blocks, and local operators with lights. Construction is NEMA I with polyurethane foam gasketing.
Interior lighting is high pressure sodium high bay type fixtures in the waste handling and process equipment areas. Fluorescent fixtures are installed within the electric room, control room, laboratory and other office areas. Lighting levels are as follows:
Waste Handling Areas - 30 foot candles
Process Equipment Areas - 40 foot candles
Office and Control Room - 80 foot candles
Exterior lighting consists of wall and pole mounted fixtures. High pressure sodium lamps are utilized to provide illumination levels necessary for vehicular and pedestrian safety.
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The Utility Warehouse at (503) 239-5157
Developed and Maintained by RMA Inc.
Portland, Oregon