ash bottom case long gerald 2015 by: may presented · 2015-06-25 · ash transport water dry...
TRANSCRIPT
Coal‐Fire
d Po
wer Plant Bottom Ash
Wet‐To‐Dry Con
versions / Case Stud
ies
Presen
ted By: G
erald Long
May 2015
2015
Wo
rld
of
Co
al A
sh (
WO
CA
) C
on
fere
nce
in N
asvh
ille,
TN
- M
ay 5
-7, 2
015
htt
p:/
/ww
w.f
lyas
h.in
fo/
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Regulatory Upd
ate/
Implications
/Com
pliance Timeline
Bottom
Ash Han
dling Technical A
lternatives
Discussion Overview
© 201
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ratio
n. A
ll Righ
ts Reserved.
Key Re
gulatory Actions
Coal Com
bustion Re
sidu
als (CC
R)
Issued
Decem
ber 1
9, 201
4
CFR Pu
blication: April 17
, 201
5
Goals
‐Groun
dwater Protection Be
nefits
‐Preven
ting Future CCR
Impo
undm
ent C
atastrop
hic Failures
Efflu
ent Lim
itatio
ns Guide
lines (E
LG)
Prop
osed
Rules Issued
April 20
13
Final Rules: C
onsent Decree = Septem
ber 3
0, 201
5
Goals
‐Strengthen
Steam
Electric
Pow
er Plant Disc
harge Co
ntrols
‐Re
duce Surface W
ater Pollutant Disc
harges
© 201
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Coal Com
bustion Re
sidu
als (CC
R) Ruling
Overview
Regulatio
n Focus Areas:
Locatio
n Re
strictio
ns: A
quife
r, Wetland
s, Fault Zone
s, Seism
ic Zon
es,
Unstable Areas
De
sign Crite
ria: Lined
/Unlined
, Leaking/N
ot Leaking, Structural Integrity
Ope
ratin
g Crite
ria: Flood
Con
trol, Fugitive Dust C
ontrol, Inspe
ctions
(Weekly/Mon
thly/Ann
ual)
Groun
dwater M
onito
ring and Co
rrectiv
e Actio
n
Closure Re
quire
men
ts and
Post‐closure Care
Re
cordkeep
ing, Notificatio
n, and
Internet Postin
g
© 201
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ts Reserved.
Coal Com
bustion Re
sidu
als (CC
R) Ruling
Regulatory Tim
eline –ExistingCC
R Surface Im
poun
dmen
ts
04/1
5
Upd
ated
Pa
rt 2
57
Publ
ishe
d to
Fe
dera
l R
egis
ter
10/1
5
Fugi
tive
Dus
t Con
trol P
lan,
W
eekl
y In
spec
tions
,
Mon
thly
Mon
itorin
g,
La
unch
Rec
ordk
eepi
ng,
Not
ifica
tions
& W
ebsi
te
01/2
016
04/1
7
Emer
genc
y A
ctio
n Pl
an
Initi
ate
Clo
sure
Ac
tivity
01/2
4
Com
plet
e C
losu
re
Activ
ity
Doc
umen
t if
exis
ting
Surf
ace
Impo
undm
ents
ar
e Li
ned/
Unl
ined
2016
2017
2018
2019
2024
2015
Com
plet
e In
itial
Ann
ual
Insp
ectio
n
Inst
all
Perm
anen
t M
arke
r
Floo
d C
ontro
l Pla
n,C
losu
re &
Pos
t-Clo
sure
C
are
Plan
s, S
truct
ural
As
sess
men
t
10/1
6
Inst
all G
roun
dwat
er
Mon
itorin
g Sy
stem
, Sa
mpl
ing
& An
alys
is
Prog
ram
, Det
ectio
n M
onito
ring
Prog
ram
10/1
7
Com
plet
e de
mon
stra
tion
for
plac
emen
t abo
ve a
quife
r and
co
mpl
ete
dem
onst
ratio
ns fo
r w
etla
nds,
faul
t are
as, s
eism
ic
zone
s an
d un
stab
le a
reas
10/1
804
/19
© 201
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ts Reserved.
ELG Ruling
Steam Electric
Main Re
gulatory Options
Wastestream
sTechno
logy Basis fo
r the
Main Re
gulatory Options
3a3b
34a
FGD W
astewater
BPJ D
etermination
Chem
ical Precipitatio
n +
Biological Treatmen
t for units
at a facility with
a to
tal w
et‐
scrubb
ed capacity
of
>200
0MW; B
PJ fo
r <200
0MW
Chem
ical Precipitatio
n +
Biological Treatmen
t Ch
emical Precipitatio
n +
Biological Treatmen
t
Fly Ash Tran
sport
Water
Dry Han
dling
Dry Han
dling
Dry Han
dling
Dry Han
dling
Bottom
Ash Transpo
rt
Water
Impo
undm
ent
(equ
alto BPT
)Im
poun
dmen
t (equ
alto BPT
)Im
poun
dmen
t (equ
alto BPT
)
Dry Han
dling/ Closed
‐loop
for u
nits >40
0W;
Impo
undm
ent (eq
ualto
BPT) fo
r units <40
0MW
Combu
stion Re
sidu
al
Leacha
teIm
poun
dmen
t (equ
alto BPT)
Impo
undm
ent
(equ
alto BPT)
Impo
undm
ent
(equ
alto BPT)
Impo
undm
ent
(equ
alto BPT)
FGMC Wastewater
Dry Ha
ndling
Dry Ha
ndling
Dry Ha
ndling
Dry Ha
ndling
Gasificatio
n Wastewater
Evaporation
Evaporation
Evaporation
Evaporation
Non
chem
icalMetal
Cleaning
Wastes
Chem
ical Precipitatio
nCh
emical Precipitatio
nCh
emical Precipitatio
nCh
emical Precipitatio
n
EPA will cho
ose (1) o
f the
(4)
Options and
issue as fina
l in
Septem
ber 2
015
© 201
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ratio
n. A
ll Righ
ts Reserved.
Fly Ash Wet‐to‐Dry Con
versions (A
ll 4 Options)
Re
maining
wet fly ash system
s will be converted to dry sy
stem
s
Existing wet back‐up
system
s will be de
commissione
d and will likely
requ
ire add
ition
al re
dund
ancy fo
r prim
ary dry system
s
Bottom
Ash W
et‐to‐Dry Con
versions
Und
er 3 of 4
regulatory options, utilities will have to determine if
existing im
poun
dmen
ts can
meet B
PT re
quire
men
ts (T
SS, o
il and grease)
Utilities will also
have to weigh
BA WTD
con
version costs a
gainst CCR
Subtitle D requ
iremen
ts: “Must rem
ove solids and retrofit with
a
compo
site liner or cease re
ceiving CC
R’s w
ithin 5 years of e
ffective date
and close the Unit”
For O
ption 4a, all gene
ratin
g un
its >40
0 MW will have to im
plem
ent B
A WTD
con
versions; gen
erating un
its <40
0 MW will have to evaluate BA
WTD
con
version costs a
gainst BPT
requ
iremen
ts
Implications of E
LG Ruling
© 201
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ll Righ
ts Reserved.
Pow
er E
ngin
eerin
g, F
ebru
ary
2013
, UC
C S
FC, S
CE&
G-W
ater
ee S
tatio
n, S
outh
Car
olin
a
Bottom
Ash W
TD Con
version Alternatives
Continuo
us Dew
atering & Recirculation System
(CDR
) with
Rem
ote SFC’s
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Regulatory Upd
ate / Im
plications / Com
pliance Timeline
Bottom
Ash Han
dling Technical A
lternatives
Discussion Overview
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Bottom
Ash W
et‐To‐Dry Con
versions
Technical A
lternatives Subm
erged Flight Con
veyor –
SFC™
Long
‐Term Econo
mical Cho
ice (Low
O&M Costs)
Simple Solutio
n if Space is Available
Re‐Circulating Hydraulic System (3
Options)
No Ch
anges U
nder Boiler, Uses Existing Ho
pper
Minim
izes Outage Re
quire
men
ts
Dry Hop
per P
neum
atic Con
veying
–PA
X™
No Water, Returns Heat B
ack to Boiler
Easie
st 100
% Dry Option to M
ove Ash Out of B
oiler B
uilding
Mecha
nical B
ottom Ash Con
veying
No Water, Returns Heat B
ack to Boiler
Co
ntinuo
us Rem
oval of B
ottom Ash
© 201
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nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Bottom
Ash W
TD Con
version Alternatives
Und
er Boiler S
ubmerged Flight Con
veyor (SFC)
Co
ntinuo
us Rem
oval of A
sh
Low Pow
er Con
sumption
Easily Incorporates M
ill Rejects
Indu
stry Stand
ard on
New
Units fo
r past
30 years
© 201
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nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Bottom
Ash W
TD Con
version Alternatives
Subm
erged Flight Con
veyor (SFC)
© 201
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nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Minim
al Outage Time for C
onversion
Co
ntinue
to Use Existing Bo
ttom
Ash Hop
pers
Bottom
Ash W
TD Con
version Alternatives
Conven
tional D
ewatering & Recirculation System
© 201
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ratio
n. A
ll Righ
ts Reserved.
Bottom
Ash W
TD Con
version Alternatives
Settling and Surge Tanks
© 201
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nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Bottom
Ash W
TD Con
version Alternatives
Continuo
us Dew
atering & Recirculation System
(CDR
) with
Rem
ote SFC’s
CD
R System
with
Rem
ote SFC’s
Co
mbine
s SFC
Techno
logy with
Co
nventio
nal Recirculation System
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Bottom
Ash W
TD Con
version Alternatives
Continuo
us Dew
atering & Recirculation System
(CDR
) with
Rem
ote SFC’s
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Bottom
Ash W
TD Con
version Alternatives
Bottom
Ash Dew
atering and Clarificatio
n System
with
Rem
ote SFC’s
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Bottom
Ash W
TD Con
version Alternatives
Bottom
Ash Dew
atering and Clarificatio
n System
with
Rem
ote SFC’s
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Bottom
Ash W
TD Con
version Alternatives
Bottom
Ash Dew
atering and Clarificatio
n System
with
Rem
ote SFC’s
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Bottom
Ash W
TD Con
version Alternatives
Bottom
Ash Dew
atering and Clarificatio
n System
with
Rem
ote SFC’s
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Bottom
Ash W
TD Con
version Alternatives
Bottom
Ash Dew
atering Ba
sins
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Med
ium and
fine
particulates m
ay not achieve
desired moisture conten
t of 1
5‐20
% in
basins
Bottom
Ash Dew
atering Ba
sins
Desig
n/Pe
rformance Con
siderations
Ash may have to be moved
and
spread to achieve th
e moisture conten
t suitable for lan
dfill com
paction
© 201
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nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Must con
side
r poten
tial plugging of dew
atering screen
s
Bottom
Ash Dew
atering Ba
sins
Desig
n/Pe
rformance Con
siderations
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Bottom
Ash Dew
atering Ba
sins
Desig
n/Pe
rformance Con
siderations / Risk Analysis
Per C
CR re
quire
men
ts, b
asins will still re
quire
subsurface line
r system and
groun
dwater m
onito
ring
system
, and
must b
e 5 ft. abo
ve upp
ermost a
quife
r
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Bottom
Ash Dew
atering Ba
sins
Desig
n/Pe
rformance Con
siderations / Risk Analysis
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Bottom
Ash Dew
atering Ba
sins
Desig
n/Pe
rformance Con
siderations / Risk Analysis
Risk Ana
lysis must con
side
r relative proxim
ity to
local
waterways/flo
od plain fo
r poten
tial m
igratio
n of ash
wastewater and
solid
s during a pe
ak storm
event,
particularly re
lativ
e to pen
ding
ELG
requ
iremen
ts
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Pow
er E
ngin
eerin
g, F
ebru
ary
2013
, UC
C S
FC, S
CE&
G-W
ater
ee S
tatio
n, S
outh
Car
olin
a
Bottom
Ash W
TD Con
version Alternatives
Pneu
matic Ash Extractor (PAX
) System & M
echanical Bottom Ash System
Pow
er E
ngin
eerin
g, F
ebru
ary
2015
, UC
C P
AX
Syst
em, D
uke-
May
o St
atio
n,
Nor
th C
arol
ina
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Dry Bottom Ash –PA
X System
Pr
oven
Tec
hnol
ogy
Easi
ly R
etro
fitte
d Ar
ound
Stru
ctur
al B
arrie
rs
Prov
ides
Impr
oved
Hea
t Rec
over
y
Doe
s N
ot R
equi
re W
ater
for C
onve
ying
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Dry Bottom Ash –PA
X System
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Dry M
echa
nical B
ottom Ash
Sp
ace
for I
nclin
ed R
amp
Se
cond
ary
Con
veyo
r(s)
[Mec
hani
cal S
how
n]
© 201
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nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
Tech
nolo
gy A
ltern
ativ
es
1 =
Wor
st, 5
= B
est
Scal
eR
e-C
irc S
yste
mU
nder
Boi
ler
Dra
g C
hain
Dry
Col
lect
ion/
Pneu
mat
ic
Con
veyi
ng (P
AX)
DR
Y
1-5
(Hyd
raul
ic)
(Mec
hani
cal)
(Pne
umat
ic)
(Mec
hani
cal)
Crit
eria
for D
eter
min
ing
Tech
nolo
gy S
elec
tion
WT
SCTo
tal
SCTo
tal
SCTo
tal
SCTo
tal
Wat
er U
sage
/Ava
ilabi
lity
22
43
65
105
10
Out
age
Tim
e Li
mite
d5
525
420
210
315
Tota
l Ins
talle
d C
ost
21
25
103
62
4
Ope
ratio
n &
Mai
nten
ance
Cos
t2
24
510
36
48
Pow
er C
onsu
mpt
ion
21
24
82
45
10
Boile
r Hou
se C
orrid
or A
vaila
bilit
y5
525
315
525
15
Mul
tiple
Uni
t Syn
ergi
es5
525
210
420
210
Biom
ass
/ Unb
urne
d C
arbo
n C
once
rns
11
11
14
45
5
Wei
ghte
d To
tal S
core
8880
8567
Decision An
alysis Process
© 201
5. United Co
nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
ELG & CCR
Ruling
Typical W
et‐to‐Dry Ash Co
nversio
n Project D
urations
R
ules
will
likel
y dr
ive
doze
ns o
f WTD
ash
con
vers
ion,
pon
d cl
osur
e, d
ry la
ndfil
l and
was
tew
ater
trea
tmen
t pro
ject
s
Pote
ntia
l to
test
the
capa
city
of U
tiliti
es, A
E Fi
rms,
Tec
hnol
ogy
Prov
ider
s &
Inst
alla
tion
Con
tract
ors
Task
Januar
yFebrua
ryMa
rchApr
ilMa
yJun
eJuly
August
Septem
berOct
oberNov
ember
Decem
berJan
uaryFeb
ruary
March
April
May
June
JulyAug
ustSep
tember
Octobe
rNovem
berDecem
berJan
uaryFeb
ruary
March
April
May
June
JulyAug
ustSep
tember
Octobe
rNovem
berDecem
berJan
uaryFeb
ruary
March
April
May
June
2015
2016
2017
2018
Plan
ning
Study
/
Spec. D
evelop
men
t/
Perm
itting
Requ
est for Propo
sal/
Procurem
ent
Engine
ering
Procurem
ent/
Fabrication
Constructio
n/
Commission
ing
TOTA
L PR
OJECT
DURA
TION
36‐42 mon
ths
2015
2016
2017
6‐12
mon
ths 3‐6 mon
ths
9‐12
mon
ths
12 m
onths
12‐18 mon
ths
2018
© 201
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ratio
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ll Righ
ts Reserved.
Que
stions
Que
stions ?
© 201
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nveyor Corpo
ratio
n. A
ll Righ
ts Reserved.
United Co
nveyor Corpo
ratio
n
Gerald Long
Geraldlon
g@un
itedcon
veyor.com