Pit>-Ao6x^'ie

I TECHNICAL LIBRARY

TECHNICAL REPORT ARLCD-TR-78033

ECONOMIC ANALYSIS OF THE HOTARY KILN

AND FLUIDIZED BED P & E INCINERATORS

VINCENT J. dCCONE ALAN P. GRAVES

MERADCOM, FT. BELVOIR, VA

JOSEPH S. SANTOS, PROJECT LEADER ROBERT SCOLA. PROJECT ENGINEER

ARRADCOM, DOVER, N.J.

^^ff-O^^ ^ 9f

AD-E400 220

SEPTEMBER 1978

US ARMY ARMAMENT RESEARCH AND DEVELOPMENT COMMAND LARGE CALIBER

WEAPON SYSTEMS LABORATORY DOVER, NEW JERSEY

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED.

The views, opinions, and/or findings contained in this report are those of the author (s) and should not be construed as an official Depart- ment of the Army position, policy or decision, unless so designated by other documentation.

Destroy this report when no longer needed. Do not return to the originator.

»; .ii ■!» )yU>^^' LC.(^-\,

ERRATA

Technical Report ARLCD-TR-78033

ECONOMIC ANALYSIS OF THE ROTARY KILN AND FLUIDIZED BED P & E INCINERATORS

Vincent J. Ciccone Alan P. Graves

MERADCOM, Ft. Belvoir, VA

Joseph S. Santos, Project Leader Robert Scola, Project Engineer

ARRADCOM, Dover, NJ

September 2978

The AD-E number on this report was assigned incorrectly. The number should be changed to AD-E400 220.

30 October 1 978

'vrsr^-r^f 1JTf;;'W'"'r'j' ■;■

iiNniA<^?^iFiFn SECURITY CLASSIFICATION OF THIS PAGE (When Data Enlarad)

REPORT DOCUMENTATION PAGE 1. REPORT NUMBER

Technical Report ARLCD-TR-78033

2. GOVT ACCESSION NO.

4. TITLE (and Subtitle;

ECONOMIC ANALYSIS OF THE ROTARY KILN AND FLU IDlZED BED P&E INCINERATORS

'■ vlncent J. Ciccone, MERADCOM Alan P. Graves, MERADCOM Joseph S. Santos, Project Leader, ARRADCOM Robert Scola, Project Engineer ARRADCOM

READ INSTRUCTIONS BEFORE COMPLETING FORM

3. RECIPIENT'S CATALOG NUMBER

5. TYPE OF REPORT BL PERIOD COVERED

Final 6. PERFORMING ORG. REPORT NUMBER

8. CONTRACT OR GRANT NUMBERfs;

9. PERFORMING ORGANIZATION NAME AND ADDRESS

US Army Mobi lity Equip Rsch and Dev Command Petroleum & Environmental Technology Div Ft. Belvoir, VA

11. CONTROLLING OFFICE NAME AND ADDRESS

ARRADCOM, TSD Scientific & Tech info Division (DRDAR-TSS) Dover, NJ 07801

U. MONITORING AGENCY NAME » ADDRESSf//(UWorent from Controlling Oltlca)

ARRADCOM, LCWSL Manufacturing Tech Div (DRDAR-LCM-S) Dover, NJ 07801

10. PROGRAM ELEMENT. PROJECT, TASK AREA & WORK UNIT NUMBERS

LCM-S 12. REPORT DATE

September 1978 13. NUMBER OF PAGES

104 15. SECURITY CLASS, (ol thia report)

Unclassified ISa. DECLASSIFI CATION/DOWN GRADING

SCHEDULE

16. DISTRIBUTION STATEMENT fo/thfa Report)

Approved for public release; distribution unlimited.

17. DISTRIBUTION STATEMENT fo/ the abatract entered In Block 20, // dlllerent from Report)

18. SUPPLEMENTARY NOTES

19. KEY WORDS fConlinue on reverse side If naceaaary and Identify by block numierj

Economic analysis Discriminant Present value unit cost Propel I ants & explosives Fluidized bed Sensitivity analysis Rotary kiIn

20. ABSTRACT (Canttmie aa nreram abta ft irxcvaaaiy ami idetUlty by block number) In the evaluation of alternate systems, it is necessary to consider the

economic factors associated with each system. The economic analysis of the rotary kiln versus the fluidized bed incinerator was performed using the preseni value unit cost method. The method considers capital costs, operating costs, time horizons, depreciation, interest and other related factors. In all cases considered, the fluidized bed incinerator was the preferred alternative.

J 00/^2^73 1473 EDITION OF t NOV 65 IS OBSOLETE UNCLASSIFIED

SECURITY CLASSIFICATION OF THIS PAGE (Whan Data Entered)

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SECURITY CLASSIFICATION OF THIS PAOefWh«o Dmtm Bnlmnd)

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TABLE OF CONTENTS

Summary

Introduction

Discussion

Conclusions

References

Distribution List

Tables

1 Simulated Design Capacity and Daily Loading

Capital Costs for 250 Ib/hr Incinerator Systems

Calculated Capital Costs for Various Capacity Systems

Calculated Savings by Using Fluidized Bed

2

3

4

5 Sensitivity Analysis for Variations in Capital Costs of 250 Ib/hr Fluidized Bed

Page No.

1

2

4

7

8

94

9

10

n

12

13

Figures

1 Flow diagram—rotary kiln incinerator system.

2 Flow diagram—fluidized bed incinerator system

3-79 PVUC and discriminant value charts for

250 Ib/hr systems

14

15

16

TABLE OF EQUIVALENTS

Metric Unit Enqlish Unit Metric Unit Enqlish Unit

kiloqrams-kg pounds-lb $/kq . $/lb

80 177 0.04159 0.09170

91 200 0.04213 0.09288

113 250 0.04282 0.09441

227 500 0.04370 0.09634

272 600 0.04478 0.09872

340 750 0.04567 0.10069

454 1,000 0.04634 0.10217

567 1,250 0.04721 0.10407

680 1,500 0.04830 0.10649

794 1,750 0.04965 0.10946

907 2,000 0.05800 0.12787

1,021 2,250 0.05900 0.13008

1,134 2,500 0.06030 0.13294

1,814 4,000 0.06194 0.13656

2,722 6,000 0.06397 0.14102

3,629 8,000 0.08792 0.19382

4,082 9,000 0.08873 0.19562

4,536 10,000 0.08978 0.19794

5,443 12,000 0.09022 0.19891

6,350 14,000 0.09030 0.19908

7,257 16,000 0.09074 0.20004

8,164 18,000 0.09111 0.20088

9,072 20,000 0.09130 0.20128

10,886 24,000 0.09201 0.20285

12,701 28,000 0.09223 0.20333

13,608 30,000 0.09276 0.20450

14,515 32,000 0.09289 0.20479

16,329 36,000 0.09343 0.20598

18,143 40,000 0.09398 0.20718

19,051 42,000 0.09468 0.20873

21,772 48,000 0.09483 0.20906

24,494 54,000 0.09556 0.21068

27,216 60,000 0.09666 0.21310

226,796 500,000 0.09810 0.21629

453,592 1,000,000 0.10215 0.22520

680,389 1,500,000 0.10987 0.24222

849,125 1,872,000 0.11150 0.24581 0.11361 0.25046 0.11627 0.25633 0.11956 0.26358

TABLE OF EQUIVALENTS CONT'D

Metric Unit English Unit

meters-m feet-ft

1.5 5 67,1 220

meters-m inches-In

0.0016 1/16 0.0025 0.1 0.0508 2 0.1270 5

°C

32.2 90 37.8 100

SUMMARY

Incinerator technology has been studied for many years as a possible alternative to open burning in disposing of waste propell- ants and explosives in an environmentally acceptable manner. As the technical feasibility of various incinerator systems became established, attention was focused on the economic factors associated with each system. Consequently, at the request of the Manufacturing Technology Division, ARRADCOM, a study was undertaken by the Petro- leum and Environmental Technology Division of the Army Mobility Equipment Research and Development Command (MERADCOM) to evaluate and compare two of the leading incinerator concepts, the fluidized bed and the rotary kiln. A dual approach was taken: at ARRADCOM a fluidized bed incinerator was planned and funded for evaluation, while a "best available", off-the-shelf rotary kiln was installed at the Radford Army Ammunition Plant. Both were operated on the pilot plant scale.

The present value unit cost (PVUC) method of analysis was used in the evaluation. In this method, a computerized mathematical model is used to consider capital costs, operating costs, depreciation, interest, and other related factors over various time periods and load (operating) rates. The output yields the PVUC per pound of material Incinerated. The TNT/slurry weight ratio was 25^ for these calcu- lations and the data used for the analysis were derived from actual pilot plant testing. The rotary kiln data were obtained from runs at 250 Ib/hr and the fluidized bed data from runs at 177 Ib/hr (250 Ib/hr § 61%).

A discriminant (the PVUC difference between the two alternatives) was evaluated as the quantified indicator of the more practical al- ternative. A review of all of the cases considered and evaluated indicated that the fluidized bed is the preferred system because its lower operating costs result in major cost savings. The sensitivity of the discriminant to variations in capital costs was also calcu- lated. This analysis showed that, with even a 40% increase in capital cost, the fluidized bed is still preferred over the rotary kiln because it is the operating cost (not the capital) that significantly affects the PVUC value. For example, a 40^ increase in capital cost differential reflects only a 13/6 change in the discriminant.

The PVUC model can be used to evaluate any number of alternative designs if sufficient operating data are available. Efficiently used, it provides management with the economic data necessary to make viable decisions when choosing among various alternatives.

INTRODUCTION

The primary objective of this study Is to evaluate the economics of two specific waste incinerators designed to satisfy the environmental requirements for pollution abatement at ammunition manufacturing and loading plants.

The evaluation technique used, the Present-Value Method, is consistent with AR 37-13 (ref 1). This method employs a structured mathematical model which evaluates the alternatives and allows fcr direct comparison on an equitable cost basis. A re I event cost figure, called the Present-Value Unit Cost (PVUC), is determined and applied. A determinant,6XJ (the difference between the calcu- lated PVUC's for eaclTal+ernatJVfe) is examined over selected planning horizons (j). It indicates the practicality of a particular scheme in the total analysis (ref 2).

The two basic systems considered in this study are the rotary kiln incinerator and the fluidized bed incinerator systems. A diagram of a simplified rotary kiln is shown in figure 1; the fluidized bed setup, in figure 2.

The scope of the study embraces design capacity, operating capacity, economic life, time horizons, capital costs, and operating costs. Pertinent data on these points were prepared for input into the PVUC model.

To evaluate different sized systems, a design capacity range of 250 to 2500 Ib/hr at increments of 250 Ib/hr coupled with a range of operating conditions was considered (table 1). For example, a 1000 Ib/hr design capacity system was evaluated under four different operating conditions: at 35%, 61%, 1005^ and 1005^ at mobilization of the total daily design value. The systems were considered to be operated on an 8-hour shift, thereby indicating a simulated load or ideal capacity equal to the rated design multi- plied by 24. A 1000 Ib/hr system was capable of incinerating 24,000 pounds of explosive waste per day. The use or operating percentage factor was then applied to this total capacity. On this basis, there were 40 different design cases available for consid- eration in the economic evaluation.

The planning horizons used in each simulation run varied from 5 to 25 years (the expected economic life of the system) in incre- ments of 5 years. The individual cost functions used for determining the PVUC's for each alternative were those obtained in an associated study conducted for MERADCOM by the Value Engineering Company, Alexandria, VA (ref 3).

Thus, with the primary elements of the problem approach out- lined, the fundamental task was to find and evaluate the least cost alternative to meet the incinerator design and loading requirements. A typical computer run consists of input data specification, execution of the computer program, and analysis of the printed output. The decision discriminant is examined for both algebraic sign and magnitude. For each planning horizon, three pertinent values are calculated: the decision discriminant and the PVUC's for A & B, each functional as input to the total decision making process. The solutions for the presented explosives waste incinerator alternatives were generated for the specified conditions which accounted for 40 different design and loading schemes or cases. The resulting computer outputs were collated, interpreted and tabulated.

The decision discriminant and PVUC obtained from the two in- cinerator systems, the respective planning horizons, the design capacity and daily loading, and computed annual costs are presented In table 2. The associated graphs (CALCOMP plots) for these data are shown in figures 3 through 79. The computed system capital costs for the two alternatives are shown in table 3. Table 4 shows the calculated savings estimated by selection of the fluidized bed and table 5 shows the calculated variations of the discriminant based on an increase in the capital expenditure.

DISCUSSION

The computerized methodology used In this study permits com- parison of the two Incinerator systems on the basis of Present Value- Unit Costs. Cost input data, which included capital and operating values, were collected and analyzed which also Included: a detailed literature survey; personal contact with manufacturers, distributors, and several government agencies; and the data reduction and inter- pretation gathered from these sources. The cost data collected were based on predetermined design capacity range of 250-2500 Ib/hr input of dry propellant waste and operational parameters meeting the necessary standard effluent limitation regulations and safety factors. The cost figures were the vendors' current pricing at the time of the survey.1 Capital cost is basically the cost of equipment plus instrumentatiQn_-and accessories (land or installation are excluded).

TJperational and maintenance costs include the cost of power, water, "" air, fuel, labor and replacement parts.

Incineration of waste propellants in relatively small quantities (250 to 2500 Ib/hr) differs from the incineration of large quantities of industrial and municipal solid wastes, regardless of whether rotary kiln or fluidized bed systems are used. Consequently, in some instances, vendors could not provide costs covering the entire mini mum-to-maximum range, and cost figures were extrapolated from the available data for plotting and comparison purposes. In all cases, the vendors' cost data were considered estimates, not firm quotes.

Capital and operational costs are expressed in dollars per 250-lb increment of dry propellant waste. All equipment prices are for one item, F.O.B.

The following guidelines were used to plot and interpret the reduced cost data:

1. For each unit process the data quoted by the equipment manufacturers closely approximates the costs that could be reason- ably expected on the basis of published literature and actual experience.

2. Cost figures for the same design capacity and type of equipment vary significantly from one manufacturer to another. ThI may be due to the fact that some distributors are preoccupied by sales and were not interested in taking the necessary time to pro- vide accurate cost data for this study.

1. All dollar values reflect 1974 standards.

4

3. Operating and maintenance costs differ with respect to geographical location. Consequently, in order to establish a uniform basis of comparison, it was assumed that all plants would be located in the same temperate area. Cost figures interpolated from the curve represent average values.

The design capacity considered in this study and the daily load- ing simulated in the computer runs are shown in table 1. The daily loading factor is computed by taking the hourly design capacity over a 24-hour period, the ideal capacity for any one day. The percentage factor is then applied to the total capacity to give the daily load- ing rate. This loading rate was fed into the computer model with the incinerator system assumed to be operating at its designed hourly capacity on 8-hour shifts. On this basis, the number of shifts needed to accomplish the loading was calculated and included as part of the program output. For example, if a system with a design capacity of 750 Ib/hr (6000 lb/shift or 18,000 lb/day) were simulated at 50^ loading, it would require two shift operations. It was also assumed that if any portion of a shift were Included, It would be considered a full 8-hour shift in terms of labor and operation costs.

The capital costs for the two incinerator systems at different levels of capacity are listed in table 2. These dollar figures are representative of the systems' costs in 1974.

Table 3 shows the calculated economic evaluation parameters for a typical case; that is, for a design capacity of 250 Ib/hr, given loading factors of 335^, 675^, 100^ and planning horizons of 5 through 25 years, the calculated PVUC's and average annual costs are shown based on the simulated operation of the incinerator systems.

The graphs of the PVUC and discriminant values for this 250-lb/hr design capacity case are showrn in figures 3 through 79. A direct cost comparison can therefore be made of the two systems. The estimated annual dollar savings obtained by selecting the fluldlzed bed system over the rotary kiln are shown In table 4. A similar analysis can be made for each of the 40 cases presented in this report by following the same technique as that described for the 250 Ib/hr design using the data in figure 3 through 79. A review of these plots shows that in every case, the fluidized bed system is preferred.

The sensitivity of the discriminant to variations in the capital costs for the fluidized bed was calculated (table 5). These values show how the decision discriminant varied in response to selected percentage increases In capital costs. This may also be interpreted as a variation in the difference between the capital costs of both alternatives. In this case It shows that even If the capital costs of the fluidized bed were to increase, it would still be favored over the rotary kiln.

During the fluidized bed pflot plant operations conducted at ARRADCOM during 1977, the average loading rate was 177 Ib/hr. This value closely approximates the 675^ loading rate for the 250 Ib/hr design and is closely correlated to the pilot plant operations.

The selection of any particular case or case set Is not an easy or well defined task, since the "demand" for the disposal of waste propellant and explosives cannot be predicted with any degree of accuracy; or can any valid variations be played without being considered simply random guesses. Therefore, It was assumed that the demand would be considered constant, and valid variations were approximated by varying the loading conditions. Each case, therefore, represented a design capacity and a varied operating or loading condition for each time period. Thus, although each case was dis- crete and defined, variations were simulated and played in the computer model.

,pii^;»i(>;/',

CONCLUSIONS

Based on the results of this study and the provisions for cost evaluation developed by MERADCOM (ref 3), the fluid!zed bed in- cinerator system offers an economic advantage over the rotary kiln and is recommended as the preferred system for disposal of propel I ant and explosive wastes at ammunition manufacturing plants.

REFERENCES CITED

1. "Economical Analysis and Program Evaluation of Resource

Management," AR 37-13, June 1973.

2. Ciccone, et al, "A Present Value-Unit Cost Methodology for ^^ Evaluating Municipal Wastewater Reclamation and Direct Reuse, Water Resources Bulletin, Vol. 11, No. 1, 1975.

3 "Engineering Evaluation to Determine Cost Elements for Incinerators," Report No. 1, US Army Mobility Equipment Research and Development Center, Fort Belvoir, VA., June

1974.

4. Modern Cost-Engineering Techniques, McGraw Hill, New York, 1970.

5. Joseph S. Santos and Robert Scola, "Fluidized Bed Incinerator for Disposal of Propellants and Explosives," Technical Report ARLCD-TR-78032, ARRADCOM, Dover, NJ, 1978.

TABLE 1

SIMULATED DESIGN CAPACITY AND DAILY LOADING

1 hr

DESIGN CAPACITY (lb)

8 hr 24 hr

DAILY LOADING (lb)

(7o OF TOTAL CAPACITY)

33.33% 66.66% 100!6

250 2000 6000 2000 4000 6000

500 4000 12000 4000 8000 12000

750 6000 18000 6000 12000 18000

1000 8000 24000 8000 16000 24000

1250 10000 30000 10000 20000 30000

1500 12000 36000 12000 24000 36000

1750 14000 42000 14000 28000 42000

2000 16000 48000 16000 32000 48000

2250 18000 54000 18000 36000 54000

2500 20000 60000 20000 40000 60000

Of^^^^^^ 0

TABLE 2

Capftal Costs for 250 Ib/hr Incinerator Systems

Daily Rate loading (jC) rate (lb)

I u 33 2000

66 4000

6000

MOB 6000

6-day- week

Yearly loading

rate (lb)

500,000

1,000,000

1,500,000

250-day/yr

1,872,000

312-day/yr

Planning horizon (yr)

5

^y 10

15

20

25

5

10

15

20

25

5

10

15

20

25

5

10

15

20

25

PVUC ($/lb exp) a

RK

0.26358

0.25633

0.25046

0.24581

0.24222

0.20450

0.20088

0.19794

0.19562

0.19382

0.21310

0.21068

0.20873

0.20718

0.20598

0.20479

0.20285

0.20128

0.20004

0,19908

FB

0.22520

0.21629

0.20906

0.20373

0.19891

0.14102

0.13656

0.13294

0.13008

0.12787

0.10946

0.10649

0.10407

0.10217

0.10069

0.09872

0.09634

0.09441

0.09288

0.09170

Avq Annual (k>st RK FB

$131

128

125

123

121

J05^

201

198

196

194

320

316

313

311

309

383

380

377

374

373

J1J3

JI08

105

102

99 V

141

137

133

130

128

164

160

156

153

151

185

180

177

174

172

a. RK = rotary kiln; FB = fluldlzed bed b. Nearest thousand

10

TABLE 3

CALCULATED CAPITAL COSTS FOR

VARIOUS CAPACITY SYSTEMS

^

DESIGN CAPACITY (Ib/hr)

250

500

750

1000

1250

L\ 1500

1750

2000

2250

2500

* Reference #2, (1974 dollars)

Cost In Thousands* Rotary KiIn

473 i^

513

558

606

658

715

777

844

917

996

Fluid!zed Bed

582 "-^

645

715

792

878

973

1078

1195

1324

1468

9\/ Kob4J5 <Uu^ toZJi^

1^ '(^/0FK)(,JMM'

r /o yu^ .

SOcj C/THP AjL>-/tyi cJ^\Kun<rA

TABLE 4

CALCULATED SAVINGS BY USING FLUIDIZED BED

(TYPICAL)

DESIGN CAPACITY IS 250 Ib/hr ^

LOADING RATE IS 675f -^ )^ ° 67i ^

TIME DISCRIMINANT SAVINGS ($) * (yr) (^X.i)

5 0.50919 241

10 0.83625 395

15 1.04608 494

20 1.18056 558

25 1.26667 599

* Nearest thousands. Obtained by multiplying discriminant by the capital cost of rotary kiln, here $472,600.

12

TABLE 5

SENSITIVITY ANALYSIS FOR VARIATIONS IN CAPITAL COSTS

of

250 Ib/hr FLU IDlZED BED

Year PERCENTAGE INCREASE IN CAPITAL COST DIFFERENTIAL

0% 25% 305K 35? A0%

Discriminant Variations

1.54 1.51 1.48 1.45

2.50 2.45 2.41 2.36

3.11 3.06 3.01 2.95

3.51 3.45 3.39 3.33

3.76 3.70 3.63 3.57

5 1.68

10 2.73

15 3.39

20 3.81

25 4.06

13

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DISTRIBUTION LIST

Commander US Army Materiel Development and Readiness Command ATTN: DRCDE-E

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