wte capital refurbishments · o air preheater tube bundles o superheater screen tubes o superheater...
TRANSCRIPT
© 2015 HDR, Inc., all rights reserved.
Extending the Life of WTE Facilities Another 25 Years
WTE CAPITAL REFURBISHMENTS
PRESENTATION OVERVIEW
Overview of the of U.S. WTE fleet
Typical WTE Maintenance practices and drivers for Capital Improvement Projects
Life cycle of major boiler and APC components
Super alloy overlays/materials & facility enhancement projects
80+ Facilities Currently Operating o 60+ mass burn o 10+ RDF
Major Benefits o Proven Technology o Can process 99%+ of waste stream o Direct Combustion Process o Volume Reduction of 85%+ o Generate Electricity and/or Steam o Sell Recovered Metals
OVERVIEW OF WTE FACILITIES IN US
H-POWER Kapolei, HI
Wheelabrator BRESCO Baltimore, MD
Stagnant tipping fees and competition with landfills
Drop in energy prices
Drop in ferrous metal market
Lack of regulatory incentives
Increase in O&M costs
DIFFICULT ECONOMIC CLIMATE
Annual or bi-annual scheduled outages Unscheduled
outages Extended cold iron
outages
WTE PLANT MAINTENANCE PRACTICES
DESPITE THE FACT THAT THESE FACILITIES PERFORM COMPREHENSIVE ROUTINE MAINTENANCE MANY WTE FACILITIES NEED TO INVEST SIGNIFICANT CAPITAL TO EXTEND ITS USEFUL LIFE ANOTHER 25 YEARS
WASTEC, Wilmington, NC Jackson County RRF, Jackson, MI Wheelabrator Claremont, Claremont, NH Red Wing Plant, Red Wing, MN MERC, Biddeford, ME Harford WTEF, Joppa, MD Wallingford RRF, Wallingford, CT
Since 2010, 7 facilities totaling almost
2,500 TPD of capacity have closed
WTE FACILITY SHUTDOWNS Harford Waste to Energy Facility Joppa, MD
Maine Energy Recovery Company Biddeford, ME
Components at End of Useful Life
Improve Aesthetics
Reduce O&M Costs Increase Revenues/Gain Additional
Revenue Streams
Comply with Future Emissions Requirements
CAPITAL PROJECT DRIVERS
Harford Waste to Energy Facility Joppa, MD
Maine Energy Recovery Company Biddeford, ME
TYPICAL SECTIONS OF A WTE FACILITY
FEED HOPPER & CHUTE
FEED TABLE & GRATES
ASH DISCHARGERS
BOILER WATERWALL TUBES
SUPERHEATER TUBES
SUPERHEATER TUBES
ECONOMIZER TUBES
TYPICAL SECTIONS OF A WTE FACILITY
SCRUBBER VESSEL
SCRUBBER VESSEL
SCRUBBER HOPPER
BAGHOUSE DUCTWORK
BAGHOUSE HOPPERS
BAGHOUSE ROOF
MSW HANDLING o Cranes o Grapples o Front End Processing Equipment (for RDF plants)
FURNACE o Feed Chute o Feed Table o Grate Runs o Ash Transition Chute o Ash Discharger
BOILER o Waterwall Tube Panels o Boiler Screen Tubes o Gen Bank/Economizer Bundles o Air Preheater Tube Bundles o Superheater Screen Tubes o Superheater Tube Pendants Bundles o Sootblower System o Auxiliary Burners o CO tuning/Optimization o Insulation & Lagging
APC o Flue Gas Ductwork o Scrubber Refurbishment o Baghouse Refurbishment o De-NOx/Low NOx System o Carbon Injection System o Lime Injection System o Ammonia Injection System
ASH HANDLING o Bottom Ash Vibrating Pan Conveyor o Ferrous Drum/belt Magnets o Eddy Current Separators o Belt Conveyors o Screw Conveyors o Pugmills
SITE CIVIL/ARCHITECTURAL o Receiving Floor Repairs o Receiving Pit Wall Repairs o Ash Building Floor Repairs o Ash Building Bunker Repairs o Landscaping/Repaving Work o General Building Repairs (roof/siding/painting)
BOP o High Pressure Feedwater/Steam Piping Audit/Repairs o Boiler Feedwater Pumps o Condenser Retubing o Chemical Feed System Upgrades o Closed Loop Cooling Water o Cooling Tower/Air Cooled Condenser Refurb o CEMS System Upgrades o DCS System Upgrades o Air Compressors o Turbine-Generator System o Stack o Misc Pumps & Fans
MISCELLANEOUS o Electrical Power Systems o Plant Piping & Hanger Supports o Rolling Stock o Truck Scales o Fire Protection o HVAC
CAPITAL REFURBISHMENT PROJECTS
CAPITAL REFURBISHMENT PROJECTS
Cost of refurbishment projects highly variable
Some end of term projects we are seeing most frequently: New Cranes/Grapples Ash Discharger Replacement Boiler Waterwall Panel Replacement Generator Bank Tube Replacement Economizer Bank Tube Replacement Sootblower System Upgrades
APC Flue Gas Ductwork Replacement Scrubber Rebuild Baghouse Rebuild/replacement New Truck Scales Cooling Tower Rebuild New T/G Controls
Traditional Overlay Material o Carbon Steel o Inconel 625 Super Alloys to Consider o Eutectic 3606/1433D/BTC511 o Colmonoy 88 o Conforma Clad
Areas of Application o Boiler waterwall tubes o Superheater tubes
BOILER TUBE OVERLAYS
Kennametal (www.kennametal.com) WallColmonoy (www.wallcolmonoy.com) Applied Thermal Coatings (www.appliedthermalcoatingsusa.com) Liquidmetal Coatings, LLC (www.liquidmetal-coatings.com) Joining Technologies (www.joiningtech.com) Whertec (www.castolin.com/whertec) Integrated Global Services, Inc. (www.integratedglobal.com) SprayWerx (www.spraywerx.com) AmStar (division of Alstom) (www.alstom.com) Dai-ichi High Frequency Co., Ltd. (www.dhf.co.jp/eng) Magellanmetals (www.magellanmetals.com)
ALTERNATIVE MATERIALS MANUFACTURERS & INSTALLERS
Traditional Material o Carbon Steel o 316L Stainless Steel Super Alloy to Consider o Hastelloy C-22
Areas of Application o Scrubber vessel lining o Scrubber hoppers
SCRUBBER VESSEL & HOPPER LINING
Traditional Installation Materials o Mineral wool or Roxul Insulation o Protective Lagging
Areas for application o Scrubber outlet duct/baghouse inlet duct o Scrubber and baghouse hoppers o Screw conveyors
SPRAY ON INSULATION
SPRAY ON INSULATION
SPRAY ON INSULATION
FACILITY ENHANCEMENTS
• Metals Recovery • Non-ferrous • Additional ferrous for RDF plants
• VFDS • ACC fans • ID/FD fans
• Semi Dry Ash System
• Enhanced Nox Reduction • Enhanced SNCR/SCR • Covanta’s LN NOx
Flue Gas Recirculation
© 2015 HDR, Inc., all rights reserved.
THANK YOU. QUESTION & COMMENTS Jeff Martirano, P.E. [email protected] 914-993-2038 Solid Waste Project Engineer/Manager