WTE CAPITAL REFURBISHMENTS Extending the Life of WTE Facilities Another 25 Years HDR, Inc., all rights reserved.

Transcription

1 WTE CAPITAL REFURBISHMENTS Extending the Life of WTE Facilities Another 25 Years 2015 HDR, Inc., all rights reserved.

2 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

3 OVERVIEW OF WTE FACILITIES IN US 80+ Facilities Currently Operating o 60+ mass burn o 10+ RDF H-POWER Kapolei, HI 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 Wheelabrator BRESCO Baltimore, MD

4 DIFFICULT ECONOMIC CLIMATE 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

5 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

6 WTE FACILITY SHUTDOWNS 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 Harford Waste to Energy Facility Joppa, MD Maine Energy Recovery Company Biddeford, ME Since 2010, 7 facilities totaling almost 2,500 TPD of capacity have closed

7 CAPITAL PROJECT DRIVERS Components at End of Useful Life Harford Waste to Energy Facility Joppa, MD Improve Aesthetics Reduce O&M Costs Increase Revenues/Gain Additional Revenue Streams Maine Energy Recovery Company Biddeford, ME Comply with Future Emissions Requirements

8 TYPICAL SECTIONS OF A WTE FACILITY

9 FEED HOPPER & CHUTE

10 FEED TABLE & GRATES

11 ASH DISCHARGERS

12 BOILER WATERWALL TUBES

13 SUPERHEATER TUBES

14 SUPERHEATER TUBES

15 ECONOMIZER TUBES

16 TYPICAL SECTIONS OF A WTE FACILITY

17 SCRUBBER VESSEL

18 SCRUBBER VESSEL

19 SCRUBBER HOPPER

20 BAGHOUSE DUCTWORK

21 BAGHOUSE HOPPERS

22 BAGHOUSE ROOF

23 CAPITAL REFURBISHMENT PROJECTS 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 o o o o o Electrical Power Systems Plant Piping & Hanger Supports Rolling Stock Truck Scales Fire Protection HVAC

24 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

25 BOILER TUBE OVERLAYS 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

26 ALTERNATIVE MATERIALS MANUFACTURERS & INSTALLERS Kennametal ( WallColmonoy ( Applied Thermal Coatings ( Liquidmetal Coatings, LLC ( Joining Technologies ( Whertec ( Integrated Global Services, Inc. ( SprayWerx ( AmStar (division of Alstom) ( Dai-ichi High Frequency Co., Ltd. ( Magellanmetals (

27 SCRUBBER VESSEL & HOPPER LINING 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

28 SPRAY ON INSULATION 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

29 SPRAY ON INSULATION

30 SPRAY ON INSULATION

31 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

32 THANK YOU. QUESTION & COMMENTS Jeff Martirano, P.E Solid Waste Project Engineer/Manager 2015 HDR, Inc., all rights reserved.