IAFBC Abbotsford, BC. Poultry Litter and Animal Carcass Gasification Plant Project No

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1 IAFBC Abbotsford, BC. Poultry Litter and Animal Carcass Gasification Plant Project No PROJECT MEMORANDUM 05 FUEL HANDLING SYSTEM, ALTERNATIVE #1 0 9 Oct 2010 Issued as Addendum for Final Report Rev Date Issue By Checked PJ Project Mgr. Client Document No PM 05

2 T a b l e o f C o n t e n t s 1 I N T R O D U C T I O N Background 1 2 F U E L H A N D L I N G S Y S T E M A L T E R N A T I V E # Poultry Litter Handling System Animal Tissue Handling System Fuel Feed Control System Dust Control Odour control Truck Scale / Undercarriage Wash Fire Protection Operations 3 3 C o n c l u s i o n s 4 4 D r a w i n g s 4 Project Memorandum 05, , 9 October, 2010 TOC - i

3 P r o j e c t M e m o r a n d u m I N T R O D U C T I O N 1.1 B a c k g r o u n d The initial study results were presented to the GIAC Steering Committee members, 20 September As presented, the project was not economically viable; consequently, instructions were given to reduce the capital and operating costs by undertaking several measures. In the fuel handling area, the prime measure identified for reducing the capital cost was to reduce the fuel storage capacity from 30 days to 10 days. Subsequent to the meeting and upon further study, it was found that the 10-days worth of poultry litter could be stored in (2) silos, thereby eliminating the large fuel storage hall and minimizing the overall area required for the site. Additionally, it is possible to reduce the costly odour control system to 1/10 th of the previous size. Also, the silo system has 100% live-storage, meaning that it is possible to eliminate the mobile equipment and the operating personnel in the fuel handling area. This project memorandum describes the alternative system for the fuel handling area. 2 F U E L H A N D L I N G S Y S T E M A L T E R N A T I V E # P o u l t r y L i t t e r H a n d l i n g S y s t e m There will be a single building for both poultry litter and animal tissue. Poultry litter will be delivered by self-unloading trucks with trailers. The trucks will back into the receiving building through fast-acting doors and will discharge their loads into a litter receiving hopper, which will meter the fuel into a conveyor system that will transport the litter to a scalping screen. The belt conveyor will be equipped with a self-cleaning magnet for removing tramp ferrous metal. Reject over-sized material passing over the end of the scalping screen will fall into a bunker, which will be periodically emptied and trucked to landfill. Acceptable sized material passing through the screen will fall into a bucket elevator, which will discharge into a conveyor system above the two poultry litter storage silos. Broiler litter will be stored in a 16.8m diameter x 23m high, flat-bottomed steel silo. Turkey litter will be stored in a separate 9.1m diameter x 13.9m high steel silo. Both silos will be equipped with variable speed, rotary, under-pile screw reclaimers, which will meter the litter onto a common belt conveyor running underneath the silos. This belt conveyor will discharge into another bucket elevator, which will elevate the litter up to the fuel mixer, located in an enclosed tower adjacent to the gasification building. The belt conveyor will be equipped with a belt weigh scale to measure the flow from the litter storage silos. Project Memorandum 05, , 9 October,

4 P r o j e c t M e m o r a n d u m 0 5 The fuel mixer will mix the litter and animal tissue to provide a uniform fuel quality and will discharge it into a screw conveyor system, which will transport the fuel mix to the fuel feed bins, which are located in the gasifier building. A bypass is included, which will permit the conveyor system to be emptied under an emergency situation. The fuel bins, which are supplied with the gasifier package will meter the fuel into the gasifier. 2.2 A n i m a l T i s s u e H a n d l i n g S y s t e m The animal tissue handling system remains unchanged, other than: The receiving system is housed in the same building as the poultry litter receiving system There is only (1) 10-day, animal tissue storage tank. Animal tissue will be pre-processed off-site, where it will be ground-up to a pumpable form and treated with a chemical, which will prolong its storage life. The animal tissue will be delivered in sealed containers by truck. The trucks will discharge their loads into a receiving hopper from which the animal tissue will be pumped to the storage tank. The tank will be equipped with a variable speed extractor, which will discharge into a metering pump. The metering pumping system will discharge into the fuel mixer. 2.3 F u e l F e e d C o n t r o l S y s t e m The normal fuel mixture delivered to the gasifier will be 83% poultry litter and 17% animal tissue; but the reclaim systems for each stream will be variable speed so that the amounts of material can be varied as required. Additionally, the entire fuel feed system from both streams between the storage units and the fuel feed bins will be variable speed and will be kept full; the intent being that the feed system can respond immediately to the level controls in the fuel bins thereby minimizing the lag time and enabling a near constant fuel level to be maintained. 2.4 D u s t C o n t r o l A dust control system will be installed at the fuel receiving building, which will collect dust from the poultry litter receiving hopper, the screen and the conveyor / elevator system to and from the litter storage silos. Material discharged from the dust collector will discharge onto the conveyor from the receiving building. The dust control system will consist of a high efficiency cyclone and fan and will be equipped with a spark detection and deluge system. 2.5 O d o u r c o n t r o l Air will be withdrawn from the fuel receiving building, the litter storage silos, and the animal tissue storage tank by an odour control system; thereby keeping them under a negative pressure and minimizing the leakage of odours. The odour control system will be equipped with a biofilter. All exterior conveyors will be sealed and vented to the odour control system. Project Memorandum 05, , 9 October,

5 2.6 T r u c k S c a l e / U n d e r c a r r i a g e W a s h P r o j e c t M e m o r a n d u m 0 5 All trucks entering and leaving the site will pass over a truck scale and will be weighed in and out. A truck washing and disinfecting system will be provided so that the trucks can be cleaned before re-entering the public roadways. Water will be collected, filtered and recirculated through the system. Make-up water and disinfecting chemicals will be added as required. All of the roads and yard will be paved and will be drained to a common sump, from which heavies and floaters will be removed, prior to being drained to the municipal sewer. 2.7 F i r e P r o t e c t i o n Fire protection systems will be provided for all fuel handling areas including the fuel receiving building, the storage silos, the conveyors and the truck wash building. Fire protection systems will include sprinkler systems and fire hose stations. 2.8 O p e r a t i o n s Truck Scale The truck scale is the unattended type, with control panels located adjacent to the truck driver s door. Traffic lights will be provided to control entry onto the scale. The scale will be connected via a LAN to the plant information system. Poultry Litter System The poultry litter system will be controlled by the plant operator located in the main plant control room. When a fuel delivery truck registers at the truck scale, the operator will be notified as to the type of fuel being delivered and he will start-up the appropriate equipment, adjust the relevant gates and monitor the levels in the silos. CCTV will be provided in key locations to give the operator visual contact with the area. Other systems, such as the dust control and odour control systems will also be controlled from the main plant control room via an HMI. Animal Tissue System When a truck delivering animal tissue is being processed, the truck driver will notify the plant operator via an intercom that he has dumped his load into the receiving hopper. The plant operator will start the transfer pump, which will run until the receiving hopper is empty or the tank is full. The animal tissue metering system will be controlled from the main plant control room. The operator will be able to control the appropriate blend of animal tissue and poultry litter to suit the current gasifier operating conditions. Project Memorandum 05, , 9 October,

6 P r o j e c t M e m o r a n d u m 0 5 Truck Washing System The truck washing system is entirely automatic. Sensors will detect when a truck approaches and will open the doors and start the pumps and blowers. Likewise, sensors will detect when a truck has exited the facility and will stop the pumps and close the doors. 3 C o n c l u s i o n s 1. The total site area required has been reduced substantially by 44% from 4.5 acres to 2.5 acres. 2. The fuel handling front-end loader has been replaced by a smaller machine that will be utilized for emptying bunkers and ash handling work. 3. The fuel handling system operator has been eliminated. 4. These changes have reduced the total capital cost by approximately 28% 4 D r a w i n g s In order to save study costs, we were instructed not to produce new Autocad drawings of the alternative fuel handling system. However, in order to develop the alternative system and revise the capital cost estimate, it was necessary to mark-up the process flow diagrams and the site layout. Additionally, a hand-sketch showing the elevation was developed. The mark-ups and sketches are attached for reference. Project Memorandum 05, , 9 October,