Dedicated to the Art of Performance. SOLAE, MLGW, BFI, Landfill Gas to Energy Project Memphis, Tennessee

Transcription

1 CPL-LEI Systems, Dedicated to the Art of Performance Inc. SOLAE, MLGW, BFI, Landfill Gas to Energy Project Memphis, Tennessee January 10, 2005

2 Introduction SOLAE is a soy protein based, food ingredient manufacturer with its largest of 11 plants located in Memphis, TN. SOLAE is a joint venture company majority owned by DuPont. The BFI South Shelby Landfill is approximately 5 miles away from the SOLAE Plant SOLAE works with BFI Allied Waste and CPL in order to understand landfill gas and its potential use for their facility in Memphis. 2

3 Introduction Development issues on the three (3) boilers is discussed with reference on how to allow for mixture natural gas with the new LFG CPL develops the strategy for SOLAE on how the LFG will integrate with the boilers and existing control systems. SOLAE contracts with MLGW to install 5 mile pipeline from the BFI site to SOLAE s plant across public and private land. Key concerns were reliability, cost savings and environmental impact

4 Environmental MLGW & CPL create new standards for working with LFG for acceptance by the TRA & Department of Transportation (DOT) Pipeline Safety Regulations A New MSDS is developed and approved for the site specific LFG for all parties Projected NOx emissions reductions at the SOLAE plant were 50%. SOLAE achieved Nox emissions reductions by more than 75% This Data Applies Only to the South Shelby Landfill of BFI W aste Systems o f N orth America, Inc. Issued: 4/15/04 Material Safety Data Sheet (MSDS) Section I Product N ame: BFI Landfill Gas Company N ame: BFI W aste Systems of N orth America, Inc. Product Code: BFI-LFG-001 Emergency Telepho ne N umber: (337) Chemical N ame and Synonyms: LFG, Biogas Information Telephone Number: (337) Landfill Name: BFI Waste Systems of North America, Inc. Landfill Telephone Number: (901) South Shelby Landfill Address: 5494 M alone Road City: M emphis State: Tennessee Zip C ode: Section II -Com position, Information on Components % TLV PEL Units (VO L) M ethane (M ethyl H ydride) C AS# A* NE -- Carbon Dioxide CAS# ppm Nitrogen CAS# A* NE Oxygen CAS# NE NE Ethane (M ethyl M ethane) CAS# <1 A* NE Hydrogen Sulfide CAS# < ** ppm Vinyl Chloride*** CAS# < ppm * Classified as a Simple Asphyxiant ** Ceiling C o ncentration *** Classified as a human carcinogen by NTP and IARC. Landfill Gas may also contain trace quantities (<0.1%) o f v arious other gases, primarily non-methane organic compounds (NM O Cs), not listed above. Absolute concentrations vary by site and with time. Section III - Physical D ata Boiling Point ( o F): ND Specific Gravity (Water = 1): NA Vapor Pressure (mm H g): N D Percent Volatile by Volume (%): 100 Vapor Density (Air = 1): ph: NA Solubility in Water: Appreciable Evaporation Rate: NA Appearance and Odor: Colorless Gas; Characteristic Odor, H2S has a rotten egg odor. Section IV - Fire and Explosion H azard Data Flash Point ( o F): <0 Flammable Limits (% as M ethane): LEL: 5 UEL: 15 Extinguishing M edia: C arbon D ioxide or Dry C hemical Special Fire Fighting Procedures: Use water spray o r fo g to co ol fire-exposed containers. Unusual Fire & Explosion H azards: M ay reig nite explosively if fire is extinguished before stopping leak. Section V - H ealth H azards Simple A sphyxia n ts

5 Environmental Final Environmental Statement: {The SOLAE Project while utilizing the 3500 scfm / year of landfill gas as a fuel source in lieu of fossil fuels yields the same reduction in greenhouse gases as removing over 71,600 cars from the area roads for one year or utilizing the same greenhouse gas reductions as planting 96,800 acres of trees.} 5

6 From Proposal to Contract Approximately one year from proposal to light-off of boilers Conceptual Schedule by CPL Systems SOLAE contracts with CPL, BFI and MLGW for the gas supply BFI allows open door to work on the facility prior to final contracts SOLAE structures and negotiates contracts for all parties 6 œ 9 month process 6

7 From Proposal to Contract CPL coordinates commissioning of the SOLAE boilers over weekend schedules which allows for minimal downtime prior to LFG availability CPL designs and installs the new controls at the boilers over a 65 day schedule Includes the removal and reinstallation of new CCS and BMS controls on each boiler package. CPL designs and builds the compression station at the BFI landfill 75 day build schedule ( Long lead time equipment ordered prior to final contracts)

8 From Proposal to Contract Special contracts are developed in order to facilitate work with public non profit and private partners in the project MLGW installs the 12 HDPE line across Memphis in 91 days Opps Factor for the new regulations of the MSDS completed in 12 days MLGW proves construction schedule and pigging of the line on day 90 of the project. MLGW Pipeline Installation Down Shelby Dr. in Memphis 8

9 Boiler Plant Modifications Landfill gas moisture removal and redundant knockouts New LFG fuel trains were installed Burners and boiler controls were upgraded with new BMS and CCS packages SOLAE plant communications were integrated with the new CPL HMI controls SOLAE safety and technical parameters were integrated with the new fuel SOLAE HMI Panel and Controls 9

10 Boiler Plant Modifications Automation in the controls allows for continuous switching of the LFG and NG in the event of loss of the LFG ( Seamless Transitioning ) No plant interruptions are seen as the result of the loss of LFG Optimization of the cost effective LFG is on at all times and can transition in as little as 30 seconds for either fuel supply Metering for billing and control BTU analyzer used to produce continuous data to boiler controls and custody transfer reporting Daily reports are transmitted to MLGW, SOLAE, CPL Systems, BFI Flow computers log all data for historical 10 trending

11 Boiler Controls New controllers optimize use of landfill gas and other fuels New controls allow boilers to react to changes in landfill gas pressure and energy content Second line of defense with O2 analyzers prior to delivery of gas to burners Continuous readout of BTU values from custody transfer station into controls PLC Controllers, with high levels of integrity and reliability Interlocks between burner management and combustion control PLC s Dual flame scanners Redundant I/O 11

12 BFI South Shelby Landfill Opened in 1978 as Subtitle D landfill operations Currently has more than 24 million tons of waste in place Currently accepting waste at more than 1500 tons per day Gas analysis and flow calculations show growth over the next years. Permitted to 199 height The hill is an additional tall Landfill is approximates 80 deep at this location 12

13 BFI South Shelby Landfill BFI and CPL design a plan around the control of the well field with RPH & Assoc. CPL designs capacity of system at 5000 SCFM for the project BFI has two flares which had to be incorporated into the compression and control strategy of the project Specific work was done with CPL and Brazeale,Sachse and Wilson, LLP in order to facilitate regulatory standards and a new MSDS for the LFG BFI North Flare System 13

14 Landfill Controls Automation in the controls for the switching of LFG of the flares to the pipeline Automation in the control strategy at the SOLAE boilers and communications back to the landfill compression station Safety features and redundant controls for the monitoring of LFG. O2, and BTU values Developed energy conservation strategy with pressure controls at landfill compressors and boilers at the SOLAE plant. Integrated remote control and system upgrade capability at landfill and boilers 14

15 Landfill Controls Automated controls for constant negative pressure on landfill wells to assure compliance for BFI regulations Integrated a recuperator for moisture and temperature control in the LFG Transportation of South Field gas to North Field compression site Design strategy for low pressure transportation of the LFG in the MLGW pipeline to the SOLAE facility 15

16 Landfill Compression Site 5000 SCFM Blowers and Gas Control Equipment July 10,

17 Landfill Compression Site 17

18 CPL-LEI History CPL Systems, Inc. was founded in 1995 to satisfy customers demand for a cost effective, single source solution for industrial steam systems problems. LEI Systems, Inc. merged with CPL Systems, Inc. in October of With this merger the company gained Surge Control and Production Control Systems which LEI had been operating since The marriage of CPL-LEI Systems, Inc. has allowed us to provide our customers with complete process knowledge and solutions. The combination of CPL s combustion expertise along with LEI s compression expertise gives our customer the full realm of support and technology needed in today s working environment. 18

19 CPL-LEI Systems CPL-LEI Systems is built upon the Company s success enhancing fired equipment performance for numerous companies in a variety of industry segments. CPL s customer base includes both public and private companies in a wide variety of market segments and industries. Our success solving fired equipment problems across such a diverse customer base enhances the company s capability because of the cross industry experience. Successful projects range from multifuel boilers and process heaters to Thermal Oxidizers and Heat Recovery Steam Generator (HRSG) Systems. A significant fact is that a number of customers have standardized on CPL-LEI s control system and process equipment designs. 19

20 Capabilities CPL-LEI Systems is proud of our success in providing expertise for: Green Fuel Energy Solutions Combustion Optimizations Emission Reduction and Compliance N0x Reduction Waste Heat Recovery Alternate Fuel Conversion Online Reliability and Integrity Production Control Compressor Control Surge Control Turbine Control Power Distribution Power Generation Medium BTU LFG High BTU LFG Maximized Equipment Performance Our Success is Technology and Quality Driven 20

21 Fuel Types No. 2, No. 4 and No. 6 Oil Waste Oil Streams Rice Hulls Bagasse Fuel Stoker Coal Pulverized Coal Bark/Wood Waste Stoker/Dust Suspension Fired Combination Firing Natural Gas Land Fill Gas Refinery Gas Waste Gas Streams Bio Gas WWTE 21

22 Principal Markets Aeronautics & Space Industries Paper/Plywood Mills Pharmaceuticals Wood Products Petro Chemicals Auto Makers Oil & Gas Production Companies Chemical Processing Petroleum Companies Industries Energy Industry Gas Processing Land & Exploration Companies Food Processing Salt Mining Refining Agriculture Sugar Mills 22

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24 Thanks, Thank you for your time today. David H. Mauney IV Alternate Energy Systems Team Leader CPL Systems, Inc. 280 Industrial Parkway Lafayette, Louisiana phone On The Web: 24