United States        Office of Water and     SW 176C.19
           Environmental Protection    Waste Management     October 1979
           Agency          Washington, D.C. 20460

           Solid Waste
vvEPA     European Refuse  Fired
           Energy Systems

           Evaluation of Design Practices

           Volume 19

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                                oi EPA
        and State. Sotid Waa-te Mana.gejne.nt
       EUROPEAN REFUSE FIRED ENERGY SYSTEMS

            EVALUATION OF DESIGN PRACTICES


               Hamburg:   Stellinger Moor
               West  Germany
Tkit>  tsu.p n.e.pofit.  (SW-776c.791
. the.  O^-tce. o& Sotid Wcute. undeA contract no.  6&-01-4376
 and   fie.pfioduLC.nd a& x.e.ceA.ve.d  ^fwm the. contAa.dtofi.
 The.  £f,«r.-,..».;.[ protection Agency;

          \'. :;''.,"•"! V, L'',: ': /
          2JJ  :."..••-:n P'.-..::-'.:••'". Strv--t

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         This report was prepared by Battelle Laboratories, Columbus,  Ohio,
under contract no. 68-01-4376.

         Publication does not signify that the contents necessarily  reflect
the views and policies of the U.S. Environmental Protection Agency,  nor  does
mention of commercial products constitute endorsement by the U.S.
Government.

         An environmental protection publication (SW-176c.l9)  in  solid waste
manaaement series.
                          U.S. Envlronrr.er.tal  Protection Ager.cy

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             TRIP REPORT
                 to
HAMBURG:  STELLINGER MOOR, WEST GERMANY
       EVALUATION OF EUROPEAN
    REFUSE FIRED STEAM GENERATOR
          DESIGN PRACTICES
                 to


U.S. ENVIRONMENTAL PROTECTION AGENCY


          November 16, 1977



  EPA Contract Number:  68-01-4376

  Battelle Project Number:  G-6590

     EPA-RFP Number:  WA-76-B146

                 by

Philip R. Beltz & Richard B. Engdahl
              BATTELLE
        Columbus Laboratories
           505 King Avenue
        Columbus, Ohio  43201

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                                    1
                                 PREFACE

          This trip report is one of a series of 15 trip reports on
European waste-to-energy systems prepared for the U.S. Environmental
Protection Agency.  The overall objective of this investigation is to
describe and analyze European plants in such ways that the essential
factors in their successful operation can be interpreted and applied
in various U.S. communities.  The plants visited are considered from
the standpoint of environment, economics and technology.
          The material in this report has been carefully reviewed by the
European grate or boiler manufacturers and respective American licensees.
Nevertheless, Battelle Columbus Laboratories maintains ultimate responsi-
bility for the report content.  The opinions set forth in this report are
those of the Battelle staff members and are not to be considered by EPA
policy.
          The intent of the report is to provide decision making in-
formation.  The reader is thus cautioned against believing that there is
enough information to design a system.  Some proprietary information has
been deleted at the request of vendors.  While the contents are detailed,
they represent only the tip of the iceberg of knowledge necessary to de-
velop a reliable, economical and environmentally beneficial system.
          The selection of particular plants to visit was made by Battelle,
the American licensees, the European grate manufacturers, and EPA.  Pur-
posely, the sampling is skewed to the "better" plants that are models of
what the parties would like to develop in America.   Some plants were selected
because many features envolved at that plant.  Others were chosen because
of strong American interest in co-disposal of refuse and sewage sludge.
          The four volumes plus the trip reports for the 15 European
plants are available through The National Technical Information Service,
Springfield,  Virginia  22161.   NTIS numbers for the volumes and ordering
information are contained in the back of this publication.   Of the 19
volumes only the Executive Summary and Inventory have been prepared for
wide distribution.

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                                    ii
                               ORGANIZATION
          The four volumes and 15 trip reports are organized the the
following fashion:

          VOLUME I

A  EXECUTIVE SUMMARY
B  INVENTORY OF WASTE-TO-ENERGY PLANTS
C  DESCRIPTION OF COMMUNITIES VISITED
D  SEPARABLE WASTE STREAMS
E  REFUSE COLLECTION AND TRANSFER STATIONS
F  COMPOSITION OF REFUSE
G  HEATING VALUE OF REFUSE
H  REFUSE GENERATION AND BURNING RATES PER PERSON
I  DEVELOPMENT OF VISITED SYSTEMS

          VOLUME II
J  TOTAL OPERATING SYSTEM RESULTS
K  ENERGY UTILIZATION
L  ECONOMICS AND FINANCE
M  OWNERSHIP, ORGANIZATION, PERSONNEL AND TRAINING

          VOLUME III

P  REFUSE HANDLING
Q  GRATES AND PRIMARY AIR
R  ASH HANDLING AND RECOVERY
S  FURNACE WALL
T  SECONDARY (OVERFIRE) AIR

          VOLUME IV

U  BOILERS
V  SUPPLEMENTARY CO-FIRING WITH OIL, WASTE OIL AND SOLVENTS
W  CO-DISPOSAL OF REFUSE AND SEWAGE SLUDGE
X  AIR POLLUTION CONTROL
Y  START-UP AND SHUT-DOWN
Z  APPENDIX

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                          TABLE OF CONTENTS




                                                                       Page




OVERALL SYSTEM SCHEMATIC	      1




COMMUNITY DESCRIPTION 	      1




     Geography	      1




     Solid Waste Practices	      1




          Solid Waste Generation	      1




          Solid Waste Collection	      7




          Solid Waste Disposal	     11




     Development of the System	     11




          Background	     11




          Beginning of Subject System 	     14




          Building Subject System 	     15




PLANT ARCHITECTURE	     15




     Plant Setting	     15




          Environmental Setting (Non-Pollutant Aspects) 	     15




          Plant Hygiene	     17




          Outside Design	     17




TOTAL OPERATING SYSTEM	     17




REFUSE FIRED STEAM GENERATOR EQUIPMENT	     17




     Waste Input	     17




     Weighing Operation 	     22




     Provisions to Handle Bulky Refuse	     23




     Waste Storage and Retrieval	     23

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                     TABLE OF CONTENTS
                        (Continued)

                                                                 Page
Furnace Hoppers and Feeders 	       27

The Martin Black Box	       28

Primary Air	       31

Secondary Air	       32

Air Preheater	       36

Burning Grate 	       36

Furnace Wall (Combustion Chamber) 	       40

     Stage 1 (Original Construction)  	       40

     Stage 2 (Simple Addition of Refractory)  	       42

     Stage 3 (Addition of Caps onto the Studs and More
     Refractory)	       44

Furnace Wall (Radiation First Pass) 	       44

Furance Roof	       46

     First Pass Outlet Screen Tubes Rear of Radiation First
     Pass	       48

Superheater	       50 & 51

     Stage 1 (Original Construction)	       50 & 51

     Stage 2 [Original Construction]	       50 & 51

     Stage 3 (Switch to Pressure Bent Tubes)	       54

     Stage 4 (Welded Curved Shields)	       54

     Stage 5 (Bracing Superheater Tubes)	       56

     Stage 6 (Superheater Repair Observation) 	       56

     Boiler Convection Section	       57

     Stage 1.   (Original Design)	       57

     Stage 2.   (Reducing of Soot Blowing Activity)	       57

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                          TABLE OF CONTENTS
                             (Continued)


                                                                      Page

     Economizer	      62

          Stage 1 (Original Construction) 	      62

          Stage 2 (Sootblowers Attached to Economizer Bundles).  .      62

          Stage 3 (Plugging Econimizer Tubes) 	      62

CO-FIRING	      63

          Sewage Treatment Plant Methane Gas	      63

          Commercial Number 2 Fuel Oil	      63

ENERGY UTILIZATION EQUIPMENT	      64

          Turbines	:	      64

          Power Generated and Used	      64

          Internal Steam Uses	      67

     Air Cooled Steam Condensers	      67

          Stage 1 (Original Construction) 	      67

          Stage 2 (Changing Fan Speed Instead of Pitch)  	      68

          Stage 3 (Freezing Tubes Requiring More Thermocouples)  .      68

POLLUTION CONTROL EQUIPMENT 	      69

          Stage 1 (Original Construction) 	      69

          Stage 2 (Flue Gas Water Spray Cooler)	      69

     Stack Construction	      70

     Ash Recovery	      72

PERSONNEL AND MANAGEMENT	      76

ENERGY MARKETING	      76

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                          TABLE OF -CONTENTS
                             (Continued)


                                                                      Page

ECONOMICS	     78

     Capital Investment  	     78

     Operating Costs	  .     78

          Guarantee	     81

FINANCE	     81

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                            LIST OF FIGURES

                                                                       Page

FIGURE  7-1.  CROSS SECTION OF HAMBURG:  STELLINGER-MOOR PLANT .  .      2

FIGURE  7-2.  STELLINGER MOOR PLANT LOCATION IN HAMBURG AREA ...      3

FIGURE  7-3.  VOLUME OF WASTE COLLECTION AT HAMBURG SINCE 1945,
              MILLIONS OF CUBIC METERS 	   •   4

FIGURE  7-4.  MONTHLY TREND OF BULKY WASTE COLLECTION IN HAMBURG
              FOR 1973 AND 1976	      5

FIGURE  7-5.  ADVERTISEMENT BY CITY OF HAMBURG "DON'T MISS THE
              WASTE CAN".  "KEEP HAMBURG CLEAN"  	      8

FIGURE  7-6.  CARD ANNOUNCING BULKY WASTE COLLECTION DAYS  ....      12

FIGURE  7-7.  MAP OF AREAS SERVED BY THE DIFFERENT PROCESSING
              FACILITIES	      13

FIGURE  7-8.  MAP OF STELLINGER-MOOR SANITARY PARKS.  THE SEWAGE
              TREATMENT PLANT IS AT 4	      16

FIGURE  7-9.  STELLINGER-MOOR PLANT  	      18

FIGURE 7-10.  NIGHT VIEW OF STELLINGER-MOOR PLANT  	      18

FIGURE 7-11.  FLAP-TYPE OF HINGED BUNKER DOOR  	      23

FIGURE 7-12.  UNBURNED BULKY REFUSE AFTER PASSING THROUGH
              FURNACE	      24

FIGURE 7-13.  TIPPING FLOOR NEAR BUNKER DOORS AT STELLINGER-MOOR .      25

FIGURE 7-14.  REGULATING CHAPACTERISTICS OF CONTROLLER 	      30

FIGURE 7-15.  A RELATIVELY QUIESCENT FURNACE WITH NO SECONDARY
              AIR	      34

FIGURE 7-16.  TURBULENT FLAME MIXED BY SECONDARY AIR JETS  ....      35

FIGURE 7-17.  MARTIN REVERSE ACTING GRATE  	      37

FIGURE 7-18.  METAL WASTAGE OF WATER HEADERS ABOVE THE HOT SECTION
              OF THE GRATE AT HAMBURG:  STELLINGER-MOOR  	      41

FIGURE 7-19.  OCTOBER 1976 ADDITIONS OF REFRACTORY TO HAMBURG
              STELLINGER-MOOR FURNACE //I	      43

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                     LIST OF FIGURES (Continued)

                                                                      Page
FIGURE 7-20.  MAY 1977 ADDITIONS OF CAPS ONTO STUDS AND REFRAC-
              TORY TO HAMBURG:  STELLINGER-MOOR  	    45

FIGURE 7-21.  THREE SUPERHEATER BUNDLES AT HAMBURG:  STELLINGER-
              MOOR 	    52

FIGURE 7-22.  FLOW DEFLECTION CAUSED BY ANGLE IRON SHIELDS ON
              FIRST ROW OF SUPERHEATER TUBES	    53

FIGURE 7-23.  METHOD OF WELDING CURVED 50 mm SHIELDS ON FIRST ROW
              OF SUPERHEATER TUBES 	    55

FIGURE 7-24.  ARRANGEMENT OF TUBES AND DRUMS IN CONVECTION
              SECTION	    58

FIGURE 7-25.  BOILER MAINTENANCE DATA SHEET AT STELLINGER-MOOR
              FOR RECORDING TUBE THICKNESS MEASUREMENTS ON TUBE
              ROW NO. 1	    59

FIGURE 7-26.  BOILER MAINTENANCE DATA SHEET AT STELLINGER-MOOR
              FOR RECORDING TUBE THICKNESS MEASUREMENTS ON TUBE
              ROW NO. 2	    60

FIGURE 7-27.  STEAM TURBOGENERATOR BUILT BY AEG-KANIS   	    65

FIGURE 7-28.  DIAGRAMS THERMAL AND OF ELECTRICAL SYSTEMS AT
              STELLINGER-MOOR   	    66

FIGURE 7-29.  BOTTOM OF CHIMNEY AT RIGHT 	    71

FIGURE 7-30.  STELLINGER-MOOR WASTE PROCESSING 	    73

FIGURE 7-31.  STREET SWEEPER CLEANING ROADWAY ADJECENT  TO STELLINGER
              MOOR PROCESSED RESIDUE STORAGE PILE   	    75

FIGURE 7-32.  ORGANIZATION CHART FOR HAMBURG:  STELLINGER-MOOR  .  .    77

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                            LIST OF TAB1ES   '
TABLE  7-1.   COMPOSITION OF MUNICIPAL WASTE AT HAMBURG: STELL-
              INGER-MOOR 	

TABLE  7-2.   MONTHLY CUSTOMER CHARGE FOR RENTING A SERVICED
              REFUSE CONTAINER IN HAMBURG  	

TABLE  7-3.   HAMBURG:  STELLINGER-MOOR TOTAL OPERATING
              FIGURES  	

TABLE  7-4.   DETAILED OPERATING STATISTICS FOR NOVEMBER 4, 1976
              BOILER NUMBER 1 AT HAMBURG:  STELLINGER-MOOR . .  .

TABLE  7-5.   DETAILED OPERATING STATISTICS FOR APRIL 2, 1977
              BOILER NUMBER 1 AT HAMBURG:  STELLINGER-MOOR . .  .

TABLE  7-6.   WALL TUBE THICKNESS MEASUREMENTS OF ROOF TUBES AT
              THE REAR OF THE RADIATION FIRST PASS AT HAMBURG:
              STELLINGER-MOOR  	

TABLE  7-7.   WALL TUBE THICKNESS MEASUREMENTS OF SCREEN TUBES
              AT THE REAR OF THE RADIATION FIRST PASS AT HAMBURG:
              STELLINGER-MOOR  	

TABLE  7-8.   SOLID WASTE DISPOSAL COSTS AT HAMBURG INCLUDING
              OPERATION OF LANDFILL AND STELLINGER-MOOR AND
              BORSIGSTRASSE PLANTS 	
10
19
20
21
47
49
79

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                              STATISTICAL  SUMMARY
                             Stellinger-Moor Plant

Community  description:
  Area  (square kilometers)
  Population  (number of people)
  Key terrain feature

Solid waste practices:
  Total waste generated per  day  (tonnes/day)
  Waste generation rate (Kg/person/yr)
  Lower heating value of waste (Kcal/kg)
  Collection period (days/week)
  Cost of  collection (local  currency/tonne)
  Use of transfer and/or pretreatment  (yes or no)
  Distance from generation centroid  to:
    Local  landfill (kilometers)
    Refuse fired steam generator  (kilometers)
  Waste type  input to system
  Cofiring of sewage sludge  (yes  or  no)
     Flat
2.94 n>3/person-yr -400 yg/person:
     1800
       5
      No
 MSW &  Industrial
       No
Development of the system:
  Date operation began (year)
      1972
Plant architecture:
  Material of exterior construction
  Stack height (meters)
      71.2
Refuse fired steam generator equipment:
  Mass burning  (yes or no)
  Waste conditions into  feed chute:
    Moisture (percent)
    Lower heating value  (Kcal/kg)
  Volume burned:
    Capacity per furnace  (tonnes/day)
    Number of furnaces constructed  (number)
      Yes


      1800  (Dec. 1976)

      450
      2

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  Capacity per  system (tonnes/day)   .      ,.,--,
  Actual per  furnace  (tonnes/day)        ,„  .    ,
  Number of furnaces  normally operating (number)
  Actual per  system  (tonnes/day)
Use auxiliary reduction  equipment  (yes or no)
Pit capacity  level full:
  (Tonnes)
   (*3)
Crane capacity:
  (tonnes)
   (m3)
Feeder drive  method
Burning grate:
  Manufacturer
  Type '
  Number of sections  (number)
  Length overall  (m)
  Width overall
Primary air-max
                                  0
Secondary and tertiary air-max  (m /min)
Furnace volume  (m )
Furnace wall  tube diameter  (cm)
                          2
Furnace heating surface (m )
Auxiliary fuel capability (yes or no)
Use of superheater (yes or no)
Boiler
  Manufacturer
  Type
  Number of boiler passes (number)
  Steam production per boiler
  Total plant  steam production (kg/hr)
  Steam temperature ( C)
  Steam pressure,  bar  (superheater exit)
                    900
                    No
                    7000

                    10
                    5

                 Martin
              Reverse Action
                2 x 6 = 12
                   8.93
                  4.01
                  7.0
                  630
                  Yes
                  Yes

               Walther
Two drum natural  circulation boiler
          32,000/40,000 kg/hour
          64,000/80,000 kg/hour
                 400
                42 bar

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Use of economizer  (yes or no)                                  Yes
Use of air preheater  (yes or no)                               Yes
Use of flue gas reheater (yes or no)                           Ho
Cofire (fuel or waste) input                                   	
Use of electricity generator (yes or no)                       Y6's
  Type of turbine                                   extraction-condensing turbine
  Number of turbines  (number)                                  2
  Steam consumption (kg/hr)                                 64,000/88,000
  Electrical production capacity per turbine                12.5/76.4 NW
  Total electrical production capacity                      25/32.8 MW
                             2
  Turbine back pressure (kg/m )                             0.14/0.3 bar
  User of electricity ("Internal" and/or "External")           Both
Pollution  control:
  Air:
    Furnace exit conditions
                      3
      Gas flow rate (m /hr)                                    91,560
                                 3
      Furnace exit loading (mg/Nm )                            	

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    Equipment:
      Mechanical cyclone  collector  (yes  or no)                     No
      Electrostatic precipitator  (yes  or no)                       Yes
        Manufacturer                                              Walther
        Inlet loading to  precipitator  (mg/Nra  )                     	
        'Exit - Loading from precipitator(mg/Nm )                    112
                                       3
        Legislative requirement  (mg/Nm )                          150
Water:
  Total volume of waste water (liters/hr)                          	
  Ash:
    Volume of ash (tonnes^rear)                                     73,251
    Volume of metal recovered (tonneafyear)                         11,737

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                       LIST OF PERSONS CONTACTED

Karl Heinz Arndt         Stellinger Moor, Plant Manager
Igor Schmidt             Stellinger Moor, Operations Manager
Hans Rudolf Timm         Stellinger Moor, Maintenance Supervisor
Klaus Von Borck          City of Hamburg, Landfill Engineer
Weiner Grosstueck        City of Hamburg, Chief Construction Engineer
George Stabenow          Consultant to UOP, E. Stroudsburg, Pa., U.S.A.
Heinz Weiand             Projects Manager, Martin, Munich, W. Germany

          The authors are glad to acknowledge the skilled assistance
and kind hospitality provided by these representatives.

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                                SUMMARY
          The Hamburg: Stellinger-Moor (S-M) plant Is situated in a sanitary
park which is in a light industrial area.  Hamburg apparently was the first
city to practice waste-to-energy with its 12 batch-fired incinerators with
waste heat recovery boilers back in 1896.
          The city has an innovative industrial engineered incentive program
for collectors.  In this program, collectors are paid based on container size,
distance walked and presence of stairs.  Of the waste collected, in 1976, 200,
556 tonnes were burned at S-M for a 640 tonne (706 ton) per day average.
          The report presents detailed operating data recorded every two hours
for a couple of days.  The "Martin black box" used at S-M carefully controls
steam production as a function of furnace temperature.  While not totally clear,
there is an important discussion of how secondary air can contribute to more
complete burning and corrosion reduction.
          Due to corrosion experiences many other techniques have been employed
such as the following:

          •  Furnace combustion chamber
             ••  Four kinds of refractory
             ••  Silicon carbide caps over welded studs
          •  Superheater
             ••  Original strapped curved shield
             ••  Angle iron welded to leading tubes
             ••  Compressive tube bending
             ••  Welded 2 inch curved shields
             ••  Bracing superheater bundles
          •  Convection section
             ••  Reducing sootblower activity
          •  Economizer
             ••  Attaching sootblowers to economizer
                 bundles (and not the wall)
             ••  Plugging failed economizer tubes.

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          The steam flows through two topping off condensing turbines
that produced 69,239 Mwh in 1976 .
          The air cooled steam condensers on the roof experienced problems with
freezing once when temperatures dropped to -20 C (-4 F).   Controlling the con-
denser in summer and winter is discussed.
          The electrostatic precipitator eventually went out of compliance and
now S-M is experimenting with a flue gas water spray tewer to  absorb  harmful  gases.
          An outside contractor extensively recycles ash for scrap metal and
road building material.

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                        OVERALL SYSTEM SCHEMATIC

          Figure 7-1 displays the overall system schematic for the Stellinger-
Moor plant.


                         COMMUNITY DESCRIPTI6N

                               Geography

          Figure 7-2 shows the Stellinger Moor  (S-M) plant location in
Stellinger, a northwestern suburb of Hamburg.   Of the 1,800,000 metropolitan
Hamburg population, S-M consumes waste from about 500,000 people.  Hamburg's
population has recently been declining at a rate of 10,000 people per year—
as more people move to the suburbs.
          Being a large industrial city, there  are many generators of
industrial waste.  On two observed occasions, large loads of Agfa film
were discharged into the pit.  Most of the harbor waste is diverted either
to the RFSG at Borsigstrasse or the landfill at Neu-Wulmsdorf and Hamburg.
The plant itself is located in a  sanitary park in an industrial area.
                         Solid Waste Practices

Solid Waste Generation

          Collection of waste has been spiraling upward since 1945 as shown
in Figure 7-3.  Volume has risen from 300,000 cubic meters in 1945 and is
expected to reach 6 to 6.6 million by 1980.
          Figure 7-4 shows the monthly trend of bulky wastes for 1973
(fine line) and 1976 (heavy line).
          The waste composition percentages are shown by weight and by volume
in Table 7-1.  As in many places of the world, vegetable waste as a percentage
of the total has been declining.  Surprisingly, glass is 23% by Wight and
15% by volume.

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                 MVA




                   HAMBURG   Rothenburgsort
FIGURE 7-2.  STELLINGER MOOR PLANT LOCATION  IN HAMBURG AREA

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                  Hamburgs Miill-Spirale in Mio. cbm.
                                   1980
  Von 1945= 0,3 Mio. cbm- uber 1976 = 5,46 Mio. cbm-auf 1980= 6,0-6,6 Mio. cbm
FIGURE  7-3.  VOLUME  OF WASTE COLLECTION AT HAMBURG  SINCE 1945,
             MILLIONS OF CUBIC METERS  (Courtesy of  City of Hamburg)

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          The heating values of individual components are shown as well in Table 1,
Column b.  Multiplying the percentage distribution by ,weight (Column a) by
the unit heating value (Column b) results in the heat contribution from
individual components per Kg of mixed waste (Column c).
          An average of 7.3 liters of domestic refuse was produced daily during
1976 by each resident.

Solid Waste Collection

          Both public and private organizations collect waste in the metro-
politan area as follows (1976) :
          City of Hamburg, household waste publicly collected  4,435,603 m^
          Suburbs publicly and privately collected               448,278
          Industrial waste privately collected                   575,231
                                                               5,459,112 m3

          Local officials are using Oscar of "Sesame Street" to urge people
to put all of the trash  into the garbage cans and to not spill trash onto the
ground (see Figure 7-5   ).
          The city of Hamburg has developed an industrial engineered computer
based system to control and  pay workers  and  collect  disposal fees.   Points  are
awarded and fees are charged based on location of the container (backyard,
upstairs, curb, etc.),  distance walked and container volume.  The system,
begun in 1964, was developed along with the local union.
          For those interested in details, a German language 44 page
report exists that outlines the program, prices and results.  A similar program
is described in greater detail in the Copenhagen trip report.
          As an example of the point system for collection workers, the follow-
ing was translated:
          "Points for the transportation by a waste collection for a 110 liter
( 29  gallon) waste container.

          (a)  30 points  for level ground transport up to
               22 points for walking 15 meters  (49 feet)
                8 points for tipping into truck

-------

-------
           (b)  50 points for transport up or down steps
               22 points for walking 15 meters (49 feet)
               20 points for steps
                8 points for tipping into truck.
           (f)  110 points for transport up or down steps over 50 meters
               (163 feet).
           Points are accumulated over a month duration and the workers are
paid a varying amount per 100 points as shown below:

                                         Price Paid to Worker per 100 Points
           Point Range                        Deutsch Mark       Dollars
           From 3,601 to 6,400                     .33              0.14
           From 6,401 to 9,500                     .58              0.24
           From 9,500 and above                    .29              0.12
           The point system clearly penalizes both the under and the over
producer.  There likely was concern about the long-term health and safety
of  collectors who worked too hard and long.
           The homeowner's cost of garbage removal are essentially determined
by  the size bins used, distance and the presence of stairs.  The price is
lower per  liter if larger receptacles are used.  However, because of
architectural and other reasons, this is not always possible.  In 1976,
the city used the following totals of various sizes of containers:
           •  770/1100 liter volume bulk containers—37,106
           •  110/220 liter volume house bins—304,862
           •  35/55 liter volume dwelling bins—47,933.
An average of 7.8 liters of domestic refuse was produced daily during 1976
by each inhabitant.
          A typical family will pay 3.46 DM ($1.40)  per week for rent of
a 110-liter container.   Table 7-2   shows the official rate schedule.
          Any source separation or recycling occurring in Hamburg is
accomplished by the Red Cross or other volunteer groups.
          The City of Hamburg spent 95,486,000 DM ($38,194,000)  on waste
collection and transport in 1976.   This converts to  17.49 DM per cubic
meter ($5.35/yd3).

-------
                                          10
TABLE  7-2.  MONTHLY  CUSTOMER  CHARGE FOR  RENTING A SERVICED  REFUSE
                CONTAINER  IN HAMBURG


             1.   110  littr-containtr (can or bag)
                 and  transportway without stairs or with on* stair
                 unoV 15 •          33,- Dtutscht Mark (dut classification 011)
                 fro§ 15 • to 30 •   48... Dtutscht Hark (dut classification 012)
                 over 30 •           90,— Dtutscht Nark (dut classification 013)

                 and  transportways with  two or vori stairs
                 under 15 •          48,-- Dtutscht Nark (dut classification OH)
                 froa 15 • to 30 •   63,- Dautsche Hark (dut classification 015)
                 ovtr 30 •          108,— Deutsche Hark (due classification 016)
             2.  transport by the user for
                 a  35 liter-bin     18,— Deutsche Mark (due classification 001)
                 a  55 liter-garbage-bag
                                    18,- Otutscht Hark (due classification 002)
                 a 110 liter-garbage-bag
                                    30,— Deutsche Nark (dut classification 003)
             3.  220 liter-container
                 and transportways without stairs  or with one stair
                 under 15  ">          60,— Deutscht Nark (due classification 021)
                 from 15 B to 30 n   8?,— Deutsche Nark (due classification 022)
                 over 30 «         129,- Deutsche Nark (due classification 023)

                 and transportways with tvo or tore stairs
                 under 15  «          8?,- Deutsche Nark (due classification 024)
                 fron 15 • to 30 n  102,- Deutscht Nark (due classification 025)
                 over 30 •         144,— Deutsche Nark (due classification 026)
             4.   770 liter-container
                 by a length of the transportuay froi  not tort as
                 25 n              198,- Deutscht Nark (due classification 031)

                 •ore as 25 •       297,- Deutsche Nark (due classification 032)
             5.  1100 liter-container
                 by a length of the transportway froi  not tort as
                 25 •              267,- Deutsche  Mark (dut classification 051)
                 •ore as 25 *       405,- Deutsche  Nark (dut classification 052)
             6.   900 liter-container
                                   267,- Deutsche  Nark (dut classification 041)
             7.  3300 liter-container
                                   744,- Deutsche Hark  (dut classification 061)
             8.  5500 littr-containtr
                                  1200,- Otutscht Nark  (dut classification 071)

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                                   11
           During 1976,  1,417 laborers were employed in garbage removal.
 For this they needed 331 trucks for house refuse and 30 trucks for large
.refuse.   As part of the collection workers'  contract, foreign workers are
 limited  to no more than 10 percent of the work force.

 Bulky Waste

           Bulky household waste is collected four times per year in 30
 bulky waste flat trucks.  The material will  go to any of the disposal
 sites (KFSG, rotary kiln, or landfill) depending on household distance
 from the site.
           The city is divided into 60 bulky  waste districts.   The card
 notice in Figure 7-6   is one of the 60 cards used to notify homeowners
 of pickup days.   For example, in District 9,  bulky waste will be picked
 up on November 3,  1978.
           Special pickups are arranged for waste oil, organic industrial
 chemicals,  and other bulky wastes that will  go to the rotary kiln.

 Solid Waste Disposal

           Figure 7-7   is a map portraying the disposal methods used in
 the Hamburg metropolitan area.   Landfilling  is practiced at four sites
 in the south and northeast.   The Stapelfeld  RFSG under construction should
 eliminate some of the northeast area landfilling.  Compost is made northwest
 of Hamburg in Pinneberg.  See the next section on "Development of the
 System"  for further disposal information.

                         Development  of the System

 Background

          Hamburg  has been  involved  with  refuse  to hot water  and steam
 concepts  since 1896.  This  first European experience  in converting  refuse
 to electricity was with  12  batch-fired incinerators with waste heat
 recovery  boilers  at Rohrstrasse.   Later in 1930,  six  parallel Lurgi

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                                         12
        Sudtrainigung Hamburg
                                BtttcaufbrnMhren


                SPERRMOLL-TERMINKALENDER

                       fur dm SnwrmullMzM
         Liebe Mitburgerin.
         later Mitborger,
         *b Januar 1976 kommt die Sperrmullabfuhr viermal jahrlteh, um Sic von ahem
         Hatnrat und anderen apairigan Cejanitanden zu betreien.

         Fur  lhr*n oten genanmen Sperrmullbezirfc sind folgende Tcrmine fntgetogt
         worden:
                  1976
                 & Fcbruar
                 7. Mai
                10. August
                 5. November
  1977
7. Februar
ft Mai
9. August
4. November
  1978
 &Februar
10. Mai
 8. August
 3. November
         Spurmull  at  Abftll tut privtten Htuthfltungen. dtr tich  ohne  achnitchen
         Aufwtnd durch Ztriegen, Ztmtiltn. Zartnchen Oder in ihnlicher Wtite nicht •>
         itrkleintm UBt.  d*B tr  in  dm Abftllbfhilum  gtttmmdt  wtrden ktnn.
         GtrttntbHlle and kein Sperrmull.
         SpunmuU dtrf nicht mit tndtnn Abfillen utrmocht wtrthn.
         Sfmrmull d*rf tm tm Abend vor dtm Abfuhrtmg zwachfn 20 und 22 Uhr odtr
         am Abfuhrttg zwixhtn 5 und 7 Uhr tm Fthrbmhnnnd bentitgttttllt urtrdfn.
         Bitt* hMfen Sia. Hamburg •Miberzuhatan. Mem Sie die i
         baachten und  Ihnm Sawrmiill auaacMMMidi  an  dan ganamHen Twminen
         Telefonische  Aujkuntte arteilt  die  Sudtreinigung  unter der  Rufnummer
         25795553.
         Fordern  Sic bei Wohnungiwechsel bitte einen neuen Sperrmullkalender unter
         Angabe Ihrer neuen Atwchrift an.
                                          Mit freundlichen GruSen
                                         IHRE STADTREINIGUNG
                                         Hamburg 26, BuHerdeich 19
FIGURE  7-6.   CARD ANNOUNCING  BULKY  WASTE  COLLECTION  DAYS
                   (Courtesy  of  City  of Hamburg)

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w

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                                   14
furnaces with waste heat recovery boilers began consuming refuse in. the
Borgigstrasse area.
          The third major procurement was in 1952 when two  9-ton/hour
Von Roll furnaces were added.  In 1962, three more 8.33 tonne/hour Von
Roll furnaces were added.  These furnaces were designed for 1700 Real/kg
(3000 Btu/pound) but now burn higher quality refuse at 1900 Kcal/gal
 (3420 Btu/pound).  (All heat values in "lower heating value")

Beginning of Subject System

          The Stellinger-Moor plant was  conceptualized around 1930 when
long range plans were formulated.   Basically,  community leaders agreed
that such a system should be built when the population increased enough
in the northwest suburbs.
          Fortunately in 1965, when the question was raised again, the
city had long since purchased much land for a sanitary park.   Serious
discussions began with many firms  in  1968.   Many vendors were asked to
express interest.  These five firms responded:

          •  Martin
          •  Von Roll
          •  Claudius Peters
          •  VKW*
                 *
          •  Durr
          The very competent city engineering staff prepared the "Call
for Tender".  The above  five companies submitted proposals.
          Dr. Reimers of the Hamburg consulting firm, Goepfert & Reimers,
then applied evaluation points and graded the five proposals.  Martin
apparently obtained the highest score and was chosen.
          Since  the subject plant was built, two other developments have
                                                              i
occurred.  In 1971, a private firm built Abfall Verbrennungs Geselschaft.
* Both VKW and Durr are now part of Deutsch Babcock operations.

-------
                                   15
This plant consumes  industrial  refuse  (pallets, cardboard, oil, sludges,
etc.)  in  two Wiedemann  rotary kilns.  An explosion  in 1977 shut the
facility  down for  2  months.  As a  result, again oil was mixed with house-
hold refuse in  the S-M  bunker.
          The final  development is the Staplefeld plant being built by
a consortium of  local people and Widmer & Ernst with the  Steinmueller grate.
          City  engineers emphasized  that "We have tried Lurgi, Von Roll,
Martin, and Widmer & Ernst  (Steinmueller).  We are  not married to anyone.
We'll  try them  all".

Building  Subject System

          The construction begun in 1970, was completed in 1972, 35 months
later.   There were no major problems.  A few minor problems delayed con-
struction a half year.

                          PLANT ARCHITECTURE

                             Plant Setting

          The Stellinger-Moor plant is one facility of the sanitary park
shown in  Figure 7- 8  •  The park is at the intersection of the autobahn
and a major city street.  Open fields and light industry surround the
sanitary  park.   A soccer field is  in the middle of the park separating
the wastewater treatment plant from the RFSG.
Environmental Setting
(Non-Pollutant Aspects)
          Considering the industrial setting, the plant has little objection-
able noise.   As with virtually all refuse fired steam generators, the negative
pressure minimizes odor.   Vegetative landscaping is modest but done in good
taste.

-------
              Zum S-Bahnhoi
              Stellingen
                                           Autobahnabfahrt Volkspark
                                       Wagenabstelma
          Wiegenaus

             -»-
Mullverbrennungsanlage
                                   Werkstattengebauae\
                                                  Streuguthalle
                                                      V
                                     	Sozialgebaude \
                              I  I  ^"Verwaltungs-Gebaude  )tf
         Scnnackenburgallee
1.  Operating Refuse Fired  Steam  Generator
2.  Planned Expansion of Refuse Fired  Steam Generator
3.  Collection Truck Repair Hall
A.  Collection Truck Storage Hall
5.  Administration Building For Solid  Waste Collection And Disppsal
6.  Social Hall Cafeteria and Locker Room
7.  Sewage Treatment Clarification  Plant  (Primary Treatment)
8.  Central Truck Cleaning  Facility
9.  Clarification plant (Secondary  Treatment) >
   FIGURE 7-8.     MAP OF  STELLINGER-MOOR SANITARY PARK
                  (Courtesy City  of  Hamburg)

-------
                                   17
Plant Hygiene

          A four wheel drive brush street sweeper is operated part-time to
keep the plant roads clear of debris.  The plant people had never noticed
a problem with insects or rodents.

Outside Design

          Figures 7- 9 and 7-10 show day-side and night-rear views of the
plant.  Reinforced concrete is used around the bunker and steel girders are
used around the furnace-boiler boom.
          Physically separate from the RFSG are the administration building,
social hall, truck repair shop and truck storage building.
          Ash conveyors are enclosed and the chimney is modestly low.


                         TOTAL OPERATING SYSTEM

          Table 7-3 presents gross operating figures for December, 1976,
and the complete years 1976 and 1975.  Tables 7-4 and 7-5 follow and
respectively present detailed operating readings taken every 2 hours
on November 4, 1976, and April 2, 1977.  The operation recording and
the chart dated November 4, 1976, concern Boiler No. 1 after cleaning
and at the beginning of a new period of continuous operation.  The
operation recording and the chart of April 2, 1977, concern boiler
No. 1 also, but after 3,567 hours of continuous operation.
                 REFUSE FIRED STEAM GENERATOR EQUIPMENT

                              Waste Input

          In 1976, the S-M plant received the following  tonnages  from  three
 general  sources:

-------
                              18
      FIGURE 7-9.  STELLINGER-MOOR PLANT (Courtesy of City of Hamburg)
FIGURE "-10.   NIGHT VIEW OF STELLINGER-MOOR PLANT
              (Courtesv of  Citv  of  Hamburg)

-------
                                     19
TART F  7
GROSS OPERATING FIGURES  FOR DECEMBER 1976 AND
THE COMPLETE YEARS  19.76  AND 1975 FOR HAMBURG:
STELLINGER-MOOR
December 1976
Truck Deliveries
Household trucks (number)
Industrial trucks (number)
Total trucks (number)
Waste Input
Household waste (tonnes)

Total waste (tonnes)
Boiler 1
Waste input (tonnes)
Steam generated (tonnes)
Steam / waste (tonnes / tonnes)
Operating time (hours)
Boiler 2
Waste input (tonnes)
Steam generated (tonnes)
Steam / waste (tonnes / tonnes)
Operating time (hours)
Boilers 1 and 2

Steam generated (tonnes)
Operating time (hours)
Fuel Oil 12
Delivery (liters)
Consumption (liters)
Turbine 1
Steam consumed (tonnes)
Operating time (hours)
Turbine 2
Steam consumed (tonnes)
Operating time (hours)
Turbines 1 and 2
Steam consumed (tonnes)
Operating time (hours)
Power Supply
Generator 1 (kwh)
Generator 2 (kwh) 6,
Generator total (kwh) 6,
Purchased power (kwh)
Total power available (kwh) 6,
Power Use
Sewage treat plant (kwh)
Internal plant consumption 1,
(kwh)
High Demand Peak Load (kwh) 1,
Low Demand Base Load-weak-
peak (kwh) 3,
Total power used (kwh) 6,
Water Supplv
Purchase from Hamb. W W. (»3)
Well fed cooling water (in3}
Water Uses
Consumption of H.U.U. (m3) •
Change in stock of H.W W. (m )
Sanitary uses of H W U. (m3)
H.W.W. to treatment station
(m3)
Well water to treatment
station (m3)
Well water process water (m )
Boiler feedwater addition (m3)
Residuals
Ash for roadbuildlng (tonne)
Big scrap iron (tonne)
Small scrap iron
Stumps and tires landfilled
Total recycle residuals (tonne)
3,233
198
3,431

14,469
881
3,487
18,837

9,535
22,391
2.35
744

8,640
19,888
2.30
665

18,175
42^279
2 . 33
1409

10,016
16,940

	
—

41,448
744

41,448
744

	
900,500
900,500
—
900,500

417,582
295,168

306,800

875,850
395,400

1.103
14,938

93
710
500
7.884
7,054
976

2.316
663
369
3,348

Year 1976
38,754
3,542
42,296

161,617
14,899
18,748
195,264

98,762
217,706
2.20
7119

101,794
210,286
2.07
7311

200,556
427,992
2. 13
14430

98,934
104,398

110,170
2,187

310,505
6,669

420,675
8,856

19,478,100
49,761,000
69,239,100
196.350
69,435,450

4,308.709
12,228,467

13,224,750

39,616,500
69,378.426

15,276
179.855

1,810
254
7,582
5,884
78,777
101.332
12,179

73,251
11,737
3.837
83.825
f T3/R56 Betriebsei
Year 1975
49,686
4,488
54,174

216,848
19,125
2,801
238,774

118,412
231,028
1.95
7264

115,828
226,992
1.86
7505

234,240
458,020
1.96
14769

83,004
83,183

306,258
6,059

137,090
2,872

443,348
8,931

55,043,300
23,012,000
78,055,300
209,550
78,264,850

3,963,977
12,492,885

15,467,100

46,333,650
78,257,612

12.394
177.859

645
247
7 ,429
4,320
21.03)
157,075
22.379

80.756
14,129
6,268
101,153
rgenbnlsse de. MUA II

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                                20
TABLE 7-4   DETAILED OPERATING STATISTICS FOR APRIL 2, 1977
            BOILER NUMBER 1 AT HAMBURG:  STELLINGER-MOOR


Stea» production
D. Tcvp. V. KufaUr
Injection aprajlag
Tool air
Percent to primary air
Luft tap. a. Urr»
Ovygea content
Furuce roof temperature-left
Furnace roof temperature-right
Superheater temperature
Convention aactin temperature
Schlove
ECl
Dnderflre air preeaure tight Zone 1
Uaderfire air preaaure Right Zone 2
Dnderflre air preaaure night Zone 3
Underfire air presaure Right Zone 4
Underfire air preaaure Right Zone 5
Underpin air preaaure Right Zone 6
Onderfire air preaaure Left Zooe 6
Underfire air preaaure Left Zone 5
Underflre air preeeurt Left ZAM 3
Underfire air preaaure Left Zone 2

Secondary air preaaure-front wall

Furnace «ci»o«pherlc presaure
Superheater atnoapheric prcsaure
Schlavo *conoairer
ECU eirctroatatic preclpltator
ID auctlrn fan (rpm)
Furnace control aet
Indl. control dcek
Top Fecd.-r ram
Louer Feeder raai ,
Stroke of upper atoke'r (feeder)
Stroke of lower atoker (feeder)
Indie, control deak
Setting of final taller
Setting of vibrating alag comre»or
Shift fl Shift II Shlf f «J
07 09 11 13 IS 17 1« U 23 01 03 0}
T/h 27 25 27 26 27 21 27 2* 25 25 2* 25
•C "0 435 430 430 430 430 430 425 125 430 435 435
X 35 50 35^ 40 50 45 40 35 42 36 40 *5
M3103 38 35 35 35 35 33 36 31 3» 37 37 M
X 25 25 25 25 25 25 25 25 25 25 25 25
•C 85 85 85 90 80 80 90 90 90 90 90 90
I 10 105 105 10 10 10 10 10 »5 10 10 10
•C 770 740 740 7*0 7*0 770 7W1 720 7V) 7V> TV\ jy>
•C 710 7eO 740 740 750 760 750 700 7ID 720 720 720
•C 600 580 580 5*0 590 590 590 570 590 600 595 600
•C 520 520 510 510 525 525 530 520 530 540 525 525
•C 345 345 325 330 340 340 340 335 345 350 345 345
•C 335 335 320 325 325 320 320 320 325 335 330 335
••U* 50 50 55 50 60 60 65 50 50 60 60 » 55
•aWa 60 60 60 60 60 60 60 60 60 65 65 ' 70
BWa 35 30 30 30 30 30 30 30 30 35 35 35
mUa -10 -10 -10 -10 -10 -15 -15 -10 -10 -10 -10 -10
a*Ve -20 -20 -15 -15 -15 -20 -20 -15 -15 -15 -W -?>
anWe -20 -20 -20 -15 -20 -20 -20 -2O -20 -15 -20 -20
anWa -10 -15 -10 -10 -10 -15 -10 -10 -15 -10 -15 -15
nWi 40 30 40 35 40 35 35 30 40 40 40 40
anWa 60 60 60 60 63 60 60 55 60 60 65 60
•nUa 60 65 60 50 50 JO *5 40 40 40 40 40
_Ua 400 400 400 400 400 400 400 400 400 400 400 400
mUa 500 500 500 500 500 500 500 500 500 500 500 500

nUa 10 10 10 10 10 10 10 10 10 10 10 10
ire »Va 20 IS 15 IS 70 JO ID 20 2O 20 W 2"
enUa 40 40 45 40 45 »S 45 45 50 45 45 »0
•>Va 65 6O 60 M) 70 61} M M> 70 65 65 60
u/«ln MX) 570 540 580 5M 5*0  SiO 570 5»O 600 580
I T: 72 73 73 73 M '? "3 7J 73 72 72
1 »n (to <0 «O W »o M W lio SO 8O ,JO
0-10 77777:T77777
0-10 68686SM77777777
me 220 220 220 220 210 210 210 210 210 210 210 210
n 600 600 600 600 600 600 600 600 600 600 600 600
X 60 60 60 60 60 *0 60 60 65 65 65 65
0-10 5 5' 5555555555
0-12 777777777777

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TABLE  7
               21

DETAILED OPERATING STATISTICS FOR NOVEMBER 4,  1976
BOILER NUMBER 1 AT HAMBURG:   STELLINGER-MOOR
Shift 11

Steam production
Steam temp, upstream injection spraying
Injection Spraying
Total air
Percent of primary air
Comb, air temp.
Oxygen content
Furnace roof temperature-left
Furnace roof temperature-right
Superheater temperature
Convection section temperature
Economiser exit
EGR precip. exit
Underflre air pressure Right Zone 1
Underfire air pressure Right Zone 2
Underfire air pressure Right Zone 3
Underflre air pressure Right Zone 4
Underfire air pressure Right Zone 5
Underfire air pressure Right Zone 6
Underfire air pressure Left Zone 6
Underfire air pressure Left Zone 5
Underfire air pressure Left Zone It
Underfire air pressure Left Zone 3
Underfire air pressure Left Zone 2
Underfire air pressure Left Zone 1
Secondary air pressure-front wall
Secondary air pressure-back wall
Furnace atmospheric pressure
Superheater atmospheric pressure
Convection section atmospheric pressure
Schlavo economizer
EGR electrostatic precipitator
ID suction fan (rpm)
Furnace control set
Indi. control desk
Top feeder ram
Lcwer feeder ram
Stroke of upper stoker (feeder)
Stroke of lower stoker (feeder)
Stoker speed
Indie, control desk
Setting of final roller
Setting of vibrating slag conveyor

T/h
•c
M3103
I
•c
I
•c
•c
•c
•c
•c
•c
nnWs
mnWs
mmWs
ranWs
mmWs
mmWs
tmWs
ranWs
mmWs
mmWs
mmWs
tmnUs
mmUs
mmUs
mmUs
mmWs
mmWs
mmWs
mmWs
u/mln
2
2
0-10
0-10
mm
mm
0-12
I
0-12
0-10
07
30
42'.
50
40
42
40
25
630
650
510
405
280
265
70
50
65
11
-10
-15
-15
-10
11
30
50
90
400
500
6
2
10
30
35
400
62
75
77
77
200
600
8
50
4
6
09
32
420
30
43
42
85
25
642
670
510
405
270
260
70
50
60
0
-10
-20
-11
-10
- 5
30
60
100
400
500
6
5
10
25
35
390
63
75
77
77
200
600
8
50
4
6
11
•u
425
40
43
42
80
25
630
650
480
370
260
250
40
50
30
0
-10
-20
-20
-10
- 5
30
60
100
400
500
6
5
10
25
35
350
62
75
77
77
200
600
8
50
4
6
13 15
32 30
430 425
50 50
42 40
45 45
95 110
25 8
630 620
650 630
400 475
370 365
265 260
250 245
80 75
60 50
20 30
- 5 0
-10 -10
-20 -20
-12 -15
-10 -10
0 10
45 30
70 60
100 100
400 400
500 500
6 6
10 5
20 15
30 25
35 35
410 340
62 60
80 80
77 77
77 77
200 200
600 600
92 92
60 60
4 4
6 6
Shift *2
17
30
425
40
40
45
1JO
16
610
620
470
370
245
240
80
50
30
0
-10
-20
-20
-10
0
JO
70
100
350
470
6
5
15
30
35
350
60
80
77
77
200
600
92
60
4
6
19
30
430
45
40
45
110
8
610
630
480
380
240
240
60
70
40
15
-10
-15
-15
-10
15
40
65
90
420
520
6
10
15
30
35
350
60
80
77
77
200
600
92
60
4
6
21
30
425
45
50
45
50
10
550
610
480
380
250
240
70
60
40
10
-10
-15
-15
-10
10
30
50
90
420
520
6
8
15
30
35
360
60
80
77
77
200
600
92
60
4
6
23
31
430
45
50
45
50
10
600
610
480
380
250
240
70
55
40
10
-10
-10
-15
-10
10
30
55
90
420
520
6
. 5
15
30
35
350
60
80
77
77
200
600
92
60
4
6
Shift 13
01
33
420
25
45
45
40
10
600
620
475
370
260
250
70
60
30
20
0
-15
-10
0
15
30
60
100
420
520
6
10
15
40
40
440
60
80
77
77
200
600
92
60
4
6
03
33
426
45
40
40
40
9
620
650
475
370
250
240
100
50
30
20
- 5
-15
-15
- 5
15
40
55
100
420
520
6
10
10
30
30
380
60
80
77
77
200
60^
92
60
4
6
OS
30
420
30
42
45
40
10
600
620
470
370
260
250
80
50
25
15
-10
-15
-15
- 5
15
35
50
90
420
5:0
6
3
10
30
30

60
80
77
77
2CO
600
92
60
4
6

-------
                                   22
                  Households             161,617 tonnes
                  Industry                14,899 tonnes
                  Miscellaneous           18,748 tonnes
                               TOTAL     195,264 tonnes

          This results in 640 tonnes (706 tons) per day plant consumption,
assuming burning occurs 305 days per year (1976).
          Household, commercial and light industrial wastes are consumed
in the raw state, i.e., directly from the garbage truck.   Bulky wastes,
while not encouraged, are accepted directly into the pit.   Over the years,
the waste has been getting drier and now contains about 25% moisture.  The
industrial waste portion can be very dry at 10% moisture.
          The plant was designed in 1968 for a waste with a heating value
of 1500 Kcal/kg  (2700 Btu/pound) for household waste and 2700 Kcal/kg
(4860 Btu/pound) for industrial waste.   Now, in 1977, the composite heating
value has risen to  2000 Kcal/kg ('3600 Btu/pound).
          The heating  value  is  stable during  the  seasons  except  for  rises
due  to  surges of industrial  waste.   Plant  operations commented that,  "no
matter  how big  the  pit is,  there  is  never  enough  room for proper mixing."
Loads of  tobacco fines have  caused  heat surges in the furnaces.


                           Weighing Operation

          The scale house is located near the plant entrance and the adminis-
tration building.  The plant originally purchased an inexpensive undercapacity
scale that caused much trouble.   A mechanical level is used and the ensuing
electrical resistance is measured.  Many improvements have been made to this
semi-automatic Essmann Scale manufactured in Hamburg.
          Today, the weight indication  almost never fails.  However,  the
electric printer is available only 60%  of the time.
          Several notable attitudes have developed in response to the
problems.   The local plant operations have about given up the truck scale

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                                   23
and, Instead, depend on the more reliable crane scale.  The city officials,
of course, need the information for billing and statistical purposes.  The
scale is necessary to weigh loads removed by the ash contractor.

                    Provisions to Handle Bulky Refuse

          The bulky refuse that is in the pit is handled identical to the
regular refuse.  There is no shear or shredder.  The large Martin hoppers
accommodate most bulky material.  As shown in Figure 7-12  , large
round objects  may  roll down the rather steep incline of the grate and
fall directly into the ash discharger without having been fully burned.
newer Martin grates use a final roller grate vlth a separately controlled
speed to catch some of the larger materials and increase their furnace
residence time.

                        Waste Storage and Retrieval
           The metal  doors  open with  a  flapper  effect  as  shown below in Figure
.7-11.  The doors appear in Figure  7-13.
               LI
                                   FIGURE  7-11.
FLAP-TYPE OF HINGED
BUNKER DOOR
Such a design is not  common in Europe.   It helps  the  crane operator
to see what is coming into the pit as.  it  is falling  in.   He needs  this
information to better determine how the waste should be mixed.  Often, but
not in Hamburg, this problem  is overcome by having the crane control room
located on the sides of the refuse pits.  Doors open to the  pit  that
holds 3500 tonnes (3900 tons) when level.  The pit is 54 m  (59 yds)

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                                      24
FIGURE 7-12.  UNBURNED BULKY REFUSE AFTER PASSING THROUGH FURNACE (Battelle Photo)

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                                      25
FIGURE 7-13.   TIPPING FLOOR NEAR BUNKER DOORS AT STELLINGER-MOOR  (Battelle Photo,

-------
                                  26
long, 16 m (17.5yds)  deep.   When refuse is stacked above the tipping floor
level,3500 tonnes (3850 tons) can be stored.   Therefore, 3 to 4 days' waste
can be stored.
          The cab is centered between and slightly above the two hoppers
as shown below.   The  location of hoppers  for two future  units is shown.

                                                              FUTURE!
Bunker




H



/ \
Crane
Control
Room


H










          The traveling crane was manufactured byLavis.  Its rating is 116 tonnes.
          Formerly, cables had to be replaced every 3 weeks.  Often, the
bucket would settle at a 30° to 45° angle instead of flat.  This causes the
cable to catch in between the claw and bucket.  Strand breaking can occur.
In other cases, the operator would let more cable  unwind,  causing  the
cable to kink, come out of the trolley, or snag in some way thus leading
to a breakage.
          One of the plant employees (perhaps motivated by the pay incentive
program of "more steam means more pay") came up with the idea of built-in
guide shields.  This has improved the situation and 3 months (instead of
3 weeks) is the average cable life.
          The polyp has lasted longer than expected and was replaced after
4 years.  Now, the plant has a new Landers polyp in storage that is only
one-half the weight of the existing polyp.  This will be used eventually
to replace the second polyp.
          As mentioned before, the plant people rely more on the crane
scales than the truck scales.  Four load cells are mounted on the crane.
Readings are automatically recorded in the main and the crane control
rooms when the polyp is hovering over the hopper.  They have no problems

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                                   27
 with the load cells themselves.   However,  there are occasional automatic
 recording functions that fail  and recordings must  be made manually.
           An unusual item in the pit area  is the special closet for  humans
 that can be quickly attached to  the crane  and lowered into the pit.   On
 separate occasions, a truck driver and a pit floor controller were pushed
 into the pit by backing-up trucks.   The men were rescued from the pit with
 this closet.
           In a discussion of polyp versus clam shell advantages,  the Martin
representative noted a preference for  the more expensive polyp in large
plants.  The clam shell compressing density is only  297  kg/m   (500
pounds/yd^)  compared to  475  kg/m-*  (800 pounds/yd ) obtained with the polyp.

                       Furnace  Hoppers and  Feeders

           The hopper opening has dimensions of 5.9 m  (19.4 feet) by 6.3 m
 (20.6 feet).  The hopper tapers off to the chute having dimensions of 1.5 m
 (4.9   ft) by 4.8 m  ( 15.7 ft).  Normally,  the hopper is kept empty while
the feed chute is full as can be seen  in Figure  7-1.  The chute has a water-
cooled jacket to reduce burnback.
           As the average refuse heating value has risen, there have been
more burnback instances as ignition occurs closer to the chute.  To reduce
the ignitability of  the refuse, they experimented by spraying water directly
onto the refuse in  the hopper.  Burnback was substantially reduced to once
every week or two.
           Now most of the burnback comes from large spaces in the chute due
to a bulky desk or cabinet.  Also, an  iron bar may jam the feeder, causing
normal refuse to burn but preventing new refuse from entering the combustion
chamber.  When asked if a shredder might alleviate the problem of chute-
feeder jamming, the response was that  "2 million DM ($800,000) was too high
a price to pay for solving such a minor problem".  Repairs to a shredder
or a shear might be even more expensive than repairs for occasional shut-
downs of the feeder.
          Each of the two runs per furnace  has two feeder mechanisms:  an
upper and a lower ram or pusher.   The furnace feeder total width is 4.8 m

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                                   28
(15.7  feet), i.e.,  2 x 2.40 m.   The depth is 3.5m (11.5 ft.).  The cross
section of the fuel  entry into the furnace is 11.5  m^ (124.0 ft^)  having
dimensions of 4.8 x  2.4 m (15.7  x 7.9 feet).
           Each pusher is provided at its front end with high-grade heat-
resisting chromium steel alloy bars 12 mm thick and at its rear end with
a 10 mm thick steel  plate, which is reinforced to withstand the impact of
refuse falling from  the hopper.   Each pusher is supported at its front end
by sliding noses, and at its rear end by roller bearings on each side and
guided by a vertical roller bearing.  Each pusher is operated by a hydraulic
cylinder.
           The control of the feeding device is over a range of more than
1 to 10.  The furnace feed rate can thus be set at between 10 and 2.5 tonnes
(11 and 28 tons) per hour.
          There have been some hydraulic feed system problems with sticking
valves at the pumping station.  Nevertheless, the plant operators emphasized
their preference for "hydraulic only" systems over mechanical drive systems.
As one operator stated, "we may have minor problems with the hydraulics,
but a mechanical system would actually break if jammed'1.
          Martin now always  recommends  a  system  where  the
refuse level within  the chute at  the minimum allowable  level could be
measured by a radioactive device and indicated in the crane operating cab
and in the main control room.

                           The Martin Black Box

           Over the  years, Martin engineers have developed what some people
 call the "Martin Black Box".  Actually the box is an electronic system that
 responds to furnace temperature  (or steam if desired).
           Thermocouples are placed at the furnace radiation pass.
 A maximum allowable temperature is chosen, and a slightly lower
 temperature is the  signal for system change.

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                                   29
          This temperature of 760 C (1400 F) is the "lower switch point".  The
"higher switch point" is chosen depending on the steadyness of the steam
required out of the system.  In Hamburg, where steam goes to steam
turbines, sudden surges are to be avoided.   As a result, the higher switch
point is set at 780 C (1436 F) . (see Figure 7-14 ).
          When the furnace temperature at the thermocouple location is below
the lower switch of 760 C the switch controlling feeders and stokers should
be on.
          When the temperature passes through 760 C, the switch is turned
off.  The waste continues to burn and the temperature continues to rise,
often above the 780 C limit.
          When the temperature does come back down and passes through 780 C,
the system is turned back on.
          The temperature may fall below 760 C as it is increasing its
burning rate.  Eventually the fire recovers and the temperature might
pass just over 760 C.  At this point, the system is turned off and the
cycle begins again.
          The primary and secondary air remain constant at the preset level.
While air does indeed feed the combustion with 0», it more importantly cools
the furnace gas by dilution.  Another reason for not reducing the air is that
CO will  form instead of burning completely to CO^.
           If the plant management has any valid complaint,  it  is  that  the
"main problem with the black box makes  the control  room staff  sleepy".
Battelle researchers have heard this comment elsewhere.  The concern is
that  there may be  developing problems that go undetected until  too  late
when  the system breaks down.
          An example might  be the experience Battelle  observed  in Paris:
Issy, breakdown of  the clinker roller,  due to leaking boiler tube.  The
leaking  tube was registered fully in time in the  control room.  However,
the dripping onto  the clinker roll was  not  observed until  too  late  after it
failed with siftings.

-------
                    red

                             30
                   limit value  monitoring lamp*
                          IK controller
                                                               orange
                        mm
                          I
                                                           ma*.
            760 C (1400 F)
               I

              I Set point


              */ lower s«i
              4 point
                                                          780 C (1436 F)
                                      lamit valut amtads
                               era  Jowe (odju*taW« betweevi
                          ,    o.S a*od &,5 7o  above Set poiwt )
                   t
                                                Furnace  t«mp«ratur*»
                                                 (Courtesy Josef Martin Gmbh)
FIGURE 7-14.
Regulating  G>aractenstic5  of  Coniroller

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                                   31
          Note:  The Martin position  of holding primary and  secondary
                 air constant   is  important  to their  system.  Battelle
                 researchers have  visited other systems where the
                 operator's philosophy was to "smother the hot  fire.
                 Boiler  tube corrosion may result.
                 As a memory jogger,  we have taken gross  liberties
                 with an American  advertising jingle:

                      Feed the  Air
                      Starve the Feed
                      F  A S F
                 where   "F" is  always feed
                         "A" is  air
                         "S" is  starve
                               Primary Air

          The Stellinger-Moor primary air system was highly influenced by
adverse experiences at the older Borsigstrasse plant.  At Borsigstrasse,
the primary air was taken from the upper-middle section of the bunker near
the hoppers.  The draft (suction) lifts the dust particles upwards from the
pit.  The polyp discharge at the hopper also creates much dust.
          The result at Borsigstrasse was badly worn fan blades after only
6 months operation.  To protect the blades, filters were later installed
to collect the dust.  Unfortunately, these filters became clogged after
brief service.
          The effect of these experiences on the S-M design is dramatic in that
primary air is taken from the furnace-boiler room.  For low calorific value
waste, this has the advantage of providing preheated air.  But for an existing
unit where the calorific value has risen over the years, there can be a slight
disadvantage to using the furnace-boiler room preheated air.  The resultant
very hot combustion can  help the    temperatures to rise toward  the hish
temperature corrosion region.  At present the air is still taken from the
boiler room.
          The centrifugal blower with a rated capacity of 87,000 Nm3/hour
develops a static pressure of 530 mm WS (21 in water) at JO  C (86  F).

-------
                                  32
          The S-M primary air system taking clean and warm air from the
boiler room has been 100 percent reliable.
          Each of the two lines in each of the two  grates has  six zones
under the grate  for distribution of primary air.  The dampers for sittings
removal at the bottom of the zones have sometimes clogged.  The plant people are
installing larger damper wear plates and a large pipeline for  dust removal.
          The Stellinger-Moor grate runs appear to be exceptionally wide
(Martin's maximum offering) at 2.38 (7.8 feet) compared to the normal 2.13
m (7.0 feet).  In Chicago, Illinois, the 5.49 m (18 feet) furnace has
three runs for an average of 1.83 m ( 6 feet) width.
          The orifice openings into the hoppers are blanketed or uncovered
by sliding air dampers operated by a common servomotor.
          The S-M bunker now has six natural draft roof ventilators.   The
longest time any material is in the pit is 2 weeks.   With the ventilation,
there is no in-plant odor.  The researchers neither noticed or heard com-
plaints about exterior odor.
          In many future designs, the Martin engineers are recommending
primary air vents at the bunker top—above the crane and away from the
dusty hopper but not in the boiler room.
                             Secondary Air

          Often, the secondary air is taken from the basic  primary
air system.  Most future designs will specify separate systems for primary
and secondary air.   The secondary air rating is 17,500 Nm3/hour  (10,290  scfm)
The  static secondary air pressure  is higher  than  that  for  the  primary  air  at
640  mm Ws  (25.2 in  water)  at the  same 30  C  (86  F).
          There are 16 nozzles in one row above the front wall arch and
another 16 nozzles in the rear wall.  A damper is used to control the air
volume.   However, in Martin's Japan designs, there are often three rows for
secondary air or a completely different tertiary air system due to the
high refuse moisture content.

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                                   33
          They occasionally have to reweld some of the nozzles due to high
temperature scaling of these chrome steel nozzles.  Perhaps some of this
scaling could have been prevented if studs had been welded to the water
tube walls and then covered with plastic refractory-s  This would then leave
the nozzles slightly recessed and not subject to as high a temperature.
          Battelle researchers feel that one of the reasons for Martin's
ability to control corrosion is the more complete combustion due to very
high secondary air turbulence.
          Of the many furnace photographs taken, among the most interesting
were those of Hamburg and Zurich.  Figure 7-15  is a photograph of an
anonymous furnace that illustrates the rather calm combustion environment
observed in so many European and American incinerators.  Observers can
easily see the shape of the flickering flame and details in the opposite
wall.
          We strongly suspect that in these other low  intensity furnaces
that substantial quantities of carbon monoxide (CO) may at times be released
that could contribute toward boiler tube corrosion.
          Figure 7- 16 ,  however, is entirely different.  The three Martin
plants visited (Parisrlssy, Hamburg: Stellinger-Moor  and Zurich: Hagenholz)
all had furnaces of red glowing particles rapidly bouncing through the gases
and an atmosphere where the observer could not see the opposite wall.
          To repeat,  the key figures are shown below:
                                                             Act.     Act.
                                                   Static    Nov. 4   Apr. 12
                              Maximum Air Volume  Pressure    1977     1977
                                  (Nm3/Hour)       (mm WS)   (mm Ws)  (mm Ws)
Primary Air Under Grate              87,000          530
Secondary Air Front Wall             17,500          640        400     400
Secondary Air Rear Wall              17,500          640        520     500

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                               34
FIGURE 7-15.  A RELATIVELY QUIESCENT FURNACE WITH NO SECONDARY AIR
              (Battelle Photograph)

-------
                            35
FIOURE 7-18.
TURBULENT FLAME MIXED BY SECONDARY AIR JETS
(Battelle Photograph)

-------
                                   36
          Usually the pressure is higher in the front wall nozzles if the
heating value  is high.  The higher jet momentum tends to force the intense
flame  further  down along  the grate to spread out the burning over a greater
area.

                             Air Preheater

           Stellinger Moor has an  installed  air preheater.  However,  it  is
seldom used  anymore because  the refuse  is not very  wet  and consequently
the heating  value  is very high.
           Each unit is  furnished with one steam air preheater.   The  air
preheater is installed  between the forced draft  fan and the  incinerator
and designed to preheat the  combustion  air  delivered by the FD fan from
23°C tc 120 °c  by means  of saturated  steam from the  respective boiler  drum.
The condensate is  cooled  in  the air  preheater and discharged  to  the  con-
densate  tank.
           The  air  preheater  is fabricated of galvanized plain carbon steel  tubes,
mounted  in a frame  together  with a bypass air damper.   The exit  air
temperature  is controlled by the  bypass air dampers.

                             Burning Grate

          The Martin "Reverse Reciprocating" Stoker grate is  inclined down-
ward from the feed end towards the clinker discharge end and  comprises
alternately fixed and moving steps of grate  bars.   The activated steps move
slowly counter to the downhill refuse movement.
          In this manner, the fuel bed is constantly agitated, rotated, and
again leveled out.   The glowing mass is pushed back from the  main burning
area towards the front or feeding end of the grate.   The different phases
of combustion, i.e., drying,  volatilization, ignition,  and burnout, thus
take place at the same time in close contact with one another.  Freshly fed
refuse is quickly dried out and ignited from below by the base fire always
existing at the grate front end.   (See Figure 7-17).

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                           37
                                                Secondary pif



                                                Front	.sujgension arch *

                                                Feeding  device

                                                front edge of
                                                feed  table
                                                Side wo_U _coolftr_


                                                Grgterun NoJ_


                                                Grcrte  run No. 2
v A ft T i N
 v *»,. z "
             MARTIN  REVERSE ACTING  GRATE
FIGURE 7-17.  MARTIN REVERSE ACTING GRATE  (Courtesy Josef

              Martin Gmbh)

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                                   38
          The incinerator grate is set at an angle of 26°.  As mentioned
previously, each furnace has two runs where each run is exceptionally wide
at 2.38 m (7.8 feet)—Martin's widest grate design.  The overall length is
                                                                         2
8.93 m (29.29 feet).  This results in a projected grate surface of 43.9 m
(228.5 ft2>
          Some of the  plant staff interviewed feel that perhaps three
smaller runs might have been preferable to the two very large runs.
          The Martin Stoker is subdivided lengthwise into six compartments
to which undergrate air is admitted through damper openings of different
sizes in accordance with air supply requirements over the whole grate
surface.   The opening angle of these dampers is selected by a central con-
troller and is proportioned to the desired heat release.  Each section of
grate with its air plenum and siftings hoppers are supported by a structural
steel system of ample strength to carry all of its parts and a refuse bed of
        2
500 kg/m  unit weight.  Grates and supports are sufficiently strong to with-
stand the impact of freely falling refuse from the top of the feed hopper
and chunks of slag from the furnace walls, respectively.
          The burned-out residue travels slowly down the grate under
constant agitation.  After reaching the grate end, a slowly rotating
clinker roll seizes the residue and dumps it into the quench pit.  The
grate action prevents the formation of excessive hot spots and excessive
clinker build up.  It is also this grate action which leads to only 4
percent unburned carbon.
          Side faces of the bars are machined to achieve even, uniform widths
of air gaps between adjacent bars and are arranged to prevent spreading or
bunching of individual bars.  At the sides of the grate sections, self-com-
pensating expansion blocks prevent binding of the grate bars due to heat
expansion.  This enables a constant air gap to be maintained and ensures that
the openings for combustion air are limited to approximately 2 percent of the
grate area surface.  The openings in the Martin grate bar design are set at
the front of the bar where combustion air is required, with the result that
combustion air spreads over the whole underside surface of the firebed,
regardless of any  dense objects.  To break up clinker  formation, some of
the bars have a pyramid head fixed on top.

-------
                                   39
          At the upper and lower end of each stroking movement, the adjacent
bars in all grate steps will move, by mechanical action, a distance of about
20 mm relative to each other, and this movement prevents blockage of the air
gaps.
          Each run has 17 active steps, each alternative step being of the
movable type operated by the hydraulic grate mechanism.  The grate bars are
100 mm (4 inches) wide.
          The grate bars consist of a wear and high-heat resisting 16 percent
chrome steel alloy.  Air entering the grate bars passes through the serpen-
tine channels in the underside of the bar before passing through the air slot
(less than 2 mm wide) between adjacent bars into the fuel bed.  The static
air pressure resistance to air flow thus crea.ed is higher than that of the
refuse layer on the grate.  As a result, the undergrate air is uniformly
distributed over the area of each grate zone.
          The maximum furnace throughput is 24.67 tonnes/hour (27.138 tons/
hour) or 592 tonnes/day (651 tons/day).  Since S-M has two furnaces, the
total plant capacity is 1,184 tonnes/day (1,302 tons/day).
          Martin's philosophy is to vary the feeder speed to maintain a
constant steam production rate.   Martin thus furnishes their plants with
the previously described "black box".  To repeat the steam quantity or
temperature rises above normal,  the  feeder  and  grate  are  stopped.   The  grate
stroke and the primary and secondary air remain constant.   When the tem-
perature adjusts itself lower, the grate starts again.
          This is the operating mode under normal conditions.  The plant
operators must be careful to not allow the grates to be stopped for too
long, lest the waste burn its way to the chute and burnback develops.

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          The grates are routinely inspected and maintained every 2,000
hours.  The grates are overhauled once per year.  In 5 years of operation,
they expect to replace 120 percent of the grate bars.
          The heat release rate at MCR originally designed for 1500 Kcal/kg
(2700 Btu/pound)  was 113 million Btu/hour.   Today's waste with peaks up to
2500 Kcal/kg (4500 Btu/pound)  contains 30 percent more energy and can produce
up to 168 million Btu/hour.

                   Furnace Wall (Combustion Chamber)

           The furnace wall "story " at Stellinger-Moor is the most compre-
 hensive and complex of all of the plants visited.  The plant manager, Karl
 Heinz Arndt is very experimentally oriented,  open minded and capable of
 making successful design changes.

 Stage 1 (Original Construction)

           The furnace combustion chamber is fully of water tube wall con-
 struction.   Depending on wall location, various protective refractories have
 since been added.
           The lower combustion chamber is separated from the radiation first
 pass as shown by the horizontal line in the previous  Figure 7-1 page 2, at
 a level two meters above the  front nose.  The vertical water tube walls in
 this combustion  chamber are tangent tube construction, the arches are
 welded finned tube.
           The tube outside diameter is 7 cm (2.75 inches) with a  3.2 mm
 (0.125 inches) wall thickness.  As in most plants, the wall tubes are
 made of olain carbon steel.  The front and rear arch tubes are 57 mm  (2.25
 in) diameter 0.14 in thick.
           Three  water headers slope downward, parallel and near the  grate
 as shown in Figur 7-18.  These water header collectors are only near  the
 hotter part of the grate, i.e. after drying and before burnout.  Wall thick-
 ness tests were  made on the west wall on April 22, 1977 after 27,000 hours
 of operation.  The metal wastage pattern shown in Figure 7-18 is clear.
 Maximum metal wastage occurred 500 mm  (1-1/2 feet) from the measuring base
 line and at the  hottest sidewall portion on the grate.  At the worst  point,
 the thickness was still 2/3 of the measuring base line point.

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                                         41
Measuring Baseline
            1.   Lateral Wall Collector
            2.   Upper Grate Cooler Beam - Collector
            3.   Lower Grate Cooler Beam - Collector
Distance (mm)
Wall Thickness (mm)
0
18
100
16
200
14.7
300
13.5
400
12.4
500
11.8
600
12.1
700
14.3
800
16-. 7
                 FIGURE 7-18.  METAL WASTAGE OF WATER HEADERS ABOVE
                               THE HOT SECTION OF THE GRATE AT HAMBURG:
                               STELLINGER-MOOR

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                                   42
          Installing these three tubes as sacrifice tubes appears to be an
excellent method of lowering the localized and very high gas temperatures.
These 18  mm (.719 inch) thick sacrifice tubes will be much easier to re-
place than the higher-up and harder-to-reach 3.2 mm 0.125 inch) boiler tubes.

Stage 2  (Simple Addition of Refractory)

          As time progressed and tubes began to burst up in the boiler,
plant officials began to experiment with other measures to directly pro-
tect combustion chamber tubes and to indirectly lower gas temperatures
entering the downstream boiler passes.
          Officials supplied a not-to-scale diagram dated October 29, 1976,
that shows what had just been done to the combustion chamber.  Four refractory
materials were used at locations shown in Figure 7-19.
          Plibrico, a Chicago, Illinois, headquartered firm, supplied Plistix
14 (P14) (88-90% SIC) to be used above the combustion chamber front roof
where the raw refuse enters and down along the sides of the grate where the ash
exists.   First, 6  mm (1/4 inch) studs were welded to the tubes at a density
of 467 studs per square meter (43 per square foot).  Then, Plistix 14, a 90%
Silicon Carbide material, was mixed with water and sprayed on the studded
water tube walls.
          Plibrico also manufactured the Plicast 40 (P40) which was used on
the hot portions of the studded side water tube walls at a location above
the sloping water heaters.
          The third material is Brohtal  (B) which  is a special hieb alumina
castable—a preformed brick.  Its composition is 95 per cent alumina.
An experimental section was installed very near the furnace entrance on only
one side to counter the excessive refuse abrasion  on lower side walls.  The
steel studs themselves were not only bare after 1/2 year but were also ground
down, i.e. eroded off.
          Brohtal  is also used extensively at the  second step at  several
places.   T bricks are placed in the sidewall above and at the lower end of the
sloping water headers.  Note that anchors (and not studs) are used to keep the
bricks secure.  A small amount of the Brohtal is used on the side wall just
after the fall from the second step and at the top of the third step.  Finally
Brohtal  is used just under the  second grate and across the furnace.

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                            Roof Renewed With PI4
                                                              P40
Anchor
                                                          Anchor
                               MARTIN STOKER GRATE
                                 Ash Discharge
  PI4    Plistix  14
  P40    Phcast  40
  B       Brohtal  Special High Alumina
                       Castable
  FIGURE 7-19.
OCTOBER 1976 ADDITIONS OF REFRACTORY TO HAMBURG STELLINGER-
MOOR FURNACE #1

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                                  44
Stage 3  (Addition of Caps onto the
Studs and More Refractory)

          In May 1977, when Unit 1 was down for annual overhaul, several
important changes to the wall were made.  The primary motivation was unhappi-
ness with the Plistic 14 (88-90 percent SiC).  The material did not always
stick* to the studs and 50 percent of the SiC surface area had to be repaired
every 4000 hours.  Apparently this ve-ry excellent and expensive material
does not fully bond to the studs unless the temperature can be raised
to a very high level 1200° C (2192 F) for a sufficient time, 48 hours.
          The Hamburg officials had heard of some pioneering work at the
Oberhausen,  W.  Germany RFSG.   There, the studs were covered with a processed
silicon carbide cap.  These SiC caps were pruchased from Didier Refractory
Company of Weisbaden,  W.  Germany.   Once the caps are cemented over'the studs,
the lower grade (1/3 the cost)  SiC 50 from Didier or a high alumina re- v
fractory can be applied.
                                                                         o
          Figure  7-20 shows where  S-M  people  experimentally  applied  5 m
 (54.9  ft2)  on  the  side walls.  The  SiC  is  40 mm (1.57  inches)  thick.   At
 the  time of Battelle's inspection visit in June,  1977, not  enough time had
 passed to determine results.   Officials are expecting  that  should results
 be satisfactory,  S-M  will  probably  replace more "SiC  90  directly on studs"
 with the "SiC  50  directly  on caps  over  the studs".
          Another  test  is  being  run comparing  the Brohltal  high alumina
 refractory  with the Plibrico Erocist and also  can be  seen in Figure 7-19 .
           Finally,  Fleischmann's  Fixoplanit (   138)  has been applied
 at the second  step and  under  the grate.

                    Furnace Wall (Radiation First Pass)

          Vertically  rising above  the  combustion chamber is the open radiation
 first  pass.  Unlike the fin tube walls  of the  furnace arches, these water
 tube walls  are not  welded  tangentially and have 5  mm (0.2  inches) spacing
 between 70  mm  (2.75 in)  tubes.
          As has  been seen elsewhere these unwelded tubes are
 free to bulge  either  out or  into  the radiation chamber depending on the type
 and intensity  of  compressive  stresses.

-------
Special High Alumina
Brohtal
Plibrico ErociSt
                                                Fleiscnmann
                                                Fixoplanit 138
                                     MARTIN STOKER GRATE
       FIGURE 7-20.   MAY 1977 ADDITIONS OF CAPS  ONTO STUDS AND REFRACTORY TO
                     HAMBURG:  STELLINGER-MOOR

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                                  46
          An apparently  poorly  positioned and operating rotating wall soot-
blower in 1975, after 6200 hours of operation blew a hole in a wall tube bulging
out into the furnace midway up the first pass.   It is felt that,  if the lower
fin tubes of the combustion chamber were extended further up into the first
pass, then the wall could have withstood further abuse from the sootblower
before bursting.  When the one tube burst, another 40 or 50 wall tube sections
of thinning thickness were also replaced.  There has been metal wastage at
other points and once per year, the thinning tubes are routinely replaced.
          Stellinger-Moor is one of the last units to have non-welded water
tube walls.

                             Furnace Roof

          The roof of the furnace is formed of  sloping tubes which
are  located  at the  top of  the   first pass  and  continue  over
the superheater and boiler convection section.   These tubes carry saturated
steam from the front water tube walls of the first pass directly to the top of
the boiler drum.
          Fortunately, the management has had the foresight to make a detailed
record of all measurements and everything done  to the furnaces.  A September
21, 1976 entry to the maintenance record reports on the roof tube problems.
           Such  tubes normally may be rather large but these are not.
The diameter of a new tube is 70 mm  (2.76 inches) and the original wall thickness
is 3.6 mm (.14 inches).  The measurements taken were only on tubes that had
shown signs of metal wastage, i.e. tubes numbered 16 through 41.
          As can been seen in Table  7-6  the thickness had been reduced
from the original 3.6 mm (.14 inches) down to between 1.6 and 2.3 mm  (0.06 and
0.09 inches.   Of the twenty tubes measured, all but two tubes Number 18 and 39
at 2.3 mm (0.09 inches) were replaced.  Number 41 had previously been replaced.
When the renovated system was pressure  tested,  Number 37 failed and had to again
be replaced.
          The  corrosion of these furnace suspended roof tubes was  related
to incomplete  bonding of the SiC 90 that had been sprayed over the surface of

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                                   47
     TABLE 7-6.   WALL TUBE THICKNESS MEASUREMENTS OF  ROOF TUBES
                  AT THE REAR OF THE RADIATION FIRST PASS AT HAMBURG:
                  STELLINGER-MOOR
Tube (Number)
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37*
38
39
40
41
(Boiler Number 1)
Metal Thickness (mm)
1.8
1.9
2.3


2.2
2.0
2.0
0.0
2.0
2.0




1.9
1.7
2.0
1.8
1.9
2.1
1.9
1.8
2.3
1.6

Action
Tube replaced
Tube replaced
Tube not replaced
Measurement not taken
Measurement not taken
Tube replaced
Tube replaced
Tube replaced
Ruptured and replaced
Tube replaced
Tube replaced
Measurement not taken
Measurement not taken
Measurement not taken
Measurement not taken
Tube replaced
Tube replaced
Tube replaced
Tube replaced
Tube replaced
Tube replaced
Tube replaced
Tube replaced
Tube not replaced
Tube replaced
Was previously changed
* Tube 37 was replaced.  It failed under the hydrostatic test.  It was
  replaced again.

-------
                                   48
these large tubes.  Because the tubes carry saturated steam at 253'C (488° F)  and
not the hotter superheated steam, the SIC refractory coating never got hot
enough for proper bonding, i.e. 1200 C  (2190 F).
          The plant people have decided to switch away from the SiC 90 in favor
of a high alumina plastic refractory.  In other words, the superior heat  trans-
fer characteristics of a properly bonded SiC 90 will be forgone in favor of the
cheaper and more reliable high alumina refractory.

First Pass Outlet Screen Tubes
Rear of Radiation First Pass

          The  screen tubes depicted below have experienced erosion by the
combustion gases.
                                             Furnace roof
                                 O
          The eighteen (18) tubes are 70 mm (2.76 inches) in outside diameter
and 3.2 mm (0.126 inches) in thickness.  The maintenance record book of
September 8, 1976 shows that tube number 10 burst and caused unit stoppage.
(See Table  7-7 ).  Measurements were taken that showed an uneven pattern
of greater metal wastage of center tubes.  As a result the other thin  tubes
numbered 5,6,9,12, and 13 were also replaced.

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                              49
TABLE 7-7.   WALL TUBE THICKNESS MEASUREMENTS OF SCREEN TUBES,
             AT THE REAR OF THE RADIATION FIRST PASS AT HAMBURG:
             STELLINGER-MOOR

Tube (Number)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
(Boiler Number 1)
Metal Thickness (mm)
3.3
3.3
3.3
2.8
2.4
1.8
2.5
2.9
1.8
0.0
2.7
2.2
2.3
2.8
2.7
2.8
2.9
2.9
Action




Thin and replaced
Thin and replaced
Thin and replaced

Thin and replaced
Ruptured and replaced

Thin and replaced
Thin and replaced






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                                50 & 51
          Regarding the supersonic measuring technique,  local officials reported
that the readings could be plus or minus 20% off from reality.   Therefore if
minimum succeptable thickness was, for example, 2.0 mm, then anything below
2.5 mm measurement should be replaced.  The formula is:

          X = 2.0 mm  =  2.U  -  2.5 mm
              1.0 - 20%  0.8
                             Superheater

          Three bundles of superheater vertical tubes are hung from the sus-
pended roof that has the sloping upwards screen tubes.  Once the gas flow
turns 90° from the radiation first pass, it continues horizontally through
the superheater and then the convection boiler section.  See Figure 7-21.

Stage 1 (Original Contraction)

          The basic dimensions have remained throughout the unit's life.
The plain carbon steel  (ST 35.8) used in 38.0 mm  (1.50 inches) in diameter
and 4 mm (0.16 inches)  thick.  The design provides a heating surface area
of 470 m2 (5060 ft2).
          Retractable sootblowers  are used for cleaning deposits off the
tubes.  Sootblowing has caused a fair amount of corrosion damage and has
motivated the following stages.
          These corrosion problems have developed despite the Walther Go's
originally shielded superheater tubes shown in Figure 7-21.

Stage 2 [Adding Angle Iron]

          When the leading superheater row began  failing, despite the
Walther shields, angle  iron was welded to the first row of tubes.  This had
the intended effect of  protecting the first row of tubes.  However, the
angle iron had the very damaging effect of concentrating the  flue gas as  it
was directed to the sides of second and third row tubes as shown below
in Figure 7-22.

-------
                          52
                           West
South
mm — ' •
Bund
ubes
X
East
— — 	 '
le 1
1-6 1
f


1
— " -
Bundle 2 Bundle 3
\ibes 1-14 Tubes 1-12
                                                  North
                 FIGURE 7-21.
THREE SUPERHEATER BUNDLES AT
HAMBURG: STELLINGER-MOOR

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                                               53
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-------
                                   54
           Because of the Bernoulli effect, some gases were redirected away
from going straight down the open channel and instead have nonsymetrically
hit the front and one side of the tubes in the second and third rows.  The
directing or aiming effect of the straight sided angle iron was apparently
realized and this form of shielding has been discontinued.
Stage 3  (Switch to Pressure
Bent Tubes)
          Originally  the  tubes were simply  "stretch" bent.  Unfortunately
 this  form of bending  gathers the material on the inside  curve,  while  thinn-
 ing it out on  the outside curve.  Thus, the front of the bottom loops, with
 less  original  thickness, would wear out first.
          Now, pressure bent tubes are installed as replacements.   The Wal-
 ther  Co. can provide  greater detail.

 Stage 4  (Welded Curved Shields)

          Two  factors continued to cause corrosion.  First, the retractable
 sootblower would remove deposits very efficiently and  thus enhance  the rate
 of exposed metal wastage.  The other factor was continued erosive abrasion
 by the flue gases.
          To combat these problems, in April 1977, a series of  50 mm  (2 inch)
 shields were welded next to each other along the front surface  of the first
 row of superheater tubes as seen in the several portions of Figure  7- 23
 Note  the 135  angle.  Sicromal 10 is the high temperature alloy material used for
 these curved plates.  This steel has contains silicon,  chrome,  and  aluminum.
          Perhaps 1 or 2 mm separate each shield.  Note  that the last
 shield at the bottom  of the superheater tube is extended further straight
 down  and thus away from the tube.  This provides some protection of the
 very bottom of the tube.   At the tube's upper section,  the same material
 is not welded but formed in a U shape and bolted from the back  side.
          Experience has shown that when a weld fails and the tube  fails
 it is more economical to replace the entire tube than to repair the damaged
 area.

-------
55
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-------
                                  56
Stage 5 (Bracing Superheater Tubes)

          Due to the swinging nature of the bundles from the overhead header,
S-M decided to anchor and support the bottom of the bundles.  This also true
of the economizer.

Stage 6 (Superheater Repair Observation)

          While Battelle researchers were visiting the plant on June 13,
1977, a superheater tube in Boiler 2 failed and was losing 5 tons of steam
per hour.
          Repairmen removed about 1 m (3 feet) of four other tubes in order
to get to and replace the failed tube.
          After performing hydrostatic test, the boiler was put in service,
having been out of service almost two days.

-------
                                   57
Boiler Convection Section

          The flue gases leave the superheater and continue flowing hori-
zontally as they enter the boilers'  convection section.   (Refer back to
Figure 7-1).


 Stage 1.   (Original Design)

           The two drum-bent  tube boiler convection section (and the other
 boiler sections)  were manufactured  by Walther and CIE of Cologne-Dellbruck,
 West Germany.  The section is 16 rows deep and 34 rows wide as portrayed
 in Figure 7-24.

 Stage 2.   (Reducing of Soot  Blowing Activity)

           Boiler  tube corrosion near the fixed position  sootblowers had
 been a serious problem.   As  has been told to Battelle researchers  by several
 different plant managers,  reducing  the sootblower activity can provide in-
 creased tube life with no increase  in costs.  The only penalty is  a modest
 decrease in thermal efficiency.  .Decreasing sootblower activity is recom-
 mended especially during seasons of "excess" steam production.  Methods
 exist for reducing activity,  frequency, and pressure.
          First,  as at S-M, many plants  reduce  the soot-blowing  frequency.   In
 this  case, many blowers  that had been blowing once per shift are now scheduled
 to blow 1 to  3  times  per week.
          Officials pointed out that  the actual setting of blowing  frequency
 is a  function of  where the boiler is  in  its  4,000 hour cycle between major
 overhauls.   If  in the first 1000 hours,  they blow only one third as  often as
 before.   If,  however, they were in  the last  1000 hours, they blow half  as
 much.
           Secondly,  the pressure has been reduced from 18 bars (260 psi) to
 14 to 16 bars (200 to 230 psi).
           In the  last two years that the changes  have been made, they have
 experienced only  five convection section tube failures per boiler,  ten in all.
 Four of the five  tube failures were repaired in April 1977 as  shown in Figures
 7-25 and 7-26.  Both records  are duplicated to show the method used to record
 maintenance activity.  For each major section of  the plant,  a  master sheet

-------
                                58
    Gas
    Flow
            Row
Row 16
FIGURE 7-24.   ARRANGEMENT OF TUBES AND DRUMS IN CONVECTION SECTION

-------
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-------
    ^/>r^ «£*/._   fo*S*/J^-
FIGURE 7-26.  "BOILER MAINTENANCE" DATA  SHEET AT  SI ELLINGER-MOOR  FOR  RECORDING
              TUBE  THICKNESS MEASURD1ENTS ON TUBE ROW NO.  2

-------
                                  61
is prepared having a relevant standard sketch.  These two figures show
measurement results on all 68 (2 x 34) tubes, show the 20 tubes that were
replaced because they were thin and show the four tubes that failed.

-------
                                  62
                              Economizer

          The flue gas leaving the boiler convec tionsection turns 90° and
heads downward through the five economizer bundles.

Stage 1 (Original Construction)

          Again, plan carbon steel, ST. 35.8, is the tube material.  The
tube outside diameter is 31.8 ram (1.3 inches) and the wall thickness is 2.9
                                                      2
mm (0.11 inches).  The effective heating area is 540 m .

Stage 2 (Sootblowers Attached to
Economizer Bundles)

          Because the economizer tubes would change position due to thermal
stresses, the wall-attached sootblower would then send high pressure steam
directly onto the tubes.  These moving economizers have been the cause of
four or five tubes failures per year.  To alleviate this problem, S-M has
decided to mount the sootblowers on the economizer bundles themselves.

Stage 3 (Plugging Econimizer Tubes)

          Should an economizer tube rupture, repairmen! stick steel plues into
the tube ends, thus cutting of water flow.  The tubes are ignored and not
repaired until a major overhaul after 2000 hours.  This type of plugging
does not require government inspection prior to restart.

-------
                                  63
                              CO-FIRING

Sewage Treatment Plant Methane Gas

         Formerly, methane gas from the sewage treatment plant within the
same sanitary park was fed into the boiler.   The practice has been discon-
tinued.  Today the gas is flared at the sewage treatment plant.

Commercial Number 2 Fuel Oil

         The oil fired burner port is 6 meters (20 feet) above the grate.
The burner can be swung into the opening furnace when needed.
         Usually, the oil burner is used 5 to 6 hours for start up.  During
this warm-up period the ESP temperature is raised to 180° C.  A cold
ESP will not work well.
         An unusual use is if the feed chute becomes stuck, the oil burner
can be turned on to help keep the system stabilized.

-------
                                  64
                   ENERGY UTILIZATION EQUIPMENT

         Steam for internal uses and electricity are  the energy products
from S-M.  The black box results in an observed steam temperature of 400° C
(752F) plus and minus only one degree.   The pressure is equally as steady
at 40 bar  (569 psi).

Turbines

         The two topping off condensing turbines (shown in Figure 7-27)
manufactured by   AEG-KANIS    each have steam consumption capacities of
88 tonnes (97 tons) steam/hour.  However, one is a spare and the running
turbine usually consumes only 60 tonnes (65 tons) steam/hour.
         The earlier Table 7-3  showed that the total steam consumed per
year was level from year to year 443,348 tonnes ( 488,707 tons) in 1975 and
420,675 tonnes ( 463,715 tons) in 1976.   However, in 1975, Turbine 1 carried
the load and in 1976, Turbine 2 carried the load.  This was due to planned
equipment overhaul and planned downtime of a spare turbine.
         The average generating capacity (assuming that enough steam is
available) is "two times 5 mw or 10 raw, less 1 mw for internal use",  as
was stated in the interview. The maximum generating capacity is
16.4 mw for each generator.
         Electricity is sold to the local power grid, Hamburg Electrical
Works (HEW).  Figure 7-28 shows the general electrical network feeding into
the 110 KV line of HEW.

Power Generated and Used

         Electrical power primarily is generated in the two turbogenerator
sets amounting to 69,239,100 Kwh in 1976.  This had to be augmented with
196,350 Kwh of purchased electricity from the plants major customer.(for short ups)
         Surprisingly, S-M sells to HEW its electricity for .03 DM or  3 Pf
($0.0125) per Kwh but S-M must pay this same Hamburg Electrical Works  .40 DM
or 40 Pf ($0.1667) per Kwh.  Multiplying quantity and price for 1976 gives
the following results :
*
  Using a conversion rate of 2.40 DM/$1.00

-------
                         65
FIGURE 7-27.   STEAM TURBOGENERATOR BUILT BY AEG-KANIS

-------
                                    66
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-------
                                 67
         S-M Sales              S-M Purchases
         52,841,250             196,350
         	0.03 DM             0.40 DM
      1,585,237.50 DM            78,540 DM
       $660,515                 $32,725
         The electrical power is used in the following manner:
                                                  1976
         High-demand peak load                13,224,750 Kwh
         Low-demand base load                 39,616?500
           Total sold to HEW                  52,841,250
         Sewage treatment plant                4,308,709
         Internal uses                        12.228,467
           Total uses of electrical power     69,378,426 Kwh

Internal Steam. Uses

         Steam can be drawn off the turbines at 2.5 bars (36 psia).
Steam has four key uses inside the S-M-plant:
         •  Steam sootblowing
         •  Building heating
         •  Feedwater heating
         •  Air preheating.
         Plant people reported that 10 tonnes (11 tons) of steam per hour are
used in 1/2 minute for the sootblowing cycle.  The amount, while substantial,
is only for a short time and is hardly felt at the turbine.

                     Air Cooled Steam Condensers

         The story on the S-M condenser shown  is important
to systems that might be built in the colder North American climates.

Stage 1  (Original Construction)

         In contrast to Martin's Chicago, Illinois and  Harrisburg, Pennsylvania
systems  in America with horizontal  tubes, a common European practice is  to
have tubes in sloping roofs.
         Originally  the plastic  fan blades  were reset  twice per year.  In
the winter when  not  as much  cooling was needed, they  were  set with very  little

-------
                                   68
pitch.  In the summer, the pitch was increased.  Unfortunately, the high
summer pitch would cause the plastic fan blades to .deform, slip, break, or
fall out.
         In the event that both turbines are down, the condensers can con-
dense a limited 45 tonnes (49.5 tons) steam per hour.  Thus, if a single
88 tonne/hour capacity turbine normally running at 60 tonne/hour capacity
suddenly fails, the 45 tonne/hour condenser  will be 15 tonne/hour short
in capacity.  This remaining 15 tonnes/hour would pass through the
throttling valve at a very high noise level, hence production is reduced.

         Stage 2 (Changing Fan Speed Instead of Pitch).  The problem was
resolved by setting the pitch low for winter needs and then not changing
the pitch throughout the year.  In the summer, the motor speed is now
raised.  Maintenance fan has now been greatly reduced.  They now overhaul
and balance the fans every two years.  They clean the system every early
summer with high pressure water.

         Stage 3.  (Freezing Tubes Requiring More Thermocouples).  The
sloping roof at S-M experienced freezing in six of its condenser fin tubes
once when it was -20  C (-4   F).  The single thermocouple was located on
one of the four headers and was on the protected leeward side of the
condenser.  As a result, the reading was always above the danger level.
         Unfortunately, the chill factor (temperature and wind velocity)
was much worse on the windward side and freezing occurred unnoticed.  The
first sign of a problem was when the electrical turbine tripped out.  They
now have four thermocouples, one for each header and these have readings
on both sides of the condenser.

-------
                                  69
                     POLLUTION CONTROL EQUIPMENT

         The primary means of control Is the electrostatic precipitator
(ESP), also called "electrofliter" In many European plants.  The plant is
now trying a water spray flue gas cooler to augment ESP operation in addition
to absorbtion of harmful gases.

Stage 1. (Original Construction)

          The two-field ESP manufactured by Fa, Walther Cie. is designed to
                 o
process 90,560 Nm /hr (53,250 scfm) when the furnace is operated at 130 per-
cent of nominal capacity.
         The  max flue gas entering  temperature had been around 350 C
(662  F).  This is well above recommended temperature levels and has'been
the source of later ESP high temperature corrosion and mediocre performance.
The exit temperatures ranged from 250 to 300  C (482 to 572 F).
         The maximum flow velocity is 1.15 in/sec (3.8 feet/sec).  The
insulation is 8 cm (  3.7 inches  ) thick.
         Mechanical rappers shake the flyash off and down  into the
pyramidal cones.  In wintertime, the hoppers are heated electrically.
Flyash is removed by a service conveyor leading to the ash storage  silo.
         The guaranteed particulate efficiency was 98.9 percent.  The
original construction had a single duct leading from the bottom of  the
economizer section to the electrostatic precipitator (ESP) on the building
roof.  With all new equipment and with much supervision, the plant  had
passed the air pollution compliance test with readings between 112  and 145
mg/Nm  which were below the legal limit of 150 mg/ NM3 (0.066 gr/sc'f)
adjusted to 7% CO-.
         As the years have passed, the equipment is older  and somewhat cor-
roded, plant operations may be more casual and on some occassions the refuse
feeding may be jerky.  For whatever combination of reasons, the later air
                                  3
pollution tests showed a 200 mg/Nm  result.  This was unacceptable  and some-
thing had to be done.

Stage 2. (Flue Gas Water Spray Cooler)

          Officials were advised that cooling tna flue gas going  to the
ESP would increase ESP performance and extend its life.  While not  a  require-
ment on existing units, adding a water spray would also reduce air  emissions
of HC1.

-------
                                  70
         Thus in   March,  1977  , the newly added flue gas water spray cooler
began spraying 1100 liters per hour (4.84 gallons per mln or 1.1 tonne/ hour
(1.21 ton/hour) of water.  The ensuing  tests showed that partidulate
                                                   3
emissions had sucessfully dropped  to 50 to 80 mg/Nm  .
         The testing was  done by Dr. Reimer of "P. Goepfert & H. Relmer-"
in Hamburg and Professor  Zinn of the University of Hamburg.
          For various reasons, a flue gas water spray device is an
obvious benefit.   However, all modern particulate regulations know to us
must be satisfied by an ESP.   Water sprays can only be throught of as
auxiliary beneficial items.   They cannot stand alone in refuse combus-
tion systems.
                          Stack  Construction

         The one single-flue 71 meter (220 feet) stack was limited in
height due to nearness to the flight pattern of an airport.  In addition to
the low stack, the airport authorities also wanted a low plume rising from
the stack.  Thus,  the stack was built to emit low velocity flue gas and to
accommodate four RFSG units.  However, it currently serves only two units,
so the velocity is running at half the designed low velocity.
          This may be the reason for corrosion and excessive staining on
the stack and on portions of  roof equipment.   There are vertical stains
in Figure 7-29.   The actual  staining takes place when rain drives  the
damp flue dust particles against the stack which then flow down, form-
ing reddish-brown vertical streakes.
          The top  3 m  (10 feet) of the chimney  ladder has  suffered serious dew
point  corrosion and had  to be replaced in 1976  after only  3-1/2 years of
service.  The stack is of conventional construction as  shown below.
                                            Ceramic blocks

                                            Rock wool

                                            CONCRETE

-------
                             71
FIGURE 7-29.   STAINS AT BOTTOM OF CHIMNEY AT RIGHT.  (Battelle Photograph)

-------
                                  72
                             Ash Recovery

         Ash recovery is practiced at about half of the plants that were
included in this project's survey.  In Hamburg, the Heidemann Company has
a contract with S-M to process and remove all ash.
         Mr. Siegfried Heidemann was stockpiling most of the production and
waiting for the price of this material to rise.  Mr. Arndt  pointed out that
Hamburg's sea level position provides many markets for his ash material.
Much of this plant's ash is shipped to Scandinavia and East Germany.
Heidemann buys  the raw residue  (unprocessed) for 4.50 DM ($1.80) per tonne.
He sells the processed road material for about  12 - 15 DM  ($4.80  -  $6.00)  per  tonne.
Scrap iron prices vary widely and no figure was given.
         Three Heidemann men are needed during the day to run the equipment.
         The following mass balance accounting was provided assuming 1000
refuse input tonnes:
         C02, H20 etc.  rising through the chimney      549 tonnes
         Scrap iron (large pieces collected in RFSG)     10 tonnes
         Scrap iron (mediums and fines)                  65 tonnes
         Road material, including flyash                250 tonnes
         Residue to landfill                             35 tonnes
            Total refuse input tonnes                  1000 tonnes

-------
                      73
FIGURE 7-30.
RESIDUE PROCESSING PLANT AT STELLINGER-MOOR
(Battelle Photograph)

-------
                                  74
         Twice a week, a truck takes singed tree stumps, tires, etc. to
the landfill.
         Figure 7-31 shows a street sweeper cleaning the reading adjacent
to the storage pile for processed residue.

-------
                      75




                        %i       fe
FTCURE 7-31.
STREET SWEEPER CLEANING ROADWAY ADJACENT TO
STELLINGER-MOOR PROCESSED RESIDUE STORAGE PILE
(Battelle Photograph)

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                                  76
                      PERSONNEL AND MANAGEMENT

         The organization chart shown in Figure 7-32 describes the
organization structure of Stellinger-Moor.  Herren  Opperman, Rossi,
Grosstueck, and VonBorck have city-wide responsibility and their offices
are located near Borsigrtrasse.  Mr. Arndt has about 70 people on the
payroll within plant gates.  Many employees are used for vacations and
sickness replacements as shown below:
                                             Maintenance and
                              Operations     Adminis trative     Total
         Sickness                 11               4             15
         Vacation                  5               6             11
                                                                 26
Thus, on a typical 24-hour day, 26 people will be away from work for
sickness or vacation and 44 will be actively working.
         Employees are remunerated by a basic wage.  This is supplemented
by a bonus that is a function of steam and electrical production.
                          ENERGY MARKETING

         Energy marketing is not an activity because all steam and elec-
tricity produced is used either internally, sent to the adjoining sewage
treatment plant, or sent to the Hamburg Electrical Works.  There are no
district heating or industrial steam customers.

-------
                                          77
                                      Opperman
Werner Grosstueck
Shief Constructior
   Engineering
 Hans Rudolf Timm
     Maintenance
      Engineer
        Mechanical
        7 people
        Electrical
        4 people
        Gen. Maint.
        8 people
                                        Rossi
                                        Arndt
                                    Plant Manager
                                     Igor Schmidt
                                  Operations Engineer
Shift Foremen
  5 people
                                        Crane Operator
                                          5 people
                                        Boiler Operator
                                          10 people
                                        'urbine Operatoi
                                           5 people
                                           Electrical
                                           Production
                                           5 people
                                           Mechanical
                                          Maintenance
                                           5  people
                                        General Workers
                                           10 people
                             1  Klaus Von Borck
                             A    Landfill
                             I   Engineering
                               Administrative
                                   Manager
                                  Purchasing Off
                                    ''3 people
Accounting,etc
	3 people
           FIGURE 7-32.
                          ORGANIZATION CHART FOR HAMBURG:   STELLINGER-MOOR

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                                   78
was:
                           ECONOMICS
                      Capital Investment

     The capital cost of the plant in 1972 when completed

                           Million of    Thousands of Dollars
                         Deutschmarks    At 3.19 DM/$ in 1972
Land                          2.3                  721
Substation, Connections       2.8                  878
Buildings                    14.4                4,514
Mechanical Equipment         29.0                9,091
Architect's Fee               0.7                  219
                                  49.2               15,423
Included in the above costs are the following erection costs:
     Buildings                     1.661                520
     Turbo Generators              4.226              1,325
     Air-Cooled Condenser          1.856                582
     Substation                    1.415                444
     Transmission Line             2.800                878
                                  11.958              3,749
          At the time of completion in 1972 the estimated amortization
cost for a 20-year life, with 7.5 percent interest and debt reduction of
9.25 percent per annum of the power generation equipment only including
the substation and transmission line was 1.166 million DM ($365,500 @
3.19 DM/$ in 1972).
                             Operating Costs
          The separate costs of operation for the Stellinger-Moor plant
are not available.  The combined operating costs of Stellinger-Moor and
the older Borsigstrasse Plant and of landfilling in 1976 are shown in
Table 7-8  according to the city report, "Jahresbericht der Stadtreini-
gung iiber das Rechnungsjahr 1976".

-------
                                    79
           TABLE 7-8 .   SOLID WASTE DISPOSAL COSTS AT HAMBURG INCLUDING
                        OPERATION OF LANDFILL AND STELLINGER-MOOR AND
                        BORSIGSTRASSE PLANTS
                                                Deutschmarks
 1.  Labor Costs                                 13,203,782
 2.  Material Costs                               4,380,966
 3.  External Fees                                4,160,828
 4.  Transport Costs                              1,071,528
 5.  Amortization                                 4.474,587
      5-1.  Net Costs                            27,211,085
 6.  Interest On Capital                          8,128,536
 7.  Interest On Spare Expenses                	185,155
 8.  Gross Costs less  Misc  Operating  Expenses     35,524,776
 9.  Miscellaneous Operation Expenses
      Overhead (RO, Rl)                             677,004
      Overhead (R2 - 6)                              68,613
      Spare Parts                                    44,279
      Janitor Service                                88,436
      Transport Service, Fuel                       272,660
      Truck Maintenance                             372,083
      Miscellaneous                                   2,427
      Truck Workshop                              1.825,410
10.  Total Miscellaneous Operation Expense        3,350.691
11.  Grand Total                                 38,875,467
12.  Income From Power, Residue And  Scrap         8,130,922
13.  Net Operation Costs                         30,744,545

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                                   80
          Of the total disposal costs shown in Table 7-8 which includes
landfill operation, the incinerator costs alone of the two plants in
1976 were given as follows:
                                               Peutschmarks
          Labor Costs                           10,974,713
          Material Costs                         3,817,236
          External Fees                          2,728,946
          Amortization                           3,843,752
          Overhead                               1,561,063
          Gross Operating Cost                  22,925.710
          Interest On Capital                    8,206,051
          Income                                 6,477,748
          Net Operating Costs                   24,654,013

          In terms of the tonnage of waste processed at the two plants
the gross operation cost was:
     8.99 DM/m3, 74.0 DM/tonne ($26.93/ton @ 2.5 DM/$)
          When the income for power residue and scrap is deducted the
net operation cost per ton is:
     7.12 DM/m3, 58.61 DM/tonne ($21.33 ton)
          Thus the income realized by the two plants was 15.39 DM/tonne
of refuse processed.  In terms of 1976 exchange rate of 2.5 DM/$ this
income is the equivalent of $5.60 per ton of waste processed. .

-------
                                   81
Guarantee

          The guarantee specified that 100 percent of all annual repair
maintenance costs exceeding 2 percent of the capital cost must be paid by
Martin or its subcontractors for each of the first 2 years.  For years 3
through 5, a lower percentage of costs above 2 percent had to be paid.
After 5 years, there is no guarantee.

                               FINANCE

          Funds not accumulated in the city of Hamburg's general funds
were borrowed from local banks.  Plant life was estimated to be 20 years
and presumably some of the loans were for that period of time.

-------
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                TABLE    .  EXCHANGE  RATES  FOR SIX EUROPEAN COUNTRIES,
                           (NATIONAL MONETARY UNIT PER U.S. DOLLAR)
                           1948  TO  FEBRUARY,  1978(a)

1948
1949
1953
1951
1952
1953
1954
1955
1955
1957
1953
1959
1960
1961
1962
1963
1964
1965
1966
1967
1968
1969
1970
1971
1972
1973
1974
1975
1976
1977
1978 (Feb.)
Denmark
Kroner
(D.Kr.)
4.810
6.920
6.920
6.920
6.920
6.920
6.914
6.914
6.914
6.914
6.906
6.908
6.906
6. 886
6.902
6.911
6.921
6.391
6.916
7.462
7.501
7.492
7.489
7.062
6.843
6.290
5.650
6.178
5.788
5.778
5.580
France
Francs
(F.Fr.)
2.662
3.490
3.499
3.500
3.500
3.500
3.500
3.500
3.500
4.199
4.906
4.909
4.903
4.900
4.900
4.902
4.900
4.902
4.952
4.908
4.948
5.558
5.520
5.224
5.125
4.708
4.444
4.486
4.970
4.705
4.766
W. Germany
DeuCsch Mark
(D.M.)
3.333
4.200
4.200
4.200
4.200
4.200
4.200
4.215
4.199
4.202
4.178
4.170
4.171
3.996
3.998
3.975
3.977
4.006
3.977
3.999
4.000
3.690
3.648
3.268
3.202
2.703
2.410
2.622
2.363
2.105
2.036
Netherlands
Guilders
(Gl.)
2.653
3.800
3.800
3.800
3.800
3.786
3.794
3.829
3.830
3.791
3.775
3.770
3.770
3.600
3.600
3.600
3.592
3.611
3.614
3.596
3.606
3.624
3.597
3.254
3.226
2.824
2.507
2.689
2.457
2.280
2.176
Sweden
Kroner
(S.Kr.)
3.600
5.180
5.180
5.180
5.180
5.180
5.180
5.180
5.180
5.173
5.173
5.181
5.180
5.185
5. .186
5.200
5.148
5.180
4.180
5.165
5.180
5.170
5.170
4.858
4.743
4.588
4.081
4.386
4.127
4.670
4.615
Switzerland
Francs
(S.Fr.)
4.315
4.300
4.289
4.369
4.285
4.288
4.285
4.285
4.285
i.285
4.308
4.323
4.305
4.316
4.319
4.315
4.315
4.318
4.327
4.325
4.302
4.318
4.316
3.915
3.774
3.244
2.540
2.620
2.451
2.010
1.987
(a)  Exchange Rate at end of period.
    Line "ae" Market Rate/Par or Central  Rate.
    Source:  International Financial  Statistics:   1972 Supplement; April, 1978, Volume
    XXXI, No. 4, Published by the  International  Monetary Fund.
                                                                       ya 1828s
                 4 US GOVERNMENT PRINTING OFFICE 1979-620-007/6303

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