United States Office of Water and SW 176C.5
Environmental Protection Waste Management October 1979
Agency Washington, D.C. 20460
Solid Waste
&EPA European Refuse Fired
Energy Systems
Evaluation of Design Practices
Volume 5
-------
Pne.pu.btLc.ation -tMue fan EPA
and Stats. Sotid Watte. Management Agenoce*
EUROPEAN REFUSE FIRED ENERGY SYSTEMS
EVALUATION OF DESIGN PRACTICES
Werdenberg-Llechtenstein Plant
Buchs, St. Gallen. Switzerland
Tkit, &u.p tie.pont (SW-176C..5)
the. o^-tce o& SoLLd Watte. undeA contract no. 68-01-4376
and -c6 ?ie.ptwduiC.e.d a& -^.ecexcuec/ ^om tke.
The. fandlngt, thouJLd be aWUJo(JUte,d to the.
and not to the. O^-tce o^ Sotid
Copies will be available from the
National Technical Information Service
U.S. Department of Commerce
Springfield, VA 2216T
Volume 5
U.S. ENVIRONMENTAL PROTECTION AGENCY
1979
-------
This report was prepared by Battelle Laboratories, Columbus, Ohio,
under contract no. 68-01-4376.
Publication does 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 prc^l^iof) publication ,(SW-176c.5) in the solid waste
management series.
Environmental Protection Agency
-------
TABLE OF CONTENTS
Page
PREFACE i
ORGANIZATION ii
ACKNOWLEDGEMENTS iii
STATISTICAL SUMMARY iv
Werdenberg Plant v
DEVELOPMENT OF THE SYSTEM 1
COMMUNITY DESCRIPTION 1
Geography 1
Government and Industry 3
SOLID WASTE 5
Solid Waste Generation 5
Solid Waste Collection Activities 10
Solid Waste Transfer and/or Pretreatment 10
Solid Waste Disposal 11
REFUSE-FIRED STEAM GENERATOR EQUIPMENT 11
Furnace Hopper and Feeder ..... . 16
Burning Grates 17
Furnace Wall (Combustion and First Pass Radiation
Chambers) 20
Second Boiler Pass ......... 23
Superheater » 23
Boiler (Convection Section) , . . , 24
Economizer , 25
Boiler Water Treatment 25
Primary (Underfire) Air Supply 26
-------
TABLE OF CONTENTS (Continued)
Page
Secondary (Overfire) Air Supply 26
Tertiary (Sidewall) Air Supply 29
Heat Release Rate 31
Energy Utilization Equipment 32
POLLUTION CONTROL EQUIPMENT 41
Wastewater Discharge 42
Stack Construction 42
POLLUTION CONTROL ASSESSMENT 43
Noises 44
PERSONNEL AND MANAGEMENT 44
ENERGY MARKETING 46
ECONOMICS 46
Capital Investment ..... 46
REVENUES 47
LIST OF FIGURES
FIGURE 1-la. REFUSE GENERATION AREA SHOWING THE SERVICE AREAS
IN THE CANTON OF ST. GALLEN AND IN LIECHTENSTEIN . . 2
FIGURE 1-1. PLAN OF WERDENBERG PLANT SHOWING RELATION TO
ASSOCIATED COMMUNITY SERVICE FACILITIES . 2a.
FIGURE 1-2. PROFILE OF PLANT SURROUNDED BY MOUNTAINS 4
FIGURE 1-3. SOLID WASTE COLLECTION RATES . , , . 6
FIGURE 1-4. SWISS NATIONAL SOLID WASTE DISPOSAL PATTERNS FROM
"WOHIN MIT DEN ABFALLEN", ZURICH, NOVEMBER 1976 . . 12
-------
LIST OF FIGURES (Continued)
Page
FIGURE 1-5. TRUCK DELIVERING TO REFUSE BUNKER 14
FIGURE 1-6. CONTROL ROOM WITH SCALE OPERATOR, CRANE OPERATOR
AND PLANT CONTROL ROOM OPERATOR 14a.
FIGURE 1-7. OVERALL SECTION INSIDE THE WERDENBERG PLANT .... 15
FIGURE 1-8. AN EXAMPLE OF THE ALBERTI FONSAR STEP GRATE SYSTEM
ASSEMBLED AT THE FACORY 18
FIGURE 1-9. SECTION THROUGH WERDENBERG-LIECHTENSTEIN WASTE-TO-
ENERGY PLANT 21
FIGURE 1-10. SCHEMATIC VIEW OF WERDENBERG-LIECHTENSTEIN WASTE-
TO-ENERGY PLANT 27
FIGURE 1-11. SKETCH OF AIR FLOWS TO FURNACE 28
FIGURE 1-12. WERDENBERG STEAM AND HOT-WATER DISTRIBUTION
SYSTEM 33
FIGURE 1-13. OIL-FIRED STANDBY BOILER ON TRANSPORT TRUCK .... 34
FIGURE 1-14. STEAM TURBO GENERATOR 35
FIGURE 1-15. TWO VIEWS OF AIR-COOLED CONDENSER AT WERDENBERG . . 36
FIGURE 1-16. STEAM AND HOT WATER DISTRIBUTION TRENCH AT WERDEN-
BERG 37
FIGURE 1-17. CASCADE TYPE WATER HEATER ON LEFT, FEEDWATER
TANK AND STEAM LINES ON RIGHT AT WERDENBERG .... 38
FIGURE 1-18. INSULATION, INSTALLATION AND MAP OF HOT WATER
DISTRIBUTION SYSTEM AT WERDENBERG 39
FIGURE 1-19. APARTMENT HOUSE AT WERDENBERG HEATING BY HOT WATER
FROM STEAM PLANT 40
FIGURE 1-20. ORGANIZATION CHART FOR OPERATION OF WERDENBERG
PLANT 45
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LIST OF TABLES
Page
TABLE 1-1. DELIVERIES FROM THE COMMUNITES SERVED IN 1976
(FROM PLANT REPORT) 7
TABLE 1-2. DELIVERIES IN EACH MONTH IN 1976 AND TOTALS FOR 1975
AND 1976 (FROM PLANT ANNUAL REPORT) 8
TABLE 1-3. REFUSE COMPOSITION AT THUN, 1975 9
TABLE 1-4. REFUSE UTILIZATION IN SWITZERLAND IN 1975 (FROM "WOHIN
MIT DEN ABFALLEN", ZURICH, NOV. 1976) 13
TABLE 1-5. WERDENBERG PLANT COSTS, 1976 48
TABLE 1-6. REVENUE ESTIMATE FOR 1977 49
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i
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.
-------
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
-------
Ill
ACKNOWLEDGEMENTS
We are pleased to acknowledge the highly cometent assistance
and generous hospitality of the following during our visit to the Wer-
denberg plant:
Robert Giger, Plant Manager
Hansruedi Steiner, Widmer & Ernst
Peter Nold, Widmer & Ernst
Theodor Ernst, Widmer & Ernst
Robert Hardy, U.S. Representative, Widmer & Ernst
-------
IV
STATISTICAL SUMMARY
Werdenberg Plant _
Community description:
Area (square kilometers)
Population (number of people)
Key terrain feature
900
76,685
mountainous
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)
71.8 (365-day yr)
342
2300-3360
5
No
mixed community and bulky
no
Development of the system:
Date operation began (year)
April, 1974
Plant architecture:
Material of exterior construction
Stack height (meters)
Plastic coated steel
40
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
Approximately 25 percent
2300-3360
120 (for 2800 Kcal/kg)
1 (room for 2)
-------
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)
(m3)
Crane capacity:
(tonnes)
(m3)
Feeder drive method
Burning grate:
Manufacturer
Type
Number of sections (number)
Length overall (m)
Width overall (m)
Primary air-max (m-^/hr)
Secondary and tertiary air-max (m /hr)
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 (t/hr max)
Total plant steam production (t/hr max)
Steam temperature ( C)
Steam pressure (atm)
120
133
1
133 (5 days/week)
No
1300
5
2
Hydraulic
Alberti-Fonsar
Stepped reciprocating
7 steps long
7.0
2.5 (effective)
32,000 m3/hr (20 c)
26,400 m3/hr (20 c)
142
7.61
200 (approx.)
Yes
Yes
Alberti-Fonsar
Natural circ. water tube
3
16
16
395
40
-------
VI
Use of economizer (yes or no)
Use of air preheater (yes or no)
Use of flue gas reheater (yes or no)
Cofire (fuel or waste) input
Use of electricity generator (yes or no)
Type of turbine
Number of turbines (number)
Steam consumption (t/hr)
Electrical production capacity per turbine (mw)
Total electrical production capacity (mw)
Turbine back pressure (atm)
User of electricity ("Internal" and/or "External")
Yes
No
No
No
Yes
Back pressure
1
14 t/hr
0.8 mw
0.8 mw
5.5-12 (range)
Internal, external
Energy utilization:
Medium of energy transfer
Temperature of medium ( C)
Population receiving energy (number)
Pressure of medium (atm)
Energy return medium
Steam, hot water
110-180 (water)
500 plus industry
steam 10
Water
Pollution control:
Air:
Furnace exit conditions
Gas flow rate (m /hr)
Furnace exit loading (mg/Nm )
83,000 (274c)
88 at 7% C00
-------
VI1
Equipment:
Mechanical cyclone collector (yes or no) j^o
Electrostatic precipitator (yes or no) Yes
Manufacturer Elex
2
Inlet loading on precipitator (rag/Nm ) 300
Exit - leading on precipitator (mg/Nm ) 88 at 7% CC>2
3
Legislative requirement (mg/Nm ) 100 at 7% CC>2
Scrubber (yes of no) No
Inlet loading:
H Cl (mg/Nm3)
H F (mg/Nm3)
Exit loading:
H Cl (mg/NM3)
H F (mg/Nm3)
3
Legislative requirements (mg/Nm )
Other air pollution control equipment (yes or no) Duray Dr 280
Water:
Total volume of waste water (liters/hr)
Ash:
Volume of ash (tonnes/day) 40
Volume of metal recovered (tonnes/day) ^
-------
DEVELOPMENT OF THE SYSTEM
As the waste disposal problem evolved in this area, three of the
larger communitiesBuchs, Switzerland and Vaduz and Shann (in Liechtenstein)
began discussions of possible solutions. Because some years ago composting
plants were in vogue in Switzerland, they decided to build one in Werdenberg.
It cost about 1,000,000 S.Fr. (then about $250,000) and began operation in
January, 1962. But gradually the plant became too small for the amount of
waste being generated so Incinerator I (without heat recovery) started
operation in January, 1968. It cost about 2.5 million S.Fr. However, waste
generation continued to increase at the rate of 20 percent per year and in
mid-1969, it was decided that Incinerator I was too small. Accordingly, in
1970, the local Vereins fur Abfallbeseitigung (Society for Waste Management)
invited proposals for a new incinerator, a waste-to-energy plant.
In December, 1971, the proposal of Widmer + Ernst was accepted and
in January, 1972, construction began adjacent to the old incinerator and
compost plants (see Figure 1-1). The plant was built in about 28 months and
operation began in April, 1974. It was dedicated on November 22, 1974 and
provisional acceptance was made in July, 1975. Operation continued after
the dedication while adjustments were made to firing rate and to component
operation. The plant was accepted November 1, 1975.
COMMUNITY DESCRIPTION
Geography
This relatively new and colorful plant named Werdenberg-Liechtenstein
is located on the Werdenberger Binnenkanal (Inland Canal) paralleling the
Rhine River on the border between eastern Switzerland and Liechtenstein.
(See Figure 1 -la) Actually the plant is located in the city of Buchs, Switzer-
land. The name "Werdenberg" comes from a very small neighborhood that is at
the inside edge of Buchs. The region's area is roughly 900 square kilometers
(345.3 square miles).
-------
Service area in the
Canton of St.
Location of Plant
FIGURE l-
r GENERATION AREA SHOWING THE SERVICE AREAS IN THE
CANTON OF ST. GALLEN AND IN LIECHTENSTEIN
-------
2a.
1 Truck scale
2 Tipping area
3 Waste pit
4 Air-cooled condenser
5 Furnace room
6 Steel chimney
7 Central control room
8 Feedwater treatment
9 Waste storage
10 Old incinerator
11 Service building
12 Offices and locker rooms
FIGURE 1-1. PLAN OF WERDENBERG PLANT SHOWING RELATION TO
TO ASSOCIATED COMMUNITY SERVICE FACILITIES
(COURTESY OF WIDMER & ERNST. ALBERTI FONSAR)
-------
The setting and terrain are most picturesque. The plant is set
on the flat bottoms of the Rhine Valley and nestled between snow capped
mountains. (See Figure 2.) Being so close to the canal did present founda-
tion problems and additional costs were incurred.
Buchs itself had a 1970 census population of 8,570 while the total
waste generating region had 76,685 inhabitants. After the Swiss referendum
in 1975 loosely labeled, "Swiss for the Swiss", the population declined as
Mediterrenean workers returned to their native lands. The population in
1977 is likely equal to or less than the 1970 figures.
The community population is somewhat seasonal with more people
during the winter skiing and summer vacation seasons.
Government and Industry
The government and industry employment sectors are stable with
respect to growth.
In this region of two countries and 28 cities,, there are 17
Switzerland counties and 11 Liechtenstein counties. All of the Swiss
counties are within the Canton (state) of St. Gallen.
The industrial base is varied with the following composition:
International headquarters for Hilti fastening
systems (metal and explosives) [in the past,
Hilti sent sintered magnesium pellets to the
plant.]
Hoval household boilers
Textile manufactures (trimmings)
Carpet manufactures (trimmings)
-------
FIGURE 1-2. PROFILE OF PLANT SURROUNDED BY MOUNTAINS
Werdenberg-Liechtenstein Plant
(Courtesy of Widmer + (Ernst (Alfrerti-Fonsar))
-------
Screen printing firm
Plastic tape manufacturer (plastic trimmings)
Leather shoe manufacturer (leather trimmings)
Petroleum storage
Fruit preserves processing plant (large tin cans)
SOLID WASTE PRACTICES
Solid Waste Generation
Figure 3 presents the annual pattern from 1962 to 1973 for animal,
bulky scrap iron, industrial, household and total waste collected. The rise from
4,000 tonnes (4409 tons) in 1962 to 24,000 tonnes (26,455 tons) in 1973 must be
interpreted carefully. First, these are collection rates and not generation
rates. In other words, there are fewer people throwing refuse over the hill
and more providing their waste to collectors. Secondly, the Society for
Refuse Management has been expanding its geographic territory as more
communities decide to join.
Table 1 displays the collection of various types of wastes by the
communities and their respective populations. These 76,685 people had 26,190
tonnes collected during 1976 for an average generation/collection rate of
342 kilograms per person per year (754 pounds per person per year).
The seasonal pattern shown in Table 2 depicts a 11.7% 1975 to 1976
rise in household waste collections versus a 2.8% decline in industrial
collections for an overall increase of 7.3%. The rise in household collections
came about because more communities have recently been added. The fall in
industrial pickups coincides with the European and especially the Swiss
recession. Neither an influx of people nor increased waste generation rates
could have contributed to the dramatic increase in household collections.
A recent national report presented composition as had been measured
as Thun, Switzerland in 1975. See Table 3.
-------
Animal waste
Bulky scrap iron (white goods)
Industrial waste
Household waste
Total
1962 1963
1964
1965 1966
1967 1968
1969
1970 1971
1972 1973
FIGURE 1-3. SOLID WASTE COLLECTION RATES
Werdenberg-Liechtenstein Plant
Courtesy of Widmer & Ernst (Alberti-Fonsar)
-------
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-------
TABLE 1-2. DELIVERIES IN EACH MONTH IN 1976 AND TOTALS FOR 1975 AND 1976
(FROM PLANT ANNUAL REPORT)
Month
Januar
Februar
Marz
April
Mai
Juni
Juli
August
September
Oktober
November
Dez ember
Total
1975
Difference
% + -
Maximum Month:
Maximum Day:
Household
Waste
1561440
1384744
1822910
2070220
1757510
2088730
2056470
1979360
1936810
2020540
1858180
1716660
22,253,574
19,921,940
+2,331,634
+11.7%
April 2357,
Wednesday,
Bulky
Waste
14920
16850
32450
21370
14300
17010
30500
17290
16930
29780
19310
8440
239,150*
469,130
-229,980
-96.1%
298 kilogram
7, April = 160
Industrial
Waste
215090
515946
244410
237805
265385
233230
225680
234290
265560
244960
252610
240280
3,175,246
3,234,702
-89456
-2.8%
,000 kilogram.
Animal
Waste
24750
25375
28935
26713
25560
29170
29085
26025
28125
37890
32795
36001
350,424
455,417
-104993
-29.9%
Total
Waste
1816200
1942915
2128705
2356108
2062755
2368140
2341735
2256965
2247425
2333170
2162895
2001381
26,018,394
24,111,189
+1,907,205
+7.3%
* This total for bulky waste includes only that for private haulers. Since 1976
all bulky waste delivered is combined in a single total.
-------
TABLE 1-3. REFUSE COMPOSITION AT THUN, 1975
Paper 39.66%
Glass 8.31%
Ceramic 1.23%
Metal 4.80%
Wood 5.51%
Textiles, Leather,
Rubber 6,04%
Plastics 6,57%
Kitchen waste 8,96%
Garden waste 13.42%
Misc. 5.50%
(From Wohin mit den Abfalien?" Zurich,
November 1976)
-------
10
Solid Waste Collection Activities
Throughout the region, trucks of various sizes and descriptions
collect waste material. The Society for Refuse Management licenses four
private companies to collect waste materials from households. The eight (8)
trucks owned by these four firms make two to four trips per day. Truck sizes
3 3
range from 12 to 15m (15.7 to 19.6 yards ). In addition, there are a few
commercial private haulers and several industrial companies with their own
trucks. Most "Crews work 8 hours per day - 5 days per week.
Three of the collection firms are paid by the Society and one is
paid by his local community. All are paid on a price per ton basis as
weighed at the plant scales.
Costs are distributed back to the communities based on a careful
accounting of where the waste comes from. Fees have been relatively constant
over the last three to four years.
Each household pays taxes to his respective community. As an
example, the plant manager pays 90 Swiss francs ($36) per year for his 0.5 to 0.7
tonnes generated.
Moisture ranges from 25% to 40% with 35% being average. During the
compliance test, the lower heating value was measured at 3,200 Kcal/kg
(5,760 Btu/pound)[13,398 k Joules/kg] by using the refuse fired steam
generator as a calorimeter. They now believe that the lower heating value
is ranging from 2,300 to 3,360 kcal/kg (4,140 to 6,048 Btu/pound)[ 9,628 to
14,068 k Joules/kg].
Solid Waste Transfer and/or Pretreatment
There are no transfer stations or pretreatment facilities. However,
there are some shopping center-type recycling centers where people can bring
newspapers, bottles, and cans. Color-sorted glass can be sold for 60 SF per
tonne ($26.40 per ton) while noncolor sorted glass can be sold at 40 SR per
tonne ($17.60 per ton).
-------
11
Solid Waste Disposal
This refuse fired steam generating building has, standing next to
it, a separate composting building. For several years back in the 1960's,
the national trend was to construct compost plants and also incinerators
for waste material from the composting operation. At one time there were
15 to 19 such combination facilities in Switzerland. Rarely now is the local
composting equipment run. Only nine are now operating in combination in
Switzerland. There is only one pure composting facility now in the country.
The National Report, "Wohin mit den abtailen" shows the 1975
national pattern for solid waste disposal. See Figure 5 and Table 4.
REFUSE-FIRED STEAM GENERATOR EQUIPMENT
As has been described in previous sections, the combination of
community and industrial wastes is delivered 5 days per week by eight regular
trucks plus a few private ones. Incoming trucks are weighed on an 30-ton
semi-automatic weigh scale which is operated by a plant worker who devotes
about 1/4 time to weighing. The scale operator can barely be seen (Figure 5)
as the third man at the rear of the control room. The weights, total and tare,
are printed by an electro-mechanical recorder with digital readout. The scale
is inspected, calibrated and serviced once per year. It is expected to last
more than 20 years. Figure 6 shows a truck-delivering refuse.
Figure 7 is an overall section inside of the Werdenberg plant.
There is no provision for processing bulky waste. The crane
operator is instructed to crush bulky items (up to 2m by 2m) in the pit by
dropping the 3-ton grapple on the object. Large metal objects are lifted
out and set aside for recycling which, in 1976, totalled 172 tonnes.
After each truck driver delivers a load to the pit he is expected
to sweep up his dumping area. There are four doors to the pit but only one
is used. If necessary, emergency refuse storage is available in the pits
at the old compost plant next door.
-------
12
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13
TABLE 1-4. REFUSE UTILIZATION IN SWITZERLAND IN 1975
(From "Wohin mit den Abfalien", Zurich, Nov. 1976)
Facilities
42 (65%) Incinerators
10 (15%) Combined
Burning
Composting
Plants
1 ( 2%) Compost Plant
11 (17%) Controlled
Landfills
64 (100%)
total
Type
13 (20%)With HR 1)
29 (45%) Without HR
6(9%) With HR
4(6%) Without HR
1(2%) Only Compost
Population
Served
2'560'720
1'236'733
498'750
362 '000
21-000
673 '667
5'352'870
%
39,8
19,2
7,8
5,6
0,3
10,5
83,2
Refuse
Tonnes
805'380
335M04
131'916
96'912
5 '882
194 '564
1' 570 '058
1
%.
43,8
18,2
7,2
5,3
0,3
10,6
85,4
? Uncontrolled Dumps
TOTAL
1'076'530
2)
6'429'400
16,8
100,0
269'132
1' 839 '190
14,6
100,0
1) HR = Heat recovery
2) Included is the the Principality of Liechtenstein with its population of
24,000
-------
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-------
14
FIGURE 1-6. TRUCK DELIVERING TO REFUSE BUNKER,
(COURTESY OF WIDMER & ERNST-ALBERTI-FONSAR)
-------
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-------
16
3 3
The main plant pit is 1300 m (1690 yd ) when filled level with
the tripping floor. It is 20m long, 8.5m deep and 7.5m wide (65.6 ft by 27.9 ft by
24.6 ft). It is estimated to hold 600 tonnes (545 tons) at a compressed and
3 3
settled density of 0.462 tonnes/m (645 Ib/yd ). If fire breaks out in the
pit it can be controlled by overhead sprinklers.
There are 2 Von Roll bridge cranes of 5 tonne capacity but only one
is needed. A clamshell type of bucket on each crane can lift 1/2 to 1 tonne
at a grab 2 m3 (2.62 yd^). The weight of a bucket load can be determined
from the current consumed by the caBle motor when the bucket is being lifted
at a constant rate of speed. The corresponding weight can be read by the crane
operator sitting in the control room.
The pit and crane operation is considered a very important facet of
good plant operation to assure steady feed and good mixing of refuse which
aids furnace operation.
There were problems due to inexperience during startup. If the
crane cables were not kept in tension they would jump the pulleys on the
bucket. With careful operation the cables last 2 months. With unskilled
operation they last 2 weeks. About 2 hours are required to repair broken
cables.
This plant is unusual in that the plant control room also contains
the crane operator's perch high on one side of the pit. The. room is air
conditioned. The crane is semi-automatic in that after the bucket is loaded
the crane lifts and positions it over the furnace hopper.
Furnace Hopper and Feeder
The single furnace hopper is 4m by 4m (13.1 ft by 13.1 ft) an(j the
feed chute is 2.5m by 1.2m (8.2 ft by 3.9 ft). The chute is insulated but un-
cooled. The lower portion of the chute near the furnace is low alloy steel
to reduce deterioration from high temperature. An insulated cover can be
placed over the hopper top to stop burnback if it occurs.
The single-level, ram-type inclined feeder is hydraulically driven
by a Vickers drive. It feeds intermittently about 12 strokes per hour which
-------
17
is about half the frequency of the reciprocating grate sections. The feed
is manually controlled from the control room. A spare hydraulic drive is
available. No repairs have been needed in 3 years.
Burning Grate
The Alberti-Fonsar GMP-7 stepped grate is in 7 sections which pro-
vides an average fuel bed slope of about 24 . It was fabricated in Italy by
the Fonderie e'Officine di Saronne S.p.A. using a grate material which is
25-30% chromium, 4% nickel, with some manganese and silicon. Figure 8 shows
that the grate is made up of steps which alternately are fixed and recipro-
cating. The reciprocating parts have a maximum stroke of 380mm (15 in) with
the normal stroke being 350mm (14 in) which occurs about once every 2 minutes.
As the upper step moves forward it tends to tumble the burning refuse downward
to the next step, thus providing gentle agitation. Grate temperature can be
monitored by the control room operator from indicators connected to three
thermocouples located under the grate, near the middle of the grate surface
and on a fixed grate section.
The grate sections were guaranteed for 16 months. No grate parts
have been replaced in 3 years. The manufacturer expects the grate to last
5 to 10 years. Some problem has been encountered with pluggage of the air
holes in the grate by fused aluminum and plastics. When this happens,
workmen wearing heavy wetted asbestos suits enter the partially cooled
chamber to remove or punch through the fused material in the grate holes.
Analysis of a sample of the grate residue resulted in a carbon
content of 2.21 percent. This residue is dropped when hot from the end
of the grate into a large concrete quench tank which appears as a shallow
slag basin in the lower part of Figure 7. At the deepest point, the water
in the basin is 1.7 m (5.57 ft) deep. Residues from the precipitator
and boiler passes are also dropped into this tank. The quenched residue
settles to the bottom of the tank from which it is removed continuously by
a 12 m (39 ft) drag-chain conveyor which, in turn, discharges the wet
material to two rubber belt conveyors in series which deliver it to a
three sided waste area on the ground floor.
-------
18
FIGURE 1-8. AN EXAMPLE OF THE ALBERTI-FONSAR STEP GRATE SYSTEM ASSEMBLED
AT THE FACTORY (Courtesy of Widmer * Ernst - Alberti-Fonsar)
-------
19
The manufacturer believes that they have since evolved a much
better quench-tank removal device involving a piston-driven swing gate
which tends to compress the residue as it lifts it much more nearly
vertically out of a much smaller, curved-bottom steel tank. As a result,
the discharged residue is said to have only 28 percent moisture as against
40 percent from the system at this plant. The newer system also costs less
and produces less waste water. The power consumption of the slow chain
is low; the two-motor drive totals only 8 kw, but 4 kw is now seen to have
been sufficient. However, corrosion of the chain is expected to entail
high maintenance. There is no provision to recover scrap metal from
the residue.
The wet residue which is discharged by the conveyor to the "ash
floor" is lifted by a front-end loader to a truck which carries to approx-
imately 3 km (1.9 mi) to a mountainside quarry. Occasionally the piles
are leveled with a scraper. There is no daily cover, no lining to capture
leachate and no final cover. The plant is charged only 0.50 S.Fr.
($0.20) per ton of ash residue. This landfill (doponie*) is estimated to
last 5 years.
In 1976 this plant burned 26, 191 tonnes (5.5 tons) in 4740
hours of operation, an average rate of 132.6 tonnes/day (146 tons/day).
*deponieFrench for landfill.
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20
Furnace Wall (Combustion and
First Pass Radiation Chambers)
The water-tube walled portion of the furnace, is shown in Figure
9, an open vertical passage approximately 3 m by 3.5 m (10 ft by 12 ft,
approximately) in cross section and approximately llm (35 ft) tall. Its
volume is approximately 110 m3 (3,884 ft"3). It is located directly above the
furnace and is intended to provide travel time for final burnout of the
furnace gases while allowing for radiant cooling of the gases and their
entrained dust load. In this way, partial cooling is achieved without
opportunity for obstructional deposition of hot, sticky fly ash. Ash
deposition will occur on the water-tube walls but not to the extent that
the deposit can become a major resistance to gas flow. These deposits
are removed from the water walls by manually scraping every 5,000 hours.
At the same time, the convection passes are washed.
The wall tubes are made of #35 carbon steel, 76.1mm (3.0 in)
diameter, 4mm (0.16 in) thick, spaced on 78 mm (3.1 in) centers. Thus, the
tubes are nearly touching but are not connected together by welded fins as is
done in man-% other modern plants. This tall vertical water-tube wall passage
and the main combustion furnace are both covered on the outside with 150 to
250mm (6 tc 10 in) thick high temperature insulation consisting primarily of
calcium reinforced with asbestos fibers.
The sides of the furnace are composed of two different surfaces.
Near to the grate and for about 1.5m (4 ft) above the grate the wall is
formed with about 85 air-cooled cast iron blocks made by Kunstler (Zurich)
on each side which allow a small amount of cooling air to enter the furnace
through small holes in the iron blocks and through narrow air gaps between
adjacent blocks. The blocks are about 250mm (10 in) tall and 200mm (8.5 in)
wide. Above the cast iron blocks, the furnace wall is formed by Plibrico
Super AB plastic refractory 150mm (6 in) thick backed up by 250mm '10 in)
high-temperature calcium silicate insulation.
-------
21
1 Delivery Area
2 Bunker Door
3 Refuse Bunker
4 Crane Pulpit
5 Crane
6 Refuse Grab Bucket
7 Charging Hopper
8 Incinerator Furnace
9 Step Grate
10 Ash Hopper
11 Residue Chute
12 Residue Basin
13 Residue Conveyor Belt
14 Steam Boiler
15 Air Cooled Condenser
16 Electrostatic Precipitator
17 Exhaust Gas Fan
18 Steel Chimney
19 Hot Water Heater
20 Feed Water Tank
21 Turbogenerator
22 Collected Flyash Conveyor
23 Feedwater and Heating Water
Pumps
24 Oil-Fired Stand-by Boiler
FIGURE 1-9 . SECTION THROUGH WERDENBERGrLIECHTENSTEIN WASTE-TO-ENERGY
PLANT, COURTESY WIDMER + ERNST (ALBERTI-FONSAR)
-------
22
Thus, the lower quarter of the main furnace sidewalls are cooled
only by forced air flowing behind and through the wall blocks, but the front
and rear wall of that chamber are cooled by water-wall tubes similar to the
arrangement in the large, vertical open pass above the furnace. In the
"rear wall" which actually is a rear "arch" which slopes a little more
steeply than the sloping grate, there are 40 tubes closely spaced over the
width of the furnace. The W + E engineer stated that the temperature
in the furnace is 950 C (1742 F).
This sloping rear roof is studded with 8mm (0.3 in) diameter studs,
22mm (0.9 in) long. There are about 1000 studs per square meter. These tubes
and studs are then coated with a 25mm (1 in) thick coating of Plibrico Super
AB plastic refractory. In the newer plants, 40mm thick Plibrico coating is
used. This thick coating reduces the heat absorption by the covered tubes but
is a protection against corrosion. It has been very successful here and
elsewhere. Apparently the decision to increase the refractory coating
thickness from 25mm (1 in) as used here up to 40mm (1.6 in) in newer plants
was made in order to increase the life of the coating, as this coating is
subject to deterioration from cracking as it heats and cools. In addition,
the coating is mechanically eroded and spalled by the action of heavy deposits
of fused ash which adhere to the coating then break off or are broken off
during periodic cleaning. As portions of the coating are broken away,
patching is required to maintain protection of the tubes. Apparently a
thicker coating reduces the frequency of patching required.
Welded studs and refractory coating are also utilized over the
entire lower half of the vertical, water-tube walled boiler pass immediately
above the furnace. This very common design of coating was applied after
corrosion was experienced in 1970 in a similar furnace at Baden-Brugg, which
required protection after only 2000-3000 hours operation.
The steam generating surface of the boiler is stated by the
2 2
manufacturer to be 835 m (8988 ft ).
-------
23
Second Boiler Pass
When the upward-flowing gases reach the top of the first water-tube
walled gas passage they then are turned horizontally into the entrance of a
second water-tube walled vertical pass (see Figure 9) in which the gases
are further cooled as they flow downward. These water tubes have no studs
nor coating as by this time the gases are cooled to about 650C (1203F) and
corrosion and erosion are thus no threat to water tubes.
Superheater
The partially cooled gases leaving the bottom of the second open
boiler pass then make a 180 turn and, flowing upward, enter the first bank
of horizontal steam tubes of the 2-section superheater. Final steam tem-
perature control is achieved by a spray-type attemperator between the 2 super-
heater sections.
In each row of superheater tubes there are 32 tubes. Each tube has
a 33.7mm (1.33 in) diameter and a wall thickness of 4mm (0.16 in). The
tube material in the first section is 14% chromium, 3% molybdenum and in the
second section 0.14% plain carbon steel. The spacing of the tubes horizontally
and vertically is 100mm on centers. The gas flow pattern is straight upward
through the bank as the tubes are in line and not staggered. The design
temperature for the gas entering the first superheater section is 650C (1203F).
The temperature leaving the second section is 520C (968F) .
A single cascade of falling steel shot once an hour cleans the
economizer and superheater. The top row of superheater tubes is protected
by steel shields from the impact of the falling shot. Every 5,000 hours the
economizer and superheater are cleaned by washing by a German company that
specializes in boiler cleaning.
In future designs the manufacturer favors more gas space between
the superheater tubes. They also believe that shot cleaning is preferable to
soot blowing.
The manufacturer expects that the first (bottom) row of superheater
tubes may need replacement every 10,000 to 11,000 hours owing to erosion or
corrosion or a combination of both.
-------
24
Boiler (Convection Section)
The water tube boiler is a natural circulation type built by
Alberti-Fonsar under the Eckrohr Kessel patents of Dr. Vorkauf of Berlin.
Steam capacity is 12 tonne per hour (26,460 Ib/hr) with peak capacity to 16
tonnes per hour (35,275 Ib/hr) at 40 bar (566 psia) [390 KPA ] and
395C (743F). The overall height of the boiler is approximately 18m (59 ft).
Its width is 3.7m (12 ft) and its depth from the front water wall to the rear
of the convection sections is approximately 6.2m (20.3 ft).
Temperatures are measured continuously for feedwater temperature,
economizer water outlet temperature and saturated and superheated stream tem-
peratures. These are all recorded on strip charts in the control room.
Boiler control is automatic from steam pressure but can be over-
ridden by a control element that senses overheating of the gases leaving
the furnace.
The responsible boiler operator must have a certificate of the
Federal Boiler Association which normally can be obtained after 1 year
experience plus part time schooling.
Reliability of this relatively new plant was stated to be 100
percent except for scheduled shutdowns. No major repairs have yet been
required and at least 20 year life is expected. Amortization period of
20 years is common in Switzerland.
In 1974-75, the new plant was operated at an excessive rate for only 3
or 4 days per week. The remainder of the excessive demand time, steam was
supplied by the oil-fired standby boiler. Design heat input is 14 x 10 kcal/
6 9
hr (55 xlO Btu/hr)[58.5 x 10 J/hr]. However, the actual input ranged up
to 17-18 x 106 kcal/hr (71.4 x 106 Btu/hr)[75.3 x 109 J/hr] amounting to a
20% to 29% overload. Formal warning to the owner by the manufacturer of the
possible deleterious consequences of such overloading led to subsequent
operation at more nearly normal loading. At the time of our visit, May 2-4,
1977, there appeared to have been no permanent damage resulting from the
period of overloading. However, at the end of the first 11,000 hours of
operation the first row (bottom) of horizontal superheater tubes had to be
replaced because of erosion. This could very well have been a direct result
of overfiring the system.
-------
25
On April 1, 1977 the Swiss organization of pressure vessel inspectors
issued a report on their inspection of this boiler. They reported the boiler
in good condition with some dirty surfaces but no unusual tube wastage. Some
steel supports in the superheater section showed some corrosion.
The manufacturer feels that the trend will be toward horizontal configura-
tion of vertical tubes in the convection section with periodic rapping to remove ash
deposits. To minimize danger of tube metal fatigue the amplitude of rapping
would be 0.5mm (0.02 in) with emphasis on rapid acceleration by the rapper
rather than on amplitude to dislodge the deposits.
Economizer
The economizer, see Figure 9 is located near the top of the boiler
in this third pass and consists of vertical carbon steel tubes providing a heating
2 2
surface of 165m (1,775 ft ). The 2 economizer sections are approximately 2.6mm
high, 0.9m deep and 3.2m wide (8.5 ft by 3 ft by lOtt) . So far the economizer has
required no maintenance. Cleaning is achieved by the gravity fall of a shower of
steel shot which intermittently is delivered to a distributor at the top
of the economizer from which it falls by gravity through the gas passages
in the economizer and in the superheater. The falling steel shot cleans
deposited ash from the tubes and carries it down to an ash separation system
where it is removed from the shot and is transported to be mixed in with the
grate residue. The cleaned shot is then conveyed pneumatically to the top
of the economizer to repeat the cycle. The shot cleaning process operates
about 4 minutes every hour.
Boiler Water Treatment
Feedwater is treated by ion exchange plus hydrazine to the following
specifications:
ph 7-8.5 (measured continuously)
Hydrazine <0.25 mg/liter
SiO <0.3 mg/liter
Conductivity >0.08 megohms (measured continuously)
Fe <0.05 mg/liter
Cu <0.01 mg/liter
Hardness <0.01 milli equivalent/liter.
-------
26
Primary (Underfire) Air Supply
*
The combustion air to the grate is supplied by one BSH blower
rated at 170 mm (6.7 in)WC static pressure, 194 mm (7.6 in)WC total pressure.
This air supply is taken from the refuse bunker area and is divided into
three approximately equal grate zones, each controlled by a manually set
damper adjustable from the control room. At the plant owner's request,
provisions were included to measure air flow and pressure to each zone.
3
The rated blower capacity is 32,000 m /hr (18,816 cfm).
Other than minor startup problems caused by the motor-blower
coupling, there have been no maintenance problems. The manufacturer antic-
ipates that in very dusty plants, blade deposits may induce unbalance and
vibrations which could require annual bearing replacement. In 3 years of
operation, this has not happened in this very clean plant. At earlier
plants, such unbalancing dust deposits were eliminated by changing fan
blade shape to a less efficient design which dropped blower efficiency
from about 79 or 80 percent to 75 percent.
Secondary (Overfire) Air Supply
The overfire air supply is also taken from the bunker area. Blower
capacity is 13,500 m3/hr ( 7940 cfm) at 20 C (68 F), at a static pressure of
350mm (13.8 in), total pressure of 385mm (15 in).
As is shown in Figure 10 and diagramatically in Figure 11, there are
two sets of overfire jets in each sidewall. The upper row of six jets on
each side consists of 60mm (2.36 in) diameter jets in a horizontal row about
5 m (16.4 ft) above the grate to provide air and turbulent mixing where the
burning gases pass upward from the top of the furnace combustion chamber
to the first open boiler pass. The lower row of 12 jets on each sidewall are
about 1.8m (5.9 ft) above the grate and along an inclined line parallel to the
grate. The air flow to the jets is modulated automatically according to
furnace outlet temperature by a motor operated valve. A high temperature
calls for more air to dilute and thus cool the gases.
* BSH = Buttner-Schilde-Haas
-------
27
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29
The manufacturer states that they prefer front and top (or rear)
wall jets over this sidewall jet arrangement and their future designs will
not use sidewall jets. The advantages seen for frontwall jets are:
Better mixing
Better air distribution in the furnace
Shorter flame length
Less carbon monoxide.
Tertiary (Sidewall) Air Supply
In addition to the overfire air, tertiary air is supplied near the
grate through Kilnstier cast iron blocks in both sidewalls as shown schematically
in Figure 11. This air serves both to cool the cast iron blocks and to pro-
vide an upward flowing layer of combustion air along the sidewalls for any
rich gases that may be burning there. The air comes not from the bunker
but from the furnace room. The forced air is supplied to the back
or "outside" of the blocks and flows in a generally downward direction behind
a steel baffle and then upward until it finds its way into the furnace through
the gaps around the periphery of each block. A constant flow of tertiary
air is supplied to the blocks by a separately unmodulated blower rated at
3
12,900m /hr (7600 cfm) at 20 C at a static pressure of 180mm (7.1 in)WC, total
pressure of 190mm (7.5 in)WC. The 85 cast iron wall blocks on each sidewall are
made of 27-30 percent chromium, 0.53 percent nickel, with small amounts of
titanium and molybdenum.
An alarm is sounded in the control room if the temperature of a
thermocouple on one of the blocks exceeds a set value of (300 C) (527 F).
This temperature and that of the steel structure nearby to the plate are both
recorded in the control room. At this small plant, no wall blocks have been
replaced during the 3 years of operation. Some abrasion of the blocks has
been noted where the burning refuse slides along the blocks. So far, the
eroded area appears to have lost 1 to 3mm of iron.
It can be seen that the total capacity of secondary plus tertiary
o
air is 26,400 m /hr, nearly as great as the 32,000 nrVhr available as
primary air. However, not all of this capacity is used. The operator is
instructed to regulate the overfire air supply to maintain a furnace exit
-------
30
CO of about 9 or 10 percent. This is in the range of 120 percent excess
air. From a heat recovery standpoint, it would be desirable to have the
excess air much less but this manufacturer's experience apparently is that
the higher temperatures associated with lower excess air causes metal wastage
problems.
The induced draft fan has caused some concern because of vibrations
caused either by the belt drive or by resonance in the duct system. It has
not been worsening. In other plants, this is sometimes caused by buildup
of fly ash on the fan blades. The fan is inspected once in month but has
required no maintenance except possibly replacement of a drive belt.
-------
31
Heat Release Rate
This plant is conservatively designed from the standpoint of grate
size, furnace size and boiler size. This can be judged from the following
tabulation of heat release rates:
Combustion rate
Grate Area (sloped)
Grate burning rate
At an average LHV of
the total heat released is
with grate release rates equivalent to
or
Furnace heat release
rate considering only
the volume from the
grate up to the entrance
to the silicon-carbide coated
water-tube-walled first pass:
volume
0)
120 tonnes/day
5 tonnes/hr
5.115 tons/hr
5,000 kg/hr
11,023 Ib/hr
17.5m2 (2.5 x 7.
188.A ft2
285.7 Kg/m?'-hr
58.611b/ft'2-hr
2800 Kcal/kg
14 x 10b Kcal/hr
800,000 Kcal/miT-hr
295,000 Btu/ft -hr
115.65m;:
4084 ft 3
121,055 Kcal/m -hr
13,603 Btu/ft -hr
If the SIC refractory lined water-
tube-walled volume of the first
pass is included as part of the
burning volume, an additional
26.4m , total
the heat release rate is
142m .
5014 ft
98,591 Kcal/m^-hr
11,080 Btu/ft -hr
These are all low heat release rates.
-------
32
Energy Utilization Equipment
This small 120 ton per day plant produces the most complex
assortment of energy forms, considering the plant size, that the researchers
have seen in their travels. Most of these forms can be understood by
reviewing Figure 12. These seven forms and uses are listed in order of
energy magnitude.
o Hot water for district heating
o Steam for industrial process
o Electricity for the community
o Electricity for internal use
o Steam wasted on the roof
o Steam for internal use
o Hot water for internal use
When more energy is needed than the RFSG can produce, the auxiliary
standby steam boiler shown in Figure 13 can be used.
A back-pressure steam turbine-generator, shown in Figure 14 is
used to produce two energy forms: electricity and medium quality steam. A
small back-pressure turbo-generator has a maximum electricity generating
capacity of 0.85 mw at 10 kv. Inlet pressure is 39 bar (551 psig) [8.2 x 106 Pa]
and temperature is 395 C (741 F). Outlet pressure is 6 bar (72.5 psig)
[1.05 x 106 Pa] and temperature is 250 C (482 F). The back pressure varies
between 5.5 and 12 bar. Excess steam is condensed in a forced draft air-
cooled, roof-top condenser as shown in Figure 15.
The 250 C, 6 bar exhaust steam from the turbine is cooled to
160 C, 6 bar by direct water spray and is then piped to a nearby chemical
plant which returns the condensate at 5 bar with little loss. Figure 16 Shows
the steam distribution and condensate return tunnel*
Hot water for district heating is produced in a steam-to-hot water
heat exchanger as shown in Figure 17. Hot water at 6 bar (85 psia) and a
temperature of 110-150 C (230-302 F) is delivered to the chemical plant and also
to an apartment complex involving 300 units. Figures 18 and 19 show the
district heating system under construction, the distribution pattern and
the hot water distribution and return time and the apartment building.
-------
Hochdruckdampf 39 bar, 395 C
Sattdampf
90-100°C
Heisswasservorlauf 110-180°C
ll. Refuse-fired steam generator
12. Oil-fired boiler
(3. High-pressure fe^dwater turbo-pump
J4. High-pressure feedwater motorized pump
p. Mid-pressure feedwater motorized pump
|6. Turbine steam by-pass
I?. Synchronons turbognenrator, 950 Kva
Steam temperature regulator
19. Feedwater tank and deaerator
10. Air-cooled condenser
11. Condensate pump
12. Steam-to-water cascade
13. Hot water district heating pump
14. Heat exchange for plant heating
15. District heating system
16. Feedwater treatment facility
17. Makeup water tank and pumps
18. Industry steam supply line
FIGURE 1-12.
WERDENBERG STEAM AND HOT-WATER DISTRIBUTION SYSTEM
(COURTESY WIDMER & ERNST, ALBERTI-FONSAR)
-------
34
FIGURE 1-13.
OIL-FIRED STANDBY BOILER ON TRANSPORT TRUCK
(COURTESY OF WIDMER & ERNST-ALBERTI-FONSAR)
-------
35
FIGURE 1-14. STEAM TURBO-GENERATOR (COURTESY OF WIDMER & ERNST-ALBERTI-FONSAR)
-------
36
FIGURE 1-15.
TWO VIEWS OF AIR-COOLED CONDENSER AT WERDENBERG
(COURTESY OF WIDMER & ERNST -ALBERTI-FONSAR)
-------
37
Grade level
Coarse
sand fill
Drainage
channel
Optional J
drainage zone:
Gravel bed
Retainer slab
4ft
FIGURE 1-16.
STEAM AND HOT WATER DISTRIBUTION TRENCH AT WERDENBERG
(COURTESY OF WIDMER & ERNST-ALBERTI-FONSAR)
-------
38
FIGURE 1-17.
CASCADE TYPE WATER HEATER ON LEFT, FEEDWATER
TANK AND STEAM LINES ON RIGHT AT WERDENBERG
(COURTESY OF WIDMER & ERNST-ALBERTI-FONSAR)
-------
39
FIGURE 1-18.
INSULATION, INSTALLATION AND MAP OF HOT WATER DISTRIBUTION
SYSTEM AT WERDENBERG (Courtesy of Buchswerdenberg Society
for Waste Management)
-------
40
FIGURE 1-19.
APARTMENT HOUSE AT WERDENBERG HEATED BY HOT WATER FROM STEAM PLANT
(COURTESY OF WIDMER & ERNST-ALBERTI-FONSAR)
-------
41
The total length of the distribution system is 2-1/2 km (1.5 mi). An addi-
tional 0.8 km (0.5 mi) pipeline will be added to provide heat for the railroad
station. Other buildings may be included. Where the hot water is utilized
for comfort heating, each building has a water-to-water heat exchanger to
provide 80 C (176 F) water for the building heating system.
POLLUTION CONTROL EQUIPMENT
During our 3-day visit to the plant, there was no visible plume
most of the time and even when visible, it was only barely so against a
very clean sky. The sole pollution control at this small plant is a single-
field electrostatic precipitator by Elex. Without the hopper it is 9.3 m
high, 5.7 m wide, and 5.9 m deep. It has a flow rate of 83,000 m /hr at
274 C. Average velocity is 0.67 m/sec (2.2 ft/sec). The gas composition
and dewpoint at the precipitator during the compliance test was:
C02 - 5.4 percent
H20 - 13.5 percent
Dewpoint - 51 C (124 F).
3 3
Particulates are now limited to 100 mg/Nm (0.0438 grains/ft ) corrected
to 7% C00. When this plant was designed, the allowable limit was
3 33
150 mg/Nm . When tested, it achieved 88 mg/Nm (0.038 grains/ft ) corrected
to 7% C02. Bypassing of precipitators has not been permitted since 1972.
In Switzerland, waste-burning plants are limited to gaseous
emissions of:
S02 - 300 mg/Nm3
HC1 - 500 mg/Nm3.
The precipitator and its duct configuration were tested beforehand
by Elex in a small water model to assure a uniform flow pattern. To
distribute the gas flow ahead of the charging section, there are three
perforated plates in series containing 5 cm holes. The spacing of the
collector plates is about 300 mm (11.8 in) providing 17 parallel flow passages.
Residence time is 5.9 sec. Total plate area is 1,142 m2 (12,288 ft2) with a
9 3
projected area of 952 m^ (10,243 f t ). The plates are cleaned intermittently
by a bottom rapper. The charging electrodes are cleaned by a rapper at
the top.
-------
42
Power consumption is 29 kw at 380 volts. Output capacity is 47.5 KVA
at 78,000 volts and 600 ma.
The fly ash hoppers are approximately 50 degree inverted pyramids
electrically heated and covered with 10 cm (4 in.) of insulation. The
collected ash is removed continuously by screw conveyors which discharge
into the main residue quench tank.
The precipitator was guaranteed to achieve 97.5 percent efficiency
and to emit no more than 100 mg/Nm^, wet gas corrected to 7 percent C02«
It achieved better than that: 88 mg/Nm^, wet at 7 percent C02-
So far, the precipitator has needed no repairs. It is cleaned
once per year when the boiler is cleaned. For personnel protection, the
access doors cannot be opened before an 8-multiple key sequence is processed.
To achieve even lower particulate emissions from future plants,
the manufacturer is considering the use of two-field precipitators.
Wastewater Discharge
The wastewater rate from the residue quench tank is about 200
liters/hr (0.9 gpm). System blowdown rate is 160 liters/hr (0.7 gpm). The liquid
discharge from the feedwater treatment system is neutralized before discharge.
All of these waste liquids plus washroom wastes go to the adjacent sewage
treatment plant.
Stack Construction
At the customer's request, the 1.3 m dia (4.3 ft) insulated steel
stack is only 40 m (131 ft) tall, 12 m (39.4 ft) above the plant roof. Most
of the steel stack is carbon steel. The top 4 meters (13.1 ft) and the bottom
0.5 meters (1.6 ft) are stainless steel. It was fabricated by Lufttechnik +
Metallbau, subsidiary of Widmer + Ernst. Flue gases from the oil-fired stand-
by boiler are fed into the stack just above the roof. At roof-level, a
continuous opacity meter manufactured by Durug (Hamburg) measures flue
gas opacity which is recorded in the control room.
-------
43
POLLUTION CONTROL ASSESSMENT
Although the overall appearance of Swiss cities and countryside
is immaculate, this low environmental pollution level is achieved by a minimum
of necessary regulation. New regulations are implemented with cautious
deliberation. On the other hand, old regulations are tightened where
economically and technologically feasible. For example, in recent years,
the particulate emission limit to the atmosphere of 150 mg/Nm^ corrected to
7 percent C02 has been dropped to 100. This is equivalent to 0.0438 gr/scf or
0.083 Ib per 1,000 Ib gas. For 5,000 Btu/lb refuse (2778 Kcal/kg) this
amounts to about 0.18 lb/10 Btu input (320 g/10 Kcal) [76.4 g/GJ].
Similarly, a Swiss survey of municipal refuse shows that 50 percent
of the refuse averages about 6 kg/tonne of HC1 and that 95 percent of the
refuse burned has less than 15 kg/tonne. Potentially, this higher value could
result in about 1,700 mg/Nm3 (1.4 lb/1000 Ib) being discharged to the
atmosphere. Actually, an unknown amount will stay in the furnace, precip-
itator, and residue so probably less than 1,000 mg/Nm^ (0.8 lb/1000 Ib gas)
is emitted. The fact that scrubbers to remove HC1 from the hot gases have
not been well developed and no deleterious atmospheric concentrations of HC1
have been observed leads the government to caution in regulation of this
emission. On the other hand, since HC1 emissions are obviously undesirable,
there has been a 3-4 year effort to encourage the substitution of innocuous
plastics for PVC in the Swiss economy. This still leaves the normal sodium
chloride in refuse which constitutes about half of the total
amount of chlorine in refuse.
If eventually scrubbers to remove HC1 become necessary, the regu-
latory staff is well aware of their disadvantages:
Scrubber sludge
Additional cost
Corrosion
Visible wet plume
Acid wastewater
Efficiency on fine particulates often low.
Hence, the Swiss concensus is not to require scrubbers unless HC1 removal is
proven highly necessary. Meanwhile, the PVC content of municipal refuse is being
monitored and each plant will be tested for HCl emission about every 2 years.
-------
44
Noises
This plant, along the inland canal is surrounded by industry
and cultivated fields, is remote from human habitations and noise has been
no problem. According to Swiss regulations, no plant can emit at its
boundary noise exceeding:
55 db (A) at night
65 db (A) in the day
75 db (A) peaks.
PERSONNEL AND MANAGEMENT
Seventy six (76) delegates are chosen (one for each 1000 inhabitants)
to represent them on the Verein fur Abfallbeseitigung (Society for Refuse)
Management). These 76 delegates elect an operating Board of Directors.
The Board of Directors hires the Plant Manager, who in turn, hires the
remainder of the staff.
This plant operates 5 days per week with only two operators on each
of four shifts plus a weigh-scale operator in the day shift and the Plant
Manager, Robert Giger and his assistant. In addition to the refuse fired
steam generator building activity, the two managers are responsible for the
compost plant and the separate Incinerator I - now the community's pathological
incinerator.
Figure 11 shows the organization for the RFSG only. During weekends,
when only the standby oil boiler is fired, one of the shift bosses must be
ready to respond to an automatic alarm in his home. In other words, the
plant produces hot water, steam, and electricity continuously on weekends -
but with no personnel routinely on duty.
Approximate monthly take-home pay is as follows:
General Manager - 3500 SwFr ($1400)
Shift Boss - 2600 SwFr ($1040)
Crane Operator - 2500 SwFr ($1000).
j Scale operator - 2200 SwFr
-------
45
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-------
46
Vacations are given in accordance with age as follows:
Age under 45-3 weeks
Age 45-50 - 4 weeks
Age 5CH- - 5 weeks.
The shift boss is expected to have a Federal license as a mechanic
or electromechanic.
ENERGY MARKETING
The plant General Manager handles all energy sales. Steam and
hot water prices are set so as to compete with the rising cost of fuel oil.
At the time of our visit (May 2-3, 1977), No. 2 oil in Switzerland cost
approximately 0.30 SF/liter ($0.45/gal) or the equivalent of 375 SF/tonne
($167.91/ton). The plant sells hot water at 20 SF/Gcal which is 56 percent
of the cost of No. 2 fuel oix burned at 90 percent overall efficiency.
ECONOMICS
Capital Investment
The capital investment expenditures were available only in gross
form as shown below:
Refuse fired generator building and 13,000,000 SF ($5,200,000)
contents
Office and workshop-separate 1,000,000 SF ($400,000)
building and contents
Hot water distribution system 3,500,000 SF ($1,400,000)
Steam distribution system to 500,000 SF ($200,000)
chemical plant
Fortunately, the 1976 annual expenditures were available in
detail as shown in Table 6.
-------
47
Revenues
The most consistent picture can be seen in the 1977 estimate of
revenues as shown in Table 7. The revenue budget has been set lower than
1976 due to expected lower costs. This table of revenues showing the 12
sources of annual revenues dramatically portrays the revenue raising potential
for a single 120 tonne per day refuse fired steam generator with a standby
oil boiler. Since the RFSG plant only operates 5 days per week, the standby
oil boiler is regularly used. The reader is again reminded that these
revenues are for the total four-building complex. Dump fees for animal waste
and from sale of compost are the only revenues not tied to the RFSG.
Even in winter there are times when some steam must
be condensed, which also consumes electricity for driving the con-
denser fan. In 1978 the heating system was to be extended which
will increase revenues with same increase in amortization.
-------
48
TABLE 1-5. WERDENBERG PLANT COSTS, 1976
Swiss Francs
Expense
Revenue
Operating Expense
Capital Costs
Maintenance and Repair
Building Maintenance
Equipment Maintenance
Compost Facilities
Refuse Burning Plant
Animal Incineration
District Heating Lines
Tools and Furniture
Trax (?)
TOTAL
Depreciation
Insurance
Supplies
Electricity
Miscellaneous Supplies
Diesel Oil
Heating Oil and Gas
Cleaning Materials
Lubricants
Chemicals
TOTAL
Administration
Landfill and Hauling
Front-end loader, rental
Truck rental
Scrap Iron Disposal
Gretschans Landfill
Buchserbert Landfill
TOTAL
Miscellaneous Expense
Special Expense
Canal Connection
General Fees
Sale of Compost
Sale of Scrap Iron
Used Oil Processing
Sale of Heat
Sale of Electricity
SUBTOTALS
BALANCE
BUDGET PLANNING
TOTAL
60,223.60
81,626.07
5,178.20
5,633.35
1,481.50
96,582.15
131.20
96.00
218.80
6.008.50
115,379.70
1,685,998.15
85,795.00
58,711.30
8,386.35
4,426.65
235,171.35
1,461.00
2,310.30
3,734.00
314,700.95
13,330.20
45,360.50
2,275.00
81,354.75
128,314.85
5,219.10
80,103.95
3,832,691.57
578.65
3,833,070.22
244.45
430.95
3,384,848.75
467.80
9,555.10
27,208.77
346,401.45
60.297.25
3,828,779.12
4,291.10
3,833,070.22
-------
49
TABLE 1-6. REVENUE ESTIMATE FOR 1977
Charge
Annual
Revenue Category Volume
Old
(S.Fr.)
New
(S.Fr.)
New
Revenue
(S.Fr.)
Dump Fee Household & Bulky
Waste
Dump Fee, Industrial Waste
Dump Fee, Animal Waste
Dump Fee, Scrap Iron
Subsidized Head Tax
Sale of Compost (1976 data)
Sale of Scrap Iron
Sale of Waste Oil
Sale of Warm Water (District
Heating
Sale of Steam (Chemical Industry
Process Steam)
Sale of Electricity (1/2)
Internal Credit for Electricity
(1/2)
TOTAL REVENUES
20,000 Tonnes
3,000
300
150
76,685
Tonnes
Tonnes
Tonnes
People
90 80 1,600,000
120 100 300,000
150 150 45,000
200 200 30,000
12 10 766,850
468
5,000
25,000
} 320,000
} 50,000
3,142,318
Werdenberg-Liechtenstein Plant, Courtesy of the Society for Refuse Disposal,
1976 Annual Report, Widmer + Ernst (Alberti-Fonsar)
-------
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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
1950
1951
1952
1953
1954
1955
1956
1957
1958
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
6.891
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
Deutsch 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
Kronor
(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
4.285
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, Mo. 4, Published by the International Monetary Fund.
ycr 18286
U S. GOVERNMENT PRINTING OFFICE 1979 u20-007/6313
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