United States Office of Water and SW 176C.7
Environmental Protection Waste Management October 1979
Agency Washington, D.C. 20460
Solid Waste
vEPA European Refuse Fired
Energy Systems
Evaluation of Design Practices
Volume 7
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Pfiz.pubtLcjnuU.OYi 444ue ^on. EPA
and State. Sotid Wo&ie Management
EUROPEAN REFUSE FIRED ENERGY SYSTEMS
EVALUATION OF DESIGN PRACTICES
Uppsala Plant
Sweden
Tkii> fup lepoit (SW-776c.7) deicixcb&s wonk
the, 0 £ face. o£ Solid WaAte. undeA contract no. 68-01-4376
and -u> ie,psioduc.e.d 06 fie.ceA.ve.d fafiom the.
The & AhouJLd be attfu.bate.d to the
and not to the O^ice o& SoLid
Copies will be available from the
National Technical Information Service
U.S. Department of Commerce
Springfield, VA 22161
Volume 7
U.S. Environmental Protection ^
Region V, Library
230 South Daarbern Street
11033:), lllir.jis 606Q4
U.S. ENVIRONMENTAL PROTECTION AGENCY
1979
-------
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
view and policies of the U.S. Environmental Protection Agency, nor does
mention of commercial products constitute endorsement by the U.S.
Government. - v «,
" vf:\'-$*
• 'St-
An environmental protection publication (SW-176c.7) in the solid waste
management series.
UA Environment Protection /
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TRIP REPORT
to
UPPSALA PLANT, SWEDEN
on the contract
EVALUATION OF EUROPEAN REFUSE-FIRED
STEAM GENERATION DESIGN PRACTICES
to
U.S. ENVIRONMENTAL PROTECTION AGENCY
May 3, 1978
EPA Contract Number: 68-01-4376
EPA RFP Number: WA-76-B146
by
Richard B. Engdahl and Philip R. Beltz
BATTELLE
Columbus Laboratories
505 King Avenue
Columbus, Ohio 43201
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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.
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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
LIST OF PERSONS CONTACTED 1
UPPSALA STATISTICAL SUMMARY 2
SUMMARY 5
COMMUNITY DESCRIPTION 6
Industry 8
SOLID WASTE PRACTICES 9
Solid Waste Generation 9
Solid Waste Collection 9
Solid Waste Disposal 10
DEVELOPMENT OF THE SYSTEM 12
PLANT ARCHITECTURE 14
REFUSE-FIRED STEAM GENERATOR 17
Refuse Storage and Retrieval 17
Heat Input 25
Furnace Hopper 25
Burning Grate in Furnace No. 4 25
Furnace Wall 29
Heat Release Rate 34
Boiler 38
Primary Air 40
Secondary Air 40
Auxiliary Incinerators 40
ENERGY UTILIZATION 43
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TABLE OF CONTENTS
(Continued)
Page
POLLUTION CONTROL EQUIPMENT 47
Residue Disposal 47
Chimney 54
POLLUTION CONTROL ASSESSMENT 56
EQUIPMENT PERFORMANCE ASSESSMENT 58
PERSONNEL AND MANAGEMENT 61
ENERGY MARKETING 62
ECONOMICS 66
Operating Costs 66
Revenues 67
FINANCE 71
APPENDIX A
Pulverizing Plant for Construction and Industrial Waste
at Uppsala A-l
LIST OF TABLES
Table 12-1. Performance Test Data on Precipitator No. 2 Serving
Furnace No. 4 48
Table 12-2. Results of Gaseous Emission Measurements From
Original Three Furnaces at Uppsala 57
Table 12-3. Operating Data for the Uppsala Energy System for
1974 and 1975 59
Table 12-4. Typical Autumn Month Operation Data for Uppsala
Heat Power Company, October, 1977 64
Table 12-5. Comparison of Costs for Electricity and District
Heat for a Newly Built Residence Connected to
the Uppsala Kraftvarme AB 70
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LIST OF FIGURES
Page
Figure 12-1. Map of Hot-Water District Heating Network at
Uppsala Showing Three Main Heating Plants
and Two Small Isolated Plants
Figure 12-2. Weight of Refuse Received Annually at the
Bolanderna Plant 11
Figure 12-3. District Heating and Incineration Plant at
Bolanderna 15
Figure 12-4. Plan of Bolanderna Facility for District Heating
and Solid Waste Burning 16
Figure 12-5. Truck Entrance Ramp to Uppsala 18
Figure 12-6. Arrangement of Uppsala Plant 19
Figure 12-7. Scissors-Type Hydraulically Driver Shear Adjacent
to Hopper 4 20
Figure 12-8. Safety Railings Around Tipping Chutes 22
Figure 12-9. Arrangement of Components of Bolanderna
Incinerator Plant 23
Figure 12-10. Partial Section of Uppsala Plant Showing in
Upper Left the Scissors Type Shear for Bulky
Refuse, the Hydraulic Pump Room, Control Room
for Furnace No. 4, and Afterfurnace Chamber 24
Figure 12-11. Cross Section of Furnace No. 4 and Boiler No. 3
at Uppsala 26
Figure 12-12. Empty Feed Hopper Showing Line of Flame Beneath
Double Flap Doors at Uppsala 27
Figure 12-13. Sketches of Grate Action 28
Figure 12-14. Bruun and Sorensen Cast Alloy Grate Bars 30
Figure 12-15. Furnace Bottom Ash Chute Discharging Into Ash
Vibrating Steel Conveyor at Uppsala 31
Figure 12-16. Interior of Furnace No. 4 Before Firing 33
Figure 12-17. Inside of Older Two-Grate Furnace at Uppsala 35
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LIST OF FIGURES
Page
Figure 12-18. Older Furnace Looking Toward the Feed Chute
and Drying Grate at Uppsala 36
Figure 12-19. Rear of Furnace No. 2 at Uppsala 37
Figure 12-20. Shot Pellet Cleaning Feed System at Uppsala 39
Figure 12-21. Auxiliary Waste Incinerators at Uppsala 41
Figure 12-22. Auxiliary Incinerator Building in Foreground
Showing Round Horizontal Duct Which Conveys
the Exhaust Gases to Boiler No. 3 for
Heat Recovery 42
Figure 12-23. Control Panel in the Oil-Fired District Heating
Plant at Bolanderna, Uppsala 44
Figure 12-24. Control Panel for Bolanderna Furnace No. 4,
Uppsala 45
Figure 12-25. Installation in Uppsala of Roadway Tubing
System for Snow Melting 46
Figure 12-26. Electrostatic Precipitators Retrofitted for
Units //I and //2 Outside at Uppsala 49
Figure 12-27. Ducts Leading to Base of Ten Flue Chimney at
Uppsala 50
Figure 12-28. Vibrating Steel Conveyor Dumping Bottom and
Fly Ash Into Container at Uppsala 51
Figure 12-29. Precipitators at Uppsala and Long Horizontal
Ducts Leading to the Base of the Multiflue
Chimney 52
Figure 12-30. Detachable Ash Hoppers on Automatic Roller
System at Uppsala 53
Figure 12-31. Chimney Tube Arrangement at Uppsala 55
Figure 12-32. Schematic of Uppsala Heating System 63
Figure 12-33. Installation of Hot Water Distribution Piping 65
Figure 12-34. Past and Predicted Trend of Net Operating
Cost of Refuse Burning Plant After Credit
is Taken for the Value of Heating Recovered 68
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LIST OF PERSONS CONTACTED
Niels T. Hoist
Bengt Hogberg
S. A. Alexandersson
Hans Nordstrom
Hans Nyman
Karl-EricBerg
Hans Nomann
Hans Sabel
Bruun and Sorensen A/S
The Waste Treatment Department
Aaboulevarden 22
8000
Aarhus C, Denmark
Telephone: (06) 12 42 33
Telex: 6-45 92
Bruun and Sorensen A/S
Stockholm Representative
Bruun and Sorensen A/S
Manager, Waste Treatment Dept.
Uppsala Plant Engineer
Uppsa? a Kraftvarme AB
Sopfor braenningsanlaggningen
Bolandsverket
Bolandsgatan
Box 125
S-7510U
Uppsala, Sweden
Telephone: (018) 15 22 20
Uppsala Chief Engineer
Uppsala Works Engineer
Uppsala Managing Director
Uppsala Works Director
The authors wish to express our sincere thanks to these
representatives for their very skilled assistance and kind hospitality.
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UPPSALA STATISTICAL SUMMARY
Community Description:
Area (square kilometers)
Population (number of people)
Key terrain feature
200
150,000
Rolling
Solid Waste Practices:
Total waste generated (tonnes/year) (1975)
Waste generation rate (kg/person/day)
Lower heating value of waste (Kcal/kg) (estimated)
Collection period (days/week)
Cost of collection (local currency/tonne)
Use of transfer and/or pretreatment
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)
86,355
1.5
5
10 Skr
No
No
Development of the System:
Date operation began (year)
1951
Plant Architecture:
Material of exterior construction
Stack height (meters)
Brick
100
Refuse-Fired Steam Generator Equipment:
Mass burning (yes or no)
Waste conditions into feed chute:
Moisture (percent)
Lower heating value (Kcal/kg) (estimated)
Volume burned:
Capacity per furnace (tonnes/day)
Yes
2,450
84,84,108
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Number of furnaces constructed 4
Capacity per system (tonnes/day) (maximum) 348
Actual per furnace (tonnes/day) 50
Number of furnaces normally operating 3
Actual per system (tonnes/day) 200
Use auxiliary reduction equipment (yes or no) Yes
Pit capacity level full:
(tonnes) 360
(m3) 2400
Crane capacity (2):
(tonnes) 0.6
(m3) 4
Drive method for feeding grate No feeder
Burning grate (Unit No. H only):
Manufacturer Bruun and Sorensen
Type Sectional, rocking
Number of sections 3
Length overall (m) 8.1
Width overall (m) 2
Primary air-max (Nm /hr) ?
Secondary air-overfire air-max (Nm /hr) ?
Furnace volume (m ) 50
Furnace wall tube diameter (cm) None
2
Furnace heating surface (m ) None
Auxiliary fuel capability (yes or no) No
Use of superheater (yes or no) No
Boiler:
Manufacturer Maskinverkin
Type (No. M Unit only) Nat. cir. water tube
Number of boiler passes 1
Steam production per boiler (kg/hr) 15,000
Total plant steam production (kg/hr) 10,000
Steam temperature ( C) 138
Steam pressure (bar) 15
Use of economizer (yes or no) No
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Use of air preheater (yes or no) No
Use of flue gas reheater (yes or no) No
Cofire (fuel or waste) input No
Use of electricity generator (yes or no) • No
Energy Utilization:
Medium of energy transfer Hot water
Temperature of medium (°C) 120
Population receiving energy (number)
2
Pressure of medium (kg/m )
Return temperature ( C) 70
Pollution Control:
Air:
Furnace exit conditions:
Gas flow rate (Nnr/hr)
Furnace exit loading (mg/Nm") 15 to 38
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SUMMARY
Until 1959, there was very little district heating in Uppsala, a
city of 150,000, and no recovery from wastes. Then in 1960, the mayor and
city council decided to build two large oil-fired district heating loops
and a waste-to-energy plant to supply steam to generate hot water for a
part of the demand. The first waste-burning boilers and furnaces began
operating in 1961, with a burning capacity of 6 tonnes/hr (6.6 tons/hr).
Two more furnaces were added in 1965 and 1971. About 50,000 tonnes are
burned per year. A new remote pulverizing station and landfill handles
industrial waste.
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COMMUNITY DESCRIPTION
The city, which is over 1,000 years old with a population of
about 150,000, stands 75 km C45 mi) northwest of Stockholm on a plain
which is estimated to have been under shallow water as recently as 3,000
to 4,000 years ago as an aftermath of the Ice Age. The community has a
long history of being in the forefront of knowledge. The University was
500 years old in 1977. Scheele discovered oxygen and chlorine there about
200 years ago. Linnaeus did most of his pioneering botanical research
there.
Until 1863, Uppsala was a small town dominated by craft guilds
which prevented growth and there was much poverty and unemployment. But in
1863, new Swedish laws ended the dominance of the craft guilds and the
principle of free trade was established by law. The city then began to
grow rapidly. The Uppsala City Council met for the first time in January,
1863. At the same time, municipal government began for 48 small
neighboring communities. The last consolidation was in 1971 when seven
rural districts joined. These together now (1978) form the municipality of
Uppsala. There are 81 councillors, elected every 3 years. Nearly 2,000
citizens are on municipal boards and committees, and the city employs
10,000 people. The official city brochure* declares: "This story of the
development of city government over the last 100 years is also the story
of the rise of democracy in Swedish society and its development into a
welfare state".
Figure 12-1 shows the Uppsala District Heating Network.
* Uppsala, published by the City of Uppsala (1977).
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Gamla Uppsala
,
Nyby
Husbyborgsverket
Haga
District Heating
\ Power Generation
\ and Waste Burning
Plant at Bolanderna
Gottsunda
FIGURE 12-1. MAP OF HOT-WATER DISTRICT HEATING NETWORK AT UPPSALA SHOWING
THREE MAIN HEATING PLANTS AND TWO SMALL ISOLATED PLANTS
(COURTESY UPPSALA KRAFTVARME AB)
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Industry
The service sector dominates Uppsala's industry and comprises 6?
percent of the total employment. The largest industry,
Volvo-Bagslogsverken, produces auto parts and outboard motors.
Portia-Pharmacia, the refuse plant's largest steam customer, has 1,250
employees and sends blood plasma substitutes worldwide. One quarter of the
industrial employment is in workshop industries in graphics, food
processing, wood, and cement products. Much active research is evolving
new products.
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SOLID WASTE PRACTICES
Solid Waste Generatipn
In 19751 the waste-burning plant received 51,355 tonnes (56,490
tons) of household and commercial waste. Since the Fall of 1972,
industrial wastes have gone to the new Hovgarden Pulverizing Plant and
sanitary landfill. Prior to then, such wastes were sent to several old
landfills. The annual tonnage of such wastes was about 35,000 tonnes
(38,500 tons) per year. This is expected to increase at the rate of 3 to 4
percent per year.
Discussions have been had with the cities of Enkoping, 30 km (18
mi) away, and Sigtuna, 20 km (12 mi) about possibly processing their waste
at the Uppsala facilities.
Papermills in the vicinity are recycling some waste paper but at
present, they have reached their limit in the amount they can use and the
excess comes to the Bolanderna plant for burning.
Solid Waste Collection
The city street administration operates approximately 25
collection vehicles of 2 to 3 tonne capacity each which collect 5 days per
week, once per week from each residence. Plastic bags are used which are
generally deposited by the householder beneath some shelter to minimize
moisture pickup. The trucks operate from 6:30 a.m. to 3:00 p.m. although
their routes are generally completed by 1:00 p.m. The plant receives about
200 tonnes (220 tons) per day.
The total refuse to the plant of 51,355 tonnes (56,490 tons) in
1975 plus approximately 35,000 tonnes of industrial waste pulverized for
the Hovgarden landfill, or a total of 86,355 tonnes (94,990 tons) in 1975.
This amounts to 236 tonnes/day (260 tons/day). For the population of about
150,000, this is 1.5 kg/person/day (3-37 lb/person/day).
Very little industrial waste is received at the Bolanderna plant
as normally it goes to the pulverizer at Hovgarden. A bulky waste shear
installed in 1970 will be described later.
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10
Figure 12-2 shows the trend of annual waste input to the plant
since 1969, when the input was only about 38,000 tonnes (41,800 tons). In
1974, it was 50,878 and in 1975, 51,355 tonnes (56,490 tons). There has
been some discussion of bringing in more industrial waste after it is
first pulverized at Hovgarden. Also, there have been some discussions
toward receiving wastes from possible transfer stations at a number of
distant communities as much as 70 km (43 mi) away. If these additional
quantities are arranged, it is estimated tht 7-day, 24-hour operation
could nearly double the capacity of the present facility.
At present, the maximum radius of collection is 30 km (18 mi),
but about 90 percent of it is collected within a radius of 8 km (5 mi).
Solid Waste Disposal
The old landfills in the area are now being phased out and
industrial and noncombustible waste goes to the Hovgarden pulverizing
plant and landfill. The details of this site are described in an
attractive brochure which is included in Appendix A.
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11
tn
0)
c
c
o
so ooo-
45 000
•H
0)
u
0)
ft!
0)
£ 40 000
ft!
i
1969
1970
1971
1972
1973
1974
1975
1976
Year
FIGURE 12-2.
WEIGHT OF REFUSE RECEIVED ANNUALLY AT THE
BOLANDERNA PLANT (COURTESY OF UPPSALA
KRAFTVARME AB)
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12
DEVELOPMENT OF THE SYSTEM
The Uppsala waste-to-energy plant is a part of a much larger
environmental improvement and energy conservation program that was started
by the City Council in 1960. In that year, it was decided to construct a
plant for the production and distribution of district heat. The plans
included also a thermal power station, an installation for the production
of electrical and thermal energy, and a waste-to-energy plant.
The first delivery of heat was in August, 1961, from a portable
oil-fired boiler, and the first permanent hot water generator at the
Kvarngarde Plant began operating in September, 1962. Since then, expansion
has materialized into a larger oil-fired hot water station in the
Bolanderna Plant (built in three stages in 1965, 1968, and 1971) and into
a peak load plant in Husbyborg (1975). Certain areas are still taken care
of by portable oil-fired boilers until the expansion of the main network
to these areas can be economically justified.
In the waste incineration plant, which began operating at
Bolanderna in 1961, the steam produced is used to heat water for district
heating. The initial installation of two furnaces rated at 3 tonnes/hr and
supplying hot gas to two waste heat boilers was built in 1960 by
Kochum-Landsverk and began operation in 1961. A third similar but larger
(3-5 tonne/hr) was added in 1965- A fourth furnace system, burning 5
tonnes/hr and feeding a third boiler, began operation in 1970. This newer
installation built by Bruun and Sorensen is the principal subject of this
report.
Two smaller incinerators burn separately biological wastes and
contaminated dextrose solution from the Portia-Pharmacia plant. The hot
waste gases from the latter are mixed with those from the larger furnaces
ahead of the waste heat boilers. The useful thermal energy recovered from
all wastes, about 34 Gwhr* (thermal) (122,171 GJ) in 1975,'is only a small
part, 2.5 percent, of the total energy produced by the entire system,
1.373 Gwhr, but its recovery results in a much more acceptable solution to
the solid waste problem than the old landfills. Also, in the summer, a
major fraction of the hot-water needs of the community are met with energy
derived from the solid wastes.
* Gigawatt-hours equals 1 billion watt-hours.
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13
An added part of the environmental improvement program in 1971
was the Hovgarden pulverizing plant and fully controlled landfill which
could well serve as a model for future residue-disposal designs (see
Appendix A).
In the 1950's, at the site of the new pulverizing plant, there
was a compost plant. However, a market was not developed for the compost.
Hence, the decision was made in 1960 to burn the household wastes and
later, in 1970, to build the pulverizing plant for industrial wastes.
The waste-to-energy plant was designed by the engineering staff
of the Uppsala Thermal Power Company (Uppsala Kraftvarme AB). This is
unusual for Sweden where normally the city engages a consulting
engineering firm to design, purchase, and supervise construction.
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14
PLANT ARCHITECTURE
The Bolanderna incineration system is incorporated in the large
district heating plant at that site. Figure 12-3 shows the main brick
structure which is dominated by the unusual 100 m (328 ft) chimney
comprised of 10 separate flues serving the heating boilers, the four main
incinerators, and two small specialized waste incinerators without heat
direct recovery.
Figure 12-1 shows the plan of the Bolanderna facility. At the
lower part of the plan, Items 6, 1, and 8, are the incinerators. The
chimney, Item 5, is adjacent to the main power plant, Item 2; hence,
elevated duct work, not shown, conducts the incinerator exhaust gases to
the chimney, a distance of 160 m (100 ft).
The approach to the facility is dominated visually by the four
huge oil-storage tanks in a line parallel to the main highway. These tanks
reflect a system policy which is to maintain enough oil for a year's
heating operation. The daily expense of financing and operating this large
storage enters into the total operating cost of the district heating
system.
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15
Ten-Flue
Chimney
Electrical
Generating
Power Plant
Conventional Oil-Fired
Heating Plant
Tipping Floor
of Refuse
Burning Plant
FIGURE 12-3. DISTRICT HEATING AND INCINERATION PLANT AT BOLANDERNA
(COURTESY UPPSALA KRAFTVARME AB)
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16
1. Administration
Building
2. Power Plant
3. Condenser
4. Water Heating
5. Chimney
6. Waste-Burning
Plant
7. Biological Waste
Incinerator
8. Dextrose Waste
Incinerator
9. Waste Oil
Station
10. Oil Storage
Tanks
11. Entrance
12. Workshop
13. Service Building
14. Meat Processing
Plant
FIGURE 12-4.
PLAN OF BOLANDERNA FACILITY FOR DISTRICT
HEATING AND SOLID WASTE BURNING
(Courtesy Uppsala Kraftvarme AB)
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17
REFUSE-FIRED STEAM GENERATOR
Refuse delivered to the plant is weighed as the trucks arrive,
their weight and tare being recorded by means of plastic identification
cards issued to the drivers. The scale is sensitive to 20 kg (4U Ib). A
few trucks are weighed through manual operation of the scale. Some
difficulty with the weigh system was encountered at first because of the
weather effects on the recording system. The system was made by
Stathmos-Lindell.
The new tipping floor is elevated about 10 m (33 ft) above
ground level. Figure 12-5 shows the gently sloped helical ramp, installed
in 1971) outside the structure. The original tipping floor was near ground
level but was elevated to enable a larger bunker for greater storage
capacity.
Figure 12-6 shows the plant arrangement. The cranes and bunker
serve all four furnaces but only No. 4, the newest, the Bruun and Sorensen
furnace system, is shown in this figure.
Refuse Storage and Retrieval
The maximum refuse storage volume of the bunker is 2400m (3140
yd3). At a density of 15U kg/m3 (252 Ib/ft ), this represents a storage of
360 tonnes ( 396 tons), which is about one day supply if all four
furnaces operated at full rated capacity which is about 360 tonnes/day
(400 tons/day).
Figure 12-7 shows a scissors type of hydraulically driven shear
which is provided adjacent to hopper No. 4 for reduction of bulky refuse.
It is fed by the crane operator who also operates the shear by remote
control. As will be discussed later, the system fed by the fourth hopper
tends to receive more of the highly combustible refuse. The shear will
accept pieces up to 4 m (13 ft) across and reduces them to about 0.3 n (1
ft) pieces.
When the fourth boiler furnace system was added in 1971, a
second crane was added and a new crane control room was positioned near
the shear and between hoppers No. 3 and No. 4, shown earlier in Figure
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18
FIGURE 12-5.
TRUCK ENTRANCE RAMP TO UPPSALA. THIS WAS ADDED IN
1971 TO ENABLE OPERATION WITH A MUCH DEEPER BUNKER
WHICH MORE THAN DOUBLED REFUSE STORAGE CAPACITY
(BATTELLE PHOTOGRAPH)
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19
1. Crane and Bucket
2. Refuse Bunker
3. Crane Operator's Station
4. Furnace
5. Afterburner Chamber
6. Steam Boiler
7. Electrostatic Precipitator
8. Induced Draft Fan
9. Primary Air Zones
10. Residue Conveyor
11. Waste Oil Tank
FIGURE 12-6.
ARRANGEMENT OF UPPSALA PLANT
(COURTESY BRUUN AND SORENSEN)
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20
FIGURE 12-7.
SCISSORS-TYPE HYDRAULICALLY
DRIVEN SHEAR ADJACENT TO
HOPPER 4 (COURTESY OF
BRUUN AND SORENSEN)
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21
12-5, above the hopper. The crane bucket is positioned send-automatically
above any hopper selected by the crane operation.
Figure 12-8 shows safety railings at the tipping chute. A
portion of the bulky waste shear is in the background.
Figure 12-9 shows the component arrangement of the Uppsala
plant. The original three furnaces installed in 1960 are manifolded to
feed hot gas to either of two steam boilers. The fourth furnace, installed
in 1970, serves a third, larger boiler. The nominal capacities of the
components are as follows:
Furnace 1
Furnace 2
Furnace 3
Furnace 4
TOTAL REFUSE CAPACITY
tonnes/hr
3.0
3-0
3-5
5.0
tons/hr
3-3
3-3
3-9
5.5
tons/day
72
84
84
108
16.0
348
Boiler 1 10.0
Boiler 2 15-0
Boiler 3 15.0
TOTAL STEAM CAPACITY 40.0
11.0
16.5
16.5
44.0
88,000 Ib/hr
However, these total capacities are only ratings as the plant was not
intended to and never operates all components at full capacity. Usually
some components are down for service. The actual average plant burning
rate for 1976, 51,000 t/d was the equivalent of an average rate of about
200 tons/day based on a 5-day week. This is about 52 percent of rated
capacity.
Figure 12-10 shows a partial elevation of the new portion of the
plant added in 1971 •
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FIGURE 12-10.
PARTIAL SECTION OF UPPSALA PLANT SHOWING IN UPPER LEFT THE
SCISSORS TYPE SHEAR FOR BULKY REFUSE, THE HYDRAULIC PUMP
ROOM, CONTROL ROOM FOR FURNACE NO. 4, AND AFTERFURNACE
CHAMBER (COURTESY OF BRUUN & SORENSEN)
-------
25
Heat Input
No measurements of refuse heat value have been made for the
Uppsala plant. The design of the newer unit, No. 4, was based on a value
of 2,450 kcal/kg (4,410 Btu/lb) (13,257 kJ/kg). The original three
furnaces installed by Kockum-Landsverk in 1960 were based on a heat value
of 2,200 kcal/kg (3,960 Btu/lb) (9,211 kJ/kg).
Furnace Hopper
Figure 12-11 shows the Brunn and Sorensen installation. The
vertical outwardly tapered steel refuse chute feeds directly onto the
sloping grate without assistance by any feed mechanism except the feeding
action of the grate itself. For the first three furnaces built by
Kockum-Landsverk (now a part of Volund), the feed chutes are not provided
with dampers to control burnback. Instead, the height of the
gravity-packed refuse in the chute is depended upon as a seal. However,
with furnace No. 4 installed in 1970, the confinement of the existing roof
structure and the height of the top of the Brunn and Sorensen grate
imposed an upper limit on the length of the feed chute. Thus, to control
burnback in the chute, a double flap damper was installed. The operators
have had no problem with burnback.
Figure 12-12 shows a view into the empty hopper where a thin
line of flame is visible between the mating halves of the flap damper.
Burning Grate in Furnace No. 4
This plant does not use a refuse feeder to feed the refuse on to
the grate. This grate is a 30-degree sloping sectional grate depicted in
Figure 12-13- As shown in the lower three sketches of the figure, the
grate sections oscillate rotationally in a coordinated rocking motion such
that the burning refuse is induced to cascade downward along the sloping
grate in a wave-like motion, thus slowly agitating the fuel bed so as to
prevent compaction, voids, and consequent irregularity in air flow. The
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INCINERATOR
SYSTEM
FIGURE 12-13. SKETCHES OF GRATE ACTION
(COURTESY OF BRUUN AND
SORENSEN)
-------
29
motion of each grate section is controlled by an adjustable timer.
The moving part of the grate is formed of three sections with
six horizontal shafts in each section. The grate bars are fixed to the
shafts. Figure 12-14 shows two typical grate bars which are 0.5 m (1.6 ft)
long. The lower bar in the figure is 50 mm (2 in) wide. The upper one is a
new design of bar which is 100 mm (4 in) wide. Recent experience at
Horsens, Denmark with a test section of the newer bar revealed that fine
ash is less likely to adhere in the interstices between the bars; hence,
less cleaning is required to maintain the gaps free for uniform air flow.
New bars have been installed in all of the first grate section, and it is
planned to change also the other two grate sections. The new and old bars
are cast by a Swedish affiliate of Bruun and Sorensen using an alloy of 23
percent chromium, 1.5 percent silicon. 0.2 percent nickel, and 0.25
percent molybdenum. They are guaranteed for 10,000 hours.
The grate is 2 m (6.5 ft) wide and 8.1 m (26.6 ft) long with a
total area of 16.2 m2 (17*4.3 ft ) . At the rated capacity of 5 tonnes/hr
(5.5 tons/hr), this provides a burning rate of 308.6 kg/m /hr (63-1
o
Ib/ft /hr), a typical burning rate in many plants. However, this is only
an average, and since the plant does not operate at high rate at night,
peak burning rates probably are much higher.
The burned residue falls from the end of the grate into a
sprayed quench chute which drops it then onto a series of vibrating
conveyors shown in Figure 12-15-
No details were obtained on the grates in the three older
furnaces except that it was pointed out that the steel support members
between the grate steps are water cooled. This uses about 10,000 m /yr of
city water (3,002,600 gal/yr). Some of this water is then used for spray
quenching the grate residue.
The primary air supply to the first three furnaces is not zoned.
In the fourth furnace, there are three separate zones, manually adjustable.
Furnace Wall
As with many small refuse-fired furnaces, these four furnaces
are not water cooled. Their completely refractory construction has been
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FIGURE 12-15. FURNACE BOTTOM ASH CHUTE DISCHARGING INTO ASH VIBRATING
STEEL CONVEYOR AT UPPSALA (Battelle Photograph)
-------
32
satisfactory except for a major error in installation of too-widely spaced
support anchors in Furnace No. J», which has caused much breakage and some
occasional collapse of firebrick but has now been corrected. The revision
was partly at the owner's expense in the form of labor and partly at the
expense of Bruun and Sorensen for the new refractory and more closely-
spaced hangers.
Figure 12-16 shows the interior of the new No. U furnace and
grate before firing. The width of the furnace is 2 m (6.5 ft) and the
grate length, almost all of which is shown, is 8.1 m (16.6 ft). At the far
end of the photograph is the offset opening where the hot gases leave the
furnace at about 1,000 C (1,832 F) and make a tangential entry beyond into
the aftercombustion chamber. The height of the roof arch above the. lowest
end of the grate is approximately 6 m (19-7 ft). The volume of the furnace
is about 50 m (1,765 f t ) . The volume of the refractory-1ined
aftercombustion chamber is also 50 m (1,765 ft^). That chamber has an
internal diameter of 4.6 m (15 ft) and an external diameter of 5-3 m (17-4
ft). The gases leave the chamber at its top.
In Figure 12-16, immediately above the grate, is a very dark
wall area on both sides that consists of cast iron plates cooled only by
radiation and convection to the surroundings. These plates are used to
resist erosion by the motion of the burning refuse against the wall. The
cast iron surface extends upward about 500 mm (20 in) above the grate. For
community refuse, it has been Brunn and Sorensen's experience that air
cooling or water cooling of these plates are unnecessary. For furnaces
burning highly combustible industrial refuse, water cooling of the plates
is used.
Immediately above the cast iron wear plates in Figure 12-16 is a
narrow band of silicon carbide brick. These also resist erosion, will
stand much higher temperature than cast iron, and have the desirable
characteristic of resisting the adherence of molten slag.
The remainder of the furnace wall is built of Hoganas firebrick,
;
tradenamed "Krona", which is rated to withstand 1,600 C (2,912 F).
Originally, the first three furnaces were lined with "Chamotte" brick
which is a naturally occurring clay which becomes a high-grade refractory
when fired. However, it is expensive: 1^4 Skr/brick ($2.80 g 5 Skr/$). All
-------
33
FIGURE 12-16.
INTERIOR OF FURNACE NO.
A BEFORE FIRING
(COURTESY OF BRUUN
AND SORENSEN)
-------
34
four furnaces are now built of Krona, which costs about M Skr/brick
($0.80), The wall thickness for Furnaces 1 through 3 is 1-1/2 brick.
Furnace No. H is only one brick thick. This causes a higher rate of heat
loss which helps prolong the life of the refractory. Figure 12-17 shows a
view upward above the grate in Furnace No. 1. The slag adhering to the
wall does not accumulate to much greater thickness and is considered a
protection for the refractory.
Figure 12-18 shows a similar thin slag coating on the roof arch
in Furnace No. 1.
Similar slag deposits were observed in Furnace No. 1. At some
points, the deposit appeared to have been hot enough to flow down the wall
but no erosion nor massive slag buildup was evident.
There is no slag accumulation in the aftercombustion chamber
following Furnace No. iJ.
Heat Release Rate
In Furnace No. ^, the rated input of 5 tonnes/hr (5.5 tons/hr)
into 50 m (1,765 ft-) of furnace volume corresponds to a heat release
rate (at 2,450 kcal/kg) (^,H10 Btu/lb) of 2^5,000 kcal/m3/hr (27,49*4
Btu/ft3/hr) (1,025 kJ/m3/h''. This is a relatively high heat release rate
but there are three factors that mitigate its intensity: (1) part of the
burning and heat release occurs in the af tercombustion chamber, (2) the
relatively thin refractory wall helps to cool the furnace although, of
course, at a price in terms of energy efficiency, and (3) the furnace is
not operated steadily at rating. On the other hand, each time rating is
reached for a time and then burning is reduced, the refractory wall is
subject to considerable expansion and contraction. However, since the
early problem with inadequately spaced wall anchors was corrected, there
has been little wall maintenance required. The walls in the older three
furnaces are patched every 3 months and during the annual 2-week plant
maintenance period.
Figure 12-19 shows the exterior of Furnace No. 2.
-------
35
FIGURE 12-17. INSIDE OF OLDER TWO-GRATE FURNACE AT UPPSALA
(Battelle Photograph)
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Boiler
All three boilers serving the four furnaces are water-tube
boilers producing saturated steam at 15 bar (217.6 psia) (1,500 kPa).
Saturation temperature is 138 C (389 F). The first two boilers use forced
circulation. Boiler No. 3, built by Maskinverken, Kallhall, Sweden, under
a license from Combustion Engineering Co. of Windsor, Connecticut, U.S.A.,
uses natural circulation. The boiler capacities are:
tonne/hr Ib/hr
No. 1 10 22,000
No. 2 10 22,000
No. 3 .15 33,000
TOTAL 40 88,000
As seen earlier in Figure 12-9, the three boilers and four
furnaces are cross manifolded so that various combinations can be
operated. However, all three boilers and all four furnaces are rarely
operated all at the same time.
Boiler No. 3, the newest boiler, is formed of an outer enclosure
of wall tubes plus banks of horizontal convection tubes.
All three boilers are cleaned continuously by falling aluminum
pellets. Figure 12-20 shows a part of the pellet recirculation system. The
pellet storage bin holds 30 kg (66 Ib) of pellets. Owing to attrition,
about 15 kg (33 lt>) of pellets must be added per month. The melting point
of the pellets is about 750 C (1,382 F). The maximum gas temperature
entering the boiler is about 700 C (1,292 F). Incidentally, with 1,000 C
leaving the furnace and 700 C entering the boiler, this 300 C cooling
represents a substantial energy loss in passing through the
aftercombustion chamber but, at the same time, undoubtedly contributes to
the slag-free trouble-free operation of that chamber as a gas mixing,
burning, and dust removal device.
About every 3 weeks, it is necessary to clean dust accumulations
up to 50 mm (2 in) thick at the entrance to Boiler No. 3. The deposit is
-------
39
FIGURE 12-20. SHOT PELLET CLEANING FEED SYSTEM AT
UPPSALA (Battelle Photograph)
-------
40
easily brushed away and steam jets will be tried to remove it more easily.
No other boiler cleaning is required.
The boiler feedwater is treated and supplied from the main
oil-fired boiler plant.
The average steam production rate is 2.UM kg/kg refuse.
Primary Air
For Furnaces No. 1 through 3» there is a single primary air
zone. For Furnace No. 4, there are three zones.
Secondary Air
For all furnaces, the secondary air is supplied by the primary
air blower. In Furnaces No. 1 through 3> there is only one sidewall
secondary air port 250 by 500 mm (10 by 20 in) controlled manually as
needed!. In Furnace No. U, the secondary air is automatically regulated bya
smoke density meter.
Auxiliary Incinerators
Figure 12-21 shows the two small auxiliary incinerators at the
plant. The oil-fired pathological waste unit receives bags of waste fed
semi-automatically from a carrousel shown on top of the chamber. The
incinerator for contaminated liquid dextrose is an oil-fired horizontal,
refractory chamber. The exhaust gases from the dextrose unit are passed
through Boiler No. 3 for heat recovery.
Figure 12-22 shows, in the foreground, the building which houses
the dextrose incinerator. The horizontal, round duct above the building
conveys that incinerator's exhaust gases to Boiler No. 3 for heat recovery.
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41
FIGURE 12-21.
AUXILIARY WASTE INCINERATORS AT UPPSALA. THE TOP
PHOTOGRAPH SHOWS A PATHOLOGICAL WASTE INCINERATOR
WHICH RECEIVES BAGS OF WASTE FROM A CAROUSEL ON
TOP OF THE CHAMBER. THE LOWER PHOTOGRAPH SHOWS
THE HORIZONTAL OIL-FIRED INCINERATOR FOR CONTAMINATED
DEXTROSE (COURTESY UPPSALA KRAFTVARME AB)
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ENERGY UTILIZATION
About half of the energy from refuse is used as hot water in
district heating. The other half goes as 15 bar (217 psia) saturated steam
to 10 industrial customers. The largest of these is the Portia-Pharmacia
Plant which has 1,250 employees and uses about 30 tonnes (66,000 Ib/hr) of
steam/hour. The district hot water system receives water at 120 C (2*48 F)
and returns it at 70 C (158 F). Some of the return water serves as
condenser cooling water for the turbo-electric generators in the adjacent
oil-fired power plant.
Other steam customers are a meat packing factory, two bakeries,
and a laundry. About 75 percent of the residences in the dense part of
Uppsala are connected to the district heating system. It is hoped to
increase this to 95 percent by 1980. In 1975, the length of distribution
system was 160 km (100 mi).
Figure 12-23 shows the central panel in the oil-fired district
heating plant at the Bolander plant.
Figure 12-2M shows the control panel for the newest
incinerator—No. b.
Figure 12-25 shows the installation of heated water tubing for
snow melting at Uppsala.
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FIGURE 12-25.
INSTALLATION IN UPPSALA OF ROADWAY TUBING SYSTEM
FOR SNOW MELTING (COURTESY UPPSALA KRAFTVARME AB)
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47
POLLUTION CONTROL EQUIPMENT
Originally in 1962, this plant had only mechanical dust
collectors for air pollution control. Then at the time the fourth furnace
was installed in 1970, two electrostatic precipitators were installed
serving all furnaces, as seen earlier in Figure 12-7- An unusual feature
of Precipitator No. 1 serving Furnaces No. 1 through 3, is that it is
followed by a multiple cyclone dust collector because of concern that
large flakes of charred paper would escape the precipitator. There are 200
cyclones, each 200 mm (7-9 in) in diameter. However, similar cyclones were
not included in Precipitator No. 2 because the af tercombustion chamber
following No. i\ furnace usually breaks and burns any such large flakes
before they reach the precipitator.
Table 12-1 shows the results of performance tests on No. 2
precipitator in 1972. The resulting particle emission rate of 15 to 38
^ (0.0066 to 0.017 grains/scf) is well within the Swedish (Statens
Naturvardsverk) standard of 85 mg/Nm .
The second precipitator has required almost no maintenance. Only
one electrode has needed replacement in 5 years. There is some wet
corrosion of the steel expansion joints in the long duct leading outdoors
from the precipitators to the chimney. These joints have, therefeore, been
replaced by heavy-coated nylon fabric. However, in the precipitator
serving the first three boilers, 100 electrodes have been replaced since
1971 due to corrosion.
The dust hoppers are heated and when the system is no't
operating, a fan circulates air in the hoppers to prevent moisture buildup.
Figure 12-26 shows the exterior of Precipitator No. 1. Figure
12-27 shows the ducts leading the exhaust gases to the chimney.
Residue Disposal
Figure 12-28 shows the discharge end of the vibrating conveyor.
Figure 12-29 shows the precipitators and long horizontal ducts leading to
the base of the chimney. Figure 12-30 shows the detachable residue hoppers
on rollers for collection of the residue for truck disposal.
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48
TABLE 12-1. PERFORMANCE TEST DATA ON PRECIPITATOR
NO. 2 SERVING FURNACE NO. 4 (COURTESY
OF UPPSALA KRAFTVARME AB)
Date (1972)
Time of Day
Waste Burning Rate, kg/h
Steaming Rate, kg/h
3
Gas Flow Rate, Nm /sec
Gas Flow Rate, Nm /hr
Gas Flow Velocity, m/ sec
Gas Temperature in Precip. , C
Gas Temperature before Precip., C
Moisture, Volume Percent
Humidity, Percent
Dew Point, C
C09 Leaving Boiler, Percent
C0« Entering Precipitator , Percent
Draft After Boiler, mm Water
Damper Position, Percent
Precipitator Voltage, kv
2
Plate Current, mA/m
Primary Current, A
Dust Loading
Wet Gas, Entering, mg/Nm3
Wet Gas, Leaving, mg/Nm
Dry Gas, Entering, mg/Nm
3
Dry Gas, Leaving, mg/Nm
Collection Efficiency, Percent
Dust Collection Rate, kg/h
Test 1
8:08 a.m.-
9:41 a.m.
4,560
11,500
8.13
29,300
0.71
205
210
—
—
—
7.5
8.0
58
35
31.7
0.33
55.7
0.694
0.013
0.789
0.015
98.13
22.9
Test 2
11:00 a.m.-
1:46 p.m.
4,560
15,100
8.13
29,300
0.71
208
216
13
0.7
51
9.9-10.1
9.7
70
36
33.5
0.33
55.7
0.815
0.017
0.937
0.020
97.91
22.9
Test 3
2:51 p.m.-
4:30 p.m.
4,560
14,900
8.13
29,300
0.71
208
218
11
0.6
48
9.3-9.4
8.0
69
34
32.5
0.33
55.8
0.687
0.034
0.772
0.038
95.06
22.9
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49
FIGURE 12-26. ELECTROSTATIC PRECIPITATORS RETROFITTED FOR UNITS
#1 AND #2 OUTSIDE AT UPPSALA (Battelle Photograph)
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FIGURE 12-28.
VIBRATING STEEL CONVEYOR DUMPING BOTTOM AND FLY ASH
INTO CONTAINER AT UPPSALA (Battelle Photograph)
-------
52
FIGURE 12-29.
PRECIPITATORS AT UPPSALA AND LONG HORIZONTAL
DUCTS LEADING TO THE BASE OF THE MULTIFLUE
CHIMNEY (COURTESY UPPSALA KRAFTVARME AB)
-------
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The quenched residue is hauled ^. 4 km (7 mi) to the Hovgarden
landfill, which is described in Appendix A.
Chimney
Figure 12-2 earlier showed the unusual chimney 100 m (328 ft)
tall. It consists of 10 insulated, corten steel tubes supported from a
reinforced concrete framework. The flues serve many different boilers and
furnaces at the installation.
Figure 12-31 shows the cross-section of the flue arrangement
within the chimney. The base of the tubes are fastened to a concrete
platform 15 m (49 ft) above the ground. The tube stays connecting them to
the support frame utilize sliding joints to allow for thermal expansion.
The insulation on the tubes is 200 mm (7-9 in) thick encased in corrugated
aluminum.
So far, there has been little maintenance required. A crane at
the top enables a workman to be lowered inside idle tubes for inspection
and repair.
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55
SCALE
1:100
Flue
No. Facility Served
1 Power Boiler
2 Power Boiler
3 Spare
4 Heating Boiler 5 and 6
5 Heating Boiler 4
6 Heating Boiler 3
7&8 Heating Boiler 1 and 2
9 Steam Boiler
10 Refuse Boiler 1
11 Refuse Boiler 2
Internal
Diameter,
Meters
2.75
2.75
2.25
2.00
1.45
1.45
1.65
0.90
1.20
1.70
Dimensions of
Connected Duct
Width x Height,
Meters
2.2 x 3.6
2.2 x 3.6
.8 x 2.5
2 x
2 x
5 x
.8
.8
1.8
6 x 0.5
0.8 x 1.8
1.5 x 1.8
FIGURE 12-31.
CHIMNEY TUBE ARRANGEMENT AT UPPSALA (COURTESY
UPPSALA KRAFTVARME AB)
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56
• ' < V.\V ' '.' POLLUTION CONTROL ASSESSMENT' ' AV.
The exceptionally low emission measured from the precipitators
and the unusually thorough design of the Hovgarden shredder and landfill
described in Appendix A combine to make this an exemplary system
environmentally.
A new regulation of the national environmental control agency,
Statens N;Naturvardsverk jt (SNV), requires that any plant emitting more
than 40 mg/Nm of total acid equivalent must undertake studies to seek
feasible means for control. Th^ acid equivalent discharged at Uppsala
appears to be near to that upper limit. HC1 ranges from 14 to 79 mg/dry
Nm measured at 6.4 percent CO . This is much lower than measured
elsewhere in Sweden.
Wastewater is sent to the sewage treatment plant at a treatment
cost of 2 Sk/m3 ($0.0015/gal).
Table 12-2 shows the results of gaseous emission measurements in
1974 at Uppsala by the laboratory staff of Aktiebolaget Atomenergi. The
data are for the emissions from Furnaces 1, 2, and 3. The sampling point
was 5 m (16 ft) ahead of the precipitator. A six-point traverse was made
during each test across a square duct about 1 m (3.3 ft) square.
The SO results shown in Table 12-2 were stated to be comparable
to other Swedish results established in the government publication,
"Atmospheric Pollution Problems in Waste Materials Incineration",
Publication No. 1969:6 by Statens Naturvardsverk. However, the HC1
emissions in Table 12.2 we,e stated to be about half those measured
elsewhere. This type of variation is not uncommon in refuse burning. The
amount of HC1 discharged depends greatly on the amount of pvc burned.
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57
TABLE 12-2.
RESULTS OF GASEOUS EMISSION MEASUREMENTS FROM
ORIGINAL THREE FURNACES AT UPPSALA (APRIL 23,
1974) (COURTESY UPPSALA KRAFTVARME AB)
Test Number
Time of Day
Steam Production Rate, tonnes/
hr
Gas Volume Sampled, Nm
CO , Percent Dry Gas
0~, Percent Dry Gas
SO , mg/Nm , Dry Gas
3
S02, mg/Nm corr. to 10
Percent C02
3
HC1, mg/Nm , dry gas
3
HC1, mg/Nm , corr. to 10
Percent C02
1
9:00-9:45
22.4
0.106
110
170
73
114
2
9:57-10:47
22.4
0.111
110
170
79
124
3
11:00-11:48
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0.078
f /.
i r\ A
J.U . t
210
330
34
53
4
12: 12:45
23.9
0.103
60
90
14
22
Note: 1 mg/Nm
= 0.378 ppm
1 mg/Nm HC1 = 0.672 ppm HC1.
-------
58
EQUIPMENT PERFORMANCE ASSESSMENT
Table 12-3 shows the 1974 and 1975 operating results for the
entire Uppsala district heating and power system. In 1975, the waste
burning plant produced 80 Gwh (58.9 x 10 Gcal) (273 x 106 MBtu) in the
form of saturated steam at 15 atm (220 psia). This was 5.4 percent of the
total heat production in the entire system.
The waste burning plant achieved its energy recovery and waste
disposal function with minimal cost.
-------
59
TABLE 12-3. OPERATING DATA FOR THE UPPSALA ENERGY SYSTEM
FOR 1974 AND 1975 (COURTESY UPPSALA KRAFT-
VARME AB)
Electricity Production, Gwh
Hot Water From Power Plant, Gwh
(a)
Hot Water From Three Heating Plants , Gwh
Hot Water From Central Heating Plant, Gwh
Steam Production From Waste, Gwh
Steam Production From Others , Gwh
Heat From Heat Exchanger, Gwh
Total Production (Hot Water + Steam), Gwh
Delivery of Hot Water From Four Plants, Gwh
Delivery of Hot Water From Central Plant, Gwh
Delivery of Steam (Pharmacia, Farmek, KW) , Gwh
Oil Consumed:
3
Power Plant (for Power) , m
Power Plant (for Hot Water) , m
(a) 3
Three Heating Plants for Hot Water v , m
3
Central Heating Plant, m
3
Bolandsverket Plant for Steam, m
3
Total Oil Burned, m
Specific Oil Consumption (Three Plants +
Power Plant) , Mwh/m3
T
Specific Oil Consumption, Central Plant, Mwh/mJ
3
Oil From Coastal Terminal to Storage, m
Waste Burned, tonne
Waste Plant Evaporation Rate, kg/kg
1974
313
655
463
24
80
41
38
1,263
1,017
22
56
36,943
63,303
44,580
2,987
4,128
115,643
9.3
7.4
173,179
50,878
2.44
1975
520
1,020
206
34
81
32
30
1,373
1,166
31
59
62,834
99,930
21,453
4,034
3,296
129,051
9.6
7.7
188,182
51,355
2.44
-------
60
TABLE 12-3. (Continued)
Length
Volume
Income
From
From
From
Rate
of District Heating System, m
3
of Hot Water Circulated, m
Hot-Water Customers, 1,000 Skr
Steam Customers, 1,000 Skr
Delivery of Refuse, 1,000 Skr
(c)
of Income From Heat Customers, ore/kwh
164
13
63
2
1
Tipping Fee, Skr/tonne
1974
,201
,486
,355
,588
,888
6.10
37.11
189
15
73
2
1
1975
,656
,386
,801
,898
,693
6.
33.
17
62
(a) The three heating plants are: Bolandsverket, Kvarngardesverket, and
Husbyborgs Verket (see map on page 7).
(b) Other small steam sources are Sunrod and Kymmene.
(c) 1 skr = 20 ore.
-------
61.
PERSONNEL AND MANAGEMENT
Chief Engineer, Hans Nyman, directs the overall plant through
his staff, Hans Nordstrom, Plant Engineer, and Karl-Eric Berg, Works
Engineer, and an assistant works engineer.
The plant does not now operate on weekends. The work-week is now
38.5 hours with 170 hours per month. Every ninth week, each worker works
for shorter days. The regulation 4-week vacation will be extended to 5
weeks in 1978.
On the three daily shifts, there are five workers as follows:
• Crane operator
• Slag and residue handler
• Boiler-furnace operator
• Scale operator
• Mechanic (and on call for scale).
There is a possibility that more refuse will be coming from
neighboring cities. To handle the extra volume, 7-day operation will be
planned for which it is expected nine additional wo-kers will be needed,
three for each of three weekend shifts.
-------
62
ENERGY MARKETING
Figure 12-32 illustrates schematically how the energy, from
refuse is integrated into the much larger district heating system operated
by the Uppsala Kraftvartne AB (Uppsala Power Heat Corp.). The/bulk of the
energy required for the system is obtained from the burning of oil in a
200 mw power plant and in the central heating plants. At the bottom of
Figure 12-23 is depicted the refuse-fired steam plant which supplies some
steam for heating water for the central heating system plus process and
heating steam to a number of industrial plants including the
Portia-Pharmacia, a meat packing house, two bakeries, and a laundry.
Table 12-4 shows the input-output data for the power and heating
complex at Uppsala for the month of October, 1977- The steam-to-refuse
production ratio of 2.26 is slightly lower than the average for this plant.
The total energy input for the month from oil was about 110 x
103 Gcal (assuming 10 Gcal/m3) (39-7 MBtu)* The enthalpy of the 12,056
tonnes (13,262 tons) of steam produced by the refuse plant was 667 Kcal/kg
(1,200 Btu/lb) or a total refuse-to-energy output of 8,300 Gcal. This is
8.0 percent of the oil energy input to the system for October, 1977.
Figure 12-33 shows the installation of additional hot water
piping at Uppsala.
150,200 Btu/gal.
-------
63
Oil-Fired
Steam Boiler
Thermal Power
Plant
Oil Supply Tank
Hot Water District
Heating System
Oil-Fired
Hot Water Boiler
Refuse-Fired
Steam Generator
Electricity
Distribution
Central Heating
Plants
Steam-to-Water
Heat Exchanger
Supply to Steam
Industries
Refuse-Fired
Steam Plant
Condensate Return
FIGURE 12-32.
SCHEMATIC OF UPPSALA HEATING SYSTEM
(COURTESY UPPSALA KRAFTVARME AB)
-------
64
TABLE 12-4 . TYPICAL AUTUMN MONTH OPERATION DATA FOR
UPPSALA HEAT POWER COMPANY, OCTOBER, 1977
Total Oil Consumed, m3 10,994.2
Refuse Burned, tonne 5,342
Steam Produced, tonne
Refuse Plant 12,056.0
Other Steam Boilers (from oil) 3,333.7
Electricity Consumed by Refuse Plant, kwh 368,960
Steam-to-Refuse Production Ratio 2.26
Electricity Produced, Mwh 29,494.8
Oil Consumed in Electricity Generation, m 3,353
Electricity Consumed in Power Plant, kwh 151,316
Total Steam Delivered, tonne 12,231
Steam Used Internally, tonne 3,158.7
Condensate Returned, tonne 3,463.2
Electricity Consumed in Pumping
District Heating Water, kwh 875,900
Waste Oil Received, kg 37,620
Waste Oil Burned, kg 0
Biological Wastes Received, kg 2,604
3
Oil Consumed for Boiler wastes, m 2,800
Dextrose Waste Received, kg 0
-------
65
FIGURE 12-33.
INSTALLATION OF HOT WATER DISTRIBUTION PIPING
(COURTESY UPPSALA KRAFTVARMEWERKE AB)
-------
66
ECONOMICS
The costs of the various stages of construction of the Uppsala
waste plant were approximately as follows:
Million Thousand
Skr $
1962 Furnaces 1 & 2 by Kockum-Landsverk 3.4 850
and Boiler 1
1965 Furnace 3 by Kockum-Landsverk 1.0 250
and Boiler 2
1971 Furnace 4 by Bruun & Sorensen i».o 1,000
and Boiler 3
1971 New Crane 0.15 38
1971 Precipitators 1.3 325
1971 Bulky Waste Shear 0.2 50
1971 New Ramp to Increse Bunker Depth 1.0 150
TOTAL 11.05 2,763
NOTE: This report uses two monetary conversion factors: (1) 1962-1972
costs @ 4 Skr/$; and (2) 1974-1978 expenses and revenues § 5
Skr/$.
The plant operating management estimates that replacement in
1977 of the whole system would cost about 60 million Skr ($12 million @ 5
Skr/$).
In 19731 the original chimney was replaced at a cost of about 1
million Skr ($250,000).
Operating Costs
For the year 1976, the following owning and operating costs were
«
paid for processing 52,040 tonnes (57,244 tons) during the year:
-------
67
Thousand
Thousand $,
Skr (6 5 Skr/$)
Amortization (15 years, 10*) 1,547 309
Staff Salaries and Wages 768 154
Fringe Benefits (Including Pension) 323 65
Repair and Maintenance 933 187
Building Maintenance and Cleaning 80 16
Electricity Consumption 280 56
Administration 232 46
TOTAL OWNING AND OPERATING COST 4,163 833
This resulted in a unit cost for 1976 of 80 Skr/tonne
($l4.54/ton @ 5 Skr/$).
Revenues
As already shown in Table 12-3, for 1974 and 1975 the tipping
fees were:
• 1974: 1,888,000 Skr for 50,878 tonnes or 37-1 Skr/tonne
• 1975: 1,693,000 Skr for 51,355 tonnes or 34.0 Skr/tonne.
This is the equivalent of $6.75 and $6.18 per short ton, respectively. As
already stated, the 1976 operating cost was 80 Skr/tonne ($ 14.54/ton). No
data were obtained on revenue from .the portion of the district heat load
supplied by the waste plant, but the above data would indicate that the
income from that source would amount to about $8.00/ton (44 Skr/tonne) of
waste. Plant staff indicated that the costs for heating are adjusted
periodically to approximately support actual owning and operating costs.
Figure 12-34 shows the past and expected future trend of the net
cost to the heating system of operating the refuse-to-energy plant. The
cost in 1976 is shown to have reached a recent peak of about 44 Skr/tonne.
In the future, the curve predicts a steep reduction in cost to the heating
system because the expected rise in foreign oil prices will enhance the
value of the heat from the refuse. The prediction curve is calculated from
the following equation:
-------
68
OJ
c
o
50
40
3 30
60
c
•H
c
S 20
M
U-t
o
03
o 10
1972
1974
1976
1978
1980
Year
FIGURE 12-34.
PAST AND PREDICTED TREND OF NET
OPERATING COST OF REFUSE BURNING
PLANT AFTER CREDIT IS TAKEN FOR
THE VALUE OF HEAT RECOVERED
(COURTESY UPPSALA KRAFTVARME AB)
-------
69
Annual Cost of Plant Operation _ KB = net cost to heating system.
Annual Refuse Burned
where:
B = cost of oil (48 Skr/nr in November, 1975)
and:
k = empirical factor relating heat from refuse to heat from
heavy oil considering inherent efficiencies of utilization
k = 0.15 to 0.16 depending on plant conditions and volume of
waste.
Thus, for the year 1979, processing 50,000 tonnes, if the total
operating cost is 90 Skr/tonne and the cost of heavy oil has risen to 600
T
Skr/m", the net cost will be zero:
90 - 0.15 (600) = 0 Skr/tonr.e.
In November, 1975, the cost of oil delivered at the coastal
terminal at Gavle was 350 Skr/tonne (about 350 Skr/m ). Interest on the
storage of 1 year's oil supply was MO Skr. Tax was 50 Skr. Thus, the total
oil cost then was 485 K/mJ.
Table 12-5 shows the electrical and heating charges for a
typical residence served by the total Uppsala system. The three columns
are for an electrically heated residence and two hot-water-heated ones
based on an old oil icst and a new (lower) oil cost according to the
formula discussed above. However, the portion of this revenue example
which actually flows to the waste-to-energy plant is not revealed in the
table. At a 1976 operational cost of 80 Skr/tonne of refuse and an
evaporation rate of 2.44, that operational cost would be 33-79 Skr/tonne
steam f $f-. lH/short ton 0 5 Skr/$).
-------
70
TABLE 12-5. COMPARISON OF COSTS FOR ELECTRICITY AND DISTRICT
HEAT FOR A NEWLY BUILT RESIDENCE CONNECTED TO THE
UPPSALA KRAFTVARME AB (FROM A TABULATION PREPARED
BY JANS ERIKSSON, VARMVERKET, SEPTEMBER 27, 1976)
2 2
External Surface of Residence Including Basement: 109 m (1,173 ft )
Maximum Heat Load: 12.5 Mcal/h (52.3 MJ/h) [49,600 Btu/h]
Equivalent Electrical Load: 15 kw.
Heat Consumption
Household Electricity Consumption
TOTAL
Fees (Skr)
Fixed Charge
Consumption Charge
Reduced Charge Bonus
Electrical Subscriber Fee
Power Consumed Cost
Tax
SUM OF OPERATION COSTS
Facility Costs (Skr)
Installation Cost for Heat
District Heat Connection Charge
Electricity Connection Charge
Sum of Connection and Installation
Ten-Year Prorated Annual First Cost
Forty Percent Tax on Annual First
Cost
Summary of Total Annual Cost (Skr)
Tax
Operation Cost
TOTAL
TOTAL IN $ @ 5 Skr/$
Electric
Heat
27,600
4,500
32,100
Cost
;;
—
900
2,247(c)
642
3,789
7,000
—
2,000
9,000
900
360
360
3,789
4,149
$829.80
Old District
Heat Rate,
kwh (thermal)
29,800
4,500
34,300
Cost
1,103
l,435(a)
2,538
230
450(d)
90
3,308
14,000
3,100
2,000
19,100
1,910
764
764
3,308
4,072
$814.40
New Rate,
kwh
(thermal)
29,800
4,500
34,300
Cost
1,340
l,284(b)
2,236
230
450(d)
90
3,306
14,000
4,850
2,000
20,085
2,009
804
804
3,306
3,810
$762.00
(a) Based on a cost of heavy oil of 400 Skr/m3 (30 c/gal).
(b) Based on a heavy oil cost of 359 Skr/m3 (27 c/gal).
(c) Electricity cost of 7 ore/kwh (0.7 Skr/kwh) (7c/kwh).
(d) Electricity cost of 10 ore/kwh (1 Skr/kwh) (10 c/kwh).
-------
71
FINANCE
Of the total of 11.05 million Skr ($2,763,000 § 5 Skr/$) of the
original capital cost, 3.4 million Skr was borrowed from commercial
lending sources. An additional 6.7 million Skr was financed from reserves
from previous operations of the heating system. Out of present operations,
it is planned to build up a reserve for the community of about 3 million
Skr.
The refuse burning plant is to be amortized over 15 years at a
nominal interest rate of 10 percent. Plant staff remarked that they would
find it difficult to imagine operating the facility as a private
enterprise.
-------
APPENDIX A
PULVERIZING PLANT FOR CONSTRUCTION AND
INDUSTRIAL WASTE AT UPPSALA
-------
The Hovgarden
Pulverizing Plant
?=? F? F? F=? F?
Uppsala
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General data
Exemption from the consent >
lion Distance from cit> centre
Pro- Calculated canucitv of dumping aret
w tJ
c: c:
c c:
O £
~ c
--UJ
Committee for Env ironme
obtained from the National
£ £
c E;
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o p
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u a*
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3 13
lection Board
City Council grants funds
c c
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11
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Designing and planning work
Stage 1 started
r r
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February 1
August 1
Stage 11 started
Pulverizing plant in operation
Technical data
Compensation n"ii'n oir
) kg Punfving plant
8
ri
O.
60
C
JC
Uj
5
•s
§
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High-grade chemical plant with
> m3 lamellar sedimentation, capacity
F
k\V F
lour
V. o -1-
<£ S
u, G
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o "'
oo
-t
a.
Piilceriung plant
Tipping pocket, volume
Pulveriser- Haremag, type A
Motor, electric
Crushing capacity
Staff
— -t
Chief engineer
Operating stall
Builder
Administration
-a
~2
CO
•3
£
Q.
y
C
3
2
_=3
«
s.
G.
D
1
Uppsala Municipal Services Di
Cleaning Department
1
C
c
1
Participants in designing and
Consultant:,
etc. Uppsala Municipal Services Division
ipmg areas.
.instruction,
5- 3
~ GO
1 . Roads, open spaces, culverts
2 Architectural design, buildin
Sydsvenska Ingenjorsbvran, Malmo
Vattenbyggnadsbyran, Stockholm
Elektrokonsult, Uppsala
in reservoir
-
machinery design, etc.
3. Purifying plant and compen;
4 Electrical designs
Machinery .suppliers
Hazemag AG. Munster, West Germ.
Toledo-Reliance AB. Stockholm
'J
orj
ta>
-5
?
"c
13
1. Pulverizing plant, including i
2. Weighing equipment
Transportkonstruktloner AB. Stockh
'j
o
v
3. Telpher equipment
4. Machinery, pumping equipn'
M
£*
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(/)
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73
/
punt'ung plant
EC
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BtiiUtiivj contractor!.
Stage 1
Stage II
S-
C-
C.
ZJ
C
3
-:5
u
7i
%
5
^
5
Bvggproduknon AB. Uppsala
Karneb El AB, Upps.lla
(a) High-tension installation
(b) Low-tension installation
Photographs and production I
Kditorial Committee
i
^
05 :
< \
2 <
m -
j, j:
1 ;
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£i C
Superintendent Phil. lie.
Jan at Uhr Jan Sidenwall
.A. InformationMndiMii AB, Uppsala IS*
03
~f
c
H
Translated into English h\ Neil
Csl
oo
cn
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\c^
eg
m
m
is led\iu special drains (2)
oir. the volume ot incom-
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r>
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to a reservoi
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-------
TABLE . EXCHANGE RATES FOR SIX EUROPEAN COUNTRIES,
(NATIONAL MONETARY UNIT PER U.S. DOLLAR)
1948 TO FEBRUARY, 1978ia>
1948
1949
1950
1951
1952
1953
1954
1955
1956
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
6.891
6.916
7.462
7.501
7.492
7.439
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
-•.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
Deutscn Mark
(O.M.)
3.333
4.200
4.200
4.200
4.200
4.200
4.200
4.215
4.199
4.202
4.17S
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
3.329
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
5.136
5.200
5.148
5.180
4.180
5.165
5.180
5.170
5.170
4.358
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
4.235
4.288
4.285
4.235
4.285
-..2S5
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.
ft US GOVERNMENT PRINTING OFFICE 1979 -620-007/6304
yo 1828g
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|