BIBLIOGRAPHIC DATA
SHEET
                       EPA/530/SW^7d.1
                                                                    PB   234   715
4. ; it '• ai-.l -i; >t ic ;•.
   Franklin, Ohio's
   Solid Waste^ndFiber Recovery Demonstration  Plant;
   Final Report  (Two  volumes)	
                                                                    5- Report Date
                                                                    6.
7. Author' s I
   N. Thomas Neff
                                 °Kej
                                                                    8- Performing Orgam/.at ion Kept.
                                                                       No.
9. Performing Organization Name and Address
   A. M. Kinney,  Inc.
   Consulting Engineers
   Cincinnati, Ohio   H5219
                                                                     10. Project/Task/Work Unit No.

                                                                         G06-EC-001914	
                                                                     11. Contract/Grant No.

                                                                         Final
   sponsoring <'r^ani/ation Name ami \,Mress
   U.S. Environmental Protection Agency
   Office of Solid Waste Management Programs
   Washington, D.C.   20h60
                                                                     13. lype of Report & Period
                                                                       Covered
                                                                     14.
15. Supple mentar y Notes
   Interim report  available from NTIS as  PB 213

16. Abstracts
   The Franklin, Ohio,  resource recovery  demonstration project  has elicited widespread
   interest.  This  report was prepared to:   (l) present a preliminary analysis
   of the solid vaste  disposal and fiber  recovery portions of .the project; (2) provide
   preliminary data by which others may be  guided in evaluating emerging solid waste
   disposal and resource recovery technologies.  The historical development of this
   EPA-sponsored project and a general description and evaluation of the process used
   are included.  The  preliminary plant economics presented are based on construction
   costs and the first 12 months of operation.   The plant began functioning in June 1971
   is    now in regular operation recovering .ferrous metals and paper fibers which are
   sold to local industries,
17. Kcv \^ or\l s ,irui Oocu'iK-m Ana
                           .  17a. Descriptors
   *Refuse disposal,  *Materials recovery,   Incinerators — refuse  disposal, Size reduction
   (comminution),  Wet mills, Magnetic separators, *Reclamation — salvage, Sludge disposal
17'r>.  I 1, [ .,) IL' , Or..-n-t n lej ') erm-.

   *Solid waste  disposal,  ^Resource recovery,  Fluid bed incinerator, Solid waste
    separation technology, Liquid cyclone  separator, Paper fiber  recovery system, Sewage
    sludge disposal, Franklin (Ohio)
                                        Reproduced by
                                          NATIONAL TECHNICAL
                                         INFORMATION  SERVICE
                                          U  S Department of Commerce
                                             Springfield VA 22151
                       13B
IS. K .11 i .U-l i i: , -i .it t :IK tit

    Release to public
                                                         19. .set unty <  las-. ( I lu
                                                           Report)
                                                                 . \Ss|l'll-P
                                                         20. Set unty ( lass i i in-.
                                                           P.,Ve
                                                              i'\t I.ASXII-ii 11
21. \n. of P<
                                                                              IJSCOMM-DC 4<>3.:
-------

-------
                                231051
                             FRANKLIN, OHIO'S

        SOLID WASTE DISPOSAL AND FIBER RECOVERY DEMONSTRATION PLANT

                               Final Report

                                 VOLUME I
                     This  report  (SW-47d.l) was prepared
for the City of Franklin,  Ohio, under demonstration grant No. G06-EC-00194
            from the Office  of Solid Waste Management Programs
                   by N. THOMAS NEFF and N. WAYNE OKEL
        A.  M.  Kinney,  Inc.,  Consulting Engineers, Cincinnati, Ohio
      A summary report (SW-47d.3)  on this project is being published
                  by the U.S.  Government Printing Office
                    U.S.  ENVIRONMENTAL PROTECTION AGENCY

-------
This report has been reviewed by the U.S. Environmental
Protection Agency and approved for publication.  Approval
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 or recommendation for use by the U.S. Government.
An environmental protection publication in the solid waste
management series (SW-^ 7d.1).

-------
                                            Aerial  View  of  Franklin Plant
                             FOREWORD
     The initial objective of this project, started in 1968, was to
demonstrate an innovative solid waste disposal technique utilizing
wet grinding and subsequent incineration.  Later the scope of the pro-
ject was expanded to recycle portions of the solid waste stream.  The
facility located in Franklin, Ohio, and designed and operated by the
Black Clawson Co., presently includes the capability to separate
reusable paper fibers and ferrous metals for recycling prior to dis-
posing of the remaining solid wastes.  Further construction has re-
cently been completed which has added to the plant the capability
to recover color-sorted glass and aluminum.  This pilot plant repre-
sents one of the first successful resource recovery facilities in the
country.
                                111

-------
     In addition to disposing of all the municipal solid wastes
generated in Franklin, Ohio, the plant also incinerates sludge from a
nearby sevage treatment plant.  This project represents a significant
advance in the state of the art of resource recovery and residuals
management.  This small system is a completely unique environmental
control complex which has been toured by visitors from many parts of
the world.
     This report is based on data collected during the first 12 months
of plant operation, i.e., June 1971 through May 1972.  As such, much
of the information and conclusions presented herein are outdated.
Nevertheless, this report, in two volumes, does present much data
which may be of interest to people in the solid waste management and re-
source recovery fields.  Hence the report was prepared for publication.
     The plant has continued to run on a regular basis since May 1972,
and a more rigorous and comprehensive evaluation program is now under-
way.  The current evaluation is being conducted under a separate
EPA contract with the Systems Technology Corporation (Systech) of
Dayton, Ohio.  Their report should be available in early 1975-  We
wish to acknowledge the contribution made by David G. Arella, who served
as the government's officer on this project from December 1971 to
August 197*K

                                  — ARSEN J. DARNAY
                                    Deputy Assistant Administrator
                                      for Solid Waste Management
                                 IV

-------
                                   INDEX
SECTION
  VOLUME I
PAGE
               Abstract 	   vlil

     I         Summary and Conclusions	     1

               A.  Summary	     1
               B.  Response to Objectives 	     3
               C.  Conclusions 	     4
               D.  Recommendations	     4

    II         History and Development of Project 	     6

   III         Operations Analysis 	    11

               A.  General Description of Process 	
               B.  Description and Evaluation of Process Streams  	
               C.  Operating Problems and Process Improvements  	

    IV         Economic Analysis	

               A.  Construction Costs 	
               B.  Actual and Projected Operating Costs  	

  VOLUME II

     V         Unit Operations Analysis 	    57

               A.  General Equipment Requirements	    57
               B.  Solid Waste Disposal Plant Equipment  	    58
               C.  Fiber Recovery Plant 	    76
               D.  General Plant Equipment  	    82

    VI         Influent and Effluent Analyses 	    84

               A.  Operating Data Summary 	    85
               B.  Analytical Data Summary  	   134
               C.  Graphic Representation of Testing Results  	   152
               D.  Sampling, Testing and Analytical Procedures  	   169

-------
APPENDIX                           TITLE                                  PAGE




   A           Bowser-Morner Reports 	  174




   B           A. M. Kinney, Inc., Test Reports 	  235




   C           The Black Clawson Company Status Reports 	  266






ILLUSTRATIONS




  VOLUME I




Frontispiece       Aerial View of Franklin Plant 	   ill




Figure 1.          Environmental Control Complex Flow Diagram 	   12




Figure 2.          Plant Layout 	   13




Figure 3.          Receiving Floor 	   14




Figure 4.          Hydrapulper  	   15




Figure 5.          Magnetic Separator and Liquid Cyclone 	   18




Figure 6.          Fluid Bed Reactor 	   20




Figure 7.          Cyclone Rejects and Junk Remover Rejects  	   26




Figure 8.          Paper Fiber  Being Loaded for Shipment 	   29




                                 TABLES




Table 1            Material Balance	   22
                                     \Ji

-------
ILLUSTRATIONS




  VOLUME II




Figure 1.




Figure 2.




Figure 3.




Figure 4.




Figure 5.




Figure 6.




Figure 6a.




Figure 7.




Figure 8.




Figure 9.




Figure 10.




Figure 11.




Figure 12.




Figure 13.
               TITLE                                    PAGE









Waste Load Variation	  155




Rejects to Landfill	  156




Reusable Paper Fiber Recovered 	  157




Proximate Analysis of Reactor Feed	  158




pH Various Plant Waters 	  159




Settleable Solids in Various Plant Waters (By Volume).  160




Settleable Solids in Various Plant Waters (By Weight).  161




Biochemical Oxygen Demand of Various Plant Waters  ....  162




Total Dissolved Solids in Various Plant Waters  	  163




Total Suspended Solids in VaVious Plant Waters  	  164




Total Volatile Solids in Ash Slurry  	  165




Total Solids in Ash Slurry  	  166




Junk Remover Rejects Non-Magnetic Fraction 	  167




Cyclone Rejects Analysis	  168
                                     v/\'i

-------
                               ABSTRACT


     Title;   System for  total  refuse disposal by  fluid mechanical separation
             of  solid wastes and  fluid bed oxidation of combustibles, and
             reclamation of paper fibers.

     Grantee:  City of Franklin,  Ohio
              35 East Fourth  Street
              Franklin, Ohio   45005

     Project Director:   Bernard F.  Eichholz, City Manager

     Project Started:  Sep. 24, 1968

     Project Ended; Feb. 28,  1973

     Project Objectives:  To  design,  construct,  operate, and  evaluate a demonstra-

tion plant  for disposal  of municipal  solid waste  and  for the  recovery of metals,

glass, and  paper fibers  therefrom.

     The system  was designed  to receive  virtually unsorted municipal solid waste

and to separate  it by  using  a fluid-mechanical  process.  Reusable paper fibers,

metals, and noncombustibles  are separated in the process,  and the  remaining com-

bustible solids  are mixed with sewage sludge from an  adjoining sewage  treatment

plant, and  then  burned in a  fluid bed incinerator.

     Results of  Project:  The plant is in daily commercial operation as the

principal solid  waste disposal facility  for the City  of Franklin and adjacent

areas.  The technical capability of the  Wet Processing and Disposal system has

been successfully  demonstrated.  The Fiber Recovery system initially produced

yields of paper  fiber lower than anticipated,  but has undergone further develop-

mental work to  increase  yield.

     Actual operating costs during the term covered by this report are higher

than originally  anticipated due  to low usage (40 tons per day) and due to
                                    viif

-------
inflation.  However,  sufficient data and  operating  experience have been obtained




to permit cost projections for plants of  larger capacities, which indicate  lower




operating costs.




     Summaries, tables and graphs are included to present actual construction




and operating costs,  as well as influent  and effluent  operational data.




     This report  was  submitted in fulfillment of Project No. G06-EC-00194 under




the partial sponsorship of the Office of  Solid Waste Management  Programs,




Environmental Protection Agency.
                                   /x

-------
             FOR iiORc INFORMATION ABOUT THE FRANKLIN  PLANT
Solid Waste and Huer Recovery Demonstration Plant for the  City of
     Franklin, Ohio:   An Interim Report.   N.T.  Neff.   U.S.  Environmental
     Protection Agency, 1972.   33 p.   Distributed by  National  Technical
     Information Service, U.S. Department of Commerce, Springfield,  Va.
     22152, as P3-213 646.   Price for paper copy is $4.85;  for micro-
     fiche, 31.45.

lidste Processing Corr.plex. Emphasizes Recycling.   William Herbert and
     Wesley A. Flower.  Public Vlorks, 102(6):  78-81, June  1971.
     Reprinted by Office of Solid Waste Management Programs,  U.S.
     Environmental  Protection  Agency, 1972.

Glass and Aluminum Recovery in Recycling Operations.   William Herbert
     and Wesley A.  Flower.   Public Works, 102(8):  70, 110, 112, August
     1971.  Reprinted by Office of Solid Waste  Management Programs,
     U.S. Environmental Protection Agency, 1972.

Solid Waste Recycling at Franklin, Ohio.  William Herbert.   In Proceedings
     of the Third Mineral Waste Utilization Symposium, Chicago, March
     14-16, 1972.  (Jointly sponsored by U.S. Bureau  of Mines and Illinois
     Institute of Technology Research Institute.)

Are!la, David G.  Wet-Processing Solid Waste for Resource Recovery:   A
     Summary Report on the Franklin,  Ohio, Demonstration Project.   Summary
     report (SK-766a). Grant No. G06-EC-00194.   U.S.  Environmental Protection
     Agency, Washington, DC  20460.  (In press.)
                                     X

-------
                   SECTION I - SUMMARY AND CONCLUSIONS







     A.  Summary.  Evaluation of cost and operational data obtained during the




demonstration operation period of the Franklin, Ohio, Solid Waste Disposal and




Fiber Recovery Plant shows that the system for solid waste disposal has1 been




successful.  The fiber recovery system initially produced yields of paper fiber




less than anticipated, but has undergone further developmental work to increase




yield.  The solid waste disposal portion of the plant has been in operation since




May 1971, and the fiber recovery portion has been in operation since June 1971.




         The Franklin project has grown from two simple objectives into a multi-




faceted complex with additional primary objectives and several corollary projects.




Originally, the objectives were :




         1.  To demonstrate, on n commercial scale, the Hydrasposal* system for




disposal of municipal solid waste.  This is an innovative wet-grinding and fluid




separation process whereby noncombustibles are removed for recycling or landfillin




and the organic residue is burned in a fluid bed reactor.




         2.  To provide an economical means for disposal of the solid waste




from the Franklin area, since the capacity of the City's landfill would reach




its limit  in another  three or four years.
     *Copyrighted trademarks of The Black Clawson Company, Middletown, Ohio,




 for  systems  for the disposal of solid wastes and for the recovery of paper




 therefrom, covered by various U.S. patents.

-------
         In rapid succession, other primary objectives were added to the project.




These were:




         3.  To demonstrate the Fibreclaim* process for recovery of paper fiber




from wet-ground municipal solid waste.




         4.  Magnetically separate and reclaim ferrous metals from the Hydra-




pulper* reject stream.




         5.  Demonstrate that raw sewage sludge can be burned in conjunction




with the organic residue from the Hydrasposal process, thereby eliminating the




need for sludge digestion equipment in an associated sewage treatment plant.




         Other corollary projects have evolved as a result of this demonstration




facility.  These are:




         1.  A waste glass reclamation process presently is being built to receive




the reject stream from the liquid cyclones, and further process it to separate an




aluminum fraction, as well as color-sorted glass cullet.  This demonstration




facility is being jointly  funded by the Environmental Protection Agency and the




Glass Container Manufacturer's  Institute.




         2.  An industrial liquid waste disposal facility presently is in the




early planning stages.  This plant would utilize the  fluid bed reactor portion




of  the  Hydrasposal system  to incinerate the collected and blended wastes during




times when the reactor is  not being used to incinerate solid waste  and sewage




sludge.  This  facility is  expected to safely dispose  of approximately 14,000




gallons per day  of oils and  solvents,  which are now being dumped on the land,




or  otherwise disposed of  in  a polluting manner.

-------
     B.  Response to Objectives.   The operational data presented in this report




show the following response to these objectives:




         1.  Routinely, on a commercial scale, essentially unsorted municipal




solid waste is being successfully wet-ground and  separated in the Hydrasposal




system,




         2.  The volume of material going to landfill has been reduced by




approximately 95 percent.  During the period that the plant has been in operation,




it has never been necessary to divert collection  trucks to the former landfill




for the disposal of Franklin's garbage.




         3.  Relatively small ungrindable items,  such as tin cans, are being




removed from the Hydrapulper slurry and the ferrous fraction is being magnetically




separated and sold for recycling as scrap metal.




         A.  Recyclable paper fiber is being removed from the slurry by the




Fibreclaim process.




         5.  The nonrecoverable organic residue is being burned in a fluid bed




reactor in conjunction with raw sewage sludge from the adjoining sewage treatment




plant.




         While fiber recovery is being achieved,  the rate of recovery is substan-




tially less than initially predicted.  The recovered fiber is regularly pumped




as a slurry to a nearby manufacturing plant which buys it for use in conjunction




with other fibers  to produce roofing felt.




         The cost  data reported by  the plant operators, Black Clawson Fibreclaim,




Inc.,  indicate that  the Franklin plant is not commercially viable at the present




throughput rate.   If the  tonnage received could be increased to full capacity,




Black  Clawson projects that operating losses could be reduced.  (See Economic




Evaluation Section.)

-------
     C.  Conclusions.   The conclusions that may be drawn from this evaluation




are as follows:




         1.  The technical successes achieved in operating this plant have




warranted the Federal support received, and have advanced the technology of




solid waste disposal and resource recovery methods.




         2.  Continued Federal support in funding additions and improvements to




the plant would be warranted and would provide the means for significant innova-




tions  in the technology of a now-proven process.




         3.  The impact on the environment of the Franklin plant is favorable,




and the planned expansion of the plant will be entirely consistent with all




environmental objectives.




         4.  On the basis of the information obtained from Black Clawson, commer-




cial viability is clearly a function of plant throughput.




     D.  Recommendations.  On the basis of  these evaluations and conclusions,




the following  recommendations are made.




         1.  The City of Franklin, Ohio, should continue the operation of the




facility and endeavor to renew its operating contract with Black Clawson Fibre-




claim,  Inc., with modifications  suggested  in Recommendation 2  below.




         2.  Although the plant  is a developmental and  sales tool  for Black




Clawson, the City should allow Black Clawson to increase dumping  fees, consistent




with  Federal price  increase  guidelines, and thus make Black Clawson's continued




participation  more  attractive to Black Clawson.




         3.  The  independent  evaluation study  proposed  by  the  Environmental




Protection Agency,  Office  of Solid  Waste Management  Programs,  should include




provision  for  additional  and improved  operational  monitoring instrumentation

-------
that it was not possible to provide within the limited funds available for  the




original construction; and a rigorous,  analysis of all operating costs, which




was not obtainable for the purposes of  the evaluation.

-------
              SECTION II - HISTORY AND DEVELOPEMENT OF PROJECT






     The Franklin project was begun in 1968,  when the city realized that its




landfill would be full in another 3 to 4 years.   Studies of new sites  were




meeting the usual opposition from residents who did not want a  landfill near




their properties.




     One of the members of the Franklin City Council was Mr. Joe Baxter, Jr.,




an engineer employed by the Shartle-Pandia Division of The Black Clawson Company,




Middletown, Ohio, manufacturers of paper mill machinery.  Mr. Baxter conceived




the idea of utilizing an array of this machinery to pulp solid  wastes , auto-




matically eject nonpulpable objects from the pulper, hydrodynamically separate



finely chopped noncombustibles, and burn the residual pulped combustibles in a




fluid bed reactor, in the same manner as sewage sludge is burned.




     Entirely at the expense of The Black Clawson Company, a pilot plant was




built in the Research and Development Laboratory of their plant at Middletown, to




prove that the idea was feasible.  The Black Clawson Company retained the services



of A. M. Kinney, Inc., Consulting Engineers, to evaluate the process.  Pilot plant




tests showed that municipal solid waste could be pulped in  a Hydrapulper, that the




noncombustible content of the refuse could be separated from the organic residue,




that mixing sewage sludge with the combustible remainder increased the filter-




ability of the sludge, and that  the remainder being  land-filled and covered bi-




weekly  constituted a 90  to 95 percent reduction in landfill volume.




      Since the Middletown pilot  plant did not include  a fluid bed reactor, other




pilot operations were performed  to determine the combustion characteristics of




 the  pulped organic residue.  Pilot plant  tests were  performed in a Copeland

-------
teactor and a full scale test was made in the Dorr-Oliver,  Inc.,  sludge-burning




reactor at the Ocean City, Maryland, sewage treatment plant,  both using organic




rejects from the Middletown pilot plant.




     On the basis of the feasibility study, application was made, under the Solid




Waste Act of 1965, for a demonstration grant to design and  build a plant in




Franklin, Ohio, using commercial-size equipment, which would  demonstrate this




innovative method at minimum cost, and at the same time would solve the solid




waste problem of the City of Franklin.




     Grant No. 1-D01-U1-00194 was received on Sep. 24, 1968,  and the City re-




tained A. M. Kinney, Inc., to prepare a preliminary Design  Manual to establish




design concepts and estimated construction costs.




     During this period, the Miami Conservancy District became responsible for




the water quality of the Great Miami River, and started planning a regional sewage




treatment plant for the Franklin area.  They acquired a tract of land adjacent to




the southwest edge of the City, and offered a part of this  property to the City




as the site for the solid waste plant.  The inter-relationship of the two plants




is shown in Figure 1.  Provisions were made in the construction of the solid




waste plant for the connections to the sewage treatment plant which was completed



after the solid waste plant was in operation.




     Also during this time, further developmental work was  done by The Black



Clawson Company in the application of other paper mill-type equipment to the




separation of reusable paper fiber from the aqueous slurry.  The pilot plant at




Middletown was expanded to prove the feasibility of this process.  On the basis




of the pilot plant results, a supplementary grant application was made and funds




were awarded to include the Fibreclaim process in the Franklin plant.

-------
     The solid waste system Design Manual and the fiber recovery system Design




Manual, both prepared by A. M. Kinney, Inc., for the City of Franklin,  formed




the bases for award of the construction grants No. 2-G06-EC-00194-02 and




3-G06-EC-00194-1S1, which was made on Mar. 2, 1970.  Final design drawings and




specifications were then prepared, and lump sum bids were solicited in accordance




with the laws of the State of Ohio governing bidding for municipal projects.




Construction and equipment contracts were awarded, and A. M. Kinney, Inc., was




retained by the City to supervise construction of the plant.




     While the solid waste and fiber recovery plant was being built, the Glass




Container Manufacturers Institute (GCMI) announced that it had completed a series




of tests and trial operations using the glass-rich fraction separated from the




pulped refuse by the liquid cyclone in the Middletown pilot plant.  Using a train




of screening and classifying  equipment to separate extraneous material, the GCMI




equipment train was capable of recovering an aluminum-rich stream and color-sort-




ing glass cullet using a Sortex optical sorter.




     GCMI proposed that the City of Franklin apply for a supplementary grant  to




add this subsystem to the  Franklin plant, on the  condition that GCMI would reim-



burse  the City for the matching funds.  Award of  this grant  (No.  3-G06-EC-00194-




03S2)  was made by  the Environmental Protection  Agency, Office of  Solid Waste



Management Programs on June  8, 1971.  Construction of this addition is now com-




plete  and  initial  operation  began  in  July,  1973.




     Construction  of  the  solid waste  plant  was  completed on May  17, 1971, and the




 fiber  recovery  plant  was  completed  on June  28,  1971.  The plant was dedicated on




Aug.  11,  1971,  by  Mr. Richard D.  Vaughan, then  Director  of the Office of  Solid




Waste  Management Programs, Congressman  Walter E.  Powell  of  the  8th  District  of

-------
Ohio, and Mr. Bernard F. Eichholz, City Manager, City of Franklin,  Ohio.




     The Miami Conservancy District (MCD)  in expanding its role from flood con-




trol of the Great Miami River to that of total water management of  that stream,




recognized that a major source of pollution was industrial waste liquids being




dumped in sewers, streams, and land draining to the river.  The MCD commissioned




a survey study of these pollutants and of  possible alternative disposal center




be built at Franklin to take advantage of  the Hydrasposal system's  integral




fluid bed reactor.  The reactor at Franklin is capable of incinerating many of the




industrial liquid wastes, and is expected  to be used a maximum of two shifts per




day, five-and-a-half days per week through most of the 1980's.




     The City of Franklin retained A. M. Kinney, Inc., to prepare specifications




for the design, construction, and operation of a receiving, storage, and blending




facility to be added to the solid waste recycling-sewage treatment  complex.  Pro-




posals were received by public bidding, and a firm was selected to  operate the




industrial liquid disposal facility, conditional upon receipt of Federal assis-




tance.  Application for a Federal grant to build the facility was made by the




City.




     Although there is more to be added, the Franklin Environmental Control Com-




plex has attracted inquiries and visitors from many parts of the world.




     Because it is a commercial plant, operating in regular daily service to the




City and its environs, and demonstrates a new approach to resource recovery and




solid waste disposal, visitors have come from nearly every state of the Union,




and from such foreign countries as Sweden, Australia, Italy, Japan, and Great




Britain to observe its operation.

-------
     The future of the plant is not only a function of the completion of the other




parts of the complex, but is largely dependent upon the economic viability of its




operation.  The process lends itself to more innovation, so that other recovery




facilities may be added in the future to reduce its operating costs.  In addition,




the Franklin area is experiencing a rapid residential and commercial growth rate,




as a result of which the economics of increased throughput may be realized in the




foreseeable future.
                                    10

-------
                    SECTION III - OPERATIONS ANALYSIS






     A.  General Description of Process.   In the overview,  the Solid Waste




Disposal and Fiber Recovery Plant is composed of two major  divisions, the




Hydrasposal System and the Fibreclaim System.  Each of these integral systems




may be considered to be composed of several subsystems.  The flow of material




through the plant, and the relationship of the plant to the Sewage Treatment




Plant, is shown in Figure 1.  The physical arrangement of equipment within the




Solid Waste Disposal and Fiber Recovery Plant is shown in Figure 2.




         1.  Hydrasposal System




             a.  Receiving and Weighing Subsystem.  As shown in these diagrams,




refuse is delivered to the plant by private contractors and individual citizens.




All incoming refuse, except that from passenger vehicles and small pickup trucks,




is weighed and recorded at the scale.  The vehicles dump their loads onto the




concrete receiving floor, as shown in Figure 3 from which the refuse is pushed




onto the feed conveyor by a front-end loader.




             b.  Wet Grinding and Separation Subsystem.  The conveyor feeds the




refuse into the Hydrapulper at a controlled rate, as shown in Figure 4.  The




Hydrapulper is a Black Clawson Model SW pulping machine, 12 feet diameter, and




equipped with a 300 horsepower motor.  Water which has been removed from subse-




quent  stages of the process, and fresh water from the  sewage treatment plant




discharge are mixed with the refuse, and all pulpable  and friable materials are




converted by the action of a high speed cutting rotor  in the bottom of the Hydra-




pulper tub  into a water slurry having approximately A  percent solids content.




Pieces of metal, tin cans, and other nonpulpable and nonfriable materials are
                                    11

-------
Figure 1.   Environmental control complex  flow diagratr
                                12

-------
                                                                                     Ed W
                                                              CO

                                                              B
I

CO

CO
W
z
erf
w co
CO CO
                                                                          0!!
                                                                          W
   8
   o
   z
   §
                                                                                     CO CO
                                                                                     CO CO
£
o
CO
CO

B
                             ZH
                             6 CO
                                                                    PS H  H
                                                                    o z
                                                               I   I
                                                                    S8
                                                                        I
         	5  g  g  PS M w 3
      EtJPSOOOWtaapS
      3COHUOO< t
                                                              co  co u re >-

                                                              I  I  I   I   I   I   I   I   I
            *:
            Z  Pi
      _     ^  W
33    >*  ^  H
CO CJ U  O     Z tM
^C M    ci  w  w r^i PS
tSHOUOQPaO
   W M  P3  <  ^    H
^ Z 3  I  PM  OS Ed O
zocyzoQz<
3"Oa
i-jS^jzcoaoM
                                      ad
                                      o
                                                                                                      <
                                                                                                      U
                                                                                                      3
                                                                                           I  I
                                   M  W
                                   BH  PQ
                                                                                                      M
                                                                                                    I   I
Figure  2.     Plant  layout
                                             13

-------
Figure 3.   Receiving floor
                              14

-------
ejected from the Hydrapulper through an opening in the side of the tub,  and pass




down a chute to a specially designed bucket elevator known as the junk retnover.




In t'lis chute they receive a preliminary washing by the water which is being




recycled back into the pulper.  The junk remover discharges the materials into




a rotating drum washer, where the washing action is continued.  They are then




conveyed under a magnetic separator where tin cans and other ferrous objects are




separated for recycling.  The nonferrous materials are collected for landfill




burial.




             The slurry is extracted from the Hydrapulper through 7/8 inch dia-




meter holes in a perforated plate located beneath the rotor in the bottom of the




tub.  In addition to paper fiber, the slurry contains almost all of the organic




content of the refuse, plus most of the glass, small pieces of metal, ceramics,




and heavy plastics.  To remove the inorganics, the slurry is pumped to the liquid




cyclone, where the heavier materials are separated by centrifugal action.  Since




the end of the demonstration period a second cyclone has been installed in series




with the original cyclone to increase the effectiveness of this operation.




             The heavier materials pass into a chamber in the bottom of the




liquid cyclones from which they are discharged into the liquid cyclone rejects




conveyor and conveyed  into hoppers for landfill disposal.  The glass and aluminum




recovery system will interface with the solid waste plant at the discharge of




the liquid cyclone rejects conveyor.




         2.  Fibreclaim System.  After nearly all the metals and glass have




been removed for recycling, the slurry normally is pumped to the Fibreclaim




process for extraction of paper fiber.  A three-way valve in the liquid cyclone




"accepts" piping permits the Fibreclaim system to be by-passed whenever it is
                                    15

-------
necessary, or desirable, to do so.  In this process,  the long paper-making  fibers




are mechanically separated from nonrecyclable coarse  organics, such as rubber,




textiles, leather, yard waste, high wet strength paper,  paper coatings and  fillers,




paper fines, and very small pieces of glass,%dirt,  and sand.




             a.  Screening and Cleaning Subsystem.  At the end of the demonstration




period, the coarse contaminants were being removed  in two stages of screening.   The




first stage was a Black Clawson VR Classifiner,  in  which the  acceptable material




was passed through a screen having 1/8 inch diameter  openings.  The second  stage




screen was a Selectifier screen having 1/16 inch diameter openings.  This arrange-




ment has since been modified.




             The fine glass and dirt is removed by  pumping the material accepted




by the Selectifier screen through a battery of centrifugal cleaners.  Separation




of the organic fines from the longer, reusable fibers is accomplished by passing




the slurry over an inclined, slotted fine screen known as a Hydrasieve, manufactured




by the Bauer division of Combustion Engineering Company.  The longer fibers are




retained on the screen, while the fines pass through the 0.020 inch slots.




             b.  Fiber Dewatering and Re-Dilution Subsystem.   Finally, the re-




claimed  long fibers are dewatered in two stages.  The first stage is a Black




Clawson  Hydradenser, which  is an  inclined screw conveyor type thickener which




removes  most of  the water.  Additional water is removed by squeezing the partially




dewatered  pulp in a cone press manufactured by the Rietz Manufacturing Company.




The pulp is delivered by screw conveyor either to a waiting  truck or shipping




container  at 40  to  50 percent moisture or  to a tank in which  the fiber is rediluted




with  the sewage  plant effluent water, and pumped directly  to  the Logan-Long Com-




pany,  which buys  them  for  use  in  making dry  felt for asphalt  roofing.
                                     16

-------
Fig.Sa-Magnetic Separator
Fig.5b—Liquid Cyclone
 Figure 5.   Magnetic separator and liquid cyclone
                          17

-------
             The unrecoverable organic rejects from the fiber recovery operations




are combined and pumped to a storage tank.   From the storage tank they are returned




to the Hydrasposal system.




         3.  Hydrasposal System




             a.  Dewatering and Sludge Addition Subsystem.   As the organic rejects?




are drawn from the storage tank at a desired rate they are  dewatered to 40 percent:




solids content in two stages.  An inclined screw thickener  (Hydradenser) discharges




to a Rietz cone press.  The press discharges to a screw conveyor which breaks the




dewatered cake into lumps 5/8 inch to 1-1/2 inches in size.  Sludge from the ad-




joining sewage treatment plant is mixed with the organic rejects between the




Hydradenser and the cone press and the combined mixture is dewatered without




the aid of flocculating agents in the press.  The combined wastes are then fed




through a rotary feeder into a pneumatic conveyor system which delivers the




material to the fluid bed reactor.




             b.  Fluid Bed Reactor Subsystem.  The  fluid bed reactor  is a 25 foot




inside diameter vertical cylindrical unit supplied  by Dorr-Oliver, Inc.  In  this




unit, room  temperature air is blown by a 500 horsepower Spencer blower into a




windbox at  approximately 4-1/2 psig.  The air flows upward through a  perforated




plate and  gravel dispersal layer  into a layer of sand, which it fluidizes.  When




starting up from a  cold condition the fluidized bed is initially  preheated by oil




burners.   After  the fluidized sand reaches  operating  temperature  of 1200 F to




1400  F, organic  rejects are  injected  and burned.  Continued  injection of the




organic rejects  supplies  sufficient heat value  to continue combustion, so that




no auxiliary  fuel  is required  in  normal operation.  For shutdown  periods in  ex-




cess  of  24 hours,  small quantities  of fuel  oil  are  used to maintain bed temperature,
                                     18

-------
Figure 6.   Fluid bed reactor

-------
             The exhaust gases are cleaned  of  particulate  matter  In  a venturi




scrubber, and are discharged through a gravity separator as  a clean, nonpolluting,




odorfree white plume.  Ash-laden scrubber water is bled off  to the sewage  treat-




ment plant, and is used as a settling agent in that process.




     B.  Description and Evaluation of Process Streams.  The impact  of  the




Franklin plant on the environment can be measured only by  comparison of the




inflows, which formerly were dumped or buried, with the outflows  which  are now




either recycled, passed on to downstream treatment facilities, or emitted into




the air.  The material flows within the Hydrasposal and Fibreclaim processes are




considered proprietary information by Black Clawson.  This section of  the report,




therefore, is confined to the environmental impact concept.   The  material balance




given  in Table I, provides an overview of this analysis.   Subsequent paragraphs




give additional details of the various influent and effluent streams.
                                    20

-------
                                                    TABLE I
Weigh-In and Receiving

  Material In:

  Unsorted Solid Waste:

  Material Out:

  Unprocessible Material to
    Landfill:

  Material to Process:

  Total Material Out:


Hydrasposal and Fiber Recovery

  Material In:

  Solid Waste from Receiving:

  Raw Sewage Sludge:

  City Water:

  Total Material In:

  Material Out:

  Non-Ferrous Scrap to Landfill:

  Ferrous Scrap Recovered:

  Cyclone Rejects to Landfill:

  Waste Water:

  Fiber Recovered:

  Organic Rejects to Reactor:

  Evaporated Water:

  Total Material Out:
MATERIAL BALANCE
Wet Weight
(Tons)
13,900
220
13.680
13,900
13,680
0
144,100
157,780
450
930
1,390
116,000
310
17,970
20,900*
157,950
Percent
Moisture
20*
20*
20*
20
20
0
100
93
6
20
15
100
10
53
100
93
Water
(Tons)
2,800
40
2,760
2,800
2,760
0
144,100
146,860
30
190
210
116,000
30
9,520
20,900*
146,880
Dry Solids
(Tons)
11,100
180
10,920
11,100
10,920
0
0
10,920
420
740
1,180
0
280
8,450*
0
11,070
                                       0.1
.01
1.3
                                80




                                 1.4

                                78.6

                                80.0
78.6

   0



78.6



 3.0

 5.3

 8.5



 2.0

60.8



79.6


 1.2
*No measured data for these items.  Value extrapolated from other data.


The above material balance derived from raw data shows that errors in weight and flow measurements have

averaged less than 4 percent over the period of this report.  Since some input and output data were

estimated this is considered acceptable accuracy.
                                                      21

-------
         1.  Solid Waste Receipts.   Between May 31,  1971,  and  August  20,  1972,  a




total of 13,856 tons of refuse were received at the  plant.  Of this amount,




13,633 tons were processed through  the system.




             Although categorization of wastes was requested,  it has  not  been




recorded.  The plant operators, however, estimate that 85  to 90 percent of the




receipts are from residential sources.




             The tonnage received and not processed  consisted  primarily of large




items which are not grindable by the Hydrapulper, such as  vehicle tires,  large




steel drums, iron and wooden furniture, industrial pallets, automotive parts,




major household appliances, building demolition waste, dead tree trunks,  and




lumber.




             The Hydrapulper has proven able to process some items not originally




considered as processable, such as dead small animals, aluminum lawn furniture,




small appliances, television sets,  light drums, and some  industrial wastes.




             Solid wastes are collected in th? Franklin area by commercial haulers.




Incoming refuse  from  these haulers is received from packer trucks, and open dump




trucks.  Individuals  and  small haulers bring refuse in pickup trucks, station




wagons,  rental trailers,  and automobiles.  Obviously processable loads are dumped




on  the  receiving floor  and pushed  onto  the  feed conveyor  by means of a front-end




loader.  One plant operator acts as weighmaster,  receiving clerk, cashier, and




loader  operator.  It  is incumbent  upon  this operator  to scan  the incoming loads




and the material being  pushed  onto the  conveyor  to  extract unprocessable materials,




During  early  operations,  several instances  occurred where ungrindable  items were




charged into  the Hydrapulper with  resulting downtime  while  the  object was removed,




and,  if necessary,  repairs were made  to the Hydrapulper.  When  these materials
                                    22

-------
are spotted, they are pulled out,  set aside,  and  periodically sold  as  scrap  to  a




junk dealer.  Unsaleable items must be landfilled,  but these amount to only  about




1-1/2 percent of the tonnage received.  A design  change was  made which virtually




eliminated Hydrapulper downtime resulting from damage by this type  of  material.




         2.  Junk Remover Rejects.  Of the tonnage  processed, approximately




10 percent is ejected by centrifugal action through the junk chute  of  the Hydra-




pulper into the junk remover.




             The magnetizable, or ferrous, fraction averages 67-1/2 percent  of




the junk remover rejects, or 6.7 percent of the total refuse received.  This




consists mostly of cans, but also contains bottle tops, spark plugs, nails,  bolts




and an infinite variety of unrecognizable pieces.  This material is dumped into




detachable truck bodies in which it is hauled several times  a week  to  a nearby




steel company  (Armco) which pays the equivalent price of No. 2 bundles (presently




$13.30 per short ton) for it.




             No further recycling process is immediately contemplated  for the




nonmagnetizable rejects.  These rejects average 3.2 percent of the refuse tonnage




received, and are disposed of in the nearby plant landfill.




             Typical analyses of the junk remover reject streams are as follows:




             Sixty-eight percent of junk remover rejects are collected by the




magnetic separator.  Approximately 75 percent of this fraction is all-steel cans




and steel cans with aluminum  tops, while the remaining 25 percent usually is




spark plug's, nuts, bolts, wire, and automobile and appliance parts.  Of the




32 percent of  the junk remover rejects not collected by the magnetic separator




approximately  13 percent is nonferrous metal, 1 percent is ferrous  metal missed




by the separator, about 37 percent is miscellaneous objects such as rubber,
                                     23

-------
heavy plastics, stones, and large pieces  of glass,  and approximately  49  percent

is organic materials and water.

         3.  Liquid Cyclone Rejects.   Approximately 10 percent,  by weight,  of

the total refuse received is separated by the liquid cyclone.

             An average of analyses of the rejects  from the single liquid cyclone"

used during the demonstration period, shows this stream consists of:

             Description                            Percent (Dry Basis)

             Clear glass                                   37.9
             Green glass                                    4.2
             Amber glass                                   18.1            60.2

             Magnetic metals                                3.6
             Aluminum                                       2.3
             Other metals                                   0.6             6.5

             Large stones  (larger than No. 4 mesh)                           4.8

             Loss on ignition                                               8.3

             Miscellaneous materials  (plastics, rubber, etc,)              20.2

             Total                                                        100.0

             The waste  glass plant now under construction will receive  its input

from  the  liquid cyclone  discharge conveyor.  At present, however,  this  material,

along with nonferrous  junk remover rejects and  the unsaleable, unprocessable

material,  is buried  in  the plant  landfill.  During the demonstration period, the

cyclone rejects contained  a higher percentage of adherent  organic  material than

was  originally anticipated.  The  second  cyclone has helped  to reduce the amount

of this material,  but  the  waste  glass plant equipment  train will  include washing

and  screening  operations to ensure its removal, before color sorting the glass.

These contaminants will be returned  to the main plant  for  burning.

             Figure 13 in  Volume  II  shows  the  trends  in analyses  of  cyclone

rejects during the report  period.
                                     24

-------
Figure 7.   Cyclone rejects and junk remover rejects

-------
         4.  Recovered Fiber.   Fiber recovery operation  began  during  July  1971,




and continued through Aug. 28,  1971.  During this period 76.3  tons  of fiber




(air dried basis) were produced,  which was sold to the Logan-Long Company  of




Franklin, Ohio, manufacturers  of  roofing products.




             On Aug. 28, 1971,  fiber production for Logan-Long Company was




stopped because of operating problems on their paper machine.   Between Sep.  1




and Sep. 15, 1971, Logan-Long Company evaluated the performance of  their machine




using no reclaimed fiber.  During this same period, The  Black Clawson Company




and Logan-Long Company conducted  laboratory investigations into the cause  of the




problems.  The results of these investigations are discussed in Subsection C of




this section under the heading of "Operating Problems and Process Improvements."




             Fiber recovery operations were resumed in September and October to




produce fiber for a series of experimental papermaking tests being made by the




St. Regis  Paper Company, and were again resumed in November for Logan-Long Company




after both they and The  Black Clawson Company made process changes which enabled




Logan-Long to use the  recycled fiber.




             The quality of recycled fiber, when processed in a paperboard mill




equipped  to  eliminate  lipids and fines, is reported to be good.  No  analytical




data on the  experimental  paper and  board manufactured from the recovered fiber




have been reported.   The Logan-Long Company has reported that the fiber is  the




equivalent of  the composite of the  corrugated board, old newsprint,  and mixed




paper  currently  used  by them in  the production of  roofing felt.




              The  commercial viability  of  the  fiber recovery process  depends  not




only on the physical  usefulness  of  the fiber,  but  also  on the financial return




which  would result  Trom the additional  capital required  for this adjunct to  the
                                    26

-------
Hydrasposal system.  The Black Clawson Company reported for the "Interim Report,"

that the oven-dried fiber yield at the Franklin plant was 5 to 7.6 percent of thp

refuse tonnage received at the plant, compared to the 18 percent yield indicated

by the Middletown pilot plant operation and several experimental runs at Franklin

For this Final Report, The Black Clawson Company stated the yield was 1 percent

of the total refuse received.  Since the end of the demonstration period, several

modifications to the system have been made which have increased the yield to a

reported 14 percent of the total tonnage received.  The cost figures obtained for

the Interim Report showed the Fiber Recovery operation increased the operating

deficit.  No separate cost figures for the Fibreclaim system were made available

for the Final Report.

             The tonnage of fiber produced during the report period is shown in

Figure 3 in Volume II.

         5.  Waste Water.  Now that sewage sludge is being dewatered and burned

in the fluid bed reactor, part of the total waste water discharge is that which

has conveyed the sludge to the solid waste plant.  This water is segregated to

prevent contamination of the plant process water with untreated sewage water.

             Process water is constantly withdrawn from the system to reduce the

level of total and dissolved solids in the process water.  This is replaced with

fresh water makeup.  During the period of this report, this makeup was supplied

entirely from City water but the present operation uses treated effluent water

from the sewage treatment plant.

             An average analysis of the waste water is as follows:

             pH                                   5.6
             Five day BOD                     3,973 mg/liter
             Suspended solids                 5,119 mg/liter
             Total dissolved solids           3,739 mg/liter
             Settleable solids                5,675 mg/liter
                                   27

-------
Figure 8.   Paper fiber being loaded for shipment
                               28

-------
             Temporarily, the waste water was piped to an aeration basin installe<

by MCD to serve until the sewage treatment plant was completed.   The treated watei

was then discharged to ground absorption.  This water is now piped directly to

the sewage treatment plant.

             Detailed analyses of the various plant waters are given in Volume II

         6.  Sewage Sludge.  Because the area waste water treatment plant built

by the MCD had not been completed, no sewage sludge was burned during the report

period.

         7.  Ash Slurry.  Approximately 35 gpm of ash slurry is bled from the

scrubber-separator water recirculating system.  This quantity can be varied to

limit the amount of total solids in this system, but it is now run at a constant

rate because of failure of the flowmeter supplied with the scrubber.

             An average analysis of the nsh slurry water is as follows:

             pH                                   8.9
             Total solids                     14,715 rag/liter
             Suspended solids                 12,438 m^/liter
             Dissolved solids                  2,732 rag/liter
             Settleable solids                 9,941 rag/liter
             Total volatile solids             1,483 mg/liter

             Variations in the chemical and physical properties of the ash slurry

are shown in the Analytical Data Summary in Section VI-B.  Before the MCD sewage

treatment plant was completed, the ash slurry was temporarily discharged to

surface drainage.  When  the sewage treatment plant became operational, this

slurry was then connected to the industrial primary clarifier where it is now

used as a settling agent.  (See Figure 1).
                                    29

-------
         8.   Stack Gases.   The products  of  combustion  from the  fluid  bed  reactor




are conveyed through a downflow venturi  scrubber,  then up  through  a gravity




separator column before being discharged to atmosphere.




             From Dec. 28,  1971, through Jan. 4,  1972, a field  crew from




Environmental Sciences, Inc., of Pittsburgh, Pennsylvania, performed  a series of *




three tests covering simultaneous sampling of the emissions from the  fluid bed




reactor and the emissions from the scrubber serving the reactor.  The data taken




consisted of the collection and analysis of the particulate and gaseous emissions




in the stack gases.  Also during each test, samples of the inlet and  outlet




scrubber water, and of organic rejects fed to the reactor were  collected, so that




a complete material balance could be performed on the entire system.




             The purpose of the testing program was to determine the  air pollution




emissions from the fluid bed reactor in order to certify to the City of Franklin




and to the State of Ohio the quantity and nature of the air pollutants being




emitted from the process.  Tests of the fluid bed reactor and the venturi scrubber




were also needed by A. M. Kinney, Inc., to prepare this comprehensive evaluation




of the treatment process.  The  testing program permitted  the determination of the




emissions from the fluid bed reactor when operating at normal operating capacity




at steady state, as well as  the determination of the collection efficiency of the




venturi scrubber serving the  fluidized bed reactor.
                                     30

-------
             Based upon the results of the three tests performed on the inlet and

outlet of the scrubber, the following average results were reported by Environ-

mental Sciences, Inc.
             Scrubber dry solids removal efficiency
             Scrubber condensables removal efficiency
             Solid particulate loss on ignition (900 C)
                  Parameter

                  Grain loadings - grains per
                   standard dry cu ft (SDCF) at
                   12 percent carbon dioxide

                  Grain loadings - grains pe*-
                   SDCF - acutal reading

                  Condensables - percent

                  Particulate flow - Ib/hr

                  Volumetric flow rate SDCF
                   per minute

                  Gas temperature - F

                  Water - percent

                  Sulfur dioxide—parts per
                   million  (ppm)
Inlet

     4.5



     2.542


     1.0

   358

16,500


  1400

     5.5

 45
98.8 percent
23.5 percent
 3.3 percent

Outlet

  0.076
  0.043


 45.5

  6.11
190

 34.1

less than 7
                  Nitrogen oxides—ppm                143            125

                  Aldehydes                           none           none

                  Hydrocarbons                        none           none

                  Carbon monoxide                     trace          trace

                  Chlorides—Ib/hr                      4.7            0.43

             The data given above show  that  the effluent from the fluid bed

 reactor contains only a trace of combustible material, either as gases or solids.

 These  results  indicate that the reactor  is an efficient thermal oxidizing system.
                                    31

-------
The venturi scrubber and mist separator remove about 98 percent  of  the dry and




condensable particulate.  Since the scrubber system operates at  a differential  of




only 7 inches of water, its performance is considered excellent.




             The impinger water was very acidic and analysis indicated unmeasurably




small amounts of nitrates and fluorides, with most of the soluble,  condensable    «




material in the form of sulfates and chlorides.  The scrubber water is only




slightly acidic (pH approximately 6.0) and a chemical analysis indicated large




amounts of solids and dissolved particulates, with high quantities  of sulfate and




chlorides, and only minor amounts of other ions.




             The quality and quantity of the particulate and gases  theoretically




emitted from the reactor and the measured quantities of material picked up by




the scrubber water system did not balance well with the measured concentrations




of pollutants in the stack gas due to errors involved in:   (1) obtaining a




representative sample of scrubber water;  (2) estimating scrubber water flows and




refuse  fuel consumption; (3) an accurate  fuel analysis;  (4) not chemically




analyzing  the solid particulate collected during  the test,  and  (5) miscellaneous




problems  that could be  Isolated and solved only by  extensive research.




             These  test^ show  that the  emissions  from  the scrubber are below the




limit of  0.1 grain  per  standard dry cubic foot of  gas  flow  (corrected  to  12 percent




carbon  dioxide)  set by  the  process equipment  specifications, which were based  on




Federal guideline specifications  in effect at  that  time.




             Regulations adopted  by the State  of  Ohio  Air Pollution Control Board,




on Jan. 28,  1972, with an  effective date  of  Feb.  15, 1972,  limit dust  emissions




from incinerators to  0.1 pounds of particulate matter  per 100 pounds  of dry
                                    32

-------
combustible refuse charged, as determined by ASME power test  Code  PTC-27  when

operating at the manufacturer's maximum rating.   Converting the results of  these

tests to this basis, shows an average emission rate of 0.07 pounds per 100  pounds

of refuse burned in the reactor.

             In an independent test conducted by Dorr-Oliver, Inc., in April 1972,

results showed an emission rate of 0.09 pounds per 100 pounds of refuse burned.

The increase is believed to be due to the fact that the venturi cone had  been

tipped over.  Since that test, the venturi cone has been replaced.

         9.  Organic Rejects.  Although it is not an external stream, the fuel

feed to the fluid bed reactor also was monitored during the evaluation period in

order to gather operating data on this key element of the Hydrasposal system.

The physical characteristics of the reactor sand bed and the ash from the reactor

fuel are also analyzed at monthly intervals.

             The average analyses of the organic rejects are as follows:

             Ultimate Analysis                            Percent

                Moisture                                   52.26
                Carbon                                     24.20
                Hydrogen                                    3.14
                Oxygen                                     15.55
                Nitrogen                                    0.07
                Sulfur                                      0.10
                Ash                                         4.88

             Proximate Analysis                           Percent

                Moisture                                   52.26
                Volatile                                   37.82
                Ash                                         4.88
                Fixed carbon                                5.01

                Heating value  (oven dry basis) 7,454 Btu per pound
                                    33

-------
             Figure 4 in Volume II illustrates the variations  in proximate analyses



of the reactor fuel.  Individual tests are tabulated and summarized in Appendix A.



        10.  Auxiliary Fuel.   No. 2 commercial fuel oil is used to preheat the bed



sand in the fluid bed reactor in order to bring it up to minimum operating tempera-



ture.  When the bed reaches this temperature, feeding the dewatered organic rejec'ts



is begun, and, under normal operation, all of the rejects burn without support



fuel.  Under unusual or upset conditions, such as periods of intermittent organic



reject feeding, it has been necessary to fire supplementary fuel through oil guns



located within the static bed level to maintain minimum bed temperature.  During



the period of this report a total of 44,770 gallons of fuel oil were used, including



approximately 4,600 gallons used during a period when organic rejects were drawn ofl



intermittently for test purposes, thus interrupting continuous feed to the reactor.



        11.  City Water.  During the demonstration period covered by this report,



City water was used as  the sole source of makeup water to the system.  Now that the



sewage treatment plant  has been completed, its effluent is being recycled for use
                                                                         /


as process water.  Usage of City water is being continued, in the venturi scrubber



sprays and as seal water.



             Actual quantities of City water  used were recorded  for only 12 weeks



of the evaluation period due  to  extremely erratic and unreliable operation of  the



City water meter.   Based on such of those readings  as were deemed  reliable, City



water usage was  estimated  on  a weekly basis  to be a total of  34,598,200 gallons



 for  the  entire evaluation  period, or  an  average of  2,537  gallons per  ton of



 refuse processed.   This is equivalent of 263  gpm.
                                     34

-------
             Similarly, waste water discharged was estimated to be 27,855,000




gallons for the entire evaluation period.  This results in an average of 2,043




gallons per ton of refuse processed, or 212 gpm.




        12.  Electric Power.  Electric power service to the plant is supplied by




The Cincinnati Gas & Electric Company, through a single 2,000 kilovolt-ampere (kva)




transformer and meter serving both the Hydrasposal and Fibreclaim systems.  A




separate temporary connection was installed to serve the floating aerator in the




temporary waste water treatment basin.  The sewage treatment plant is served by




its own transformer and meter.




             Power consumption for the report period was a total of 2,390,400




kilowatt-hours (kwh).  No measurement of the division between Hydrasposal and




Fibreclaim systems is available.




             The unit consumption of electric power during report period is com-




puted as follows:




             2,390,400 kwh consumed, divided by the 13,633 tons processed, equals




175 kwh per ton of refuse.  Because this quantity includes the start-up period




it is to be considered as order-of-magnitude only.




        13.  Rejects to Landfill.  The three streams which go to landfill are




summarized as follows:




             a.  Unprocessable Refuse Received.  Consists of large or heavy un-




grindable or unfriablc items.  This fraction averages approximately 0.66 tons




per day or 1-1/2 percent  (by weight) of refuse received.




             b.  Nonferrous Junk Remover Rejects.  Consists of smaller ungrindable




or unfriable materials.   This  fraction averages approximately 1.45 tons per day,




or 3.2 percent  (by weight) of  the refuse received.
                                    35

-------
             c.  Liquid Cyclone Rejects.   Consists of  inorganic rejects,  3/4  inch

and smaller, which have passed through the extractor plate of the Hydrapulper,,

This stream contained an average of 8-1/2 percent putrescible organics with the
                                                                                  •
single cyclone used during the demonstration period.

                 All of the cyclone rejects, which now go to landfill, average     •

approximately 10 percent (by weight) of the refuse received.

                 In the summer of 1973, this stream will be diverted to the waste

glass recovery system, where the glass and aluminum between 1/8 inch and 3/4 inch

will be recovered for recycling.  T;'_ remaining undersize and oversize material,

stones, plastics, and metals will continue to go to landfill, but the putrescible

organic portion will be returned to the Hydrasposal system for incineration in

its fluid bed reactor.

                 The total of reject streams going to landfill during the report

period averaged 15 percent of the tonnage received.  No total measurement of

volume to landfill was made, but this fraction is estimated to be less than

5 percent of  the total volume received at this plant.

                 Figure 2 in Volume II shows the variations in quantities and

constituents  of the material taken  to the plant  landfill.  Quantities are reported

by  the plant  operators on an oven-dried basis, in order to eliminate variations

in  actual tonnage due  to varying moisture contents.

     C.  Operating Problems and Process Improvements.  While  the  physical data

in  this report are concerned primarily with quantitative  and  qualitative analysis

of  external process  streams,  the overall effectiveness of  the Franklin demonstra-

tion plant  is dependent on  its  internal operation.
                                    36

-------
         The problems which have affected overall plant operation,  and the




improvements which have been made, are thus an integral part of this analysis.




         1.  Refuse Receiving.  For economy reasons, the refuse receiving area




was designed as an open-ended, high-walled shed.  The basis for computation of




receiving floor space was that the entire area, except for walking  aisle space,




would be used for receipts.  This has proved impractical for operation of the




front-end loader.  As a result, when a number of trucks arrive within a short




time span, it is necessary to accumulate the refuse on the ramp leading to the




receiving floor until the peak is worked off.  Although this has been unsightly,




and outside operation of the front-end loader during inclement weather is incon-




venient, the plant operators believe that no remedial action is economically




justifiable.         A




             Another operating problem was the presence of maggots  in the apron




conveyor pit and sump, on the receiving floor, and on the operating floor.  This




problem was worst during the first summer of operation, but it has  been controlled




since then by the regular use of insecticides.




             A continuing problem is tire wear on the front-end loader.  The




operating conditions for this machine result in the need for replacement of the




tires approximately every 6 months despite a switch to solid heavy-duty industrial




tires.




             To compensate for maintenance downtime on the front-end loader, the




plant service truck was purchased with a snowplow blade, which permits its use in




pushing refuse onto the conveyor.
                                     37

-------
         2.  Hydrasposal System.




             a.   Hydrapulper.




                 (1)  It was found In initial operation the apron conveyor caused




large quantities of dust and dirt to fall out onto equipment and personnel below




it, and that the Hydrapulper was  splashing dirty water over the floor and visitors,




Therefore, a fiber glass cover was fitted over the Hydrapulper and conveyor,




equipped with access doors and a  monorail for access to the pulper.  Rapid access




is needed in order to remove ungrindable materials and to work on the rotor.




                 (2)  A high maintenance item is replacement of the swing hammers




on the rotor of the Hydrapulper.   During the report period, life of the hammers?




was reported to be about 300 operating hours, and replacement time was reported




to be approximately one hour.  Development work has improved the effectiveness




and service life of the hammers.




                 (3)  Retrieval of unprocessable material that inadvertently




entered the Hydrapulper, and repair of damage caused by it, caused some minor




service interruptions during early operating periods.  A design change to the




Hydrapulper has apparently  corrected the damage problem, and operators have




learned to watch the material on  the conveyor more closely.  Outages of  this type




have ranged from 1/2 hour to 2 days.




                  (4)  Excessive vibration of the Hydrapulper occurred during the




initial operation  period.   The addition  of heavy crossbracing  to  the pulper




supporting structure has  largely  eliminated  this problem.




              b.   The Hydrapulper  dump  pump has  been a  relatively  high maintenance




problem,  primarily due  to the highly abrasive material it  handles.   The  pump




 casing and other  wetted parts have  been  subject to  repeated  replacement.
                                     38

-------
             c.  Hydradensers.  The lack of consistent performance by the solid




waste plant Hydradensers (dewatering screws) was the subject of continuing




developmental work.  Their erratic water removal characteristics and the need for




frequent adjustment has had an adverse effect on experimental work on the burning




of organic rejects, and on the plant maintenance costs.  Design changes have now




corrected this situation.




             d.  Fluid Bed Reactor.




                 (1)  The following three problems related to the sand bed of the




reactor have occurred during -.his report, period:




                      A gradual attrition of the sand in the fluid bed, caused by




the mechanical agitation of the sand, has resulted in fine particles of silica




being carried over into the scrubber-separator and the buildup of silicon-rich




scale in the separator.  This was manifested as stones which caused some damage




to the scrubber water pump, until the operators began to inject a dispersion agent




into the system.  This chemical, similar to that used in boiler water treatment,




tends to keep  the scale soft and in suspension in the scrubber water.




                      A gradual agglomeration of the sand and its retention of




mineral ash and glass particles, resulted in an increase in the size of the bed




sand particles.  This became evident from sieve analyses and increases  in fluid-




izing air blower horsepower requirements.   In February 1972, it became  necessary




to replace the entire sand bed, because of  accumulation of large masses of




agglomerated sand.  The operating contractor has instituted a program of periodic




replacement of the sand bed, and has reduced the maximum operating temperature




limit.
                                     39

-------
                      Slag tends to build up at the  top  of  the  reactor  chamber  and

in the cross-over flue from the reactor to the venturi scrubber.   In some places

deposit had reduced the flow area of this duct by more than half.   This had been
                                                                                  •
attributed to excessive free-board temperatures causing low-melting-point ash to

deposit in the duct.  Consequently, the point of fuel feed  to the  reactor has beerv

lowered, and the plant operators have reset the controls to maintain a  1,400 'F

maximum free-board temperature.

                 (2)  During early operations the rotary feeder which passes the

pulped organic rejects into the pneumatic feeder supply to  the fluid bed reactor

repeatedly plugged and constantly limited the firing rate.   To overcome this

problem, this feeder was replaced with one of a different design with the result

that plant throughput capacity has been noticeably increased.

             e.  Miscellaneous.  A number of relatively minor additions and

corrections were made during the demonstration period, to improve the operation

of the Hydrasposal process.  Among these have been modifications to the junk

remover to eliminate excessive water carryover, relocating access doors in the

Junk  remover, changes  in  instrumentation and control, and provision of  an additional

access door and  sand removal spout in  the fluid bed reactor.  In addition, the

original  1,500 kva power  transformer was replaced with a 2,000 kva  transformer  in

order to  provide the additional  electrical  power capacity required  for  the waste

glass recovery plant and  for changes in  the  fiber recovery process.

              f.  Plant Design  Limitations.   The  requirement  of minimal  first cost

placed limitations on  the design of  the  Franklin plant which have resulted in

-------
several operating problems that cannot be economically corrected.  Among those




which should be considered in the design of future plants are:




                 In addition to the previously mentioned space problem in the




receiving area, limited space in the Hydrasposal area has resulted in a crowded




equipment arrangement, which in turn makes difficult access to some areas for




maintenance and housekeeping.




                 A somewhat annoying operating problem is the excessive amount of




process water spillage on the operating floor in the Hydrasposal area.  While the




amount of water on the floor may not be considered excessive by contemporary paper




mill standards, it is excessive from both a housekeeping and sanitary standpoint.




In future designs, consideration should be given to improving drainage in this




area.




                 Another problem at the Franklin plant for which there appears to




be no simple solution is the high noise level around the Hydrapulper.  While future




plants may be able to overcome this problem, the Franklin plant layout precludes




construction of sound-attenuating walls.  However, it should be noted that the




operator's station at Franklin is in the control room, where the sound level is




below the 80 dbA continuous occupancy limits of the Occupational Safety and Health




Act, and that occupancy of areas having sound levels higher than 80 dbA is abnor-




mal and for a relatively short time.




         3.  Fibreclaim System.




             a.  Fiber Quality.  As stated heretofore, fiber recovery production




for the Logan-Long Company was stopped on Aug. 28, 1971, because of problems




experienced on their paper machine when using the recycled fiber from the solid




waste plant.  The Black Clawson Company later reported that tests made by
                                     41

-------
Logan-Long Company with their paper machine, and tests made by The Black Clawson




Company in their laboratory indicated the cause of the problem was the concentra-




tion of lipids and fines which occurred when the recirculating process water




system, (known in the pulp and paper industry as the "white water system"),  was




closed up; i.e., when a higher percentage of the total white water flow was




recirculated, a lesser amount bled off to waste, a therefore less "fresh water"




added to the system.  This action caused an increased amount of lipids and fines




to be present and to adhere to the fiber.




                 In the papermaking operation, as at Logan-Long Company, water




is removed from the newly formed sheet by pressing it out through a series of




wringers, called press rolls.  The sheet of paper is supported at the press rolls




by a very porous woolen blanket, which also serves as a medium whereby the




pressed-out water may be removed; i.e.,  the water leaves through the pores in  the




blanket.  The fines and lipids apparently fill up these pores, resulting in




reduced life of the blankets.




                 The condition was corrected temporarily by employing an excessive




amount of fresh water  in the  fiber recovery operation, with equivalent increased




bleed-off from  the  system  to  reduce  the  equilibrium level of  fines and lipids  in




the white water, and by installation  of  a high pressure shower to clean  the




blanket on  the  Logan-Long  Company paper  machine.  Since that  time, The Black




Clawson Company has  installed a  flotation clarifier in the white water recycling




system to reduce  this  contamination.   Logan-Long  now  regularly uses the  recovered




fiber in  their  production  process.
                                     42

-------
             b.  Fiber Yield.   Primarily due to problems associated  with scaling




up from pilot plant to full-scale commercial operation,  the yield of recovered




fiber has been substantially below expectations.




                 The screening system,  which selectively sorts out the recyclable




long fibers, was sized according to secondary fiber paper mill standards.  The




screens were found to be inadequate due to the much higher quantities of plastics,




rubber, etc., present in the solid waste slurry.  As a result, the fiber recovery




department could not operate at the capacity of the balance of the plant.  Several




experimental runs were made at reduced  overall capacity, and the anticipated yield




of more than 20 percent on an air-dried (10 percent moisture) basis, was realized.




Additional screening capacity was installed and improvements made to the reject




screening system so that yields now are estimated by The Black Clawson Company to




be about 14 percent of the tonnage received during the period when the plant is in




operation.
                                   43

-------
                     SECTION IV - ECONOMIC ANALYSIS



     A.  Construction Costs.  The following construction cost report,  prepared


by A. M. Kinney, Inc., is based on value of the process equipment contract at
                                                                                  :

the end of the demonstration period, and the final contract values for the con-


struction contracts.  The final value given for the mechanical contract includes


$3,230 for installing additional nozzles and temporary scaffolding to  make the


stack gas analysis.  The process equipment contract was kept open after the end


of the demonstration period to cover process changes in the Fibreclaim System.


         The general construction work, including site development, grading,


foundations, structural and miscellaneous steel, building work, paving, painting,


and landscaping, was done by the Monarch Construction Company of Cincinnati, Ohio.


         The mechanical construction, including installation of all Owner-


furnished process equipment, contractor-furnished mechanical equipment, piping,


ductwork, instrumentation heating, ventilating, and plumbing was done by Hughes-


Bechtol, Inc., of Dayton, Ohio.


         Electrical construction work, including furnishing and installing


temporary construction power and all lighting, electrical conduit, wire,  fixtures


and equipment, grounding system, electrical controls, and instrumentation was


done by the Gustav Hirsch Organization, Inc., of Columbus, Ohio.


         Sprinkler construction work including furnishing and  installing  all


materials for  the  sprinkler system  in  the  receiving area, was  done by  the


Cincinnati  Sprinkler  Company of Cincinnati, Ohio.
                                     44

-------
         The sound system for the project included furnishing of equipment for




an industrial page-party phone and speaker system.  This was done by J. W.




Thompson Company of Middletown, Ohio.  Installation was under the electrical




contract.




         Process equipment includes the Hydrapulper, liquid cyclone, tanks, pumps,




fluid bed reactor, venturi scrubber and gravity separator, screens, process




instruments, and controls.  This was supplied by the Shartle-Pandia Division of




The Black Clawson Company of Mlddletown, Ohio, who also supplied the process




design information, including flow r*»tes, pressures, consistencies, and equipment




dimensions and weights.  The only breakdown of this contract available is between




the solid waste disposal plant and the fiber recovery plant.  No details of this




breakdown, such as the cost of individual items of equipment, cost of subcon-




tracted systems (such as the reactor, scrubber and separator), or the cost of




process engineering have been released by The Black Clawson Company, so that the




detailed breakdown into operation centers, given in the following pages, repre-




sents the authors' estimate of these costs.




         The miscellaneous equipment listed in the General Cost Summary Includes




such items as the plant service truck, forklift truck, front-end loader, drop-




bottom hoppers, cash register and office furniture.  The items were purchased




from several equipment suppliers on the basis of competitive, public bidding.




         Construction costs are shown in the General Cost Summary on the follow-




ing pages.  The breakdown of construction costs by operation centers represents




estimated cost allocations, based on a detailed review of contractor's payment




requests for various portions of the work, such as structural concrete, process




piping, etc.
                                     45

-------
                          CITY OF JRANKLINy,OHIO

                   SOLID WASTE AND  FIBER RECOVERY PLANT

                              COST ANALYSIS

                     GENERAL CONSTRUCTION COST  SUMMARY

                              ACTUAL COSTS
Item
    City
Unreiobursed
                                                        Solid Waste Plant
Federal Share    City Share
     Total
Process equipment

Construction
 General construction
 Mechanical construction
 Electrical construction
 Fire protection
 Sound system.-
    Sub-total

Miscellaneous equipment

Present construction and
 equipment contracts

Engineering (as of
 Dec. 31, 1971)

Total
$ 2,250.00     $  506,564.67    $  253,282.33   $  759,847.00
$   779.00
$   779.00
$ 3.029.00
$ 3,029.00
$  152,260.34
   179,075.33
    66,765.15
     2,900.00
	445.11
$  401,445.93

    24,771.23
$  76,130.16
   89,537.67
   33,382.57
    1,450.00
	222.55
$ 200,722.95

   12.385.59
$  228,390.50
   268,613.00
                                                   4,350.00
                                                     667.66
$  602,168.88

    37,156.82
$  932,781.83   $ 466,390.87   $1,399,172.70
                   81.994.12
                   40.997.06
   122,991.18
$1,014,775.95   $507,387.93    $1,522,163.88
                                     46

-------
                                                    General Site
	Fiber Recovery Plant	       Improvements
Federal          Black Clawson                    Miami Conservancy        Combined
 Share               Share            Total        District Share           Totals


$ 121,651.33     $   60,825.67     $ 182,477.00     $    —              $  944,574.00


$  48,346.67     $   24,173.33     $  72,520.00     $  3,465.50          $  304,376.00
   65,317.99         32,659.01        97,977.00        6,973.00             374,342.00
   31,082.58         15,541.28        46,623.86          —                 146,771.58
                                                                              4,350.00
      —         	—               —              —                     677.66
$ 144,747.24     $   72,373.62     $ 217,120.86     $ 10,438.50          $  830,507.24

    1.663.20     	831.60         2,494.80          —                  39.651.6;


$ 268.061.77     $  134.030.89     $ 402.092.66     $ 10.438.50          $1,814,732.8(
                     41.138.55        41.138.55          —                 164,129.7.'
$ 268,061.77     $  175,169.44     $ 443,231.21     $ 10,438.50          $1,978,862.5'
                                     47

-------
                         CITY  0? FRANKLIN, OHIO

                   SOLID WASTE AND  FIBER RECOVERY PLANT

          BREAKDOWN OF CONSTRUCTION COSTS BY OPERATION CENTERS

                              ACTUAL COSTS
I tea
Totil construction and
Unreimbursed
  Work For
    City
                                                       Solid Waste  Plant
Weighing and
 deceiving
 Hydrapulping
And Separation
Process equipment
Construction
General construction
Mechanical construction
Electrical construction
Fire protection
Sound system
Sub-total
Miscellaneous equipment
$ 2,250,00

$ —
779.00
*-—
$ 779.00
—
./ 21,127.00

94,782.06
9,079.00
9,840.00
4,350.00
166.00
$118,217.06
20,056.94
$ 339,720.00

68,517.15
142,523.00
55,249,99
334.00
$ 266,624.14
17,099.48
                                                             .  r* %  .  ,
                                $ 3,029.00      $159,401.00 '-  .? $ 623,443.62
                                           48

-------
       Solid Waste Plant
 Fluid Bed
  Reactor
 Solid Waste
 Plant Total
 Fiber
Recovery
 Plant
  General Site
  Improvements
(Charged to MCD)
Totals
$399,000.00
$  759,847.00    $182,477.00
                                  $  944,574.00
$ 65,091.29
117,011.00
35,057.73
—
167.66
$217,327.68
—
$




$

228,390.50
268,613.00
100,147.72
4,350.00
667.66
602,168.88
37,156.82
$ 72,520.00
97,977.00
46,623.86
—
—
$217,120.86
2,494.80
$ 3,465.50
6,973.00
—
—
—
$ 10,438.00
._
                                                                    $  304,376.00
                                                                       374,342.00
                                                                       146,771.58
                                                                         4,350.00
                                                                    	667.66
                                                                    $  830,507.24

                                                                        39,651.62.
$616,327.68
$1,399,172.70    $402,092.66
                $ 10,438.50
                    $1,814,732.86
                                     49

-------
         The construction costs were tabulated from the original fixed price




contracts to which was added the amount of the various change orders.   A sub-




stantial number of change orders were issued which is not unusual for a




developmental project such as this, where scale-up problems must be solved while




construction and operation is proceeding.                                         '




         The original fixed price contracts exceeded original estimates of plant




cost because the early estimates were based on preliminary flow sheets and equip-




ment arrangements.  The final design of the plant included many items such as the




plant service truck, hoppers, air compressors, fuel oil storage and supply system




which were not envisioned in early estimates.  The sizes and space requirements




for some equipment turned out to be larger than initially anticipated, partic-




ularly in the case of the fluid bed reactor and its ancillary equipment.




         The construction cost figures shown in the following table are estimated




for a 150 ton per day plant similar to the Franklin plant but built without




Federal assistance at 1972 prices.  They are based on The Black Clawson Company




estimates that a complete, installed plant identical to the Franklin plant




would cost about $3,000,000.  This estimate includes building, foundations,



process equipment, reactor, auxiliary equipment,  instruments, controls, and




engineering  for complete  functional Hydrasposal and Fibreclaim plant, but does




not  include  cost of  land, nor does it include  cost of  any standby equipment.
                                     50

-------
                    PROJECTED CONSTRUCTION COSTS FOR

                     SIMILAR FACILITY BUILT IN 1972
150 Ton per day plant
estimated at 1972 costs
Hydraposal
Fibreclaim
Total
Process equipment
Construction
General construction
Mechanical construction
Electrical construction
Sub-total
Miscellaneous equipment
Total construction and
equipment
Engineering
Total
$
$
$
$
$
1,140,000
340,000
400,000
150,000
890,000
55,000
2,085,000
165,000
2,250,000
$ 360,000
$ 120,000
160,000
70,000
$ 350,000
5,000
$ 715,000
35,000
$ 750,000
$ 1,500,000
$ 460,000
560,000
220^000
$ 1,240,000
60,000
$ 2,800,000
200,000
$ 3,000,000

B. Actual and Projected
Operating Costs
         1.  Tabulated Cost Data

             The following two pages show the operating cost analysis, exactly as

reported by Black Clawson Fibreclaim, Inc.  These cost figures are reported to be

the actual expenses paid by the operating contractor during the period noted.  To

avoid misleading the reader, the authors have prepared an additional table of

"Estimated Total Operating Costs", which includes certain additional costs which

have been paid directly by the City of Franklin, and which should be included in

the cost of plant operation.  These charges include insurance, debt service on the

total investment, and cost of city water.  This table is presented immediately

following the Black Clawson Flbreclaim, Inc., report.

                                     51

-------
COLUMN
                     BLACK CLAWSON FIBRECLAIM,  INC.
             SUMMARY OF INCOME AND EXPENSE - FRANKLIN PLANT
                  MAY 17,  1971 THROUGH AUGUST 31,  1972
  I.
  II.
Actual operating revenues and costs of the Franklin Plant period
above.  The Tonnage disposed of 13,554 was limited to the total
supplied by the Franklin community (approximately 40 tons per day)
and not the Plant's available capacity (198 tons per day i.e.
9 T/hr. x 22 hrs./day).

Projected operating costs for the same period based on present rate
of disposal (9 tons per hour x 22 hrs./day x 330 days/yr.) and
current rate of fiber yield (14%).
Tons Processed
                                          13,554
                                                                    II
                                                      65.340
                                     AMOUNT    PER TON
                                                 -AMOUNT
               PER TON
INCOME

  Dump Fees
  Metal Sales
  Fiber Sales
       Total

OPERATING EXPENSES

  Labor - Operations
  Labor - Maintenance
  Supplies
  Materials - Repairs & Maint.-
                     Building
  Materials - Repairs & Maint.-
                     Equipment
  Fuel Oil
  Power
  Other Expenses
         Total
 Grant Proceeds

 Profit (Loss)  from operations
                       $  79,932   $  5.90
                          13,615      1.00
                           4,686       .35
                       $  98,233   $  7.25
                          56,988      4.21
                          30,485      2.25
                          11,099        .82

                           4,365        .32

                          80,711      5.95
                           2,045        .15
                          60,311      4.45
                          22,464      1.66
                        $  268,468    $  19.81

                        $(170,235)   $(12.56)

                        $  113.490    $  8.37

                        $  (56.745)   $  (4.19)
$ 385,506
   65,340
  228.690
$ 679,536
  141,250
   37,500
   16,000

    4,365

  305,794
    2,837
  162,697
   33.971
$ 704.414

$( 24.878)
$  5.90
   1.00
	3.50
$ 10.40
   2.16
     .57
     .25

     .07

   4.68
     .04
   2.49
     .52
$ 10.78

$(   .38)
                                    52

-------
                      BLACK CLAWSON FIBRECLA1M,  INC.
                          FOOTNOTES TO STATEMENT
1.  Fiber yield during the specified period was 1% in contrast to the present
    14% yield.  Subsequent to August 30, 1972, the expiring date of the grant
    period, the Fibreclaim Department of the Franklin Plant has increased the
    yield using procedures developed in Black Clawson's Middletown, Ohio Pilot
    facilities.

2.  A grant of $145,166 was received from governmental funds during the period
    covered by this report.  The grant's purpose was for both operating and
    start up costs.  The grant was not to exceed two-thirds of the total loss.
    The total loss Including start up costs was in excess of this amount.  For
    purposes of this report the $145,166 grant has been applied up to the two-
    thirds limitation against the operating loss of $170,235.  The remaining
    $31,676 has been applied against start up expense as explained in Footnote 3.

3.  The statement above presents the actual operating cost for the solid waste
    disposal system at Franklin, Ohio.  The statement excludes extraordinary and
    nonrecurring expenses of $147,108 (net after grant proceeds of $31,676),
    which were incurred due to start up, special demonstrations and evaluations.
    Additional costs of $54,421 were incurred in debt servicing payments to the
    City of Franklin.
                                     53

-------
                           TOTAL OPERATING COSTS
Tons Processed
                                           13,554
                                           II
                                         65,340
                                       AMOUNT     PER TON     AMOUNT
                                               PER TON
INCOME

  Dump Fees
  Metal Sales
  Fiber Sales
     Total
EXPENSES

  Operating Labor
  Maintenance Labor
  Maintenance Materials -
  Maintenance Materials -
  Fuel Oil
  Power - Electrical
  Operating Supplies
 *Miscellaneous Expenses
  Insurance
  Debt Service
  Water Cost
     Total

Net Loss
Building
Equipment
            $  79,900   $  5.80    $ 385,500
               13,600      1.00       65,340
                4.700       .34      228.690
            $  98,200   $  7.14    $ 679,530
$










57,000 $
30,500
4,500
81,000
2,000
60,300
11,100
3,800
11,300
195,000**
17,300
4.16
2.23
0.30
5.91
0.15
4.40
0.81
.28
.82
14.23
1.26
$ 141,250
37,500
4,500
305,800
2,800
162,700
37,500
3,800
11,300
195,000
82,900
$
$
$









$
5,
1.
3.
10,,
2.,
„
((
4,.
(i
2,,
„
tl
it
2,,
1.
15.
90
00
50
40
16
57
07
68
04
49
57
06
17
98
26
05
            $ 473,800   $ 34.55    $ 985,050
            $(380,800)  $(27.81)   $(305,520)  $(4.65)
*Miscellaneous expenses includes office supplies, telephone, plant security and
  equipment rental.
**6%  interest for 25 years.
                                      54

-------
          2.  Analysis of Cost Data




              The operating cost data presented in the foregoing tables provide




an overview for those who are interested only in results of the plant as a whole.




For those interested in an academic, in-depth analysis of the costs associated




with the various plant subsystems and operations, the data made available for




this report are notably deficient, and provide an example of the necessity for




establishing and enforcing cost-reporting criteria and procedures at the outset




of future demonstration projects.  Had these requirements been firmly established




before construction began, much more complete and accurate data undoubtedly would




have been available.




              The cost elements which have been reported reflect an increase




over the originally estimated operating costs.  The authors attribute this




increase to:




              1.  Increased maintenance and power costs resulting from equipment




added to improve fiber yield, reclaim magnetic metals, etc.




              2.  Higher than anticipated overhead costs on operating labor.




              3.  Higher cost of makeup water to system due to higher unit cost




of city water as compared to the cost of sewage plant effluent water as antici-




pated; and  also due to increased volume of water required.




              4.  Inflationary trends which occurred from 1969, when the original




estimates were made,  to the 1971-72 period of this report.
                                    55

-------
               FOR MORE INFORMATION ABOUT THE FRANKLIN PLANT
Herbert, W.   Solid waste recycling at Franklin,  Ohio.    In
     Proceedings; Third Mineral Waste Utilization Symposium,
     Chicago, Mar. 14-16, 1972.  U.S. Bureau of Mines and
     Illinois Institute of Technology Research Institute.


Herbert, W., and W.A. Flower.  Glass and al^uminum recovery in recycling
     operations.  Public Works. 102(8):70, 110, 112, Aug.  1971.   Reprinted,
     [Cincinnati], U.S. Environmental Protection Agency, 1972. 2 p.
     (Environmental Protection Publication SW-96.J.)
Herbert, W., and W.A. Flower.  Waste processing complex emphasizes
     recycling.  Public Works, 102(6):78-81, June 1971.  Reprinted, [Cin-
     cinnati], U.S. Environmental Protection Agency, 1972.  4 p.
     (Environmental Protection Publication SW-97.J.)
Neff, N.T.  Solid waste and fiber recovery demonstration plant for the
    y6lty of Franklin, Ohio; an interim report.  Environmental Protection
     Publication SW-47d.i.  U.S. Environmental Protection Agency, 1972.
     83 p.  (Distributed by National Technical Information Service,
     Springfield, Va., as PB-213 646.)
Neff, N.T.  Solid waste and fiber recovery demonstration plant for the
     city of Franklin, Ohio; final report,  v. 1, 2.  U.S. Environmental
     Protection Agency, 1974.   (In  pxete; to be distributed by National
     Technical Information Service, Springfield, Va.)

-------