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
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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
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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).
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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
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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
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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
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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
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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
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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
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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
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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.)
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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.
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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.
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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.)
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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
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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.
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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
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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.
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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
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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.
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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.
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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
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Figure 1. Environmental control complex flow diagratr
12
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Figure 3. Receiving floor
14
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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
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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.
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Fig.Sa-Magnetic Separator
Fig.5b—Liquid Cyclone
Figure 5. Magnetic separator and liquid cyclone
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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
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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
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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
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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
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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
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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
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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
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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
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Figure 8. Paper fiber being loaded for shipment
28
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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.)
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