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905R79113
RESOURCE RECOVERY FACILITIES
IN THE UNITED STATES
This list was compiled by David B. Sussman,
Resource Recovery Division, Office of Solid Waste.
It reflects the best available information
as of November 1978.
U.S. Environmental Protection Agency
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RESOURCE RECOVERY FACILITIES
This report summarizes the status of resource recovery
facilities in the United States that recover and utilize
energy and material from municipal solid waste. The list
includes only plants which are operating commercially or
under construction, and also includes demonstration facili-
ties. Technologies are categorized as follows: waterwall
combustion - mass burning; waterwall combustion - processed
waste; mechanical processing to produce refuse-derived fuel
(RDF); starved air modular incinerators; pyrolysis; co-
disposal; and materials recovery. Throughput is actual for
operating plants, and design for plants under construction.
Date listed-is year of start-up.
EPA DEMONSTRATIONS
Franklin Ohio. 50 TPD. 1971. Wet pulping process to
recover low grade paper fiber for use in a roofing felt
mill. Plant also can recover iron, glass, and aluminum. At
present, fiber is not used for roofing felt because of drop
in market demand but as a fuel in a fluid bed furnace to
dispose of sewage sludge. Wet pulping process developed
here being replicated in Hempsted, New York, and Dade County,
Florida, for energy production. Codisposal portion of
demonstration being replicated in Duluth, Minnesota. An EPA
evaluation on Franklin has been completed and is available
through NTIS (PB-234 715, PB-234 716). This process was
developed by the Black Clawson Company. (See waterwall
combustion - processed waste and codisposal.) One processing
line.
St. Louis, Missouri. 150 TPD. 1972. Shredding and
air classification process (one processing line) to produce
a fluff refuse-derived fuel that was burned as a supplement
to coal in a large pulverized coal utility boiler. This was
the most successful demonstration in that it is being widely
replicated. (See waterwall combustion - processed waste and
RDF.) The demonstration plant also recovered ferrous metal.
The technical, economic, and environmental viability of
separating the organic (fuel fraction) portion of MSW from
the inorganic (non-combustible) portion was established at
this plant. An EPA evaluation of this process has been
completed and is available through NTIS (PB-272 755) . The
plant was shut down in 1976 after a successful demonstration
period.
Baltimore, Maryland. 800 TPD. 1975. This was the
first attempt to construct a full-sized resource recovery
facility using pyrolysis as an energy recovery technology.
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MSW was first shredded (two shredders, but both fed a
single processing line) and fed into a large rotary kiln
pyrolysis reactor where temperatures of about 2000F the
organic material in the waste stream was broken down into a
combustible gas. This gas was then burned in a secondary
combustion chamber and the heat released was used to gener-
ate wet steam for district heating. The plant was completed
in early 1975 but had many major mechanical, thermal, and
emissions problems and had to undergo a series of modifi-
cations. At present, the City is adding air pollution
control equipment and a new, larger secondary combustion
chamber. During shakedown operation, the plant operated
intermittently but, nevertheless, did dispose of 70,000 tons
of waste, generated 250 million pounds of steam that was
sold for $750,000. This process was developed by Monsanto
Enviro-Chem Systems, Inc., who are no longer in the solid
waste business. An EPA evaluation of the process as it was
designed and modified has been completed. The final report
is in draft form and will be published late this year.
San Diego County, California. 200 TPD. 1978. A
pyrolysis process developed by the Occidental Research
Corporation that was to convert the organic portion of MSW
into a liquid fuel (highly oxygenated complex organic oil)
through flash pyrolysis. The MSW, after extensive prepara-
tion to a fine dust-like material (two-stage shredding and
air classification) (single processing line), is heated to
900F in less than two seconds in a vertical shaft. The
oils, gases, and char produced are separated. The gas and
char are used internally in the process and the oil was to
be burned as a substitute for #6 fuel oil in a utility
boiler. The plant also recovered iron, glass, and aluminum.
Numerous mechanical and thermal problems have prevented the
process from running for more than a day at a time. As yet,
only small amounts of liquid have been produced and they
were not up to specification. The future of this project is
unknown. Numerous modifications will be required to correct
deficiencies that are known at this time. Occidental is
studying the system deficiencies and should ascertain the
viability of continuing with the process this year. EPA has
started an evaluation of the process.
Wilmington, Delaware. 1,000 TPD. This demonstration
project will recover energy in the form of superheated
steam for industrial process use and codispose of 50 tpd
of dry sewage sludge. The steam will be generated by a
waterwall combustor firing processed waste Ccrude fluff
RDF) . The sludge will be co-combusted in the steam generator
and/or composted in controlled aerobic digesters to produce
marketable humus. Ferrous metals, aluminum, and glass will
also be recovered.
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Unprocessed Waste - i'lass Burning
Herrick. New York. 600 TPD. 1952. Two batch fed
refractory wall incinerators with, waste heat boilers. Produces
wet steam for inhouse generation of electricity. Very old
technology. Plant will be shut down when Hempstead plant
comes on line.
Chicago, Illinois. (Southwest plant) 1,200 TPD.
1963. Old design refractory incinerator with waste heat
boiler. Wet steam used for in-plant use.
Chicago, Illinois. (Northwest plant.) 1,600 TPD.
1971. Modern waterwall unit. Chute to stack components
designed by Martin (large European system builder}. Pro-
duces wet steam for in-plant use. Steam market was not
developed when system was first put on line. However, a
steam line is being built to a nearby industrial user.
Meets pollution standards.
Harrisburg, Pennsylvania. 720 TPD. 1972. Another
Martin unit. Wet steam for in-plant use. Steam line under
construction to tie into existing distribution system to
industrial users. Sludge codisposal module under construction
(see codisposal). Plant undergoing modernization program
to optimize steam production. Two furnaces. Meets air
emissions standards.
Oceanside, New York. 750 TPD. 1965. Orginally had
three batch feed refractory furnaces, two with waste heat
boilers. The two with heat recovery have been replaced with
waterwall units and continuous feed. American A&E design.
Wet steam used for in-plant electricity generation. Plant
has had many problems with corrosion and erosion of boiler
tubes. New ESP's are meeting State emissions standards.
Saugus, Massachusetts. 1,200 TPD. 1976. Most modern
waterwall unit in the United States. Von Roll design. Pri-
vate plant. Joint venture of Uheelabrator-Frye and DeMateo
Construction Co. Superheat steam - 845F - exported to GE
plant about 1 mile away and used for electricity generation,
process and space heat, and turbine testing. Largest Von
Roll furnaces (two) to date. Has had superheater and grate
problems. Appear solved by using special alloys. Plant has
not run at capacity as yet because of solid waste nonavaila-
bility. GE does not always take full load of steam. Met
emission standard of .05gr/DSCF.
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Nashville, Tennessee. 400 TPD. 1974. Two waterwall
furnaces; A&E design; B&W boiler; Detroit stoker grates.
Superheat steam for downtown heating loop. Steam also runs
chiller for downtown cooling loop. Four pipe distribution
system belongs to Nashville Thermal Co. (the public utility
that runs the plant) . No dump fee; however. City pays an
annual subsidy to "Thermal." Plant had major problems during
start-up that required expensive modifications. Air pollu-
tion devices (low energy scrubbers) were ineffective and were
replaced with ESP's. Stack test at .02gr/DSCF. This is
the cleanest stack on a waterwall unit anywhere in the world.
This plant was not designed to the state-of-the-art and
problems will probably continue to appear and require
correction.
Braintree, Massachusetts. 240 TPD. 1971. This small
waterwall (one furnace) has been supplying wet steam to an
industrial customer. Plant after modifications to the ESP's
meets Mass, emissions standards.
Norfolk, Virginia. 360 TPD. 1967. U.S. Navy Plant.
Burns shipyard waste (one furnace) (dunnage, etc.) and
supplies wet steam to ships in port. Supplies about 10% of
yard demand.
Portsmouth, Virginia. 175 TPD. 1978. U.S. Navy plant.
In shake-down. At shipyard. Same principle as plant at
Norfolk.
Hampton, Virginia. 400 TPD. Joint project of NASA,
USAF, and the city. Two 200 TPD furnaces to be operated
at 160 TPD. A&E design. Steam for NASA complex. Under
construction.
Processed Waste - Primary Fuel
These plants, all of which are under construction,
prepare the waste by shredding, some air classification,
magnetic metals removal, and screening, and bum the
predominantly organic material in a hog fuel type boiler
with a grate to produce steam. Normally the shredded
waste (coarse RDF) is the only fuel, but a few plants are
under design that plan a 50-50 mixture of coal and coarse
RDF. The fuel can also be produced by wet pulping, as
developed in Franklin. This approach is being implemented
in Hempstead. Two processing lines feeding one boiler are
typical.
Akron, Ohio. 1,000 TPD. Superheat steam for urban
and industrial heating and cooling. Iron recovery.
Construction to be completed this year.
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Albany, New York. 750 TPD. RDF prepared at one site;
shipped across town to boiler located adjacent to State
office buildings. Steam used for heating and cooling.
Ferrous recovery. Possible nonferrous recovery from
boiler bottom ash. To be operational in 1980.
Ilempstead, New York. 2,000 TPD. Wet pulping process.
Fuel fraction dewatered to 50% moisture and burned in a
hog fuel boiler. Superheated steam to generate electricity
sold to the grid. Generators belong to electric utility.
Ferrous, aluminum and glass recovery. Operational in early
1979.
Niagara .Falls, New York. (Hooker Chemical). Construction
just started. Privately owned; to supply steam to chemical
plant.
Norfolk, Virginia. 2,000 TPD, plus coal for topping
and backup. Three stoker furnaces. Superheat steam for
electric generation and back pressure steam. Electricity
and steam used at Naval shipyard. Construction to start shortly.
Processed Waste - Supplemental Fuel (RDF)
All plants are based on the St. Louis demonstration and
mechanically separate the organic (fuel) fraction from the
noncombustible or heavy fraction. The fuel produced is a
fluff RDF (except Bridgeport - dust RDF) and is burned in
suspension as a supplement to coal in large electric
utility boilers. All plants use the same general processing
philosophy, although the individual processing steps vary
from plant to plant. The processes are size reduction
(shredding) (SH); air density separation (air classification)
(A/C); screening (SC); trommeling (T); ferrous (magnetic
metals) removal (M); aluminum recovery (AL); and glass
recovery (usually as an aggregate) (G).
Ames, Iowa. 170 TPD. 1975. SH; M; SC (to be added
in fall 1979); SH; and A/C. AL and G module not operating.
One processing line. RDF used at municipal power plant in
spreader stoker boilers and a suspension fired boiler
modified with dump grates. EPA evaluations ongoing; reports
available from Office of Research and Development,
Cincinnati (EPA 600/2-77-205).
Chicago (Crawford), Illinois. 1,000 TPD. 1977. In
shakedown. SH; M; A/C; and SH. M from A/C heavy fraction
also. Two processing lines. RDF to be used at Commonwealth
Edison's Crawford plant. EPA evaluation planned.
Milwaukee, Wisconsin. 1,200 TPD. 1977. In start-up.
Undergoing some modifications to increase RDF quality.
SH; A/C; SH; M; and SC. M, AL, and G from heavy fraction.
Two lines. RDF used at Wisconsin Electric*s South Creek
plant.
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Bridgeport, Connecticut. 1800 TPD. Under construction.
Start-up late 1978. SH; SC; A/C'" dryer; addition of chemical
embrittlement agent; heated ball mill pulverizer; SC. M, G,
and AL from heavy fraction. Two lines. Powdered RDF (Eco-
Fuel II - propriatary process) used at United Illuminating
Devon plant.
Monroe County/ New York. 2,000 TPD. Under construction.
Shake-down in 1979. SH; A/C; SC; and SH. M, G, and AL from
heavy fraction. Two lines. RDF used at Rochester Gas and
Electric *s plant
z Lane County (Eugene) , Oregon. 500 TPD. In start-up.
SH; SC; A/C; and SH. M from heavy fraction. One processing
line. No market for RDF yet. Probably will be burned along
with wood waste (hog fuel) in University of Oregon plant or
other hog fuel boiler in area. RDF fuel value based on
price of hog fuel, not coal. EPA evaluation planned.
Starved Air Modular Incinerators with Heat Recovery
These devices are shop fabricated, small, two chambered,
non-agitated bed, incinerators with waste heat boilers,
placed in the hot flue gas stream. Their maximum design
throughput is a nominal one ton per hour. Originally, the
units were batch fed and operated cyclically (charge, burn,
cool down, remove ash) ; however, the state-of-the-art is
now continuous feed and continuous ash removal and all new
systems built in the last year reflected this advancement.
Because the bed is not agitated and waste heat boilers
are used in lieu of waterwalls, these units are not as
efficient in energy production or burnout quality as water-
wall combustion units. However, their costs are much lower
and they do not require air pollution control equipment in
many areas.
Siloam Springs, Arkansas. 20 TPD. 1975. Two Consumat
Units. Cyclic. Wet steam to cannery.
Blytheville, Arkansas. 50 TPD. 1975. Four Consumat
Units. Cyclic. Wet steam to light industrial customer.
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Groveton, New Hampshire. 30 TPD. 1975. Two ECP units.
Cyclic. Wet steam to paper plant. Units operate 4 1/2 days
per week on plant waste (paper, sawdust, etc.). 1 day per
week on MSW.
North Little Rock, Arkansas. 100 TPD. 1977. Four
Consuiaat units. Continuous operation. Two units feed 1
boiler. Wet steam to a creosoting plant. Plant waste which
consists mostly of wood scrap from ends of railroad ties is
burned in the incinerators. Twenty five percent of heat
input at times comes from wood waste. EPA evaluation is
underway. Will be completed in spring 1979.
Crossville, Tennessee. 60 TPD. 1978. Two Farrier
units. Continuous operation. Wet steam to rubber plant.
Plant rubber waste is burned with the MSW at the 25 per-
cent rate.
Salem, Virginia. 100 TPD. 1978. Four Consumat units.
Continuous operation. Wet steam to rubber company. Presently
in shake-down.
Genesee County, Michigan. 100 TPD. Two 50 TPD
Consumat units. Under construction.
In addition to the above listed units, 2O to 40 of the
small systems are operating on in-house waste at industrial
facilities and institutions. Some of the more noteworthy
locations are: the Pentagon; Andrews Air Force Base (U.C.);
Mayport, Florida, Havy Base (U.C.); Rockwell Plant, Marysville,
Ohio (EPA evaluation underway) ; Moore plant, Bonesdale,
Pennsylvania; John Deere Plant, Dubuque, loway and Briggs—
Stratton Plant, Michigan.
Pyrolysis
There are no pyrolysis plants in commercial operation
today. Baltimore and the small modular incinerators could
be considered pyrolysis plants because a combustible gas is
produced in the primary chamber and burned in another. How-
ever, this is not really pyrolysis. The Union Carbide Purrox
Plant, South Charleston, West Virginia, is a 200 TPD pilot
plant that has operated for periods of up to 90 days. It is
ready for commercialization at this time, although Union
Carbide has not as yet sold one.
Codisposal
Franklin, Ohio. 50 TPD MSW/10 dry TPD sludge. 1971.
Sludge at 5% solids is mixed with pulped MSW a.t 2Q% solids
and the mixture is dewatered to 45% solids in a cone press
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and combusted in a single fluidized bed furnace. No energy
is recovered; however, the solid waste provides the energy
necessary to burn the wet sludge.
Duluth, Minnesota. 400 TPD MSW/66 dry TPD sludge.
Under construction. 20% solids vacuum filtered sludge is
combusted with RDF in two fluidized bed furnaces. Steam
recovered is used for heating and cooling the plant buildings
and to drive steam powered plant equipment. EPA evaluation
planned.
Central Contra Costa County (Concord), California.
Proof of concept demonstration. RDF was used as a fuel in
lieu of natural gas in a multiple hearth sludge furnace.
Furnace was operated in a starved air mode (pyrolysis) .
Technique is being replicated at a new advanced wastewater
treatment plant in California and is being considered in a
number of other locations. None are under construction as
yet.
Harrisburg, Pennsylvania. 14 dry TPD sludge. Sludge
drying and disposal module being built next to the waterwall
combustion unit. The sludge, at 5% solids, will be pumped
from the POTP a few blocks away to vacuum filters. After
dewatering to 20% solids/ the sludge enters one of four
steam heated Bethlehem "porcupine" dryers. The dryers will
use 20,000 pounds of steam an hour. The moisture evaporated
from the sludge will be condensed in a contact condenser with
the liquids going gack to the POTP. The gases will be com-
busted in the furnace. The dry sludge, at 10% moisture,
will be burned in the furnace along with solid waste.
Glen Cove, New York. 250 TPD MSW/25 dry TPD sludge.
Construction to start late summer, 1977. A single refrac-
tory wall solid waste mass burning unit with a waste heat
boiler. Wet steam will generate electricity for the POTP.
Sludge will be vacuum filtered to 20% solids and metered
into the furnace in such a way that it will remain on top
of the bed of refuse and burn.
Other
Pompano Beach, Florida. Department of Energy project.
Recovery of methane gas from anerobic digestion of solid
waste and sewage sludge in a closed vessel. This H&D
project is under construction/shake-down and should start
up this year.
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Palos Verdes, California. Methane recovery from an
existing landfill. Started up in 1975. Determine generation
rates, life, economics, etc., of concept.
Materials Recovery
The following plants recover materials from municipal
solid waste. Some of these plants could recover energy
in the form of RDF if and when markets are located. In
addition to these, approximately 40 landfill shredding
plants recover ferrous metals.
Baltimore County, Maryland. 550 tpd. 1976. This is
a demonstration plant funded by Maryland Environmental
Services, a State agency. The plant is basically an RDF
plant with ferrous, aluminum and glass recovery. The SDF
is presently landfilled, but it has been test burned at
various facilities. There are plans to build a boiler to
generate steam for a possible customer at some time in
the future. Ferrous is sold and glass and aluminum recovery
is carried out on an experimental basis.
Hew Orleans, Louisiana. 650 tpd. 1978. National
Center for Resource Recovery demonstration plant. Recovering
ferrous, aluminum, nonferrous and glass. Organic fraction
used in landfill/land reclamation operation. Organic fraction
could be upgraded to RDF and burned if suitable market is
located. Probably after land reclamation project is
completed.
Altoona, Pennsylvania. 30 tpd. 1963. Small
composting plant. Only municipal solid waste composting
plant left in operation. Compost used as a carrier in
light weight fertilizer mixes (lawn and garden products) .
Operated by private company. Takes organic waste from
city, about 50 percent of city's total.
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