United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EPA-453/B-93-O21
April 1993
Air
Municipal Waste Combustor
Operator Training Program
Instructor's Guide
U.S EPA Headquarters Library
Mail code 3404T
1200 Pennsylvania Avenue NW
Washington, DC 20460
202-566-0556
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MUNICIPAL WASTE COMBUSTOR
OPERATOR TRAINING PROGRAM
INSTRUCTOR'S GUIDE
Prepared for:
U. S. Environmental Protection Agency
Industrial Studies Branch/BSD
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
April 13, 1993
ENV'fm'':"v
WASHINGTON, iK. .•
"SON AGENCY
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NOTICE
This instructor's guide and the course manual constitute the training materials for a model
state training program which addresses the training needs of municipal waste combustor (MWC)
operators. The course manual generally describes the generic equipment design features,
combustion control relationships, and operating and maintenance procedures which are designed
to be consistent with the purposes of the Clean Air Act Amendments of 1990.
This training program is not designed to replace the site-specific, on-the-job training
programs which are crucial to proper operation and maintenance of municipal waste combustors.
Proper operation of combustion equipment is the responsibility of the owner and
operating organization. Therefore, owners of municipal waste combustors and organizations
operating such facilities will continue to be responsible for employee training in the operation
;ind maintenance of their specific equipment.
DISCLAIMER
This instructor's guide and the course manual were prepared for the Industrial Studies
Branch, Emission Standards Division, U. S. Environmental Protection Agency. It was prepared
in accordance with USEPA Contract Number 68-CO-0094, Work Assignment Number 7. Partial
support was also provided by the University of Virginia through its Sesquicentennial Associates
Program.
The contents of this document are reproduced as received from the contractor. The
opinions, findings and conclusions expressed are those of the authors and not necessarily those
of the U. S. Environmental Protection Agency. Any mention of product names does not
constitute an endorsement by the U. S. Environmental Protection Agency.
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AVAILABILITY
This document is issued by the Office of Air Quality Planning and Standards of the U.
S. Environmental Protection Agency. It was developed as part of a set of training materials to
assist operators of municipal waste combustors in becoming certified as required by the federal
and state regulatory agencies.
Individual copies of this publication are available, free of charge, to state regulatory
agencies and other organizations providing training of operators of municipal waste combustors.
Copies may be obtained from the Air Pollution Training Institute (APTI), USEPA, MD-17,
Research Triangle Park, NC 27711. Others may obtain copies, for a fee, from the National
Technical Information Service, 5825 Port Royal Road, Springfield, VA 22161.
Although this government publication is not copyrighted, it does contain some
copyrighted materials. Permission has been received by the authors to use the copyrighted
material for the original intended purpose as described in the section titled Course Manual
Introduction. Any duplication of this material, in whole or in part, may constitute a violation
of the copyright laws, and unauthorized use could result in criminal prosecution and/or civil
liabilities.
The recommended procedure for mass duplication of the course materials is as follows:
Permission to use this material in total may be obtained from the APTI, provided the
cover sheet is retained in its present form. Permission to use part of this material may
also be obtained from the APTI, provided that the APTI and the authors are properly
acknowledged.
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TABLE OF CONTENTS
Page
Notice and Disclaimer i
Availability ii
Course Materials Introduction 1
Course Preparation Instructions 4
Course Agenda 5
Jte-Test Pre-Test-1
Post-Test Post-Test-1
J^esson Plans
1. Introduction 1-1
2. Environmental Concerns and Regulations 2-1
3. Municipal Solid Waste Treatment 3-1
4. Characterization of MSW Fuels 4-1
5. Combustion Principles I: Complete Reactions 5-1
6. Municipal Waste Combustors 6-1
7. Combustion Principles II: Thermochemistry 7-1
8. Design & Operation of MSW Handling Equipment 8-1
9. Combustion Principles HI: Reaction Processes 9-1
10. Design & Operation of Combustion Equipment 10-1
11. Design & Operation of Gas Flow Equipment 11-1
12. NSPS: Good Combustion Practice 12-1
13. Instrumentation I: General Measurements 13-1
14. Instrumentation II: Continuous Emissions Monitoring 14-1
15. Air Pollution I: Introduction 15-1
16. Air Pollution II: Products of Incomplete Combustion 16-1
17. Air Pollution HI: Nitrogen Oxides 17-1
18. Air Pollution IV: Metals and Ash 18-1
19. Flue Gas Control I: Paniculate Matter (PM) 19-1
20. Flue Gas Control H: Acid Gas Removal 20-1
in
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21. Flue Gas Control HI: NOx Control 21-1
22. Automatic Control Systems 22-1
23. Control Room Operations 23-1
24. Operating Practices 24-1
25. Troubleshooting of Combustion Upsets 25-1
26. Special System Considerations I: Water Treatment 26-1
27. Special System Considerations n: Electrical Theory 27-1
28. Special System Considerations ffl: Turbines & Generators 28-1
29. Risk Management I: Preventive Maintenance 29-1
30. Risk Management Hi Safety 30-1
IV
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COURSE MATERIALS INTRODUCTION
The course materials were developed for the U. S. Environmental Protection
Agency (USEPA) in support of improving the air pollution control practices at
municipal waste combustors (MWCs). The USEPA was required to develop a model
state training and certification program for solid waste incinerator operators under
Title III, Section 129 of the Clean Air Act Amendments of 1990. The Instructor's
Guide is an integral part of the model state MWC operator training and certification
program. As such, state and regional air pollution control agencies are encouraged
to develop training programs which make use of this manual.
This Instructor's Guide and the corresponding Course Manual make up the
materials for the model state training program which addresses the training needs
of municipal waste combustor (MWC) operators.
The Instructor's Guide presents information generally required by course
directors and instructors, including an agenda, copies of tests, specific information
about each learning unit, and masters for making overhead projection transparencies
or slides.
The Course Manual of the training program describes the equipment design
features, combustion control relationships, and operating and maintenance
procedures which are designed to be consistent with the purposes of the Clean Air Act
Amendments of 1990.
TRAINING PROGRAM GOAL
The primary goal of the training program is to provide an adequate level of
understanding to MWC operators to successfully complete the requirements of the
ASME QRO Standard for provisional certification as resource recovery facility
operators.
The training program focuses on the knowledge required by operators for
understanding the basis for proper operation and maintenance of municipal waste
combustors. Particular emphasis is placed on the various aspects of combustion
which are important for environmental control. Fundamental information is related
to applications and to the operator's own work experiences. Trainees are encouraged
to comment and ask questions during the training program. Such discussion will
both increase the utility of the program and make it more interesting.
The program was designed to augment the normal site-specific, on-the-job and
supervised self-study training programs which are provided by the vendor, owner or
operating company. The program is not a substitute for such operator training.
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TRAINING PROGRAM INTENDED AUDIENCE
The training program concentrates on the range of MWC units covered by the
ASME Standard for Qualifications and Certification of Resource Recovery Facility
Operators (ASME QRO-1-1989). This includes unit sizes from capacities as small as
24 tons/day up through the regional waste-to-energy plants which may have
capacities greater than 4,000 tons/day. Therefore, the course focuses on the special
training needs of operators of the larger sizes of MWC units which typically have
continuous ash removal systems and an intermittent or continuous waste feeding
system. This course does not focus on the training needs of operators of small batch-
fired incinerators.
Other persons who are expected to be trainees in this program include MWC
operating and management staff members, technical managers, mechanics and
maintenance personnel, instrument and control technicians, general engineers and
design engineers.
In addition, regulatory officials, particularly those involved in permit review,
are expected to find this program both informative and useful.
COURSE LIMITATIONS
To the extent possible, these course materials were written in a manner
consistent with USEPA policy regarding municipal waste combustors and the
demonstrated features of good combustion practice.
Detailed administrative and legal aspects of unit operations are not
emphasized in the program because the regulations under which units operate will
vary with location and time. Operators are urged to obtain specific regulatory
information and permit requirements from the owner/operator organization.
INSTRUCTOR'S GUIDE ORGANIZATION
The Instructor's Guide presents information generally required by course
directors and instructors, including a sample agenda, copies of a pre-test and post-
test, objectives and discussion questions for each learning unit, and masters for
making overhead projection transparencies or slides.
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COURSE MANUAL ORGANIZATION
The Course Manual presents information in the subject areas addressed in the
AS ME examination for provisional certification as Chief Facility Operators and Shift
Supervisors. Additional information about qualifications may be obtained from a
review of the ASME Standard. The Course Manual will also be useful in state and/or
private entity training programs which are conducted under equivalent state
standards for operator training and certification.
The sequence of topics was selected to reinforce the integration of the basic or
fundamental aspects with the more familiar applied materials. Generally, a unit of
fundamental information is followed by an applications unit. For instance, units on
combustion chemistry are interspersed with units on equipment design and operation.
The Course Manual begins with an introduction of the training program and
its relationship to the operator certification process. The program considers the
operator's role in the regulatory environment and in public relations.
This Course Manual focuses on the technical and operational aspects of good
combustion practices in MWC units. The characteristics of municipal solid waste
(MSW), its fuel properties, and the influence of waste processing are presented.
These are followed by learning units on combustion principles and MWC equipment
features. Next comes a sequence on good combustion practices, air pollution control,
instrumentation, and flue gas treatment. The training program concludes with
consideration of automatic control theory, control systems, trouble shooting, special
system considerations, and risk management.
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COURSE PREPARATION INSTRUCTIONS
This course requires 4.5 days for a complete presentation. Planning and
administrating the activities are the responsibilities of the course director. This
includes making provisions for activities before and during the course as follows:
1. Making arrangements for scheduling and announcing the course.
2. Recruiting an appropriate group of instructors who have:
a. general knowledge of the design principles and operational aspects of
MWC equipment and specific expertise in their assigned topical area.
b. relevant practical and operational experience.
c. knowledge of the job requirements of operators.
d. an understanding of their responsibilities and the ability to instruct
adult MWC operators.
e. a positive attitude about environmental management.
3. Briefing of the instructors before the course (emphasizing the course schedule
and accommodations and the requirement of preparation before the course,
including projection materials) and providing feed-back during the course.
4. Arranging for accommodations, including proper classroom size and seating,
projection equipment, and possible provisions for breaks and meals.
5. Managing and confirming course registration.
6. Arranging for the preparation and distribution of the course materials (agenda,
Course Manual, roster, "name tents," pretest and post-test, certificates, and
critique or feed-back sheets).
7. Providing appropriate lecture presentations.
8. Maintaining continuity and coordination throughout the course, such as asking
questions and leading discussions with the participants, grading tests,
requesting course critique, and preparing certificates of course completion.
PROGRAM AGENDA
The training program is designed around a 4.5-day sequence of learning units
in which the agenda follows the sequence in the manual. However, the course agenda
can be rearranged to accommodate the special scheduling needs of the speakers.
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DAY & TIME
Agenda for
MUNICIPAL WASTE COMBUSTOR OPERATOR TRAINING
Date
Location
Sponsor
SUBJECT SPEAKER
9:40- 10:15
:.0:25- 11:00
11:10- 12:00
Registration & Pre-Test
1. Introduction
Regulatory Requirements: Training/Certification
Purpose of Pre-Test and Post-Test
ASME Certification Procedures
2. Environmental Concerns and Regulations
Public Concerns & Historic Issues
Solid Waste and Air Pollution Regulation
Operator's Role in Public Relations
3. Municipal Solid Waste Treatment
Integrated Waste Management
MSW Mass Burn - RDF Fuel Processing
4. Characterization of MSW Fuels
Sources and Types of Solid Wastes
Characterization of Fuel Properties
1:00 - 2:00 5. Combustion Principles I: Complete Combustion
Balanced Chemical Reaction Equations
Stoichiometry & Excess Air
2:10- 3:15 6. Municipal Waste Combustors
Mass Burn: Refractory/Waterwall, Excess-Air
Modular Mass Burn: Starved-Air/Controlled-Air
RDF Units
3:30 - 4:30 7. Combustion Principles n: Thermochemistry
Heating Value, Capacity, and Load
Distillation & Ignition Temperatures
Combustion Temperatures & Heat Sinks
Stoichiometric Considerations
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DAY & TIME SUBJECT SPEAKER
Tuesday
8:30 - 9:30 8. MSW Handling Equipment
Undesirable MSW Components
Variable MSW Fuel Considerations
Handling, Feeding and Grate Equipment
. Ash Removal & Disposal
9:45 - 10:45 9. Combustion Principles HI: Reaction Processes
Reactions & Incomplete Combustion
Oxidation & Reduction
Flame Types & Bed Burning
11:00 - 12:00 10. Design & Operation of Combustion Equipment
Direct Bed & Suspension Firing
Two-Stage & Excess Air Combustion
Boiler & System Configurations
Operational Considerations
1:00- 1:40 11. Design & Operation of Gas Flow Equipment
Air & Flue Gas Flow Path
Fans, Dampers & Draft
Dew Point, Slag & Soot
1:50 - 2:30 12. NSPS: Good Combustion Practice
GCP Requirements
Technology-Based Emission Limits
Indicators of GCP, Surrogates
Typical System Operating Ranges
2:40 - 3:20 13. Instrumentation I: General Measurements
Purposes of Instrumentation
Thermocouples, Pressure Gages
Flow Meters
Weight Scales
3:30 - 4:30 14. Instrumentation n: Continuous Emission Monitors
Parameters Monitored
Extractive & In-Situ CEMs
Measurement Concepts
Special Operating Concerns
Calibration & Drift Requirements
6
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DAY & TIME
Wednesday
SUBJECT
SPEAKER
8:30- 9:20 15.
9:30 - 10:10 16.
13:20-11:00 17.
11:10-12:00 18.
Air Pollution I: Introduction
Fuel & Operations Dependent Emissions
Smoke
Concentrations & Corrections
Combustion Efficiency, Excess Air
Air Pollution n: Products of Incomplete Comb.
Carbon Monoxide
Surrogates
Dioxins and Furans
Air Pollution ID: Nitrogen Oxides
Fuel NOX Formation
Thermal NOX Formation
Air Pollution IV: Metals & Ash
Characterization of MWC Metals
Emissions as Vapors & Particles
Measurements & Operational Concerns
Groundwater, Ash Testing, Ash Treatment
1:00- 2:00 19.
2:15- 3:15 20.
3:30- 4:30 21.
Flue Gas Control I: Paniculate Matter
Combustion System Factors
Fabric Filtration Concepts
Fabric Filter Design & Operation
ESP Concepts Design & Operation
Venturi Scrubber Design & Operation
Flue Gas Control II: Acid Gas Removal
Spray Dryer Absorber Systems
Dry Sorbent Injection Systems
Wet Scrubbers with Wet Collection
Flue Gas Control HI: NOX Control
Combustion Modifications
Reburning with Natural Gas
Selective Non-Catalytic Reduction Systems
Thermal De-NO^ & Urea Operational Factors
Selective Catalytic Reduction Systems
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DAY & TIME
SUBJECT
SPEAKER
Thursday
8:30- 9:30 22.
Automatic Control Systems
Automatic Control Concepts
Boiler & Combustion Control Parameters
Single, Two & Three Element Controllers
Micro-processor Based Control Systems
MWC Control System Applications
9:45 - 10:45 23.
11:00-12:00 24.
Control Room Operations
Operator Functions
Operating Systems Controlled
Panel Mounted Instruments
Graphic Screen Displays
Operator Control Actions
Operating Practices
Responsibilities & Functions
Safety & Standard Operating Procedures
Combustion, Boiler, Water Treatment Systems
Combustion System Start-Up & Shut-Down
APCD System Start-Up & Shut-Down
1:00- 2:00 25.
2:15- 3:15 26.
3:30- 4:30 27.
Trouble Shooting of Combustion Upsets
Combustion System Upsets
Indicators of Combustion Quality
Fuel & Air System Upsets
Temperature & Draft Upsets
Special System Considerations I: Water Treatment
Boiler Water Impurities & Problems
Water Treatment System Components
De aeration, Chemical Treatment, Slowdown
Indicators of Water Quality
Special System Considerations II: Electricity
Electrical Parameters & Ohms Law
Apparent Power, Reactive Power, Power Factor
Transformer Principles
3-Phase Fundamentals
Circuit Breakers, Rectifiers, Inverters
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SUBJECT
SPEAKER
9:30 - 10:15 29.
10:30-11:15 30.
'11:15 - 12:00
12:00
Special System Considerations IE: Turbine/Gen.
Impulse Steam Turbine Features
Reactive Steam Turbine Features
Turbine/Generator System Configurations
AC Generator Design & Operational Features
Abnormal Turbine Generator Conditions
Risk Management I: Preventive Maintenance
Potential Economic Losses
Features of Preventive Maintenance
In-Service Maintenance
Outage Maintenance Planning
Risk Management II: Safety
Operator Responsibilities
MWC System Safety Hazards
Standard Safety Considerations
Personal Protection Equipment
Symptoms of Illness
Post Test
Course Closure and Evaluation
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MUNICIPAL WASTE COMBUSTOR OPERATOR TRAINING
PRE-TEST
Instructions: The entire test is to be taken as a closed book test.
Each question has only one best answer.
Circle the letter corresponding to the best answer on the Answer Sheet.
1, Identify the largest constituent component of average MSW (based on weight):
a. yard wastes
b. glass & metal
c. paper & cardboard
d. miscellaneous
Identify the following item which is a chemical element in MSW:
a. volatile matter
b. sulfur
c. paper and cardboard
d. water
3.
Identify the component material in MSW which is composed of organic
materials:
a. aluminum
b. pottery
c. glass
d. fixed carbon
4. Identify the following item which is not included in the proximate analysis:
a. volatile matter
b. hydrogen
c. fixed carbon
d. moisture
e. ash (inorganic)
Pre-Test-1
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5. Identify the following item which is not a source of MSW according to the
Federal New Source Performance Standards:
a. industrial wastes
b. household wastes
c. commercial wastes
d. institutional wastes
e. medical waste discards
6. The moisture content of MSW:
a. is almost constant at 25%.
b. will be increased if yard clippings are included.
c. is directly related to the amount of hydrogen in the organic matter.
d. is not changed by the processing of MSW to RDF.
e. all of the above.
7. Before the recent initiatives for recycling, the average individual in industrial
communities produced an average individual in rural areas.
a. about the same MSW as
b. more MSW than
c. less MSW than
d. much less MSW than
8. The primary reason behind the increased public scrutiny about ash disposal
practices is their concern about:
a. metals recycling.
b. heavy metals leaching into the ground water.
c. developing methane gas as an alternative energy source.
d. recycling everything.
e. recycling to reduce the waste stream by at least 25%.
9. The source reduction part of an integrated solid waste management system is
designed to:
a. separate metals and glass from the municipal solid waste.
b. increase the fraction of organic material being composted.
c. stimulate the development of markets for recycled materials.
d. reduce toxicity of MSW through substitution of less toxic component
materials.
e. all of the above.
Pre-Test-2
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10. Identify the feature which is not required in the design of sanitary landfills
under current RCRA requirements:
a. a double liner.
b. a leachate collection system.
c. a leachate monitoring system.
d. a methane gas monitoring system.
e. a methane gas powered electric generator system.
11. Composting is an important factor for MWC unit operations because:
a. it removes materials from the waste which tend to burn poorly and to
cause an increase in nitrogen oxide emissions.
b. is the cheapest way to handle wastes.
c. it makes a lot of money.
d. all of the above.
e. none of the above.
!.2. Identify the most important public relations characteristic of an operator:
a. trustworthy
b. sharp looker
c. college educated
d. good speaker
13. The Clean Air Act
a.
b.
c,
d.
14. In the
allows the states to establish MWC regulations that are more strict than
the federal standards.
prohibits the states from having MWC regulations that are more strict
than the federal standard.
instructs the USEPA to set MWC emission standards which correspond
to the maximum degree of control possible.
does not allow the consideration of economics in the setting of new
source performance standards.
, the U. S. Congress authorized the USEPA to require the
states to regulate existing MWC units.
a. Standards of Performance for New Stationary Sources, MWCs
b. Comprehensive Environmental Response Compensation and Liability Act
c. Clean Air Act
d. State Implementation Plan Act
Pre-Test-3
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15. The Clean Air Act requires each state to submit plans for implementing air
pollution control and the EPA to review and approve them. If this is not done
the state will be:
a. under threat of losing their ability of regulate air pollutants.
b. under threat of losing all federal highway funds.
c. both of the above.
d. neither of the above.
16. The USEPA NSPS for new MWC units does not require regulation of:
a. carbon monoxide.
b. carbon dioxide.
c. nitrogen oxides.
d. hydrogen chloride.
e. dioxins/furans.
17. Identify the MSW characteristic or component that is unacceptable at all MWC
facilities.
a. wet MSW
b. batteries
c. medical waste discards
d. tires
e. radioactive wastes
18. Explosion at MWCs can be caused by
a. explosive munitions in the MSW.
b. gas cylinders in the MSW.
c. liquid drums of solvents in the MSW.
d. loss of water in the boiler.
e. all of the above.
19. Slowdown is a standard operation in MWC boilers to achieve control of the:
a. pH in the boiler water which could cause fireside corrosion.
b. dissolved solids in the boiler water which could cause carry-over
problems.
c. dissolved gases in the feedwater which would lead to formation of
deposits which often lead to tube failures.
d. hardness of the condensate and the accumulation of deposits on the
condenser.
e. silica level in the feedwater which could harm the feedwater pump.
Pre-Test-4
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20. More than the optimum amount of preventive maintenance will result in:
a. a substantially improved unit availability.
b. reduced operating and maintenance costs.
c. increased operating and maintenance costs.
d. the need to overhaul equipment more often.
21. Composting is part of the recycling element of an integrated solid waste
management system. Composting in a windrow is designed to provide:
a. anaerobic decomposition of organic material.
b. aerobic (biological) decomposition of organic material.
c. high temperatures and lots of moisture to speed the decay process and
prevent the formation of odors.
d. all of the above.
22. Identify the recycling program activity which can reduce the potential quantity
of formation of MWC acid gases.
a. plastic removal
b. metal removal
c. glass removal
d. paper removal
23. An average higher heating value of the MSW is somewhere around:
a. 3,000 Btu/lb.
b. 5,000 Btu/lb.
c. 7,000 Btu/lb.
d. 9,000 Btu/lb.
24. In general, the higher heating value of a large batch of MSW can vary from
2,000 Btu/lbm to a maximum of about depending upon how much
mixing occurs and what is being charged:
a. 3,000 Btu/lb
b. 5,000 Btu/lb
c. 8,000 Btu/lb
d. 25,000 Btu/lb
Pre-Test-5
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is to reduce the size of MSW pieces to
25. The primary activity of a
around 2.5 inches across.
a. Trommel screen
b. hammer mill shredder
c. flail mill
d. air classifier
e. disc screen
26. An OSHA required lock-out procedure is designed to:
a. keep members of the public out of facilities where they could get hurt.
b. keep workers from being damaged by the unexpected discharging of
hazardous materials by carelessly opening hopper doors and observation
hatches.
c. lock circuit breakers in the "off1 position during maintenance to prevent
electrocutions.
d. make employees aware of their basic right to have a safe workplace.
27. A pH value of 7.0 is an indication that the:
a. water is acidic and potential tube corrosion will be a problem.
b. water is basic and water tube corrosion will be a problem.
c. water is basic but water tube corrosion problems are probably under
control.
d. water is neutral, neither basic or acidic.
28. The excess air which is typically found in the gases leaving the final
combustion zone of a MWC unit is about:
a. 2 to 4 percent.
b. 6 to 10 percent.
c. 20 to 40 percent.
d. 50 to 100 percent.
29. A refractory coating on the waterwall surfaces below the over-fire air ports will
a. reflect more of the radiant energy back to the combustion zone.
b. reduce the amount of heat extraction from the waterwalls.
c. prevent the sequential oxidation and reduction reactions on the metal
walls.
d. cause higher combustion gas temperatures.
e. all of the above.
Pre-Test-6
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30. A properly operating in situ monitor indicates 200 ppm of SO2 in the flue gas,
and the moisture in the flue gas is known to be 15%. If an extractive
instrument which has an in-line dryer indicates 235 ppm of SO2> then
a. the two instruments are reading consistently.
b. the extractive instrument is reading too high.
c. the extractive instrument is reading too low.
31.
32.
33.
34.
A properly operating extractive CEMS instrument indicates 200 ppm of S02
and 9% oxygen in the flue gas. The standard emission concentration of S02
corrected to 7% flue gas oxygen would be:
a.
b.
c.
200ppmofS02.
greater than 200 ppm of S02
less than 200 ppm of SO2.
The uncontrolled particulate emissions in the flue gas (at the entrance to the
APCD) from modular, starved-air incinerators is about that of
conventional excess-air, grate fired, mass burn systems.
a. half
b. twice
c. ten times
d. one tenth
e. the same as
The overall amount of excess air used in typical RDF fired MWCs is about _
that of conventional grate firing, mass burn systems.
a. 50 to 75 percent
b. 80 to 90 percent
c. the same as
d. 25 to 50 percent more than
e. double
The NSPS for new MWCs sets an upper limit on the temperature of the flue
gas entering the air pollution control device. The limit was established to:
a. assure that there would be no condensation of flue gas in the APCD.
b. minimize formation of dioxin/furan compounds.
c. maximize the APCD particulate collection efficiency.
d. assure that there would not be any fires in the ESP or baghouse.
Pre-Test-7
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35. Mercury emissions are a particular problem for combustion systems such as
MWCs, because:
a. the MWC combustion environment provides unique conditions for
vaporizing mercury.
b. mercury is easily vaporized because it has a very high vapor pressure,
even at relatively low temperatures.
c. mercury causes ash particulates to become sticky.
d. mercury substantially increases the weight of MWC ash.
36. Which of the following statements about NOx emissions from MWC systems
is not correct:
a. The temperature levels are generally too low to cause significant
formation of "thermal NOx."
b. The majority of the NOx is emitted as NO2.
c. The dominant source of NOx formation is oxidation of nitrogen in the
fuel ("fuel NOx").
d. Flue gas recirculation will not be an effective NOx control technique for
MWCs.
37. Flue gas carbon monoxide concentrations can be used by the operator (and
regulator) to indicate:
a. overall combustion efficiency in the boiler.
b. the color of the plume.
c. the temperature of the fuel bed material on the grate.
d. the quality of the bottom ash.
e. all of the above.
38. One of the main concerns about MWCs which stimulated the development of
new air emissions standards was the release of dioxin/furan emissions. Since
these pollutants are toxic compounds, USEPA had congressional authority to
regulate MWC emissions by establishing a national emission standard for
hazardous air pollutant (NESHAP). If the USEPA had used that authority,
which of the following statements would be true:
a. Regulations could be applied only to new units.
b. Economic impact would be a consideration in setting the emission limits.
c. The same emission limits would apply to both new and existing MWCs
of the same size range.
Pre-Test-8
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39. In any combustion system, a portion of the inorganic material (ash) in the fuel
will be released as fly ash. For a pulverized coal fired utility boiler, about 70%
of the ash leaves the boiler as fly ash. The approximate fraction of the ash
which leaves a modular starved air facility as fly ash is:
a. 60 - 80%.
b. 40 - 60%.
c. 15 - 40%.
d. 5 -15%.
e. less than 5%.
40. Why do RDF systems use travelling grates?
a. RDF pieces are so small that they would jam-up the air passageways if
burned on pusher grates.
b. RDF requires a thin fuel bed to prevent particulate entrainment.
c. About half the RDF burns in suspension. The RDF on the grate does
not clump up and need the physical bed mixing to provide air.
d. RDF has more aluminum and glass than mass burned MSW. This
would cause more clinkering if reciprocating grates were used.
41. When underfire air blows through the bed of MSW on a grate or hearth, the
burning process generally proceeds:
a. from the hearth or grate up.
b. from the top surface down toward the grate.
c. as a uniformly distributed flame condition throughout the entire bed.
42. The fraction of carbon which is converted to C02 in a modern, water-wall MWC
unit is:
a. about 25-40%.
b. about 70-85%.
c. about 85-95%.
d. greater than 95%.
Pre-Test-9
-------
43. The efficiency of a modern, water-wall (integral boiler) MWC unit based on the
conversion of fuel energy (higher heating value) to steam energy is:
a. about 25-40%.
b. about 65-80%.
c. about 85-95%.
d. greater than 95%.
44. Designers of MWCs generally limit the steam temperatures to around 800°F
and the pressure to around 800 psia because
a. unit efficiency is greater at higher pressures and temperatures.
b. to go to higher temperatures and pressures would increase the cost of
the pumps.
c. of concern about chloride corrosion on the metal surfaces in the
superheater if higher temperatures are used.
d. it is easier to maintain temperature and pressures at these values.
45. Soot blowing or rapping is performed on a routine basis to:
a. keep a proper cake loading on the air pollution control devices.
b. remove slag from the furnace walls.
c. to remove ash build-up from the tube surfaces in the convection section.
d. discharge excess steam produced in the boiler.
e. provide attemperation to maintain the desired temperature of superheat
steam.
46. The main purpose of a deaerator in a MWC boiler water system is to:
a. remove moisture from the air supply.
b. remove dissolved gases from the condensate or feedwater.
c. introduce additives to the water system for control of scaling.
d. remove suspended solids, total solids, and silica from the boiler water.
47. When the MWC facility is off-line, the turbine generator is maintained on the
turning gear to:
a. provide auxiliary power for the plant.
b. maintain alignment between the turbine and generator shafts.
c. maintain synchronization of the rotor and the electro-magnets in the
generator.
d. provide a minimum level of friction heating to the lubricating oil, even
under cold weather conditions.
Pre-Test-10
-------
48. Extractive CEM units for measuring flue gas concentrations have special
features which:
a. either dry the gas or provide a. significant amount of dilution before it
is analyzed.
b. keep the gas at the stack temperature to prevent chemical reactions.
c. provide for automatic calibration without the need of calibration gases.
d. are less reliable than in situ units because their temperatures are lower.
49. Sampling extraction lines from the stack to instrument panel are heated to:
a. keep water from condensing out of the gas and clogging the sample lines.
b. accommodate the fact that CEMS have faster response times if the
gases are hot.
c. keep organic gases from condensing out of the gas and causing a low
reading at the total hydrocarbon or unburned hydrocarbon analyzers.
d. accommodate the fact that certain CEMS will only function if the
sample gases are above the boiling point of water.
50. The power produced by a MWC electric generator is indicated as 45 MW and
50 MVA, therefore:
a. something is definitely wrong with the calibration of the electrical
instruments.
b. the real power is actually 50 MW.
c. the apparent power is actually 45 MW.
d. the power factor is 0.9.
e. the reactive power is 50 MVAR.
Pre-Test-11
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NAME:
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11.
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USTOR OPERATOR TRAINING
NSWER SHEET
wer on this Answer
26.
27.
28.
29.
30.
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34.
35.
36.
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Pre-Test- Answer-1
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NAME: CORRECT ANSWERS
MUNICIPAL WASTE COMBUSTOR OPERATOR TRAINING
PRE-TEST ANSWER SHEET
Instructions: Enter the appropriate answer on this Answer Sheet.
1.
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Pre-Test Answer Sheet-2
-------
MUNICIPAL WASTE COMBUSTOR OPERATOR TRAINING
POST-TEST
Instructions: The entire test is to be taken as a closed book test.
Each question has only one best answer.
Circle the letter corresponding to the best answer on the Answer Sheet.
'i. Identify the following item which is not included in the ultimate analysis:
a. carbon
b. sulfur
c. volatile matter
d. moisture
e. ash (inorganic)
Identify the following item which is an inorganic material in MSW:
a.
b.
c.
d.
e.
paper
silica
wood
tomato
plastic
Which of the following items is excluded by the NSPS definition of MSW:
a. hazardous waste oils
b. tires
c. household wastes
d. commercial wastes
e. institutional wastes
The nitrogen oxide emissions from typical MWC units tends to peak in the
summer on Mondays because the MSW composition includes the:
a. waste products from the parties which occur on the weekends.
b. increased moisture because of rain on the weekends.
c. increased packaging materials from weekend commercial activity.
d. increased yard wastes.
e. all of the above.
Post-Test-1
-------
5. Until the recent initiatives for recycling, the average individual in affluent
communities produced those in economically depressed areas. ^^
a. about the same MSW as
b. more MSW than
c. less MSW than
6. Monofills, in comparison with regulated hazardous waste landfills,
a. can receive more types of waste materials.
b. can receive only one type of waste material.
c. have less exacting design and monitoring requirements,
d. have more exacting design and monitoring requirements.
7. Identify the feature which does not meet the design requirements of monofills
under current RCRA regulations:
a. a single liner system.
b. a leachate collection system.
c. a leachate monitoring system.
d. a methane gas monitoring system.
e. a methane gas collection device.
8. A boiler water pH of 9.8 with a feed water pH of 8.5 would be an indication of:
a. the feedwater being more acidic than the boiler water.
b. the feedwater being more basic than the boiler water.
c. the need to overhaul the deaeration system as it is not operating
properly.
d. a fairly normal set of operating conditions at a MWC waterwall unit.
9. Identify the final control element of an automatic system which controls the
drum level in a boiler:
a. level indicator.
b. level controller.
c. feedwater regulator valve.
d. set point.
e. all of the above.
Post-Test-2
-------
10. A steam turbine/electric generator set produces three-phase electric energy
where the current lags the voltage. Identify the statement which is incorrect:
a. the real output power is measured by a power-meter in kW or MW.
b. the real output power is determined by multiplying the indicated voltage
by the indicated current.
c. the apparent power is determined by multiplying the indicated voltage
by the indicated current.
d. the reactive power would not be zero.
e. the power factor is the ratio of the real power to the apparent power.
11. In the , the U. S. Congress instructed the USEPA to set standards for
sanitary landfills.
a. Standards of Performance for New Stationary Sources, MWCs
b. Comprehensive Environmental Response Compensation and Liability Act
c. Clean Air Act Amendments of 1990
d. Resource Conservation and Recovery Act of 1984
12. The federal USEPA EG for existing MWC units does not require regulation of:
a. carbon monoxide
b. nitrogen oxides
c. sulfur oxides
d. hydrogen chloride
e. dioxins/furans
13. The NSPS establishes the following surrogate for MWC units during normal
operations (and other surrogates for use in the annual performance test):
a. opacity as the normal operating surrogate for MWC metals.
b. dioxin/furan emissions as the normal operating surrogate for MWC
organic emissions.
c. particulate matter as the normal operating surrogate for MWC metals.
d. carbon dioxide as the normal operating surrogate for MWC organics.
14. Identify the task which is generally not a function of the weigh scale
operations:
a. determine the amount of expense to charge each truck.
b. determine the amount of material received each day.
c. redirect inappropriate loads of waste materials to other facilities.
d. determine the carbon & metals composition in the ash leaving the unit.
e. determine the weight of the ash leaving the unit.
Post-Test-3
-------
15. Identify the element of an integrated solid waste management system which
is generally considered to be the disposal technique of last resort.
a. incineration
b. recycling
c. landfill
d. source reduction
16. The leachate collection system in a sanitary landfill is designed to:
a. cause rainwater to flow away from the waste in the landfill cells.
b. collect any groundwater that gets below the lower flexible membrane
liner.
c. collect seeping precipitation and waste decomposition liquids that
accumulate above the liner.
d. be a flexible membrane which acts as a low permeability cap over the
cells after the landfill is closed.
17, Identify the single feature of recycling programs which does not improve the
combustion quality of MSW charged into a mass burn MWC.
a. composting
b. metal removal
c. glass removal
d. paper removal
18. A general RDF program can the heating value of the MSW entering the
combustion unit:
a. increase by about 10%.
b. decrease by about 10%.
c. increase by about 25%.
d. decrease by about 25%.
19. An average higher heating value of the conventional RDF is somewhere
around:
a. 2,000 Btu/lb.
b. 4,000 Btu/lb.
c. 6,000 Btu/lb.
d. 8,000 Btu/lb.
Post-Test-4
-------
20. The ash fusion temperature of MSW varies from about 1,300°F to
compared with 2,100 to 2,500° F for bituminous coal:
a.
b.
c.
d.
1,600° F.
2,100° F.
2,500° F.
6,000° F.
5,1. The primary activity of a
a. Trommel screen
b. hammer mill shredder
c. flail mill
d. disc screen
is to break open plastic bags of MSW:
22. The primary activity of a
the larger pieces.
a. Trommel screen
b. hammer mill shredder
c. flail mill
d. magnetic separator
is to segregate the metal and grit pieces from
23. A population of 100,000 people on average produces about:
a. 320 tons-MSW/day.
b. 1,000 Ib-MSW/day.
c. 320,000 Ib-MSW/day.
d. 3,200,000 lb-MSW/year.
24. A pH value of 9.0, which is typical of boiler feedwater, is an indication that
the:
a. water is acidic and potential tube corrosion will be a problem.
b. water is basic and excessive water tube corrosion will probably occur.
c. water is basic but water tube corrosion problems are probably under
control.
d. water is approximately neutral, so that tube corrosion problems are
probably under control.
Post-Test-5
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25. The theoretical amount of air required to burn a pound of average MSW with
no excess air is about:
a. 0.5 pounds.
b. 3 pounds.
c. 6 pounds.
d. 12 pounds.
26. Silicon carbide coatings are generally placed on the waterwall surfaces below
the over-fire air ports primarily to
a. reflect the combustion energy and keep the waterwalls from over-
heating.
b. prevent the sequential oxidation and reduction reactions on the metal
walls.
c. eliminate carbon monoxide formation.
d. reduce the costs of water treatment.
27. A properly operating in situ monitor indicates 300 ppm of SO2 in the flue gas,
and the moisture in the flue gas is known to be 20%. If an extractive
instrument which has an in-line dryer indicates 320 ppm of SO2, then
a. the two instruments are reading consistently.
b. the extractive instrument is reading too high.
c. the extractive instrument is reading too low.
28. A properly operating extractive GEMS instrument indicates 200 ppm of SO2
and 9% oxygen in the flue gas. The standard emission concentration of SO2
corrected to 7% flue gas oxygen would be:
a. 200ppmofS02.
b. 233 ppm of S02.
c. 171 ppm of SO2.
29. The overall amount of excess air in the flue gas leaving a modular, starved-air
incinerator burning MSW is about that of conventional excess-air, grate
firing, mass burn systems.
a. half
b. twice
c. ten times
d. one tenth
e. the same as
Post-Test-6
-------
30. Volatile metals tend to be concentrated on the sub-micron particulate matter
in the MWC exhaust. This phenomena occurs because:
a. those metals are contained on small diameter particulates in the waste
fuel.
b. upon being heated in the furnace, they swell up and burst into lots of
fine particles.
c. they are absorbed and/or condensed onto the available surfaces of the
particulate matter, which are mostly associated with small particulates.
Nitrogen oxides formed from molecular nitrogen in air is referred to as
"thermal NOx." It is given this name because:
a. nitrogen oxide burns the skin.
b. its formation has a negative impact on the thermal efficiency of the
boiler.
c. the formation reaction rate increases greatly with increasing
temperature.
d. when it is formed the combustion gas will begin to glow with a
yellow/brownish color.
32. By injecting ammonia or urea into the furnace, reduction reactions are
established which will convert NOx into molecular nitrogen and other
molecules. The optimum temperature range for such reactions to occur is
around:
a. 2,100-2,300 °F.
b. 1,600-1,800 °F.
c. 1,200- 1,400 °F.
d. 800-1,000 °F.
33. A potential problem with ammonia or urea injection for NOx control is the
formation of a white plume. This is caused by:
a. steam in the flue gas condensing more rapidly.
b. formation of ammonium chloride which condenses as a white particulate
in the plume.
c. urea and ammonia which are white materials injected into the flue gas.
d. ammonium sulfate being formed in the flue gases.
Post-Test-7
-------
34. In any combustion system, a portion of the inorganic material will leave the
combustion zone in the flue gas as fly ash. For a pulverized coal fired utility
boiler, about 70% of the ash leaves the boiler as fly ash. The approximate
fraction of the MSW fuel's solid residues which leaves a mass burn, waterwall
unit with a grate as fly ash is:
a. 50 - 80%
b. 30 - 50%
c. 5 - 25%
d. 1-5%
35. Why do some mass burn excess-air units use pusher grates?
a. Pieces of mass burn materials clump together and are too large to get
good carbon burnout on a travelling grate
b. A larger fraction of the mass burn materials burn in suspension, which
causes higher bed temperatures which would destroy travelling grates.
c. Mass burn units have more glass and aluminum which would melt and
produce a lot more clinkers if it were burned on a travelling grate.
d. none of the above
36. On average, the combustion gases leaving the burning region of the fuel bed
in an excess-air waterwall unit will generally be under:
a. fuel-rich (starved-air or reducing) conditions.
b. approximately stoichiometric conditions.
c. fuel-lean (excess air) conditions.
37. Using the regulatory definition, the combustion efficiency of a modern, water-
wall MWC unit (based on the flue gas carbon monoxide to carbon dioxide ratio)
is:
a. about 25-40%
b. about 70-85%
c. about 85-97%
d. greater than 99%
Post-Test-8
-------
33.
The overall energy conversion efficiency of a modern, water-wall MWC unit
based on fuel energy to electrical energy production is:
39.
40.
a. about 20-30%
b. about 30-50%
c. about 85-95%
d. greater than 95%
During start-up, auxiliary fuel burners are used to preheat the boiler. The
operator is required by NSPS Good Combustion Practice to assure that:
a. the furnace temperature is high enough to assure burnout of organics
and CO coming from the fuel bed.
b. the grate bars are at the proper temperature level prior to waste
charging.
c. the auxiliary firing rate is sized adequately to produce steam at the
unit's rated capacity.
Initiation of air pre-heating (energy from either steam or flue gas) during
normal operations of a mass burn MWC is an operator decision which will be
primarily based on which of the following factors:
a. a need for less steam production.
b. the general moisture content of the waste.
c. the amount of plastic material in the waste fuel.
d. all of the above.
41. Which of the following characteristics are typical for a deaerator?
a. preheating condensate to around the saturation temperatures at 5 to 50
psig pressure.
b. cooling the condensate to less than 212° F.
c. superheating condensate but at a slight vacuum.
42. The feedwater pumps in a MWC steam system are designed to:
a. raise the feedwater pressure at the pump to about 65% of the boiler
design pressure.
b. raise the feedwater pressure at the pump to the full boiler operating
pressure.
c. raise the feedwater pressure at the pump to above the boiler operating
pressure.
d. recirculate water from the turbine to the condensate hot well prior to
entering the economizer.
Post-Test-9
-------
43. The turbine generator rotational speed must be slowly increased from the
turning gear rate to synchronization speed to:
a. make certain that the turning gear disengages at the right time.
b. assure that the rotational speed never exceeds 3600 rpm.
c. allow for expansion of the rotor and casing.
d. provide a smooth transition from single phase to three phase power
production.
44. In situ instruments for measuring flue gas concentrations have typical features
which:
a. allow them to give readings which are identical with those of extractive
monitoring instruments.
b. provide concentration readings which are higher than extractive
instruments due to the influence of water vapor.
c. are more reliable than extractive systems because of their high
temperature exposures.
d. allow for monitoring the gas under its actual stack conditions.
45. The reason that the maximum operating pressure and temperature are set as
they are is because of the difficulty:
a. associated with fire side corrosion and deposits on superheater tubes.
b. in maintaining water chemistry at higher temperatures and pressures.
c. associated with deposits inside the superheater tubes.
d. associated with repairing tube failures at higher pressures.
46. A modern MWC facility was equipped with both in situ and extractive
monitors for CO and a moisture analyzer. The in situ monitors indicated 64
ppm CO, while the extractive monitor indicated 75 ppm CO. The moisture
analyzer reading was 15%. Indicate your evaluation of the situation:
a. The in situ monitor reading was too low.
b. The extractive system was reading too high.
c. Both instruments were reading correctly.
d. There was an air leak in the extractive system sampling line.
Post-Test-10
-------
47. Chemiluminescent NOx monitors must be routinely calibrated with both a
span gas and a zero gas. The need for the zero gas calibrations is because:
a. The photomultiplier tube, which produces an electrical signal (dark
current) even when no gas is flowing through the detection cell, must
have a method to calibrate the zero condition.
b. Clean dry gas helps to clean out the capillaries within the instrument.
c. The measurement technique is based on the ratio of oxygen to nitrogen
in standard air.
d. The zero gas serves as an internal standard for correcting the
measurement to a desired percent O2.
48. Identify the following statement which is incorrect.
a. Dry hydrated lime (calcium hydroxide) is a common material injected
into the flue gas by dry sorbent injection systems for acid gas control.
b. A hydrated lime (calcium hydroxide) slurry is a common solution which
is used in spray dryer absorber systems for acid gas control.
c. A slaker is a device which mixes water and pebble lime (calcium oxide)
and creates a slurry whose temperature is raised by the chemical
changes which occur during the process.
d. A slaker is a device which mixes water and pebble lime (calcium oxide)
and creates a slurry which is subsequently heated to around 170°F by
an auxiliary heat source.
49. The most toxic of all polychlorinated dibenzo-p-dioxins is
a. 2,3,7,8 tetrachlorinated dibenzo-p-dioxin.
b. penta chlorodibenzo-p-dioxin.
c. octa chlorodibenzo-p-dioxin.
d. mono chlorodibenzo-p-dioxin.
50. The required annual sampling procedures for measuring particulate mass
emissions and dioxin/furan emissions both rely on a form of measurement
based on a modification of the standard EPA .
a. Method AP 42
b. Method 5
c. Method 12
d. Method lll(b)
Post-TesMI
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NAME:
1.
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4.
15.
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8.
9.
10.
11.
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USTOR OPERATOR TRAINING
JNSWER SHEET
wer on this Answer
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
a
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Post-Test Answer Sheet-1
-------
NAME: C 0 R R E C T ANSWERS
MUNICIPAL WASTE COMBUSTOR OPERATOR TRAINING
POST-TEST ANSWER SHEET
Instructions: Enter the appropriate answer on this Answer Sheet.
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Post-Test Answer Sheet-2
-------
LESSON PLAN NUMBER 1
INTRODUCTION
Goal: To introduce the participants to the goals of the training program
and requirements for Operator Certification.
Objectives: Upon completion of this unit, an operator should be able to:
1. Discuss the regulatory basis for operator training requirements.
2. Understand that the regulatory procedures regarding certification
may vary from state to state, but that the certification
requirements should be equivalent to those of the ASME Standard.
3. Understand the purpose of the Pre-Test and the Post-Test in the
current training program.
4. Distinguish between the testing in the training program and the
testing requirements for ASME Certification.
5. Name the three parts of the ASME General Examination for
Provisional Certification as a Chief Facility Operator or Shift
Supervisor.
6. Discuss the qualifications required for Operator Certification as a
Chief Facility Operator or Shift Supervisor under the ASME
Standard.
Lesson Time: Approximately 30 minutes
Suggested
Introductory
Questions:
1. Where do you learn about what's happening in the area of
municipal solid waste regulation?
2. The EPA has developed regulations for MWCs under the Clean Air
Act Amendments. How has this influenced what is happening at
your facility?
1-1
-------
r
Presentation
Summary
Outline:
Introduction
Regulatory Requirements: Training/Certification
Purpose of Pre-Test and Post-Test
ASME Certification Procedures
Projection
Slides:
See the following pages.
Source
of
Graphics:
Slide 1-8
"Memorandum on Provisional Certification Examination,"
Addressed to Individuals Interested in QRO Provisional
Certification, by Alan Bagner, Director of Accreditation and
Certification, ASME, 345 East 47th Street, New York, NY 10017,
December 26, 1991.
1-2
-------
Slide 1-1
CLEAN AIR ACT AMENDMENTS
(CAAA) OF 1990
Develop Training & Certification
Require Operators to be Trained
Publish New Source Performance Standards
& Emission Guidelines
Regulate Through State Plans
-------
Slide 1-2
MUNICIPAL WASTE
COMBUSTOR OPERATOR
TRAINING PROGRAM
Goal: Adequate Understanding to Pass
ASME General Examination for
Provisional Certification
-------
Slide 1-3
MUNICIPAL WASTE
COMBUSTOR OPERATOR
TRAINING PROGRAM
Focus: Basis for Equipment Operation and
Maintenance
Basis for Good Combustion Practice
and Environmental Control
-------
Slide 1-4
COURSE MANUAL
ORGANIZATION
1 Introduction
2,12 Environmental Concerns & Regulations
3,4 Characteristics of MS W
5-9 Combustion Principles
6-11 MWC Equipment Features
13,14 Instrumentation
15-21 Air Pollution Control
22-23 Automatic Control
24-25 Operating Practices & Upsets
26-28 Special System Considerations
29-30 Risk Management
-------
Slide 1-5
TRAINING PROGRAM
TESTING
Pre-Test
Post-Test
Same Form and Difficulty
Measures Training Effectiveness
-------
Slide 1-6
ASME PROVISIONAL
CERTIFICATION
Provisional Certification Requirements
• High School Diploma or Equivalent
• Five Years of Acceptable Experience
• Pass General Examination
-------
Slide 1-7
ASME PROVISIONAL
CERTIFICATION
EXAMINATION
General Examination (Written)
• Solid Waste Management (25%)
* Theory (25%)
• Operations (50%)
-------
Slide 1-8
ASME GENERAL EXAMINATION
SUBJECT AREAS
Parti
Part 2
Part3
25% of examination
25% of examination
50% of examination
Solid waste collection,
transfer and management,
covering the following:
Theory, covering
the following:
Operation of a resource
recovery facility,
covering the following:
• Municipal solid
waste composition
• Collection techniques
• Seasonal and industrial
impact on the character
of refuse
• Ash disposal
• Landfills
• Composting
• Environmental
public relations
• Environmental
regulations and
requirements
• Combustion
• Chemistry
• Thermodynamics
• Material science
• Mechanical and
electrical operation
and technology
• Air pollution
control technology
• Air emission
stack monitoring
• Material handling
equipment
• Boiler operations
• Generator and
turbine operations
• Ash handling and
disposal operations
• General operations
and maintenance
procedures and
techniques
• Worker safety
• Control room operations
• Continuous emissions
monitors and their
calibration
Courtesy of ASME Codes & Standards, printed with permission
-------
Slide 1-9
LEARNING UNITS IN ASME
EXAM AREAS
Part 1, Solid Waste Management (25%)
Learning Units: 2, 3, 4, 12
Part 2, Theory & Technology (25%)
Learning Units: 5, 7, 9, 13, 15, 16, 17,
20,21,22,27
Part 3, Operations (50%)
Learning Units: 6, 8, 10, 11, 12, 14, 15,
18,23,24,25,26,28,29,30
-------
Slide 1-10
ASME CERTIFICATION
EXAMINATIONS
Operator Certification
Operator Examination (Oral)
* Site-Specific Equipment
• Operations & Maintenance
• Procedures & Regulation
-------
Slide 1-11
ASME OPERATOR
CERTIFICATION
QUALIFICATIONS
Shift Supervisor
Chief Facility Operator
• Hold a Valid Provisional Certification
• 6 Months Acceptable Experience as
Shift Supervisor or
Chief Facility Operator
• Pass a Site-Specific Operator Exam
-------
-------
LESSON PLAN NUMBER 2
ENVIRONMENTAL CONCERNS AND REGULATIONS
Goal: To provide a review of the general regulatory environment related
to MWC unit operations.
Objectives: Upon completion of this unit, an operator should be able to:
1. Discuss the basis for public concerns about waste management.
2. Relate to the history of the development of landfill and incineration
issues.
3. Name the primary federal legislative acts which provide for federal
regulation of solid waste and the emission of air pollutants.
4. List the major air pollutant emissions from incinerators which are
regulated.
5. Explain the relationship between federal legislation and local air
pollution and solid waste management regulations.
6. Identify the regulatory acronyms: RCRA, NESHAP, CAA, NAAQS,
PSD, NSPS and SIP.
7. Identify some important aspects of an operator's role in public
relations.
Lesspn Time: Approximately 35 minutes
Suggested
Introductory
Question: What is your favorite acronym?
Presentation
Outline: Environmental Concerns and Regulations
Public Concerns & Historic Issues
Solid Waste and Air Pollution Regulation
Operator's Role in Public Relations
Projection Slides: See the following pages.
2-1
-------
Slide 2-1
PUBLIC RELATIONS IN
WASTE MANAGEMENT
Out of Sight, Out of Mind
Concern About Health & Environment
Toxic and Carcinogenic Air Pollution
Ground Water Contamination
-------
Slide 2-2
ACRONYMS
NIMBY: Not in My Back Yard
YIMBY: Yes, in My Back Yard
BANANA: Build Absolutely Nothing
Anywhere Near Anybody
NIMTO: Not in My Term of Office
-------
PUBLIC RELATIONS
PHENOMENA
Basis for Public's Mistrust
Impact of Past "Acceptable Practices"
Concern About Waste Disposal Costs
-------
Slide 2-4
HISTORIC LANDFILL ISSUES
• Close Dumps
• Regulate Sanitary Landfills
* Ground Water Contamination
• Superfund Clean-Up
-------
Slide 2-5
FEDERAL SOLID WASTE
LAWS AND REGULATIONS
Resource Conservation & Recovery Act, RCRA
Subtitle C: Hazardous Waste Regulation
Manifest System
Hazardous Waste
Incineration Standards
Subtitle D: Solid Waste Regulation
Sanitary Landfill Standards
-------
Slide 2-6
HISTORIC INCINERATION
ISSUES
• Smoke & Odor From Incinerators
• Toxic Emissions
• Ground Water Contamination From Ash
-------
Slide 2-7
INCINERATOR AIR
POLLUTANTS
Paniculate Matter (PM)
Carbon Monoxide
Nitrogen Oxides
MWC Acid Gases
Hydrogen Chloride & Sulfur Dioxide
MWC Organics
Dioxins, Furans & Other Organics
MWC Metals
Lead, Cadmium, Mercury & Other
Metals
-------
Slide 2-8
FEDERAL AIR POLLUTION
LAWS & REGULATIONS
Clean Air Act, CAA
State Implementation Plans
State Rules & Regulations
Must be at Least as Strict as
the Federal Guidelines and
Approved by the USEPA
-------
Slide 2-9
NATIONAL AMBIENT AIR
QUALITY STANDARDS
(NAAQS)
Criteria Air Pollutants (emitted by sources)
Secondary Air Pollutants (formed
indirectly)
Non-Attainment Areas
Prevention of Significant Deterioration,
PSD
-------
Slide 2-10
CRITERIA POLLUTANTS
Paniculate Matter (PM)
Sulfur Dioxide
Carbon Monoxide
Nitrogen Dioxide
Lead
Ozone
-------
Slide 2-11
NATIONAL EMISSION
STANDARDS FOR HAZARDOUS
AIR POLLUTANTS (NESHAP)
Identify Toxic Air Pollutant Emissions
Set Maximum Emission Limits
Apply Equally to New & Existing Units
-------
Slide 2-12
CLEAN AIR ACT
AMENDMENTS OF 1990
New Units: New Source Performance
Standards
Existing: Emission Guidelines
-------
Slide 2-13
PUBLIC RELATIONS IN
WASTE MANAGEMENT
Problems Which Are "Owned" Can Be Solved
Public Must Be Informed
Environmental Controls Are Available
Method of Payment Required
-------
Slide 2-14
PUBLIC RELATIONS
POSITIVES
Good Signs
• Clean Air Act Amendments of 1990
• Recycling
• Waste Minimization
• Conservation and Renewable Energy
-------
r
Slide 2-15
OPERATORS1 ROLE IN
PUBLIC RELATIONS
Operators Must
• Be Trustworthy
• Be Certified as Being Qualified
• Know What is Expected
• Demonstrate Willingness to
Execute Responsibilities
File Reports
Communicate
Assure Safety
-------
LESSON PLAN NUMBER 3
MUNICIPAL SOLID WASTE TREATMENT
Goal: To provide additional information about the characteristics of
municipal solid waste and the processing and disposal options.
Objectives: Upon completion of this unit, an operator should be able to:
1. Name the major components of an integrated waste management
program.
2. Describe why recycling and composting generally improve the MSW
fuel properties.
3. Describe the basic composting process.
4. Name the general design feature requirements of a modern
sanitary landfill.
5. Contrast a monofill with a modern sanitary landfill.
6. Describe the primary actions of Trommel screens, shredders, air
classifiers, and magnetic separation units in RDF-Fluff preparation.
Lesson Time: Approximately 35 minutes
Suggested
Introductory
Questions:
1.
2.
3.
4.
What is an integrated waste management system?
What is a MRF?
Why are MWC ash residues often disposed in a monofill?
What is the difference between a monofill and a hazardous waste
landfill?
3-1
-------
Presentation
Summary
Outline:
Projection
Slides:
Source
of
Graphics:
Slide 3-7
Slide 3-13
Slide 3-14
Slide 3-15
Slide 3-16
Municipal Solid Waste Treatment
Integrated Waste Management
MSW Mass Burn
RDF Fuel Processing
See the following pages.
Redrawn from: Donald A Wallgren, "Modern Landfill Technology:
The Cornerstone of an Integrated Solid Waste Management
Program," Integrated Solid Waste Management. Frank Kreith,
editor, Genium Publishing Corporation, Schenectady, NY, 1990, p.
129.
Joseph G. Singer, Combustion, Fossil Power. 4th Edition,
Combustion Engineering, Inc., Windsor, CT, 1991, p. 8-22.
J. D. Blue et al., "Waste Fuels: Their Preparation, Handling, and
Firing," Standard Handbook of Power Plant Engineering, Thomas
C. Elliott, editor, McGraw Hill Book Co., NY, 1989, pp. 3-145 to 3-
146.
J. D. Blue et al., "Waste Fuels: Their Preparation, Handling, and
Firing," Standard Handbook of Power Plant Engineering. Thomas
C. Elliott, editor, McGraw Hill Book Co., NY, 1989, pp. 3-145 to 3-
146.
J. D. Blue et al., "Waste Fuels: Their Preparation, Handling, and
Firing," Standard Handbook of Power Plant Engineering, Thomas
C. Elliott, editor, McGraw Hill Book Co., NY, 1989, pp. 3-145 to 3-
146.
3-2
-------
Slide 3-1
INTEGRATED SOLID WASTE
MANAGEMENT
• Source Reduction
• Recycle and Reuse
• Landfill
• Incinerate
-------
Slide 3-2
SOURCE REDUCTION - WASTE
MINIMIZATION
Reduce Quantity
• Improve Efficiency
• Improve Product Life
• Reusable Versus Throwaway
• Packaging Materials
Reduce Toxicity
• Material Substitution
-------
Slide 3-3
RECYCLING
Positive Public Perception
Separation of Reusable Products
Raw Material Markets
Conserve Natural Resources
Reduce Environmental Impact
Extend Landfill Life
-------
Slide 3-4
COMPOSTING
Aerobic Decomposition (with Oxygen)
Biological Microorganisms Required
Produces Carbon Dioxide & Moisture
Anaerobic (Without Oxygen) Decomposition
Produces Methane
-------
Slide 3-5
COMPOST MARKET
REQUIREMENTS
• Process Requirements
• Pre-Processing
• Post-Processing
• Market Development
-------
Slide 3-6
LANDFILL REQUIREMENTS
UNDER RCRA
• Containment System
Cap System
Bottom Liner
• Leachate Collection & Treatment
• Groundwater Monitoring
• Gas Monitoring & Collection
-------
-------
Slide 3-8
MONOFILL
Special Landfill
Hazardous Waste: Concentrations
Below Specified Limits
• MWCAsh
• HWIAsh
• Hazardous Waste
• Chemical Waste
-------
Slide 3-9
MUNICIPAL WASTE
COMBUSTORS, MWC
Incineration
Volume Reduction
Waste-to-Energy Resource Recovery
Volume Reduction & Energy
-------
Slide 3-10
MUNICIPAL WASTE
COMBUSTORS
Mass Burning Units
Refuse Derived Fuel (RDF) Units
-------
Slide 3-11
FRONT-END PROCESSING
Elimination of Undesirable Materials
Size Reduction
Pre-Combustion Materials Recovery for
Refuse-Derived Fuel, RDF
-------
Slide 3-12
RDF PROCESSING EQUIPMENT
• Flail Mill Shredder
• Trommel Screen
• Magnetic Separator
• Eddy Current Separator
• Hammer Mill Shredder
• Disk Screen or Air Classifier
-------
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-------
Slide 3-14
HAMMER MILL SHREDDER
Drive
Motor
Ballistic
Rejection
Hammers
Neck
Section
Discharge
From Standard Handbook of Pcwer Placi Engineering. Thomas C. Ellioit, editor.
McGraw Hill Book Co.. NY. 1989, reprinted with permission
-------
Slide 3-15
TROMMEL ROTARY
SCREEN
Oven
Feed .
10-14 RP1*
From Standard Handbook of Power Plan; Engineering Thomas C. Elliott, editor,
McGraw Hill Book Co.. NY, 1989. reprinted with permission
-------
Slide 3-16
AIR CLASSIFIER
Rotary
Feeder
Control
Damper
From Standard Handbook of Power Plant Engineering. Thomas C. Elliott, editor.
McGraw Hill Book Co., NY. 1989, reprinted with permission
-------
Slide 3-17
POST COMBUSTION
PROCESSING
Ferrous Metal Extraction From Ash
-------
-------
LESSON PLAN NUMBER 4
CHARACTERIZATION OF MSW FUELS
Gcal:
Objectives:
1.
2.
3.
4.
5.
6.
8.
9.
10.
11.
To provide general information about municipal solid waste (MSW)
fuel and refuse derived fuel (RDF) and other types of wastes,
including their definitions, sources, and fuel property
characteristics.
Upon completion of this unit, an operator should be able to:
Identify the following acronyms: MSW, RDF, MWC, MWI, HWI.
List the community sectors which are the sources of municipal solid
waste.
Name some types of wastes excluded from municipal solid waste.
Identify the primary constituents (components) of medical wastes.
Identify the major constituent groups of hazardous wastes.
Be able to estimate the annual average quantities of MSW
produced by a given population size.
Characterize the seasonal variations in MSW composition and in
the quantity produced.
Distinguish between a chemical element and component material.
List the major categories in the proximate analysis of a fuel.
Contrast the variability of size and composition between typical
MSW and conventional fuels.
Contrast the fuel properties of general municipal solid waste with
refuse derived fuel (RDF).
4-1
-------
Lesson Time: Approximately 50 minutes
Suggested
Introductory
Questions:
1.
2.
3.
How much MSW does the average person in the USA produce per
day?
Is the average of MSW produced in (Europe; industrial USA
communities; rural USA communities) greater than or less than the
average of MSW produced in the United States?
What is the most important characteristic of MSW affecting
operations in your unit?
Presentation
Summary
Outline: Characterization of MSW Fuels
Sources and Types of Solid Wastes
Characterization of Fuel Properties
Projection
Slides:
See the following pages.
4-2
-------
Slide 4-:
SOLID WASTE ACRONYMS
HWI Hazardous Waste Incinerator
MRF Materials Recovery Facility
MSW Municipal Solid Waste
MWC Municipal Waste Combustor
MWI Medical Waste Incinerator
RDF Refuse Derived Fuel
-------
Slide 4-2
CHARACTERIZATION OF
WASTE COMPOSITION
Source
Type
Material Constituents
Ultimate Analysis (Element by Weight)
Proximate Analysis (Group by Weight)
-------
Slide 4-3
MUNICIPAL SOLID WASTE
SOURCES:
Household Waste
Commercial (Retail)
Institutional
Specific Items
-------
Slide 4-4
MUNICIPAL SOLID WASTE
EXCLUDES:
• Industrial Process Waste
• Segregated Medical Waste
• Hazardous Waste
• Specific Items
-------
S'ide 4-5
MEDICAL WASTE SOURCES
Human & Animal Diagnosis
Human & Animal Treatment
Human & Animal Immunization
Processing of Biologicals
-------
Slide 4-6
REGULATED MEDICAL WASTES
Heterogeneous Mixture of Materials Capable of
Producing Infectious Diseases in Humans
1. Cultures & Stocks of Infectious Agents &
Associated Biologicals (Including Vaccines)
2. Human Pathological Wastes (Human Tissues,
Organs, Body Parts, Body Fluids)
3. Blood & Blood Products
4. Sharps (Needles, Syringes, Scalpel Blades,
Pipettes, Broken Glass)
5. Contaminated Animal Carcasses & Body Parts
6. Isolation Wastes
7. Unused Sharps
-------
Slide 4-7
HAZARDOUS WASTE
CONSTITUTES DANGER TO
Public Health
Welfare
-------
Slide 4-8
HAZARDOUS WASTE
• Oils
• Flammable Organics
• Toxic Metals & Solvents
• Explosives
• Salts, Acids, Bases
-------
Slide 4-9
INCINERATOR INSTITUTE
OF AMERICA
CLASSIFICATIONS
TYPED
Type 1
Type 2
Type 3
Type 4
Type 5
Type 6
Type?
Trash with 8,500 btu/lb.
10% moisture, 5% incombustible
Rubbish with 6,500 btu/lb.
25% moisture, 10% incombustible
Refuse with 4,300 btu/lb.
50% moisture, 7% incombustible
Garbage with 2,500 btu/lb.
70% moisture, 5% incombustible
Human & animal parts, with 1,000 btu./lb.
85% moisture, 5% incombustible
Industrial by-product wastes which
are gaseous, liquid & semi-liquid
Industrial solid by-product waste
rubber, plastic, wood wastes
Municipal sewage sludge wastes
residue from processing of raw sludge
-------
Slide 4-10
MSW
C OMPOSITION/GENER ATION
Weight Million
Percent Tons/Yr.
Paper & cardboard
Yard wastes
Metals
Glass
Plastics
Food wastes
Wood
Rubber & leather
Textiles
Miscellaneous
Total
40.0
17.6
8.5
7.0
8.0
7.3
3.6
2.6
2.2
3.2
100.0
71.8
31.6
15.3
12.5
14.4
13.2
6.5
4.6
3.9
5.8
179.6
-------
Slide 4-11
ESTIMATE OF DAILY MSW
FOR A REGION
Example Population: 200,000 persons
Per Capita Production: 3.2 Ib/day/person
Daily Amount Produced: 640,000 Ib/day or
320 tons/day
-------
Slide 4-12
AVERAGE ULTIMATE
ANALYSIS
Element
Carbon
Hydrogen
Oxygen
Nitrogen
Chlorine
Sulfur
Inorganics (ash)
Moisture
As Received
Percent by
Weight
25.6
3.4
20.3
0.5
0.5
0.2
24.3
25.2
Dry Basis
Percent by
Weight
34.2
4.5
27.1
0.7
0.7
0.2
32.6
Total
100.0
100.0
-------
Slide 4-13
EXAMPLE RDF PROXIMATE
ANALYSIS
Yr. Average
Percentage by
Weight
Range During Year
Mimimum
Value
Maximum
Value
Moisture
26.6
2.3
42.2
Ash
21.7
10.8
34.5
Volatile Matter 43.6
34.9
60.4
Fixed Carbon 8.1
0.0
21.6
-------
Slide 4-14
COMPARISON OF MSW AND
COAL VALUES
Higher Heating Value (Btu/lb)
MSW 2,000- 7,700
Bituminous Coal 9,000 -13,500
Fuel Oil 18,000-20,000
Normal Fuel Size
MSW
Pulverized Coal
Stoker Coal
Powder to 6 ft.
Fine Powder
1/32 in.-1.2 in.
Ash Fusion Temperature (°F)
MSW 1,300-1,600
Bituminous Coal 2,100 - 2,500
-------
Slide 4-15
MSWFUEL VARIABILITY
Wet, Dry
Large Pieces, Small Particles
Combustibles, Incombustibles
Uniformity of Composition
-------
Slide 4-16
EXAMPLE OFMSW
COMPOSITION
MSW RDF
Percent Percent
Paper and Cardboard 46.6 78.8
Miscellaneous 18.9 6.6
Glass 9.5 1.4
Natural Organics 6.6 1.5
Wood 6.4 4.3
Metals 6.4 0.7
Plastics 3.2 5.1
Textiles 1.7 1.6
Tar 0.7 0.0
Total 100.0 100.0
-------
Slide 4-17
EXAMPLE OF ULTIMATE
ANALYSIS
Element
Carbon
Hydrogen
Oxygen
Nitrogen
Chlorine
Sulfur
Inorganics (Ash)
Moisture
MSWAs
Received
Percent by
Weight
22.2
5.4
33.3
0.3
0.2
0.2
16.4
22.0
RDF As
Received
Percent by
Weight
30.0
6.0
37.2
0.2
0.2
0.2
7.8
18.4
Total 100.0
100.0
-------
Slide 4-18
EXAMPLE OF ULTIMATE
ANALYSIS
Element
MSW
Dry Basis
Percent by
Weight
RDF
Dry Basis
Percent by
Weight
Carbon
Hydrogen
Oxygen
Nitrogen
Chlorine
Sulfur
Inorganics (Ash)
28.5
6.9
42.7
0.4
0.2
0.3
21.0
36.7
<
45.6
0.3
0.2
0.2
9.6
Total
100.0
100.0
-------
Slide 4-19
RDF BOILER FUEL
DESCRIPTION
Class
1 Raw MS W fuel. Used as a fuel in the as-discarded
form; oversized bulky waste items have been removed.
2 Coarse RDF. Processed to a coarse size with or without
ferrous metal separation, 95% passing thru a 6-inch
mesh screen.
3
Prepared RDF. Processed to remove 90% of ferrous
metal, glass, and other inorganics, sized with 99%
passing thru a 6-inch square mesh screen.
Recovery Prepared RDF. Equivalent
with aluminum, other non-ferrous &
to Class 3, but
very repare . quvaen o ass , u
aluminum, other non-ferrous & glass removed for
ret sal PR.
market sales.
5 Fluff RDF. Shredded; metals, glass and other
inorganics removed, sized for 95% passing thru a
2-inch mesh screen.
6 Densified RDF. Combustibles compressed or densified
into pellets, slugs, cubettes, briquettes, etc.
-------
Slide 4-20
ASTM FUEL CLASSIFICATIONS
RDF-1 Municipal solid waste used as a fuel in
(MSW) as-discarded form, without oversized bulky
wastes
RDF-2 MSW processed to coarse particle size, with or
(c-RDF) without ferrous metal separation, 95% passing
thru a 6-inch mesh screen
RDF-3 Shredded fuel derived from MSW, with
(f-RDF) processing to remove metal, glass and other
inorganics, 95% passing thru a 2-inch square
mesh screen (Fluff RDF)
RDF-4 Combustible-waste fraction processed into a
(p-RDF) powdered form, 95% passing thru a 10-mesh
(.035-inch) screen
RDF-5 Combustible-waste fraction densified or
(d-RDF) compressed into the form of pellets, slugs,
cubettes, briquettes, etc.
RDF-6 Combustible-waste fraction processed into a
liquid fuel
RDF-7 Combustible-waste fraction processed into a
gaseous fuel
-------
LESSON PLAN NUMBER 5
COMBUSTION PRINCIPLES I: BASIC COMBUSTION
Goal: To provide basic information about the chemical changes which
take place during MSW combustion.
Objectives: Upon completion of this unit, an operator should be able to:
1. List five chemical elements in MSW (from ultimate analysis).
2. Contrast the behavior of organic and inorganic materials during
combustion.
3. Name examples of hydrocarbon (organic) material found in MSW.
4. Name examples of inorganic material found in MSW.
5. List three major products of complete combustion of MSW.
6. List two major products of incomplete combustion of MSW.
7. State the general meaning of a stoichiometric fuel/air mixture.
8. Describe the application of a fuel's ultimate analysis in calculating
the combustion air required.
9. State the approximate theoretical amount of air required for
burning each pound of MSW.
10. Define excess air and compare its definition with that of theoretical
or stoichiometric air.
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Questions:
1.
3.
Which is better: rich or lean combustion?
What are the differences between excess air, excess oxygen,
theoretical air and stoichiometric air?
5-1
-------
Presentation
Summary
Outline: Combustion Principles I: Basic Combustion
Balanced Chemical Reaction Equations
Stoichiometry & Excess Air
Projection
Slides:
See the following pages.
5-2
-------
Slide 5-1
BASIC COMBUSTION CONCEPTS
Fuel & Air Characteristics
Products of Complete Combustion
Complete Combustion Reactions
Excess Air Considerations
-------
Slide 5-2
COMBUSTION: CHEMICAL
REACTION
Rapid Oxidation (Fuel & Oxygen)
Heat & Light Given Off
Products of Combustion:
Oxides
Other Compounds
-------
Slide 5-3
COMBUSTIBLE SUBSTANCES
Organic - Hydrocarbons
• Paper, Wood, Plastic
• Fossil Fuels
• Renewable Fuels
-------
Slide 5-4
NON-COMBUSTIBLE
SUBSTANCES
Inorganic
Metals
Glass, Sand
Ceramics, Concrete
-------
de 5-5
ULTIMATE ANALYSIS
Component
MSWAs
Received
Percent by
Weight
RDF As
Received
Percent by
Weight
Carbon
Hydrogen
Oxygen
Nitrogen
Chlorine
Sulfur
Inorganics (Ash)
Moisture
22.2
5.4
33.3
0.3
0.2
0.2
16.4
22.0
30.0
6.0
37.2
0.2
0.2
0.2
7.8
18.4
Total
100.0
100.0
-------
Slide 5-6
ATOMIC STRUCTURE OF
MATTER
Atoms
Molecules of One Element
Molecular Compounds
Mixtures
"String Compounds"
-------
Slide 5-7
AIR
Mixture of Oxygen and Nitrogen
Oxygen -.21% by volume
Nitrogen - 79% by volume
3.76 moles of nitrogen per mole of oxygen in air
-------
Slide 5-8
DEFINITION OF A POUND-MOLE
Mass or Weight of Gas Equal to its
Molecular Weight in Pounds
A Unique Number of Molecules,
Regardless of the Gas
379 Cubic Feet of Gas at Standard
Conditions, Regardless of Gas
-------
Slide 5-9
STOICHIOMETRIC
(THEORETICAL) AIR-FUEL
MIXTURE
Fuel Completely Burned
Oxygen Completely Consumed
Products of Complete Combustion Are Formed
-------
Slide 5-10
PRODUCTS OF COMPLETE
COMBUSTION
• Carbon Dioxide
• Water (vapor)
• Sulfur Dioxide
• Hydrogen Chloride (acid)
• Nitrogen (molecular)
• Oxygen (molecular)
-------
Slide 5-11
PRODUCTS OF INCOMPLETE
COMBUSTION
Carbon Monoxide
Dioxins
Furans
-------
Slide 5-12
OTHER COMBUSTION
PRODUCTS
Nitrogen Oxides
Metal Vapors
Metal Oxides
Metal Chlorides
-------
Slide 5-13
CHEMICAL REACTION
EQUATION
Carbon: C + O > CO
-------
Slide 5-14
BALANCED CHEMICAL
REACTION EQUATIONS
COMBUSTION IN OXYGEN
Carbon:
Hydrogen:
Sulfur:
Chlorine:
C +
CO
O
O
H2 + 2 Cl
2
2H0
SO-
2HC1
-------
Slide 5-1.5
BALANCED CHEMICAL
REACTION EQUATIONS
Each Type of Atom Is Conserved
Each Element's Mass Is Conserved
Total Mass Conserved
The Number of Molecules Is Not Conserved
-------
Slide 5-16
EXAMPLE OF BALANCING A
COMBUSTION EQUATION
Methane, CH,, with Stoichiometric Oxygen
L4'
CH4 + 2 02
CO2 + 2H2O
-------
Slide 5-17
COMBUSTION REACTIONS
IN AIR
3.76 moles of nitrogen in air per mole of oxygen
-------
Slide 5-18
EXAMPLE OF BALANCING A
COMBUSTION EQUATION
Methane, CH., with Stoichiometric Air
'4'
CH4 + 2 O2 + 7.52 N2
CO, + 2H,O + 7.52 N,
JL *• **
-------
Slide 5-19
EQUIVALENT MOLECULAR
FORM OF MSW
1-22 H20
-------
Slide 5-20
THEORETICAL COMBUSTION
OF MSW IN AIR
2.165 O2 + 8.14 N2
1.85 CO
3.92 H2O
8.15 N
2 . 2 . 2
0.006 HC1 + 0.006 SO
-------
Slide 5-21
MASS ANALYSIS OF
STOICHIOMETRIC FUEL
AND AIR MIXTURE
Reactants
1.22H20
2.165 O
8.14 N,
Moles Molecular Weight
Wt Ib/mole Ib
1.0
1.22
2.165
8.14
61.6
18
32
28
61.6
22.0
69.3
227.9
Total
380.8
-------
Slide 5-22
EXCESS AIR
Air in Excess of Theoretical
Fraction: Extra/Theoretical
Symbol: EA
Total Supply Air is (1+EA) x (Theoretical Air)
Oxygen in Flue Gas is EA x (Theoretical
Oxygen)
-------
Slide 5-23
METHANE COMBUSTION IN
THEORETICAL AIR
CH. +2O, +7.52N
4
— If »t*S 4m> J. 1 — r
CO2 + 2 H2O + 7.52 N2
METHANE COMBUSTION IN
EXCESS AIR
CH4 + (1 + EA) (2) O2 + (1 + EA) (7.52) N2 —
CO, + 2H,O + (1+EA)7.52N? + (EA) (2) O.
-------
Slide 5-24
METHANE COMBUSTION,
20 PERCENT EXCESS AIR
CH4 +2.4O2 + 9.024 N2
CO2 + 2 H2O + 9.024 N2 + 0.4 O2
-------
Slide 5-25
PRODUCT GAS ANALYSIS,
METHANE @ 20% EA
Products
CO,
H20
Total
Dry Gas Total 10.424
Moles
1.0
2.0
0.4
9.024
12.424
Molar Wt.
Ibm/mole
44
18
32
28
Mass
Ibm
44.0
36.0
12.8
252.7
345.5
309.5
-------
-------
LESSON PLAN NUMBER 6
MUNICIPAL WASTE COMBUSTORS
Goal: To provide descriptive information about modern combustion
equipment used for burning MSW.
Objectives: Upon completion of this unit, an operator should be able to:
1. Identify the important developments in the evolution of incineration
system performance which have led to current technology.
2. Characterize the major features of the older large mass burner
units which used refractory walls and lots of excess air.
3. Note the similar and contrasting features of most large mass burn
units (with refractory materials covering the waterwalls) with those
of the refractory-wall modular starved-air units.
4. Distinguish between starved-air and controlled-air units.
5. Describe the typical two-stage combustion features of modular mass
burners.
6. Contrast the combustion environment in an integral boiler with
that of a refractory wall unit with a waste heat recovery boiler.
7. Describe the unique features of a mass burner unit designed with
an integral rotary waterwall primary chamber.
8. Compare the unique features of an integral rotary waterwall with
those of a rotary kiln incinerator.
Lesson Time: Approximately 60 minutes
Suggested
introductory
Activity:
1.
During the introduction of MWC technology, consider requesting
selected individuals to describe the general features of the MWC unit
which they operate. Projection of an illustration of the basic unit
design will be helpful. You may want to ask them to describe the best
features or those which cause the most operational "headaches."
6-1
-------
Presentation
Summary
Outline:
Projection
Slides:
Source
of
Graphics:
Slide 6-3
Slide 6-4
Slide 6-6
Slide 6-8
Slide 6-9
Slide 6-10
Slide 6-12
Slide 6-14
Slide 6-15
Slide 6-17
Municipal Waste Combustors
Mass Burn: Refractory/Waterwall, Excess-Air
Modular Mass Burn: Starved-Air/Controlled-Air
RDF Units
See the following pages.
J. A. Danielson, Air Pollution Engineering Manual. AP 40, Second
Edition, U. S. Environmental Protection Agency, May 1973, p. 472.
J. E. Williamson et al., "Multiple Chamber Incinerator Design
Standards for Los Angeles County," Los Angeles County Air Pollution
Control District, October 1960.
Municipal Incineration. A Review of Literature. AP-79, U. S.
Environmental Protection Agency, 1971.
Georg Stabenow, "Results of Stack Emissions Tests at the New
Chicago Northwest Incinerator," ASME J. Engineering for Power, pp.
137-141, July 1973.
Steam. Its Generation and Use. 39th Edition, Babcock and Wilcox,
New York, 1978, p. 16-3.
Steam, Its Generation and Use, 39th Edition, Babcock and Wilcox,
New York, 1978, p. 16-3.
Scott Siddens, "A Decade of Innovation in WTE Incineration," Solid
Waste and Power. April 1990, pp. 16-23.
"Controlled Air Incineration," Joy Energy Systems, Inc., Charlotte,
NC, Undated Brochure.
"Integrated Waste Services, Information Summary," Consumat
Systems, Inc., Richmond, Virginia, Undated Brochure.
"Prepared Fuel Steam Generation System," ABB Resource Recovery
Systems, Windsor, Connecticut, Undated Pamphlet.
6-2
-------
S Lide 6-1
ORGANIZATIONAL STRUCTURES
BUILDER OWNER OPERATOR
Vendor
Public
Public
Vendor
Public
Private/Vendor
Vendor
3rd Party Private/Vendor
Vendor
Vendor
Vendor
-------
Slide 6-2
EVOLUTION OF MWC DESIGNS
Single Chamber, Flue-Fed
Multiple Chamber
Refractory Wall Incineration
Mass Burn Waste-to-Energy
Modular
RDF Waste-to-Energy
-------
Slide 6-3
SINGLE CHAMBER
FLUE-FED INCINERATOR
Combustion chamber
Geuout door
Underfire air pen
-------
o
H
0*
a
g
0
!!
« 13
«£.s
4s c s n
U 3 CJ O
U
I
cs J= to
»
-------
Sli.de 6-fi
REFRACTORY-WALL,
MASS BURN
High Excess Air
High Gas Velocities
Particle Entrainment
Smoke
Shut Down in Late 1970s
-------
Slide 6-6
REFRACTORY WALL
INCINERATOR
•s' ••''!''•^_'V/ 'x// •'////// i I i I i i . V V.\\\\\».
I'N^.-^N.ww •
I '! \ \ \ L .^ A\\'
•- « ->« v-.^vx".
M " u \ V\VA \\\v
,' I! I i \ \
\\\\
Courtesy of ABB Combusuor, Er.iineenng, Inc.
-------
Slide 6-7
WATERWALL MASS BURN
Waste-to-Energy
European Designs
ESP for Paniculate Control
-------
I
u;
CC
i
-------
U
o
u
g
Ji
o
sr
u
-------
O
U
O
H
U
•o
1
I
ec
-------
Slide 6-11
ROTARY WATERWALL
MASS BURN
Mass Burn or RDF Fired
• Rotary Waterwall Section
• Fixed Waterwall Section
-------
§
n
I
0
o
u
S
|
c
-------
Slide 6-13
MODULAR MASS BURN
Factory Manufactured
Refractory-Wall
Controlled-Air, Starved-Air
Low Velocity in Primary
Low Particulate in Entrainment
Solids Retention for Burn-Out
-------
-------
Slide 6-15
MODULAR INCINERATOR
WITH ENERGY RECOVERY
O
1. Automatic Feed System
2. Primary Chamber
3. Transie- Rams
4 Secondary Chamber
5. Steam Generator
6. Steam Separator
7. Energy Duct
8. Emissions Control System
9. Exhaust Stack
10. Emergency By-Pass
11. Wet Asn Sump
12. Ash Conveyor
Counesy of Consumat Systems, Inc.
-------
Slide 6-16
RDF UNITS
Waste Processing of RDF
Utility Pulverized Coal Units
Suspension Firing
Spreader Stoker Units
Suspension & Grate Burning
Co-Firing with Coal
-------
H
C/5
O
u
efi
C
"S
I
cs
-------
-------
LESSON PLAN NUMBER 7
COMBUSTION PRINCIPLES II: THERMOCHEMISTRY
Goal: To provide basic information about the energy which is released
during MSW combustion.
Objectives: Upon completion of this unit, an operator should be able to:
1. Understand the concept of a higher heating value (heat of
combustion).
2. Cite representative higher heating values of MSW, wood and coal.
3. Contrast a fuel's heating value on an "as received basis" with that
of a "dry basis".
4. Estimate a unit's load or operating capacity [Btu/hr] using a known
MSW charging rate [Ib/hr] and an assumed heating value [Btu/lb].
5. Characterize the differences between moisture and volatile matter.
6. Describe the influence of temperature on distillation of volatile
gases.
7. Recognize the differences in the general ranges of ignition
temperature of MSWs fixed carbon and volatile matter
(hydrocarbon gases).
8. Name three heat sink materials which influence combustion.
9. Identify combustion parameters that would be reduced if water was
sprayed into the primary chamber of a modular starved-air unit.
10. Explain why, under excess air conditions, an increase in the excess
air will cause combustion temperatures to decrease.
11. Explain why, under starved-air conditions, an increase in the air
supply will cause an increase in the combustion temperature.
7-1
-------
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Questions
1.
2.
3.
Presentation
Summary
Outline:
When someone refers to the heating content of a fuel are they
referring to a "higher heating value" or a "lower heating value"?
What is the difference between an ultimate and a proximate
analysis?
Why aren't tests for determining the heating value of your waste
feed routinely performed at your facility?
Combustion Principles II: Thermochemistry
Heating Value
Capacity and Load
Distillation & Ignition Temperatures
Combustion Temperatures
Heat Sinks
Stoichiometric Considerations
Projection
Slides:
See the following pages.
7-2
-------
Slide 7-1
THERMOCHEMICAL
CONCEPTS
Heating Values & Load
Ignition Temperatures
Combustion Temperatures
Temperature Control Methods
-------
Slide 7-2
HEATING VALUES
Higher Heating Value (HHV)
Bomb Calorimeter
Water Formed is Condensed
Lower Heating Value (LHV)
Computed from HHV
Assumes Water Formed is Vapor
-------
Hide 7-3
HEATING VALUES OF
SELECTED FUELS
FUEL
Methane
Fuel Oil, #6
Coal, PA Bitum
Coal, WY Subbitum
Wood, White Pine
Wood, White Oak
Lignite, ND
MSW, Ames., IA
RDF, Ames, IA
MSW, Ames, IA
Wood, Fresh Cut
HHV
Btu/lb
23,875
18,300
13,800
9,345
8,900
8,810
7,255
6,372
6,110
4,830
4,450
BASIS
Dry
As Received
As Received
As Received
Kiln Dried
Kiln Dried
As Received
Dry
As Received
As Received
As Received
MOISTURE
%
0.0
0.7
1.5
25.0
8.0
8.0
37.0
0.0
6.5
24.2
50.0
-------
Slide 7-4
UNIT RATED CAPACITY
MSW Charging Rate
tons/day
Ib/day
Ib/hour
UNIT OPERATING LOAD
Gross Energy Input
Btu/hour
-------
Slide 7-5
UNIT OPERATING LOAD =
FUEL CHARGING RATE x HHV
Example: 500 tons/day unit
4,500 Btu/lb HHV
UNIT OPERATING LOAD =
500 tons/day x 2,000 Ib/ton x
4,500 Btu/lb x 1 day/24 hours
UNIT OPERATING LOAD =
188,000,000 Btu/hr
-------
Slide 7-6
IGNITION TEMPERATURES
PHASE AT 60° IGNITION
MATERIAL F & 14'7 PSIA TEMP., ° F
Sulfur S°lid 470
Charcoal S°Hd 650
Gasoline Liquid 663-702
Acetylene GaS 589-825
Fixed Carbon Solid 765-1115
Hydrogen GaS 1065-1095
Methane GaS 1170-1380
Carbon Monoxide GaS 1130-1215
Benzene
Liquid 1335
-------
Slide 7-7
EXAMPLE OF RDF
PROXIMATE ANALYSIS
Percentage
by Weight
Moisture
26.6
Ash
21.7
Volatile Matter
43.6
Fixed Carbon
8.1
Total
100.0
-------
Slide 7-8
ADIABATIC COMBUSTION
CONDITIONS
Energy Release from Combustion
No External Heat Losses
Heats Combustion Product Gases
Vaporizes Moisture
-------
Slide 7-9
COMBUSTION TEMPERATURE
CONTROL
• Fuel Modulation
• Heat Transfer to Surroundings
• Heat Sink Materials
-------
Slide 7-10
HEAT SINK MATERIALS
Water in Fuel
Nitrogen
Excess Air
Flue Gas
Water Sprays
-------
Slide 7-11
WATER SPRAYS
Reduce Fuel-to-Air Ratio
Reduce Temperature
Reduce Velocity
Reduce Opacity
Reduce Fires in the Charge Hopper
-------
Slide 7-12
STARVED-AIR UNITS
Two Stage Combustion
Lower Velocities in Primary
Primary Chamber: Gasifier
More Primary Air
Higher Primary Temperatures
Secondary Chamber: Excess Air Combustion
-------
Slide 7-13
EXCESS AIR COMBUSTION
Excess Air - Heat Sink
More Excess Air
Temperature Reduction
-------
-------
LESSON PLAN NUMBER 8
DESIGN & OPERATION OF MSW HANDLING EQUIPMENT
Goal: To provide information about the design and operational aspects of
MSW handling, feeding, grate/hearth, and ash removal equipment.
Objectives: Upon completion of this unit, an operator should be able to:
1. List key elements in the solid materials flow path from the weight
scale to ash disposal for a continuous operating MWC unit.
2. Describe the importance of eliminating undesirable materials from
the waste stream before charging into a MWC.
3. Describe operating strategies which can help overcome the
combustion problems caused by a highly variable fuel.
4. Contrast the typical handling and feeding equipment found at the
three general types of MWC units (mass burn, modular, RDF).
5. Identify the operator controlled parameters associated with a ram
feeding system and a gravity fed hopper system.
6. Describe the four principal activities or zones which are found on
grate burning systems.
7. Name the major types of grate designs.
8. Describe typical reasons for a grate malfunction or break-down.
9. Describe the operator requirements associated with bottom ash and
fly ash removal systems.
10. Discuss environmental issues associated with ash disposal.
8-1
-------
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Questions:
1.
2.
3.
What are some waste materials that are designated as undesirable
or untreatable at your MWC unit.
Give three examples of wastes which have a detrimental impact
either on MWC equipment or on unit performance.
Give examples of wastes which are acceptable for combustion in
some larger MWC mass burner units, but not at some smaller
units.
4. What system causes operators the most trouble?
*
5. Why don't mass burn units use travelling grates?
6. Why don't RDF units use pusher grates?
Presentation
Summary
Outline:
MSW Handling Equipment
Undesirable MSW Components
Variable MSW Fuel Considerations
Handling, Feeding and Grate Equipment
Ash Removal
Ash Disposal
Projection
Slides:
See the following pages.
Source of
Graphics:
Slide 8-7
Municipal Waste Combustors: Background Information for Proposed
Guidelines for Existing Facilities. U.S. Environmental Protection
Agency, EPA-450/3-89-27e, August 1989, p. 5-41.
8-2
-------
Slide 8-8 Joseph G. Singer, Combustion Fossil Power, 4th Edition,
Combustion Engineering, Inc., Windsor, CT, 1991, p. 12-20.
Slide 8-10 W. D. Turner, Thermal Systems for Conversion of Municipal Solid
Waste. Vol. 2: Mass Burning of Solid Waste in Large-Scale
Combustors: A Technology Status Report. Report ANL/CNSV-TM-
120, Vol. 2, Argonne National Laboratory, December 1982, p. 26.
Slide 8-13 "Field and Enforcement Guide, Combustion and Incineration
Sources," U.S. Environmental Protection Agency, APTD-1449.
Slide 8-14 Georg Stabenow, "Design Criteria to Achieve Industrial Power
Plant Reliability in Solid Waste Processing Plants With Energy
Recovery," Proceedings of the 1978 ASME Solid Waste Processing
Conference. Chicago, pp. 427-446, May 1978.
Slide 8-15 Miro Dvirka, "Direct Co-Burning of Unprepared Municipal Solid
Waste and Sludge," Proceedings of the 1982 ASME Solid Waste
Processing Conference. New York, p. 114, 1982.
Slide 8-16 " "Field and Enforcement Guide, Combustion and Incineration
Sources," U.S. Environmental Protection Agency, APTD-1449.
Slide 8-17 J. D. Blue et al., "Waste Fuels: Their Preparation, Handling, and
Firing," Standard Handbook of Power Plant Engineering. Thomas
C. Elliott, editor, McGraw Hill Book Co., NY, 1989, pp. 3-134.
S'ide 8-18 Municipal Waste Combustors: Background Information for Proposed
Guidelines for Existing Facilities. U.S. Environmental Protection
Agency, EPA-450/3-89-27e, August 1989, pp. 5-41 and 9-7.
and
W. R. Seeker, W. S. Lanier and M. P. Heap, Municipal Waste
Combustion Study. Combustion Control of Organic Emissions. U.S.
Environmental Protection Agency, EPA-530-SW-87-021-C, May
1987, p. 5-52.
Slide 8-23 "Control Techniques for Particulate Emissions from Stationary
Sources," Volume 1, EPA 450/3-81-005a, U. S. Environmental
Protection Agency, September 1982.
8-3
-------
Slide 8-1
SOLID MATERIALS FLOW
PATH
1. Weight Scales
2. Tipping Floor, MSW Storage Pit
3. Front-End Processing Equipment
4. Charge Hopper, Feeder Device
5. Combustion Chamber Grate
6. Ash & Fly Ash Collection Devices
7. Ash Removal System
8. Ash Disposal at Landfill/Monofill
-------
Slide &-2
SCALE OPERATOR
FUNCTIONS
1. Restrict Delivery to Facility
2. Basis for Tipping Fees
3. Processed Waste
4. Unprocessed Wastes
5. Ash
6. Recovered Materials
-------
Slide 8-3
UNACCEPTABLE AND/OR
UNDESIRABLE MATERIALS
1. Not Permitted-Hazardous, etc.
2. Cause Damage-Explosion, Breakage
3. Restrict Operations—Blockage
4. Incombustible
-------
Slide 3-4
ISSUES OF FUEL
VARIABILITY
1. Fuel Size
2. Heating Value
3. Volatility
4. Fuel Moisture
5. Ash (incombustibles)
-------
Slide 8-5
OPERATING STRATEGIES
FOR FUEL VARIABILITY
1. Source Separation
2. Front End Process
3. Mix Wet and Dry Wastes
4. Compensate Through
Equipment Design
-------
Slideg-6
RECEIVING AND FEEDING
EQUIPMENT
GENERAL:
Receiving Area (Tipping Floor)
Storage Pit or Area
MODULAR MASS BURN UNITS:
Front Loader
Hydraulic Ram Feed System
LARGER MASS BURN UNITS:
Overhead Crane & Grapple
Gravity-Fed Charge Hopper
RDF UNITS:
Conveyors & Processing Equipment
Gravity-Fed Charge Hopper
Air Swept Distributor
-------
DC
-------
Slide 8-8
AIR SWEPT DISTRIBUTOR
SYSTEM FOR RDF
ROTARY
AIR DAMPER
BALANCED
DAMPER
DISTRIBUTOR
SPOUT
Counesv of Detroit Slokcr Company
-------
Slide 8-9
FUNCTIONS OF GRATES
AND HEARTHS
1. Support MS W During Dyring
2. Support MSW During Volatilization
3. Distribute Under-Grate Air
4. Stir, Tumble and Mix Wastes
5. Support MSW During Burn-Out
6. Deliver Bottom Ash to Ash Pit
-------
o
H
Cfl
P
OH
O
-------
Slide 8-11
GRATE DESIGNS
1. Reciprocating Stoker Grate
2. Reversed Reciprocating Grate
3. Rocking Grate
4. Vibrating Grate
5. Roller Grate
6. Travelling Chain Grate
7. Refractory Lined Rotary Kiln Grate
8. Rotating Waterwall Grate
-------
Slide 8-12
RECIPROCATING STOKER
GRATE
Fixed
-------
Slide 8-13
REVERSED
RECIPROCATING GRATE
Fixeo Point Ptvos
From proceedings of the 1978 ASME Solid Wasie
Processing Conference, reprinted with permission
-------
Slide 8-14
OSCILLATING OR ROCKER
GRATE
JLaiaed poiiaon
Normal
-------
Slide 8-15
BARREL OR ROLLER
GRATE
-------
Slide 8-16
TRAVELLING GRATE
RDF
AkSoppiy
Ccartesv of Decroit Stoker Comran\
-------
Slide 8-17
ROTATING WATERWALL
GRATE
Water-
Cooled
Tubes
Courtesy of Wesiinghouse Eleciric Corporation
-------
Slide 8-18
GRATE MALFUNCTIONS
1. Overheating (Thermal Stresses)
2. Corrosion, Erosion
3. Blockage
4. Hydraulic System Problems
5. Deposits from Molten Metal
6, Breakage by Heavy Objects
-------
Slide 8-19
ASH REMOVAL LOCATIONS
1. Grate Siftings
2. Bottom Ash
3. Boiler Ash
4. Fly Ash
-------
Slide 8-20
REMOVAL OF GRATE
SIFTINGS & BOTTOM ASH
Water-Filled Quench Tank
• Submerged Drag Chain Conveyor
• Ram Type Ash Discharger
• Grizzly Scalper
• Belt or Vibrating Conveyor
• Magnetic Separator
-------
Slide 8-21
REMOVAL OF BOILER ASH
& FLY ASH
Collection Hopper
• Automatically Operated Air-Locks
• Screw or Dry Drag Chain Conveyor
• Pneumatic Conveyor
• Bucket Elevator
-------
Slide 8-22
f MOTOR OPERATED ROTARY
AIR-LOCK
'Ash Hopper
Rotary Valve Air Lock
-------
Slide 8-23
ASH REMOVAL SYSTEMS
1. Continuous Operation
2. Intermittent Operation
3. Batch Operation
-------
Slide 8-24
ISSUES REGARDING ASH
DISPOSAL IN LANDFILLS
* Environmental Impact
* Landfill or Monofill
* Leachate Effect on Groundwater
Heavy Metals Concentrations
• Fugitive Emissions
-------
-------
Goal:
Objectives:
1.
2.
3.
4.
5.
6.
7.
8.
LESSON PLAN NUMBER 9
COMBUSTION PRINCIPLES III: REACTION PROCESSES
To provide basic information about variable combustion features.
Upon completion of this unit, an operator should be able to:
Discuss some of the important but complex reaction characteristics.
Recognize that an increase in temperature generally increases the
rate of reaction.
Describe the influence of mixing (sometimes called turbulence) of
the fuel and oxygen on the completeness of combustion.
Describe what happens when a flame impinges on the wall of a
furnace as an example of the influence of reaction time on the
completeness of combustion.
Name the two important products of incomplete combustion.
Characterize the features of an oxidizing and a reducing
environment.
Contrast the combustion phenomena in a blue flame with that of a
yellow flame.
Discuss the combustion processes in a fuel bed with an under-grate
air supply and the reasons that products of incomplete combustion
are formed.
9-1
-------
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Questions:
1.
A camp stove (which typically uses either propane or gasoline) is
designed to burn with a blue flame. However, it often produces a
yellow flame when it first starts to burn. Why?
A camp stove's yellow flame will causes black deposits on the
pots/skillets, whereas a blue flame will not. Why?
Why would an increase in underfire air cause the O2 level in the
flue gas to fall and the CO level to rise?
Presentation
Summary
Outline:
Combustion Principles III: Reaction Processes
Multiple Reactions
Incomplete Combustion
Oxidation & Reduction
Flame Types
Bed Burning
Projection
Slides:
Source
of
Graphics:
Slide 9-13
See the following pages.
G. C. Williams et al., "Design and Control of Incinerators," Final
Report to Office of Research and Monitoring, U. S. Environmental
Protection Agency, Grant Number EC-00330-03, 1974.
9-2
-------
Slide 9-1
COMBUSTION REACTION
PROCESSES
Oxidation & Reduction
Incomplete Combustion
Reaction Rate Variables
Flame Phenomena
Bed-Burning
Gasification
Oxidation of Carbon Monoxide
-------
Slide 9-2
IMPORTANT REACTION
CHARACTERISTICS
1. Multiple Reactions Occur in
Combustion
2. Reactions May Not Go to Completion
3. Reactions Are Somewhat Reversible
4. Reaction Rates Increase with
Temperature
5. Reactions Are Influenced by
Concentrations
6. Reactions Are Limited by Mixing
7. Compositions Vary with Temperature
-------
Slide 9-3
REACTIONS OF CARBON
AND HYDROGEN IN
OXYGEN
C + O
CO
H2 + 0.5 O
H2O
0.5 O,
C + O
O
CO
+ O
2
2H2O
2 HO
2 OH + H2
CO + 2 OH
CO, + H2O
^ ^
-------
Slide 9-4
CONSEQUENCE OF
MULTIPLE REACTIONS
Not All Reactions Can Go To Completion
Some Components May Be Depleted
-------
Slide 9-5
PRODUCTS OF
INCOMPLETE COMBUSTION
Carbon Monoxide
Dioxins and Furans
-------
Slide 9-6
REASONS FOR INCOMPLETE
COMBUSTION
1. Variable Fuel Properties
2. Irregular Fuel Feeding Characteristics
3. Inadequate Air Supply
4. Improper Distribution of Air
5. Incomplete Mixing of Oxygen & Fuel
6. Inadequate Temperature
7. Premature Cooling of Combustible Gases
-------
Slide 9-7
REACTION RATES
Rate of Chemical Change
Forward Reaction (Production)
Reversed Reaction (Dissociation)
-------
Slide 9-8
OXIDATION AND
REDUCTION REACTIONS
Lean Mixture - Oxidizing Atmosphere
Oxidation Reaction
Converts Reactants to Products
Rich Mixture - Reducing Atmosphere
Reduction Reaction
Converts Products to Reactants
-------
Slide 9-9
REACTION RATE
DEPENDS UPON
Temperature
Mixture Concentrations
Stirring Process (Turbulence)
-------
Slide 9-10
PRE-MIXED GASEOUS FUEL
COMBUSTION
Blue Flame Combustion:
Natural Gas in an Appliance
-------
Slide 9-11
DIFFUSION-LIMITED
COMBUSTION
Yellow/Orange Flame Combustion:
• Inadequately Pre-Mixed Air & Fuel
• Dark Flame Tips
• Black Deposits on Adjacent Surfaces
-------
Slide 9-12
BED BURNING PROCESSES
Diffusion Limited Combustion
Volatile Gases
Fixed Carbon
Diffusion Limited Rame
-------
O
3
P
t.
O
SI
o
o
o
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^
8
n
O
O
O
CM
cy
-------
Slide 9-14
BASIC BED-BURNING
PROCESS
Gaseous Products Leaving Fuel Bed
H2O, CO2, CO, Methane, Hydrogen
Solid Products
Char (Fixed Carbon)
Solid Residues
Inorganic Materials (Ash)
-------
Slide 9-15
REACTIONS WITH CHAR
C + O2 -
C + H2O
C + CO
2
CO2
CO + H
2
2 CO
(1)
(2)
(3)
-------
Slide 9-16
DESTRUCTION OF
CARBON MONOXIDE
CO + OH > H + CO2 (1)
CO + 2 OH > CO2 + H2O (2)
CO + O > CO2 (3)
-------
LESSON PLAN NUMBER 10
DESIGN & OPERATION OF COMBUSTION EQUIPMENT
Goal: To provide applied information about combustion chamber and
boiler/heat exchanger design and operation.
Objectives: Upon completion of this unit, an operator should be able to:
1. Contrast the overall excess air conditions in a water-wall furnace
with the conditions in the primary chamber of a modular unit.
2. Contrast the differences between integral boilers and waste heat
recovery boilers.
3. Compare the underfire air, velocity, and particle entrainment
features in the primary chamber of a modular starved-air unit with
those of an excess-air, waterwall unit.
4. Describe the benefits of maintaining steady primary chamber and
furnace temperatures by controlling air supply.
5. Contrast the influence of increasing charging rate on the primary
chamber temperature in a starved-air unit with that of furnace
temperature in an excess air unit.
6. Describe what will happen to the furnace temperature and carbon
monoxide levels if the underfire air supply of a grate burning
(excess-air) system is increased.
7. Describe what will happen to the furnace temperature if the
overfire air supply of a grate burning system is increased.
8. Describe what will happen to the primary chamber temperature if
the underfire air supply of a modular starved-air system is
increased.
9. Identify heat transfer as the phenomena which links the gas-side
operational features to the water-side in a waterwall unit.
10. Discuss the wall temperatures, metal wastage and maintenance
concerns which have led to many furnaces now having their
waterwalls covered with refractory materials.
10-1
-------
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Questions
1,
2.
3.
4.
Presentation
Summary
Outline:
If the moisture content increases from 20% to 30%, how much will
the peak flame temperature drop? (Does the answer depend upon
the amount of excess air?)
In what ways are excess-air units better than starved-air units?
What advantages do starved-air units have over excess-air units?
What does the operator or controller do to meet an increased
demand for steam production in an excess-air unit?
Design & Operation of Combustion Equipment
Direct Bed & Suspension Firing
Two-Stage Combustion
Excess Air Combustion
Boiler & System Configurations
Operational Considerations
Projection
Slides:
See the following pages.
Source
of
Graphics:
Slide 10-3
Slide 10-6
"Integrated Waste Services, Information Summary," Consumat
Systems, Inc., Richmond, Virginia, Undated Brochure.
S. E. Sawell and T. W. Constable, "NITEP: Assessment of
Contaminant Leachability from MSW Incinerator Ash," Proceedings
of an International Workshop on Municipal Waste Incineration.
Sponsored by Environment Canada, Montreal, Quebec, October 1-2,
1987, p. 335-336.
10-2
-------
Slide 10-8 Hazardous Materials Design Criteria. U.S. Environmental
Protection Agency, EPA-600/2-79-198, October 1979.
Slide 10-9 J. H. Pohl and L. P. Nelson, "Research Required to Generate Power
from Municipal Solid Waste," Report to Southern California Edison
Company, Rosemead, CA, Submitted by Energy and Environmental
Research Corporation, February, 1985, p. 6-47.
Slide 10-10 Joseph G. Singer, Combustion Fossil Power. 4th Edition,
Combustion Engineering, Inc., Windsor, CT, 1991, p. 8-18.
Slide 10-11 W. D. Turner, Thermal Systems for Conversion of Municipal Solid
Waste. Vol. 2: Mass Burning of Solid Waste in Large-Scale
Combustors: A Technology Status Report. Report ANL/CNSV-TM-
120, Vol. 2, Argonne National Laboratory, December 1982, p. 149.
10-3
-------
Slide 10-1
MWC DESIGN OPTIONS
1. Fuel Processing
2. Charging Method
3. Stoichiometric Design
4. Chamber Wall Construction
5. Energy Recovery Design
-------
Slide 10-2
CHARGING METHOD
• Direct Bed
• Suspension-Fired
• Air-Swept Spreader
-------
Slide 10-3
STOICHIOMETRIC DESIGN
Excess-Air
Starved-Air (Two-Stage)
-------
Slide 10-4
STARVED-AIR, TWO-STAGE
COMBUSTION UNIT
To Boiler
Feed Ram
Ash Transfer flams
Fossil Fuel Burner
Primary Chamber
Ash Sump
Air Tube
Ash Discharge Ram
Ash Chute
Ash Quench
Counesy of Cortsumat Systems. Inc.
-------
Slide 10-5
ENERGY RECOVERY
DESIGNS
Fire-Tube Boiler
Waste-Heat Boiler
Integral Boiler
-------
o
PQ
-------
Slide 10-7
CHAMBER WALL
CONSTRUCTION
Refractory-Wall
Waterwall
-------
o
H
W
oo
W
*
-------
Slide 10-9
WATERWALL FURNACE
ENCLOSURE
Courtesy of Detroit Stoker Company
-------
Slide 10-10
DOUBLE-PASS RADIANT
SECTION WATERWALL UNIT
Steam Drum
Two Stage
Superheater
Imerstage
Desuperneater
. """Economizer
Pusher Grate
Courtesy of ABB Combustion Engineering, Inc.
-------
H
Z,
o
u
-------
Slide 10-12
BOILER COMPONENT
EQUIPMENT
Radiant Section
• Feed-Water Heating
• Evaporation
Convective Section
• Superheater
• Evaporator
• Economizer
(Feed-Water Heater)
-------
Slide 10-13
FEEDWATER HEATING
Economizer: Energy from Flue Gas
Feedwater Heaters: Energy from Steam
Closed Feedwater Heater
Shell & Tube Heat Exchanger
Open Feedwater Heater
Deaerating Heater
-------
Slide 10-14
GENERIC TYPES OF
COMBUSTION EQUIPMENT
Excess Air Unit
• Mass Burn or RDF
• Waterwall and Rotary Waterwall
• Integral Boiler
Starved-Air (Controlled-Air) Unit
• Mass Burn
• Refractory Wall (Modular)
• Waste-Heat Boiler
-------
Slide 10-15
GENERIC COMBUSTION
COMPARISONS
Excess-Air Unit
• Gasification & Combustion in Fuel Bed
• Complete Combustion in Furnace
• Relatively High Gas Velocities
• Relatively High Particle Entrainment
• Residue Has Good Carbon Burn-Out
Starved-Air Unit
• Gasification in Primary Chamber
• Relatively Low Gas Velocities
• Relatively Low Particle Entrainment
• Acceptable Carbon Burn-Out of Residue
-------
Slide 10-16
OPERATIONAL
CONSIDERATIONS
Steady Combustion Temperatures
• Steady Energy/Steam Production
• Steady Heating of the Fuel Bed
* Steady Mixing
• Constant Residence Time
-------
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-------
Slide -0-18
OPERATIONAL
CONSIDERATIONS
Excess-Air Conditions
• Increase in Secondary Air Supply:
Decrease in Furnace Temperature
• Increase in Fuel Charging Rate:
Increase in Furnace Temperature
Starved-Air Conditions
• Increase in Primary Air Supply:
Increase in Primary Gas Temperature
• Increase in Fuel Charging Rate:
Decrease in Primary Gas Temperature
-------
Slide 10-19
STARVED-AIR UNIT
OPERATIONAL
CONSIDERATIONS
PRIMARY AUXILIARY FUEL BURNER
Preheat Refractory
Initiate Ignition
Increase Gas Temperature
Increases the Volatilization Rate
SECONDARY AUXILIARY FUEL BURNER
Preheat Refractory
Increase Secondary Gas Temperature
Reduces Smoking
Reduces Incomplete Combustion
-------
Slide 10-20
EXCESS-AIR WATERWALL
UNIT OPERATIONS
Heat Transfer
From the Gas Side
To the Water/Steam Side
-------
Slide 10-21
EXCESS-AIR WATERWALL
UNIT OPERATIONS
To Meet Increased Steam Demand:
Increase Grate Agitation & Under-fire Air
Increases Fuel Supply & Burning Rate
Increases Gas Temperatures & Heat
Transfer
Reduce Over-Fire Air (Overall Excess Air)
-------
Slide 10-22
EXCESS-AIR WATERWALL
UNIT OPERATIONS
Increased Fuel Moisture
Gas Temperature Will Drop
Gas Temperature Can Be Restored
Reduce Air Supply (Excess Air)
Increase Fuel Supply (Grate Agitation)
-------
Slide 10-23
METAL WASTAGE IN
EXCESS-AIR UNITS
Erosion (High Temperatures)
• Temperature Control
• Velocity Control
• Rapping Rather Than Soot Blowing
Corrosion
• Oxidation/Reduction Oscillations
• Chlorine (HC1) Reactions
• Metal Reactions
-------
LESSON PLAN NUMBER 11
DESIGN & OPERATION OF GAS FLOW EQUIPMENT
Goal: To provide applied information about the design and operation of
gas flow equipment, including fans, dampers and ducts.
Objectives: Upon completion of this unit, an operator should be able to:
1. Identify the major component equipment along a typical air and
flue gas flow path.
2. Describe the function of the: boiler/evaporator, superheater,
economizer, feedwater heater, and air preheater.
3. Describe the difference between a forced draft fan and an induced
draft fan.
4. Name two control devices which can be used to regulate the amount
of air flow delivered by a fan.
5. Define furnace draft and indicate its typical units of measurement.
6. Discuss the advantage to operators of having the combustion
chamber designed and operated with a modest amount of draft.
7. Discuss an example of the combustion consequences associated with
operating a furnace with more draft than specified in its design.
8. List two equipment changes that an operator would consider as
methods for restoring proper draft.
9. Describe why dew point considerations are important in ducts and
air pollution control equipment.
10. Discuss the proper strategy for soot blowing and/or superheater
rapping to dislodge slag.
11. Discuss the parameters an operator would review in order to
determine if significant deposits were on a heat exchanger's surface.
Lesson Time: Approximately 40 minutes
11-1
-------
Suggested
Introductory
Questions:
1.
2.
3.
4.
Presentation
Summary
Outline:
Projection
Slides:
Source of
Graphics:
Slide 11-2
Slide 11-3
Slide 11-4
Slide 11-6
Slide 11-7
If your FD fan has guide vanes on the fan inlet, what do they do?
What are your experiences with variable speed fans?
What advantages do fixed speed fans have over variable speed fans?
What is the main advantage associated with rapping the
superheater rather than soot blowing?
Design & Operation of Gas Flow Equipment
Air & Flue Gas Flow Path
Fans, Dampers & Draft Design and Operation
Dew Point Considerations
Slag & Soot Formation and Removal
See the following pages.
"Prepared Fuel Steam Generation System," ABB Resource Recovery
Systems, Windsor, Connecticut, Undated Pamphlet.
W. D. Turner, Thermal Systems for Conversion of Municipal Solid
Waste. Vol. 2: Mass Burning of Solid Waste in Large-Scale
Combustors: A Technology Status Report. Report ANL/CNSV-TM-
120, Vol. 2, Argonne National Laboratory, December 1982, p. 86.
Steam, Its Generation and Use. 39th Edition, Babcock and Wilcox,
New York, 1978, p. 17-6.
Joseph G. Singer, Combustion Fossil Power. 4th Edition,
Combustion Engineering, Inc., Windsor, CT, 1991, pp. 14-14.
Joseph G. Singer, Combustion Fossil Power. 4th Edition,
Combustion Engineering, Inc., Windsor, CT, 1991, pp. 14-14.
11-2
-------
Slide 11-1
II
TYPICAL AIR & FLUE GAS
FLOW PATH
1. Forced Draft Fan
2. Air Preheater
3. Under-Fire Air
Over-Fire Air
4. Furnace (Radiant Section)
5. Convective Section Heat Exchangers
Superheater
Evaporator (Boiler)
Economizer
Air Preheater (Flue Gas Side)
6. Air Pollution Control Devices (APCDs)
Scrubber (Wet or Dry)
Fabric Filter (Baghouse) or
Electrostatic Precipitator (ESP)
7. Induced Draft Fan
8. Stack
-------
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-------
-------
Slide 11-4
CENTRIFUGAL FAN WITH
INLET VANE DAMPERS
Single-
Width
Rotor
Inlet Vane Control
Backward Curved
Blades
Courtesy of Babcoek and WUcox
-------
Slide 11-5
METHODS OF
CONTROLLING AIR FLOW
1. Variable Speed Fan
2. Damper in Duct
3. Variable Inlet Vane Damper
-------
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-------
Slide 11-8
DRAFT
Negative Pressure (Vacuum)
Measured in Inches of Water
Must be Maintained in Furnace
-------
Slide 11-9
DEW POINT
Threshold for Condensation Temperature
• Typically Value is Around 300° F
• Fuel Moisture Dependent
• Ambient Air Moisture Dependent
• Water Spray Dependent
-------
Slide 11-10
SLAG AND SOOT DEPOSITS
Slag on Combustion Chamber Walls
Soot on Heat Exchanger Surfaces
-------
LESSON PLAN NUMBER 12
NSPS: GOOD COMBUSTION PRACTICE
Goal: To provide general information about the NSPS requirements for
good combustion practices at MWC units.
Objectives: Upon completion of this unit, an operator should be able to:
1. List two major constituents in each of the following NSPS defined
technology-based emission groups: MWC acid gases, MWC metals,
& MWC organics.
2. Define a surrogate and identify the surrogates for MWC metals and
for MWC organics.
3. Discuss the reasons for controlling flue gas CO emissions.
4. Identify the four monitored parameters which are required by the
NSPS to indicate Good Combustion Practice at waste-to-energy
MWC units.
5. Discuss why the flue gas temperature at the inlet to an ESP or
baghouse is controlled.
6. Discuss the information that is needed in order to determine if an
example inlet flue gas temperature at an ESP or baghouse is
acceptable.
7. Indicate whether an example primary (or secondary) combustion
chamber temperature is within the generally recommended
operating range for a modular staved air incinerator.
8. Discuss the reasons for controlling flue gas O2.
9. Indicate whether an example flue gas 02 reading is within the
recommended operating range for a particular type of MWC unit.
12-1
-------
Lesson Time: Approximately 40 minutes
Suggested
Introductory
Question:
1.
How has "GCP" impacted the operations at your MWC unit?
Presentation
Summary
Outline:
NSPS: Good Combustion Practice
Basis of GCP Requirements
Technology-Based Emission Limits
Indicators of GCP
Surrogates
Typical System Operating Ranges
Projection
Slides:
Source
of
Graphics:
Slide 12-6
Slide 12-7
See the following pages.
W. R. Seeker, W. S. Lanier, and M. P. Heap, "Municipal Waste
Combustion Study, Combustion Control of Organic Emissions," U.S.
Environmental Protection Agency, EPA-530-SW-87-021-C, June
1987, p. 3-13.
James D. Kilgroe et al., "Combustion Control of Organic Emissions
from Municipal Waste Combustors," Combustion Science and
Technology. Vol 74, 1990, p. 237.
12-2
-------
Slide 12-1
NEW UNITS: NEW SOURCE
PERFORMANCE STANDARDS
EXISTING: EMISSION GUIDELINES
Emission Limitations
Good Combustion Practices
Continuous Monitoring Systems, CEMs
-------
Slide 12-2
TECHNOLOGY-BASED
EMISSION GROUPS
MWC Metals
MWC Organics
MWC Acid Gases
-------
Slide 12-3
SURROGATES
For MWC Metals:
• Particulate Matter, PM
• Opacity
For MWC Organic s:
• Dioxin/Furan (PCDD/PCDF)
• Carbon Monoxide
For MWC Acid Gases:
• Sulfur Dioxide
• Hydrogen Chloride
-------
Slide 12-4
NSPS/EG EMISSION LIMITS
Emission
New Unit
> 250 tpd
Existing Unit
> 250 tpd
Existing
Facility
> 1100 tpd
MWC Organics
(PCDD/PCDF)
ng/dscm 30
MWC Metals
(PM)
mg/dscm 34
Sulfur Dioxide
% Removal
ppm-volume
Hydrogen
Chloride
% Removal 95
ppm-volume 25
Nitrogen Oxides
ppm-volume 180
125*
69
50
25
NA
60
34
80
30
50
30
70
30
90
25
NA
* Note: Limit for RDF Stoker Unit is 250 mg/dscm
-------
Slide 12-5
• NSPS/EG CARBON
MONOXIDE LIMITS, PPM
Type of MWC Unit New Existing
Modular 50 50
Mass Burn Waterwall 100 100
Mass Burn Refractory 100 100
Mass Burn Rotary Waterwall 100 250
RDF Stoker 150 200
Coal/RDF Co-Fired 150 150
Bubbling Fluidized Bed 100 100
Circulating Fluidized Bed 100 100
-------
Slide 12-6
GENERAL COMBUSTION
SYSTEM CO - O2
RELATIONSHIP
A - INSUFFICIENT AIR
B - APPROPRIATE OPERATING REGION
C - "COLD BURNING"
6 9
OXYGEN CONCENTRATION
-------
Slide 12-7
EXAMPLE CO - O2
RELATIONSHIP FOR RDF
UNIT
SCO
~ 600-
I
o
u
400 -
200-
-------
Slide 12-8
PARAMETERS MONITORED
FOR GCP
Carbon Monoxide
Opacity: Not to Exceed 10%
Load: Not to Exceed 110% of Load of
Most Recent Dioxin Test
Temperature of Flue Gas into APCD
Not to Exceed by 30° F That of
Most Recent Dioxin Test
-------
Slide 12-9
COMBUSTION CONDITION
INDICATORS
• Opacity
• Temperature
Furnace or Primary & Secondary
Flue Gas Entering APCD
• Draft
• Carbon Monoxide
• Carbon Dioxide
• Oxygen
• Steam Flow Rate (Load)
-------
Slide 12-10
MODULAR UNIT
COMBUSTION INDICATOR
RANGES
PARAMETER
Opacity, %
Primary Temperature, ° F
Secondary Temperature, ° F
Draft, in WG
APCD Inlet Temperature, ° F
Oxygen, %
Carbon Monoxide, ppm
LOW
0
1,200
1,800
0.05
0
HIGH
10
1,400
2,200
0.15
450
12
50
-------
Slide 12-11
MASS BURN WATERWALL
COMBUSTION RANGES
PARAMETER LOW HIGH
Opacity, % 0 10
Furnace Temp, at Fully-Mixed 1,800 2,000
Height, ° F
APCD Inlet Temperature, ° F 450
Oxygen, % 6 12
Carbon Monoxide, ppm 0 100
-------
Slide 12-12
RDF WATERWALL
COMBUSTOR RANGES
PARAMETER
Opacity, %
Furnace Temp, at
Fully-Mixed Height, ° F
APCD Inlet
Temperature, ° F
Oxygen, %
Carbon Monoxide,
ppm
LOW
0
1,800
3
0
HIGH
10
2,000
450
9
150
-------
LESSON PLAN NUMBER 13
INSTRUMENTATION I: GENERAL MEASUREMENTS
Goal: To provide introductory information about the measurement of
temperatures, pressures, and flow rates of gases and liquids.
Objectives: Upon completion of this unit, an operator should be able to:
1. Describe the operating principles of a thermocouple.
2. Express the limitations associated with placement of a
thermocouple.
3. Name other instruments and/or techniques which are used to
indicate temperatures.
4. Describe the operating principle of a manometer pressure gage.
5. Describe the operating principle of a Bourdon tube pressure gage.
6. Provide examples where differential pressure (DP) cells,
diaphragms and bellows gages are used.
7. Indicate applications where pressure transmitters offer considerable
advantages, relative to direct reading instruments.
8. Contrast the operational features of pitot tubes and orifice plates
which use differential pressure devices to indicate flow.
9. What is the major limitation of rotameters and turbine flow meters.
10. Describe the operational similarities of equal arm balances,
platform scales, and strain gage driven scales.
13-1
-------
Lesson Time: Approximately 40 minutes
Suggested
Introductory
Questions
1.
What can happen to cause a thermocouple to give a false reading?
Presentation
Outline:
Projection
Slides:
Instrumentation I: General Measurements
Purposes of Instrumentation
Thermocouples
Pressure Gages
Flow Meters
Weight Scales
See the following pages.
Source of
Graphics:
Slide 13-5
Slide 13-6
Slide 13-7
Slide 13-8
Slide 13-9
Slide 13-12
Robert T. Corry et al., "Instruments and Control," Mark's Standard
Handbook for Mechanical Engineers. Eighth Edition, Edited by T.
Baumeister, et al., McGraw Hill Book Company, NY, 1978, p. 16-13.
Adapted from: "Gas Temperature Measurement by Acoustic
Pyrometer," Boilerwatch Model 31AP-H, Scientific Engineering
Instruments, Inc., Sparks, NV.
Edgar E. Ambrosius et al., Mechanical Measurement and
Instrumentation. Ronald Press, New York, 1966, pp. 360-361.
Robert T. Corry et al., "Instruments and Control," Mark's Standard
Handbook for Mechanical Engineers. Eighth Edition, Edited by T.
Baumeister, et al., McGraw Hill Book Company, NY, 1978, p. 16-9.
J. P. Holman, Experimental Methods for Engineers. McGraw Hill
Book Company, New York, Fifth Edition, 1989, p. 213.
Robert T. Corry et al., "Instruments and Control," Mark's Standard
Handbook for Mechanical Engineers. Eighth Edition, Edited by T.
Baumeister, et al., McGraw Hill Book Company, NY, 1978, p. 16-15.
13-2
-------
Slide 13-13 Robert T. Carry et al., "Instruments and Control," Mark's Standard
Handbook for Mechanical Engineers. Eighth Edition, Edited by T.
Baumeister, et al., McGraw Hill Book Company, NY, 1978, p. 16-16.
Slide 13-14 Robert T. Corry et al., "Instruments and Control," Mark's Standard
Handbook for Mechanical Engineers. Eighth Edition, Edited by T.
Baumeister, et al., McGraw Hill Book Company, NY, 1978, p. 16-17.
Slide 13-15 Robert T. Corry et al., "Instruments and Control," Mark's Standard
Handbook for Mechanical Engineers. Eighth Edition, Edited by T.
Baumeister, et al., McGraw Hill Book Company, NY, 1978, p. 16-17.
Slide 13-16 Edgar E. Ambrosius et al., Mechanical Measurement and
Instrumentation. Ronald Press, New York, 1966, p. 252.
Slide 13-17 Edgar E. Ambrosius et al., Mechanical Measurement and
Instrumentation. Ronald Press, New York, 1966, p. 255.
13-3
-------
Slide 13-1
PURPOSE OF
INSTRUMENTATION
1. Supervision of Operations
2. Automatic Control Signals
3. Management Data
4. Pollutant Emissions Surveillance
-------
Slide 13-2
GENERAL MEASUREMENTS
1. Temperature
2. Pressure
3. Flow Rate (Velocity)
4. Weight
-------
Slide 13-3
TEMPERATURE
EQUIVALENTS
>C = (5/9) (°F - 32)
'F = (9/5) °C + 32
>K (Kelvin) = °C + 273.15
'R (Rankin) = °F + 459.67
-------
Slide 13-4
TEMPERATURE
MEASUREMENTS
Thermometer - Expansion of a Liquid
Dial Thermometer - Expansion of Metals
Thermocouple - Thermoelectric Potential
Thermistor/RTD - Electrical Resistance
Infrared Temperature Probe - Infrared Energy
Optical Pyrometer - Infrared Energy
Acoustic Temperature Probe - Speed of Sound
Temperature Paint - Change of Color
-------
Slide 13-5
THERMOCOUPLE
TEMPERATURE
MEASUREMENT DEVICE
Hot
junction
Millivoltmeter
(cold junction
compensation)
L
Iron
^
Lead wire
onstanton
XCold
junction
.rv, stM.rii.rd HandhooV fry Mrrhaniwl Eneinggn. eighth edition.
edited by T. Baumeister. el al.. McCraw HiU Book Company. NY. 1978. reprmtcd wiih permission
-------
tt
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-------
Slide 13-8
BOURDON TUBE GAGE
Bourdon tube
Scale
Pointer
Hairspring
Pinion
Case
From Mark's Standard Handbook for Mechanical Er.pineer;. eighth edition.
ciiled by T. Baunieister. ct ai., McGraw Hill Book Company. NY. 1978. repruiied with permission
-------
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-------
Slide 13-10
PRESSURE TRANSMITTER
Low Voltage Electrical and
Low Pressure Pneumatic Signals
Easy to Transmit
Safety Considerations
-------
Slide 13-11
MEASUREMENT OF FLUID
FLOW
MEASURING DEVICE
Pitot Static Tube
Orifice Plate
Venturi
Propeller-Type
Rotameter
APPLICATION
Combustion Air Flow
High Steam & Water Flow
(Large Pressure Drop)
High Steam & Water Flow
(Small Pressure Drop)
Medium Air & Water Flow
Low Water Flow
-------
Slide 13-12
PITOT TUBE
r
Static opening
Impact
opening
Manometer
i
F:'om Mark's Standard Fu::d':>o.•'>' for Mcchar.icai Er.cir.eers. eighth edi'.ior.,
edited by T. Baumeisicr, et al., McGraw Hiii Book Company. NY. 1978. reprinted wiih permission
-------
Slide 13-13
ORIFICE PLATE -
PRESSURE DIFFERENCE
Flange
Orifice plate
Upstream
tap
Vena contracta
Downstream tap
From Mark's Standard Handbook for Mechanical Engineers, eighth edition.
edited by T. Baumeister. ei al.. McGraw HiU Book Company. NY, 1978, reprinted with permission
-------
Slide 13-14
PROPELLER TYPE
FLOWMETER
i£\
Bearing
Propeller
1
1
Magnetic fp
sensing element-'
Amplifier
Recorder
fro1" Mark's Standard Handbook for Mechanical Engineers, eighth ediiion.
edited by T. Baumeister, <:i al.. McGraw Hill Book Company, NY, 1978, reprinted with permission
-------
Slide 13-15
ROTAMETER
inlet
Rotameter
tube
Metering
float
Scale
From Mark's Standard Handbook for Mechanical Engineers, eighth edition.
edited by T. Baumeistcr. et ai., McCra* Hili Bock Company, NY, 19"?8. reprinted with permission
-------
Slide 13-16
0
EQUAL ARM BALANCE
From Edgar E. Ambrosius et .ii.. Mechanical Measurement and lnMrj~.jnt3;ipn. Ronald Press. NT. 1966,
reprinted with permission
-------
Slide 13-17
PLATFORM SCALE LEVER
SYSTEM
Adjustable
counterpoise
for balance
purposes
O'
0 1 7 3 4/ I & 7 8 9 10
Beam
W2 pan
weights
wv
T
W,
•Platform
\
From Edgai E. Ambrosius et al.. Mechanical Measurement and Imtnimeniation. Ronald Press, NY, 1966,
reprinted with permission
-------
LESSON PLAN NUMBER 14
INSTRUMENTATION II: CONTINUOUS EMISSION MONITORING
Goal: To provide information about the special features of continuous
measurement of air pollutant emissions.
Objectives: Upon completion of this unit, an operator should be able to:
1. List at least five parameters which are monitored by GEMS.
2. Distinguish between extractive and in situ continuous monitoring
equipment.
3. Describe the operating principles and maintenance requirements of
an opacity monitor.
4. Identify the basic measurement concept used in dispersive and
nondispersive instruments for measuring gaseous concentration.
5. Identify the basic measurement concept used in chemiluminescent
instruments for measuring gaseous concentration.
6. List three operational problems which can cause extractive CEMs
to give invalid measurements.
7. List two special operational problems which can cause in situ
CEMS to give invalid measurements.
8. Describe the general procedures for calibrating CEMS.
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Questions:
1. Name the CEMS in your plant.
2. How many of your instrument readings are directly transmitted to
a local or state regulatory agency?
3. What CEMS problem has caused the most difficulty for operators?
14-1
-------
Presentation
Summary
Outline:
Projection
Slides:
Instrumentation II: Continuous Emission Monitoring
Parameters Monitored
Extractive & In-situ CEMs
Measurement Concepts
Special Operating Concerns
Calibration & Drift Requirements
See the following pages.
Source of
Graphics:
Slide 14-4
Slide 14-5
Slide 14-6
Slide 14-10
Slide 14-11
Slide 14-12
J. A. Moore, "Key Measurements in Power Plants," Standard
Handbook of Power Plant Engineering. Thomas C. Elliott, editor,
McGraw Hill Book Co., NY, 1989, p. 6-61.
J. A. Moore, "Key Measurements in Power Plants," Standard
Handbook of Power Plant Engineering. Thomas C. Elliott, editor,
McGraw Hill Book Co., NY, 1989, p. 6-61.
James Jahnke and G. J. Aldina, Handbook. Continuous Air
Pollution Source Monitoring Systems. Technology Transfer, EPA
625/6-79-005, June 1979.
James Jahnke and G. J. Aldina, Handbook. Continuous Air
Pollution Source Monitoring Systems, Technology Transfer, EPA
625/6-79-005, June 1979.
James Jahnke and G. J. Aldina, Handbook^ontinuous Air
Pollution Source Monitoring Systems. Technology Transfer, EPA
625/6-79-005, June 1979.
Robert Holloway, W. S. Lanier, and S. B. Robinson, "Alternative
Approaches to Real-Time Continuous Measurement for Combustion
Efficiency of Hazardous Waste Incinerators," Contract 68-03-3365,
Work Assignment 03 Report to U. S. Environmental Protection
Agency, Office of Solid Waste and Emergency Response, March 25,
1987.
14-2
-------
Slide 14-14 James Jahnke and G. J. Aldina, Handbook. Continuous Air
Pollution Source Monitoring Systems. Technology Transfer, EPA
625/6-79-005, June 1979.
Slide 14-15 James Jahnke and G. J. Aldina, Handbook. Continuous Air
Pollution Source Monitoring Systems. Technology Transfer, EPA
625/6-79-005, June 1979.
Slide 14-17 John Richards, "Municipal Waste Incinerator Air Pollution Control
Inspection Course," Submitted to U. S. Environmental Protection
Agency, June 1991.
14-3
-------
Slide 14-1
CONTINUOUS EMISSION
MONITORING SYSTEMS
1. Temperature
2. Fluid Flow Rate (Velocity)
3. Opacity
4. Concentrations of Gases
-------
Slide 14-2
TYPICAL CEMS USED AT
MWC UNITS
1. Temperature of Gas Entering APCD
2. Steam Row Rate (Load)
3. Opacity
4. Carbon Dioxide
5. Oxygen
6. Carbon Monoxide
7. Sulfur Dioxide
8. Nitrogen Oxides
9. Hydrogen Chloride
-------
Slide 14-3
CATEGORIES OF CEMS
In-situ:
Stack Mounted Analyzer
Extractive:
Sample Flows to Remote Analyzer
-------
CC
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-------
Slide 14-7
EXTRACTION TYPE OF GAS
ANALYZER
• Extraction of Gas Sample by a Probe
• Removal of Particulates
• Removal or Compensation for Water
• Transport to Remote Detector/Analyzer
• Conversion from Wet Basis to Dry Basis
-------
Slide 14-8
WATER REMOVAL OR
COMPENSATION SYSTEMS
1. Desiccant
2. Refrigeration
3. Dilution
4. Heating of Sample Line
-------
Slide 14-9
ABSORPTION SPECTROSCOPY
Dispersive Absorption
Differential Absorption
Nondispersive Absorption
Gas Filter Correlation Method
-------
li
-------
Q
W
ID
Vi
-------
tu
t <->
X CC
C =>
13 O
cn
--'rV
vr
cv
-------
Slide 14-13
OTHER ANALYTICAL
TECHNIQUES
Chemiluminescence
Electrocatalytic
-------
Slide 14-14
CHEMILUMINESCENCE
ANALYZER
Photomutttpiier
Tube
Sample
Exhaust
Signal
-------
Cd
H
U
-------
Slide 14-16
GAS ANALYZER
MAINTENANCE PROCEDURES
• Routine Calibration
- Zero Gas or Filter
- Span Gas or Filter
* Delivery System Bias Checks
- Probe Blockage
- Probe Leaks
• Electrical Circuit Problems
- Component Replacement
-------
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-------
LESSON PLAN NUMBER 15
AIR POLLUTION I: INTRODUCTION
Goal: To provide introductory information about the formation of air
pollutants, their measurement as gaseous concentrations, and the
correction of concentrations to a standard-dilution basis.
Objectives: Upon completion of this unit, an operator should be able to:
1. List air pollutants whose emissions depend on combustion quality.
2. List air pollutants whose emissions depend on fuel composition.
3. List air pollutants whose emissions are dependent on the
temperature of the flue gas entering the particulate control device.
4. Identify three different compounds or groups of compounds which
can cause the appearance of white smoke.
5. What is the physical meaning of a ppm, as applied to gas
concentrations in a mixture.
6. Discuss the basis for correcting particulate concentrations to a
standard dilution basis, such as in "corrected to 7% O2."
7. Describe how to correct CO concentrations to a standard basis of
7% 02.
8. Define a grain, as used in "grains per standard cubic foot corrected
to 1% O2."
9. Be able to calculate combustion efficiency based on the definition
which considers conversion of carbon monoxide to carbon dioxide.
10. Describe how to compute excess air percentages from the dry gas
concentrations of carbon dioxide, oxygen, and carbon monoxide in
the stack gases.
15-1
-------
Lesson Time: Approximately 50 minutes
Suggested
Introductory
Questions:
1.
Why are emission concentrations "corrected," and what is the
difference between an emission corrected to 12% CO2 and 7% O2?
Presentation
Summary
Outline:
Air Pollution I: Introduction
Fuel Dependent Emissions
Operations Dependent Emissions
Smoke
Concentrations
Corrections to Standard Dilutions
Combustion Efficiency
Excess Air
Projection
Slides:
See the following pages.
15-2
-------
Slide 15-1
t>
COMBUSTION SOURCE AIR
POLLUTANTS
Fuel Dependent
Combustion Quality Dependent
APCD Temperature Dependent
-------
Slide 15-2
FUEL DEPENDENT
AIR POLLUTANTS
Acid Gases
• Sulfur Oxides
• Hydrogen Chloride
• Nitrogen Oxides (Fuel NOX)
Metals (Heavy Metals)
• Lead
• Cadmium
• Mercury
Carbon Dioxide
-------
Slide 15-3
COMBUSTION DEPENDENT
AIR POLLUTANTS
Products of Incomplete Combustion (PIC)
- Smoke
- Particulates
- Carbon Monoxide
- Volatile Organic Hydrocarbons
- MWC Oreanics
!•—
Dioxins & Furans
Nitrogen Oxides
-------
Slide 15-4
SMOKE & PARTICULATES
Black Smoke
Carbon in Particulates
Particulates
Removed by APCDs
White Smoke
Condensed Hydrocarbon Gases
Ammonium Chloride
Water Droplets (Not Smoke)
Blue Smoke
Ammonium Sulfate
Brown Smoke
Nitrogen Oxides
-------
Slide 15-5
APCD TEMPERATURE
DEPENDENT AIR POLLUTANTS
MWC Organics (Dioxins/Furans)
Metal Vapors (Mercury)
I
-------
Slide 15-6
GAS CONCENTRATIONS
MOLECULAR FRACTIONS
MOLE FRACTIONS
-------
Slide 15-7
IDEALIZED
(STOICHIOMETRIC, COMPLETE)
COMBUSTION OF MSW
1-22 H20 + 2.165 O2
8.14N2
1.85 CO2 + 3.92 Hf> + 8.15 N2 +
0.006 HC1 + 0.006 SO,
„ , ^ Wet Gas Dry Gas Dry Gas
Product Gas _, , ' , x, , ^
Moles Moles Mole %
C02
H20
N2
HC1
S02
1.85
3.92
8.15
0.006
0.006
1.85
8.15
0.006
0.006
18.48
81.4
0.06
0.06
Total 13.932 10.012 100.00
-------
Slide 15-8
EQUIVALENCE OF GAS
CONCENTRATIONS
Mole Fraction x 100 » Percentage
Mole Fraction x 1,000,000 —> ppm
Percentage x 10,000 » ppm
-------
Slide 15-9
GAS CONCENTRATIONS AT
STANDARD DILUTION
Example: CO Concentration Limit
50 ppm at 7% O2 on a
Dry Gas Basis
-------
Slide 15-10
EQUATION FOR CONVERTING
TO 7% OXYGEN
Assume COm is the Measured Dry Gas CO
expressed as a ppm or %
O2m is the Measured Dry Gas 02
expressed as a percentage
CO (@ 7% 02) = C0m x (21 - 1)1(21 - 02m)
= C0m x
- 0)
-------
Slide 15-11
PRODUCT GAS ANALYSIS,
METHANE @ 20% EA
Wet Gas Dry Gas Dry Gas
Moles Moles Mole %
CO2
H20
02
N2
CO
1.0
2.0
0.4
9.024
0.001
1.0
0.4
9.024
0.001
9.59
3.84
86.56
0.01
Total 12.425 10.425 100.00
-------
Slide 15-12
CONVERSION OF GAS
CONCENTRATIONS TO
7% OXYGEN
Let: COm = 100 ppm
02m = 3.84% (dry gas)
CO (@ 7% 02) = C0m x (21 - 7)/(21 - O2m)
= 100 x (14)/(21 -3.84)
= 81.6 ppm
-------
Slide 15-13
CONVERSION OF
PARTICIPATES TO
7% OXYGEN
Let: PMm = 0.035 gr/dscf (Paniculate Matter)
O2m = 3.84% (Measured Dry Gas O2)
PM (@ 7% 02) = PM,,, x (21-7)/(21 - O2m)
= 0.035 x (14)/(21 - 3.84)
= 0.0286 gr/dscf @ 7% O
2
-------
Slide 15-14
EQUATION FOR CONVERTING
TO 12% CARBON DIOXIDE
Assume CO is the Measured Dry Gas CO
TO
Expressed as a ppm or %
CO, is the Measured Dry Gas CO
2m *•
Expressed as a Percentage
CO (@ 12% CO,) = C0m x (12/C02m)
-------
Slide 15-15
EXAMPLE CONVERSION TO
12% CARBON DIOXIDE
Let: COm = 100 ppm
C02m = 9.59% (dry gas)
CO (@ 12% C02) = C0m x (12/C02m)
= 100 x (12/9.59)
= 125 ppm
-------
Slide 15-16
CONVERSION OF [gr/dscf]
TO [mg/dscm]
Basic Identities:
1 pound [Ib]
1 pound [Ib]
1 gram [g]
1 foot [ft]
= 7,000 grains [gr]
= 453.6 grams [g]
= 1,000 milligrams [mg]
= 0.3048 meters [m]
For Dry Gases at Standard Conditions:
1 dry standard cubic foot = 1 [dscf]
1 dry standard cubic meter = 1 [dscm]
1 cubic ft [dscf] = 0.0283 cubic meters [dscm]
So That:
Therefore:
1 [gr/dscf] =
1 [gr/dscf] x (1 lb/7,000 gr) x (454 g/lb)
x (1000 mg/g) x (1 dscf/0.0283 dscm)
1 [gr/dscf] = 2,290 [mg/dscm]
-------
Slide 15-17
EXAMPLE APPLICATION OF
THE CONVERSION FACTOR
Basic Identity: 1 [gr/dscf] = 2,290 [mg/dscm]
Given: 34 [mg/dscm]
Therefore: 34 [mg/dscm] =
34 [mg/dscm] x (1 [gr/dscf] / 2,290 [mg/dscm])
= 34 [mg/dscm] = 0.015 [gr/dscf]
-------
Slide 15-18
EQUATION FOR
COMBUSTION EFFICIENCY
(BASED ON CARBON
COMBUSTION TO CO2)
C.E. (%) = 100% x
CO
2m
co
m
or
C.E. (%) = 100% x
1 -
CO
m
co
m
-------
Slide 15-19
EXAMPLE COMBUSTION
EFFICIENCY CALCULATION
Let CO2m be 9.59 percent
COm be 0.01 percent (100 ppm)
C.E. (%) = (100% x C02m)/(C02m + C0m)
= (100% x 9.59)7(9.59 + 0.01)
= 99.9%
-------
Slide 15-20
DETERMINATION OF EXCESS
AIR FROM DRY GAS
ANALYSIS
Assume CO2m is the Percent Dry Gas CO
COm is the Percent Dry Gas CO
O2m is the Percent Dry Gas O2
2
Therefore N,m = 100 - (CO7m + COm + O2m)
And EA = (02ra - 0.5 COm)/(.264 N2m - O2m +
0.5 C0m)
-------
Slide 15-21
EXAMPLE DETERMINING
EXCESS AIR
Let CO2m =9.59%
COm =0.01%
02m =3.84%
Therefore N2m = 100 - (CO2m + COm + O2m)
N2m = 100 - (9.59 + 0.01 + 3.84)
= 86.56
And EA = (02m - 0.5 COm)/(.264 N2m - O2m +
0.5 C0m)
EA = (3.84 - 0.005)/(.264 x 86.56 - 3.84 + 0.005)
EA = 0.20 > 20%
-------
-------
LESSON PLAN NUMBER 16
AIR POLLUTION II: PRODUCTS OF INCOMPLETE COMBUSTION
Groal: To provide introductory information about the formation and
control of products of incomplete combustion, such as carbon
monoxide, dioxins and furans.
Objectives: Upon completion of this unit, an operator should be able to:
1. List the general groups of products of incomplete combustion.
2. Identify dioxins and furans as two of the groups of compounds
regulated as MWC organic emissions.
3. Name the surrogate used for monitoring MWC organic emissions
during normal operations.
4. Describe the assumptions associated with using dioxins and furans
as the annual performance test surrogate for MWC organic
emissions.
6. List three possible combustion chamber conditions which would
lead to the formation of dioxins and furans.
7. Describe the mechanism for formation of dioxins/furans in the
paniculate collection device.
8. Describe how the amount of carbon entering the APCD can
influence the amounts of dioxins/furans in the stack emissions and
the amount collected with fly ash.
9. Describe the two methods used in regulations for establishing
scales of MWC organic emissions.
Lesson Time: Approximately 40 minutes
Suggested
Introductory
Question:
1. What is the conceptual difference between EPA's regulatory limits for
dioxin/furan and the TCDD toxic equivalent method used by some
states?
16-1
-------
Presentation
Summary
Outline:
Air Pollution II: Products of Incomplete Combustion
Carbon Monoxide
Surrogates
Dioxins and Furans
Projection
Slides:
Source
of
Graphics:
Slide 16-4
See the following pages.
"Municipal Waste Combustion Study, Report to Congress," U.S.
Environmental Protection Agency, EPA-530-SW-87-021-a, June 1987,
p. 55.
16-2
-------
Slide 16-1
PRODUCTS OF INCOMPLETE
COMBUSTION (PICs)
Smoke & Particulate Matter
Carbon Monoxide
MWC Organics (Dioxins & Furans)
Volatile Organic Hydrocarbons
-------
Slide 16-2
SURROGATES FOR MWC
ORGANIC EMISSIONS
Routine Operations: Carbon Monoxide
Annual Stack Test: Total Dioxins/Furans
-------
Slide 16-3
DIOXINS/FURANS (CDD/CDF)
Dioxins (CDD)
Polychlorinated Dibenzo-p-dioxins
Furans (CDF)
Polychlorinated Dibenzofurans
-------
Slide 16-4
DIAGRAMS OF DIOXIN AND
FURAN STRUCTURES
Cl
Cl
Example Dioxin
Example Furan
-------
Slide 16-5
CONDITIONS WHICH
CONTROL DIOXINS/FURANS
Combustion Zone
Adequate Temperature & Mixing
Fly Ash Collection Device
Low Temperature
-------
Slide 16-6
FORMATION OF MWC
ORGANICS
Combustion Zone
Relatively Low Combustion Temperatures
Poor Mixing - Pockets of Rich Mixtures
High Particulate Loadings
Operating Above Unit Capacity
-------
Slide 16-7
FORMATION OF
MWC ORGANICS
APCD: ESP or Fabric Filter
Catalytic Formation on Fly Ash
High Operating Temperatures (450°F)
Low Carbon Loadings in Stack Gas
More Dioxin/Furan Emissions
Less Retained in Collected Fly Ash
-------
Slide 16-8
ANNUAL TEST FOR
DIOXINS/FURANS
Stack Test: EPA Method 23
Total Dioxins/Furans
Gaseous & Solid
-------
Slide 16-9
II
REGULATORY BASIS FOR
EMISSIONS LIMITS
NSPS: Total Mass of All Dioxins and Furans
Some States: Toxic Equivalent Limitation
Determine Mass of Each Isomer
Toxicity Level Assigned to Each Isomer
Multiply Masses by Levels to Obtain Total
-------
-------
LESSON PLAN NUMBER 17
AIR POLLUTION III: NITROGEN OXIDES
Goal: To provide information about the formation of nitrogen oxides.
Objectives: Upon completion of this unit, an operator should be able to:
1. List the major sources of NOx emissions.
2. Identify the two major oxides of nitrogen which are important in
combustion.
3. Discuss the influence of the emissions of nitrogen oxides on the
formation of photochemical smog and acid rain.
4. Name the two distinguishing categories of NOx which relate to the
sources of nitrogen, formation mechanisms, and control techniques.
5. Identify the dominant method of NOx formation which occurs in
MWC units.
6. Contrast fuel NOx formation mechanisms with those of thermal
NOx.
Lesson Time: Approximately 40 minutes
Suggested
Introductory
Questions
1. What is the difference between thermal NOx and fuel NOx?
2. What is the major type of NOx formed in MWCs?
3. Why don't your NOx emissions drop very much when it rains?
4. Why do your NOx emissions go up in the summer?
17-1
-------
Presentation
Summary
Outline: Air Pollution III: Nitrogen Oxides
Fuel NOx Formation
Thermal NOx Formation
Projection
Slides:
Source
of
Graphics:
Slide 17-6
See the following pages.
W. R. Seeker, W. S. Lanier, and M. P. Heap, "Municipal Waste
Combustion Study, Combustion Control of Organic Emissions," U.S.
Environmental Protection Agency, EPA-530-SW-87-021-C, June 1987,
pp. 4-10.
17-2
-------
Slide 17-1
SOURCES OF NITROGEN
OXIDES
Mobile Combustion Sources
Automobiles, Trucks
Stationary Combustion Sources
Power Plants, Heaters
Natural Combustion Sources
Forest Fires, Volcanoes
Non-Combustion Sources
Nitric Acid Manufacturing
-------
Slide 17-2
NITROGEN OXIDES
Nitric Oxide (NO)
Nitrogen Dioxide (NO2)
Nitrous Oxide (N2O)
Nitrogen Trioxide (N2O3)
Nitrogen Pentoxide (N2O5)
-------
Slide 17-3
ENVIRONMENTAL CONCERNS
ABOUT NOX
Acid Rain
• Damage to Structures
• Damage to Water Quality & Fish Life
• Sudden Release of Acids
Photochemical Smog
• Impairs Human Health, Respiration
• Stunts Growth of Vegetation
• Oxidizes Materials
-------
Slide 17-4
GENERALIZED
PHOTOCHEMICAL REACTION
EQUATIONS
NO, + Solar Energy »NO + O
O +
O.
O3 + NO
O + CxHy
0
CxHy
NO, +
^t
> Stable Products + Radicals
-> Stable Products + Radicals
Radicals + CH
Radicals + NO
Radicals + NO,
Stable Products + Radicals
Radicals + NO2
Stable Products
Radicals + Radicals > Stable Products
-------
Slide 17-5
FORMATION OF NOX —
CONVENTIONAL POWER
PLANTS
FUEL NO
A.
Combustion of Chemically-Bound
Nitrogen in the Fuel with Oxygen
THERMAL NO
A»
High Temperature Reaction of
Oxygen and Nitrogen from Air
-------
£z
*i
X
H
0^
-------
Slide 17-7
IDEALIZED REACTION
EQUATION FOR MSW TO
PRODUCE MAXIMUM FUEL
NO WITH 50% EXCESS AIR
C,85H5.402.08N02C1006S006 + 1.22H20
1.5 a O2 + 5.64 a N2 - > bCO2+
cH,O + dN, + eHCl + fSO9 +
L, I, £
g NO + .5 a O
^f*r
-------
Slide 17-8
CONSERVATION EQUATIONS
Carbon: 1.85 = b
Hydrogen:
Oxygen:
Sulfur:
Fuel N:
AirN:
5.4 + 2(1.22) = 2c + e
2.08 + 1.22 + 3a = 2b +
c + 2f + g + a
0.006 = f
Chlorine: 0.006 = e
0.02 = g
5.64(2a) = 2d
-------
Slide 17-9
SOLUTION OF CONSERVATION
EQUATIONS
a = 2.175; b=1.85; c = 3.92; d= 12.26;
e = 0.006; f = 0.006; g = 0.02
-------
Slide 17-10
IDEALIZED COMBUSTION OF
MSW TO PRODUCE
MAXIMUM FUEL NO WITH
50% EXCESS AIR
+ 1-22 H.O + 3.262 O2
1.85CO2 + 3.92 Hf) + 12.26
+ 12.26N
N2 + 0.006 HC1 + 0.006 SO2
+ 0.02 NO + 1.09CX
Droduct Gas
C02
H20
HC1
S02
NO
02
Wet Gas
Moles
1.85
3.92
12.26
0.006
0.006
0.02
1.09
Dry Gas
Moles
1.85
12.26
0.006
0.006
0.02
1.09
Dry Gas
Mole %
12.04
80.49
0.04
0.04
0.13
7.16
Total
19.152
15.232
100.00
-------
Slide 17-11
COMBUSTION MODIFICATIONS
FOR FUEL NO,,
• Two-Stage Combustion
• Excess Air - Stoichiometric Control
• Controlled Mixing - Low NO Burners
C? X
-------
Slide 17-12
COMBUSTION MODIFICATIONS
FOR THERMAL NOX
Thermal NCL
A
Not a Significant Source of MWC NOX
Thermal NOX Control Techniques
Limit Peak Combustion Temperatures
Heat Sinks (Flue Gas, Steam)
Control Mixing to Reduced Hot Spots
Control Stoichiometry
-------
Slide 17-13
FLUE GAS CONTROL OF NOX
Catalytic and Non-Catalytic
Reducing Agent Injection
-------
-------
LESSON PLAN NUMBER 18
AIR POLLUTION IV: METALS AND ASH
Goal: To provide information about the emission of heavy metals from
MWC units and the environmental concerns related to their
disposal.
Objectives: Upon completion of this unit, an operator should be able to:
1. List three MWC metals.
2. Describe the environmental issues associated with emission of
MWC metals in the stack gases.
3. List the surrogate which is continuously monitored as an indication
of MWC metal emissions.
4. List the surrogate which is typically measured during a stack test
and used as an indication of MWC metal emissions.
5. Describe the environmental issues associated with release of MWC
metals from the combustion residues disposed in landfills and
4fet monofills.
6. Discuss the problems associated with proper sampling and
laboratory testing to determine a meaningful measurement of the
potential for ash leaching from a landfill or monofUl.
Lesson Time: Approximately 50 minutes
Suggested
Introductory
Questions:
1. How would you know if MWC ash is hazardous?
2. Since MSW is not a hazardous waste, why is it argued that MWC
fly ash should be handled as a hazardous waste?
18-1
-------
Presentation
Summary
Outline:
Air Pollution IV: Metals & Ash
Characterization of MWC Metals
Emissions as Vapors & Particles
Measurements & Operational Concerns
Groundwater
Ash Testing
Ash Treatment
Projection
Slides:
See the following pages.
18-2
-------
Slide 18-1
METAL COMPOSITION
IN MSW
Example Composition of MSW:
6.4% Metals
16.4% Inorganic (Ash)
Major Toxic Metals: Lead, Cadmium,
Mercury
Other Trace Metals: Antimony, Arsenic,
Barium, Beryllium,
Chromium, Nickel,
Silver, Thallium
-------
Slide 18-2
EXAMPLE OF METALLIC
CONSTITUENTS IN ASH
Silicon
Iron
Calcium
Sodium
Aluminum
Titanium
Manganese
Potassium
Zinc
Lead
Copper
Molybdenum
Barium
Chromium
Selenium
Arsenic
Cadmium
Mercury
Silver
30. %
10.
8.
6.
3.
0.7
0.6
0.4
0.3
0.2
0.1
0.1
0.05
0.02
0.004
0.003
0.003
0.0006
0.0006
-------
Slide 18-3
COMMON TERMS WHICH
CHARACTERIZE METALS
Toxic Metals
Threat to Human Health
Heavy Metals
High Molecular Weight
Trace Metals
Found in Low Concentrations
-------
Slide 18-4
NSPS: MWC METALS
Metals and Metal Compounds Emitted in
Exhaust Gases from MWC Units
Particulate Matter (Solid and Liquid)
Vapors (Gas)
-------
Slide 18-5
METAL PATHWAYS
IN MWCs
High Melting Point (Non- Volatile) Metals
* Form Oxides, Chlorides, Sulfides
• Remain in the Solid Residue (Ash)
Low Melting Point (Volatile) Metals
• Form Liquids Which Solidify When
Cooled
• Form Vapors Which Condense When
Cooled, Are Adsorbed onto Fly
Ash, or Remain as Vapor
-------
Slide 18-6
TOXIC METALS AS AIR
POLLUTANTS
Participates
Gases (Vapors)
-------
Slide 18-7
TOXIC METALS WITH
LARGEST CONCENTRATIONS
Lead, Mercury and Cadmium
Lead - Particulate
Mercury - Particulate and Vapor
Cadmium - Particulate
-------
Slide 18-8
CONTROL STRATEGY FOR
METAL AIR POLLUTANTS
Provide for Condensation and Adsorption
by Controlling APCD Temperature
Collect Metals as Particulates
-------
Slide 18-9
SURROGATES
For MWC Metals (Except Mercury):
Participate Matter, PM
Opacity
-------
Slide 18-10
HEAVY METALS -
OPERATIONAL CONCERNS
* Procedures to Prevent Exposure
• Special Equipment (Suits, Aspirators)
• Personal Monitors
-------
Slide 18-11
TOXIC METALS AS GROUND
WATER POLLUTANTS
• Organic Decomposition to Form Acids
• Acid Extraction of Heavy Metals from Ash
• Leakage of Leachate into Ground Water
-------
Slide 18-12
IS MWC ASH HAZARDOUS
OR NON-HAZARDOUS?
Answer Varies from State to State
• Regulatory Definitions
• Toxicity Test Requirements
• Ash Sampling Procedures
-------
Slide 18-13
LABORATORY PROCEDURES
FOR TOXICS
EP - Extraction Procedure Toxicity Test
(an early procedure)
TCLP - Toxicity Characteristic Leaching
Procedure (EPA Method 1311)
EPA Method 1312 - Synthetic Precipitation
Leach Test for Soils
EPA Method 3050 - Acid Digestion of
Sediments, Sludges & Soils
-------
Slide 18-14
MWC ASH TREATMENT &
UTILIZATION
Treatment Before Disposal
• Chemical Extraction
• Chemical Additives
• Compaction
• Vitrification
Create Useful End-Products
• Road-Bed Aggregate
• Landfill Cover
• Ash/Concrete Blocks
-------
LESSON PLAN NUMBER 19
FLUE GAS CONTROL I: PARTICULATE MATTER (PM)
Goal: To provide information about the control of particulates.
Objectives: Upon, completion of this unit, an operator should be able to:
1. Name three general indicators of APCD performance.
2. Identify three design factors which influence particulate
entrainment in the flue gas.
3. List four general types of APCD devices which can be used for
collecting particulate matter.
4. Describe three of the collection mechanisms associated with the
collection of particles by fabric filters.
5. Discuss what a filter cake is and how it influences collection
efficiency.
6. Define the air to cloth ratio for a fabric filter.
7. List the three characteristic methods for removal of collected fly ash
from a fabric filter.
8. Characterize the sequence of actions required by the collection
mechanism of an ESP.
9. Describe the primary method used for removal of collected fly ash
from an ESP.
10. Discuss why the ash resistivity influences the performance of ESPs.
11. Name the monitored electrical parameters for ESP transformer-
rectifier sets.
12. Describe why oscillations are expected in the secondary field
voltages and currents of ESP transformer-rectifier sets.
13. List three parameters which influence ash resistivity.
19-1
-------
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Questions:
1.
2.
3.
What makes a filter cake function as a good filter?
Why do you change the filter in your home heating system?
Which system will be "better" at collecting sub-micron particles:
an ESP, a baghouse, or a venturi scrubber?
Presentation
Outline: Flue Gas Control I: Particulate Matter
Combustion System Factors
Fabric Filtration Concepts
Fabric Filter Design & Operation
ESP Concepts, Design & Operation
Venturi Scrubber Design & Operation
Projection Slides: See the following pages.
Source of Graphics:
Slide 19-8
Slide 19-9
Slide 19-10
Slide 19-12
Slide 19-15
Slide 19-19
Control Techniques for Particulate Emissions from Stationary Sources,
Volume 1, U. S. Environmental Protection Agency, EPA-450/3-81-
005a, September 1982. Courtesy of George A. Rolfes Company.
Illustrations of Reverse-Gas-Cleaned Baghouse, ABB Environmental
Systems, ABB Flakt, Inc., April 1992.
Illustrations of Shake/Deflate-Cleaned Baghouse, ABB Environmental
Systems, ABB Flakt, Inc., April 1992.
APTI Course SI:412B. Electrostatic Precipitator Plan Review-Self
Instructional Guidebook. U. S. Environmental Protection Agency,
EPA-450/2-82-019, July 1983.
PEI Associates, Operation and Maintenance Manual for Electrostatic
Precipitators. EPA-625/1-85-017, September 1984.
J. Joseph and David Beachler, APTI Course SI:412C. Wet Scrubber
Plan Review-Self Instructional Guidebook. U. S. Environmental
Protection Agency, EPA-450/2-82-020, March 1984.
19-2
-------
Slide 19-1
PARTITIONING OF SOLID
RESIDUES
Combustion System Example Values, %
Bottom Ash Fly Ash
Pulverized Coal 30 70
RDF-Spreader 25 75
Mass Burn - Grate 90 10
Modular Starved-Air 98
-------
Slide 19-2
INDICATORS OF
PARTICULATE COLLECTION
1. Visible Emissions
2. Opacity GEMS
3. APCD Inlet Gas Temperature
4. Stack Test Results
-------
Slide 19-3
PARTICLE ENTRAINMENT
FACTORS
1. Particle Size, Shape & Density
2. Fuel Charging Method
3. Underfire Air Velocity
4. Fuel Burning Rate
5. Primary Zone Velocity
-------
Slide 19-4
TYPES OF PARTICULATE
APCDs
1. Fabric Filters
2. Electrostatic Precipitators
3. Venturi S crabbers
4. Mechanical Collectors
-------
Slide 19-5
FABRIC FILTER
COLLECTION MECHANISMS
1. Inertial Impaction
2. Direct Interception
3. Diffusion
4. Electrostatic Attraction
-------
Slide 19-6
FABRIC FILTER
DESIGN FACTOR
Air-to-Cloth Ratio
Total Air Flow/Filter Surface Area
Average Velocity through Filter
-------
Slide 19-7
CLASSES OF FABRIC FILTER
SYSTEMS
1. Pulse-Jet
2. Reverse-Air
3. Shaker
-------
Slide 19-8
PULSE JET FABRIC FILTER
Clears Air Plenum-
Blow Pipe.
, V V °/
Eac Retainer
ToCaan Air Cutlet
, anc Exhauster
Tuc-jar r:Uer Ears
Roiarv Vaive Air Le
Courtesy of George A. Rolfes Company
-------
U
fa
I
I.
^
'i
T3
z
Is
U.
cs
s
3
-------
H
y
5
t-
ffi
o
Cs
•3
o
'£.
j
4
es
-------
Slide 19-11
INDICATORS OF FABRIC
FILTER PERFORMANCE
Opacity
Pressure Drop
-------
Slide 19-12
ELECTROSTATIC
PRECIPITATOR
Rappen
Qein gu
out
Discharge
electrodes
Shell
Collecuon
eiecsoces
Hoppers
-------
Slide] 9-13
ESP DESIGN COMPONENTS
High Voltage Equipment
Step-Up Transformer
High Voltage Rectifier
Shell Enclosure for Support & Insulation
Vertical Wires - Discharge Electrodes Wires
Vertical Plates - Collection Electrodes
Multiple Horizontal Gas Flow Paths
Rappers
Hoppers
-------
Slide 19-14
ELECTROSTATIC
COLLECTION PROCESS
High Voltage lonization of Molecules
Corona & Electric Fields Created
Charges Transferred to Particulates
Migration of Particulates to Plates
Removal of Particulates
-------
o
H
U
-------
Slide 19-16
ESP PARTICULATE REMOVAL
Charged Particle Adheres to Plate
Dry Removal - Mechanical Rappers
Wet Removal - Water Sprays
Delivery to the Hopper
-------
Slide 19-17
FACTORS AFFECTING ESP
PERFORMANCE
1. Particle Size Distribution
2. Specific Collection Area
Area/Gas Row Rate
3. Gas Stream Properties
Velocity
4. Ash Resistivity
Temperature
Moisture
Composition (Carbon)
-------
Slide 19-18
ESP MAINTENANCE &
OPERATIONAL FEATURES
1. Discharge Electrode Voltage
Automatic Controls
Transformer-Rectifier Data
2. Electrical Component Failure
3. Rapper Operation
4. Air Leakage
Excessive Temperature Drop
Corrosion of Metals
Fugitive Dust
5. Start-up and Shut-Down
Heating; Purge Air
-------
Slide 19-19
r
VENTURISCRUBBER
DIRTY FLUE GAS
CYCLONIC MIST
ELIMINATOR
-------
Slide 19-20
KEY VENTURI SCRUBBER
CONTROL VARIABLES
• Pressure Drop
• Liquid/Gas Flow Rate Ratio
• Scrubber pH
-------
Slide 19-21
DISADVANTAGES OF
VENTURI SCRUBBERS
• High Energy Requirements,
Pressure Drop
• Liquid Waste Residue
• Corrosion and Erosion
-------
-------
LESSON PLAN NUMBER 20
FLUE GAS CONTROL TECHNOLOGY II: ACID GAS REMOVAL
Goal: To provide information about the control of HC1 and SO2 acid gases.
Objectives: Upon completion of this unit, an operator should be able to:
1. Identify the two types of equipment most often used for acid gas
control in MWC units.
2. Describe the relative advantages and disadvantages of the wet
scrubber combination system of a venturi scrubber and packed
tower.
3. Identify the two major chemical products formed when MWC acid
gases react with the calcium hydroxide sorbent solution.
4. Contrast the design features of a spray dryer and fabric filter
system with those of dry sorbent injection and fabric filter system
for acid gas control.
5. Discuss the operational advantages of dry sorbent injection and
fabric filter systems relative to those of spray dryer and fabric filter
systems.
6. Describe the function of a slaker.
7. Discuss the reasons for heating the fluid transfer lines from a
slaker to a spray atomizer.
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Questions
1.
2.
What is the general range of the amount of hydrated lime (calcium
hydroxide) which must be used in a spray dryer to achieve acceptable
acid gas removal from MWC flue gas?
Would a fine water spray by itself remove much HC1; much S02?
20-1
-------
Presentation
Outline: Flue Gas Control II: Acid Gas Removal
Spray Dryer Absorber Systems
Dry Sorbent Injection Systems
Wet Scrubbers with Wet Collection
Projection
Slides:
See the following pages.
Source of
Graphics:
Slide 20-3
Slide 20-4
Slide 20-5
Slide 20-8
Slide 20-10
Theodore G. Brna, "Cleaning of Flue Gases from Waste Combustors,"
Combustion Science and Technology. Vol. 74, 1990, pp. 83-98.
Hospital Incinerator Operator Training Course: Volume 1. Student
Handbook. U. S. Environmental Protection Agency, EPA-450/3-89-003,
March 1989, p. 4-16.
"Prepared Fuel Steam Generation Systems," ABB Resource Recovery
Systems, Windsor, Connecticut, Undated Pamphlet.
Robert G. Mclnnes, "Spray Dryers and Fabric Filters: State of the
Art," Solid Waste & Power. April 1990, pp. 24-30.
J. Joseph and David Beachler, APTI Course SI:412C. Wet Scrubber
Plan Review-Self Instructional Guidebook. U. S. Environmental
Protection Agency, EPA-450/2-82-020, March 1984.
20-2
-------
Slide 20-1
ACID GAS REMOVAL
TECHNIQUES
Dry Scrubbers
Spray Dry Absorber
Dry Sorbent Injection
Wet Scrubber - Packed Tower
-------
Slide 20-2
BEST DEMONSTRATED
TECHNOLOGY
• New MWC Units
Good Combustion Practices
Spray Dry Absorber & Fabric Filter
• Large Existing Plants
Good Combustion Practices
Dry Sorbent Injection & ESP
• Very Large Existing Plants
Good Combustion Practices
Spray Dry Scrubber & ESP (or FF)
-------
H
C-
O
CX2
C/3
en
r3
«
-------
Slide 20-4
SPRAY DRYER ATOMIZER &
REACTION CHAMBER
Slurry Atomized to Fine Droplets
High Speed Rotary Atomizer
High Pressure Air Atomizer
Reaction Chamber Provides Residence Time
for Acid Absorption on the Slurry Droplets
Slurry Droplets are Dried by Hot Flue Gas
Flue Gases are Cooled by Evaporation
-------
tt
CM
CO
2
u
-------
Slide 20-6
SPRAY DRYER OPERATIONAL
CONSIDERATIONS
1. Slurry How Rate
Exit Acid Gas Concentration
2. Adequate Drying of Slurry Droplets
Atomizer Maintenance
3. Overall Drying Conditions
Exit Dry Bulb Temperature
Exit Wet Bulb Temperature
Exit Dry Bulb-Wet Bulb Difference
Inlet-Exit Dry Bulb Difference
4. Slurry Water Content
Exit Dry Bulb Temperature
5. Air Leakage Prevention
6. Maintenance of Hopper Temperatures
-------
Slide 20-7
SPRAY DRYER
OPERATIONAL PROBLEMS
1. Slurry Droplets Sticking on Wall
2. Liquid Carryover
3. Caking of Solids on Fabric Filter
4. Ash Hopper & Removal System
Plugging
-------
o
H
O
C/2
00
6
(N
U
-------
Slide 20-9
DRY SORBENT
OPERATIONAL PROBLEMS
Ash Removal from Collection Hopper
• Air Impactors
• Vibrators
• Hopper Heaters & Insulation
• Maintenance of Air Seals
-------
Slide 20-10
PACKED BED WET
SCRUBBER
DIRTY EXHAUST
CLEAN EXHAUST
A
SHELL
MIST ELIMINATOR
LIQUID SPRAYS
PACKING
-------
Slide 20-11
WET SCRUBBER
APPLICATIONS
Advantages
• Handles Gases & Participates
Disadvantages
• May Not Be Able to Meet Standards
• High Pressure Drop (Energy Cost)
• Liquid Residue Produced
• Corrosion and Erosion of Metals
-------
-------
LESSON PLAN NUMBER 21
FLUE GAS CONTROL TECHNOLOGY III: NOx CONTROL
G-oal: To provide information about the control of nitrogen oxide
emissions.
Objectives: Upon completion of this unit, an operator should be able to:
1. List the major combustion modification parameter which is
controlled when trying to limit fuel NOx formation.
2. List two generic types of MWC units in which the first combustion
zone can be said to act as a low-NOx burner.
3. Describe the special features of the selective non-catalytic reduction
(SNCR) process.
4. Name the two reagents most often considered for the selective non-
catalytic reduction process.
5. Discuss the major operational problems associated with NOx
control through reagent injection in the SNCR process.
6. Describe the major operational difference between NOx control
through ammonia injection and urea injection in the SNCR process.
7. Discuss the major advantages and operational problems associated
with NOx control through the selective catalytic reduction (SCR)
process.
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Question:
1.
Why do some MWCs with ammonia or urea injection NOx controls
have white plumes?
21-1
-------
Presentation
Summary
Outline: Flue Gas Control III: NOx Control
Combustion Modifications
Reburning with Natural Gas
Selective Non-Catalytic Reduction Systems
Thermal De-NOx & Urea Operational Factors
Selective Catalytic Reduction Systems
Projection
Slides: See the following pages.
21-2
-------
Slide 21-1
POSSIBLE NOX CONTROL
TECHNIQUES FOR MWCs
Combustion Modification
• Combustion with Limited Excess Air
• Two-Stage Combustion Design
• Three-Stage Combustion Design
Flue Gas Treatment
• Selective Non-Catalytic Reduction
(SNCR)
• Selective Catalytic Reduction (SCR)
-------
Slide 21-2
COMBUSTION MODIFICATION
FOR FUEL NOX CONTROL
A.
1. Combustion with Limited Excess Air
-------
Slide 21-3
COMBUSTION MODIFICATION
FOR FUEL NOX CONTROL
2. Two-Stage Combustion in Starved-Air Units
Sub-Stoichiometric Primary Combustion
Excess Air Secondary Combustion
-------
Slide 21-4
POSSIBLE NOX CONTROL
TECHNIQUES FOR MWCs
3. Three-Stage Combustion Design
Gas Reburning
Controlled Mixing - Low NOX Burner
-------
Slide 21-5
FLUE GAS NOX CONTROL
Selective Non-Catalytic Reduction (SNCR)
Selective Catalytic Reduction (SCR)
-------
Slide 21-6
BEST DEMONSTRATED
CONTROL TECHNOLOGY
Selective Non-Catalytic Reduction (SNCR)
Reagents: Ammonia, Urea, Other Compounds
-------
Slide 21-7
SNCR PERFORMANCE
FACTORS
Reagent Selection
Temperature Region: 1600° - 1800° F
CO Concentration
Residence Time
Reagent Injection Rate Keyed to NO
Gas Mixing Efficiency
-------
Slide 21-8
COMPETING REACTIONS
OF AMMONIA
Reduction:
NH3 + NO + 0.25 O2 > N2 + 1.5 H2O
Oxidation (Flue Gas Too Hot):
NH, + 1.25 O7 > NO + 1.5 H9O
D L. £•
No Reaction (Cool Flue Gas, Ammonia Slip):
NH, > NH,
-------
Slide 21-9
CHEMICAL
DECOMPOSITION OF UREA,
CO (NH2)2
CO (NH2)2 » NH3 +
HNCO (Iso-cyanuric acid)
-------
Slide 21-10
SELECTIVE NON-CATALYTIC
REDUCTION (SNCR)
Operational Problems
Furnace Temperature Variations
Spatial and Temporal Variations
NO Increases if T > 2,000° F
Ammonia Slip - Can React to Form
Ammonium Chloride & White Smoke
-------
Slide 21-11
SELECTIVE CATALYTIC
REDUCTION (SCR)
Reagent: Ammonia
-------
-------
LESSON PLAN NUMBER 22
AUTOMATIC CONTROL SYSTEMS
o
Goal: To provide introductory information about design and operational
features of automatic control systems.
Objectives: Upon completion of this unit, an operator should be able to:
1. Describe the major automatic control system elements in a simple,
single-element controller, such as a furnace draft controller.
2. Define a set-point.
3. List four of the gas-side control parameters (manipulated variables)
which are often used by MWC combustion control systems.
4. List some water-side control parameters (manipulated variables)
which are often used in MWC combustion control systems.
5. Identify four types of final control elements which are often used in
MWC control systems.
6. Describe the functions of a two-element controller.
7. Identify the trim control concept as one used to fine tune a control
variable such as excess air.
8. Contrast the combustion controls of a waste-to-energy unit with
those of conventional fuel fired boilers.
9. Contrast the basic combustion control strategies of a water-wall
MWC unit with those of a modular starved-air unit.
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Question:
1.
2.
What type of system activity is the most difficult to automate?
What is a combustion control system interlock?
22-1
-------
Presentation
Summary
Outline:
Automatic Control Systems
Automatic Control Concepts
Boiler & Combustion Control Parameters
Single, Two & Three Element Controllers
Micro-processor Based Control Systems
MWC Control System Applications
Projection
Slides:
See the following pages.
Source
of
Graphics:
Slide 22-9
Slide 22-10
Slide 22-11
Slide 22-12
Reprinted by permission. Copyright® Instrument Society of America
1988. From "Boiler Feedwater and Steam - Controlling for Safety and
Efficiency," Videotape from ISA's Boiler Control Series.
Reprinted by permission. Copyright® Instrument Society of America
1988. From "Boiler Feedwater and Steam - Controlling for Safety and
Efficiency," Videotape from ISA's Boiler Control Series.
Reprinted by permission. Copyright® Instrument Society of America
1988. From "Boiler Feedwater and Steam - Controlling for Safety and
Efficiency," Videotape from ISA's Boiler Control Series.
Reprinted by permission. Copyright® Instrument Society of America
1988. From "Boiler Feedwater and Steam - Controlling for Safety and
Efficiency," Videotape from ISA's Boiler Control Series.
22-2
-------
Slide 21-1
MWC SYSTEMS REQUIRING
CONTROL
1, Crane Operation
2. Combustion Control System
3, Ash Handling System
4. Flue Gas Cleaning System
5. Turbine-Generator
6. Feedwater Demineralizer Plant
7. Boiler Feedwater & Condensate
8. Motor Controllers
9. Cooling Water
-------
Slide 22-2
AUTOMATIC CONTROLS
SYSTEM FUNCTIONS
1. Modulating Control
2. Sequential Control Logic
3. Process Monitoring
-------
Slide 22-3
TYPES OF AUTOMATIC
CONTROL SYSTEMS
1. Pneumatic
2. Hard-wire Electronic Analog
3. Programmable Logic Controllers
Microprocessor-Based
Distributive Control Systems
-------
(N
04
o
-J
fa
• •
ft*
o
o
-J
0
°
u
H
LU
c/
-------
Slide 22-5
AUTOMATIC CONTROL
SYSTEM ELEMENTS
1. Manipulated Variable (Parameter)
2. Measuring Device (Transducer)
3. Feedback Signal
4. Set Point (SP)
5. Controller
6. Actuating Signal
7. Final Control Element (FCE)
8. Status Indicator
-------
Slide 22-6
GAS-SIDE CONTROL
PARAMETERS
1. Air Flow Rate
2. Opacity
3. Oxygen Content
4. Carbon Monoxide
5. Draft
6. Combustion Temperature
7. Flue Gas Temperature at APCD
-------
Slide 22-7
WATER-SIDE CONTROL
PARAMETERS
1. Steam Temperature
2. Steam Pressure
3. Steam Flow Rate
4. Drum Level
5. Feedwater Flow Rate
-------
Slide 22-8
FINAL CONTROL
ELEMENTS
1. Grate Speed/Ram Speed
2. Timer Delay Period (Dwell Time)
3. Valve Position
4. Damper Position
5. Motor/Fan/Pump/Turbine Speed
Variable Speed Drive
-------
Slide 22-9
SINGLE-ELEMENT
CONTROL SYSTEM: DRAFT
Furnace
dnfi f PT M-
SP
Furnace-
draft
cuiiu oiler
i
Furnace
Adaption of a figure from the Instrument Society of America
-------
Slide 22-10
SINGLE-ELEMENT
CONTROL SYSTEM: DRUM
LEVEL
Steam drum
water level
SP
LC
I
Feedwater
FCE
Counesy of the Instrument Society of America
Boiler
-------
Slide 22-11
TWO-ELEMENT CONTROL
SYSTEM: DRUM LEVEL
Steam
Boiler
Counesv of the Instrument Society of America
-------
Slide 22-12
THREE-ELEMENT CONTROL
SYSTEM: DRUM LEVEL
Steam
Boiler
Courtesy of the Instrument Sociery of America
-------
Slide 22-13
MICRO-PROCESSOR BASED
CONTROL SYSTEM
BTEAM
PLUS QAS AIR CXYOEN STEAM OFWCITY
-------
Slide 22-14
TRIM CONTROL FEATURES
1. Oxygen Trim Control
2. Flue Gas APCD Temperature Control
-------
Slide 22-15
CONTROL SYSTEM
COMPARISONS
Conventional Fuels
Gas & Fuel Oil
Coal
Municipal Solid Waste
-------
Slide 22-16
WATER WALL MWC
CONTROL FEATURES
Base Load
Steady Combustion Temperature
-------
Slide 22-17
STARVED-AIR UNIT
CONTROL SYSTEMS
Two-Stage Combustion Design
Steady Combustion Temperatures
Low Primary Air Flow
Long Solids Residence Time
Air Controlled in the Secondary
-------
Slide 22-18
CONTROL SYSTEM
INTERLOCKS
GEMS Operational Requirement
High Carbon Monoxide
Auxiliary Burner Flame Sensor
Fan Running During Pre-Ignition Purge
-------
LESSON PLAN NUMBER 23
CONTROL ROOM OPERATIONS
Goal: To provide introductory information about the operation of MWC
control systems.
Objectives: Upon completion of this unit, an operator should be able to:
1. Discuss the three main operator control functions which are
conducted in the control room.
2. List five systems which are typically monitored in the control room.
3. Identify the panel-mounted device which is often used to
continuously indicate and record unit load.
4. Discuss three of the different graphic screen displays which provide
unit operations information from a microprocessor-based distributed
control system.
5. List four parameters which are monitored in the control room to
provide information about feed water conditions.
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Questions:
1.
3.
Ask one of the participants to describe normal control room
communications problems.
What can you learn from a TV monitor which focuses on the region at
the end of the grate?
How might what you see from such a TV monitor influence CO
emission concentrations?
23-1
-------
Presentation
Summary
Outline:
Control Room Operations
Operator Functions
Operating Systems Controlled
Panel Mounted Instruments
Graphic Screen Displays
Operator Control Actions
Projection
Slides:
See the following pages.
23-2
-------
Slide 23-1
OPERATOR CONTROL
FUNCTIONS
1. Monitor System Operations
2. Evaluate Conditions
3. Institute Appropriate Changes
-------
Slide 23-2
OPERATING SYSTEMS
• MSW Handling
• Combustion
• Boiler & Feedwater
• Power Generation
• APCD & Ash Removal
• Electrical Service
• Water Treatment
• Cooling Water
• Fire Protection
-------
Slide 23-3
CONTROL ROOM
COMMUNICATIONS
Operator/Unit Interface
Receive Operating Information
Transmit Instructions
-------
Slide 23-4
PANEL MOUNTED
INSTRUMENTS
• Analog Displays
• Digital Displays
• Status Indicator Lights
• Annunciators
• Alarms
• Television Monitors
• Recording Devices
Circular Charts
Strip Charts
-------
Slide 23-5
GRAPHIC SCREEN DISPLAYS
• Alpha/Numeric
Menus, Lists, Warnings
• Two-Dimensional Equipment
Schematic with Data
• Individual Component
• Groups of Equipment
• Overview of Performance
• Trends of Selected Data
-------
Slide 23-6
COMBUSTION SYSTEM
MONITORS
• Opacity
• Carbon Monoxide
• Oxygen
* Acid Gas Concentrations
* Air & Flue Gas Temperatures
• Television Monitors
-------
Slide 22-7
BOILER & FEEDWATER
MONITORS
• Steam Pressure & Temperature
• Steam Row Rates
• Water Pressure & Temperature
• Feedwater Row Rates
• Feedwater pH & Conductivity
-------
Slide 23-8
OPERATOR-INITIATED
CHANGES
• Transmit Direct Signals
Motors, Pumps, Switches
• Transmit Signals to Controllers
Modify Set-Points
Initiate Start-Up or Shut-Down
• Request Maintenance
-------
LESSON PLAN NUMBER 24
OPERATING PRACTICE
Goal: To provide general information about the safe and efficient
operation of MWCs, including special combustion and boiler
considerations during unit start-up and shut-down.
Objectives: Upon completion of this unit, an operator should be able to:
1. Discuss the operator's major responsibilities regarding safety.
2. List the major safety hazards which can occur in MWC units, and
discuss the operational procedures which are designed to minimize
such hazards.
3. List the general types of damage which can occur to MWC boilers,
and describe measures taken to reduce the potential damage.
4. Discuss the general operator activities performed to assure that
proper combustion conditions are maintained during normal
operations.
5. Discuss the general operator activities performed to assure that
proper boiler conditions are maintained during normal operations.
6. Identify the general sequence of events required in starting up a
waterwall unit.
7. Describe the general sequence of events required in a routine shut-
down operation of a modular starved-air unit.
8. Describe procedures undertaken to prevent blinding of fabric filter
systems during start-up.
9. Describe normal procedures undertaken to prevent fabric filter
systems from operating at too high a temperature.
24-1
-------
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Question:
1. Ask one of the participants to describe normal start-up procedures.
Presentation
Summary
Outline: Operating Practices
Responsibilities & Functions
Safety & Standard Operating Procedures
Combustion, Boiler, Water Treatment Systems
Combustion System Start-Up & Shut-Down
APCD System Start-Up & Shut-Down
Projection
Slides: See the following pages.
24-2
-------
Slide 24-1
OPERATING
RESPONSIBILITIES
1. Maintain S afety of People
2. Maintain Safety of Equipment
3. Operate Within Legal Regulations
4. Optimize Equipment Performance
-------
Slide 24-2
OPERATOR JOB FUNCTIONS
Automatic Control System Manager
Equipment Operator
What Is Happening?
Why?
What Are the Options?
What Are the Consequences?
-------
Slide 24-3
TYPICAL WALK-DOWN
CHECK-LIST
1. Fuel Charging & Pit Operations
2. Fuel Bed Uniformity
3. Fuel Bed Clinkering
4. Slag Deposits on Waterwalls
5. Equipment Noise/Overheating
6. Ash Leaks, Blockages, Conditions
7. Pumps, Fans & Dampers
8. Water & Oil Leaks (Valve Packing)
9. Safety Valve Leaks
10. Soot-Blowers (Confirm Operation)
11. Hydraulic Systems (Temp., Pressure)
-------
Slide 24-4
OPERATOR REQUIREMENTS
1. Know the System Characteristics
2. Assess the Operating Conditions
3. Identify Potential Modifications
4. Make Timely Decisions
5. Establish Proper Procedures
6. Keep Proper Records
-------
Slide 24-5
POTENTIAL MAJOR
HAZARDS
1. Loss of Water
2. Explosive Mixture of Fuel/Air
3. High Pressure Steam Pipe Rupture
-------
Slide 24-6
STANDARD OPERATING
PROCEDURES
1. Safe Practices & Systems
2. Emergency Procedures
3. General Operations
4. Routine & Major Maintenance
5. Start-Up and Shutdown
6. Testing and Calibration
-------
Slide 24-7
POLLUTANTS INFLUENCED
BY OPERATIONS
1. Air Pollutants
Smoke
Particulates
Gases
2. Waste-Water Discharge
3. Odor
4. Noise
-------
Slide 24-8
NORMAL OPERATING
SYSTEM CONTROLS
1. Combustion
2. Boiler
3. Boiler Water Treatment
4. Air Pollution Control Devices
-------
Slide 24-9
COMBUSTION CONTROL
Air and Fuel Transients
Operator Activities
Review System Performance
Improve Equipment Setting
-------
Slide 24-10
GRATE BURNING
OPERATOR CONTROL
1. Under-fire Air to Each Zone
Damper Controls
Supply Air Pressure
Draft
2. Fuel Bed
Waste Feed Rate
Bed Thickness & Uniformity
Bed Agitation
3. Over-fire Air Supply Pressure
-------
Slide 24-11
BOILER CONTROL
Drum Level
Load
Steam Temperatures
Feedwater Conditions
Operator Activities
Review System Performance
Make Furnace Observations
Soot Blowing (Automatic/Manual)
Detect Tube Failures
-------
Slide 24-12
BOILER WATER TREATMENT
Oxygen & Dissolved Gases
Carbonates
Acidic or Alkali Conditions
Operator Activities
Monitor Conditions
Chemical Treatment
Blowdown
-------
Slide 24-13
COMBUSTION SYSTEM
START-UP
1. Prepare Boiler For Ignition
Inspect Boiler
Test Components:
Fans, Pumps, Safety Valves
Clean Gas-Side of Boiler
Chemically Clean Water-Side
Fill Boiler with Water
Static Test Boiler at Pressure
Adjust Control System Settings
-------
Slide 24-14
COMBUSTION SYSTEM
START-UP
2. Warm Up Boiler
Purge Air & Ignite Burner
Maintain Minimum Air Flow
Vent Air from Drum & Headers
Limit Thermal Stresses
Vent Steam from Economizer
Boil-Out the Superheater
-------
Slide 24-15
0
COMBUSTION SYSTEM
START-UP
3. Begin to Charge MSW
Ignition
Enable Automatic Controls
Monitor Auxiliary Systems
-------
Slide 24-16
COMBUSTION SYSTEM
UNIT SHUTDOWN
Stop Feeding Waste into Unit
Burn the Fuel on the Grate
Operate Auxiliary Burners as Necessary
Allow Steam Pressure to Decay
Limit the Cool Down Rate
Maintain APCD Temperatures
-------
Slide 24-17
APCD SYSTEM START-UP,
SHUTDOWN, UPSET
Water Freeze Protection
Preheat Fabric Filter
Dew Point Controls
Flue Gas Redirection upon Bag Rupture
Controls to Prevent Slurry Solidification
High Temperature Protection of Bags
-------
-------
LESSON PLAN NUMBER 25
TROUBLESHOOTING OF COMBUSTION UPSETS
Goal: To provide information about the corrections to combustion upset
conditions.
Objectives: Upon completion of this unit, an operator should be able to:
1. Discuss the possible indicators of blockages in the fuel handling
system (conveyors, hoppers) and possible operator responses.
2. Identify the problems associated with a sudden change in fuel
properties, such as a load of plastics or wet fuel suddenly arriving
on the fuel bed.
3. Identify the indicators and abnormal features associated with
operating with a fuel bed thickness that is too high or too low.
4. List the indicators of improper combustion air delivery and
distribution.
5. List the consequences of excessive gas temperatures in the upper
combustion regions.
6. Discuss the possible control actions to be considered in the event of
too high or too low a temperature in the primary chamber of a
starved-air unit.
7. Discuss the possible control actions to be considered in the event of
too high or too low a temperature in the secondary chamber of a
starved-air unit.
8. Discuss the general operator actions in the event that the
combustion chamber draft is too high or too low.
9. List the indicators of a water tube rupture and how such failures
will change the combustion process.
10. Discuss the options available to operators in the event of a pit fire.
25-1
-------
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Question:
1.
What do you do if the feed water rate goes up but the power generation
level is steady?
Presentation
Summary
Outline:
Troubleshooting of Combustion Upsets
Combustion System Upsets
Indicators of Combustion Quality
Fuel Upsets
Air System Upsets
Temperature Upsets
Draft Upsets
Projection
Slides:
See the following pages.
25-2
-------
Slide 25-1
TYPICAL COMBUSTION
UpSETS
1. MSW/RDF Charging System
2. Grates
3. Combustion Air Supply
4. Waterwalls/Tubes
5. Ash Handling
6. Power Failures/Excursions
-------
Slide 25-2
INDICATORS OF
COMBUSTION QUALITY
1. Opacity
2. Carbon Monoxide
3. Temperature (Furnace & APCD)
4. Oxygen
5. Visual Appearance of Fire
6. Total Hydrocarbon
7. Furnace Draft
8. Air Supply Pressures
-------
Slide 25-3
PERSONAL COMBUSTION
OBSERVATIONS
• Combustion Conditions
• Bottom Ash
-------
Slide 25-4
FUEL PREPARATION &
HANDLING
1. Wide Swings in Fuel Properties
Fuel Moisture: Mix Wet & Dry MSW
2. Feed Hopper/Conveyor — Bridging
Maintain Proper Charging Level
Redirect Undesirable Materials
3. Grapple/Loader Breakdown
4. Pit Fire
Charge Into Unit
Extinguish with Water/CO2
-------
Slide 25-5
UPSETS ASSOCIATED WITH
FUEL PROBLEMS
1. Improper Feed Rate
Too High
Too Low
- Excessive Gas Temperatures
- High Steam Production
- Poor Burn-out of the Ash
- Insufficent Fuel
- Low Combustion Temperatures
- Low Steam Production
2. Improper Fuel Bed Thickness
Too High - Improper Air, Poor Burn-Out
Too Low - Entrainment
3. Sudden Change in Fuel Properties
High Moisture - Reduced Temperatures
High Volatiles - Increased Temperatures
High Inorganics - Reduced Temperatures
-------
Slide 25-6
UPSETS ASSOCIATED WITH
FUEL PROBLEMS
REMEDIES:
• Regulate Grate Agitation
• Regulate Underfire Air Supply
• Regulate Charging Rate
• Change MSW Mixing Conditions
• Modify Trim Control System Settings
-------
Slide 25-7
COMBUSTION AIR UPSETS
Underfire Air Supply
Low Pressure - Inadequate Oxygen
High Pressure - Excessive Entrainment
Poor Distribution (Front/Rear)
Overfire Air Supply
Low Pressure - Inadequate Mixing
High Pressure - Excessive Gas Cooling
Poor Distribution, Mixing
Fuel Bed Thickness, Clinkers
Too Thick - Delayed Burning
Too Thin - Particulate Entrainment
Clinkers - Prevents Air Flow
Air Intrusion from Feed Hoppers
-------
Slide 25-8
COMBUSTION AIR UPSETS
REMEDIES:
Check Draft Gage Readings
Adjust Fan Controls/ Dampers
Modify Fuel Charging Rate
Remove Clinkers
-------
Slide 25-9
COMBUSTION
TEMPERATURE UPSETS
1. High Temperature in Upper Region
Refractory or Metal Damage
Excessive Slagging
Remedy:
Increase Overall Air Supply
Reduce the Underfire Air Supply
Reduce the Feed Rate
-------
Slide 25-10
COMBUSTION
TEMPERATURE UPSETS
2. Low Temperature in Upper Region
Inadequate Combustion
Inadequate Energy Production
Remedy:
Increase Underfire Air Supply
Decrease Overfire Air Supply
Increase the Feed Rate
Increase Auxiliary Fuel Burning
-------
Slide 25-11
FURNACE DRAFT
CONDITION UPSETS
1. Excessive Draft
High Velocities & Poor Mixing
Excessive Paniculate Entrainment
2. Inadequate Draft
Low Velocities & Pressure
Transients, Puffing
3. Operation with Positive Pressure
Exterior Fly Ash Accumulation
Gases/Smoke Leaking Out of Furnace
Combustion Quenching
Pollutant Exposure to Personnel
Damage to Furnace Structure
Torching - Flames Down Through Grates
Damage to Grates & Air System
-------
Slide 2542
FURNACE DRAFT
CONDITION UPSETS
REMEDY
Balance Forced Draft Fan/Dampers
and Induced Draft Fan/Dampers
-------
LESSON PLAN NUMBER 26
SPECIAL SYSTEM CONSIDERATIONS I: WATER TREATMENT
Goal: To provide information about general boiler water treatment.
Objectives: Upon completion of this unit, an operator should be able to:
1. List three general types of impurities found in boiler
feedwater/steam systems.
2. List two continuous operating instruments which can be used to
measure water quality in the boiler feedwater/steam system.
3. Define blowdown and discuss why it is required.
4. Discuss the generic steps required for removal of gases in a
deaerating feedwater heater.
5. Identify two gaseous impurities removed in a deaerating feedwater
heater.
6. Contrast the water treatment required for cooling-water with that
of waste-water treatment.
7. Describe generally how an ion exchange process works to remove
hardness and minerals from water.
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Question:
1. Ask operator participants to discuss their knowledge of water
treatment problems at MWC units which resulted in major outages.
2. Ask them to describe the effective remedies which were used to
overcome the particular problems.
26-1
-------
Presentation
Summary
Outline:
Special System Considerations I: Water Treatment
Boiler Water Impurities & Problems
Water Treatment System Components
Deaeration, Chemical Treatment, Slowdown
Indicators of Water Quality
Projection
Slides:
See the following pages.
Source
of
Graphics:
Slide 26-7
Slide 26-8
David F. Dyer and Glennon Maples, Boiler Efficiency Improvement.
Boiler Efficiency Institute, Auburn, AL, 1981, p. 8.28.
Frederick M. Steingress and Harold J. Frost, Stationary Engineering.
American Technical Publishers, Inc., Homewood, IL, 1991, p. 87.
26-2
-------
Slide 26-1
IMPURITIES OF RAW
WATER
Composition Varies with Source
• Chemical Wastes
• Organic Wastes & Bacteria
• Oxygen & Dissolved Gases
* Dissolved or Suspended Minerals
• Suspended Solids
-------
Slide 26-2
CHEMICAL COMPOUNDS
Acids: Hydrogen Ions in Solution
Bases: Metal-Hydroxyl Ions in Solution
Salts: Compounds of Acids & Bases
-------
BOILER WATER
IMPURITIES
1. Dissolved Gases
2. Dissolved Minerals — Hardness
3. Dissolved & Suspended Solids
-------
Slide 26-4
BOILER WATER PROBLEMS
Corrosion of Metal Tubes
Scale Build-Up Inside Tubes
Contamination of Steam:
Deposits in Tubes & Turbines
-------
Slide 26-5
INFLUENCE OF SCALE ON
METAL TEMPERATURES
Scale
Tube Without
Scale
Tube With
Scale
-------
Slide 26-6
WATER TREATMENT FOR A
STEAM GENERATOR
MAKE-UP WATER
i
CLARIFIER
SOFTENER
DEAERATOR
VENT
STORAGE TANK
* *
PUMP
PEEDWATER
BOILER
SLOWDOWN
STEAM
TURBINE
OR
CUSTOMER
SUPERHEATED STEAM
ELECTRICITY
LOW PRESSURE STEAM
CONDENSER
I
CONDENSATE
PUMP
PURIFICATION
-------
Slide 26-7
BOILER WATER
PROBLEMS & REMEDIES
1. Dissolved Gases
Metal Corrosion & Pitting
Remedy:
Deaeration
Chemical Scavengers
-------
Slide 26-8
TRAY-TYPE DEAERATING
FEED WATER HEATER
STEAM
INLET
WATER INLET
SPRAY
TRAY SECTION
TO BOILER FEED PUMP
Courtesy of Boiler Efficiency Institute
-------
Slide 26-9
DEAERATING FEEDWATER
HEATER & FLASH TANK
• Boiler
Vent
Continuous
Slowdown
Line
Bashing
Steam
Makeup
Water
Steam to
Feedwater Heater
Automatic Makeup
Water Valve
Internal
Overflow
Line
—IP^ Internal
-J— A Overflow
Line
To Feedwater
Pump
To
Waste
Rash Tank
Feedwater Heater
Frederick M. Steingiass and Harold ). Frost, Stationary Engineering. American Technical Publishers, Inc.,
Homewood. IL, 1991, printed with permission
-------
Slide 26-10
BOILER WATER
PROBLEMS & REMEDIES
2. Dissolved Minerals — Hardness
Increase Metal Corrosion
Form Scale & Sludge
Remedies:
Water Softeners
Condensate Purification
-------
Slide 26-11
BOILER WATER
PROBLEMS & REMEDIES
3. Dissolved & Suspended Solids
Causes Carry-Over of Impurities
Damages Superheater, Valves,
Turbine
Remedy:
Boiler Water Slowdown
-------
Slide 26-12
INDICATORS OF WATER
QUALITY
1. pH — Indicates Acidic/Alkali Quality
< 7: Acidic; 7: Neutral; > 7: Basic
2. Conductivity of Steam & Feedwater
Microsiemens/cm
3. Total Dissolved Solids in Boiler Water
Microsiemens/cm
4. Alkalinity
Equivalent Calcium Carbonate, ppm
5. Hardness — Ability to Dissolve Soap
Calcium & Magnesium Salts, ppm
6. Silica — Silicon Dioxide, ppm
-------
LESSON PLAN NUMBER 27
SPECIAL SYSTEM CONSIDERATIONS II: ELECTRICAL THEORY
Goal: To provide general electrical theory as required for understanding
the operation of the transformer/rectifier and steam turbine driven
electrical generator equipment
Objectives: Upon completion of this unit, an operator should be able to:
1. Apply Ohms Law to a single loop DC electrical circuit. -
2. Discuss the difference between AC and DC electricity.
3. Describe the features of voltage being out of phase with current,
apparent power, real power and reactive power in AC systems.
t
4. Define a power factor.
5. Identify the reason for the difference between real electrical power
which is expressed in MW units and apparent electrical power
which is expressed as MVA.
6. Discuss the basic theory of an electrical transformer, indicating the
importance of the number of windings.
7. Discuss the diversity of 3-phase power wiring systems which are
used by electrical system designers.
8. Discuss the basic purpose of a circuit breaker, rectifier and
inverter.
Lesson Time: Approximately 60 minutes
Suggested
Introductory
Question:
1. Ask operator participants to make some basic Ohms Law and power
calculations, including the calculation of a power factor from a
knowledge of real power and apparent power.
27-1
-------
Presentation
Summary
Outline:
Special System Considerations II: Electrical Theory
Electrical Parameters & Ohms Law
Apparent Power, Reactive Power, Power Factor
Transformer Principles
3-Phase Fundamentals
Circuit Breakers, Rectifiers, Inverters
Projection
Slides:
See the following pages.
Source of
Graphics:
Slide 27-11
Frederick M. Steingress and Harold J. Frost, Stationary Engineering.
American Technical Publishers, Inc., Homewood, IL, 1991, p. 326.
27-2
-------
Slide 274
BASIC ELECTRICITY
• Ohms Law
• DC vs. AC Current
• Electrical Phases
• Power
• Transformer
• Rectifier
-------
Slide 27-2
ELECTRICITY & CURRENT
Electricity
Flow of Electrons
Direct Current: DC
Steady Flow of Electrons
Current
Rate of Electron Flow
-------
Slide 27-3
ELECTRICITY - FLUID
FLOW ANALOGY
Parameter
Flow Rate
Driving
Force
Electricity
Electron Flow/Current
(amps)
Electrical Potential or
Voltage Difference
(volts)
Fluids
Fluid Flow
Pressure
Difference
(psi)
-------
fe
OH
9 9 9 9 T
-------
Slide 27-5
OTHER BASIC
ELECTRICAL PROPERTIES
1. Conductor - Material Which Permits
Electrons to Flow
2. Resistance - Opposition to Flow
3. Ohm - Unit of Resistance to Flow
4. Insulator - Material with High
Resistance
5. Circuit - The Path of Electrical
Current From a Source
Through Various
Conductors and Devices
-------
Slide 27-6
OHMS LAW
Voltage = Current x Resistance
E = I x R
or
I = E
^^^^^•^•w
R
-------
Slide 27-7
ELECTRICAL POWER
Watt — Unit of Electrical Power
-------
Slide 27-8
DC ELECTRICAL POWER
Power = Voltage x Current
or
P =E x I
P = (I x R) x I
or
= I2 x R
P = E x (E)
R
R
-------
CJ TT CO CD O
9999V
eBniioA
ON
-------
Slide 27-10
AC ELECTRICAL POWER
Power = Voltage x Current x Power Factor
P = E x I x cos 0
or
P = (I x R) x I x cos 0
= I x R x cos ©
or
P = E x (E) x cos
"R"
= E2 x cos 0
R
-------
Slide 27-11
AC ELECTRICAL POWER
Apparent Power is Current times Voltage
Papparent = E X I, [KVA]
Power Factor:
Power Factor = cos 0 = P/Papparent
Reactive Power is Imaginary Power
Prp!,rtivp = E x I x sin 0 , [KVAR]
-------
Slide 27-12
TRANSFORMER WINDING
SCHEMATIC
Coils
440V
I
220V
1
Primary Coil
Secondary Coil
Step-down Transformer
-------
y
2
H
ou
u
HH
H
a
ffi
u
*- o
9 9 9 9 T
-------
Slide 27-14
CIRCUIT BREAKER:
Controls the Flow of Electricity
RECTIFIER:
Converts AC Electricity to DC
INVERTOR:
Converts DC Electricity to AC
-------
LESSON PLAN NUMBER 28
SPECIAL SYSTEM CONSIDERATIONS III: TURBINE GENERATOR
Goal: To provide an overview of the main components and operation of a
steam turbine/electrical generator set.
Objectives: Upon completion of this unit, an operator should be able to:
1. Identify the impulse turbine as the type of steam turbine which is
designed with nozzles to convert high pressure steam into high
velocity steam which drives the revolving turbine blades.
2. Identify the reaction turbine as the type of steam turbine which
uses fixed turbine blades to serve as the nozzles to convert high
pressure steam to high velocity steam which drives the revolving
turbine blades.
3. Discuss the overall arrangement of the major steam flow
components associated with a steam turbine and generator set.
4. Discuss the features of a condenser as a heat exchanger where low
pressure steam condenses on the outside of tubes through which
cooling water flows.
5. Identify key factors associated with start-up of a turbine/generator
set.
6. Discuss the importance of electrical synchronization in connecting a
turbine/generator set to the grid.
7. Identify various possible abnormal turbine generator operating
conditions and the design features which are taken to prevent such
occurrences.
Lesson Time: Approximately 45 minutes
Suggested
Introductory
Question:
1.
Ask operator participants to discuss their experiences and any special
problems associated with bringing a turbine generator system up and
keeping it connected to their utility grid.
28-1
-------
Presentation
Summary
Outline:
Special System Considerations III: Turbine Generator
Impulse Steam Turbine Features
Reactive Steam Turbine Features
Turbine/Generator System Configurations
AC Generator Design & Operational Features
Abnormal Turbine Generator Conditions
Projection
Slides:
See the following pages.
Source of
Graphics:
Slide 28-4
Slide 28-5
Slide 28-6
Slide 28-7
Slide 28-8
Frederick M. Steingress and Harold J. Frost, Stationary Engineering.
American Technical Publishers, Inc., Homewood, IL, 1991, p. 231.
Frederick M. Steingress and Harold J. Frost, Stationary Engineering.
American Technical Publishers, Inc., Homewood, IL, 1991, p. 236.
Adapted from: Kenneth Wark, Jr., Thermodynamics. Fifth Edition,
McGraw Hill Book Company, New York, 1988, p. 739.
Frederick M. Steingress and Harold J. Frost, Stationary Engineering.
American Technical Publishers, Inc., Homewood, IL, 1991, p. 251.
Frederick M. Steingress and Harold J. Frost, Stationary Engineering.
American Technical Publishers, Inc., Homewood, IL, 1991, p. 323.
28-2
-------
Slide 28-1
I
o
ENERGY
RECOVERY/CONVERSION
OPTIONS
Produce and Sell Steam
Produce and Sell Both Steam
& Electricity
Produce and Sell Electricity
-------
Slide 28-2
TURBINE GENERATOR
SYSTEM CONFIGURATIONS
• Steam Turbine
• Electrical Generator
• Condenser, Hotwell, & Air Ejector
• Condensate Pump & Heater
• Deaerator
• Feedwater Pumps & Heaters
-------
Slide 28-3
STEAM TURBINE TYPES &
FEATURES
• Impulse Steam Turbine
• Reaction Steam Turbine
• Impulse-Reaction Steam Turbine
• Multiple Stages
• Conversion of Thermal Energy
• Production of Mechanical Energy
-------
Slide 28^
IMPULSE TURBINE BLADE
CONFIGURATION & FLOW
PARAMETERS
Fixed Blades
Revolving Blades
Second-stage
Nozzle
Second-stage
Revolving
Blades
initial
Steam Pressure
Exit
Steam Pressure
Initial
Steam Velocity
N
I/ I
I L
Steam Vekxaty
Tune
From Frederick M. Sieingrass and Harold J. Frost, Stationary Engineering. American Technical Publishers. Inc.,
Homewood, IL. 1991, printed with permission
-------
Slide 28-5
REACTION TURBINE
CONFIGURATION & FLOW
PARAMETERS
Revolving Blades (2
Fixed Blades M
Fixed Blades
Revolving Blades
Initial
Steam Pressure
Exit
Steam Pressure
Initial
Steam Velocity
Exit
Steam Velocity
Time
"rom Frederick M. Sieingrass and Harold J. Frost. Stationary Engineering. American Technical Publishers, Inc..
Homewood, IL. 1991, printed with permission
-------
Slide 28-6
STEAM GENERATOR
EQUIPMENT & FLOW
SCHEMATIC
Generator
Condenser
Hot
Well
o
o
10
o
Feedwater
Pump
Condensate
Pump
-------
ffi
U
Q
O
u
i
**
I
1
c
u
tu
v
II
•o !=
e ~-
S -
rr
09
C-J
(J
o. r
-------
Slide 28-8
AC GENERATOR
Frame
Rotor
Stator
Slip Rings
Fan
Stator Leads
From Frederick M. Siemgress and Harold J. Frost, fttatipnarv
Homewood, IL. 1991, printed with permission
American Technical Publishers. Inc.,
-------
Slide 28-9
TURBINE GENERATOR
OPERATION
• Cold Start
• Synchronization
• Shut-down
-------
Slide 28-10
GENERATOR
SYNCHRONIZATION WITH
UTILITY GRID
11 1
ABC
A-C
BUSES
SYNCHRONIZING
LAMPS
L3
o-
L2
o
LI
SYNCHROSCOPE
INCOMING
GENERATOR
-------
Slide 28-11
TURBINE GENERATOR
SYNCHRONIZATION
Synchroscope: Phase Angle Meter
• Clockwise Rotation
• Counterclockwise Rotation
• Stationary Indicator
• Indicator Pointing Upward
-------
Slide 28-12
TURBINE GENERATOR
ABNORMAL CONDITIONS
• Water Induction
• Excessive Vibration
• High Bearing Temperatures
• High Back-Pressure
• Speed Control
-------
LESSON PLAN NUMBER 29
RISK MANAGEMENT I: PREVENTIVE MAINTENANCE
Goal: To provide general information about the management of risks as
related to the optimization of operating equipment
Objectives: Upon completion of this unit, an operator should be able to:
1. List four types of economic losses which the owner may sustain
because of major equipment malfunctions.
2. Discuss the general goals of a preventive maintenance program.
3. List typical equipment corrective maintenance which can be
performed while the MWC unit is in service.
4. Discuss the use of maintenance records and operating logs in
identifying the need for equipment maintenance and evaluating the
effectiveness of a preventive maintenance program.
5. Name the various types of personnel who need to be involved in
establishing an annual inspection outage.
6. List example component equipment which could require major
repair (overhaul) during a planned MWC unit outage.
7. Identify the two boiler codes which have relevance for a boiler
inspection.
Lesson Time: Approximately 45 minutes
Suggested
Introductory
Q nestion:
1. Ask operator participants to discuss their experiences with the use of
maintenance records and operating logs in identifying the need for
equipment maintenance and evaluating the effectiveness of a
preventive maintenance program.
29-1
-------
Presentation
Summary
Outline:
Risk Management I: Preventive Maintenance
Potential Economic Losses
Features of Preventive Maintenance
In-Service Maintenance
Outage Maintenance Planning
Projection
Slides:
See the following pages.
29-2
-------
Slide 29-1
RISK MANAGEMENT
PRINCIPLES
1. Achieve A Fair Return
2. Minimize Potential for Losses
-------
Slide 29-2
ASPECTS OF RISK
MANAGEMENT
1. Insurance Against Production &
Casualty Losses
2. Evaluation of Current Conditions
3. Evaluation of Probability
4. Consideration of Economics
5. Consideration of Intangibles
-------
Slide 29-3
POTENTIAL ECONOMIC
LOSSES
1. Cost of Maintenance Program
2. Personal Injury
3. Equipment Repair/Replacement
4. Lost Revenue — Tipping Fees
5. Lost Revenue — Energy Sales
6. Extra Landfill Costs
7. Extra Transportation Costs
8. Fines — Regulatory Violations
9. Contractual Noncompliance Losses
-------
Slide 29-4
OPERATOR
RESPONSIBILITIES
1. Safety
2. Production (System Operations)
3. Preventive Maintenance
4. Corrective Maintenance
5. Record Keeping & Communications
-------
Slide 29-5
GOALS OF PREVENTIVE
MAINTENANCE
1. Minimize Total Operating Costs
2. Enhance Equipment Life
3. Assure Equipment Reliability
4. Restore Unit Performance
5. Minimize Down-Time
-------
Slide 29-6
FEATURES OF A
MAINTENANCE PROGRAM
1. Review Vendor Recommendations
2. Identification of Problems
3. Evaluation of Options
4. Communication & Planning
5. Implementation
-------
Slide 29-7
IN-SERVICE MAINTENANCE
1. Follow Recommended Procedures
2. Know Special Design Features
3. Know Operational Relationships
-------
Slide 29-8
OUTAGE MAINTENANCE
1. Make & Update an Outage Plan
2. Arrange for Materials/Services
3. Make Detailed Inspections
4. Revise Plans as Necessary
5. Follow Proper Procedures
6. Inspect Upon Conclusion
-------
LESSON PLAN NUMBER 30
RISK MANAGEMENT II: SAFETY
Goal: To provide information about the management of risks associated
with general and personal safety.
Objectives: Upon completion of this unit, an operator should be able to:
1. List the general responsibilities of all staff members in the area of
safety.
2. Identify the two major potential hazards of furnace and boiler
systems.
3. List other potential MWC system safety hazards.
4. List six types of personal protection equipment
5. Discuss the general safety issues associated with noise, rotating
equipment, hot metal surfaces and ladders.
6. Discuss special MWC hazards associated with entering a fabric
filter bag house, combustion chamber, or other confined space.
7. Identify special hazards associated with MWC combustion chamber
viewing ports.
8. Discuss the fire safety procedures associated with the pit area.
Lesson Time: Approximately 45 minutes
Suggested
Introductory
Questions:
1. Ask operator participants to discuss their experiences with special
MWC hazards associated with entering a fabric filter bag house,
combustion chamber, or other confined space.
2. Ask operator participants to discuss their experiences with the general
safety issues associated with noise, rotating equipment, hot metal
surfaces and ladders.
30-1
-------
Presentation
Summary
Outline:
Risk Management II: Safety
Operator Responsibilities
MWC System Safety Hazards
Standard Safety Considerations
Personal Protection Equipment
Symptoms of Illness
Projection
Slides:
See the following pages.
30-2
-------
Slide 30-1
GENERAL HEALTH
& SAFETY
1. Recognition of Hazards
2. Consequences of Exposures
3. Standard Safety Procedures
4. Personal Protection Equipment
-------
Slide 30-2
MAJOR HAZARDS OF
OPERATIONAL SYSTEMS
1. Water Side Explosions
Due to Loss of Water
2. Gas Side Explosions
Due to Explosive Mixtures
-------
Slide 30-3
OTHER MWC SYSTEM
SAFETY HAZARDS
1. Exposure to MSW
2. Pit Fires & Explosions
3. Combustion & Boiler Systems
4. Removal of Blockages
5. Observation Hatches/Hopper Doors
6. Operations in Confined Spaces
-------
Slide 30-4
STANDARD SAFETY
CONSIDERATIONS
• Electrical Shock
• Exposure to Corrosives
• Noise & Vibration
• Exposure to Rotary Equipment
• Awkward Access
• Movement of Heavy Objects
• Welding & Metal Forming
• Fire Hazards
-------
Slide 30-5
PERSONAL PROTECTION
EQUIPMENT
1. Ear Protection
2. Heavy Gloves
3. Hard Hat
4. Respirator
5. Goggles
6. Safety Shoes
7. Proper Clothing
-------
Slide 30-6
SYMPTOMS OF ILLNESS
1. Headaches
2. Lightheadedness
3. Dizziness
4. Nausea
5. Loss of Coordination
6. Difficulty in Breathing
7. Chest Pains
8. Exhaustion
-------
TECHNICAL REPORT DATA
(Please read Inttntcitonj on Ike reverie before completing)
T. REPORT NO.
EPA-453/B-93-021
3. RECIPIENT'S ACCESSION NO.
4. TITLE ANO SUBTITLE
Municipal Waste Combustor Operator Training Program
Instructor's Guide
5. REPORT DATE
April 1993
B. PERFORMING ORGANIZATION CODE
7. AUTHORIS)
J. Taylor Beard, W. Steven Lanier, and Suh Y. Lee
I. PERFORMING ORGANIZATION RE?
[^PERFORMING ORGANIZATION NAME ANO ADDRESS
I Energy & Environmental Research Corporation
18 Mason Lane
Irvine, CA 92718
10. PROGRAM ELEMENT NO.
TT CONf RACT/GRANf NO.
68-CO-0094
13. SPONSORING AGENCY NAME AND ADDRESS
DAA for Office of Air Quality Planning and Standards
Office of Air and Radiation
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
14. SPONSORING AGENCY CODE
200/04
IS. SUPPLEMENTARY NOTES
Michael G. Johnston, EPA/Office of Air Quality Planning and Standards
"16. ABSTRACT
The Instructor's Guide, along with the Course Manual (EPA-453/B-93-020) ,
constitute a model State training program to address the training needs of
municipal waste combustor (MWC) operators. The training program focuses on
the knowledge required by operators for understanding the basis for proper
operation and maintenance of MWC's with particular emphasis on the aspects of
combustion which are important for environmental control. The training
program includes general introductory material relative to municipal solid
waste (MSW) treatment and MSW as a fuel. The bulk of the program addresses
the principles of good combustion. The potential sources of air pollution
emissions and their control are discussed. Instrumentation, automatic control
systems, control room operations and practices, and the troubleshooting of
upsets are presented. Special system considerations are included: water
treatment, electrical theory, and turbines and generators. Finally, risk
management procedures such as preventive maintenance and safety considerations
are addressed.
The training program fulfills the requirements of the Clean Air Act of
1990, as amended, for the development of a model State training program.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS
Municipal Waste Combustors
Operator Training
Incinerators
MB. DISTRIBUTION STATEMENT
I Release Limited
Air Pollution Control
19. SECURITY CLASS iThit Report/
Unclassified
20. SECURITY CLASS I This page i
Unclassified
13B
21 NO. OF PAGS
589
22. PRICE
f PA for*. 2220-1 («•». 4-77) PREVIOUS
KOiT'ON 'S OBSOLETE
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