WATER POLLUTION CONTROL RESEARCH SERIES • 17070 EBP 07/71
      COMPUTERIZED DESIGN AND
COST ESTIMATION FOR MULTIPLE-HEARTH
          SLUDGE INCINERATORS
U.S. ENVIRONMENTAL PROTECTION AGENCY

-------
            WATER POLLUTION CONTROL RESEARCH SERIES

The Water Pollution Control Research Series describes the
results and progress in the control and abatement of pollution
in our Nation's waters.  They provide a central source of
information on the research, development, and demonstration
activities in the water research program of the Environmental
Protection Agency, through inhouse research and grants and
contracts with Federal, State, and local agencies, research
institutions, and industrial organizations.

Inquiries pertaining to Water Pollution Control Research
Reports should be directed to the Chief, Publications Branch
(Water), Research Information Division, R&M, Environmental
Protection Agency, Washington, B.C. 20460.

-------
            COMPUTERIZED DESIGN AND COST ESTIMATION
            FOR MULTIPLE-HEARTH SLUDGE  INCINERATORS
                               by
                        Dr.  W.  Unterberg
                         R.  J.  Sherwood
                      Dr.  G.  R. Schneider
Rocketdyne,  A Division of North American Rockwell Corporation
                Canoga  Park,  California   91304
                             for the

               Office of Research and Monitoring

                ENVIRONMENTAL PROTECTION AGENCY
                      Project  #17070 EBP
                      Contract #14-12-547
                           July 1971
       For sale by the Superintendent of Documents, U.S. Government Printing Office
                  Washington, B.C., 20402 - Price $1.50

-------
                       EPA REVIEW NOTICE
This report has been reviewed by the Environmental Protection
Agency and approved for publication.  Approval does not signify
that the contents necessarily reflect the views and policies of
the Environmental Protection Agency, nor does mention of trade
names or commercial products constitute endorsement or recom-
mentation for use.
                              ii

-------
                            ABSTRACT
A digital subroutine was developed for the preliminary design and
cost estimation of an optimum multiple-hearth-furnace system for
sewage sludge incineration.  The subroutine provides the dimensions
and ratings of incinerator components; the requirements for auxiliary
fuel, power and labor; and all cost elements for the incineration
system.  The computer subroutine may also be used for the thermal
analysis of an existing or planned incinerator without optimization
and cost features.

The subroutine was primarily based on field data from nine operating
municipal incineration plants, each having from one to four furnaces.
The ranges of the furnace variables were 200 to 4500 Ib dry solids per
hour, 5 to 11 hearths, 6.0 to 22.25 -ft diameter, and 85 to 2327 sq ft
hearth area.  Operating schedules and thermal cycling were considered,
together with their influence on effective capacity, hearth replace-
ment, and fuel consumption.  Field data were correlated with the
principal furnace parameters, and costs were normalized to 1969
dollars.  Where possible, "non-dollar" expenditures, such as man-
hours, pounds of fuel and kilowatt-hours, were established.  Unit
costs were then used to convert all non-dollar expenditures to
dollars and hence to extract an annual total incinerator cost and a
cost per ton of dry solids.  A user's guide to input selection and
numerical examples are included.

This report was submitted in fulfillment of Project Number 17070 EBP,
Contract 14-12-547, under the sponsorship of the Environmental
Protection Agency.
                               111

-------
                             CONTENTS
SECTION
ABSTRACT
  I
  II
  III
  IV
  V
  VI
CONCLUSION AND RECOMMENDATIONS
INTRODUCTION
MHF SLUDGE INCINERATION SYSTEM
  Description and Operation
  Economics
  System Definition and Cost Components
THERMAL ANALYSIS
  Sludge Combustion and Reactions of Chemical
    Additives
  Heat Balance
  Auxiliary Burner Selection
  Exhaust Gas Composition
  Scrubber Water for Exhaust Gas Saturation
DATA ACQUISITION
  Data Requirements
  Field Data
DATA REDUCTION AND CORRELATION
  Economic Indicators and Labor Rates
  Incinerator Capacity
  Installed MHF Capital Cost
  Cooling Air Fans and Combustion Air Blowers
  Exhaust Gas Scrubbers and Precoolers
  Building Cost
  Engineering Fee
  Land Cost
  Hearth Replacement Material, Labor, and
    Frequency
  Normal Maintenance Material and Labor
  Operating Labor
PAGE
iii
  1
  3
  5
  5
 10
 11
 13

 13
 16
 18
 19
 20
 23
 23
 24
 39
 39
 42
 46
 49
 53
 53
 53
 53
                                                                  61
                                                                  62
                                 v

-------
                                                               FAG:
VI      DATA REDUCTION AND CORRELATION (Continued)
          Electrical Power Consumption
          Thermal Cycling: Yearly Hours
          Thermal Cycling: Heat and Fuel Requirements
          Total MHF Heat Release
VII     DESCRIPTION OF SUBROUTINE
          Subroutine Options
          Ground Rules
          Computations
VIII    USER'S GUIDE TO INPUT SELECTION
          Information Input
          MHF Data Input
          Sludge Stream Input
          Air Data and Stream Temperature Input
          Chemical Reaction Input
          Auxiliary Fuel Burner Input
          Environment Input
          Financial Input
          MHF Selection Input
IX      USE OF SUBROUTINE
          Input Format
          Fortran Program
          Numerical Examples
X       ACKNOWLEDGEMENTS
XI      REFERENCES
XII     GLOSSARY
XIII    APPENDIX: FORTRAN IV LISTING
 68
 63
 76
 76
 83
 83
 86
 87
 95
 95
 95
 95
 97
 98
 98
 99
100
101
103
103
111
112
125
127
131
1ST

-------
                              FIGURES

                                                               PAGE
 1     MULTIPLE HEARTH INCINERATOR-TYPICAL SECTION               6
 2     MHF FLOW AND EQUIPMENT DIAGRAM                            7
 3     MHF DESIGN CAPACITY VS MHF SIZE                          44
 4     MHF INSTALLED CAPITAL COST                               48
 5     COOLING AND COMBUSTION AIR: HORSEPOWER VS WET
         SLUDGE RATE                                            51
 6     COOLING AND COMBUSTION AIR: AIR FLOW VS HORSEPOWER       52
 7     ENGINEERING FEE STRUCTURE                                56
 8     COST OF NORMAL MAINTENANCE PARTS AND SUPPLIES            64
 9     NORMAL MAINTENANCE LABOR                                 65
10     OPERATING LABOR                                          67
11     POWER CONSUMPTION                                        70
12     MHF HEATUP TIME                                          73
13     ASSUMED MHF THERMAL CYCLES                               74
14     MHF STANDBY HEAT REQUIREMENT                             78
15     MHF HEATUP HEAT REQUIREMENT                              79
16     SCHEMATIC OF THERMAL ANALYSIS OPTION (NCASE = 0)         84
17     SCHEMATIC OF THERMAL ANALYSIS AND COST OPTION
          (NCASE > 0)                                            85
18     COMPUTATION A: MHF DESIGN AND OPERATION OUTPUT
          (SHEET 1 OF 3)                                         88
19     COMPUTATION A: MHF DESIGN AND OPERATION OUTPUT
          (SHEET 2 OF 3)                                         89
                                vn

-------
                             TABLES

NO.                                                            PAGE
 1     Summary of MHF Sewage Sludge Incinerators                 26
 2     Summary of Steady State Operation per MHF
         (Annual Averages)                                       27
 3     MHF Air, Ash and Gas Temperatures                         29
 4     MHF Hearth Temperatures                                   30
 5     MHF Air Sources                                           31
 6     Maintenance Log for Minnaapolis-St. Paul from
         Annual Reports 1951-1965                                32-7
 7     Summary of Economic Indicators for Capital
         Equipment and Materials                                 40
 8     Summary of Economic Indicators for Labor                  41
 9     Standard Sizes of Multiple-Hearth Furnace Units           45
10     MHF Installed Capital Cost                                47
11     Cooling Air Fans and Combustion Air Blowers               50
12     Exhaust Gas Scrubbers and Precoolers                      54
13     Engineering Fee Structure                                 55
14     MHF Land Area                                             57
15     Hearth Replacement Material and Labor                     59
16     15 Years Hearth Replacement History: Three
         Minneapolis-St. Paul MHF's                              60
17     Yearly Normal Maintenance Material and Labor              63
18     Operating Labor                                           66
19     Electrical Power Consumption                              69
20     MHF Heatup Rates and Times                                72
21     Yearly Cold, Heatup, and Standby Hours per MHF            75
22     Thermal Cycling Heat Requirements per MHF                 77
23     Total MHF Heat Release                                    81
24     Computation A: MHF Design and Operation Output
         (Sheet 3 of 3)                                          90
25     Computation C: Non-Dollar Output per MHF                  92
26     Computation D: Cost Output, Dollars                       93-4
                              viii

-------
               I.  CONCLUSIONS AND RECOMMENDATIONS
CONCLUSIONS
1.  A digital computer subroutine for multiple-hearth furnace sewage
    sludge incineration, suitable for inclusion in the WQO/EPA
    Executive Program for design and cost of the entire wastewater
    treatment systems, has been prepared.  It realistically considers
    and models the furnace operating schedule, thermal cycling, hearth
    replacement schedule, standby capacity, etc., as well as the more
    usual«technical and financial relationships.

2.  In-depth data from field visits to furnaces of various sizes with
    preferably lengthy and well-documented operating histories have
    proven essential in providing needed information for modeling.

3.  This model should remain useful for some time to come - it allows
    for ^updating of specific functional relationships, numerical coef-
    ficients and economic indicators as more and better data become
    available.
RECOMMENDATIONS
1.  To assist in updating this model, additional and/or more reliable
    data should be generated, e.g., in the following areas: effect of
    thermal cycling on life of hearths and other components; extent
    to Xtfhich dewatering chemicals in the sludge undergo chemical reac-
    tion in the furnace; analyses of stack and scrubber gases; and
    effect of automation on maintenance and required labor.

2.  This model should be kept up-to-date by incorporation of additional
    and/or more reliable data.  It should be used for preliminary design
    and its predictions compared with actual performance and costs.

3.  Basic combustion research should be carried out to ascertain the
    controlling mechanisms in MHF sewage sludge incinerators for the
    purpose of (a) improving their efficiency, e.g., in terms of
    increasing the hearth loading (in Ib per hr per sq ft), and
    (b) even more important, establishing reliable design and operating
    criteria for minimizing air pollutants in the exhaust gases.
    Knowledge in these areas would greatly improve both the technology
    and the usefulness of the mathematical model.

-------
                        II.  INTRODUCTION
The Water Quality Office of the EPA (formerly Federal Water Quality
Administration) has developed an Executive Digital Computer Program
(Ref. 1) as a tool for the process designer and water resource
planner.  This program contains the logic to compute the cost and
performance of any group of wastewater treatment processes arranged
in any configuration including recycle streams.  Models for individual
processes are each represented in the executive program by subroutines.
Models for about 15 individual processes have so far been developed.

One of the most important treatment areas is the ultimate disposal of
the wastewater concentrate, or sewage sludge, to the environment.
Incineration of the sewage sludge is an important ultimate disposal
process.  The overall aim of this effort was to develop a subroutine
for the multiple-hearth-furnace incineration of sewage sludge.  This
subroutine x^as to be suitable for integration into the Executive
Program.

The specific objectives for the subroutine were taken to be:

1.  Optimize design and operation for a multiple-hearth-furnace
    sewage sludge incineration system as part of an entire x\rastewater
    treatment plant, existing or planned.

2.  For the optimum system, provide a breakdown in expenditures by
    "non-dollar" categories (man-hours, kilowatt-hours, etc.), and
    money  (capital cost, total annual cost, cost per ton dry  solids)
    in 1969 dollars.

3.  Write  the subroutine program in the Fortran computer language
    such that it is capable of being fitted into the Executive
    Program, occupying a place between sludge dewatering and  ash
    disposal processes.

The approach taken toward meeting the stated objectives of the program
consisted  of combining the rational engineering analysis of the
various physical phenomena occurring in the multiple-hearth furnace
with design, operational, and economic data obtained from field visits
to operating installations varying in size and capacity.  Special
attention was to be paid to the realistic modeling of operating and
maintenance schedules of multiple-hearth furnaces (MHF's) where such
data were available because of their effect on costs.

Chapter III, which follows, discusses existing literature on  MHF
Sludge Incineration Systems from the standpoints of operation and
economics, and defines the system to be modeled.  Chapter IV  is
devoted to the Thermal Analysis of MHF Incineration, based on

-------
material and energy balances combined with technical requirements.
Chapter V describes Data Acquisition from nine field visits and other
sources.  Chapter VI contains the complete compilation of tables and
figures generated in the process of Data Reduction and Correlation.
Chapter VII is a Description of the Subroutine, with inputs, outputs,
and the calculation scheme.  Chapter VIII is the User's Guide to Input
Selection, in which the factors affecting selection of each input are
discussed, including also a standard set of inputs.  Chapter IX, Use
of Subroutine, explains the input format and presents numerical
examples in the form of printouts of inputs and outputs.  Chapters X,
XI, and XII contain Acknowledgements, References, and Glossary.  The
Appendix contains the Fortran IV listing  of the subroutine.

-------
              III.  MHF SLUDGE INCINERATION SYSTEM
DESCRIPTION AND OPERATION
Rabbled-hearth furnaces have been in use for nearly a century, initi-
ally for roasting ores.  The present air-cooled multiple-hearth fur-
nace (MHF) is essentially the Herreshoff design of 188y,  It has been
used for sewage sludge incineration since the 1^30's.  The multiple-
hearth furnace is a unique combustion device.  Unlike other frrnaces
designed for the combustion of solid waste materials, this furnace
employs no open burning grates.  Furthermore, unlike most incinerators,
the combustion zone is in the central part of the vertical furnace
structure and not outside in another connecting chamber.  The advan-
tages of the MHF include simplicity, ease of control, flexibility of
operation and durability.

A typical section through a multiple-hearth furnace is illustrated in
Fig. 1 taken from Burd (Ref. 2).  A typical incineration system com-
prising the furnace and ancillary equipment is diagrammed in Fig. 2.
The furnace proper consists of a number of annular hearths stacked
horizontally at fixed distances one above the other inside a refractory-
lined, vertical, cylindrical steel shell.  A centrally located cast iron
shaft which runs the full height of the furnace supports cantilevered
rabble arms (2 or 4) above each hearth.  Each arm contains several
rabble teeth which rake sludge spirally across the hearth below the
arms as the latter rotate with the central shaft.  The sewage sludge
(dewatered to about 25 percent solids) is fed in at the periphery of
the top hearth (IN-hear'h) and raked by the rabble teeth towards the
center to an opening through which it falls to the next hearth (OUT-
hearth).  On this hearth, the sludge is raked outward to the periphery
where it drops to the next IN-hearth below.  This in-out process is
continued on down the furnace.  Thus, the sludge and gas streams move
counter-current to one another, the sludge passing down the furnace
and finally turning into ash, while the combustion air flows over
each hearth as it moves upward, finally exiting as flue gas at the
top hearth.

Combustion air generally is of three kinds: (1) recycled cooling air
which has traveled up through the hollow central shaft and is then, in
part, ducted to the bottom hearth, as shown in Figs. 1 and 2; (2) ambient
air from a blower, usually located at a central hearth in conjunction
with auxiliary fuel burners (Fig. 2); and (3) ambient air admitted
through adjustable ports and doors at various points into the furnace
which is slightly below atmospheric pressure because of the induced
draft (Fig. 2).

-------
                                          COOLING AIR DISCHARGE

                                             FLOATING  DAMPER

                                                       SLUDGE INLET
FLUZ  GASZS OUT
RADBLE AR:.;
AT EACH HEARTH
  DRYING ZOXZ
  COMBUSTION
      ZONE
  COOLING ZOMZ
           ASH
       D! S C H A P> G Z
-RABBLE ARM
    DRIVE
                               'COOLING AIR FAN
                               FIGURE 1

                           TYPICAL  SECTION
                        MULTIPLE  HEARTH
                            INCINERATOR
     (from Third:  "Sludge Handling and Disposal,"  FWTCA Report WP-20-'i)

-------
Wet


S ludcc
In
Recycled
Cooling A

-•»•
Conveyor*


i
ir
Coo
Air
Fan
Tl
i



Central
Shaft

W-

ling (c
From V ^
^
j
t
'J.
Rejected Cooling Air Scrubber 1
Exit Gas T
MHF Exhaust Gas
	 1

-

~
•«•-



f Ash
Disc
^ 1 /^ Induced
"I f O 1 Draft Fan*
PrecoolpT- f / \
Water
Auxiliary Scrubber
•» . r"'l 1 P 1 ^^^•"•— *" ^>^>
Pre- Wet Water

s*^\ X

bustion Air from Blower* \. /
and Adjustable Ports and ] f
Doors | [
Drain for
barge Scrubber and
Prec'ooler
 * Electric Motor Drive
** Pump with Motor Drive
FIG. 2.  MHF FLOW AND EQUIPMENT DIAGRAM

-------
Isheim (Ref. 3) has given details of the materials and methods of
present-day MHF construction.  Of particular interest are the design
features at the points of maximum temperature in the central hearths.
To permit temperatures up to 2000 F, rabble arms and teeth are cast
of a nickel-chrome alloy, and the vertical furnace wall is provided
with a 13.5 in. thickness of insulation.  This is made up of 4.5 in.
firebrick next to the combustion zone, followed by .9 in. block type
insulation next to the outer steel shell.

The effect of rabbling is continually to "plow up" the solids and
break up lumps of material to expose more surface on each hearth to
heat and oxygen.  In this way, drying, combustion and heat exchange
occur at high rates.  Owen (Ref. 4) has suggested that the incinerator
be divided into three zones (indicated in Fig. 1):


Zone 1 - Sludge Drying

Sludge containing approximately 75 percent water is fed to.the top
hearth, to be heated and dried by the exhaust gases.  The gases are,
in turn, cooled to temperatures ranging from 500 F to 1200 F (800 F
typical) as they pick up moisture and leave the furnace.  The actual
exit temperature depends upon the moisture and calorific value of the
sludge as well as the amount of additional fuel used.  In general, the
wetter the feed, the lower the gas outlet temperature, and the cleaner
the exhaust gas (Harris, Ref. 5).  Owen (Ref. 4) collected data on
sludge in Zone 1, finding that its temperature generally did not exceed
160 F  (wet bulb temperature) and its moisture content did not fall belo
about 48 percent water.  However, cake with this moisture content does
ignite as it is contacted by upflowing oxidizing gases at 1400 F
("thermal jump").


Zone 2 - Sludge Combustion

After ignition, the volatile solid matter is burnt in a high-temperatur
zone, usually in the 1400 to 1600 F range.  This has been found adequat
to destroy odors.  The major portion of the fixed carbon is burnt in th
lower hearths of the combustion zone after the volatiles have been in-
cinerated.  Excess air, typically 50 to 100 percent over theoretical,
is required to maintain combustion temperatures in the 1400 to 1600 F
range.  The excess air also promotes complete combustion and a clean
exhaust.


Zone 3 - Ash Cooling

On the lower hearths of the furnace, the descending hot ashes are
cooled as the rising combustion air is heated.  The ash discharge
temperature will always exceed that of the entering combustion air,
be it ambient or recycled cooling air.

-------
Generally, the heat of combustion of sewage sludge lies near 10,000 Btu
per pound of volatile solids.  Whether or not additional fuel will be
needed for incineration depends mainly on (1) the amount of water left
in the sludge after vacuum or mechanical filtration, (2) any filtration
aid used (quantity and compound, e.g., lime and ferric chloride, or some
polyelectrolyte), and (3) whether the sludge is raw or has undergone
anaerobic digestion (which converts some of the combustible solids to
C02 and CH^).  Generally, sludge is autogenous when the solids content
exceeds some 25 to 30 percent, with a volatile content (in the solids)
about 70 percent.  If added energy is required, auxiliary gas, oil, or
grease burners located at central hearths (Zone 2) are used, with an
independent ambient air supply from a blower.

Exhaust gases from the multiple hearth sludge incinerator are practi-
cally free from odors and need not be raised to 1400 F in an after-
burner to destroy odors (Sawyer and Kahn, Ref. 6).  The reason for
this is that the odor-producing compounds are not distilled from the
sludge on the top hearths (Harris, Ref. 5).° Distillation of volatiles
from sludge containing 75 percent moisture does not occur until 80-90
percent of the water has been driven off and by this time presumably
the sludge is down far enough in the incinerator to encounter gases
hot enough to burn the volatiles.

The size of MHF's used for sewage sludge incineration varies typically
from small 6-hearth, 6 ft outer dia (O.D.) units with 85 sq ft total
effective hearth area to 12-hearth, 22.25 ft O.D. units with over 3100
sq ft hearth area.  Sebastian and Cardinal (Ref. 7) give a table of
standard furnace sizes, with hearth areas, to cover the above-mentioned
range.  When sizing incinerators, a hearth loading, or burning rate, in
the range of 7 to 12 Ib wet sludge per hr per sq ft hearth area, is
usual.  The central shaft turns at a few rpm, and the rabbling is so
arranged that a sludge depth of an inch or so exists at the design
sludge flow, for good operation.

An important factor in MHF operation is the pollutants in the flue gas.
It should be realized that, with the typical values cited previously,
100 Ib of wet sludge may require some 300 Ib of combustion air  (without
auxiliary fuel).  The outflow from the incinerator is then the very
desirable small amount of 10 Ib ash combined with 390 Ib of flue gas.
In order to prevent a water pollution problem from turning into an air
pollution problem, it is important to reduce unburned hydrocarbons,
oxides of nitrogen and particulates to an absolute minimum in the
exhaust gases.  Incinerator emissions and their treatment are treated
in the book edited by Corey  (Ref. 8) and an article by Niessen and
Sarofim (Ref. 9).  The latter present data on the incinerator residence
time required to cut down combustible particulates, as a function of
temperature and oxygen concentration.

The provision of wet scrubbers, often preceded by pre-coolers,  to
remove particulates from exhaust gases is quite standard nowadays,
see Fig. 2.  Two factors must then be considered: disposal of scrubber

-------
water, and formation of steam plumes.  If the hydraulic method of ash
disposal is used, the ash is mixed with water from the scrubber, and
after thorough agitation, the mixture is pumped as an ash slurry to
a lagoon.  Otherwise, Kalika (Ref. 10) describes designs for scrubber
water recirculation, with particle collection by settling.  He also
gives the conditions for formation of steam plumes, primarily an
esthetic problem, in terms of temperature and humidity ratio of the
scrubbed gas.
ECONOMICS
The economics of MHF sewage sludge incineration have heretofore been
studied mainly from an overall cost standpoint.  Lacking adequate data,
Smith  (Ref. 11) estimated total annual cost, capital cost and combined
operating and maintenance cost - all in terms of one variable, the ary
solids incineration rate.  The capital cost estimate was for a rotating-
hearth furnace, and the other costs for an unspecified type of furnace.
Burd (Ref. 2) quoted a manufacturer's brochure which gave MHF costs
based  on the size of the population served, and translated this into
a total annual cost per ton of dry solids.  MacLaren (Ref. 12) made
an MHF estimate of a similar nature.  Recently, two FWQA-sponsored cost
studies have been completed on sewage sludge incineration by fluidized-
bed furnaces (Refs. 13 and 14), but this type of furnace is physically
quite  different from the multiple-hearth.

Studies of MHF sludge incineration have been made for specific commun-
ities.  Sebastian and Cardinal (Ref. 7) presented costs for city popu-
lation equivalents ranging from 10,000 to 1 million (dry solids varying
from 360 to 36,000 per annum).  Quirk (Ref. 15) developed costs for a
city of 100,000 (2530 tons of dry solids per annum) in some detail.
Weller and Condon (Ref. 16) discussed MHF selection factors and their
application to Kansas City, Missouri (average dry solids 30,400 tons
per annum).  Mick and Linsley (Ref. 17) compared actual performance
and cost data for the year 1955 in four cities covering a range in
population from 1/2 to 2 million (Buffalo, Cleveland, Detroit, and
Minneapolis-St. Paul).  The range in dry solids was from 7,242 to
84,290 tons per annum.  Mick and Linsley pointed out the difficulties
of securing good operation at all times and presented some of the
practical considerations.

Burd (Ref. 2) has stated that a general literature review, presumably
based  on the references cited above, yielded a range in MHF incinera-
tion costs of $8 to $40 per ton of dry solids, exclusive of dewatering
or ash disposal.  Twenty dollars per dry ton was cited as an average.
The trend seemed to be towards a lower cost per dry ton as plant
capacity increased.
                                10

-------
The Committee on Municipal Refuse Practices  of .the American  Society
of'Civil Engineers  (Ref. 18) listed  the  parameters which  generally
influence.the- cost  of'incineration.  These included,  in addition  to
technical-and cost  factors, the design and operational factors  listed
below?

    .1.  Skill of operating labor., their-productivity, and
        operating schedule
    2.  .Management  competence
    3.. Record keeping procedures
    4.  Extent 'of standby facilities'built in

It is.certainly an  aim of this study'to  incorporate  quantitatively the
effects-of operating schedule and standby facilities  (1.  and 4. above).
SYSTEM DEFINITION AND  COST  COMPONENTS
The system which  forms  the  subject  of  this  model  comprises  only  the
components of  the MHF incinerator proper, as  shown schematically in
the MHF Flow Diagram of-Fig.  2'.  This-includes  the hearths  (consisting
of castings and refractory);  central shaft  with rabble  arms and  teeth;
fans  and blowers  for introducing cooling, combustion  and  auxiliary air;
auxiliary fuel burner;  precooler and scrubber for exit  gases, with water
pump  and induced  draft  fan;  the various  electric  motor  drives; and
associated instrumentation  and controls.

Occupying a place between sludge dewatering and ash disposal processes,
the MHF Incineration System includes '.(!)• a  conveyor for the incoming
sludge, but none  of  the dewatering  equipment  upstream,  (2)  ash discharge
duct, but none .of the ash slurrying or disposal components  downstream,
and  (3) s.crubber  gas exit duct (with induced  draft fan),  but no  high
-stack for gas  discharge.  ~The expenditures  of fuel, power,  and labor
are only those associated .with the  system components  as here defined.
The incinerator building, the engineering fee and the land  occupied by
the system are optional capital cost components which the user may
elect to include.

The-cost components  which the model is to compute .for the system above
will-  consist of capital and total costs  which may be  summarized  as
follows:

    Total Capital Cost

        broken down  into:  Installed Capital  Equipment
                            Building -  optional
                            Engineering. Fee  .-  optional
                            Land - optional
                                 11

-------
Total Cost, per Year and per Ton Dry Solids

    broken down into:   Total Capital Charges
                       Replacement Parts (Hearths)
                       Materials and Supplies  (Normal Maintenance)
                       Fuel
                       Power
                       Labor:   Operating
                               Replacement Maintenance
                               Normal Maintenance
                           12

-------
                       IV.  THERMAL ANALYSIS
The previous Chapter has described the functioning of MHF sewage
sludge incinerators.  The desired conversion of wet sludge to ash plus
exhaust gases is only feasible if sufficient heat can be generated to
evaporate the water (typically 75 w/o in the sludge) and burn the
resulting dried sludge.  The known quantities are usually (1) the sludge
composition and properties (including the heat value of the volatiles);
(2) the desired temperatures of the exit streams (ash, gases, cooling
air) for satisfactory operation; and (3) the desired minimum percent
excess combustion air.  The heat and mass balances for the steady-state
thermodynamic system represented by the furnace (Fig. 2) can then be
combined with the stoichiometry of the combustion of sludge volatiles
and any other chemical reactions occurring (such as calcination of any
calcium carbonate in the sludge) to solve for the unknowns.

The unknowns include  (1) actual percent excess air for combustion of
volatiles and the corresponding air flow required, (2) any additional
heat required from an auxiliary fuel burner, (3) the resulting burner
fuel and air flows, (4) the exhaust gas composition, and (5) the
resulting scrubber water requirements, if any, to saturate the exhaust
gases.  The equations and procedures from which the unknowns are calcu-
lated are presented in this Chapter.

Description of each of the terms in all of the equations would unduly
lengthen this Chapter and interrupt the continuity of the development.
Consequently, the bulk of the nomenclature is included in the Glossary
(Chapter XII) and only essential terms are explained in the text.  It
is strongly recommended that the reader reproduce the pages in the
Glossary to avoid the need for constantly turning pages.

The Thermal Analysis option of the computer subroutine is described in
Chapter VII and the Fortran listing appears in the Appendix.
SLUDGE COMBUSTION AND REACTIONS OF CHEMICAL ADDITIVES
It is assumed that the incoming sludge stream from the dewatering
device immediately ahead of the incinerator has a known composition
in terms of the reactive solids, i.e., sludge and chemical additives.
With an ultimate sludge analysis in terms of elemental C, H, 0, N,
and S and a sludge heat value  (higher calorific value) determined in
a bomb calorimeter, the equilibrium combustion products composition at
a specified volatile/air mixture ratio and initial temperature and
pressure can be found by minimizing the free energy of the system.
In the most general (high-temperature) case, hundreds of compounds
may form because of dissociation effects.
                                 13

-------
In the present case, no adiabatic flame temperatures above 2000 F were
considered, nor any rich mixture ratios.  For stoichiometric and lean
mixtures (excess air), then, the sludge air combustion products were
taken to be C02, H20, S02, N£, and 02.  The initial conditions are
at sludge temperature (taken as datum) and 1 atmosphere pressure.  All
combustion and chemical reactions take place at one atmosphere.  All
calculations refer to one MHF.  The Glossary (Chapter XII) defines all
symbols used.

The theoretical (stoichiometric) oxygen flow (Ib/hr) is then


       P(32S - PVGJL   [FRV0(1)-3niW(3) + FRV0(2).SPM
       P02S - PV0L   ELMW(1).SPMWU; + ELMW(2)   2
where

       PV0L  =  (PSLU) (PERV) (PERS) 710,000                       (2)
With the specified minimum excess percentage (PXAIR) , the total  air
flow (Ib/hr) is
where 0.233 is the weight fraction of oxygen in air

Knowing the fraction of cooling air recycled (FRAIR) and the  total
cooling air flow in standard cu ft per hr (SCFCL) then gives  the
ambient combustion air to be supplied by the combustion air blower  as

       PAIRA = PAIRT - PAIRS                                      (4)

where

       PAIRS = 28.84 (SCFCL (FRAIR) /379                          (5)

where 28.84 is the molecular weight of air, 379 is the volume in
cu  ft of  1 Ib-mole of gas at 60 F and one atmosphere.

Allowance was made for three types of chemical additives in the
dewatering process, namely, lime  (calcium monoxide CaO or  calcium
hydroxide, Ca(OH)2), ferric chloride (anhydrous Feds or FeCl3«6H20
crystal)  and alum  (aluminum sulfate, Al2(S04) 3'14H20) .  The reaction
of  these  additives with the sludge produces calcium carbonate CaC03 ,
ferric hydroxide Fe(OH)3, and aluminum hydroxide A1(OH)3.  It was
assumed that the concentrations of these compounds in the  incoming
                                 14

-------
sludge stream are known from the previous  process  step  (sludge
dewatering) .  In the incinerator,  these  compounds  undergo endothermic
reactions according to the following  equations  (heats of  reaction from
Refs. 19 and 20) :

       CaC03 +. X(761 Btu/lb CaCO ) =  X CaO(s) + XCC>2 +  (1-X)  CaC03 (6)


       Fe(OH)  + Y(225 Btu/lb Fe(OH),) = 1.5Y HO  + 0.5Y  FeJD (s)
             J                      J          L           I  5
                                                                    (7()
                       Fe(OH)3
       Al(O'H)  + Z(380.8 Btu/lb Al(OH)  )  =  1.5Z  HO  + 0.5Z Al 0 (s)
             j                         J          ;            Z J   (g)
               + (1-Z) A1(OH)3
.where
       X  =  FCAC is fraction  CaCO,.  decomposed

       Y  =  FFE is fraction Fe(OH)   decomposed

       Z  =  FAL is fraction Al(OH)   decomposed

Considering the combustion  of  the  sludge and  the reactions of the
chemicals, the flowrates  of gaseous  products  (excluding contributions
from auxiliary fuel combustion and initial sludge water)  are:

            , (Ib C00/hr) = (PV0L-FRV0(1)'SPMW(1)/ELMW(1))
                 '  2                                               (9)
                          + (44.011  FCAC.  PCAC. PS0L/10,008)
       WS(2),  (Ib H20/hr)  =  (PV0L.  FRV0(2)-SPMW(2)/ELMW(2))

                           +  (27  PFEHY.  FFE.  PS"0L/10,687)
                                                                    (10)
                           +  (27  PALHY.  FAL.  PS0L/7800.3)
       WS(3),  (Ib 02/hr)  = P02S.  PXAIR/100                         (11)


       WS(4),  (Ib N_/hr)  =  (PV0L.  FRV0(4).  SPMW(4)/ELMW(4))
                                                                    (12)
                          +  (0.767.  PAIRT)

where 0.767 is the weight fraction of  nitrogen in air
                                 15

-------
       WS(5), (Ib S02/hr) = PV0L. FRV0(5). SPMW(5)/ELMW(5).      (13)

where

       PS0L = PERS. PSLU/100                                     (14)

       PERW = 100-PERS                                           (15)


HEAT BALANCE


The total heat supplied (QIN) comes from three sources: heat  from
combustion of the volatiles (QV0LT), heat from the recycled shaft
cooling air (QARIN), and heat from the incoming ambient air  (QAMBA),
assumed to be above sludge temperature, the datum.  All gaseous  (low
pressure) specific heats were taken as functions of T from Ref.  21.

       QIN = QV0LT + QARIN + QAMBA.                              (16)

where

       QV0LT = QV0L . PV0L.                                      (17)

                        >.TAIRI
       QARIN = PAIRS   /       CPA.dT                            (18)
                       TSLI
                             -TAMB
       QAMBA = PAIRA        /        CPA.dT.                      (19)
                            TSLI
The total heat required (QREQ) to raise the combustion products  to
TEX and the ash to TASK is made up of eight components, as shown below
(all in Btu/hr) :

       QREQ = HASH + HWSL + QC00L + QCAL + QFE + QALHY
                                                                 (20)
              + QTRAN + QSEN.

where

       HASH = PASH. CPASH (TASK - TSLI)                          (21)

       PASH = PS0L (100-PERV)/100                                (22)

       HWSL = HWSEN + HWVAP + HWGAS.                             /23)
                                16

-------
where
       HWSEN = PWAT. CPWAT (212-TSLI)
       PWAT - PSLU  (100-PERS)/100
       HWVAP =970 PWAT
                          /EX
       HWGAS = PWAT.    I      CPS.dT
                       212
                                             TAIRI
       QC00L (total cooling air) = PAIRC    /      CPA.dT
                                            TAMB
       PAIRC = 28.84 SCFCL/379
       QCAL = 761 PCAC. PS0L. FCAC/100
       QFE = 225 PFEHY. PS0L. FFE/100
       QALHY = 380.8 PALHY. PS0L. FAL/100
       QTRAN = (HR + HC)  (TSUR - TAMB) SAREA
                                  (24)
                                  (25)
                                  (26)

                                  (27)


                                  (28)

                                  (29)
                                  (30)
                                  (31)
                                  (32)
                                  (33)
       HR (Ref. 22) = 0.1713
fTSUR + 460
     100
riAMB + 460
     100
                         ^;TSUR-TAMB)
                                (34)
       SAREA = 3.142 (HDIA)  (0.5 HDIA + 4 NHEAR)
       HC  (Ref. 22) =0.29  (1+0.255 VAMBF)  (TSUR-TAMB)
                          .25
                              (HDIA)
               NUMSP
       QSEN =
 TEX

TSLI
CP(I).dT + 1048 WS(2)
                      (35)
                     .25
                      (36)
                      (37)
The excess of supplied over required heat is
       QNET = QIN - QREQ
                                      (38)
If QNET is positive, TEX is above its assumed value and  excess  air must
be added to reduce TEX to its desired value and QNET  to  approximately
zero.  This is carried out by iterating on PXAIR over equations (3)
through (38).  In this case, no auxiliary fuel is required.
                                17

-------
If QNET is negative, auxiliary  fuel  must  be  burned at a temperature
above TEX to provide the heat for  the  gases  to reach TEX.
AUXILIARY BURNER SELECTION



The burner must supply additional  fuel  and  air.   The theoretical
(stoichiometric) oxygen requirement  (Ib  oxygen per Ib fuel) for the
burner is


         _FRFU(1) CPMVI,ox ,  FRFU(2)  SPMW(3)    FRFU(5)
          ""• T TUTT T f 1 \   rlW \ J ) I  r-,-r t rrv S n\   l*\      *  T!1T11*TT/F'\


           -FRFU(3)
ELMW(l) *rLLW^J T ELMW(2)   2      • ELMW(5)              (3g)
The burner air  (Ib per Ib fuel) needed  for  a  specified burner percent
excess air (EXAFU) is

   BURAI = BURN0  (1 + (EXAFU/100))/O.233                            (40)

The combustion products  (Ib per Ib  fuel)  are  then

   BRN(l) = FRFU(l) SPMW(1)/ELMW(1)                                 (41)

   BRN(2) = FRFU(2) SPMW(2)/ELMW(2)                                 (42)

   BRN(3) = (BURN0) (EXAFU)/I00                                     (43)

   BRN(4) = FRFU(4) + .767 BURAI                                    (44)

   BRN(5) = FRFU(5). SPMW(5)/ELMW(5)                                (45)
The heat  (Btu per Ib fuel)  to raise  these  products to TEX is

           NUMSP             TEX

   DHBUR  =  ^   BRN(I)    /      CP(I) .dT +  1048 BRN(2)            (46)

             1              TSLI
The percent available heat  from  the burner  (or  combustion efficiency
of the fuel) is
   FEFF =  (QFU - DHBUR)/QFU
                                                         (47)
because the QFU is based on  cooling  the  products  back down to sludge
temperature.


The gross heat requirement  (Btu/hr)  is then

   QGR0S = QNET/FEFF
                                 18

-------
The total burner heat requirement  (Btu/hr)  is

   QBUR = QGR0S (1 + (BUREX/100))                                  (49)

where BUREX is a specified percent excess burner  capacity.

The fuel flowrate (Ib/hr) needed is

   WGTF = QBUR/QFU                                                 (50)

and the burner flowrate is

   WBAIR (Ib/hr) = (WGTF) (BURAI)                                  (51)

or

   SCFAI (scfh) = 379 WBAIR/28.84                                  (52)

A quantity of some interest is  the burner heat  in BTU  per  scf  of
burner combustion air, given by

   BTUV = QBUR/SCFAI                                               (53)


EXHAUST GAS COMPOSITION


The exhaust gases are increased by the  amount of  the burner  combustion
products making the total flow  for the  Ith  species

   T0T(I) (Ib/hr) = WS(I) + WGTF.BRN(I)                            (54)

or

   V0L(I) (cu ft/hr) = 10.73 T0T(I)  (TEX +  460)/(SPMW(I))(PSCRE)   (55)

where

   PSCRE = 14.696 - (4.2  (ELE)/9000)                               (56)

is a linear fit from 0 to 14,500 ft  of  the  NACA Standard Atmosphere.

The total exhaust flow is

                  NUMSP
   GT0T (Ib/hr) =  ^  T0T(I)                                     (57)

                   1=1
                                 19

-------
°r               NUMSP
   TV0L (acfh) =  ^  V0L(I)                                      (58)
                  1=1
The exhaust density (Ib/cu ft) at TEX and  entry  to  the  scrubber is then
   ROEX = GT0T/TV0L                                                (59)

SCRUBBER WATER FOR EXHAUST GAS SATURATION

The scrubber exit specific volume (cu ft per  Ib  of  dry  gas)  is
   VSAT = 10.73 (1+  [PSWAT /(PSCRE-PSWAT)])(TSCRB + 460)/(DRYMO.PSCRE)
                                                                   (60)
where
   PSWAT = 1.78885 exp [15.9014  (TSCRB-121.48)/(TSCRB + 460)]      (61)
representing a curve fit of water vapor pressure data.

   DRYMO =    /_/      SPMW(1).V0L(I)/VDRY                          (62)
           1=1,3,4,5
   VDRY = TV0L - V0L(2)                                            (63)
The saturated exit gas flowrate  from the scrubber  (acfm)  is
   VSCEX = GDRY.VSAT/60                                            (64)
where
   GDRY = GT0T - T0T(2)                                            (65)
The scrubber water flowrate  to saturate the exit gas is
   rTArno^ /iu/u ->   PSWAT. SPMW (2). GDRY    mrt  ,„,
   WATSC (Ib/hr) = DRYM0 (pscR^-PSWAT) ' T0T(2)                    (66)
or
   VWATS (gpm) = WATSC/(8.345) (60)                                (67)
If the water content of the  gas  entering the  scrubber equals or exceeds
the saturation level, no extra water is needed  for  saturation.
                                 20

-------
The Thermal Analysis Subroutine uses the results of the Sections
titled "Heat Balance" and "Exhaust Gas Composition" to print out
a heat balance (which contrasts the required vs supplied heat quanti-
ties) and a mass balance (which considers all streams: sludge, ash,
air, exhaust gas and auxiliary fuel) for the MHF system.
                                21

-------
                      V.  DATA ACQUISITION
DATA REQUIREMENTS
The Thermal Analysis described in Chapter IV consists of thermodynamic
relationships among the various streams (characterized by flowrate,
composition, and temperature) which flow in and out of the MHF incin-
erator.  Practical considerations dictate the values or ranges of
values which certain streams must assume to ensure satisfactory opera-
tion.  These technical considerations, discussed in Chapter III, include;

    1.  Hearth and exhaust gas temperature level high enough to
        prevent odors;

    2.  Hearth, exhaust, and ash temperatures low enough to prevent
        failure of furnace parts due to overheating;

    3.  Heatup and cooldown transients slow enough to prevent
        failure of refractory due to thermal stresses;

    4.  Combustion efficiency and percent excess air high enough
        to keep pollutants in exhaust gas below maximum allowable
        concentrations.

Requirements for effective operation include:

    1.  Efficient operating schedule, well integrated with operation
        of entire wastewater treatment plant;

    2.  Good use of operating manpower, considering operator skill
        and integration with the rest of the treatment plant;

    3.  Effective maintenance schedule to maximize the processing
        capacity of the MHF.

A field study of a number of operating MHF sludge incinerators was con-
sidered the best means to acquire data on the design and operational
factors listed above, and on their relationship to costs.  Hopefully,
the field study was to provide information on how the simultaneous
requirements set forth above were met in practice.  At the same time,
the data were to be used to model various relationships which could be
used  to optimize MHF incineration systems for many applications in a
rational manner.
                                23

-------
FIELD DATA
It was thought essential to study municipal incineration plants which
varied as to number of MHF's; size and capacity of a unit MHF; sludge
type and composition; plant operating mode; and manufacture.  The
scope of the project permitted a survey in depth at seven locations.
A selection procedure narrowed the dozens of cities in the U.S. with
MHF sludge incinerators down to these seven cities, comprising nine
incineration plants:

     Cleveland, Ohio (2 incineration sizes)
     Minneapolis-St. Paul, Minnesota (installed 1938; 1951)
     Kansas City, Missouri
     Battle Creek, Michigan  (2 incineration sizes)
     Saginaw, Michigan (installed 1963)
     Hatfield, Pennsylvania
     Bridgeport, Pennsylvania

In addition to the in-depth data on the nine basic incineration plants,
capital cost and other limited data were obtained on another four
plants located at:

     South Tahoe, California
     Minneapolis-St. Paul  (installed 1965)
     Saginaw (installed 1969)
     East Rochester, New York

In order to get the most out of the field visits, a carefully thought-
out set of "Instructions to Field Personnel" was developed to cover
all aspects (design, performance, operation, cost).  Through coordi-
nation with the FWQA, and state and local authorities (as applicable),
as much advance information as possible was gathered before the actual
visits.  The visits took place in the latter half of 1969 and were
conducted by engineering personnel with a design and/or operation
background in MHF sludge incineration.

For each of the seven cities visited, a comprehensive Field Report
was written by the field engineer.  The information in these reports
was obtained from actual inspections .and conversations with plant
personnel, and from records on file.  Each Field Report was subjected
to three reviews before being finalized.  The seven Field Reports ate
on file with the WQO-EPA Project Officer whose name appears in the
Acknowledgements  (Chapter X) of this report and are available for
inspection by qualified requestors.
                               24

-------
The task of reducing and correlating data from' the Field 'Reports was
not straightforward because data were reported differently and some-
times were not available.  A second contact was made in about; half
the cases studied to obtain clarifications "or. additional information
of a detailed nature.  To verify installed capital costs, the con^-
sulting engineers associated with all the incinerators were contacted
for their records.

Data, which could be worked up in numerical form and presented in
useful correlations, ,appear^JLn the next Chapter (VI) on Data Reduo-
tion and Correlation.  The present chapter contains field information
useful in itself, discussed below.
Summary of MHF Installations

Overall data on the 13 plants mentioned above are presented in Table 1.

Effectively, the incineration plants studied in depth  (ifos. 1 through
9) provide variations in

    Number of furnaces              From 1 to 4
    Single-furnace design capacity  From 200 to 4500 Ib dry solids per hr
    Number of hearths               From 5 to 9 per furnace
    Outer diameter                  From 6 to 22.25-ft. •
    Effective hearth area           From 85 to 2327 sq ft per furnace
    Total solids in sludge          From 20 to 53 weight percent


Summary of Annual Average NHF Steady-State Operation

The annual utilization of MHF incinerators, by capacity and time, for
all plants studied, is shown in Table 2.  The nominal  operating sche-
dule, which varied from round-the-clock down to 16 hr  per week, is
seen to have a large effect on the annual "load factor".  This is the
product of two quantities X and Y.  The quantity X is  the total annual
operating hours divided by the number of round-the-clock hours per year.
The quantity Y is the actual dry solids flow rate in the operating
incinerator divided by the design dry solids flowrate.

In one plant, (MHF No. 1), less than the total number  of MHF's ran at
one time, while in another plant  (MHF No. 6) the annual amount incin-
erated exceeded the nominal value, due to operation at over-capacity
and over-time.  In yet another plant (MHF No. 3), only 2 of the 3
total units operate simultaneously, so that there is always a" standby
unit.  The operating schedule is an important factp'r in the .Subroutine,
see Chapters VI, and VII.
                                 25

-------
                                                    TABLE  1
                           SUMMARY OF MULTIPLE HEARTH FURNACE SEWAGE SLUDGE INCINERATORS
MHF
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
MHF
Incinerator
Location
Cleveland
Minn. -St. Paul
Kansas City
Cleveland
Battle Creek
Battle Creek
Saginav
Hatfield
Bridgeport
South Taboe
Minr.-St. Paul
Saginaw
East Rochester
B=Bid
C=Contract
First
Operating
Year
1966
1938, 1951
1966
1940
1966
1962
1963
1967
1964
1967C
1965C
1969B
1963C
No. of
MHF's
4
3,1
3
4
1
1
1
1
1
1
3
1
1
MHF Unit Data
Outer
Dia,
Ft-In
22-3
22-3
22-3
18-9
18-9
18-9
16-9
10-9
6-0
14-3
22-3
22-3
10-9
No. of
Hearths
9
8
8
8
6
5
6
5
6
6
11
6
5
Hearth
Area,
Ft2
2327
2084
2084
1425
1068
890
845
230
85
575
2808
1560
230
Opg.
Data
Period
Years
19—
66-69
38-68
67-69
58-66
68-69
62-67
66-69
67-69
69
Not
Part
of Main
Study
Dry S
Rate/
Avg.
Lb/Hr
4167*
3600
4500*
2083*
2050*
1625*
1880
400
200*
900*
6250*
5170*
480*
olids
^fflF
Max.
Lb/Hr
7910
5080
4800
5370
3650
1690
2820
480
336*
_
6775*
—
600*
Avg.
Total
Solids,
Wt. %
25*
35-27
29
25*
26
26
53**
20
25*
15*
25*
45***
25*
Avg.
Hearth
LoadS,
Dry Lb
Hr Ft2
1.79*
1.73
2.16*
1.47*
1.92*
1.83*
2.22
1.74
2.35*
1.57*
2.23*
3.32*
2.09*
Mfr.
B=BSP
N=Nerco
B
N
N
N
B
N
N
N
N
B
B
N
B
NO
            *  Design
            ** High Oil/Grease Content

-------
                                                     TABLE  2




                           SUMMARY OF STEADY-STATE OPERATION PER MHF (ANNUAL AVERAGES)

-
MHF
No.
1


2


4
7



3
5

6


9

8




Location
Cleveland


Minn. -St. Paul


Cleveland
Saginaw



Kansas City
Battle Creek

Battle Creek


Bridgeport

Hatfield


Eff.
Hearth
Area per
MHF,
Sq Ft.
2327


2084


1425
845



2084
1068

390


85

230


Total
No.
of
MHF's
4


4


4
1



3
1

1


1

1


Nominal
Steady-State
Operating
Schedule
Fraction of
Full Time
1.0
(24 Hr x
7 Day/Wk)








0.714
(24 Hr x
5 Day/Wk)



0.357
(12 x 5)
0.095
(8 x 2)

Year
or
Period
1966
1967
1968
1966
1967
1968
62-65
1966
1967
1968
1969
67-69
1968
1969
1964
1965
1967
1969

67-69


Actual
Steady-State
Operation
Fraction of
Full Time,
(x)
.260
.223
—
.885
.889
.855
.718
.851
.846
.920
.930
.476
.654
.666
.597
.759
.796
.2975

.033
.080
Actual
Design
Dry
Solids
Flov
Ratio
(Y)
.723
.690
—
.590
.670
.813
.621
1.06
.99
1.01
.996
.775
1.03
.937
.846
1.075
1.012
.848

__


Actual Tons/Yr
Full-Time' De-
sign Tons/Yr
= Load Factor
(X).(Y)
.188
.154
.230
.520
.595
.691
.446
.900
.837
.926
.926
.369
.675
.624
.505
.816
.806
.252

__

N)

-------
MHF Air. Ash and Gas Temperatures

Table 3 collects available data, which vary widely due to different MHF
"technical" operation, e.g., ash discharge temperatures vary over hun-
dreds of degrees.  Much of this spread is probably due to differences
in the temperature of the incoming combustion air, which may vary
hundreds of degrees, depending on whether it is mainly ambient or
recycled cooling air.
MHF Hearth Temperatures

Table 4 shows that hearth temperature profiles were only available for
about half the furnaces visited.  Except for the Hatfield plant, all
MHF's in the table are quite comparable, having 5 and 6 hearths and a
small variation in hearth area  (845 to 1068 sq ft).  They appear to be
well-operated, with a 1600-1700 F maximum at hearth 3, a bottom hearth
at 450-500 F, and a top hearth at 800-920 F,  For MHF Nos. 5, 6, and
7, the top hearth temperature is measured above the hearth, and so is
close to the exit gas temperature (Table 3).  For MHF No. 8, the 160 F
on the top hearth is the sludge temperature, probably the wet bulb
temperature mentioned in Chapter III.
MHF Air Sources

Table 5 indicates the variety of adjustable openings to admit ambient
air to MHF's.  All the units are operated manually, and in many cases
the degree of openings of doors, ports and registers is left to a
subjective judgment, based on experience.  Every MHF, of course, has
a cooling air fan and a combination air blower.  It is interesting to
note that in Minneapolis  (MHF No. 2) cooling air is recycled to
hearths 4 and 6, as well as to the bottom hearth 8.
Maintenance Log for Minneapolis-St. Paul from Annual Reports 1951-65

Table 6 is a detailed compilation of every maintenance action listed
in the annual reports by "General Maintenance" and by individual incin-
erator.  This record is unique among the plants studied, and gives an
idea of what maintenance may be necessary in a well-run MHF subject
to round-the-clock operation.  In Chapter VI, these data are used as
a basic for extraction of a 25 yr lifetime hearth replacement for
incorporation into the Subroutine.
                                 28

-------
                                TABLE 3
                 MHF  AIR,  ASH AND GAS TEMPERATURES
MHF
No.
1
2
3
5
7
8
9

Location
Cleveland
Minn. -St. Paul
Kansas City
Battle Creek
Saginaw
Hatfield
Bridgeport

Percent
Excess
Air
(Est.)
50
(Est.)
50
(Est.)
50-60
(Est.)
80
20
50
(Est.)
50

Cooling
Air Exit
Temp, °F
200

300

380

250-
350
Vented**
Ash
Temp, °F

100
> 850
180
350-
400
750
150

Combustion
Gas Exit
Temp, °F
800-
1000
800
685
800
1000-
1360
750
350
800

Scrubber
Exit
Temp, °F

No
Scrubber*
165
180
170



Furnace
Draft,
in Water
-0.1
-0.2
-0.25 to
-0.3
-.02
-0.9
-2
-0.2

*  Dust-precipitating flue used instead
** Cooling air not recycled

-------
                                                    TABLE  4

                                             MHF HEARTH TEMPERATURES
MHF No.
Location
MHF Size
Hth. Area, Sq Ft.
Shaft RPM
Hearth
Number
1 (top)
2
3
4
5
6
5
Battle Creek
18.75 Ft.OD x 6 Hth
1068
1.0
Rabble
Arms
4
4
4
2
2
2
Rabble
Teeth
15
16
17
19
17
19
Temp.
°F
800*
1200*
16/1700*
16/1700
1200*
500
6
Battle Creek
18.75 Ft.OD x 5 Hth
890
1.0
Rabble
Arms
4
2
2
2
4
Rabble
Teeth
16
15
16
15
16
Temp.
0 F
800*
1200
16/1700*
1200*
500*

7
Saginaw
16.75 Ft.OD x 6 Hth
845
2.0
Rabble
Arms
4
4
4
2
2
2
Rabble
Teeth
12
14
12
13
11
14
Temp.
O p
920
1700
1720
124*
—
450*
8
Hatfield
10.75 Ft.OD x 5 Hth
230

-------
              TABLE    5
                 MHF AIR SOURCES
MHF No.
Location
Air Sources
            Cleveland
                   Comb, air blower,
                   Cooling air
                   Opened doors (full open 3000 SCFM ea)
                   Burner air
            Minneapolis-
              St. Paul
                   Comb, air blower (?00 CFM)
                   Cooling air (Fed to HTH 4, 6, & 8)
                   Opened doors (2'6" x 16-1/2")
            Kansas City
                   Cooling air @ 300 F fed at HTH 8
                       (2500 CFM @ 2-1/2" ELO)
                   Peep doors 4-1/2" x 7" (300 SCFM
                       .25" BUG)
                   Comb,  air blower used only with
                       burners on
            Battle Creek
                   Comb, air blower (3000 SCFM)
                   Opened furn. doors (865 SCFM-13"xl7")
                   Air ports (l4 SCFM @ .02" W)
                   Cooling air to HTH 5
                   Burner air
            Saginaw
                   Comb, air blower
                   Opened doors (l850'SCFM @ 0.09" W)
                   Ports (235 ft^/min @ 0.09" W)
            Hatfield
                   Cooling air to hearth 5
                   Burner air
            Bridgeport
                   Ports
                   Burner registers
                   Slightly open doors
                   (3-6 Ib air/lb dry sludge)
                                31

-------
                                TABLE  6

                MAINTENANCE LOG FOR MINNEAPOLIS-ST. PAUL
                     FROM ANNUAL REPORTS 1951 - 1965
NOTES:  (l) When no items are recorded for the 4 individual incinerators
            (B, C, D, E), refer to general maintenance (A) for that year,
            especially for arm and tooth maintenance.
        (2) ppter = precipitator
A.  General Maintenance
    1951    (Minor maintenance)
            2 rabble arms replaced with rebuilt arms
            20 new rabble teeth
            Brick repaired in all incinerators
            2 panels in the dust ppter flue were rebricked
            1 channel support reinforced
            Sludge feeders rebuilt
            New-plates welded around no 3 hearth of all incinerators.

    1952    2 rabble arms replaced with rebuilt arms
            2 rabble teeth replaced with used teeth
            Inner lining of chimney repaired
            Top 8 ft. of acid-resistant brick in chimney were replaced

    1953    5 rabble arms replaced - only 1 with new arm
            24 rabble teeth
            Steel plates and brick in dust ppter replaced

    1954    6 rabble arms replaced in incinerators No. 1, 2, 3
            81 rabble teeth replaced in incinerators No. 1, 2, 3
            Few liner bricks replaced in fly ash ppter-

    1955    Ash pump overhauled
            10 rabble arms replaced
            80 rabble teeth replaced

    1956    Fly ash ppter flue replaced
            Extensive duct work changes made
            16 rabble arms replaced - 4 scrapped
            58 rabble teeth replaced

    1957    12 rabble arms replaced - 1 scrapped
            55 rabble teeth replaced

    1958    Nominal repair
            2 rabble arms repaired
                                       32

-------
                           TABLE 6 (Continued)
A.  General Maintenance (Continued)

    1959    3 rabble arms replaced (none scrapped)
            18 rabble teeth replaced
            Brick work in boilers repaired
            Oil preheater insulated
            Paddle alarm devices installed on the incinerator conveyor belts

    1960    Nominal brick work
            11 rabble arms replaced
            44 rabble teeth replaced
            Remote controls for central shaft drive installed on incinera-
                 tors No. 2, 3, and 4

    1961    Light maintenance
            7 rabble arms replaced (none scrapped)
            9 rabble teeth replaced

    1962    New belt installed on south incinerator belt conveyor
            North incinerator belt drive overhauled
            4 rabble arms replaced
            3 rabble teeth replaced

    1963    Ash sluicing pump P-57 overhauled
            5 rabble arms replaced
            A few rabble teeth replaced

    1964    Repairs of dust ppter & water cooled damper guides
            Damper guides reanchored
            Ducts rebuilt and lined with castable refractory and then
                 insulated on exterior
            11 rabble arms replaced
            A number of rabble teeth replaced
            Sump Pumps - new triple ball floats and switches installed

    1965    Ash pump P-56, P-57 had sheave changes to increase pump speed
            Ash pump P-56 had complete overhaul
            General inspection and repair of incinerators
            Some teeth replaced


B.  Incinerator #1 (first full operating year:  1939)

    1951    Minor maintenance

    1952    Minor maintenance

    1953    Minor maintenance
                                       33

-------
                            TABLE 6 (Continued)
B.  Incinerator #1 (Continued)
    1954    Hearths 2 and 4 completely rebuilt from steel shell
            Hearth 3 rebuilt from brick wall
            Insulation and wall brick between 2-4 replaced

    1955    Hot gas ducts insulated on top half-saddles and pipe columns
                 installed
            2 low (rabble) arms replaced
            9 teeth replaced

    1956    Hearth 1 rebuilt
            Hearth 3 ring of brick added
            Hearth 6 several bricks replaced
            Hearths 4 and 6 lute caps rebuilt
            Several arms and teeth replaced

    1957    OK

    1958    Nominal

    1959    Bottom bearing replaced for first time

    1960    Exterior shell plates welded on at hearths 2 and 3
            Central shaft Reeves drive overhauled
            Plates welded on cooling tower

    1961    Bricks replaced
            4 rabble arms replaced
            7 rabble teeth replaced

    1962    Down for repairs at close of year

    1963    5 rabble arms were replaced
            A few rabble teeth were replaced
            Some brick work on 2 hearths replaced

    1964    Broken rabble arms on hearth 3 and on hearth 5 replaced
            Burner box (southeast) was rebuilt
            Bypass damper replaced with rebuilt damper

    1965    Repacked shaft at cooling air inlet
            5 rabble teeth installed
            Oil burner installed on hearth 4


C.  Incinerator #2 (first full operating year:  1939)
    1951    Minor maintenance

    1952    Minor maintenance

    1953    Minor maintenance
                                      34

-------
                            TABLE  6  (Continued)
C.  Incinerator #2 (Continued)
    1954    Hearths 2, 3, and 4 were rebuilt and insul. and brick vail
                 replaced
    1955    Hot gas ducts insulated on top half-saddles & pipe columns
                 installed
            Hearths 2, 3, and 4 were rebuilt-cont. from 1954
            Repair to wall brick and burner boxes
            8 rabble arms replaced
            51 rabble teeth replaced

    1956    Hearth 6 - several wall brick were replaced
            Hearth 1 - being rebuilt

    1957    Hearth 1 rebuilding completed
    1958    Nominal

    1959    Nominal

    1960    Bottom bearing replaced (first time)
            Exterior shell plates welded at hearths 2 and 3
            Remote control of central shaft drive installed
    1961    1 burner box repaired

    1962    OK
    1963    OK

    1964    5 rabble arms replaced (2 on hearth  2, 1 on hearth  4,
                 1 on hearth  5, and 1  on hearth  ?)
            A number of rabble teeth replaced
            2 burner boxes on hearth 4 and 1 on hearth 6 repaired
            Hearth 6 brick work bad; hearth was virtually rebuilt
            Bypass damper and seat installed
            Reeves drive on central shaft overhauled
            Small oil burner installed on hearth 2
            Smoke indicator installed
    1965    Cooling fan and motor drive belts replaced
            General inspection

D.  Incinerator #3 (first full operating year:  1939)
    1951    Minor

    1952    Replaced bottom bearing on bottom of central shaft

    1953    Hearth No. 2 relaid
            Wall brick from underside of hearth 1 to top of hearth 3 re-
                 placed
                                       35

-------
                              TABLE 6 (Continued)
D.  Incinerator #3 (Continued)
    1954    Hearth No. 4 rebuilt from steel shell
            Hearth No. 3 rebuilt from brick vail

    1955    2 burner boxes replaced
            4 teeth replaced

    1956    1 burner box replaced
            Some arms replaced

    1957    Some brick replaced
            Lute cap on hearth 2 rebuilt

    1958    Nominal

    1959    Nominal
    1960    Exterior shell plate veld on at hearths 2 and 3
            Central shaft Reeves drive overhauled;  gear reducer over-
                 hauled and rebuilt

    1961    3 rabble arms replaced
            2 rabble teeth replaced
            Arm hub on central shaft on hearth 4 built up by velding
            1 burner box repaired
    1962    2 rabble arms replaced
            3 rabble teeth replaced
    1963    OK

    1964    4 rabble arms replaced (l lov arm on hearth 4, 1 broken arm
                 on hearth 5,  2 arms on hearth 2)
            Some rabble teeth replaced on hearths 1 and 4
            Burner box partly replaced (southeast box on hearth 4)
    1965    Cooling fan - nev belts and sheaves installed
            Reeves drive - nev shaft support bearings and belts installed
            Oil burner installed on hearth 4 - vater-cooled damper replaced

E.  Incinerator #4 (first full operating year:  1952)

    1951    Incinerator installation is completed
    1952    OK

    1953    OK

    1954    OK

    1955    Hearth 3 rebuilt and 2 rings of brick added to increase drying
                 area
            Bell on cooling air realigned and repacked
            Burner boxes rebuilt to conform to other incinerators
            16 teeth replaced


                                         36

-------
                              TABLE 6 (Concluded)
E.  Incinerator #4 (Continued)
    1956    5 rabble teeth replaced
    1957    Lute cap of hearth 6 replaced
    1958    Nominal
    1959    Nominal

    1960    Nominal
    1961    Nominal

    1962    Bottom button bearing replaced
            2 rabble arms on hearth 1 replaced (none scrapped)
    1963    1 burner box repaired
            A few rabble teeth replaced

    1964    2 new rabble arms installed on hearth 4
            5 new teeth installed on hearth 4 and teeth on hearth 1
            Burner box on hearth 4 was rebuilt
    1965    General inspection
            Lute ring on hearth 4 replaced
            Insulation replaced on central shaft
            2 burner boxes on hearth 4 repaired
            Cooling air fan-new motor bearings and outboard bearing in-
                 stalled
            Water cooled damper repaired
            Rabble teeth replaced on hearth 2
            Oil burner installed on hearth 4
                                       37

-------
Comparison with Air Pollution Codes

Among all the cities visited, only one, Cleveland, has an air pollu-
tion standard of any kind.  As of 15 October 1969,.the maximum' allow-
able emission of particulates in the flue gas of existing incinerators
was 0.2 Ib per 1000 Ib stack gas, or 200 parts per million by weight.
A flue gas analysis taken in 1966 on MHF No. 1 gave a value of 0.064
to 0.069 per 1000 Ib (within the specification) at the stack breeching,
reduced from 0.772 at the furnace outlet by scrubber action.
                                 38

-------
                VI.  DATA REDUCTION AND CORRELATION
The preceding chapter on Data Acquisition contains tabulations of raw
data, such as experimental temperatures at various points in the MHF's.
Such information is useful as a guide to operating a MHF sewage sludge
incinerator from the viewpoints of MHF life and air pollution.  Other
raw data, on the various operational and cost components must be cor-
related in terms of meaningful variables to model the effects of size
and passage of time.  For cost items, it is necessary to establish
a framework of economic indicators which allow all data taken in
the past to be expressed in 1969 dollars.  For equipment and
material, and also the "non-dollar" expenditures  (man-hours, kilowatts,
land, etc.) the effect of plant size or capacity must be included.

The review of prior studies of MHF sewage sludge incineration economics
in Chapter III gave little indication on how numbers quoted were
derived from basic data.  Therefore, it was decided to base correla-
tions on variables which resulted in good fits, and for which a
realistic rationale could be established.  The Sections in this
Chapter (except the first, which deals with Economic Indicators)
pertain to the operational and cost items considered important in
the subroutine.
ECONOMIC INDICATORS AND LABOR RATES

The conversion of all costs to 1969 dollars required adjustments to
raw data obtained during the previous three decades on capital equip-
ment and other materials, and on the cost of all the types of labor
involved.  Much effort was devoted to arriving at realistic conver-
sion methods which are summarized in Tables 7 and 8, standardized to
1969.  The principal considerations are detailed in the following
paragraphs, by column.

Installed Capital Equipment (Col. 1, Table 7) - The cost of installed
MHF incinerator systems was considered to be the sum of the fabricated
equipment costs (castings, blowers, motors, controls, etc.) and the
charges for construction.  Castings include the center shaft, rabble
arms, teeth and other structural components.  A cost ratio of 60%
equipment/40% construction was taken as typical, based on industry
experience.  The Average Marshall and Stevens Equipment Cost Index
(Ref. 23) and the Engineering News Record Construction Cost Index
(Ref. 24) were combined in the 60/40 ratio to produce the MHF
Capital Cost Index (Col. 1 of Table 7).
                                39

-------
            TABLE  7

  SUMMARY OF ECONOMIC INDICATORS
FOR CAPITAL EQUIPMENT AND MATERIALS

      (Standardized to 1969)
Year
1938
9
1940
1
2
3
4
1945
6
7
8
9
1950
1
2
3
4
1955
6
7
8
9
1960
1
2
3
4
1965
6
7
8
1969
MHF
Installed
Capital
Cost
(1)
25.6
25.2
25.7
27.5
29.7
30.3
31.0
31.5
36.8
44.7
48.8
49.0
51.4
55.0
55.9
57.3
58.6
60.9
65.8
70.2
72.2
74.5
76.0
76.6
77.7
78.7
80.4
82.1
85.3
89.0
93.8
100.0
Normal
Maintenance
Parts &
Supplies
(2)
--



41.8
45.5
46.8
49.1
54.6
56.3
59.0
59.9
62.3
66.4
69.8
71.2
73.5
75.0
76.3
78.1
79.7
81.7
83.7
86.8
89.9
94.5
100.0
MHF
Castings
Cost
(3)




50.1
54.2
56.8
59.6
65.7
66.5
69.2
71.1
73.2
79.1
84.2
85.9
87.4
87.4
86.8
87.5
87.6
88.0
88.9
91.1
93.3
96.2
100.0
Refractory
Cost
(4)
30.5
30.1
30.6
32.1
34.1
34.3
34.4
34.7
42.1
51.2
55.5
55.5
57.4
61.4
61.5
62.1
63.2
64.9
71.0
77.0
79.4
81.4
82.7
82.3
82.6
82.7
84.0
85.2
87.5
91.8
95.5
100.0
                 40

-------
                TABLE 8

SUMMARY OF ECONOMIC INDICATORS FOR LABOR
         (Standardized to 1969)

Year
1958
9
1960
1
2
3
4
1965
6
7
8
1969
Labor Categories

Operating
Index
(1)
62.1
65.2
68.3
70.6
73.5
76.0
78.4
81.7
85.0
88.7
93.6
100.0
$ Per Hr
(2)
2.41
2.53
2.65
2.74
2.85
2.95
3.04
3.17
3.30
3.44
3.63
3.88
Maintenance
and Castings
Index
(3)
71.2
73.5
75.0
76.3
78.1
79.1
81.7
83.7
86.8
89.9
94.5
100.0
$ Per Hr
(4)
2.90
2.99
3.06
3.11
3.18
3.25
3.33
3.41
3.54
3.66
3.85
4.07

Refractory
Index
(5)
60.5
63.7
66.6
68.6
71.1
72.9
75.2
78.4
81.9
85.9
91.4
100.0
$ Per Hr
(6)
2.97
3.13
3.27
3.37
3.49
3.58
3.69
3.85
4.02
4.22
4.49
4.91

-------
Normal Maintenance Parts and Supplies (Col. 2, Table 7) - The Plant
Maintenance Cost Index (Ref. 25) was used for updating normal main-
tenance materials.  This index actually is a mix of labor and mater-
ials, but was here adopted for materials alone.

MHF Castings Cost (Col. 3, Table 7) - The Process Machinery sub-com-
ponent of the Equipment component of the Plant Cost Index (Ref. 26)
was used for castings.  Of the seven sub-components, it is the one
which appeared most representative of castings.

Refractory Cost (Col. 4, Table 7) - The Clay Products component of the
Marshall and Stevens Equipment Cost Index  (Ref. 23) was adopted for
the furnace brick.

Operating Labor (Cols. 1 and 2, Table 8) - In this  (and every other
labor category) there are regional differences, but their considera-
tion was felt to be an unwarranted refinement in view of the other
simplifications made.  The National Average Hourly Gross Earnings per
Nonsupervisory Worker in Electric, Gas, and Sanitary Services (Ref. 27)
were selected.  The 1969 rate was $3.88 per hour.

Normal Maintenance Labor  (Cols. 3 and 4, Table 8) - As for Normal
Maintenance Parts and Supplies, the variation of the associated labor
was also represented by the Plant Maintenance Cost Index (Ref. 25).
Ref. 28, which dealt with a wage survey in the Industrial Chemicals
industry, was used to obtain absolute hourly rates.  From the mainten-
ance standpoint, it was felt that the duties, and therefore wages,
would be comparable.  The Nationwide Average of all Maintenance
Skills  (varying from janitor to instrumentation repair) for November
1965 was given in Ref. 28 as $3.41 per hour which corresponded to a
1969 rate of $4.07 according to Ref. 25.

Casting Replacement Labor (Cols. 3 and 4, Table 8) - This was taken
to be identical in all respects to the Normal Maintenance Labor
above,  in view of similar skills being involved.

Refractory Replacement Labor (Cols. 5 and  6, Table  8) - This work
involves bricklaying and  is more highly paid than Normal Maintenance.
The National Average Straight Time for Masonry, Stonework and. Plas-
tering  (Ref. 29) was adopted, with its 1969 rate of $4.91.
INCINERATOR CAPACITY

The usual indicator of capacity in wastewater  treatment  is  a  flowrate.
In incineration,  typically,  the rate at which  dry solids are  processed
is a variable  indicative of  capacity.  In  terms of  economics, however,
a "hardware" variable is preferable, so that cost may be linked  to  a
physically measurable size or mass.  The obvious variable here is the
total  effective hearth area  (FHA), sq  ft, .which is  a function of the
                                 42

-------
outer iliameter and number of hearths in the furnace.  Strictly speaking,
FHA ±s the gross hearth area less the area lost to center shaft, drop
holeis and lute caps.  The ratio which connects dry solids flowrate in
Ib per hr (DSF) and effective hearth area is the hearth loading  (HLD)
expressed in Ib dry solids per hour per sq ft.

Table 1 lists the hearth loadings in the last column, derived from
hearth area and average (or design) dry solids flowrates.  Fig.  3 is
a plot of the points, with the least-square fit

        FHA = 0.501 (DSF), or HLD = 1.996                            (68)

A comparison of this value with the values in the next-to-last column
of Table 1 shows that most of the installations surveyed were designed
within 10% of the fitted value, with the more recent MHF's showing
the higher hearth loadings.  It should be noted that the range of
sludge total solids content, considering all installations studied,
was from 15 to 53 percent by weight, or conversely, 47 to 85 percent
water by weight.  It is suggested that Eq. (68) represents current
practice over the stated range of moisture content.  While it may
seem surprising that HLD tends to be constant independent of sludge
moisture content, this may indicate that a much larger fraction  of
the total hearth area is used for combustion of dried sludge than for
drying of the wet sludge.

The field survey and perusal of manufacturers' brochures indicated
that for sewage sludge incineration current preferred practice for
unit MHF's was a range in number of hearths (NHEAR) from a minimum of
6 (although 5-hearth furnaces are in use) to a maximum of 12; and in
internal diameter from 4.5 ft to 20 ft.  The "heavy-duty" wall thick-
ness of 13.5 in. (rather than 9 or even 6 in.) was considered prefer-
able, giving an outer diameter (HDIA) range from 6.75 to 22.25 ft.
Actually, the largest sewage sludge incineration MHF in use today is
a 22.25 ft dia - 12 hearth installation which has been operated  in
Toronto, Canada, since 1968.  With these ranges, a set of 59 standard
unit MHF sizes resulted, arranged in ascending order by effective
hearth area (FHA) in Table 9.  The range in FHA from 85 to 3120  sq
ft was considered to provide enough flexibility in selection of
optimum furnaces from the subroutine.

These results formed the basis for three decisions:

    1.  Effective hearth area (FHA) was taken as the physical
        variable indicative of furnace capacity.

    2.  A value of HLD = 2 was taken as a minimum in MHF
        design.

    3.  The unit MHF sizes will be restricted to 59 standard
        values (FHA range from 85 to 3120) as shown in Table 9.
                               43

-------
     10,000
CO
Q
 CO
"O
•H
I-l
 O
en
 tx
 a
 '„
 o
 >
03
O
Q
      5,000
         o

      2,000
1,000
  500
        200
           50
                                                 I
                                                                           Data from
                                                                            Table 1
                                                                                  Numerals
                                                                                  are  MHF
                                                                                  Numbers
                 100         200              500       1,000

                       Effective Hearth  Area per M1IF (FIIA), sq  ft

                         FIG. 3.   MHF DESIGN CAPACITY VS. MHF SIZE
2,000
5,000

-------
                    TABLE  9

STANDARD SIZES OF MULTIPLE-HEARTH FURNACE UNITS
No. of Hearths (NHEAR):         3       6 to 12
Wall Thickness, Inch:                >  13.5
Outer Diameter, Ft. (HDIA):            6.75 to 22.25
Effective Hearth Area, Sq. Ft. (FHA):  85 to 3320
FHA
Sq. Ft.
85
98
112
125
126
140
145
166
187
193
208
225
256
276
288
319
323
351
364
383
411
452
510
560
575
672
760
845
857
944
HDIA
Ft.
6.75
6.75
6.75
7.75
6.75
6.75
7.75
7.75
7.75
9.25
7.75
9.25
9.25
10.75
9.25
9.25
10.75
9.25
10.75
9.25
10.75
10.75
10.75
10.75
14.25
14.25
14.25
16.75
14.25
14.25
NHEAR No.
Hearths
6
7
8
6
9
10
7
8
9
6
10
7
8
6
9
10
7
11
8
12
9
10
11
12
6
7
8
6
9
10
FHA.
Sq. Ft. .
988
1041
1068
1117
1128
1249
1260
1268
1400
1410
1483
1540
1580
1591
1660
1675
1752
1849
1875
1933
2060
2084
2090
2275
2350
.2464
2600
2860
3120
HDIA
Ft.
16.75
14.25
18.75
16.75
14.25
18.75
16.75
20.25
16.75
18.75
20.25
16 . 75
22.25
18.75
20.25
".-, H>.75
* a
18.75
22.25
20.25
18.75
20.25
22.25
18.75
20.25
22.25
20.25
22.25
22.25
22.25
NHEAR No.
Hearths
7
11
6
8
12
7
9
6
10
8
7
11
6
9
8
12
"~ 10
7
9
11
10
8
12
11
9
12
10
11
12
                    45

-------
INSTALLED MHF CAPITAL COST

In practically all cases,  the largest item contributing to total MHF
cost (per annum or per ton of dry solids processed) is the capital^
charges.  The conventional method of financing public works by muni-
cipal and other bonds, typically with a 25-year payoff period, and the
custom of soliciting bids  for each individual job from qualified
vendors are the principal  factors in determining the capital charges.
It is well known that few  price lists for equipment are issued by waste-
water processing equipment manufacturers, even for items of "shelf"
availability.  It is difficult to establish the exact value for a
piece of equipment such as a furnace because contracting is usually
by competitive bidding. In the present case, all the MHF units
examined were built by two vendors: BSP Corporation of San Francisco,
and Nichols Engineering and Research Company (NERCO) of New York.
The conversion of original costs (some dating as far back as 1938)
to 1969 levels was made according to Column 1 of Table 7.

Table 10 gives the breakdown of installed capital costs, which include
the metal and refractory parts of the furnace proper, assembled with
the various air blowers, fuel injectors, drive motors, scrubbers, con-
trols, instrumentation and other accessories necessary to the operation
of the furnace.  The installed cost does not include consulting
engineering fees, sludge dewatering, ash handling and disposal,
building or land.  Surprisingly, the field visits with few exceptions
did not produce good capital cost data - many capital cost figures
were approximate or not known.  It was then decided to contact the
consulting engineers on the various installations; in all cases
cooperation was excellent  and files going back decades yielding
desired information and in some cases also corrections of field data.
One bonus was that the 9 basic units examined could be expanded to
13, for capital cost only, because the installed costs of other
recently constructed MHF sludge incinerators were made available to
this program.  Hearth area was chosen to be the variable indicative
of capacity because it related directly to hardware and so to its
first cost.

In three of the units only combined costs of incineration, dewatering,
disposal, etc., were available, so estimates were made for the incin-
eration cost alone.  Table 10 indicates the data sources and the
nature of any adjustments  made.  The contract dates are the basis for
dollar cost conversion.

Fig. 4 is a log-log plot of the 13 points (cost vs hearth area).  A
least-square fit of the points to a power function resulted in an
exponent of 0.60, which happens to be the "classical" value for
chemical process equipment.  No doubt, this close an agreement is
fortuitous but it does point up the chemical process aspect of incin-
eration.  Some inflationary trend was noted with the cost adjustment
                               46

-------
         TABLE  10




MHF INSTALLED CAPITAL COST
MHF
No.
1
2A
2B
3
4
5
6
7
8
9
10
11
12
13
Location
Cleveland
Minn. -St. Paul
Minn . -S t . Paul
Kansas City
Cleveland
Battle Creek
Battle Creek
Saginaw
Hatfield
Bridgeport
South Tahoe
Minn. -St. Paul
Saginaw
East Rochester
(B-Bid)
Contract
Year
1963
1938
1950
1964
1938
1966
1960
1963
1967
1964
1967
1965
1969B
1963
No.
of
MHF's
4
3
1
3
4
1
1
1
1
1
1
3
1
1
Unit MEF
Hearth
Area, Ft2
2327
2084
2084
2084
1425
1068
890
"845
230
85
575
2808
1560
230
Source for Costs;
Remarks
(CE=Consulting Engrs.)
Havens & Emerson (CE)
Toltz,King,Duvall,Anderson(CE)
1951 M-St.P. Sanitary District
Report (19th Annual), p. 86
Black & Veatch (CE)
Havens & Emerson (CE); bulky
combustion air preheater
included.
McNamee, Porter & Seeley (CE);
Elaborate controls included.
Malcolm Pirnie & Co.(CE); Estd
cost of building subtracted.
Hubbell, Roth & Clark (CE)
Tracy Engineers, Inc. (CE)
George B. Mebus , Inc. (CE); costs
of MHF components available.
South Tahoe Public Util. Dist;
Estd.devatering etc. costs
subtracted.
Toltz ,King,Duvall ,Anderson(CE);
Estd debater . costs subtracted.
Metcalf and Eddy (CE)
Lozier Engineers (CE)
Orig. Cost
per Unit
MHF (1000$)
376
127
163
247
99
380
241
197
225
74
233
816
630
80
1969 Cost
per Unit
MHF (1000$)
478
496
314
338
386
446
317
250
253
92
~262
993
630
102

-------
               1000
oo
         M
         O
         O
         -p
         V)
         O
         O
         a
         -p
         c.
         a
         cd
         -P
 O
 to
 c
 a
 to
 O
£
                                                                                        Data from

                                                                                        Table 10
                                                                                        Numerals
                                                                                        are MHF
                                                                                        Numbers
                200 -
                               100
                               200             500         1000

                          Effective Hearth Area per MEIF  (FHA.),  sq ft

                             FIG. 4.  MHF INSTALLED CAPITAL  COST
2000
5000

-------
chosen in that MHF's for which contracts had been signed in or after
1966 tended to fall above the least-squares line, while MHF's ordered
before 1951 tended to fall below the line.  The equation of the least
square line is the power function

        CGI = 5464 (FHA)0'60                                         (69)
COOLING AIR FANS AND COMBUSTION AIR BLOWERS


It is, of course, quite possible to determine the required capacities
of cooling air fans and combustion air blowers given the dimensions
of the flow channels, the cooling rate required to maintain adequate
apparatus operating life, the sludge feed rate and combustion air
(including excess air) requirements.  Consideration of heat transfer
correlations, friction factors, thermodynamics, and stoichiometry
could then be used to predict the blower and fan requirements.  However,
manufacturers of MHF's have presumably already solved this problem
empirically or otherwise with every furnace delivered.  A rea-
listic procedure, then, consists of utilizing information
on fans and blowers collected during the field visits.  Table 11 and
Figs. 5 and 6 show all the available data points on air/flowrate, fan
and blower horsepower, and wet sludge rate, contributed by half the
plants visited.  Straight-line fits through the origins of Figs. 5
(horsepower vs wet sludge rate) and 6 (air flowrate vs horsepower)
give the following results:

                         Combustion Air

    Blower rated hp = 0.15 per daily ton of wet sludge
    Air Flow at 16 osi = 150 scfm per rated hp
    i.e., air flow = 22.5 scfm per daily ton of wet sludge

                           Cooling Air

    Fan rated hp = 0.08 per daily ton of wet sludge
    Air flow at 8 in. water = 450 scfm per rated hp
    i.e., air flow = 36 scfm per daily ton of wet sludge

The correlation of cooling air with wet sludge rate is convenient here
because of the need for an a priori value for cooling air flow as an
input to the Thermal Analysis (Chapter IV).  The crude procedures used
are considered adequate for this preliminary-design purpose since the
contribution of the cooling air stream to the MHF energy balance is
small.  For accurate sizing of combustion air blowers and cooling air
fans, however, more details must be taken into account, especially for
high daily sludge tonnages.  The data in Table 11 are obviously
insufficient for elaboration into equipment design parameters.
                                49

-------
                                  TABLE  11




                  COOLING AIR FANS AND COMBUSTION AIR BLOWERS
MHF
No.
1
2
3
4
5
6
7
8
9
Location
Cleveland
Minn. -St. Paul
Kansas City
Cleveland
Battle Creek
Battle Creek
Saginaw
Hatfield
Bridgeport
Hearth
Area/MHF
sq ft
2327
2084
2084
1425
1068
890
845
230
85
Avg. Wet
Sludge
T on/Day (a)
200
144
186
—
94.6
75
42.5
24
9.6
Cooling Air
Fan
HP
15
7.5
15
—
7.5
7.5
5
3
0.5
Flow
SCFM^)
6000
—
7190^
—
3490
3490
—
—
—
Combustion Air
Blower
HP
30
25
15
—
7.5
30
7.5
3
2
Flow
SCFM^C'
—
—
3300
—
1180
3000
990
—
—
(a)   Product of design dry  solids  flowrate and total solids w/o.




(b)   At static  head of 8  in. water.




(c)   At pressure of 16 OSI  (OSI =  oz per sq in)




(d)   Adjusted from 13  in. water
                                         50

-------
h
•H

*"  O
faC >
C  O
•H l-l
p-i pq
o
O  1+
o n
  O
tl -H
0) -H

>
  a
  O
  c
  CO
     30
     20
     10
                I
                                                 2X

                                                    o
                                                    2
                                         Data from

                                         Table 11

                                         Numerals

                                         are MHF

                                         Numbers


                                               I
        0
                                                                    200
        50              100           150

Design (Average) Vet  Sludge  Flow per MHF

              Tons  per  2'i-lir Day

  •  Cooling Air                X	 Combustion Air
                    FIG.  5.   COOLING AND COMBUSTION AIRt

                             HORSEPOWER VS. VET SLUDGE RATE

-------
0)
2
o
o
a
o
•H
-H
0]
a

1
o
o
o

bO
O
O
                       10


                              Data from

                              Table 11


                              Numerals

                              are  MHF

                              Numbers
                           20
                Rated Horsepower of Cooling Air Fan

                     or Combustion Air Blower
     O
Cooling Air
	Combustion Air
               FIG. 6.  COOLING AND COMBUSTION AIR:

                        AIR FLOW VS HORSEPOWER
                             52

-------
EXHAUST GAS SCRUBBERS AND PRECOOLERS


Data on these Items were collected in Table 12 in an attempt at a cor-
relation similar to that made for cooling air fans and combustion air
blowers.  The data gives an idea of the relative magnitude of the gas
and water flows, but are not complete enough for a correlation.


BUILDING COST


Installed capital cost for an MHF never includes the building, if any,
in which the furnace is housed.  In many cases, furnaces are installed
in existing buildings, or the latter may be enlarged.  When entirely
new buildings accompany the furnace, the costs may vary widely.  In
the 1965 Minneapolis-St. Paul contract (MHF No. 11, Table 10), one
new building housed four incinerators with dewatering equipment, con-
trols, instrumentation, lockers, lunch room and service facilities.
An estimate of the cost of that portion of the building applicable to
incinerators alone gave a ratio of building cost to incinerator
installed cost  of 0.513.  For the Battle Creek 1960 contract (MHF No. 5)
the same ratio was estimated as 0.667.  No other examples of simultan-
eous furnace and building construction came to light.  Obviously, the
cost of a new building is significant compared to the MHF installed
capital cost.
ENGINEERING FEE


Under the current system of contracting for treatment plant equipment,
a fairly consistent fee structure has evolved for consulting engineers,
as a percentage of the net construction cost, here taken as the
installed cost of the MHF plus building, if any.  Table 13 lists per-
centages recommended in the states of Kansas, Missouri, and Ohio (Ref.
30) and by the American Society of Civil Engineers (Ref. 31).  For the
present purpose, the Missouri fee structure was selected as being in
the middle of the range of fee structures examined.  A plot of the
values in Table 13 for absolute engineering fee vs installed cost
appears on Fig. 7.  The least-square power law fit for these points,
in the cost range from $10,000 to $5 million is

        EFC = 0.5 (CCI + BGC)°'846                                    (70)
LAND COST

One of the advantages of an MHF (which is built "up" rather than "but")
is the small land area occupied.  As shown in Table 14, the four avail-
able data points were used to establish a ratio of land area to
                                 53

-------
                                                    TABLE  12




                                      EXHAUST GAS SCRUBBERS AND PRECOOLERS
MHF
No.
1
2
3
4
5
6
7
8
9
Location
Cleveland
Minn. -St. Paul
Kansas City
Cleveland
Battle Creek
Battle Creek
Saginav
Hatfield
Bridgeport
Hearth
Area Per
MHF, Sq. Ft.
2327
2084
2084
1425
1068

845
230
85
•X-
Avg. Wet
Sludge
Ton/Day
Per MHF
200
144
186
—
94.6

42.5
24
9.6
Precooler
Gas
CFM @ °F
Yes
Water
GPM @ PSIG
140
(No Scrubber - Dry
Flue Precipitation)
90,000
@ 1400
—
24, 200
@ 1350

—
200
@ 60
—
30
@ 75

—
Yes
Y(
33
Cyclone Scrubber
Gas
CFM @ °F
23,600
@ 175

49,000
@ 180
—
13,100
@ 187

Yes
Water
GPM @ PSIG
50
(10 HP
Booster Pump

100
@ 60
—
85
@ 75

(10 HP Pump)
Yes
Y(
33
t_n
          *Product of design dry solids flowrate and total  solids w/o.

-------
               TABLE  13




       ENGINEERING FEE STRUCTURE
Correlating Equation:  Y = 0.5X
                               0.846
Installed
Cost
(MHF
Plus
Building)
Dollars
(x)
10,000
25,000
50,000
100,000
200,000
300,000
400,000
500,000
750,000
1 Million
5 Million
Fee, Percent of Installed Cost
Kansas
Engin.
Soc .
1962
Ref. (30j
Med.-High

12.5
11.1
10.0
9.0
8.0
6.75
5.9
5.2
4.0
3.5
—
ASCE
Median
1967 Ref. (31)
Complexity:
Aver-
age

—
—
9.4
8.25
7.3
6.85
6.5
6.25
5.85
5.6
4.75
Above
Avg.

—
—
12.7
10.75
9.25
8.6
8.1
7.75
7.25
6.8
5.8
Missouri
Soc. Prof.
Engrs .
Pre-1968
Ref. (30)
Minimum
-*
13.0
12.0
11.0
10.0
8.25
7.25
7.0
6.75
6.25
5.75
4.67
Ohio
Soc. Prof.
Engrs .
Pre-1968
Ref. (30)
Minimum

—
—
—
12.0
9.75
9.0
8.63
8.4
7.6
7.2
5.84
Selected
Absolute
Engineer-
ing Fee
(Missouri
Minimum)
Dollars
(Y)
1,300
3,000
5,500
10,000
16,500
21,750
28,000
33,750
46,875
57,500
233,500
                  55

-------
    10
 tn
 h
 ta
 o
O
 o
PH
 O

 O

 C
1H

 fct
    10'
                     I    I   I
                                                                                         I   I
10
   10-
                     I    I   I
                                            I    I   I
                                                                               Data from

                                                                               Table 1?
                             10-
                                                10
10'
                             Net Cost of Construction  (CCI  + BGC),  Dollars


                                   FIG. 7.  ENGINEERING FEE STRUCTURE
10C

-------
                                                  TABLE 14




                                              MHF LAND AREA
MHF
No.
1
2
5
6

Location
Cleveland
Minn-St. Paul
Battle Creek
Battle Creek

N, No. of
Incinerators
4
4
1
1

D0, Outer
Diameter, Ft.
22.25
22.25
18.75
18.75

.785 N D02
Superficial
Area, Sq Ft
1555
1555
276
276
(x)
Land Area,
Sq Ft
9000
6400
1300
1190
(Y)
Ui
            Least Square X-Y Fit of Straight Line Through Origin:   Y = 4.938 X

-------
superficial circular area based on MHF outer diameter.  This ratio
was found to be KLA = 4.938.  In all cases, the land area is a small
fraction of an acre, and thus a minor cost item.
HEARTH REPLACEMENT MATERIAL, LABOR, AND FREQUENCY


During the life of a MHF it may become necessary to replace one or
more hearths because of their deterioration due to exposure to high
temperature and to heating/cooling cycles.  Based on hardware exper-
ience, estimates were made for material and labor required to replace
the two components which make up a hearth: castings (e.g., rabble
arms and structural supports) and refractory (brick lining of hori-
zontal and vertical hearth surfaces).

Table 15 shows that all replacement expenditures per hearth increase
with diameter.  Castings are more expensive than refractories from
the material standpoint, while the amount and unit cost of refractory
replacement labor exceed those for castings (see columns 4 and 6  of
Table 8 ).  Correlating polynomials for all four hearth replacement
expenditure items were fitted to the data in Table 15.  The equations
are valid for Outer Diameter (HDIA) values from 6 to 23 feet and apply
to replacement of one hearth;

    On-Site        CAST = 1081 - 220 HDIA +89.5   (HDIA)1*5       (71)
    Castings
    Material

    On-Site        REFR =  458 - 120 HDIA +14.6   (HDIA)2         (72)
    Refractory
    Material

    Casting        CLH  = 7.47 - 0.105 HDIA + 0.0299 (HDIA)2       (73)
    Man-Hours

    Refractory     RLH  =69.1-0.105 HDIA + 0.530  (HDIA)2'25    (74)
    Man-Hours

Frequency of hearth replacement should preferably be based on the life-
time history of a MHF.  As indicated by Table 6, part of a lifetime
replacement history was available for the three Minneapolis-St. Paul
units commissioned in 1940, during the period 1951-1965.  Table 16
compiles the number of hearth castings and refractories replaced
during the 15-year period.  For the castings, it was assumed that
each rabble arm replaced was equivalent to 1/4 casting and each tooth
to 1/40 casting.  The result is that the equivalent of 44 hearth
castings and 10 hearth refractories were replaced during years 11
through 25.  With the assumption that the replacement frequency for
the first 10 years was only half of that during years 11 through 25,
the following tabulation results:
                                58

-------
                                                      TABLE 15




                                       HEARTH REPLACEMENT MATERIAL AND LABOR
Outer
Diameter, Ft
(13.5 in Wall)
"HDIA"
10.75
14.25
16.75
18.75
22.25
Castings (One Hearth)
On-Site Material,
1969 $
"CAST"
1907
2695
3410
4455
5511
Labor ,
Man-Hours
"CLH"
10
12
14
16
20
Refractory (One Hearth)
On-Site Material,
1969 $
"REFR"
913
1661
2365
3542
4950
Labor ,
Man-Hours
"RLE"
192
288
336
480
640
VD

-------
                 TABLE 16
   15 YEARS HEARTH REPLACEMENT HISTORY:
     THREE MEMEAPOLIS-ST. PAUL MHF'S
          (Operating Since 1939)
Each MHF:  8 Hearths = 20 Arms + 138 Teeth



Year
1951
1952
1953
1954







1955


1956



1957
1958
1959
1960
1961

1962

1963
1964


1965


MHF No.
Hearth No.
All
All
All
3/2
1/2
1/3
1/4
All
2/2
2/3
2/4
I/All
2/A11
3/A11
All
1/1
1/3,4,6
2/1
All
All
All
All
V
3/
3/
V
V
V
2/
3/
V
Castings
Rabble
Teeth

No.
20
2
24




81



9
51
4
58



55
—
18
44
7
2
3
-
-
-
-
-
5

Equiv.
0.50
0.05
0.60




2.00



0.25
1.25
0.10
1.45



1.40
—
0.50
1.10
0.20
0.05
0.075
—
—
—
—
—
0.125
Rabble
Arms

No.
2
2
5




6



2
8
-
16



12
2
3
11
4
3
2
2
5
2
5
4
—

Equiv.
0.50
0.50
1.25




1.50



0.50
2.00
—
8.0



6.0
0.5
0.75
5.00
1.00
0.75
0.50
0.50
1.25
0.5
1.25
1.0
—
15-Yea- Totals
Total
Hearth
Equiv .
1.00
0.55
1.85




3.50



0.75
3.75
0.10
9.45



7.40
0.50
1.25
6.10
6.20
0.80
0.58
0.50
1.25
0.50
1.25
1.00
0.12
42.90
Refractory

Total
Hearths



1
1
1
1

1
1
1




1
1
1













10
                   60

-------
                                        Castings   Refractories

    Hearths replaced during years
    11 through 25 (in 3 MHF's, each
    8-hearth)                             42.9        10

    Equivalent MHF's replaced during
    years 11 through 25                    1.79        0.42

    Equivalent MHF's replaced during
    years 1 through 10 (at half
    rate of years 11 through 25)           0.60        0.14

    Equivalent MHF's replaced during       2.39        0.56
    total 25-year life                    (CRL)       (RRL)
                  _/
Conditions at 'Minneapolis-St. Paul were relatively "mild", e.g.,
temperatures below 1600 F, primary sludge with high total solids, no
sulfur in the auxiliary fuel, and, perhaps most important, 24 hr per
day (HPD) operation.  This meant few cooldown/heatup cycles and con-
sequent low thermal stress.  It was decided to use the replacement
rates above (rounded off) for all 24 HPD furnaces, and a rate twice
as high  (to account for increased cycling) for all furnaces which
operated less than 24 hr per day, i.e.:

    CRL = 2.5 for HPD = 24 and 5.0 for HPD less than 24
                                                                   (75)
    RRL = 0.5 for HPD = 24 and 1.0 for HPD less than 24
NORMAL MAINTENANCE MATERIAL AND LABOR


Multiple hearth furnace maintenance has a periodic component (hearth
replacement, see previous section) and a continuous component (normal
maintenance).  The latter involves for the most part regularly sched-
uled inspection (for wear, corrosion and failure), servicing, (e.g.,
lubrication of rotating machinery) and adjustment (e.g., of instrumen-
tation) of all MHF components which may undergo changes as a result
of operation and mere exposure to the environment.

The field survey produced sketchy and incomplete information.  In par-
ticular, normal maintenance was sometimes lumped in with operation or
hearth replacement.  Frequently, labor and material (the latter called
Parts and Supplies) were often reported as a combined dollar expendi-
ture.  The variables to be correlated were assumed to be expenditures
per elapsed calendar time, rather than per operating time, because
normal maintenance efforts and environmental deterioration are both
related to calendar time.  Physical size, expressed as hearth area
was taken as the dependent variable, although its influence would be
expected, and, in fact, was found to be minor.
                                61

-------
Table 17 shows data from six MHF's for normal maintenance material
and labor, Fig. 8 is a plot for Parts and Supplies, and Fig. 9 a
similar plot for labor, both for annual expenditures as a function
of hearth area.  Least-square power law fits for these curves are
as follows:

  Annual Parts and Supplies AMSY = 570 (FHA)0<°23, 1969 Dollars     (76)

  Annual Labor              ANMM = 120 (FHA) '    , Man-Hours        (77)
OPERATING LABOR

Since this item is usually the second-largest component of the total
annual cost (the first being capital charges), considerable effort
was expended in obtaining realistic data.   These are listed in Table
18 where the raw data are converted to Equivalent (i.e., considering
supervision) Non-Supervisory Man-hours per MHF per 24 hr Operating
Day (0MD).  In the absence of other information, the non-supervisory
man-hours were increased by 10% to account for the cost of supervi-
sion.   Where supervisory man-hours were available, a supervisory
hourly rate 1-1/2 times the non-supervisory rate was adopted.

Fig. 10 is a plot of the 10 points of Table 18 on a 0MD vs FHA log-
log graph.  The data indicated that there was a minimum operating
labor level in "small" plants, independent of the MHF size.  This
level was taken to be 0MD = 6.  These plants, too, operated the MHF
on 8-hr shifts (compared to round-the-clock operation for the other
plants), contributing to higher specific labor costs.  The remaining
points (except two) were correlated by a 45° line (indicating direct
proportionality) which met the minimum 0MD at FHA = 719.  The cor-
relation then becomes
  For FHA equal to or less than 719 sq ft:  0MD = 6

  For FHA greater than 719 sq ft:           0MD = 0.008343 (FHA)
(78)
The two points which lie below the correlating line on Fig. 10 repre-
sent Saginaw and South Tahoe.  In Saginaw, the incineration is con-
tinuous and requires no auxiliary fuel in view of the 45 w/o solids
content; at South Tahoe two other MHF's (for lime recalcination and
activated carbon regeneration) are part of the same plant and all
three MHF's are operated jointly.  Reduced operating labor would be
expected in these two plants, and the dashed line parallel to the
main line represents a 1/3 reduction, which is reasonable.

A direct proportion relationship means that no advantage in operating
labor cost is gained by having fewer larger MHF's in a plant, i.e.,
there is no "large economy size".  While at first this appears
                                62

-------
                                             TABLE  17


                            YEARLY NORMAL MAINTENANCE MATERIAL AND LABOR

MEF
No.
2

3

5

6
7
9




Location
Minn. -St. Paul

Kansas City

Battle Creek

Battle Creek
Saginaw
Bridgeport



No.
of
MHF's
4

3

1

1
1
1
_

Hearth
Area
Sq.Ft./MHF
"FHA"
2084

2084

1068

890
845
85


Parts and Supplies


Year
1965

1969


1969

1969
1969



All
MHF's
$/Yr.
7,292

5,000


3,000

2,400
2,000*



Per MHF
1969 $/Yr.
"AMSY"
2,178

1,667

1,500

1,500
2,400
2,000


Labor

Raw Data

Year
1965

1969


1969

1969
1969



Expenditure
$12,084
(4 MHF's)
$18,000*
(3 MHF's)

2,000 Man-Hr
(2 MHF's)
720 Man-Hr
*20fo of Total
Labor (6.3
Man-Hr/Day)


Man-Hr ./Yr.
Per MHF
"ANMM"
880

1,473

1,000

1,000
720
460


*Estimate


Correlating Equations:


  Parts and Supplies:  AMSY


               Labor:  ANMM
         0 023
570 (FHA) *    ,  1969 $ per year

         0 307
120 (FHA.)     ,  Man-Hr  per year

-------
Maintenance
ies (AMSY),
per Year
to *•
0 0
0 0
0 0
rH D. 00
co a. ^
E S a
O r*1*
* "c « 1000
«M CO
o o^
CO *O
-tJ -fj o^
00 h I-H
0 CO
^nn
i i i i
9
•, 	
, —
MB^^Oi
—

1 1 1 1






1 1
— .— — — ^-^— •— '


1 1
1 1 1 1
7
O
•— »M^— »—•
60
^

i i i i
i i i i
„« 	 i
A
*5

i i i i
i i
_3
•^^KB«Hi^^>BW
•2
Data from
Table 17
Numerals
from MHF
Numbers
' 1
50
100         200             500         1000        2000

         Effective Hearth Area per MHF (FHA.), sq ft
5000
                        FIG.  8.   COST OF NORMAL MAINTENANCE
                                 PARTS AND SOTPLIES

-------
     2000
o <
o ^^^

0} F-i
n 03
o a;
I—1  CO
OS  fH
E  3


If
   C
      1000
                                                                              Data  from

                                                                              Table  17
                                                                              Numerals

                                                                              are MHF

                                                                              Numbers
      250
          50
                     100          200             500         1000         2000


                              Effective Hearth Area per MIIF  (FHA),  sq  ft



                                   FIG. 9.   NORMVL MAINTENANCE LABOR
5000

-------
                                              TABLE  18




                                            OPERATING LABOR
    NMII = Non—supervisory Man—hours
SMH = Supervisory Man-hours
MET
No.
1
2
3
4
5
6
7
8
9
10
Location
Cleveland
Minn. -St. Paul
Kansas City
Cleveland
Battle Creek
Battle Creek
Saginaw
Hatfield
Bridgeport
South Tahoe
No.
of
MHF's
4
4
3
4
1
1
1
1
1
1
Hearth
Area
Sq Ft /MHF
2327
2084
2084
1425
1068
890
845
230
85
575
Raw Data (for 24-Hr. Operating Day)
1969 Unless Stated
(72 NMH + 8 SMH) per Day for 4 MHF's
66 NMH per Day for 4 MHF's (1965)
40$ (est.) of (Dewater + Incin.) Labor
(80 Equivalent NMH/Day for 2 MHF's)
40 NMH per Day for 4 MHF's (1958)
8 NMH per Day
8 NMH per Day
4 NMH per Day
6.4 NMH per Day - No SMH
80$ (est.) of Total Labor (6.3 NMH per Day)-No SMH
$19.93/Day at $5.65 Equivalent Hourly Rate
Equivalent
NMH per MHF
per 24-Hr.
Operating Day
21.0**
18.2*
16.0
11.0*
8.8*
8.8*
4.4*
6.4
5.0
3.5
* Equivalent NMH (Est.) = 110$ of Actual NMH (For Supervision)




**Supervisory Hourly Rate (Est.) * 150$ of Non-supervisory Rate

-------
I cfl
G Q
o
,C
-P O
Cd ^tH
li
  0}
  p*
      30
      20
            1   1  1  I
            till
                                        !
I
                                                     i  i   I  i
                                                            /
                                                        .
                                                   10  /
                                                /
III)
        50
                              Data from
                              Table 18
                              Numerals
                              are MHF
                              Numbers
_L
                    100         200             500          1000         2000
                            Effective  Hearth Area  per  MHF  (FHA),  sq  ft
                                — — — Plants  with Labor Savings
                                         5000
                                    FIG.  10.   OPERATING LABOR

-------
unrealistic, it should be noted that a-recent study of over 1500
U. S. treatment plants by Michel, Pelmoter and Palange (Ref. 32) was
interpreted by Smith (Ref. 33) to indicate that the total labor
(mainly operating) was almost directly proportional to the plant
design capacity independent of plant size.  Admittedly, this was the
result of an overall statistical study of all types of conventional
wastewater treatment plants; other overall plant studies (e.g.,
McMichael, Ref. 34) indicate a -savings for larger plants.  Obviously,
the relation between operating labor and capacity for specific
processes will vary with the process.
ELECTRICAL POWER CONSUMPTION

Good records are usually kept of electrical power consumption, by
kilowatt-hour and dollar.  Since power is consumed mainly during
operating periods, a measure of cumulative powqr usage is the cumu-
lative tonnage of treated sludge.  Th£ quantity kilowatt-hour per
ton dry solids (PDS) was selected as the variable.  Table 19 shows
the data points which are platted^on Fig. 11 on a log-log plot vs
FHA.  The figure shows that PDS decreases as FHA .increases.  Ten of
the eleven points were correlated (for FHA up to 2808 sq ft) by the
function

  PDA = 29.6 - 6.55 x 10~9 (FHA - 2808)3 + 4.94 x 10~16 (FHA-2808)5   (79)

The one uncorrelated point is for the Minneapolis furnaces  (No. 2)
which employed natural draft and had no wet scrubber, thereby reducing
power usage below the level of the forced' draft, wet scrubber
installations.
THERMAL CYCLING: YEARLY HOURS


When MHF's are not operated round the clock, the question arises of
how best to schedule the on-off cycles, so that MHF life and operating
time are not curtailed to the point of inefficiency.  In addition to
cycling as part of the operating schedule, at least one annual cold
MHF inspection is advisable.  Due to the inability of refractory to
sustain tensile loads which may result from thermal stresses, it is
important to limit the temperature differences within the material by
limiting the heatup and cooldown rates.  Although experts differ on
details, there is a general consensus that somewhere in the temperature
range from ambient to operating (say, 70 to 1500 F) a "soak" period
should take place for reasons of stress equalization within refractories.
In this study, 1200 F was chosen as the "soak" temperature, and also
as the "standby" heating temperature, when the furnace is to be inactive
for short time periods, such as overnight, or even weekends.  This
soaking should be carried out both during heatup and cooldown.
                                 68

-------
                                              TABLE   19
                                     ELECTRICAL POWER CONSUMPTION
MHF
No.
1
2
3
4
5
7
8
9
11
Location
Cleveland
Minn. -St. Paul
Kansas City
Cleveland
Battle Creek
Saginaw
Hatfield
Bridgeport
Minn. -St. Paul
Hearth
Area/MHF
Sq Ft
"FHA"
2327
2084
2084
1425
1068
845
230
85
2808
No.
of
MHF's
4
4
3
4
1
1
1
1
3
Data
Year
1967
1967
'67-'69
'62- '65
1968
1969
1969
1969
1968
Actual Avg. per MHF
1000 's KWH
per Year
94.7
—
216
205
229
541
—
17.3
—
Dry Solids
Tons/Year
3296
—
7272
4064
6060
7620
—
221***
—
KWH
per Ton
Dry Solids
28.8
5.2*
29.7
50.6
37.8
71.0
98.9**
78.4
35.7
  *Lov Value:  Natural Draft - No Wet Scrubber
 **Estimated from HP and Sludge Flow Ratings
***Estimated from Ash Flov Rates

-------
Cfl
e
   CO
  •o
 C
 O r-l
••-I O
•+-> 09
 C.

 § r?
 03 T3
 C
 O C
O O
 O
 o ,s
•H  I
u
0
C.
CO
      100
50
       20
10

                                          I

                                                                             11
         50
              100
200              500          1000        2000

  Effective Hearth Area  per MI1F (FHA), sq ft

  Note;  MHF No. 2 not fitted, because plant

         had no wet  scrubber or induced draft fan.
                                                                                       Data from
                                                                                       Table 19
                                                                                       Numerals
                                                                                       are MHF
                                                                                       Numbers
                                                                                         Li  I  I
5000
10,000
                                           FIG.  11.   POWER CONSUMPTION

-------
The allowable rates of change of temperature are lower for large
hearth diameters and furnaces than for small ones, and are usually
specified by the manufacturer.  The field reports showed that the
large furnaces, in Minneapolis-St. Paul and Cleveland, are limited
to transient rates of 20 to 25 F per hr with soak periods of 1 to 2
days, so that it requires several days to heat up or cool down a
furnace completely.  The allowable temperature change rates increase
to 150 F per hr for the smallest MHF's examined.  The duration of the
stated transients affects the steady-state annual MHF operating per-
iod and also the fuel requirements during transients.  To limit the
temperature change rates, it is sometimes necessary to apply heat to
an MHF while it is cooling down.  In this study, however, it was
assumed that a furnace could be "bottled up" (i.e., all openings
closed off) well enough to avoid the need for heating during cool-
down.  Moreover, the heat input rate (Btu/hr) was taken to be the
same for (1) the pre-soak ambient-to-1200 F and  (2) the post-soak
1200 F-to-1500 F periods.

A unified "optimum" operational scheme for all MHF's was developed
with the help of the field data which suggested  that the furnaces
should be divided into three operational groups:

     (A) Hours per day HPD = 24  (Large cities)
        Days per week DPW =  7  MHF Nos. 1, 2, 4 (also 7)

     (B)               HPD = 24  (Intermediate cities)
                      DPW <  7  MHF Nos. 3, 5, 6

     (C)               HPD < 24  (Small cities)
                      DPW = Any MHF Nos. 8 & 9

First, a Heatup Time (CYT), hr, (also equal to cooldown time) was
developed as a function of furnace hearth area (FHA), based on
typical temperature  change rates soak times.  Table 20 shows how CYT
values were generated for several FHA levels, and Fig. 12 shows the
resulting CYT vs FHA straight-line-segment graph.

Fig. 13 depicts the two types of cycle considered: a cold cycle for
maintenance inspection for all three groups, and a hot cycle for
standby at 1200 F applicable to groups (B) and (C).  Periods during
which fuel is used at the heatup rate, standby rate, or not at all
are indicated on the figure.

Next, the total yearly cycling hours per MHF (YHUH) and yearly hot
standby hours per MHF (YSBH) were established for each operational
group in terms of CYT, N0F (total number of MHF's in plant) and SN0
(number of standby MHF's).  This information is  detailed in Table 21
which assumed two complete "cold cycle" inspections per year.  To
model standby units, it was assumed that the load was evenly distri-
buted among all furnaces on an annual basis.  Combination of the
                                71

-------
                                                    TABLE 20
                      Note:   Heatup hours
MHF HEATUP RATES AND TIMES
Cooldovn hours, but no fuel used during cooldowi
Effective
Hearth
Area, Sq Ft
"FHA"
200 ± 200
600 ± 200
1100 ± 300
1700 ± 300
2000 +
Assumed
Allowable
Heatup
Rate, °F/Hr.
150
100
75
50
25
Hours for Portions of
Complete Heatup (0-1500°F)
0-1200°F
(4/9) CYT
8
12
16
24
48
1200°F Soak
(4/9) CYT
8
12
16
24
48
1200-1500UF
(l/9) CYT
2
3
4
6
12
Total
Heatup,
Hours
"CYT"
18
27
36
54
108
Assumed
Hours for
Inspection
(8/9) CYT
16
24
32
48
96
VJ
Ni

-------
    110
•rt
E-i
 a

 o
•xs
r-t
 O
 o
 01
 o
                                                                                —  Table 20 Data
                                                                                   Adopted for    —

                                                                                   Computer

                                                                                   Program
                                                                                  i      I
                                     1000                            2000


                               Effective Hearth  Area per MIIF (FHA), sq ft


                                        FIG.  12.  MHF HEATUP TIME
3000

-------
        t
D
+>
C3
^
QJ
G.
s
o
EH
HOT CYCLE
1500 j 	 v . / »
1200









1/Q _/
\ K

*,



4
V

^ 	 No Fuel


/
*


I
•^ 	 Night, Weekend, 	 'H^
P+o.


^ — Ileatup Fuel


S^ 1/Q
                       COLD CYCLE
                                Heatup Fuel
                                                                  Standby Fuel
                            Maintenance
                            Inspection
                                                                         Time  (CYT units)
               FIG. IJ.  ASSUMED MHF THERMAL CYCLES

-------
                                                     TABLE 21
                                    YEARLY COLD, HEATUP, AND STANDBY HOURS PER MHF
                           Assumption:   Load evenly distributed among NjZfF on annual basis
Opera-
tional
Group
(A)
(B)
(c)
Hr.
per
Day
HPD
24
24
<24
Days
per
¥eek
DPV
7
<7
Any
Type
of
Cycle
Cold
Hot
Cold
Hot
Cold
Hot
Cold Hours
(No Fuel Used)
Hours
per
Cycle
17
-g*y
—
17
-g*y
9*y
17
-g-xy
|xy
Cycles
per
Year
2
—
2
52
2
52 DP¥
Hrs.
per
Year
34
-g*y
None
34
-gxy
52
-gxy
34
-gxy
52
-gxy
.DPW
Heatup Hours
(0-1200, 1200-1500°F
Hours
per
Cycle
5
9Xy
—
5
?xy
9^
5
gxy
|*y
Cycles
per
Year
2
—
2
52
2
52 DP¥
Hrs.
per
Year
10
-g*y
None
10
-gxy
52
-g*Y
10
-gxy
52
-9 xy
.DP¥
Standby Hours
lat 1200°F)
Hours
per
Cycle
4
9^
—
4
9Xy
(7-DP¥)
.24 y
4
?xy
24 y{7-DP¥)
y(24-BPD)
Cycles
per
Year
2
—
2
52
2
i*
52
52 DP¥
Hrs.
per
Year
8
9Xy
None
8
?xy
1248 y
•(7-DP¥)
8
9*y
y[8736
-52(HPD)(DP¥)]
Ol
       Abbreviations:   x » CYT;  y - (N0F-

-------
YHUH and YSBH components in Table 21 leads to  the  following  relation-
ships for total hours:
(A)  YSBH = (8/9)  (CYT)  (N0F - SN0)/(N0F)

    YHUH = (10/9)  (CYT)  (N0F - SN0)/(N0F)
                                                                    (80)

                                                                    (81)
     (B) YSBH =  (N0F - SN0)  [(8/9)  (CYT) + 1248  (7-DPW) ] / (N0F)       (82)

        YHUH =  (62/9) (CYT) (N0F - SN0.)/(N0F)                       (83)
     (C) YSBH =  [(N0F - SN0)/(N0F)]
                                [(8/9)CYT] + [8736-52(HPD)(DPW)J
    YHUH = [(N0F - SN0)/N0F] (CYT/9) [10 + (52 DPW) ]
(84)
                                                                    (85)
THERMAL CYCLING: HEAT AND FUEL REQUIREMENTS


From the field data, hourly standby and heatup heat requirements,  in
terms of million Btu per hour, were developed as function's  of  the
effective hearth area.  Table 22 shows the available data,  reasonable
on heatup and scant on standby.  Linear least-square equations are
fitted to the standby data, plotted on Fig. 14, and the heatup data,
plotted on Fig. 15:
Standby. Heat Requirement
    Btu per hr

Heatup Heat Requirement
    Btu per hr
                                      =
                                    x
                                      =


As might be expected, the standby requirement is a small  fraction  of
the heatup requirement.  The sum of the products (YSBH) • (SBQ)  and
(YHUH) • (HUQ) is the total annual heat requirement for  thermal  cycling.
Division of this sum by the heating value  (Btu per Ib)  of  the  fuel to
be used then provides the annual fuel consumption for  thermal  cycling.
The steady-state fuel consumption is found from the Thermal  Analysis
(Chapter IV) as explained in Chapter VII.
TOTAL MHF HEAT RELEASE


The basic energy balance, developed in detail  in Chapter  IV,  matches
the combined heat energy contained in the incoming  sludge and aux-
iliary fuel to the sum of the outgoing heat flows.  The latter are
associated with the exhaust gases  (including heat required for
                                76

-------
               TABLE  22




THERMAL CYCLING HEAT REQUIREMENTS PER MHF
MHF
No.
1
2
3
4
5,6
7
8
9
Location
Cleveland
Minn.-
St. Paul
Kansas City
Cleveland
Battle
Creek
Saginaw
Hatfield
Bridgeport
Hearth
Area
"FHA"
Sq.Ft.
2327
2084
2084
1425
1068,
890
845
230
85
Opg.
Year
1966
1959
1969
62-65
(Avg)
1969
1969
1969
1969
Standby (Avg. per Year per MHFl
Oil,
Gal
/Btu \
\Gal /
16,535
(l.39x!05)
204
(l.39xl05)

Gas,
Cu Ft
/ Btu \
\Cu Ft /
207.5
(600)
Yearly
Heat,
106Btu
2298
Stand-
by >
Day/Yr
130.5

3.15xl06
(600)
400/Hr
(896)
506

55.1




Heat
per Hr,
10° Btu
.734
.383
.358
Heatup (Avg. per MBF)
Fuel
Qty.
/Btu \
^Unit /

25,700
Gal/Yr
(l.39x!05)
25,000
Cu Ft/Wk
(880)
14,000
Cu Ft/Wk
(896)
900
Gal/Cy
(l.4x!05)
6100
Cu Ft/Cy
(936)
200
Gal/Cy
(l.4x!05)
Heat
Rate,
106 Btu

3572
per
Year
22
per
Week
12.54
per
Week
126
per
Cycle
5.71
per
Cycle
1.4
per
Cycle
Cy/Yr
(Hr/Cy)

15
(60)
1 per
Week
(5)
1 per
Week
(9)
8
(72)
(12)
(3)
Heat
per Hr,
10b Btu

3.97
4.4
1.39
1.75
0.475
0.467

-------
00
c-
o
w

   (H
-P ,=
c
O S-,
E 0)
o a.
I*
t* 3
3 -P
crpq


^ s
-p o
a -H
                                                                                 Data from Table  22
                                                                                 Numerals are

                                                                                 MHF Numbers
                                              1000                           2000


                                        Effective Hearth Area per MHF  (FHA),  sq ft
                                                                                                     3000
                                          FIG.  14.   MHF STANDBY HEAT REQUIREMENT

-------
Cf
-p
a;
E
P -H
c-pq
O)
« 03
  C
-t-> O
03 -r-l
O i— I
EC r-l
CO
a>
                                                                          Data from Table  22

                                                                          Numerals are
                                                                          MOF Numbers
                                                                              I
                                                                                     I
                                       1000                           2000

                                Effective  Hearth Area per  MHF (FHA), sq ft

                                  FIG.  15.  MHF HEATTJP HEAT  REQUIREMENT
3000

-------
evaporation of the water content of the sludge), the ash, the part of
the cooling air rejected to the atmosphere, and the furnace heat
losses to the environment.   The Thermal Analysis described in Chapter
IV calculates the steady-state fuel requirements when sludge proper-
ties, minimum percent excess air, temperatures of the exhaust stream,
and some minor parameters are specified.

Another approach to finding fuel requirements is to examine the
records of operating sludge incinerators for historical sludge and
fuel flows and properties.   The sum of the heat energies released by
the sludge and fuel, normalized on the basis of some MHF capacity
variable, might be proven of value as an empirical guideline.  Of
several tried, the quantity Total (Fuel + Sludge) Heat Release in
Million Btu per Ton Wet Sludge appeared to be the most useful.  Table
23 gives average annual fuel and sludge data for all the furnaces
visited in the field.  The  Total Heat Release computed from these
data appears in the last column, with values varying between 3 and 7.

The Total Heat Release is between 3.5 and 4.5 for most of the furnaces
investigated.  Values much above 4.5 are probably excessive (since
they are out of step with the current practice) and could indicate
either higher exhaust stream temperatures than in most incinerators,
or excessive use of cooling or combustion air.  The highest value
listed in Table 23, 7.0 for Saginaw, is the result of (1) the high
calorific value of the sludge volatiles and (2) the high concentra-
tion of solids in the sludge.  The Saginaw MHF could be operated
quite well with a much wetter sludge, thereby reducing filtration
costs or could be used as a source of thermal energy for other tasks.

The Kansas City MHF plant also appears to operate at a high heat
usage per ton of sludge.  Since the Kansas City sludge has about an
average solids content and  heat release, the reason here would appear
to be the use of excess fuel perhaps accompanied by enough excess air
to maintain a reasonable exhaust temperature.

The Cleveland MHF's, on the other hand, have a Total Heat Release of
about 3.   This is quite low and indicates a colder exhaust temperature
than the average operating  MHF or perhaps a smaller amount of excess
air and cooling air than is in use elsewhere.

It is realized that the suggested criterion is empirical.  It should
be tested against operating data from other MHF's to establish the
extent of its validity.
                                 80

-------
                                                     TABLE   23




                                               TOTAL MHF HEAT RELEASE
MHF
No.
1
2
3
4
5

6


7


8
9
Location
Cleveland
Minn. -St. Paul
Kansas City
Cleveland
Battle Creek

Battle Creek


Saginaw


Hatfield
Bridgeport
Year
or
Period
1966
1967
1966
1967
67-69
62-65
1968
1969
1964
1965
1967
1966
1967
1968
1969
1969
1969
Sludge (Yr. Avg. )
Btu/Lb
Volatiles
9,530
10,000
10,500
10,070
104*

104*


13,970


io4*
7000/Lb. Dr
V-t.%
Vola-
tiles
43.7
43.3
71.8
69.5
59.9
43.9
57.0
54.8
•• 56.5
58.4
63.7
• 44.8
46.7
48.2
51.1
65(est.)
y Sol.
(est.)
R"X"
10b Btu
Per Ton
Dry Sol.
8.33
8.25
14.4
13.9
12.6
9.4
11.4
11.0
11.3
11.7
12.7
12.5
13.0
13.2
14.3
13.0
14.0
"Y"
All Fuel
(Yr. Avg.)
10b Btu per
Ton Dry Sol.
5.4
4.25
0.375
0.50
4.0
4.0
4.46
6.15
7.60
3.45
4.18 •
None


—
14.0
"Z"
Avg. Tot.
Solids,
Vt.fo in
Sludge
23.0
23.4
27.5
28.2
29.4
23.4
26.0
26.1
24.7
26.6
24 -J5
45.9
47.
47..
48.
20. (est.)
13.5(est.)
"Z(X+Yj"
Avg. Total
(Fuel + Sludge)
IO6 Btu per
Ton Vet Sludge
3.16
2.92
4.06
4.06
4.88
3.14
4.47
4.12
4.67
4.03
4.17
5.74
6.1
6.2
6.92
—
3.78
OQ
                        * Assumed value

-------
                   VII.  DESCRIPTION OF SUBROUTINE
SUBROUTINE OPTIONS


The subroutine developed is a single computer program with two options:

     1.  Thermal Analysis Option  (NCASE = 0)

     2.  Design Cost Option       (NCASE > 0)

These options are specified by the value assigned to the variable
NCASE (number of cases) on the first input data card.  The subroutine
was written in Fortran IV computer language and is compatible with the
IBM 1130 and IBM System 360 digital computers.  The Fortran IV sub-
routine listing is enclosed in the Appendix.  Chapter VIII is a
User's Guide to Input Selection wherein each input variable (to both
options) is listed and discussed.  Chapter IX describes the mechanics
of the input format and contains  a set of sample input data cards, as
well as printouts for a numerical example of each option.

The Thermal Analysis Option (TAO) essentially performs the calculations
detailed in Chapter IV, "Thermal Analysis".  For a unit MHF supplied
with a sludge flow of given magnitude and characteristics TAO finds the
steady-state flows of combustion air and auxiliary fuel to maintain a
specified excess air percentage for combustion of sludge volatiles and
specified temperatures of cooling air, exhaust gas and ash at dis-
charge.  The TAO is useful for checking an existing or planned incin-
erator from a technical performance standpoint.  The Design and Cost
Option (DCO) performs the task of designing and costing an incinerator
system (which may consist of one  or more MHF's) to incinerate a given
sludge flow considering operating schedule, maintenance factors, and
costs.  The DCO includes the TAO  in its entirety.  The DCO features a
variable "MHF Selection Input" which the user should employ for the
design and costing of a number of differently operated incineration
systems for the purpose of choosing an optimum system.

The interrelationship between the two options may be seen from the
respective calculation outlines depicted in the schematics of Fig. 16
for the TAO and Fig. 17 for the DCO.  The rectangular boxes on these
figures contain all the individual inputs in the groupings discussed
in Chapter VIII.  On the TAO Schematic (Fig. 16), there are 5 boxes
of technical inputs: for Sludge Stream, Air Data and Stream Tempera-
tures, Auxiliary Fuel Burner, Chemicals Reaction Data, and Environ-
ment.  Only the remaining box (MHF Data Input) is non-technical.
The entire TAO computation (detailed in Chapter IV) is given the
designation "B".
                                83

-------
      Au.\ 11 iary fuel
       Burner Input
      XAMJT  XEIJ1
      QFU    XAMF(l
      BURI1X  FRF(l)
      EXAFU
Air Data and
Stream Temp-
  er at urea
   Input
PXA1R TSL1
SCFCL TKX
FIUIR TASH
TAIRI TSCRB
oo
Sludpe Stream Input
PSLU QY0L  XKLY
PERS PCAC  XAMV'(l)
PERV PFFJIY FRV(l)
     PALIIY
 Data Input
1ID1A
NHEAR
                                                         \/
                                                         B
                                                      THERMAL
                                                      ANALYSIS
                                                      COMPUTA-
                                                        TION
Fjivironuient
   Input
   '1 AMB
   TSHl
   VA>tBM
   ELF,
                                                        V
                                                   THERMAL OUTPUT
                                           Air For Volatiles Combustion
                                           MIIF Heat  Balance
                                           Airxiliary Burner Selection
                                           >DIF Exit  Gas Data
                                           MIIF Mass  Balance
                           FIG.  16.   SCHEMATIC  OF  THERMAL ANALYSIS OPTION
                                      ~':(NCASE = 0)

-------
oo
        Air Data and
        Stream Temp-
          eratures
           Input
        PXAIR  TSL1
        SCFCL  TEX
        FRAIR  TASK
        TAIRI  TSCRB
       Auxiliary Fuel
        Burner Input
EXAFU NELF
QFU   XAMF(l)
BUREX FRF(l)
      Chemicals Reac-
        tion Input
           FCAC
           FFE
           FAL
        Environment
          Input
        TAMB VAMBM
        TSUR ELE
                        Sludge Stream Input
                        PWS  QVjZiL  NELV
                        PERS PCAC  NAMV(l)
                        PERV PFFJIY FRV(l)
                             PALHY
MI3F Selection Input
   I1PD   SNjZ(
   TDPW  ADF
Financial Input
 SLF     UFC
 YIR     UPC
 NAMFU   ULC
 KEFR    BFR
 0LR     ANMR
 CRR     AMRR
                                         MIIF Design and
                                        Operation Output
                         Thermal Output
                                   Non-Dollar Output
                                                                        Cost Output
                          FIG. I?.  SCHEMATIC OF DESIGN AND COST OPTION
                                          :(NCASE > 0)

-------
Reference to the DCO schematic (Fig. 17) reveals that it, too, features
the same 5 technical input groups, but, in addition, has a Financial
input and an MHF Selection input.   Four sets of computations are
involved, designated "A" through "D";  of these "B" is the TAO compu-
tation.  Before describing these computations in detail, mention should
be made of some ground rules which were evolved based on the nature of
the field data (Chapter V) and the results of the data correlation
(Chapter VI).
GROUND RULES
1.  The MHF selection input is made variable to provide numerous incin-
    erator designs from which an optimum may be chosen.  The MHF
    Selection input consists of• four quantities, two indicative of
    the operating schedule (hours per day and days per week), and two
    indicative of the reliability to be built into the system (number
    of standby units and number of units above the minimum required).
    As these four quantities assume different values, different incin-
    eration system designs and costs will be generated, and the optimum
    will be the one which satisfies the most important criteria of the
    user.  If this is minimum cost, then a smaller number of larger
    furnaces, associated with zero standby and excess units, would
    probably result, but at a sacrifice in reliability and flexibility.
    Alternatively, the schedule inputs may be varied to find the
    "optimum for a plant yet to be built, or to adjust the changes in
    operation of an existing plant.

2.  Incineration is assumed to take place only during all or part of
    regular operating hours for the treatment plant as a whole.  It
    was considered definitely too costly to operate the incinerator
    outside of regular plant hours by itself.  Incineration takes
    place 52 weeks in the year, except for 2 yearly.shutdowns for
    maintenance inspection.  For incinerators which do not operate
    continuously, hot standby operation at 1200 F is assumed, e.g.,
    for a weekend period or portions of every day.  Further, the heatup
    and cooldown is taking place according to the temperature change
    rates (which vary with incinerator size) in Chapter VI.  Implicit
    in these assumptions is the ability of the dewatering and any
    sludge storage equipment to adapt to the incineration flowrates
    and schedules.

3.  Each incineration system was considered to consist of one or more
    standard furnaces of the same size (some of them on standby) so
    that the entire plant sludge load could be incinerated in steady-
    state operation, excluding the cycling operations referred to
    in 2. above.  The furnace sizes were limited to standard dimensions
                                86

-------
    as used in practice, varying in hearth area from 85 to 3120 sq ft,
    representing 59 discrete furnaces from 6 to 12 hearths and 6.75 to
    22.25 ft outer diameter, all with a wall thickness of 13.5 inches
    (Table 9).  From Fig. 3 and Table 1, incinerator sizing was based
    on a loading rate nearest to 2 Ib dry solids per hr per sq ft
    effective hearth area.  The approach was only made from the high
    side because the more recent recommendations of manufacturers are
    slightly greater than 2 Ib/hr sq ft.

4.  The correlation of field data (Chapter VI) showed that the cost
    per MHF for equipment and operating labor was unaffected by the
    number of MHF's operating in parallel.  Therefore, as far as pos-
    sible, the technical and cost computations are carried out for a
    single MHF first, and then extended to an incineration system
    consisting of several furnaces.

5.  Auxiliary fuel consumption and combustion air flow during steady-
    state MHF operation were based on the Thermal Analysis computations
    ("B") and not on field data.  Air flowrates and excess percentages
    were generally not accurately measured in the field, and estimates
    were regarded as inferior to calculation.  Fuel consumption, of
    course, was measured, but since it is a function of air flow, good
    correlation was not possible.

6.  The user may choose to include one or more of the following com-
    ponents of capital cost: building, land, and engineering fee, in
    addition to the installed equipment.
COMPUTATIONS
A.  Design and Operation Output (Three sheets: Fig. 18, Fig. 19, and
    Table 24).  The aim of this computation is to design an incinera-
    tion system satisfying (1) the MHF Selection input as to scheduling
    and standby capacity, (2) the Sludge Stream input as to total load,
    and (3) the Table (Table 9) of standard MHF sizes available.
    Basically, the imposed scheduling determines the time fraction of
    steady-state operation which requires a furnace of larger hearth
    area than with full-time operation, since sludge flow is directly
    proportional to hearth area FHA (Eq. 68).  However, a larger
    furnace gives rise to a smaller steady-state operating fraction
    (Fig. 12).  A search is carried out among the table of MHF hearth
    area sizes until the inequality

       FHTAB(K) * (1 - CYCF(K)) ^ FHA ^ FHTAB(K+1)*(1-CYCF(K+1))  (88)
                                87

-------
    1TC,.  1^.  f'OMl'liTAnuX A:    MIFF  DF.SIGV  ANT) OPFJUTIOX OUTPUT
                                           (S11KI-T 1 of  3)

1 1LA -
- ™n

RVS -
IIPD *
PKRS
TDPW
IF T11A < 85
                 IF 85 <  TIIA
     XJJF  =  SN0  + 1
      DB,,  .
        FHA =  IIL\"'II>[VDPW
< 28GO
                                            \/
                                      =  1 + ADF  +
                                 DP\N'  =  TDPW
                                 F1IA  =  T!IA/(l + ADF)
                                            \f
                             CYT  =   Minimum  (18 Hours)
JtPD  =  24, DRV  =  7 	>  F  = N;
1LPD  =  24, DRV  <  7	>  F  =
ID?D  <  24, AXY  DRV 	>•  F  =
                                                                           IF TILV >  2860
                                                                        \/
                                                DRV   =   TDRV
                                                   FTIIA
                                                   \__236Q +
                                                F1LA   =   TILA/X^F
                                                            (XF-SX)i))/9 1IPD
                                     CYCi-' =  CY1 •
-------
                        From   Sheet 1 (Fig. 18)
                   LEST > FIITAB  (NIITAD)
                     Find K  such  that
              FHTAB(K) < TEST < FIITAB (K+I)
                             V
              Compute CYT =  f  (FHTAB  (K+l))
                                                   yes
                                                         WHITE  "Data out
                                                              of  Range"
                                                              EXIT
                   next case
                     CYT = f  (FIIA)
                     CYCF= CYT*F
                           = N^TAU(K)
                     IIDIA =l)ITAli(K)
           Key  t o  Symb o 1 a ;
FIITAB = FIIA  entry  in Table  9
N0TAB = NIIEAR entry in Table 9
NHTAB = No.  of  entries in Table 9
DITAB = IIDIA entry in Table 9
                    Sheet 3
                   (Table 24)
FIG. 19-   COMPUTATION A:  MI IF DRSIGN  AND UPWI/VT10N OUTPUT
                              (SHKKT  2  of  3)
                                   89

-------
                        TABLE  24






       COMPUTATION" A:  MHF DESIGN AND OPERATION OUTPUT
                             (SHEET 3 OF 3)
NOTE:     Sheet 1  =  Fig.  18




          Sheet 2  =  Fig.  19
      PSLU  =  14,000 PWS/(I - CYCF) (HPD) (DPW)




               CYCF from Sheet 2




               DPW from Sheet 1




      DSF  =  (PSLU) (PEES)




      HLD  =  DSF/FHA (FHA from Sheet l)




      YHF  =  52 (HPD) (DPW) (N^F - SN0)/N0F




              N0F from Sheet 1




              CRL from Eq. 75




              RRL from Eq. 75




      w0H  =  (HPD) (DPW)




      SCFCL (scfm)  =  36 PWS from Chapter VI
                                  90

-------
    is satisfied where

       FHTAB(K)  is the Kth entry (in ascending order)  of FHA in
                Table 9

       CYCF(K)   is the non-steady-state operating time fraction
                corresponding to FHTAB(K) according to Fig.  12

    When more than one furnace size satisfies the inequality, the
    lowest FHA is chosen, giving a higher hearth loading.  This is
    done because there is a tendency to design furnaces for too low
    a hearth loading.  The iterations necessary to make the FHA (and,
    therefore,  MHF) selection are shown in detail on Figs. 18 and 19.
    Once FHA is found, the remaining design and operation output
    variables are calculated in a straightforward fashion as shown
    on Table 24.

B.  Thermal Output;  This is fully discussed in Chapter IV.

C.  Non-Dollar Output;  Calculations are listed in Table 25.

D.  Cost Output;  Calculations are listed in Table 26.
                                91

-------
                            TABLE  25
          COMPriATIOX C:  NON-DOLLAR OUTPUT PER MHF
LAND ARLA:  ALA = 0.7854 * KLA * (HDIA)2/43, 560
  acres
       )
            KLA = 4.938 (Chapter Vl)
YEARLY FLO.:  FCY = (WGTF * YHF * (l-CYCF)) +(YSBH * SBQ/QFU)+(YHUH * HUQ/QFU)
 (Ib/year)
              YHF from Output A
              CYCF from Output A
              YSBH from Eq. 80, 82, or 84
              SBQ from Eq. 86
              YHUH from Eq. 81, 83, or 85
              HUQ from Eq. 87
YEARLY POWER:  PCY = PDS * DSF * (l-CYCF) * YHF/2000
(KW-hr/year)
               PDS from Eq. 79
YEARLY OPG. LABOR:  0LM = 0MD * YHF/ 24
(man-hr/yr)
                                              Output A)

M-AHLY NORMAL MAINT. LABOR:  ANNIM from Eq. 77 (FHA from Output A)
   (man-hr/yr)
\EARLY CASTING REPLACEMENT LABOR:  CRM = CLH * NlffiAR * CRL/SLF
         (man-hr/yr)
                                   NHEAE from Output A
                                   CRL from Eq. 75
YIARLY REFRACTORY BEPLA.CEMENT LABOR:  AMRM = RLH * NHEAR * RRL/SLF
                ir'yr)                 RLHfromEq. 74
                                      RRL from Eq. 75
                                    92

-------
                              TABLE  26
                COMPUTATION D;   COST OUTPUT,  DOLLARS
                  All Quantities From Output  C,  Ex-
                  cept FHA, HDIA, NHEAR are From
                  Output A
1.   CAPITAL COSTS PER MHF
    Installed Capital Cost:   CCI,  from Eq.  69
    Optional Building Cost:   BGC = BFB * CCI
    Optional Land Cost:   CLD = ALA * ULC
    Optional Engineering Fee:   EFC from Eq.  70
    Total Capital Cost:   TCC = CCI + BGC +  CLD + EFC

2.   CAPITAL COSTS FOR ALL MHF ' s
    CCI,  BGC, CLD:  Multiply values (l.) by N0F
    EFC:   Apply Eq.  70 to new (CCI + BGC)
    TCC:   New (CCI + BGC + CLD + EFC)

3.   TOTAL COST BREAKDOWN PER YEAR PER MHF (Averaged over  SLF)
    Total Capital Charges TCY =    _
    Replacement Parts RPY = (NHEAR/SLF)  | (CRL.CAST)  + (RRL.REFRM
                      CRL,  RRL from Eq.  75
                      CAST from Eq. 71
                      REFR from Eq. 72
    Materials . and Supplies:  AMSY from Eq. 76
    Fuel:   FUY = FCY * UFC
    Power:   P0Y = PCY * UPC
    Operating Labor:   0LY'= 0LM * j^LR
    Normal  Maintenance Labor:   ANMY = ANMM * ANMR
    Replacement Maintenance Labor  RMY = (CRM * CRR) + (AMRM * AMRR)
    Total Cost:  TCST = TCY + RPY + AMSY + FUY + P0Y + 0LY + ANMY + RMY
                                    93

-------
                       TABLE 26 (Concluded)
4.  TOTAL COST BREAKDOWN PER YEAH FOR ALL MHF's (Averaged over SLF)

    TCY:   Multiply value (3.) by (TCC (2.)  /TCC (l.))
    All Others:  Multiply values (3.) by N0F
    Total Cost:  Summation as in 3.
5.  COST PER TON DRY SOLIDS

    Divide values in 4.  by  HDSF)  (N0F)  (YHF) (l - CYCF)/2000j

6.  COSTS AS PERCENTAGE OF TOTAL

    Multiply values in 4.  by (lOO/TCST)
                                   94

-------
             VIII.  USER'S GUIDE TO INPUT SELECTION
This Chapter discusses every single input to the Design & Cost Option
and Thermal Analysis Option to assist the user in making rational
selections when he is called upon to use his judgment.  For every
input, a standard numerical value is also provided, in the event that
insufficient background information exists to make a rational selec-
tion.  The mechanics of the input format are described in detail in
the next Chapter (IX) in which a set of input data cards is repro-
duced, with instructions on how to enter the numerical values.  In the
rest of this Chapter, the symbol (D) following the Fortran name of an
input or a group of inputs designates an input only needed for the
Design & Cost option, and the symbol (T) an input only needed for the
Thermal Analysis Option.  Where no symbol appears, the input is common
to both options.
INFORMATION INPUT
L0C  (location:  The user may use up to 48 letters  (including numerals,
          punctuation and spaces) for the title.  This could be the
          city, plant, or other designation desired.

NCASE (number of cases):  Any finite number of cases  (1,2,3	) may
          be run for (D).  The value zero (0) denotes that (T) is being
          run.
MHF DATA INPUT  (T)

HDIA  (outer diameter, ft):  An input for Thermal Analysis only.

NHEAR  (number of hearths):  An input for Thermal Analysis only.


SLUDGE STREAM INPUT
PWS  (D)  (plant wet sludge flow,  ton/day): Primary input  (per 24 hr day),
          using the value of  the design  flowrate exiting  from  the sludge
          dewatering equipment immediately upstream  of the  incinerator.
          It is assumed  that  PWS may be  divided into any  number of
          MHF's without  restriction, as  indicated by optimization.  If
          unknown, use PWS =  0.0004'(Population Served),  per Ref. 7.
PSLU  (T)  (steady state wet  sludge  flow  per MHF,  Ib/hr):
          rate  for one MHF.
This is the
                                95

-------
PERS (total dry solids concentration, w/o):  Also from upstream
          process- If unknown, use PERS = 25, typical for well-
          operating vacuum filters and centrifuges.

PERV (volatiles concentration in solids, w/o):  This is the portion
          which burns, determined from analysis of the sludge.
          Typically, it varies between 65 and 85.  If unknown, use
          PERV = 75.

QV0L (higher heat value of volatiles, Btu per Ib):  This must be
          determined from a bomb calorimeter.  If the percentages by
          weight of carbon (C),  (atomic) hydrogen (H), and (atomic)
          oxygen (0) in the volatiles are known, the DuLong formula
          may be used for a reasonably good approximation to the
          calorimeter value:

             QV0L = 14,600 C + 62,000 (H - '0/8)                  (89)

          If the sludge type and the percentage by weight in the
          solids of precipitating or conditioning chemicals (PERC)
          are known, Fair, Geyer, and Okun (Ref. 35) give what
          amounts to:

             QV0L = 100 a- (ab(100 - PERC)/PERV)                  (90)

          where a = 131 and b = 10 for plain-sedimentation municipal
                    wastewater solids (fresh and digested)

                a = 107 and b = 5 for fresh activated sludge

          The general range of values is 8500 to 11,000.  If not
          otherwise estimable, use QV0L = 10,000.

PCAC (calcium carbonate in dry solid, w/o):    All three quantities are
PFEHY (ferric hydroxide in dry solid, w/o):    presumed known from the
PALHY (aluminum hydroxide in dry solid, w/o): composition of the sludge
                                              stream leading the
                                              dewatering equipment.

NELV (number of elements in the volatiles):   Provision is made for
          5 elements.

NAMV(I) (name of Ith element in volatiles)
FRV(I)  (mass fraction of Ith element in volatiles) :  The numbers are
          1 for carbon C, 2 for elemental hydrogen H, 3 for elemental
          oxygen 0, A for elemental nitrogen N, and 5 for sulfur S.
          The up to five mass fractions are to be taken from ultimate
          analysis of the sludge volatiles.   If no data are available
                                96

-------
          use this typical composition:
FRV(l)
FRV(2)
FRV(3)
FRV(4)
FRV(5)
0.55
0.06
0.35
0.03
0.01
                                   1.00


AIR DATA AND STREAM TEMPERATURES INPUT


PXAIR (minimum excess air for combustion of volatiles, percent):  Most
          sludge incinerators run with 50 percent excess air, some as
          high as 150.  The value chosen should provide the desired
          exhaust gas temperature and ensure complete volatiles combus-
          tion, but not incur unduly high auxiliary fuel consumption.
          In absence of specific considerations, use PXAIR = 75.

SCFCL (shaft cooling air flow, in scfm for entire plant (D), or in
          scfh per MHF  (T)):  From correlation of operating MHF's a
          rate of 36 scfm for each ton of wet sludge per 24 hr day
          in suggested  (Chapter VI).

FRAIR (fraction of cooling air recycled):  The fraction of cooling air
          recycled should be so chosen that the temperature rise in
          the cooling air does not exceed 200 to 300 F so that adequate
          cooling exists at the top of the shaft.  At the same time,
          the recycled  cooling air is the principal source of air for
          combustion of volatiles.  General practice seems to be to
          recycle 60 to 80 percent of the cooling air.  In absence of
          other considerations, use FRAIR = 70.

TAIRI (exit temperature of cooling air, F):  In line with the remarks
          immediately above, a value in the 275 to 375 F range is
          indicated.  In absence of specific considerations, use
          TAIRI = 325.

TSL1 (sludge inlet temperature, F):  Usually this is close to ambient
          temperature.  If unknown, use TSL1 = 60.

TEX (combustion gas exhaust temperature, F):  Based on the discussion
          in Chapter III, a range of 500 to 1100 F has been used.  A
          lower TEX would reduce the scrubber capacity needed, but
          possibly tend toward incomplete combustion.  A higher TEX
          would lead to an increase in auxiliary fuel.  In the absence
          of specific, considerations, use TEX = 800.
                                97

-------
TASH (ash discharge temperature,  F):   Operating MHF's show a variation
          from 150 to 850 F.   The optimum depends on the temperature of
          the incoming combustion air.   If the latter is mainly recycled
          cooling air, at say 325 F,  TASH must be above this level to
          avoid the impossible situation of ash leaving at a lower
          temperature than the incoming cooling air.  If the incoming
          air is mainly ambient,  TASH should be lower for good heat
          exchange.  In the absence  of  specific considerations, use
          TASH = 400.

TSCRB (scrubber exit gas temperature, F):   The main consideration here
          is formation of steam plumes.  The temperature should be low
          enough to avoid formation  of  such plumes, but high enough
          for scrubber water flows not  to  become excessive.  In absence
          of specific considerations, use  TSCRB = 175.
CHEMICALS REACTION INPUT


FCAC (fraction of calcium carbonate calcined):   The recalcination of
          limestone in an MHF requires a minimum temperature of 1650 F
          (900 C), or higher, according to some sources.   The extent
          to which this reaction takes place as a function of MHF
          parameters is not known.   Since the  reaction is endothermic,
          the higher the value of FCAC, the more conservative the
          furnace design.  Therefore,  if no data are available, use
          FCAC = 1.

FFE (fraction of ferric hydroxide reacting):  There is a  lack of infor-
          mation here, too.  In the absence of  data, for  a conservative
          design (this reaction is  also endothermic) use  FFE = 1

FAL (fraction of aluminum hydroxide reacting):   This is also an endo-
          thermic reaction with no  MHF data known.  In the absence of
          data, for a conservative  design, use  FAL = 1.
AUXILIARY FUEL BURNER INPUT


NAMFU (name of fuel):  Twelve spaces are allotted.   Designations like
          No. 2 Fuel Oil or Natural Gas are possible.

QFU (higher heat value of fuel, Btu per Ib):   This  must be determined
          from a bomb calorimeter.   There are three common fuels:  fuel
          oil, natural gas and sludge digester gas.  If no data are
          available, use typical values for these fuels, as follows:

                          QFU = 19,000 for fuel oil
                          QFU = 21,000 for natural  gas
                          QFU = 12,000 for digester gas
                                98

-------
BUREX (percent excess auxiliary fuel burner capacity):  It is customary
          to provide excess capacity in case there is an overload on
          the burner due to large excess air flow or a very wet sludge.
          In the absence of specific considerations, use BUREX = 25.

EXAFU (percent excess air for auxiliary fuel burner):  Most burners
          operate close to theoretical (stoichiometric) air/fuel mix-
          ture ratio.  This variable may be used for leaner mixtures
          (EXAFU positive, percent excess air) or richer mixtures
          (EXAFU negative, percent air deficiency).  In the absence
          of specific considerations, use EXAFU = 0.
NELF (number of elements in the fuel):
          elements.
         Provision is made for 5
NAMF(I) (name of Ith element in fuel):
FRF(I)  (mass fraction of Ith element in fuel):  The numbers are 1 for
          carbon C, 2 for elemental hydrogen H, 3 for elemental oxygen
          0, 4 for elemental nitrogen N, and 5 for sulfur S.  The up
          to five mass fractions are to be taken from ultimate analysis
          of the fuel.  If no data are available, use these typical
          compositions:
             FRF(l)
             FRF(2)
             FRF(3)
             FRF(4)
             FRF(5)
                             Fuel Oil   Natural Gas   Digester Gas
0.86
0.11
0.00
0.00
0.03
1.00
0.67
0.22
0.01
0.10
0.00
1.00
0.50
0.12
0.38
0.00
0.00
1.00
ENVIRONMENT INPUT
TAMB  (ambient temperature, F):
          TAMB = 60
 In the absence of specific data, use
TSUR  (temperature of outer surface of MHF, deg F):  The heat loss from
          the MHF to the environment by radiation and convection depends
          on TSUR.  With good insulation  (13.5 inches) and typical heat
          releases, TSUR can be kept about 100 F above ambient.  In the
          absence of specific data, use TSUR = TAMB + 100.

VAMBM (ambient air velocity, miles/hr):   The convective heat loss from
          the MHF increases with VAMBM.   For conservative design,
          average annual wind speed in vicinity of MHF, if exposed to
          environment should be chosen.   In the absence of specific
          data, use VAMBM = 5 for outdoor location, VAMBM = 0  for
          indoor location.
                                99

-------
ELE (elevation above sea level, ft):  Since the MHF operates at ambient
          pressure, which affects gas density and saturation conditions,
          it is important to use the value at the MHF location.
FINANCIAL INPUT (D)

SLF (MHF system life, years):  Not all components of the MHF have the
          same physical life, of course.  However, public wastewater
          treatment plants have generally been considered to have a
          life equal to the repayment period of the bond issue
          financing them.   Most bond issuer, have a 25-year period,
          In the absense of specific data, use SLF = 25.

YIR (yearly interest rate, percent):   For these three input para-
UFC (unit fuel cost, $ per Ib):        meters, use information per-
UPC (unit power cost, $ per kw-hr):    taining to the MHF locality.

NAMFU (name of auxiliary fuel):  See under Auxiliary Fuel Burner
          Input, above.

KEFR (engineering fee code):   If it is desired to include the fee in
          the capital costs,  put KEFR = 1; if not, put KEFR = 0.

ULC (unit land cost, $ per acre):  If it is desired to include the
          land in the capital costs, use value for MHF locality; if
          not, use Ui^C = 0.

BFR (building/MHF installed cost ratio, $ per $) :  This study only
          found two data points (BFR = 0.513, 0.667 est.).  Depending
          on the quality of the building, BFR can vary widely.  In
          the absence of any data, for a crude estimate, use BFR = 0.5.
          If building cost is not to be included, use BFR = 0.

0LR (operating labor rate, $ per man-hr):
ANMR (normal maintenance labor rate. $ per man-hr):
CRR (castings replacement labor rate, $ per man-hr):
AMRR (refractory replacement labor rate, $ per man-hr):
          Local labor rates at the time of MHF operation should be used.
          If no data available, the averages given in Chapter VI may
          serve, i.e., in 1969 dollars:

                        0LR      =      3.88
                        ANMR = CRR =    4.07
                        AMRR     =      4.91
                               100

-------
MHF SELECTION INPUT  (D)


This input permits the user to explore the effect of variations in
operating schedules  and standby units on  costs, because the subroutine
considers the "down  time" as a function of operating schedule, furnace
size, standby units, etc.  Many variations can be tried out, and the
optimum chosen from  them.

HPD  (hours per day MHF operation):  This  should be  the period for
          which operating personnel is paid,  e.g.,  an 8-hr shift,
          24-hr (round the clock,  3 shifts),  and other arrangements.
          For large  plants, one should use HPD = 24.  For smaller
          plants, HPD from 8 to 24 should be  explored.

TDPW (trial days per week MHF operation):  Generally, the output DPW
          (days per week) computed by the subroutine will be equal
          to or less than TDPW, but never larger.   In the field
          survey, actual DPW values were  2, 5, and  7 in different
          plants.

SN0  (number of standby MHF's):  Most plants surveyed had no standby
          units, one had one standby unit, and another (in effect)
          more than  one.  The benefits of standby units include (1) no
          interruption or reduction in capacity in  case of a failure
          requiring MHF shutdown,  (2) longer  calendar life per unit,
          if all the MHF's in the  plant are operated in regular rotation,
          and (3) greater flexibility in  operation  (load distribution,
          labor scheduling).  These benefits  must be balanced against
          greater initial capital  outlay.  It is recommended that
          SN0 = 0 and 1  (even 2 in large  plants) be explored.

ADF  (number of MHF's above minimum):  The subroutine computes out a
          number of  MHF's, each incinerating  at a certain steady-state
          rate.  It  may be desired to obtain  greater reliability by
          spreading  the load over  a larger number of smaller units
          (regardless of standby units).  Possibly, there may be a
          limitation on the size or capacity  of a unit MHF.  In either
          event, one may use ADF = 1,2, etc.
                                101

-------
                   IX.  USE OF SUBROUTINE
This Chapter describes the mechanics of using the Subroutine, in both
the Design and Cost and Thermal Analysis options, with a numerical
worked example for each option.  Computer time expenditures are also
indicated.
INPUT FORMAT


After the user has decided on all  the numerical inputs, guided by
Chapter VIII, he enters  them on  80-column data punch cards.  For the
Design and Cost Option,  there are  13 cards, as shown on the four sheets
of Design and Cost Input  (pp. 104 through 107).  For  the Thermal Analysis
Option, there are 11 cards, as shown on the three sheets of Thermal
Analysis Input (pp. 108 through110)-  On each card,  there are listed

      (a)  the Fortran  names of the input variables  (see
          Glossary for definitions and units);
      (b)  next to each input variable, in parentheses, the
          columns in which the numerical value is entered; and
      (c)  in the upper right-hand  corner of the description
          field the format specification of that card.

The input is sub-divided  by card number as follows:

                                 Design & Cost       Thermal Analysis
                                 	Option          	Option	

      Information                 Card 1              Card 1

      Sludge Stream                    2,3,4               2,3,4,5  (with
                                                          MHF data)

      Financial                        5,6                 -
      Air Data and Stream             7,8                 6,7
        Temperatures
      Reaction of Chemicals            9                   8

      Auxiliary Fuel Burner            10,11               9,10
      Environment                      12                  11

      MHF Selection Input,             13 & on
        repeated for each Case
                               103

-------
   DESIGN  AND  COST INPUT
                                                        SHEET  Iop4
        NUMBER
                      IDENTIFICATION
                                  DESCRIPTION  DO NOT KEY PUNCH
 i

 Lil

 IS
   •r
His
a
[49
[el

fl
[Ts

EE
[37

E»
o
f>
t
13
 49
 EC
                    1
                     73-
        1000 .
          30
           7^
                      73
    4 -
             .S'^g
             •07^
               334-
               OBI
 £
                Q/./
                                  ^ggs
                                          i22=
                               52

                               2
                                   PAL-HY (l-
                                            3 -24)
                                                                   r/2.)
                                  Ai»A^C
                                      i
                                              4r
                                                £!2bSa
                     73:-':::-.:::i:::x;:::::*S:S¥::H:::S::S::::8(3'
        I14-C-17 VELLUM

-------
    DESIGN AND COST INPUT
                                                     SHEET  2 OF 4-
       NUMBER
           7 .
        FUEL.
     2.0000..
                      IDENTIFICATION
DESCRIPTION  DO NOT KEY PUNCH
                                 UFO
             , Ol 0
[13
            4.
           .4.. .5:
           4-. 25
           j.
Ms
o _
Ui
             .4
                                  UPC.    (hi 2^
                            u e /if)
lL
          .ZS^
     .3 £.0.00. •
              z
        300.
m
         ic.
        H4-C-17 VELLUM
                                  FR.AIR
                               7
                               &

-------
               AND COST INPUT
                                                    SHEET  3OF 4
    NUMBER
                     IDENTIFICATION
DESCRIPTION  DO NOT KEY PUNCH
', }7


Ug


161
I	




:'i
i - -
           6
           6
[:•*-,
137
r —
49
~i
CL
^s
L' '.
l«
bl
Li
49
lii
^ j 	 ^.
^

.. 4 - - - -


C
fy -
N
"S! _ ^_
i
i
- . ^ — . — ^_ ^ — . — ,
.IT7...LO
. ^

i
      ^25.
        .5:-
          , 8£l
          -./' Q.3
           Ooi
                 73
                 7>
                                 PEE
                                                      Ta'g /2,g)
                            80-
         f//-afl
                                                       Y3g7zTgr/2,
                              NELP   737-4^
                                     y^^
                                NAM a
             Zf?(/7-24)
                                              \L
                           JU
                                                        4-E 12,?}
                                     ($7-4-8}
                              .80
                           /.2
    \ M-c-17 VELL'JM

-------
DESIGN
              COST INPUT
SHEET
f

bi
[25
(£7
! 	
l£L
!
1 1
1 	
[13






	
|

NUMBER
2.4.
5-,.
/ ,
/ .




IDENTIFICATION




73 - 80-
. ... .IS


DESCRIPTION DO NOT KEY PUNCH
HPD f(-/2~} (4~Fi2~.(o)
TDPW t/3-24-*)
Sti$ (2^-36)
, ADF (3~l-4-8)



_ _ 	 — t
25
QJ
[25



^.
149?
             73

     1 U-C-17 VELLL ..

-------
THERMAL ANALYSIS INPUT
SHEET ioF3

1 _'__
111
i£?

\±L
[49
EL
PI
[Ta
I25

|37

(49
J*1
O H

13
[25
III
[49
1*
rr
Il3
J25
£Z
(49
lil

C
A/
r



















c"
H
d)
N
s

NUMBER
flE c/C^(/T_^/=
cxi s £ e&UA-i-
6 Z EZ_d> .


0


17. 1
r n

1 o n n n.

Z3 • 3-
. 5"

. 5"
5




.5*50
•074-
^ 3 34.
• C>3 /
• 0 / /

IDENTIFICATION
.
: - ': / - -"



^ so-;







7 O- •'.''•" .!•!]'" P v
r 9





73 	 	 8C>
	 3


V

73 	 "80

DESCRIPTION DO NOT KEY PUNCH
L-d>C H-3-8} ( I2A4-. T /2)
i ^ • ' '



NCA^^ (4i-&o)

(7zx^/2-d)
p££S (13-24-}
PER.V ^5--S6)

QVi- (37-43)

PCAC (43- 6O)
P-PE H Y^f£/-~72.}
r ' t— * ' v ^/ * ^
PAL HY (1-12) (E /2.B;Z/2)
M£ L V LIB - 24-)




NAM V (1-4). FgV (5-12) ( & (A4~> F&'S)}
NAM V, '(&-lt\ P/^K f 17-24)
ix. -f ) ^V.f'~X
T V
NAM VNF. v FRVfj
CL
 \1*-C-I7 VELLUM

-------
THERMAL. ANALYSIS  INPUT
SHEET 2. OF .3

LJ_
l£
[25
\E
[49
IB,
L
L^
[25
IE
l«
J£l
_l _
3
D -~
Ei
i»
I*
[49
Is,
li
i
Il3
25
37
49
\*\

	 1-
!
1






















NUMBER
HtrD'ZAL GA&
. _ .14.3
&
^Z2^, 3


1 00.
30 OOC *
o.
33 0.


57 +
~7oo -
f4-0.
70-


I
/»
er
» o
..ff


-. 	 • • • • 	 i 	 * » a 	 •
IDENTIFICATION

v:;X;:;:;:;:;:::;XxX;:;X;:;:;:;:;X;:v::xox-:-x|x-

iffyf^fy^fy^^^
^iWM^fff^^f^fy&ti
...... 5




'ji&^M^M^Moti
	 H


::;x;x:x;:;:::;:|:;xix:::x;x:x:x:::x:x;::::::;:;x;:

7^;;;:S;s;S*:::^:Ss;:;>S:SS:H:;8b;
	 7




'^M:^^^^^^^
t
DESCRIPTION 00 NOT KEY PUNCH
NfrMFU 0-I2-) (3A4 F/2.G.TI2F/Z.6,}
H£>£A Gl-lft ' } •>
NH£AfL(2S-^
PBi-U (J>7-4-Z<>
w -*

PXAI? fl-iz^ (4£l2,e^
5C FOL £/Z-24)
F^AX/^ (2ST-S^^
TAZ/?I te7-4£}


TSL± (1-12.^ (4-EIZ.&)
T£* 03-24}
TASH ^ZT-36^
TSCZB 137-4-8-)


C/~* /\/^ / / /"7\ /" 2J ^ /*5 fi \
r~C/-\C. ^ I-/Z) [ 3 & /^:,o )
EF?cr 71 3 - ?4. ^
r~rc. ( /^ ^^/
F/4L fas' -3^



 1I4-C-I7 VELLUM

-------
I 13
137
  N
|5T '
        THERMAL.  ANALYSIS   INPUT
                                                         SHEET 3 of 3
       NUMBER
          2r.
           0.
                   4-
             2-A7,
             00.3
       / 70
                     IDENTIFICATION
                     7J '
                               80-
DESCRIPTION  DO NOT KEY PUNCH
                                  BUZEIX    1-
                                 ^£_Lf_.._. (17-48}
                                        L>
                                 TAMB
                                  ELE
                                 \

-------
There are several input variables which require clarification; these
are listed below, by input card number:
   Design & Cost Card 1 and
   Thermal Analysis Card 1;
   Design & Cost Cards 4 and
   11 and Thermal Analysis
   Cards 4 and 10:
   Design & Cost Card 5:
   Design & Cost Card 7:
   Thermal Analysis Card 6;
   Design & Cost Card 8 and
   Thermal Analysis Card  7;
NCASE = 0 means Thermal Analysis
        Option only.
NCASE = positive integer means number
        of MHF Selection Inputs for
        Design & Cost Option only.
        There is no limit on NCASE for
        Design & Cost Option.

Variables NAMV(I) and NAMF(I) must
take on values from the following set
(C©00, H000, 0®00, N00®, S0©@) where 0
(circle dot) indicates a blank,
        C is carbon
        H is (atomic) hydrogen
        0 is (atomic) oxygen
        N is (atomic) nitrogen, and
        S is (atomic) sulfur.

KEFR =  0 means no engineering fee
KEFR =  1 computes engineering fee per
        formula, Chapter VI.

SCFCL is in scfm (standard cu ft per
min_, for entire plant with wet
sludge flow PWS).

SCFCL is in scfh (standard cu ft per
hr, for the one MHF with wet sludge
flow PSLU).

TSL1 (TSL-one) is correct .
FORTRAN PROGRAM

The program, incorporating both  the Design & Cost Option and  the Thermal
Analysis Option, was coded in Fortran IV  compatible with both the IBM
1130 and IBM System 360 digital  computers.  The Fortran IV listing of
the program, with its permanent  data, appears  in the Appendix.  The
permanent data (26 lines, sequence numbers 99900010 thru 99930050 in
listing) are read in by the program before it  considers the user's
input.  The listing in the Appendix includes system cards for IBM
System 360 after the main program immediately  before the permanent
input data (4 lines, sequence numbers 99800000 thru 99990000  in
listing), and also at the end of the listing (1 card,  sequence
                                111

-------
number 99999999).  When the IBM 1130 is used, these cards must be
replaced by their appropriate counterparts.

In order to permit easy conversion between computer systems, the
program uses integer variables for the input and output device
numbers.  The variable IN is used for the input device while the
variable 10 is used for the output device.  IBM System 360 uses
device number 5 (five) for input and device number 6 (six) for output.
These specific values have been given for the variables IN and 10
at card numbers 00000980 and 00000990, respectively.  These cards
must be changed for systems using, device numbers other than five
and six.

The program, together with the necessary system library routines,  .
occupies 52,000 bytes on the IBM System 360.  On the IBM 1130 an.
overlay procedure may be necessary.   A list of the subroutines con-
stituting 'the program., with a. cross-reference of the 'subroutines
that call them, is given below:

                         Sequence Number
     Subroutine           of First Card         Called From

     Main Program           00000010
     INPUT                  10000010            Main Program
     HEAT                   20000000            Main Program

     BL0CK                  30000000            Main Program

     TITL                   40000000            Main Program, INPUT, PRINT

     PRINT                  50000010            Main Program

     GETDH                  68000100            HEAT

     L0CAT                  69200000            Main Program

The execution time for the program (one case for the Design & Cost
Option, and one case for the Thermal Analysis Option, see Numerical
Examples below) was 0.01 minute on the IBM System 360.
NUMERICAL EXAMPLES


One numerical example (NCASE = 1) was run for the Design & Cost Option
and another (NCASE = 0)  for the Thermal Analysis Option.  The numerical
input variables were entered in the number fields of the data cards
shown on the 7 input sheets (pp. 104 through 110) discussed in the
Section on Input Format  earlier in this Chapter.  The last page of the
Fortran IV listing in the Appendix contains the numerical inputs from
the 7 input sheets (24 lines,  Sequence numbers 00001000 through
10000011.
                               112

-------
wtLtI-PLF  HFAPTH FUPNACF S EW.AGF. S LU CC-E  INCINFRATION



               CHECK OUT  CF  SAMPLE  INPUT
                   OF  CASES  TO RE
               *  SLUDGE STREAM INPUT
1 )
PLANT V»F-T -SLLHGE
TOTAI DRY 'SOL I OS
VOL4TI.LF SCLTDS
HE\T VALUE CF VO
CArn? IM -OPY SCL
F E ( Oh ) ? I N - 0 P Y S
A| ( TM) -3 T.N OPY S
C- L^F
WA S ^
v/\ c; c
MA ss
WA SS
MA S S

SYSTF
EN1GG
UN I T
AUXTL
UNIT
LNI T
PPFRA
NOR MA
CA STI
p OF
FR-AC
r RAC
FRAC
FRAC
FRAC

v LI
Y IN
FFF
LA NO
I ARV
FLFL
PClftF
TINC,
L ^ &
NGS .
KEFRAC TCP
BUILD
F
TI
TT
TI
TI
TI

FE
TE
RA
C
F
C
R
i 'F M' F f
CNi CF
ON CF
ON CF
ON CF"
CN CF
*
FLOW
CCNCENTPAT ICN
CONCENTRATION
IATI LES
in
CLID
CUD
TS I
C
H
C
f\
S
** F
1000.0
IN SLUDGE 30 .OC
IN D.S. 70 .CC
1000C.
1B.CG
6 .CO
TON /CAY
WEIGHT 0/0
WFIC-hT 0/0
BTU/LB
WEIGHT Q/u
WEIGHT C/J
WEIGHT C/C
N VCLATI 1 FS 5
IN VOLAT
H VOLAT
IN VOLAT
TN VOLAT
IN VOLAT
INANCIAL I
I LES
I LES
I LES
ILES
I LES

0
C
0
0
0
C
OF MHF
REST PATF
TE CODE (
CST
UEL ^!
GST
CCST
LABOR
I NTENAN
RE
Y
PLACE
1=FCFMULA,
0= ZERC
RAT E)
.550
. C74
. 3? 4
.031
.011

25.0
7.0t
1
20000 .CC
AME


RATE
CF L
ME NT
REPLACEME
ING/-MHF RAT
1C



ABCP RATE
LABOR RAT
NT LABOR R





E
ATE

FUEL
0
0



Q
OIL
.025
• Git
4. Go
4.51.
4.25
5.GC
.40C


















YRS
C/0

£

$
$
$
$
$
S
$


/ACRE

/L

B
/KWH
/M
/M
/M
/M
/$
AN-HR
AN-HR
AN-HR
AN-HR

                                                                                 a
                                                                                 w
                                                                                 §
                                                                                n
                                                                                o
                                                                                en
                                                                                H
                                                                                O
                                                                                i-ti
                                                                                o\

-------
            HFAPTH  FURNACF SEUAGE SLUCCE  INCINERATION

                ( HECKCUT CF s AI^FLE INPUT


                ***  TECHNICAl  INPUT **«
                                                                          o
                                                                          w
                                                                          to
MINIMUM  FXfFSS ^ I R  Fnp CCMR  CF  VCIATILF.S
SHAFT  mPLINir, AIP FI.CW (All  MHF'S)
FRAC. TIf\ OF COCIIN'G AIR PECYCLEC
FXIT  TFwpF.PATUFF  CF CPCLING  AIR


IN'LFT  TFMPERATliPF PF SLUDGE
FXIT  TFMPFRaTUPE  CF CO^PUSTIPN  GASES
FYJT  TE^PFC « TUf-ir  TF ASH
rviT  TFMPERATUPF  CF SCPURREP  Gfl.S
                                              7 5 .0 v,  0 / '3
                                               .:'.<. .  SCFM
                                                 rc
                                                ;<. .  CFG  F
                                                6C
                                               8CO

                                                7C
        CFG F
        CFG F
        DEC F
        CEG F
                     o
                     o
                     H

                     B

                     o
FRACTICN  CACP3 TCNVERTEP TO TAG
FRAfTICN  FF(TH)^  fCMVEPTFD TC  FE2C3
FPAC.TICN  At(CH)3  CPMVEPTEO TC  ALPCS

HFAT  VALUE  CF AUXILIARY FUEL
FXCFSS  RURMFR CAPACITY
EXCESS  AIR  FCR AUXILIARY FUEL
 0 . 6C C


200GC .
 2 5.CO

w/\ 5 5
VA SS
'"ASS
MA SS
MA ss
:P OF
FRAC
FRAC
FRAC
FRAC
FPAC
ELFMCNiTS I
TI P^l
TI PN
TI CN
TI CN
TI CN
OF
CF
CF
CF
PF
C
H
C
N'
S
N AUXILI
IN
I N
I f1
IN
IN
AUX
AUX
AUX
AUX
AUX
ARY
IL I
ILI
ILI
ILI
ILI
FUEL
ARY
*RY
ARY
£RY
/!RY
FUEL
FUEL
FUEL
FUEL
FUEL
0
G
C
0
(.1
5
.861
. 103
.cr e
.oc i
.C27
8TU/LB
G/G
0/G
                                                                         co
                                                                         w
                                                                         H
     SURFACE
A MR [F NIT  AIR
FLHVATinNi
             TE^fPFPATURE
             VELPCITY
             TFN'FEFATURE
              PLANT
  100.  DEC F
   5.0  MPh
   5C .  CEG F
 5JOC .  FT

-------
               HFAF7H  FDPMCF SEWAGE  SUICGF  INC 1N F RAT ION

                    rHfCKTUT  fP  SAMPLE.  INPUT


               vhr  SFlFCTir*' INPUT  FCP  fASF   1 ***
    i;M1*  } vi" ) !\FI- A TI O SCHEDULE
    v\v.  iAf-FKLY  I f..-f I NFP ATI CM SC(
    v^Mpc-ri pr  CT/T'i-pY  ^HF  UMTS
    -v l: v P H p oF.  ,VH f-- ' S  A P PV E  <" I NI M
                                                24. 'JO  HP/DAY
                                                  5.^0  CAYS/WK
                                                     1
                • **  rHF
                                   1C CPEP AT ICN  #**
VLMPFC  I'F
••u-r  ri,Tr^ ofV-'FTFP  (13.c  I^CH  WALL)
\Ln.;c-  Pf- HCA.PTHC  PFR HHF
FF-PfT TT V/F HPAfrTH  APFA PTP  «HF
STf-.Ar>v  STAT-  l-.r.T  SLUDGE  PATF  PEP  ^HF
STFAHY  «;TAT|-  PPY  SCI.IPS  PATE  PEP  MHF
H r A P T H  I. HA n I ,\r,  .( r P Y  S PL I C1 S >
                                                     16
      9
  N., .25  FT
     12
  K.^.C  SO  FT
  i*.*. .9  L B/HR
  C31^.?  LR/HR
  2.01,  L P/HP-SO FT
                                                                                        to
                                                                                        M
                                                                                        I?'
                                                                                        n
                                                                                        o
                                                                                        CO
\r.iL}|Y  PPf; RA TJ ^,^  HPUPS  PFR WF
V.^ - K L Y  I MC I N'E P A ^ I ^  SC H EDU LE
V,":-:KIY  T N-r i fvEfFATT C^  HOURS
f VG L I N'"?  AC.  f7 P A G TI C ^  P'F  r P E R AT I r N
r VG i ::  TI fF  ( nr ATijp)
"HP  ^ASTf^^  SFTS  FfPlAC f.O TURING  I I P E
vuc  pFFQArTPRY  SETS  PEP!AGED  DUPING  LIFE
CMA!- T GPP! I r-r, ATP  ppp  WHF
     .7  HP/YR
  ?.(;C  DAYS/WK
l^u.Ut,  HR/WK
 0.21P  HR/HP
lUh.'iC  HR
  '• .50
         SfFH
                                                                                        CO
                                                                                        g
                                                                                        3
                                                                                        U)
                                                                                        o
            *** AIF  FCP  VCtATILES  CPVPUSTION
f[ !W-!ATr  rf  G fPl^G  ATP  SENT  TO  FURNACE'
f-(.M'v-fATH  |lp  AX^HM  AIR  FILTERING  FUPNAG!
TMf Hi,F TIGA l_  Alf-'  c-FOi.lIREr  FCR  VOL AT I L ES
pi,,-rr. y  F X(" •' S S  AT" rP'« V P (_ A T H. C S
r T,M.   MS  Uci" p.  rr P VM AT! LtS
                                                      .^4C -r::.  SCFH
                                                      r'tt^6?.  SGFh
                                                      2566.0 .  LB /HK
                                                      177.^7
                                                      7119V,  I.P/hR

-------
MF'.FTf- FUPNAft; SEWAGE  SLMCTF  I t"C I *'E P A T J'

     CHEcwrijT TF  S/V^PIF  INPUT

              r ASE   i

                    vx>  fHF  H r AT  RALA\TF *>••>-
                    ( SI V  SIGMF K ANT  DIGITS )

A T i-'t QU "'t V1EI^'TS
 MTAT  Fun  SI.U'^GF  r rr'pusT i rh  PPCPUCTS
 ^!^^T  FH"  si m^F  r.nsTURF  FVAPCC AT ID^'
 fir,\T  prwnvpp  i M  /\ c;p
 p v i A T i r i,j  ^^n rr^VFfTinr  i  PAT  ir.ss
 SH\FT CiTiir'-, HfAT LHSS
 MhAT  f no  I\;rrrpG  AN'HlEfT  AIR
 Hf \ T  r -M.> f A I r I ^'I^ C • C/*CO?
 HFA T  FO'J nEC Tf'PfS 1 rr,  FF ( TH) ^
                                            .  HTU/HP
                                                K. i«;;^?9ci
                                                    6 7?7?
          AT  PbOUIPF^EM
                                   1-1^0? 7'^.  BTij/hP
                                    n^^..  BTIJ/H^,
                                    67 ^4/-4 .  RTU/ h^1
                                      C)3^7"J. .  PTIJ/HR
                                      4'51^.").  "TU/I-P
                                  353^515?.  BTU/HP

                                                                 8
                                                                 H
T  I MPIJT
Hf^T FH-C"  V^l.tTILFS
MMT F--TV  i*T.r^iNG  SHAFT rooiif-'G
vf-T  MF M rEri)IREP FPPw PUPNER
TTTM  HEAT  INPUT
                                    8^7274.  FJTU/HR
                                          0.  «TU/HP
                                   53151 ^? .
                                                                                 CO
                                                                                 s
                                                                                 w
                                                                                 •C>
                                                                                 O
                        ! APY
                     R SEL ECT In^' ***
PF^rE^'T AV^.ILAHLF  I-1 FAT  FPT^  8(1 PN E R (C A I r )
r,(^nSS HfAT  PFCUI^EP  FPTO'  PlJKMPR
TTT/v|_ q^_D^P^ rAFACITVt  25. OJ  './O  E X T F S S )
'-flUT-En  P(JR\'FR  FL'M.  Fir^PATE
PL^KF' HFAT PEP'  STC  CUPK FT  TF  AJP
oc-),yprn  p tjp r c c  -. j r
^f-Tll-r^  f-IIP\cn  ; | h
                                          C.  RTIJ/HP
                                              LR/HP
                                              BTU/STF
                                            '?  L H

-------
          r  N[- APTH  FUPKAGF  SFWAGE SMJCCF.  I r- C IN F.^ AT JOM

                  CHrrk'niT  rp SAVFLF.  INPUT

                            r AS F   i
                           FX IT GAS  CAT A
S P F G, ] r s

G. r- ?
j-j "> r
n?
NO
sn?
r. TA t.s
Fir
''ASS( 1.. P/HW)
73^P.
1 39 IT .
3 '; A 1 1 .
17 '• 7 1 7 .
f \, <
? -• 3-'- .
A 1 3,'. .
?r, 15.
6 • 6 ? .
].."'<3 7.
7 1 -'. 1 .
                                                                                        M
                                                                                        O
                                                                                        O
                                                                                        CO
                                                                                        H
                                                                                        T)
 CTTV r;r  F-l.^MACF  cv J T  r, AS
'i.->.n i--,-,- fxir  vrUi-'T/in  rr  OPY  GAS
 issfu-.j SAH^A.Tfr  f-X I T  f-AS  F L HW R AT F
'M'  r- L r i-. u A r r  Tf  SATUpATF  LXIT  GAS
                         (SIX  ^1 r

'ASS  TXFLHV^
    WT T  SI. l.''T,r  F £ F OP A Tl
    i. c'M,i?r^ Pl|p^^^'  rtri  n. r
    A ,1.1 |r N T  M o  Tf  VT ) /  TII f_ s
    T;~ TA i.  r >~n r K-S  ai f.-
    -,!•-- M.lE-'r.' PUu'v;C"  -A I F-  F L H '«;!
    rr TAI.  "• <\ ss  i % f i n-.

'A SS  :;l.Tc I  C1' S
    r r i ,A j  ' -Mj r P v 1 1  f /- c;   f |_ n ^ p
    A c;i  .-, | cr M/> f, r, f-  H A T F
    '-• r  irr; TFO r ''ci I ^:^..  AT  p
    TTTAI  'M.SS  CLTc l.f V.
                              ASS  HA|. AN!Cf  ':^'-
                             -r F TC AMT  Cff>tTS)
                             y £
                                                             .''?^57  1.4/FT 3
                                                             ] 6.'' «  -">  FT3/LR
                                                     16 A 6'.'..« L ^/hP
                                                          ' .-. !. P/hV
                                                     [5'W: 17.? L 'Vi--"'
                                                     ?^54^.^  L »/HR
                                                          ' .C L "/H1'
                                                     9 JM? '•' . '< I «/t-'P
/-,'-.7.. . P. i  n/p-'
  •-)? 9 . o l.R/HK
•SU. ?, .7 LI/hi-?
  »?^. ^ I
                                  CO
                                  a
                                  M
                                  H
                                  Ln
                                  O

-------
                                         HFAFTH FuprAfF  SEWAGE  SLIJPCE  IMCIMFPAT ION

                                              CHKKCUT np  SAMPLE  INPUT

                                                       CASE   i
                                                                                                                  CO
                                        *•*«'
L AMP  APT A
YF <\ PI. Y F LF L
YF », 1. 1 v prv'T

MPr- I- A T! NO
MPpr/'A!  f-'A I MTF
                                                          TUT PUT  PER
                                               F  (AHC!|«
                                               EM  LAPTP
                                               F^FNT  IARCR
                                                                                ".0'-
                                                                                      KWh/YK
47r. 1 . 2 ^ ftN-H
1234.7 MAIV-HR/YK
  21.1 MA^-HP. /YR
 1?7.7 MAN-HP/YR
                                                                                                                  o
                                                                                                                  o
                                    K
00
                                                                       COLLARS
                       I M S T A l |. h n C 4 t1 T T ^ L  f

                       LA^1^  COST
                       F^r, IN.FTP I Mr,  F£F
                       T°TAL  CAPITAL COST
         D FPI Ar.r"EMT  » ^p TS
         MAT f-K r AI s AMP  SUP PI IF s
         FUFI
         0" E-R AT]M(;
         •.IT5MAI  M /\
         PEPL AC. FME IT  '-M I N'T F \j/*SiC (-
         TOTAL  C'"^T

'ST




MHF TTTAL
I/ Yf< ,ONE W
75744.
6 7 C ? .
1 F77.
6132.
?221 .
19005.
5556.
72 P.
] 18C66.
CNF V F F
5934R2 .
237393.
73'..
510*3.

COST PRE^KCCWN ***
•/YR, ALL MHF' S
67^379.
6v 327.
1 n H l-l ^j m
551BR.
?B9^2.
171'J'r4.
5CL''5 .
6553 .
10593/i.
ALL MHF'S
c?4 13^0.
2136535.
6572.
327862.


t/TON CRY SHL IDS
6 . S 1
L, . (-. 2
C.I 7
'.,.57
i. .3C
1.76
C.52
C .07
10.91

s~\
EC
H
f
o
i-n
S
PERCENT
63.28
5.69
1.59
5 . 2. 1
2.74
16.15
4.72
C.62
liX.OC

-------
        HEARTH  FURNACE SEWAGE si.uCGf-  INC IK-PAT ION
CHECKOUT  r:F  NC/'SE  ECUAL TO ZERO  .

            (  THERMAL ANALYSIS CNLY  )
           ***  SLUDGF STREAM INPUT ***
TOTA-l DPY SOI IDS CONCENTRATION IN SL1JHGE 17. 1C
VOLATIL^ SHLinS CONGE NTP AT I ON IN D.S. 67.0C
HEAT VALUE OF VOI.fiTILES 1000L .
C AO n 3 T N 0 R Y S C I 1 0 2^ • 20
~-(HH)3 IN PRY SOLID 0 .5C
AL(01H>3 IN HR.Y SOI 10 0.5C.
NUMBER OF ELEMENTS IN VOL AT I LES 5
N' 6 S S
^A SS
V \ S S
!*A S S
V \ ^ S

Al.jXI
WMF
NU^n
STE«
5HAF
FP AC
PXIT
INLE
r y'i T
c v I T
FRACTION OF C IN VOLAT I LES
FRACTION OF H IN VOLAT I LES
FP ACTION OF 0 IN VOLAT I LES
FRACTION1 OF N IN VOL AT I LES
FRACTION OF S IN VOLAT ILES
*** TECHNICAL INPUT ***
1 I ARv F IE L N ANE N ATU
OUTER FMAMETEP (13.5 INCH WALL)
EP OF HEARTHS PER VHP
OY STATF wfT SLUDGE f- AT E PEP MHF
MU^' FXOF^S AIR FOR CON'S OF VCLATIIES
T COOLING AI F FLOW PER MHF
TION.OF cociiNG AI p PECYCLEC
TEMPERATURE OF COOLING AIR
T TF N- P E P A T OH E OF S L I.! 0 G E
TFMPFPATIJFF- OF COMBUSTION G *S FS
TEMPERATU°f- OF ASH
inwoFOATUFF OF SCRUBBER GAS
C. 55<
0 . C 7 ^
0 . 3?^r
0.031
0.011

RAL GAS
14.30
f
222R.3
3 Of: .LI
3COo*, •
>J « U
33C .
57.
70C .
5^-1 .
7-.-.
WEIGHT C/C
WEIGHT C/'"
RTU/LP
WEIGHT r/o
Ir. EIGHT 0/C
WEIGHT .'../n






FT

t P/HR
SCFH

OEG F
TEG F
CEG F
F)EG F
EFG F
                                                                   OT
                                                                  o
                                                                  ->

-------
                           MULTIPLE HEAPTH FURNACE SEWACF SLUCGE INCINERATION

                            CHECKOUT OF MCASE ECUAL  TC  ZERO  .

                                        *•** TECHNICAL  INPUT  ***

                         FRACTION CAC03 CCN'VEPTED TO CAO            l.OOC
                         •^ACTION FF(CH)3 CCNVEPTFD  TC  FE2C3       0.500
                         FRACTION AL(CH)3 CONVERTED  TO  AL2C3       0.5CC

                         HFAT VALUE OF AUXIIIARY FUEL              20P8«. .  RTU/LB
                         EXCFSS BURNER CAPACITY                     25-.GC  0/0
                         FXOF<;<: AIR FOR AUXIIIARY FUEL               o.c   q/o
                        'NUMBED OF (-LEMFNTS IN AUXILIARY  FUEL            4
                         MASS FRACTION OF C    IN AUXILIARY  FUEL   0.739
M                        ^ASS FRAPTIPN OF (-'    IN AUXILIARY  FUEL   0.237
o                        VASS FRACTION OF o    IN AUXILIARY  FUEL   0.003
                           SS  FfACTION OF N     IN  AUXILIARY FUEL   O.C21
                             SLPFACE TEMPERATURE                     17C.  DEC-  F
                         A^RIFNT AIR VELOCITY                         C.I"  MPH
                         AMRIFNT AIR TEVPFPATURF                      65.  [) F C  F
                         ELEVATICN OF PLANT                         6265.  FT
                                  *** AIP FCP VCIATILES  CC^PUSTIPN ***

                               F"  OF  COOLING AIR SENT  TO  FURNACE          C.  SC.FH
                               F  Oc  AVRICNT AIR FNTERING FURNACE    498K.  SCFh
                               IC^L  AIR PECUIRET  FCR  VOLATILES        1R<35 .  LB/hR
                       pPRCrN'T EXfi-SS /*IP FOP VCLATILES            ICC.uC
                       TOTAt  ATP USED FCP VOLATIIES                   579C .  LB/HP

-------
                           MULTIPLE  HEAPTH FURNACE SEWAGE  SLUCGE INCINERATION
                            CHECKOUT OF  NC^SE ECUAL TC  ZERO  .
ho
                    *** MHF HEAT BALANCE  ***
                    (SIX SIGNIFICANT  CICIT5)

HEAT REQUIREMENTS
   HFAT FOR  SLUDGE  COMBUSTION PRCDUCTS
   HFAT FOR  SLUDGE  MCISTURE EVAPORATION
   HFA T REMOVED  I N  A SH
   RADIATION AND CONVECTION HEAT LCSS
   SHAFT cnot ING HFAT LOSS
   HFAT FOR  CALCINING CA0.03
   HEAT Fnp  DECOMPOSING FF(OH)3
   HEAT FOR  DECOMPOSING AL(CH)3
   TOTAL HFAT REQUIREMENT
                     HEAT INPUT
                        HFAT FPCV
                        HEAT FRO-/
                        HEAT FROM
                        ME T HFAT
                        TOTAL HEAT
              VHLATI I. ES
              INCfVING AMBIENT AIR
              INCOMING SHAFT COOLING
              EOUIRFH  FROM BURNER
               T NPUT
AIR
                                    **>s AUXILIARY PURMER SELECTION  *

                        PF&CFNT  AVAILABLE  HEAT FPCM BURNER (COLO
                        GROSS. HEAT  f:FOUIPED FRfV BURNER
                        TOTAL PIRNFR  CAPACITY( 25.oc o/o  EXCESS)
                        PEQLH-FD BURNER FUEL FLCV-PATE
                        BL«NEP HFAT PER FTC CUBIC FT GF AIR
                        PF:V)LT'3f-r FURNER ATP VOLUMETRIC FLOW RATE
                        K ' :, L T Q •- r r (j'-, ^f n A ] r v A S S F L CW RATE
85C094.
2496213.
7361.
265659.
14*312.
84673.
214.
363.
384QP85 .
25529Q9.
7157.
0 •
1289730.
3849885.
74.59
17269F8 .
2161235.
10 3 . 5
96.24
22457.
17-8.9
BTU/HR
BTU/HR
BTU/HR
BTU/HR
BTU/HR
BTU/HR
BTU/HR
BTU/HR
BTU/HR
RTU/HR
BTU/HR
BTU/HR
BTU/HR
BTU/HR

BTU/HP
BTU/HR
L8/HR
BTU/SCF
SCFH
LR/HR
                                                                                             CO
                                                                                             M
                                                                                             CO
                                                                                             M
                                   CO
                                   d!
                                   M
                                                                                             U)
                                                                                             O

-------
                                        fApTt-  FIJPNKF SEWAGE SlUCGE  I N C F N Ft- A T IDN

                                        PF  INCASE  EOl'AL Tf  7 F P.I  .
                                               VHP  EXIT HAS  CAT A
NJ
ro
                                     H2 r
                                     n?
                                     M?
                                   TPTA
                                              f'ASS (
                        22? C .
                         AA? .
                        A??8.
                           6.
                        77f c .
                               Fl CW RATES
                                       V f 1L U ^ F ( A C F H )
                                         2C270.
159573.
    93.
3257A2.
Of- M SI TV ft  FUPMACh  EXIT GAS
SPRL^RF^ L^tT VrUJN'F/Ln CF  DRY  GAS
Sf-MjBRi-P SATUPATFT  FXIT G^S  FLHWRATF
              TF IP  SATURATE  EXIT  GAS
         0.02381 LB/FT3
           U .6A2 FT2/L B
           1531. AC EM
               0 . G P M
K<
c/5
H
co
nd
G
                                                                                                       o
                                                                                                       g
                                                           PALAKGE
                                            ( SIX SIGMF ICANT CTGITS )
                          S  i ^|Fl CM«S
                          UI-T  si LDGT  FFFPFATF.
                          P^OUIRrO FUR NF^  f Ijf L F ITERATE
                          A"RIr^ T ATP  TC Vrt ATI LES
                          TTTAL  G roi I Nif, AIR
                          pFQLiP.fn PU^^F1-1  AIR FLCV.PATF
                          TPTAt  MASF  TMFlft/'
          2 22 P. 3 LB/FP
            If. 3.5 LP/HR
          379L.3 LP/HP
          22R2.R LP/HR
          1708.r' LB/HR
         10 113.9 LR/HR
                                                                              w
                                                                              o
                                                                              Mi
                         TP.TAL  »Uf  EXIT Gf^  F
                         A SM  -I SG.HA^GE RAT F
                         PT JhC TF-_n C HOLI N'G  A I P
                         TOTAL  '^ASS
                                                  775A.B L
                                                     7^.? LR/HP
                                                  22P2.8 LB/HR
                                                 10 113.9 L8/HP

-------
The Design & Cost Printout appears in 6 sheets (pp. 113 through 118).
The input data are printed out on sheets 1, 2 and part of 3; and the
outputs on the remaining sheets.  In particular, the MHF Design and
Operation output is on sheet 3, the Heat Balance on sheet 4, the Mass
Balance on sheet 5, and the expenditures and costs on sheet 6.

The Thermal Analysis Printout appears in 4 sheets  (pp. 119 through 122)
The input data are printed out on sheets 1 and part of 2, and the
outputs on the remaining sheets.  In particular, the combustion air
requirement is on sheet 2, the heat balance and auxiliary burner
selection on sheet 3, and the exit gas composition and mass balance
on sheet 4.
                                123

-------
                       X.  ACKNOWLEDGEMENTS
This project was monitored by Dr. Joseph B. Farrell as WQO-EPA Project
Officer and conducted in the Advanced Programs Division of Rocketdyne
with Dr. B. L. Tuffly as Program Manager responsible for overall
administration and Dr. W. Unterberg as Project Director responsible
for technical content.  Dr. G. R. Schneider provided significant
technical contributions while Mr. K. W. Fertig programmed the Design
and Cost Option and Mr. W. H. Moberly the Thermal Analysis Option of
the computer subroutine.  As a subcontractor to Rocketdyne, the BSP
Corporation, a Division of Envirotech Corporation, was primarily respon-
sible for carrying out the field visits and incinerator tests, as well
as providing assistance related to furnace operational matters.
Mr. R. J. Sherwood was Program Manager for BSP Corporation, and was
assisted by Messrs. L. Lombana and R. Stroshane.

The authors of this final report are W. Unterberg, R. J. Sherwood and
G. R. Schneider.

The Field Survey of MHF Sewage Sludge Incinerators could not have been
accomplished without the cooperation of the municipal authorities who
frequently assisted in furnishing records, and, in particular, the
patience and courtesy of the plant personnel who provided performance
and operational information.  Thanks are due to personnel at the
following cities and plants:

      Cleveland Southerly Wastewater Treatment Plant, Ohio
      Minneapolis-St. Paul Sanitary District, Minnesota
      Kansas City Big Blue River Sewage Treatment Plant, Missouri
      Battle Creek Sewage Treatment Plant, Michigan
      Saginaw Sewage Treatment Plant, Michigan
      Hatfield Township Sewage Treatment Plant, Pennsylvania
      Bridgeport Sewage Treatment Plant, Pennsylvania
      South Tahoe Public Utility District, California

Especially helpful were Mr. Maurice L. Robins, Superintendent and
Chief Engineer, and Mr. Scott E. Linsley, Assistant Chief Engineer,
both at Minneapolis-St. Paul, who sent records covering over two
decades of incinerator operation.  Additional information was also
provided by Mr. Walter Tresville, Director, Cleveland Southerly Plant,
and Mr. David Evans, South Tahoe.
                               125

-------
Information on installed cost,  some going back over 30 years,  was
obtained from personnel associated with the following consulting firms:

    Havens and Emerson, Cleveland, Ohio
    Toltz, King, Duvall, Anderson & Associates, St.  Paul, Minnesota
    Black & Veatch, Consulting  Engineers, Kansas City, Missouri
    licNamee, Porter and Seeley, Ann Arbor, Michigan
    Malcolm Pirnie Engineers, White Plains, New York
    Hubbell, Roth & Clark,  Inc., Bloomfield Hills, Michigan
    Tracy Engineers, Inc.,  Lemoyne, Pennsylvania
    George B. Mebus, Inc.,  Willow Grove,  Pennsylvania
    Metcalf and Eddy, Inc., Engineers,  Boston, Massachusetts
    Lozier Engineers, Rochester, New York

Welcome assistance on economic  indicators was given by Messrs.
Greenwald and Norden, McGraw-Hill Department of Economics, New York
and Mr. Robert Ball, Bureau of  Labor Statistics, U. S. Department
of Labor, Washington, D. C.

Last, but not least, the support of the project by the Water Quality
Office, EPA, through Dr. Joseph B. Farrell, the Project Officer, who
helped in numerous ways, is gratefully  acknowledged.
                              126

-------
                          XI.  REFERENCES
 1.   Smith, R., R. G. Eilers, and E. D. Hall, "Executive Digital Com-
     puter Program for Preliminary Design of Wastewater Treatment
     Systems," U. S. Department of Interior, FWPCA Report 20-14,
     August 1968.

 2.   Burd, R. S., "A Study of Sludge Handling and Disposal," U. S.
     Department of the Interior, FWPCA Report WP-20-4, May 1968.

 3.   Isheim, M. C., "The Multiple Hearth Furnace," BSP Corporation,
     San Francisco, June 1969.

 4.   Owen, M. B., "Sludge Incineration," Paper 1172, Journ.  San. Eng.
     Div., Amer. Soc. Civil Engrs.. Vol. 83, No. SA-1, pp. 1172-1
     through -25, February 1957, and "Sewage Solids Combustion,"
     Water and Sewage Works, pp. 442-447, October 1959.

 5.   Harris, S. M. , "Incineration - Multiple Hearth Furnaces," Water
     and Sewage Works, August 1967.

 6.   Sawyer, C. N. and P. A. Kahn, "Temperature Requirements for Odor
     Destruction in Sludge Incineration," Jour. WPCF. Vol. 32, No. 12,
     pp. 1274-1278, December 1960.

 7-   Sebastian, F. P. and P. J. Cardinal, "Solid Waste Disposal,"
     Chemical Engineering. Vol. 75, No. 22, pp. 112-117, October 1968.

 8.   Corey, R. C. (Ed.), Principles and Practices of Incineration,
     Wiley/Interscience, New York, 1969.

 9.   Niessen, W. R. and A. F. Sarofim, "Incinerator Emission Control,"
     Industrial Water Engineering, pp. 26-31, August 1970.

10.   Kalika, P- W., "How Water Recirculation and Steam Plumes Influence
     Scrubber Design," Chemical Engineering, pp. 133-138, 28 July 1969.

11.   Smith, R., "Preliminary Design and Simulation of Conventional Waste-
     water Renovation Systems Using the Digital Computer," U.S. Depart-
     ment of the Interior, FWPCA Report WP-20-9, March 1968.

12.   MacLaren, J. W., "Evaluation of Sludge Treatment and Disposal,"
     Canadian Municipal Utilities, pp. 23-33, 51-59, May 1961.

13.   DiGregorio, D., "Cost of Wastewater Treatment Processes," U. S.
     Department of the Interior, FWPCA Report TWRC-6, December 1968.
                                127

-------
14.   Ducar,  G.  J.  and P.  Levin, "Mathematical Model of .Sewage Sludge
     Fluidized Bed Incinerator Capacities and Costs," U. S. Department
     of the  Interior, FWPCA Report TWRC-10, September 1969.

15.   Quirk,  T.  P., "Economic Aspects of Incineration versus Incinera-
     tion-Drying," (from '"Sludge Concentration - Filtration and
     Incineration," Continued Education Series No. 113, University
     of Michigan,  Ann Arbor, p. 389) 1964.

16.   Waller, L. W. and W.  R. Condon, "Problems in the Design of Sludge
     Incinerating Systems," Proceedings 16th Annual Conference on
     Sanitary Engineering, University of Kansas, January 1966.

17.   Mick, K. L. and S. E. Linsley, "An Examination of Sewage Solids
     Incineration Costs,"  Water and Sewage Works, Vol. -104, No. 11,
     pp. 479-487,  November 1957.

18.   ASCE Committee on Municipal Refuse Practices, "Municipal Incinera-
     tion of Refuse," (Progress Report), Proc. Amer. Soc. Civil Engrs.,
     Sanitary Eng. Division, Vol. 90, Paper SA3, pp. 13-26, 1964.

19.   Rossini, F. D., et al, "Selected Values of Chemical Thermodynamic
     Properties," National Bureau of Standards Circular 500, U. S.
     Department of Commerce, Washington, D.C., 1952.

20.   Joint Army, Navy, NASA, and Air Force (JANNAF) Thermochemical
     Tables, available from Chemical Propulsion Information Agency,
     Applied Physics Laboratory, Johns Hopkins University, Silver
     Spring, Maryland (continuing series).

21.   Faires, V. M., Thermodynamics, Fourth Edition, p. 61, MacMillan
     Co., New York.

22.   Heilman, R. H., "Suggested Procedure for Calculating Heat Losses
     through Furnace Walls," Manual of ASTM Standards on Refractory
     Materials, 1957.

23.   Marshall and  Stevens Equipment Cost Index  (Average and Clay
     Products), Chemical Engineering. 5 March 1962, p. 125 (1913-1961);
     5 May 1969, p. 137 (1950-1968); 23 March 1970, back flap  (1964-1969).

24.   Engineering News Record Construction Cost Index, Business Statistics,
     1967 Biennial, U. S.  Department of Commerce, Office of Business
     Economics  (1939-1965); Construction Review, January 1970, p. 42
     (1964-1969).

25.   Plant Maintenance Cost Index, McGraw-Hill Department of Economics,
     330 W.  42nd St., New York, New York, 10036  (1947-1969).

26.   Plant Cost Index  (Average and Process Machinery), Chemical
     Engineering.  25 April 1966, p. 188 (1947-1965); 5 May 1969
     (1950-1968).

-------
27.  Average Hourly Gross Earnings per Non-supervisory Worker in
     Electric, Gas, and Sanitary Services, Business Statistics, 1967
     Biennial, U. S. Department of Commerce, Office of Business
     Economics (1958-1966); Monthly Employment and Earnings. Bureau
     of Labor Statistics, U. 3. Department of Labor (1967-1969).

28.  "Industrial Wage Survey-Industrial Chemicals," Bulletin 1529,
     Bureau of Labor Statistics, U. S. Department of Labor, October
     1.966.

29.  Masonry, Stonework, and Plastering (Straight Time Earnings,
     National Average), Monthly Employment and Earnings. Bureau of
     Labor Statistics, U. S. Department of Labor (1958-1969).

30.  Smith, R., "Cost of Conventional and Advanced Treatment of Waste-
     water." Jour. Water Poll. Control Fed., Vol. 40, No. 9, pp. 1546-1574,
    'September 1968.

31. .American-Society of Civil Engineers, Civil Engineering, p. 31,
     October 1967.

32.  Michel, R. L.-, A. L. Pelmoter, and R. C. Palange, "Operation and
     Maintenance of Municipal Waste Treatment Plants," Jour. Water
     Pollution Control Federation. Vol. 41, No. 3, pp. 335-354,
     March 1969.-

33.  Smith, R., "Estimation of Operating and Maintenance Cost for
     Wastewater Treating Processes," Internal FWPCA Memorandum,
     30 April 1969.

34.  McMichael, W. F., "Operating and Maintenance Costs," Internal
     FWPCA Memorandum, 9 August 1968.

35.  Fair, G. M., J. C. Geyer, and D. A. Okun, Water and Wastewater
     Engineering. Vol. 2. Water Purification and Wastewater Treatment
     and Disposal, p. 36-20, John Wiley and Sons, New York, 1968.
                                129

-------
                         XII.   GLOSSARY
ADF       Number  of MHF's above minimum
ALA       Incinerator  land area per MHF -  acres
AMRM      Yearly  refractory replacement labor  per MHF  - man-hr/yr
AMRR      Refractory replacement  labor  rate  -  $ per man-hr
AMSY      Yearly  normal  maintenance material cost per  MHF - $ per year
ANMM      Yearly  normal  maintenance labor  per  MHF - man-hr/yr
ANMR      Normal  maintenance  labor rate -  $  per man-hr
ANMY      Yearly  cost  of normal maintenance  labor per  MHF - $/yr

BFR       Building/MHF cost ratio - $ per  $
BGC       Cost of incinerator building  - $
BRN(I)    Species formed from combustion of  1  Ib of burner fuel - Ib
BTUV      Burner  heat  output per unit air  flow - Btu/scf
BURAI     Air for fuel burner - Ib per  Ib  fuel
BUREX     Excess  fuel  burner capacity - percent
BURNT^     Theoretical  (stoichiometric)  oxygen  for burner - Ib per Ib fuel

C         Carbon
CAST      On-site cost of castings for  one hearth - $
CCI       Installed Capital cost - $
CLD       Land cost per  MHF - $
CLH       Castings replacement labor for one hearth -  man-hr
CPA       Specific heat  of air - Btu per Ib  °  F
CPASH     Specific heat  of ash ( = 0.2)  -  Btu/lb ° F
CP(l)     Specific heat  of Ith species  - Btu per Ib ° F
GPS       Specific heat  of water vapor  (steam) - Btu/lb ° F
CPWAT     Specific heat  of liquid water (  =  1.0) - Btu/lb ° F
CRL       Complete MHF castings replaced during MHF life (SLF)-number
CRM       Yearly  casting replacement labor per MHF - man-hr/yr
CRR       Castings replacement labor rate  -  $  per man-hr
CYCF      Non-steady state (cycling) fraction  of total operation - hr per hr
CYT       Total heatup cycle time - hr

(D)       Applies only to Design & Cost Option
DCO       Design  & Cost  Option
DHBUR     Heat to raise  burner gases to  TEX  -  Btu/lb-fuel
DPC       Castings material cost per hearth  -  $
DPR       Refractory material cost per  hearth  - $
DPW       Weekly  incineration schedule  - days/wk
DRYM0     Molecular weight of dry exhaust  gas
DSF       Steady-state dry solids rate  per MHF - Ib/hr
                                131

-------
EFC
LLMV(l)
ELMWfl
EXAFU
EAL
FCAC
FFE
FCY
II LA.
FRAIR
FRFfl
FRY (I
FUY

GDRY
GT0T

H
HASH
IIC
HJDIA
HLD
IIPD
HR
HUQ

IIWGAS
HWSEN
HWSL
1IWYAP
 1
 2
 3
 4
 5

 KASE
 KEFR
 KEA
   Elevation above sea level,  or altitude-feet
   Engineering fee - $
   Elemental weight of Ith element - number
=  1,2,3.4,5)  =  12.011,  2.016,  32.0,  28.0134, 32.064
   Excess  air for auxiliary fuel burner percent

   Fraction Al(OH)3 converted  to Al^Og
   Fraction CaC03 converted to CaO
   Fraction Fe(OH)o converted  to Fe20g
   Yearly  fuel consumption per MHF - Ib/yr
   Effective hearth area  per MHF - sq ft
   Fraction of cooling air recycled
FRFU(I)     Mass  fraction of Ith element in fuel (l=l,  NELF)
FRV0(l)     Mass  fraction of Ith element in volatiles (l=l,  NELV)
   Yearly  fuel cost per MHF -  $/yr

   Total dry exhaust flow,  including burner products -  Ib/hr
   Total exhaust  gas flow,  including burner products -  Ib/hr

   Hydrogen
   Heat removed in ash -   Btu/hr                                        „
   MHF heat transfer coefficient by free and forced convection-Btu/hr ft  F
   MHF outer diameter (13.5 inch wall) - feet
   Hearth  loading (dry solids) - Ib per hr per sq ft
   Daily incineration schedule - hr per day                      ~
   MHF heat transfer coefficient by thermal radiation - Btu/hr ft  F
   Heatup  heat requirement per MHF for 0-1200 F and 1200-1500 F heating-
                                                 Btu/hr
   Heat for gas phase heating  of sludge moisture - Btu/hr
   Heat for liquid phase  heatup of sludge moisture - Btu/hr
   Heat for sludge moisture evaporation and heating - Btu/hr
   Heat for evaporation of sludge moisture - Btu/hr
                 Elements
   C (carbon)
   IE
molecular hydrogen)
molecular oxygen)
molecular nitrogen)
elemental sulfur)
        Species

CO  (carbon dioxide
HgO (water)
OQ (oxygen)
NI (nitrogen)
SDQ (sulfur dioxidf
L0C
   Number of case (MHF Selection Input)
   Engineering fee code formula or omit
   Land area constant (Chapter Vl)

   litle information - alpha-numeric
                               132

-------
MHF
          Multiple hearth furnace
N         Nitrogen
NCASE     Number of cases
NAMV(l)   Name of element in volatiles  (l=l, NELV)
NELV      Number of elements in volatiles
NAMFU     Name of auxiliary fuel
NELF      Number of elements in fuel
N0F       Total number of MHF's
NHEAR     Number of hearths per MHF
NAMF(l)   Name of element in fuel  (l=l, NELF)
NUMSP     Number of species in exhaust  gas

0         Oxygen
JZfLM       Yearly operating labor per MHF - man-hr/yr
0LR       Operating labor rate - $ per  man-hr
0LY       Yearly operating labor cost per MHF - $ per yr
0MD       Daily operating labor per MHF - man-hr/24 hr-operating day

PAIRA     Ambient combustion air rate - Ib/hr
PAIRC     Total shaft cooling air rate  - Ib/hr
PAIRS     Shaft cooling air per MHF - Ib/hr
PAIRT     Total air flow for combustion of volatiles - Ib/hr
PALHY     Aluminum Hydroxyde Al(OH)« in dry solid - v/o
PASH      Ash flow rate - Ib/hr
PCAC      Calcium Carbonate CaCO^  in dry solid - v/o
PSCRE     Atmospheric pressure at given altitude - Ib/sq in, abs.
PCY       Yearly electrical pover consumption per MHF - Kv-hr/yr
PDS       Electrical pover consumption  rate - Kw-hr/ton dry solids
PERS      Total dry solids concentration - v/o
PERV      Volatiles concentration in solids - v/o
PERW      Water concentration in sludge - v/o
PFEHY     Ferric Hydroxide Fe(OH)g in dry solid - v/o
P^2S      Theoretical (stoichiometric)  oxygen flovrate for sludge combustion-Ib/hr
P^Y       Yearly pover cost per MHF - $/yr
PSLU      Steady state vet sludge rate  per MHF - Ib/hr
PS0L      Dry sludge flovrate per MHF - Ib/hr
PSWAT     Water vapor pressure - Ib/sq  in, abs.
PV0L      Volatiles flovrate per MHF -  Ib/hr
PWAT      Sludge moisture flovrate - Ib/hr
PWS       Plant vet sludge flov - ton/day
PXAIR     Minimum excess air for combustion of volatiles - percent
                                   133

-------
QALHY     Heat for decomposing Al(OH),, - Btu/hr
QAMBA     Heat from incoming ambient air - Btu/hr
QARIN     Heat from recycled shaft cooling air - Btu/hr
QBUR      Total burner heat requirement - Btu/hr
QCAL      Heat for calcining of CaCO-Btu/hr
QC00L     Shaft cooling heat loss - Btu/hr
QFE       Heat for decomposing Fe(OH)3 - Btu/hr
QFU       Higher heat value of Fuel - Btu/lb
QGR0S     Gross burner heat requirement - Btu/hr
QIX       Total heat supplied - Btu/hr
QNET      Net heat supplied - Btu/hr
QREQ      Total heat required - Btu/hr
QSEN      Heat for sludge combustion products - Btu/hr
QTRAN     MHF radiation and convection heat loss - Btu/hr
QV^L      Higher heat value of volatiles - Btu/lb
QV0LT     Heat from combustion of volatiles - Btu/hr

REFR      On-site cost of refractory for one hearth - $
RLH       Refractory labor for one hearth - man-hr
RMY       Yearly hearth replacement labor cost per MHF - $/yr
ROEX      Exhaust gas density at entry to scrubber - Ib/cu ft
RPY       Yearly cost of hearth replacement parts - $/yr
RRL       Complete MHF refractories replaced during MHF system lifetime (SLF)

S         Sulfur
SAREA     MHF cylindrical outer area for heat loss - sq ft
SBQ       Hot standby (1200 F) heat requirement per MHF - Btu/hr
SCFAI     Burner air flowrate - scfh
SCFCL     Shaft cooling air flov
              DCO:  std cu ft per min, for vhole plant
              TAG:  std cu ft per hr, for one MHF
SHYF      Hot standby (1200 F) time - hr per yr per MHF
SLF       MHF system life - years
SN0       Number of standby MHF units
SPMW(l)   Molecular weight of Ith species - number
SPMW(I=1,2,3,4,5)  =  44.011, 18.016, 32.0, 28.0134, 64.066

T         Temperature - deg F
(T)       Applies only to Thermal Analysis Option
TAIRI     Exit temperature of cooling air - deg F
TAMB      Ambient air temperature - deg F
TAO       Thermal Analysis Option
TASH      Exit temperature of ash - deg F
TCC       Total capital cost per MHF - $
TCST      Total annual cost per MHF - $/yr
TCY       Yearly total capital charges per MHF - $/yr
                                  134

-------
TDPW      Maximum weekly incineration schedule - days/wk
TEX       Exit temperature of combustion gas - deg F
Tj?iT(l)    Total flow of Ith specie in exhaust gas, including burner products-Ib/hr
TSCRB     Exit temperature of scrubber gas - deg F
TSL1      Inlet temperature of sludge - deg F
TSUR      MHF surface temperature - deg F
TVjZfL      Total exhaust gas flow, including burner products - Ib/hr

UFC       Unit fuel cost - $ per Ib
ULC       Unit land cost - $ per acre
UPC       Unit power cost - $ per Kw-hr

VAMBF     Ambient air velocity - ft/sec
VAMBM     Ambient air velocity - mph
VDRY      Total dry gas flow of exhaust gases, including burner products at TEX -
                  cu ft/hr
VpL(l)    Total flow of Ith specie in exhaust gas, including burner products -
                  cu ft/hr
VSAT      Specific volume of scrubber exit gases - cu ft per Ib dry gas
VSCEX     Saturated total exit flowrate from scrubber - acfm
WATS     Water flow to saturate scrubber exit gas - gal/min

WATSC     Water flow to saturate scrubber exit gas - Ib/hr
WBAIR     Burner air flowrate - Ib/hr
WGTF      Burner fuel flowrate - Ib/hr
Wjfe       Weekly incineration hours - hrs/wk
WS(l)     Flowrate of Ith species (excluding auxiliary burner) - Ib/hr

YHF       Yearly total operating hours per MHF
YHUH      Yearly heatup  hours per MHF
YIR       Yearly interest rate - percent
YSBH      Yearly standby hours hours per MHF
                                    135

-------
c 	 " — 	 - 	 	 	 --- 	 	 	 "- 	 - 	 - 	 — 	 " 	 ""
c
C MULTIPLE HEARTH SLUDGE INCINERATOR PROGRAM
C CHEMICAL TECHNOLOGY AND APPLIED MATHEMATICS UNIT, ROCKETDYNE
C

C
DIMENSION ANAMS(5) , NAMEL(5> , FRV015) , FRFU(5) * TOT15)
X , VOL<5) ,NAMFU(6),FRV(5J,FRF<5J,NAMV(5»,NAMF( 5),LOCC24)
DIMENSION DITA8<591,FHTAB<59),NOTAB<59),FCYT(5),FHACY(5)
COMMON ACF, ADF, ALA, ALKX,AMRM, AMRR , AMSY, ANMM, ANMR, ANMY, AMSYA
l,AMSYP,AMYPN,ANAMS,ANMYA, ANMYP, ANYPN,BFR,BGC,BTUV, BGCAL ,BUREX
2,CCI,CLD,CLHfCRL,CRM,CRR,CYT,CYCF,CCIAL,CLDAL,DPH,DSFtDITAB
3,EFC,ELE,EFCAL,EXAFU,FAL,FCY,FFE,FHA,FPC,FRF,FRV,FUY,FCAC
4 , FRFU , FRVO, FHTAB, FRAIR, FRC02, FUYAL , FUYPC, FUYPT ,GDRY, GTOT
£ COMMON HLD,HPD,HASH,HDIA,HWSL,OLM,OLR,OLY,OLYAL,OLYPC,OLYPT
~^ l,PCY,PDS,POY,PWStPAIR,PASH,PCAC,PEFF,PERA,PERC,PERS,PERV
2,PERW,PSLT,PSLU,PAIRA,PAIRC,PAIRS,PAIRT,PALHY,PALWA,PCACO
3,PFEHY,PFEWA,POYAL,POYPC,POYPT,PSCRE,PXAIR,QFE,QFU,QIN,QBUR
4 , QC AL , QNET , QREQ , Q SEN , QVOL , QAL HY, Q AMB A , Q AR I N,QCOOL , QGROS
COMMON QTRAN,QVOLT,RLH,RMY,RPY,RRL,ROEX,RJAIR,RMYAL,RMYPC
l,RMYPT,RPYAL,RPYPC,RPYPT,SLF,SNO, SMGD,SCFAI,SCFAM,SCFCF,SCFCL
2,SCWAT,SLDEN,TCC,TCY,TEX,TMF,TOT,TAMB,TASH,TCST,TDPW,TSL1
3,TSUR,TVOL,TAIRI,TCCAL,TCSTA,TCSTP,TCTPN,TCYAL,TCYPC,TCYPT
4,TOTMF,TSCRB,UFC,ULC,UPC,VOL,VSAT,VAMBM,VAREA, VSCEX,VWATS
COMMON WOHfHGTF,WATSC,MBAIR,YHF,YIR
1,KASE,KEFR,LOC,NOF,NPX,NAMF,NAMV,NELF,NELV,NAMEL,NAMFU,NCASE
2,NHEAR,NOTAB,NRTAB,NUMEL,NUMSP
3 , IN, 10
DATA FCYT / 18. v 18. v 54. , 108. , 108 . /
DATA FHACY/ 0«, 200., 1700., 2300. , 3500. /
DATA NHTAB /59/
C DEFINE STATEMENT FUNCTIONS
FALA(X) = 4.938303 * .7853982 * X**2 / 43560.
00000010
00000025
00000030
00000040
00000050

00000070
00000080
00000085
00000090
00000100
00000110
00000120
00000130
00000140
00000150
00000160
00000170
00000180
00000190
00000200
00000210
00000220
00000230
00000240
00000250
00000260
00000270
00000280
00000700
00000800
00000810
00000900
00000905

-------
H
         "FCClfxT ="""5463.8"*  X  **  .6002739
          FCLH(X) =  7.47457 -  0.10471l*X +0.0298929*X**2
          FOMD(X) =  0.0083434*  X
          FPDS(X) = 29.6041 -  6.5523 E-09 *(X-2808.)**3+4.93916E-16
         (         *(X-2808.)**5
          FRLH(X1!__ = ^9^0762 J_«_105219*X _*^ . 529646*X**2.25	    _
         TCASTlX)  = 1080.9~5 -  219.7~32*X + 8~9.~4"8~29 *X~* * f. S~~
          FREFR(X)  = 458.024 -  120.287*X +14.5823*X**2
          FEFC(X,Y) = .50065678*(X+YJ**.84613605
          FMSY(X)  =  1569.7036  *  X**.02287259
          FANMM(XJ   = 111.8621  * X  ** .30748408
           SET CONTROL INTEGERS  FOR INPUT AND OUTPUT  DEVICE NUMBERS
IN = 5
10 = 6
  READ  INPUTDATA AND PRINT
CALL BLOCK
CALL INPUT
IF ( NCASE  )  6,6,10
 00000910
 00000915
 00000920
 00000925
 00000926
 00000930
~OOOr009lF5~
 00000940
 00000952
 00000954
 00000956
 00000970
"OOOOOWO
 00000990
 00001000
 00001010
 00001100
 00001110
c THERMAL ANALYSIS ONLY
6 CALL HEAT (IER>
IF ( IER) 5,7,5
7 CALL PRINT
GO TO 5
C REPEAT MAIN PROGRAM
10 DO 1000 KASE = I, NCASE
C
C READ AND PRINT SELECT
C
CALL TITL (2)
READ (IN, 8100) HPD,TDPW
8100 FORMAT ( 4F12.6)
ISNO = SNO
IADF= ADF

FOR EACH SELECTION INPUT
ION DATA
, SNO, ADF

WRITE (10,9100) KASE,HPD,TDPH,I.,MO, IADF
9100 FORMAT ( 1HO/ 31X,32H*** MHF SELECTION INPUT FOR CASE, 13, 4H ***
00001120
00001130
00001140
00001150
00001160
00001200
00001300
00001400
00001500
00001600
00001700
00001800
00001900
00002000
00002100
00002200
00002300

-------
H
c
c
c
c
c
c






X /// 26X,27HDAILY INCINERATION SCHEDULE, 3X,F1 1 . 2 , 7H HR/DAY
X /26X,33HMAX. WEEKLY INCINERATION SCHEDULE ,F8.2,8H DAYS/WK
X /26X, 27HNUMBER OF STANDBY MHF UNITSt 114
X /26X, 29HNUMBER OF MHF'S ABOVE MINIMUM, I 12 J
COMPUTE DESIGN REQUIREMENTS
THA = 70.*PWS*PERS/ (HPD*TDPW)
IF ( THA -85.) 50,80,80
50 NOF = U + SNO + 0.0001
N = TDPW*THA/85. + 0.0001
DPW = N
IF ( DPW) 60,60,70
60 WRITE (10,9900) K ASE, TDPW ,THA
9900 FORMAT { 1H1,9X, 8H*** CASE, 13, 6H *** / 8X,
X 20HTRIAL DAYS PER WEEK, , F6.1,37H , IS TOO SMALL FOR TOTAL
XTH AREA , Fll.2 )
WRITE (10,9910)
9910 FORMAT ( 8X,30HCASE IS NOT CONSIDERED FURTHER )
GO TO 1000
70 FHA = THA*TDPW/DPW
GO TO 120
80 IF ( THA-2860.) 100,100,90
90 DPW = TDPW
NOF = THA/2860. +1.00001
NOF = FLOAT(NOF) + ADF+SNO + .0001
FHA = THA/ FLOAT(NOF)
GO TO 120
100 NOF = 1, + ADF + SNO + 0.00001
DPW = TDPW
FHA = THA/l l.+ADF)
120 CYT = FCYT(l)
00002310
00002320
00002330
00002340
00002700
00002900
00003000
00003100
"00003200
00003300
00003320
00003340
00003360
00003380
00003400
00003420
00003440
HEAR00003460
00003480
00003500
00003520
00003540
00003560
00003580
00003600
00003620
00003640
00003660
00003680
00003700
00003720
00003740
00003760
00003780

-------
      125
      130

      135

      140
      145
                23,99 ) 140,125,125
                6.99 )  130,135,135
                ANOF/(ANOF-SNO))/<216.*DPW)
O
     ANOF  =  NOF
     IF  (  HPD  -
     IF  (  DPW  -
     F =  (  1. V
     GO  TO
     _F ±_                         _         _
     GO  TO  145        "        ""      """       "  	"
     F =  (1.+  ANOF/(OPW*(ANOF-SNO)))/(9.*HPD)
     CYCF  =  CYT  *  F
     TEST  =  FHA/(1.0 -CYCF)
     CALL  LOCAT  (  TEST,FHTAB, NHTAB,IERR,K  )
  	GO  TO  (  160,170L150,150,150  ItlERR
 150 WRITE Tl6~,9920T K A'SE ,THA, NOF~               "       	
9920 FORMAT(  1H1,9X,8H*** CASE,13,6H   ***  /  8X,
    X  18HTOTAL  HEARTH AREA,,F11.2,24HI, OR  NUMBER OF FURNACES,,I 5,1H,,
    X17H  IS  OUT  OF RANGE.  )
     WRITE  (10,9910)
     GO  TO  1000
                               FHACYt5f
160 CALL  LOCAT (  FHTAB(K-H), FHACY,5,  IERR,L)
    CYT =  FCYT{L)+(FCYT(L+1)-FCYT(L))*(FHTAB
-------
                                                                            000044W
       YHF « 52.*HPD*DPW*(ANOF-SNO)/ANOF                                   00004440
	IF < _HPD - 23.99)   175,174,174	                               00004480
  174 CRL = 2.500004485
       RRL = 0.5                                                            00004490
	GO TO 176	           .     	                        00004495_
   175 CRL = 5.0                            "   ""                   -  —--   00(5(54"500-
       RRL = 1.0                                                            00004510
	176JrfOH _*_ _HPD*DPW	    _                                             00004520
 C             "                                                             00006000
 C        COMPUTE HEAT  AND MASS BALENCE                                     00006100
_c			            __  _               _   	00006?OCL
       CALL HEATUFJO"    "  " ""                    "                        00"0~063<50
       IF (  IER)  1000,177,1000                                            00006320
J^	     	                 _                                00006400
 C      COMPUr^NOiT-^OLrATrifEClUTR'EMENTS""""                     "            00006500
 C                                                                           00006600
   177 ALA = FALA(  HDIA)     ^	        	        __	     00006800
       SB'Q = ~315T063"9 * F~HA   "  ~ "   "~       '    ~    	~          '   "  '00006900"
       HUQ *  1912.7905 * FHA                                               00006950
 	F _= (ANOF-SNO)/AN0F                                                  00006960
       IF (  HPD - 23.99)   6140,6125,6125                                   00006970
 6125 IF (  DPW - 6.99) 6130,6135,6135                                     00006980
 6130 YSBH =         __f±L ?t-*£.YI/!?- * J2*§t*l7-~P.f>w>  ?       _   _       00006990
       YHU'H =  62.*CYT/ 9. *""F" "~ r—~       —--.-  -      --     ..._.„.._..„. - 00007000
       GO TO 6145                                                           00007010
_AiA5_YSBlLf_  _?^*CYT/9.  * F                                               00007020
       YHUH = id.*CYT/9.* F                                                 00007030
       GO TO 6145                                                           00007040
 6140 YSBH =  F*l|._*CY_T/9. _* JB736.-52.*HPD*_DPW  )                          00007050
       YHUH~^           "~   F*"CYT/9. * ( 10.  + 52.*DPW)      """  "  "      "00007060"
 6145 FCY =  WGTF*YHF*(1.-CYCF)  * (YSBH*SBQ  + YHUH*HUQ)/ QFU             00007070
       IF (FHA - 2808.)  1^0,178,178                                        00007100
 " 178 PDS =29.6041                                                        00007120
       GO TO 185                                                            00007140

-------
                             191,192,192
     C
     c
ro
180 PDS = FPDS  (FHA)
185 IF( FHA-  719.13)
191 OMD = 6.0
    GO TO 193
192 OMD = FOMD(FHA)
193 PCY = PDS*DSF*(1.-CYCF)*YHF/2000.
    OLM = OMD*YHF/24.
    ANMM = FANMM(FHA)
    CLH = FCLH(HDIA)
    CRM = CLH*CRL*FLOAT(NHEAR)/SLF
    RLH = FRLH(HDIA)
    AMRM = RLH*FLOAT(NHEAR)*RRL/SLF

      COMPUTE COST  REQUIREMENTS

    CCI = FCCI(FHA)
    BGC = BFR* CCI
    CLD = ALA*ULC
    IF (KEFR) 200,200,210
    EFC = 0.0
    GO TO 220
    EFC = FEFC(CCI,BGC)
       200

       210
       220
       230

       240
       250
BGC
                       CLD + EFC
                             240
 TCC =  CCI +
 ANOF = NOF
"CCIAL  = CCI*ANOF
 BGCAL  = 3GC*ANOF
 CLDAL  = CLD*ANOF
 IF(KEFR) 230,230,
 EFCAL  = 0.0
       250
       = FEFC(CCIAL, BGCAL)                       "         ~"
       = CCIAL + BGCAL + CLDAL  *  EFCAL
        TCC*YIR/100. /( 1 . 0 -( 1. *Y IR / 100. ) **(-S LF ) )
       (FLOAT(NHEAR)/SLF)*( CRL*FC AST(HO I A )  * RRL*FREFR( HDI A )  )
        FMSY(FHA)
    GO TO
    EFCAL
    TCCAL
    TCY =
    RPY =
    AMSY
00007160
00007180
00007200
00007220
00007260
00007300
00007400"
00007500
00007600
00007700
00007800
00007900
00008000
00008100
00008200
00008300
00008400
00008500
00008600
00008610
00008620
00008630
00008700
00008800
"0000~890"6"
00009000
00009100
00009120
00009140
00009160
00~009200
00009300
00009400
00009500
00009600

-------
                                                                           00009700
                                                                           00009800
                                                                           00009900
FUY = FCY* UFC
POY = PCY*UPC
PLY » OLM*PLR
ANM'Y = ANMM*ANMR
RMY = CRM*CRR + AMRM*AMRR
TCST = TOY * RPY  + AMSY +
                                  FUY + POY + OLY  +  ANMY * RMY
       TCYAL = TCY*TCCAL/TCC
       RPYAL = ANOF*RPY
     ___ AMSYA j=_ANOF*AMSY	
       FUYAL = ANOF*FUY
       POYAL = ANOF*POY
    	pLYAL_^AJ^QFjy]iLY	
       "ANMY A = ANOF*ANMY
       RMYAL = ANOF*RMY
       TCSTA = TCYAL+RPYAL+AMSYA »FUYAH-POYAL*OLYAL»ANMYA»RMYAL
H      F = 2000, /  (ANOF~*DSF*YHF*( 1.0-CYCFD      "         '"
g      TCYPT = TCYAL*F
   	RPY_PT_»_RP YAL*F	
       AMYPN = AMSYA*F
       FUYPT = FUYAL*F
       POYPT = POYAL*F            		       	
       OLYPT = OLYAL*F
       ANYPN = ANMYA*F
       RMYPT =__RMYAL_*F	 __   „_
     ~~ tcTpN~ = fc YP T+R P Y PT+AMYP'N+FU Y pf+P OY PT+OLY PT+AN Y"PN"*IRMYP T
       F =  100./TCSTA
       T.CYPC = TCYAL*F                   	 	
       RPYPC = RPYAL*F
       AMSYP = AMSYA*F
       FUYPC = FUYAL*F             		
       POYPC = POYAL*F   ~~" '         " '   " "•"  "       *"""
       OLYPC = OLYAL*F
       ANMYP = ANMYA*F                                          ._
     " RMYPC = RMYAL*F
       TCSTP =TCYPC+RPYPC-»-AMSYP+FUYPC+POYPC*OLYPC+ANMYP-i-RMYPC
00010000
00011000
00011100
                                                                    00011200
                                                                    00011300
                                                                    _00011400_
                                                                    00011500
                                                                    00011600
                                                                    00011700
                                                                    00011800
                                                                    00011900
                                                                    00012000
                                                                    00012100
                                                                    00012200
                                                                    00012300
                                                                    00012400
                                                                    00012500
                                                                    00012600
                                                                    00012700
                                                                    00012800
                                                                    00012900
                                                                    00013000
                                                                    00013100
                                                                    00013200
                                                                    06013300
                                                                    00013400
                                                                    00013500
                                                                    00013600"
                                                                    00013700
                                                                   _p0013_80p_
                                                                    00013900
                                                                    00014000

-------
c
c
c
     WRITE OUT  ANSWERS

     CALL PRINT
1000 CONTINUE
     GO TO 5
      END
      SUBROUTINE
                 INPUT
      THIS  ROUTINE  READS AND PRINTS TITLE  INPUT,
       SLUDGE  STREAM INPUT, FINANCIAL INPUT,  AND
                                                  NUMBER OF
                                                  TECHNICAL
                                                       CASES,
                                                       INPUT
                  ANAMS(5) , NAMELC5)  ,  FRVO(5)  ,  FRFU(5) , TOl
                  AMFU(6),FRV(5),FRF(5),NAMV(5),NAMF<5»,LOC<24)
                  DITAB(59),FHTAB159),NOTAB(59)
      DIMENSION  ANAMS(5)  ,  NAMEH5) , FRVO(5
      , VOL(5),NAMFU(6),FRV(5),FRF(5),NAMV(5
      DI ME NSI ON  DITAB(59),FHTABI 59 ) ,NO TAB(59
      *-* a h*j-\ fci  »<* t-  • r\r~  A • A  A • L/ \/ A LA n u  A un n  A u «* v/
                           ,FAL,FCY,FFETFHA,FPC,FKF7F*V7
                           IR,FRC02,FUYAL,FUYPC,FUYPT,GD
                           , HD IA , HWS L , OL M , OLR , OL Y , OLY A L ,
                           R ,P ASH,~PC AC ,P EFF ,PERA, PERC , PE
                           A,PAIRC,PAIRS,PAIRT,PALHY,PAL
,FRFU,FRVO,FHTAB,FRA
COMMON  HLD,HPD,HASH
     C OMMON  HLD,HPD,HASH,HDIA,HWS L,OL M,OLR,OLY,OLY A L,OL YPC,
     , PCY,PDS,POY,PWS,PAIR,P ASH,PCAC,PEFF,PERA,PERC,PERS,PER
     ,PERW,PSLT,PSLU,PAIRA,PAIRC,PAIRS,PAIRT,PALHY,PALWA,PCA
     ,PFEHY,PFEWA,POYAL,POYPC,POYPT,PSCRE,PXAI R_, QFE , QFU, QIN ,
     , QC AL , QNET, QREQ, Q SEN, QVOL , QAL HY, Q AMB A, Q ARI N, QC'OOL . OGRO S
     rnMMnw  QTRAN.ovni T.RI H.RMY.RPY.RRI .ROF X.R.IATR . RMYAI .RM
      COMMON  WOH, HGTF , W~AT~SC , W8 A IR, Y
     1,KASE,KEFR,LOC,NOF,NPX,NAMF,NA
     2,NHEAR,NOTAB,NRTAB,NUMEL,NUMSP
     ^ . IN.in
00014100
00014200
00014300
00014400
00014500
00014600

10000010
10000020
10000030
10000040
10000050
I OTjTO'O 080
10000085
10000090
10000100
10000110
10000120
rwcroTTcr
10000140
10000150
10000160
10000170
10000180
                                                                     10000200
                                                                     10000210
                                                                     10000220
                                                                     10000230
                                                                     10000240
                                                                     T000"0~2~5~0"
                                                                     10000260
                                                                     10000270
                                                                     10000280
                                                                     10001000

-------
c
c
.p.
c

c

c
H
-p=-
VJl
c


c
c
c
c

'• " 	
READ TITLE , NO. OF CASES
READ (IN, 8000) LOC, NCASE
8000 FORMAT(24A2, 112)
READ SLUDGE STREAM INPUT
READ (IN, 8100) PWS,PERS~,PE~RV, QVOL , PCAC, PFEHY,P ALHY, NEL V
8100 FORMAT ( 6E12.8/ E12.8,I12)
READ(IN,8200) (NAMV( I ) , FRV( I ) , 1=1 ,NELV»
8200 FORMAT(6( A2,F10.6)>
IF C NCASE > 10,10,20
HEAT BALANCE RUN ONLY
10 READ UN, 8250) NAMFU,HDIA , NHEAR,PSLU
8250 FORMAT* 6 A2, F12.6, 112, F 12.6)
GO TO 30
READ FINANCIAL INPUT
20 READ (IN, 8300) SLF,YIR, KEFR,NAMFU,ULC,UFC
8300 FORMAT( 2E12.8 , 112, 6A2, 2E12.8 )
READ (IN, 8400) UPC,OLR, ANMR,CRR, AMRR,BFR
8400 FORMAT ( 6E12.8)
READ TECHNICAL INPUT
30 READ (IN, 8400) PXAIR, SCFCL.FRAIR, TAIRI
READ (IN, 8400) TSL1,TEX,TASH,TSCR B
READ (IN, 8400) FCAC,FFE,FAL
READ (IN, 8500) QFU,BUREX,EXAFU,NELF
8500 FORMAT ( 3E12.8,I12)
READ (IN, 82001 (NAMF ( I) ,FRF( I ) , 1= 1, NELF )
READ (IN, 8400) TSUR, VAMBM,TAMB,ELE
OUTPUT THE INPUT DATA
CALL TITL(2)
IF ( NCASE ) 40,40,50
40 WRITE (10,9005)
. .......10001010
10001020
10001100
10001200
10001300
10001400
10001500
10001600
10001700
10001800
10001810
10001820
10001830
10001840
10001850
10001900
10002000
10002100
10002200
10002300
10002400
10002500
10002600
10002700
10002800
10002900
10003000
10003100
10003200
	 10003300
10003400
10003500
10003600
10003610
10003620

-------
50
60
70
f
ON
80
WRI
WRI
GO
WRI
WRI
WRI
WR
WR
WR
IF
WR
WR
I
I
I
I
I
TE (10,9010)
TE (10,9015)
TO 60
TE (10,9000)
TE (10,9010)
TE (10,9020)
TE (
TE (
TE (
( NC
TE (
TE (
WRITE (
WRITE (
WRITE (
WRITE (
CALL TI
WRITE (
10,9025)
10,9026)
10,9030)
ASE ) 70,
10,9070)
10,9140)
10,9080)
10,9082)
10,9085)
10,9090)
TL(2)
10,9070)
GO TO 90
WRITE (10,9040)
WRITC (10,9050)
WRITF (10,9051)
WRIT. (10,9060)
CALL TITL(2)
WRITE (
WRITE (
WRITE (
.•0
WR
WR
WR
I
I
I
WRI
WRI
WRI
9000
9005
TE (
TE (
TE (
TE (
TE (
TE (
FORMAT
FORMAT
10,9070)
10,9080)
10,9083)
10,9085)
10,9090)
10,9100)
10,9110)
10,9120)
10,9130)
(1HO/34X,
(1HO/ 38X
NCASE
PWS
PERS,
PFEHY
(NAMV
70,80
NAMFU
PXAIR
SCFCL
FRAIR
TSL1,



PERV,QVOL,PC
,PALHY,NELV
( I ),FRV( I), I
,HDIA,NHEAR,
,TAIRI
TEX,TASH
SLF,YIR,KEFR,
NAMFU, UFC,UPC
OLR,ANMR,CRR,
PXAIR
SCFCL
FRAIR
TSL1,
FCAC,

AC
=1,NELV)
PSLU
,TSCRB
ULC
AMRR
,BFR
10003
10003
10003
10003
10003
10003
630
635
640
700
800
850
10003900
10003910
10004000
10004010
10004015
10004020
10004030
10004040
10004050
10004060
10004070
10004075
10004080
10004100
10004200
10004210
10004300
10004400
10004500
10004600
10004640
,TAI
TEX,
FFE,
RI
TASH
FAL
QFU,BUREX,EXA
(NAMFU ),FRF(
TSUR,VAMBM,TA
27H(
,25H(
NUMBER 0
THERMAL
.TSCRB
FU,NELF
I),I=1,NELF)
MB,ELE
F CASES TO BE RUN,I5,2H ) )
ANALYSIS ONLY ) )
10004650
10004700
10004800
10004
10005
10005
10005
10005
900
000
100
200
250

-------
90l6"FORMAT <1HO,36X,27H*** "SLUDGE  STREAM INPUT ***)       "  "   "     10005300
9015 FORMAT  (   IH  )                                                    10005350
9020L FORMAT (1HO, 23X.21HPLANT  WET SLUDGE FLOW ,14X,F12.1,8H TON/DAY   10005400
     X        )10005410
9025 FORMAT(24X,40HTOTAL DRY SOLIDS  CONCENTRATION IN SLUDGEt F7.2 t     10005500
   _X_12H_WEIGHT 0/0 ^?*X»?IWOLATILIE _SOLIpS CO,NCENTRATION.  IN  D«s-»   _ 10005510
     X~F10V"2rT2H WETGHT~"0/0~~,  	"  "" " ~	""	      "     "T0005600
     X/24X,23HHEAT VALUE OF.VOLATILES,  12X, F12.0,7H BTU/LB              10005700
     X/24X,18HCAC03 IN DRY  SOLID,17X,F12.2, 12H WEIGHT 0/0   )           10005800
9026 FORMAT(24X,20HFE(OH)3 IN DRY SOLID,15X,F12.2,12H HEIGHT 0/0  ,      10005900
     X/24X,20HAL(OH)3 IN DRY SOL ID,15X,F12.2,12H WEIGHT 0/0              10006000
    J<^^»3 LUMBER °.F 1*:E.ME.NTS  IN VDLATLLE.Sf4Xf II2                     10006100
     X"     )         '      """"	    ~    "    	                          10006200
9030 FORMAT(24X,17HMASS FRACTION OF  ,A2,15H  IN VOLATILES ,F13.3)       10006300
J>040^FO_R_MAT (  1HO/ 39X, 23H***  FINANCIAL  INPUT ***  )                   10006400
9050 FORMAT (IHO, 23x,i8HSYSTEM LIFE OF  MHF,irx,Fi2.i,4H YRS            10006500
     X/24X,20HYEARLY INTEREST RATE,15X,F12.2,4H 0/0                      10006600
     X/24X.42HENG FEE RATE  CODE  ( 1=FORMUL A, 0= ZERO RATE), 15             10006700
___  ^/2-4^f^4fl(0wrT-r|n^^                                                 10006800
     X)                                                                    10006810
_9051 FORMAT<24X,19HAUXILIARY FUEL NAME,16X,6A2                          10006900
     X/24X, 14HUNTT FUEL COST ," 2rx,F12.3,5H $/LB                       10007000
     X/24X,15HUNIT POWER COST, 20X, F12.3, 6H $/KWH                      10007100
     A_ J ___      __                                                      10007200
9060 FOR MAT ("""iH 0 , 23 X", 20HO PERATING L AB^OR  "R AT6V1 5X, F 12.2, 9H  $ /M AN-HR     TOOOT300 "
     X/24X,29HNORMAL MAINTENANCE LABOR  RATE,6X,F12.2,9H $/MAN-HR         10007400
     X/24X,31HCASTINGS REPLACEMENT LABOR  RATE,  4X,F12.2,9H $/MAN-HR      10007500
     X/24X,33HREFRACTORY REPLACEMENT  LABOR RATE,2X,F12.2,9H  S/MAN-HR     10007600
     X/24X,18HBUILDING/MHF  RATIO, 17X,F12.3, 4H $/$  I                   10007700
9079 f-P'™*1 J  1HO, /39X.»23J1*** TECHNICAL  INPUT *** '                     10007800
9080 "F OR'M AT" (THO",~2 3X ,~40HMI NTMUM "EXCE~SS' AIR FOR" COMB OF VOL AT IL ES 	     10007*900
     X      , F7.2, 4H 0/0                                                 10008000
     X    )                                                                10008010
9082! F'OR'MAfC  24X,30HSHAFT  COOL ING AIR  FLOW PER MHF,F17.0,5H SCFH  )"      10008050
9083 FORMATC  24X,34HSHAFT  COOLING AIR  FLOW (ALL MHF • S) ,F 13.0,5H SCFM )  10008100
9085 FORMAT(24X,32HFRACTION OF  COOLING  AIR RECYCLED , 3X, F12.3         10008200

-------
                        TEMPERATURE OF COOLING  AIR  ,  4X,F12.0,6H DEC F
                                                   SLUDGE,8X,F12.0,6H DEC
                                                   GASES,Fll.O, 6H DEG F
                                       ASH  ,12X,  F12.0,  6H DEG F
                                       SCRUBBER GAS,3X,F12.0,6H DEC F

                                       CAC03 CONVERTED TO  CAO,4X,F12.3
                                    CONVERTED  TO  FE203,F12.3
                                    CONVERTED  TO  AL203,F12.3
                                                       FUEL
F19.0,
00
    X/24X,31HEXIT
    X      )
9090 FORMAT(1HO,23X,27HINLET TEMPERATURE  OF
    X/24X,36HEXIT TEMPERATURE OF COMBUSTION
    X/24X,23HEXIT TEMPERATURE OF
    X/24X,32HEXIT TEMPERATURE OF
    X      )
9100 FORMAT  ( 1HO,23X,31HFRACTION
    X/24X,35HFRACTION  FE(OH)3
    X/24X.35HFRACTION  AL(OH)3
    X    )
9110 FORMAT  (1HO,23X,28HHEAT VALUE OF AUXILIARY
    X    7H  BTU/LB
    X/24X,22HEXCESS BURNER CAP AC ITY,13X,  F12.2,  4H  0/0
    X/24X,29HEXCESS AIR FOR AUXILIARY FUEL  ,6X,F12.2,4H 0/0
    X/24X,36HNUMBER OF ELEMENTS IN AUXILIARY  FUEL,  111 )
9120 FORMAT(24X,17HMASS FRACTION OF ,A2,19H   IN  AUXILIARY FUEL,F9.3)
9130 FORMAT  ( 1HO,23X,23HMHF SURFACE TEMPERATURE  ,12X,F12.0,6H DEG F
    X/24X,20HAMBIENT  AIR VELOCITY,15X,F12.1,  4H  MP4           "  	~
    X/2^X,23HAMBIENT  AIR TEMPERATURE, 12X,  F12.0, 6H DEG F
    X/24X,18HELEVATION OF PLANT ,  17X, F12.0,  3H FT
    X    )
9140 FORMATC1HO,23X,19HAUXILIARY FUEL NAME,16X,6A2
    X/24X,35HMHF  OUTER DIAMETER (13.5 INCH  WALL),F12.2,3H FT
    X/24X,25HNUMBER"OF HEARTHS PER MHF,10X,I 12
    X/24X,36HSTEADY STATE WET SLUDGE RATE  PER  MHF,  F11.1*6H LB/HR
    X  )
     RETURN
     END
     SUBROUTINE  HEAT  (IER)
      DIMENSION ANAMS(5)  , NAMEH5) , FRVO(5)  , "FRFUC5I , TOT(5)
    X , VOL(5) ,NAMFU(6),FRV(5),FRF(5),NAMV(5),NAMF(5),LOC<24)
      DIMENSION DITAB(59),FHTAB(59),NO TAB(59)
     COMMON  ACF,ADF,ALA,ALKX,AMRM,AMRR,AMSY,ANMM,ANMR,ANMY,AMSYA
    ItAMSYP,AMYPN,ANAMS,ANMYA,ANMYP,ANYPN,BFR,BGC,BTUV,BGCAL,BUREX
 10008300
 10008400
 10008500
 10008600
 10008700
 10008800
 10008900
 10009000
 10009100
 10009200
 10009300
 10009400
'10009500
 10009600
 10009700
 10009800
 10010000
 10010100
 100l0200~
 10010300
 10010400
 10010500
 10010600
 10010700
 10010800
 10010900
 10011000
 10020000
 10020100
 20000000
 20000080
 20000085
 20000090
 20000100
 20000110

-------
                              ,CYCF , CCI AL tC LDAL, DP W t D SF,DIT AB
                              ,FFE,FHA,FPC.FRF,FRV.FUY,FCAC
 ,KASE,KEFR,LOC,NOF,NPX,NAMF,NAf
 !,NHEAR,NOTAB,NRTAB,NUMEL,NUMSP
 I , IN,!0
 DIMENSION SPMW(5ItELMW(5), WS< 5}, DH< 6 ) ,BRN< 5)tQX(5)
 DATA SPMWfELMW/ 44.011,18.016,32,,28.0134,64.066,12.011,2.016
X,32.,28.0134,32.0647
 IER  = 0
 QCAL = 0.
 QFE = 0.
 QALHY =0.
 PCACO = 0.                 "	
 PFEWA = 0.
 PALWA =0.
 PSLT = 24.*PSLU/2000.
 NUMEL =5
 NUMSP =5                                                     _
 NPX =0           	:    '                    	"'    '
 PSOL = PERS*PSLU/100.
 PERW = 100, - PERS
 PWAT = PERW/100.*PSLU
 PERA = 100. - PERV
 20000120"
 20000130
 20000140
 20000150
 20000160
 20000170_
 20000180
 20000190
 20000200
 20000210
 20000220
 2000023jO_
 2"6o"0d240
 20000250
 20000260
 20000270
 20000280
 20001800^
 200"02TOO"
 20002200
 20002700
 20002800
 20002900
20003100
20003200
20003300
20003800
20007100
20007200
20007300
20007400
20007500
20007600
20007700

-------
    PVOL =  PERV/100.*PSOL
    PASH =  PERA/100.*PSOL
    IF(PCAC)  210,210,211
211 PMEL    =   PCAC/100.*PSOL
    PCACO =   PMEL/100. 08*44. 054*FCAC
  __ PASH_=  PASH  -  PCACO          ___
    QCAL =  PMET*FCAC*76Y.
210 TF(PFEHY)  212,212,213
213 PMEL =  PFEHY/100.*PSOL
    PFEWA = PMEL/106. 87*27. *FFE
    PASH =  PASH  -  PFEWA
    °_F_E = PMEJ-*F.F..E*225.
2f2 IF(PALHY)  214,214,215
215 PMEL =  PALHY/100.*PSOL
    PALWA = PMEL/78. 003*27. *FAL
    PASH =  PASH  -  PALWA
    QALHY = PMEL*FAL*380«,8
214 DO 168  I=1,NUMEL
168 FRVO{ I )=0.
    DO 130  I=1,NUMSP
130 BRN(I)  =0.
    DO 165  J=1,NELV
    DO 164  I=1,NUMEL
    fF(NAMV(J)  -  NAMEL(I ) )"
164 CONTINUE
    WRITE  (10,167)  NAMV(J)
167 FORMATdHl/ 5X,16HNAME
    IER =  1
   _ RETURN
166 FRVO(lT=~ FRV(j) '"
165 CONTINUE
    DO 171  J=l,NELF
    DO 172  I=1,NUMEL
    IF(NAMF(J)  -  NAMEL(I))
                            164, 166, 164
                            OF ELEMENT  ,A4,23H  INCORRECT -
                            172,173,172
           20007800
           20007900
           20008000
           20008100
           20008200
           20008300
         ~ 20008400
           20008500
           20008600
           20008700
           20008800
           20008900
       ~    20009000
           20009100
           20009200
           20009300
           20009400
           20009500
           20009600
           20009700
           20009800
           20009900
           20010000
           20010100
          " "2"0010200"
           20010300
           20010400
CASE ENDEDJ20010500
           20010600
           20010650
           20010700
           20010800
           20010900
           20011000
           20011100

-------
                                                                    2~00li200
                                                                    20011300
                                                                    200ll
172 CONTINUE
    WRITE  (10,167)  NAMF(J)
	1ER =  1	
    RETURN
173 FRFUJII *  FRF(J|
171 CONTINUE
                                                                   __
                                                                    20011400
                                                                    20011500
                                                                    20011600
                                                                   "2W11700
                                                                    20011800
                                                                    20011900
                                                                   '200T2000
                                                                    20012100
                                                                    20012200
    IF(BUREX)  230,230,231
230 BUREX  =  25.
231 PI = 3.14159
    GASR =10.73
    TEXR =  TEX *  460.
    TARIR = TAIRI  *  460.

H
vn
H
TAM8R
TSURR
TSL1R
PSCRE
TSCRR
PSWAT
= TAMB + 460.
= TSUR * 460.
= TSL1 + 460.
= 14.696 - 4. 2/9000. *ELE
* TSCRB * 460.
= 1.78885*EXP(15.9014*( TSCRR-581. 58) /TSCRR)
20012300
20012400
20012500
20012600
20012700
20012800
                     PSWAT/(PSCRE-PSWAT)1
    AIRM  =  28.84
    AMOL  =  l./AIRM*(l.+
    CPHAT -1.	     		
    CPSL  =1.
    INLET TEMPERATURE OF SLUDGE USED AS BASE TEMPERATURE FOR ENTHALPY
    HWSEN = CPWAT»(212.-TSL1)»PWAT	_^	
    HWVAP » 970.*PWAT
    HWGAS » PWAT*(l.l02*(TEXR-672.) - 66.2*{SQRTCTEXR1 -SQRTC672.!)
   X  »  416.»ALOGtTEXR/672.H
            HHSEN
           = .2
"20"OT2WO~
20013000
2oqi3iop_
20"OT3200
20013300
20013400
"20013~500~~
20013600
20013700
20013800
20013900
_20014_000__
2UO"14101D
20014200
2001V300__
2~0014400
20014500
HWSL =
CPASH s
HASH -
HWVAP + HWGAS
            PASH*CPASH*(TASH-TSL1)
VAMBF = 1.46667*VAMBM
HR =.1713*(CTSURR/100,)**4 -
HR= HR/(TSURR-TAMBR)    	
HC = .29* (( TSUR-T A~M~B J /HDI A >** .2 5
HC = HC*(1. + .225*VAMBF)
                                  
-------
         12
 = 9./A i R M
   PAIR = P02S/.233-
   CALCULATE HEAT  REQUIRED TO
   CALL GETDH(DH,TSL1R,TEXRJ
   DH(2) =  DH(2> + 1048.
  _DO 14
14 QX(I)
   QX(3)
   QX(4)
   QARIN
                                    PXAIR/100.)
                                        HEAT SLUDGE COMBUSTION PRODUCTS  TO TEX
                                                               20015200
                                                               20015300
                                                               20015400
                                                               20015500
                                                               20015600
                                                               20015_700_
                                                               20015800
                                                               20015900
                                                               20016000
                                                               20016100
                                                               20016200
                                                               20016300
         16
       = WS(I )*DH(I)
       = P02S*PXAIR/100.*DH(3)
       = QX(4)  4-  .767*PAIRT*DH(4)
       = PAIRS*!.219*(TARIR-TSL1R)
X .293E-8/3.*(TARIR**3 -TSL1R**3))
 QCOOL =  P AI RC* <.219*(T ARIR__~_.TAM_BR I
XMBR**2) - .293E-8/3.* (TARflR**3
 QAM3A = PAIRA*(.219*(TAMBR-TSL1R>
X- .293E-8/3.*(TAMBR**3 - TSL1R**3))
 QREQ = HWSL  +  HASH  •«• QCOOL * QLAL
 QREQ = QREQ  +  QFE  *  QALHY * QTRAN
 QSEN =0.        _	
 DO Tb Y=1/NUMSP
 QSEN = QSEN  +  QX(I)
 QRFQ = QREQ  *  QSEN  +     AMAX1(0.»-QAMBA)
 OVOLT = PVOL*QVOL
 QIN = QVOLT  + QARIN +  AMAXKO., QAMBA)
                                               * .171E-4*(TARIR**2-TSL1R**2)
                                                      7 1E-4*C T ARIR*«2  -
                                                               20016400
                                                               20016500
                                                               20016600
                                                              -20016700
                                                               20016800
                                                             TA20016900
                                                  171E-4*( TAMBR**2-TSL 1R**2 )
                                                               _____
                                                               20017000
                                                               20017100
                                                               20017200
                                                               20017300
                                                               20017400
                                                               20017500
                                                               20017606"
                                                               20017700
                                                               20017800
                                                               20017900
                                                               20018000

-------
           QNET = QIN -  QREQ                                                  20018100
           IFfNPXI  122,122,121                                                20018200
       122 IF (QNET  - 200.  )  50,50,60                                          20018300^
        60 NPX = NPX V  I                                                       2001:8400
           PXS = PXAIR                                                         20018500
           QNS = QNET                                                          20018600
           PXAIR = PXAIR  +  10.                                                 20018700
           GO TO 20                                                            20018800
       121 IFCABSCQNETJ - 200.)  123,123,124                                   20018900
           NPX=NPX  +  I                                                         20019000
           IF(NPX - 10)  125,125,126                                           20019100
       126 WRITE UO,127J  PXAIR,QNET
       127 FGRMATUH1/5X,55HITERATION NUMBER EXCEEDED  IN CALCULATION  FOR EXCE20019300
          XSS AIR  ,/5X,  8HPXAIR = ,F8»2,  9H  QNET = ,F8.l  )                   20019400
           GO TO  123                                                           20019500
___..    125 PXSAV  =  PXAIR                                                      20019600
^         PXAIR  =  PXAIR -  (PXAIR-PXS)/(QNET-QNS)*QNET                        20019700
           PXS =  PXSAV                                                         20019800
           QNS =  QNET                                                          20019900
           GO TO  20                                                            20020000
       123 WGTF =  0.                                                           20020100
           QNET =0,                                                           20026Y10
           PEFF =  0.                                                           20020120
       	QSROS_=	0.	     _	^9020_130	
           Q¥UR =  0.    ""   " "  '   "     "         	            ""          2d6"2"0140
           BTUV =  0.                                                           20020150
           SCFAI  = 0.                                                          20020160
           WBAIR  = 0."                                                         20020170
           GO TO  140                                                           20020200
       __5.Q_C_PN_TJJ^'JE-	-                      _                              20020?P9_
           QNET =  ABS("QNEf) ~"          ~                                       20020406
           BURNO  = FRKU( 1)/ELMW( 1 )*SP«V«{ 3) +  FRFU( 2) /ELMW( 2I*SPMW( 3) /2 . *     20020500
          XFRFU(5)/ELMW<5)*SPMW(3)  - FRFUC3)                                   20020600
           BURAI  =  BURNO/.233*<1.+EXAFU/100.)                                20020700
           BRN(l)  =  FRFU(1)/ELMW(1J*SPMW(1)                                   20020800

-------
 18
140
 2?
150
    BRN(2)  =  FRFU< •>) ,'ELMW(2)*SPMW(2)
    BRNO)  =  8DRNO*EXAFU/100.
    BRN(4)  =  FRFU(4)  + .767*BURAI
    BRN(5)  =  FRFU<5)/ELMW(5)*SPMW(5)
    CALL GETDH(DH,TSL1R,TEXR)
    DH( 2) = OH(2)  *•  1048.
    DHBUR = 0.
    DO 18 I=1,NUMSP
    DHBUR = DHBUR  +  BRN(I)*DH(I)
    FEFF = (QFU-DHBUR)/OFU
    PEFF =  100.*FEFF
    QGROS = QNET/FEFF
    QBUR =  (1.  «•  BUREX/100. )*OGROS
    WGTF =  QBUR/QFU
    WBAIR = WGTF*BURAI
    SCFAI = WGTF*6'JRAI/AIRM*379.
    BTUV =  QBUR/SCFAI
            =  WS<1) +  BRN(1)*WGTF
            =  PWAT  +  WS(2)  •»- BRN(2)*WGTF
            =  P02S*PXAIR/100.  + BRN(3)*WGTF
            =  WS(4) *  .767*PAIRT + BRN(4)*WGTF
                      BRN(5)*WGTF
TOT(1)
TOT(2)
TOT(3)
TOT(4)
TOT(5)
GTOT  =
TVOL  =
DO 22
VOL(I)
TVOL  =
GTOT  =
COPY  =
VDRY  =
ROEX  =
DRYHO =
           = WS(5)
           0.
           0.
          I=1»NUMSP
           = TOT(I)/SPMW
-------
VJ1
        VWATS
        VSCEX
        RJAIR
        TOTMF
        RETURN
        END
        SUBROUTINE BLOCK
         DIMENS"	
       X ,  VOL ... .
         DIMENSION
        COMMON
       IfAMSYP
WATSC/8.3451/60.
GDRY*VSAT/60.
PAIRC - PAIRS
 PSLU+WGTF+PAIRA+PAIRC+WBAIR
       2tNHEAR
       3 ,  IN,10
        READ (IN,10} NwntL
     10 FORMAT(5A2,2X,5A4)
        READ (IN,20) FHTAB
        READ (IN,20) DITAB
     20 FORMAT(6F12.6)
        READ (IN,30) NOTAB
 20024500
 20024600
 20024700
 20024800
 20024900
 20025100
 30000000
 30000080
 30000085
 30000090
 30000100
 30000110
 30000120
 30000130
 30000140
 30000150
 30000160
 30000170
 30000180
 30000190
 30000200
 30000210
 30000220
 30000230
 30000240
 30000250
 30000260
30000270
30000280
30001200
30001300
30001400
 30001500
30001600
 30001700

-------
  30 FORMAT(12I6J
     RETURN
     END
     SUBROUTINE  TITL(  I
      ROUTINE
WRITE HEADING
    3 t IN,10
     WRITE  (10,9000)
9000 FORMAT( 1H 1~,25X , 5 OHMULTI RLE HEARTH
    XON  )
     WRITE  (10,9010)  LOG
9010 FORMAT(1HO,26X,24A2)
     IF ( NCASE )  20,20,5
                                            NELV,NAMEL,NAMFU,NCASE
                      FURNACE  SEWAGE  SLUDGE  INCINERAT
 30001800
 30001900
 30010000
 40000000
 40000010
 40000020
 40000030
 40000080
 40000085
 40000090
 40000100
 40000110
 40000120
 40000130
 40000140
 40000150
 40000160
 40000170
 40000180
 40000190
 40000200
 40000210
 40000220
 40000230
 40000240
 40000250
 40000260
 40000270
 40000280
 40001000
140001100
 40001110
 40001200
 40001300
 40001350

-------
    5 GO TO  (  10,20),!
   1.0 WRITE  (10,9020)  KASE
 9020 FORMAT  (  1HO,  46X ,  4HCASE
   20 RETURN
      END
      SUBROUTINE  PRINT
                             13 )
                             NAMELC5) , FRVO(5)  ,  FRFU(5)  ,  T01
                             (5),FRF(5),NAMV(5),NAMF( 5),LOC<24)
                             HTAB(59).NnTAB<59)
   ' i u. in o * *-M» « 11 M i i «J * *> f  f
   VOL15),NAMFU(6),FRV
     _^ y IS^WIAT i v t_* i. T ' " 1 ^t*-T IV^%J»P^J i\^^i » T*V<* »^^"\^i^«t.f IV*«T ^^y»^^f> «
     4,TOTMF,TSCRB,UFC,ULC,UPC»VOL,VSAT,VAMBM,VAREA,VSCEX,VWATS
      COMMON  WOH,WGTF,WATSC,WBAIR,YHF, YIR
     ltK.ASE,KEFR,LOC,NOF,NPX,NAMF,NAMV, NELF ,NELV ,NAM EL » NAMFU, NC ASE
     2,NHEAR,NOTAB,NRTAB,NUMEL,NUMSP
     3  , IN,10
      TP i  wrA^Fi  ?n.?n.in
C
C
   10
 9000
            20,20,10

  PRINT DESIGN  AND  OPERATION OUTPUT
WRITE (10,9000)
FORMAT ( 1HO/35X,32H*** MHF DESIGN
AND OPERATION *** )
40001400
40001500
40001600
40001700
40001800
50000000
50000010
50000030
50000080
50000085
50000090
50000100
50000110
50000120
50000130
50000140
50000150
50000160
50000170
50000180
50000190
50000200
50000210
50000220
50000230
50000240
50000250
50000260
50000270
50000280
50000900
50001000
50001100
50001300
50001400

-------
                                                                     FT
CD
     WRITE  (10,9010)  NOF,HDIA,NHEAR
     WRITF(in,9011)  FHA,PSLU,OSF,HLD
9010 FORMAT( 1HO,22X,15HNUMBER OF MHF'S,21X,  114
    X/  23X.35HMHF OUTER DIAMETER (13.5  INCH  WALL),1X,F 14.2,3H
    X/  23X,?5HNUMBER  OF HEARTHS PER MHF,11X,I14
    X  )
9011 FORMAT(23X,29HEFFECTIVE HEARTH AREA  PER  MHF  ,7X,F14.1,6H SQ FT
    X/  23Xt36HSTEADY  STATE WET SLUDGE RATE PER  MHF,F14.l,6H LB/HR
    X/  23Xf36HSTEADY  STATE DRY SOLIDS RATE PER  MHF,F14.1,6H LB/HR
    X/  23X,27HHEARTH  LOADING (DRY SOLIDS),9X, F14.2,12H LB/HR-SQ FT
    X    )
     WRITEt10,9020)  YHF,DPW,WOH,CYCF
     WRITE(10,9021)  CYT,CRL,RRL
9020 FORMAT(1HO,22X,30HYEARLY OPERATING HOURS PER  MHF,6X,F14.1,6H HR
    X/  23X,28HWEEKLY  INCINERATION SCHEDULE ,8X,  F14.2,8H DAYS/WK
    X/  23X,25HWEEKLY  INCINERATION HOURS , 11X.F14.2, 6H HR/WK
    X/  23X,32HCYCLING AS FRACTION OF OPERATION,4X,  F14.3, 6H HR/HR
    X  )
9021 FORMAT( "23X.19HCYCLE TIME (HEATUP),  17X,F14.2,  3H HR
    X/  23X,37HMHF CASTING SETS REPLACED DURING  LIFE, F13.2
    X/  23X,40HMHF REFRACTORY SETS REPLACED DURING  LIFE, F10.2
    X   )
     WRITEt 10,9025)  SCFCL
     FORMAT  (23X,25HSHAFT COOLING AIR PER MHF,  11X,  F14.0, 5H SCFH  )
     WRITETloV9030)
     FORMAT  (  1HO/ 33X,36H*** AIR FOR VOLATILES  COMBUSTION *** )
     WRITE(IO,9040)  SCFCF,SCFAM,PAIR
     WRITE(10,9041)  PXAIR,PAIRT
9040 FORMAT(1HO,22X,39HFLOWRATE OF COOLING AIR  SENT  TO FURNACE,F11.0
    X    , 5H  SCFH
    X/"23X,40HFLOWRATE OF AMBIENT AIR ENTERI NG  FURN ACE, F10.0 ,5 H SCFH
    X/  23X,38HTHEORETICAL AIP REQUIRED FOR VOLATILES, F12.0,6H LB/HR
    X  )
9041 FORMAT(23X,32HPERCENT EXCESS AIR FOR VOLATILES  ,4X, F14.2
    X/  23X,28HTOTAL  AIR USED FOR VOLATILES ,  8X,  F14.0, 6H LB/HR
     9025
       20"
     9030
   50001500
   50001510
   50001600
   50001700
   50001800
   50001810
   50001900
   50002000
   50002100
   50002200
   50002300
   50002400
   50002410
/YR50002500
   50002600
   50002700
   50002800
   50002810
   50002900
   50003100
   50003200
   50003300
   50003320
   50003340
   50003400
   50003500
   50003600
   50003610
   50003700
   50003710
   50003800
   50003900
   50003910
   50004000
   50004100

-------
    X    )
     CALL TITL(l)
     WRITE(IO,9050)
9050 FOPMATdHO/  39X,24H*** MHF HEAT BALANCE ***
    X /  39X,24H(SIX  SIGNIFICANT DIGITS)
    X    // 20X,17HHEAT  REQUIREMENTS  )
     WRITE(IO,9060)  QSEN,HWSL
     WRITE(IO»9061)  HASH,QTRAN,QCOOL
9060 FORMAT(23X,35HHEAT FOR SLUDGE COMBUSTION PRODUCTS,!X,F14. 0,
    X    7H BTU/HR
    X/23X,36HHEAT  FOR  SLUDGE MOISTURE EVAPORATION, F14.0,7H  BTU/HR
    X )
9061 FORMAT(23X,19HHEAT REMOVED IN ASH,17Xt F14.0, 7H BTU/HR
    X/23X,34HRADIATION  AND CONVECTION HEAT LOSS,2X,F14.0,7H  BTU/HR
    X/23X,23HSHAFT COOLING HEAT LOSS ,13X,F14.0,7H BTU/HR
    X    )
     IF  < QAMBA  )  100,100,110
 100 QAMA =  ABS(QAMBA)
     WRITE(10,9070)  QAMA
9070 FORMAT  (23X,29HHEAT FOR INCOMING AMBIENT AIR , 7X,F14.0,7H
 110 WRITE(10,9080)  QCAL,QFE,QALHY,QREQ
9080 FORMAT  (23X,24HHEAT FOR CALCINING  CAC03,12X,F14.0,7H BTU/HR
    X/23X,28HHEAT  FOR  DECOMPOSING FE(OH)3,8X, F14.0,7H BTU/HR
    X/23X,28HHEAT  FOR  DECOMPOSING AL(OH)3,8X, F14.0,7H BTU/HR
    X/23X,22HTOTAL HEAT REQUIREMENT  ,  14X,F14.0, 7H BTU/HR
    X    )
     WRITE(IO,9090)
9090 FORMAT  (  1HO,19X,10HHEAT INPUT )
     WRITE(IO,9100)  QVOLT
9100 FORMAT  (  23X,19HHEAT FROM VOLATILES , 17X,  F14.0,7H BTU/HR
     IF  (QAMBA)  125,125,120
 120 WRITE!10,9110)  QAMBA
9110 FORMAT  (  23X,30HHEAT FROM INCOMING AMBIENT  AIR,6X,F14.0,7H
 125 WRITE(IO,9120)  QARIN,QNET,QREQ
9120 FORMAT(23X,36HHEAT FROM INCOMING SHAFT COOLING AIR,F14.0,7M
        50004200
        50004300
        50004400
        50004500
        50004550
        50004600
        50004700
        50004710
        50004800
        50004900
        50005000
        50005010
        50005100
        50005200
        50005300
        50005350
        50005400
        50005500
        50005600
BTU/HR)50005800
        50005850
        50005900
        50006100
        50006200
        50006300
        50006400
        50006500
        50006600
        50006700
)        50006800
        50006900
        50007000
BTU/HR)50007100
       50007200
 BTU/HR50007300

-------
     X/23X,29HNET HEAT  REQUIRED  FROM BU
     X/23X,16HTOTAL HEAT  INPUT  ,  20X,  F
     X )
      WRITEC10,9130)
 9130 FORMAT( 1HO/ 34X,34H*«* AUXILIARY
      WRITE{10,9140) PEFF,QGROS,BUREX,Q
      WRITE(10,9141) WGTF,BTUV,SCFAI,WB
 9140 FORMAT (1HO,22X,40HPERCENT  AVAILA
     X/23X,31HGROSS HEAT  REQUIRED FROM
     X/23X,22HTOTAL BURNER  CAPACITY( F6
     X            12H 0/0 EXCESS) ,F10.
     X )
 9141" FORMAT(23X,29HREQUIRED  BURNER  FU£
     X/23X,35HBURNER HEAT PER STD CUBIC
     X/23X,39HREQUIRED  BURNER AIR VOLUM
     X/23X,33HREOUIRED  BURNER AIR MASS
     X  )
      CALL TITL(l)
                                        RNER,7X,F14.0,7H BTU/HR
                                        14.0,  7H  BTU/HR
                                         BURNER  SELECTION *** )
                                        BUR
                                        AIR
                                        BLE  HEAT  FROM  BURNER(CALCI ,F10 .2
                                        BURNER,5X,  F14.0,7H BTU/HR
                                        .2  ,
                                        0, 7H  BTU/HR

                                        L TLOWRATE,7X,F14.1, 6H LB/HR
                                         FT  OF AIR,IX,F14.2,8H BTU/SCF
                                       IETRIC  FLOWRATE,F11.0,5H SCFH
                                        FLOWRATE, 3X,F14. I,6H LB/HR
MHF EXIT GAS DATA  ***
9HFLOWRATES
5X, 1 2HVOLUME( ACFH I
                                                     )
 9150 FORMAT (1HO/ 38X,25H***
     X  // 32X,7HSPECIES,11X,
     X  /  41X,11HMASS(LB/HR)
      DO 130 I = 1,NUMSP
_J iO-^ffUJJJ pt 91 60 ) AN AMS ( I ) , TOT ( I ) , VO L < I )
 9160 FORMAT ( 33X, A4, F12.0,  F16.0   )
      WRITE(IO,9170) GTOT,TVOL
 9170 FORMAT ( 31X, 6HTOTALS,  F12.0,F16.0
      VWATS = AMAXK VWATS,0.0)
      WRITE (1 0,9180) ROEX,VSAT,VSCEX,VHATS
 9180 FORMAT < 1HO/ 23X , 27HDENS ITY OF FURNACE  EXIT GAS , 9X ,F 14. 5, 7H LB/FT3
     X/23X, 34HSCRUBBER fxfT~ VOLUME/IB" OF DRY GAS ,2X, FU.3 ,  7H FT3 /LB
     X/23X,36HSCRUBBER SATURATED  EXIT  GAS  FLOWRATE, F14. 0,5H ACFM
     X/23X,35HWATER FLOWRATE  TO SATURATE EXIT GA St IX ,F14. 0,4H GPM
                                            )
9190
      WRITE(IO,9190)
      FORMAT <1HO/39X,24H***  MHF  MASS BALANCE ***
 50007400
 50007500
 50007600
 50007700
 50007800
 50007900
 50007910
 50008000
 50008100
 50008200
 50008300
 50008310
 50008400
 50008500
 50008600
 50008700
 50008800
 50008900
 50009000
 50009100
 50009200
 50009300
 50009400
 50009500_
~~5~00~09 6~<5 0
 50009700
 50009800
 50009850
 50009900
 50010000
 57J010TOO
 50010200
 50010300
 50010400
 50010500
 50010600

-------
H
O\
H
     X / 39X,24H
-------
H
ON
ro
     WRITE(TO,0260) CCI,CCIAL,BGC,BGCAL,CLD,CLOAL,EFC,EFCAL,
    X    TCCtTCCAL
9260 FORMAT( 19X,22HINSTALL ED  CAPITAL  COST ,  IX, 2F21.0
    X/19X, 13H8UILDING COST,10X,2F2 1.0
    X/19X,9HLAND COST ,14X,2F21.0
    X/19X.15HENGINEERING FEE,8X,2F21.0
    X/19X,18HTOTAL CAPITAL  COST,5X,  2F71.0 )
     WRITE(10,9270)
Q?70 FOPMAT<1HO/35X,32H***  MHF  TOTAL  COST BREAKDOWN ***  /
    X/3RX,5BH$/YR,ONE MHF   $/YR,ALL  MHF'S   $/TON DRY SOLIDS
    X       )
     WPITF(IO,9280) TCY,TCYAL,TCYPT,TCYPC,RPY,RPYAL»RPYPT,RPYPC,
    X, AMSYA, AM YPN, AMSYP , FUY, FIJ YAL , FUYPT,FUYPC                TPOY
    X,POYPT,POYPC
     WRITE (10, 9281) OLY,OLYAL,OLYPT,OLYPC,ANN|Y, ANMYA,ANYPN
    X,ANMYP,RMY,RMYAL,RMYPT,RMYPC                ,TCST,TCSTA,TCTP
9280 FORMAT  (7X,21HTOTAL CAPITAL CMARGES,10XtF10.0»F16.0,Fl7.2,F
    X/7X.17HREPLACEMENT PARTStl4X,F10.0,F16.0,F17.2,Fl4.2
    X/7X,22HMATERIALS AND SUPPLIESt9X,F10.0,F16.0,F17.2,F14.2
    X/7X,4HFUEL,27X,F10.0,F16.0,F17.2, F14.2
    X/7X,5HPOWER,26X,F10.0»F16.0,F17.2fFl4.2)
9281 FORMAT(7X,1^HOPERATING LABOR  ,16X,F10.0,F16.0,F17.2,Fl4.2
    X/7X,24HNORMAL MAINTENANCE  LABOR,7X,F10.0,F16.0,FI 7.2»F14.2
    X/7X,29HREPLACEMENT MAINTENANCE  LABOR,2X,F10.0,F16.OfFl7.2tF
    X/7X,10HTOTAL COST,21XTF10.0,F16.0,F17.2,F1A.2
    X     )
 200 WRITE( 10,400)
 400 FORMAT(lHl)
     RETURN
     END
     SUBROUTINE GETDH(DH,Tl,T2)
     DIMENSION  DH(6)
     DH(1) =  .368*
-------
DH(4)=.338*(T2-T1)-l23.8*ALOG(T2/T1)  - 41400.*(1./T2-1./Tl)
DH(5)= .1875*
-------
^ J
I F ( Y-YTI I ) ) 70,60,60
60 CONTIMJF
ISUB ^ NY-l
IEPR = 2
PF TURN
70 ISUB =1-1
RETURN
80 ISUB = I
IF ( I - NY) 85, 81 ,"5
PI I SOB = ISUB-1
85 RETURN
END
FUNCTION AMAXi(X,Y)
IF( X-Y) 2,1,1
1 AMAX1 = X
GO TO 5
? AMAX1 = Y
5 CONTINUE
RETURN
ENP
/*
//S2 EXEC AFLINK
//G.SYSABEND DO SYSOUT=A
//G. SYSIN DO *
C H P N S
0 5 .
- ^ •
145.
2^6.
t. - VJ •
364.
575.
9 88.
1260.
1580.
1875.
2350.
C02 H20 02
98.
166.
276.
383.
672.
1041.
1268.
1591.
1933.
2464.
N2 S02
112.
187.
288.
411.
760.
1068.
1400.
1660.
2060.
2600.

125.
193.
319.
452.
845.
1 117.
1410.
1675.
2084.
2860.

126.
208.
323.
510.
857.
1128.
1483.
1752.
2090.
3120.

140.
225.
351.
560.
944.
1247.
1540.
1849.
2275.

69203000
69203050
69203100
69203,^00
69203300
69203400
69203500
69203600
69203700
69203750
69203800
69203900
70000 100
70000200
70000300
70000400
70000500
70000600
70000700
70000300
99800000
99900000
99980000
99990000
99900010
99910010
99910020
99910030
99910040
99910050
99910060
99910070
99910080
99910090
99910100

-------
H
6.75
7.75
9.25
10.75
14.25
16.75
16.75
22.25
20.25
22.25
6
8
6
9
9

1000.
4.
C .55
25.
.01
75,
60.
1.0
20000.
C .861
100.
24.
CHECKOUT

6.75
7.75
10.75
9.25
14,25
14.25
20.25
18.75
18.75
20.25
7 8
6 9 1
7 8
6 10
11 10
CHECKOUT OF
30.

H .074
7.
4.0
36000.
800.
,8
25.
H .103
5.
5.
OF NCASE EQUAL
17,1
6.75
7.75
9.25
10.75
14.25
18.75
16.75
20.25
20.25
22.25
6910
0 7 11
6910
8 7 11
8 12 11
SAMPLE INPUT
70.
5
0 .334 N
1
4.5
.7
400.
.6
5.
0 .008 N
50.
1.
TO ZERO .
67.0
7.75
9.25
9.25
10.75
16.75
16.75
18.75
16.75
22.25
22.25
7 8
8 12
7 11
6 9
9 12

10000.

.031 S
FUEL OIL
4.25
300.
70.

5
.001 S
5000.
1.

10000.
6.75
7.75
10.75
10.75
14.25
14.25
20.25
18.75
18.75
22.25
9 6
9 10
6 8
8 12
10 11
1
18.

.011
20000.
5.00




.027



29.2
6.75
9.25
9.25
10.75
14.25
18.75
16.75
22.25
20.25

10
11
12
10
12

6.


.025
.4








.5
            .5
     C      0.55
      NATURAL  GA
         100.
          57.
 H     0.074
S    14.3
   30000.
    700.
0     0,334 N
           6 2
     0.
   540.
    0.031
228.33333
 330.
  70.
0.011
  99920010
  99920020
  99920030
  99920040
  99920050
  99920060
  99920070
  99920080
  99920090
  99920100
 799930010
1299930020
 799930030
 799930040
  99930050
  00001000
  00001001
  00001002
  00001003
  00001004
  00001005
  00001006
  00001007
  00001008
  00001009
  00001010
  00001011
  00001012
  10000001
  10000002
  10000003
  10000004
  10000005
  10000006
  10000007

-------
                                                                         10000008
    l«n          -5           *5                 ,                         10000009
   20R80.        25.           0.                "                         10000010
C     .^39  H      .237  G      .003   N      .021                           10000011
    170.           0.          65.         6^6b.                            gqqggqgq
/*

-------
1
.Accession Number
w
5
2

Subject Field & Group
05 D
SELECTED WATER RESOURCES ABSTRACTS
INPUT TRANSACTION FORM
Organization
        Canoga Park, California  91304
    Title
        COMPUTERIZED DESIGN AND COST ESTIMATION  FOR MULTIPLE-HEARTH
        SLUDGE INCINERATORS
 10
    Authors)
        Unterberg, Walter
        Sherwood, Robert J.
        Schneider, George R.
                                     16
Project Designation

FWQA Contract 14-12-547, Project  No.  17070 EBP
                                     21
                                        Note
 22
     Citation
 23
     Descriptors (Starred First)

        *Computer Programs, *Cost Estimate,  Capital Costs,  Operating Costs
 25
     Identifiers (Starred First)
        *Sewage Sludge, *Multiple-Hearth  Furnace,  *Incineration, *Design,j Heat Balance,
        Mass Balance, Fuel Consumption, Power  Consumption,  Maintenance Costs, Hearth
        Replacement
 27
     Abstract
        A digital computer program was  developed for the preliminary design and cost
        estimation of an optimum multiple-hearth-furnace system for sewage sludge
        incineration.  The program was  primarily based on field data from nine operating
        plants, each having one to four furnaces.  The individual furnaces covered a
        range in capacity from 200 to 4500  Ib  dry solids per hour, in number of hearths
        from 5 to 11, in outer diameter from 6 to 22 feet, and in hearth area from 85
        to 2327 square feet.  Operating schedules and thermal cycling were considered,
        the  field data were correlated  by least-square curve fits, and co.jta were norm-
        alized to 1969 dollars.  The computer  program provides the number, dimensions
        and  ratings of components; expenditures of labor, fuel and power; and all the
        cost elements for an incineration system which is to process a given flow of
        sludge having specified characteristics.  Cost breakdowns are calculated for
        capital, total cost per annum and total cost per ton dry solids incinerated.
        The  computer program may also be used  for the thermal analysis (air and fuel
        requirements, heat balance, and mass balance) of a multiple-hearth furnace
        incinerator without design and  cost features.  (Unterberg - Rocketdyne)
Abstractor
        Walter Unterberg
                               Institution
                                       Rocketdyne, A Division of North American Rockwell Corp.
 WR:102 (REV. JULY 1969)
 WRS1C
                             SEND. WITH COPY OF DOCUMENT, TO: WATER RESOURCES SCIENTIFIC INFORMATION CENTER
                                                       U.S. DEPARTMENT OF THE INTERIOR
                                                       WASHINGTON. D. C „ 20240
HJ.S. GOVERNMENT PR.NTING OFFICE: 19 7 2 484-486/244 1-,

-------