WATER POLLUTION CONTROL RESEARCH SERIES • 17070 EBP 07/71
COMPUTERIZED DESIGN AND
COST ESTIMATION FOR MULTIPLE-HEARTH
SLUDGE INCINERATORS
U.S. ENVIRONMENTAL PROTECTION AGENCY
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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.
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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
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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
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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.
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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
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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
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1ST
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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
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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
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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.
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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
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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.
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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).
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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)
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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
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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.
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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
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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
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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
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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
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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
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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
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o
f>
t
13
49
EC
1
73-
1000 .
30
7^
73
4 -
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•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
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CL
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bl
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49
lii
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C
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\L
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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
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-------
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-------
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/*
-------
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-,
-------
|