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Project No.: 0172.09.029.043 DISTRIBUTION

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Project Name: Steam Electric Rulemaking

TELEPHONE CALL RECORD

 Outgoing Call

Date: 06/22/2011 Time: 10:00 AM

Company Name: Clyde Bergemann Delta Ducon (CBDD)

Contact Name: CBDD (See below)

Phone No.: 610-560-4302

Name: EPA and ERG (See below)

GENERAL SUBJECT : Conversion Costs for Wet to Dry Bottom Ash Handling Systems

TOPICS DISCUSSED AND ACTION TAKEN

On June 22, 2011 ERG participated in a call with EPA and Clyde Bergemann Delta Ducon (CBDD). A list of 

participants is provided below:

EPA

Ron Jordan

CBDD

Craig Fleming

Gary Mooney

Ron Grabowski

ERG

Deb Bartram

TJ Finseth

Elizabeth Sabol

Notes: 

Mr. Mooney described that when costing a bottom ash submerged flight conveyor (SFC), the size of the boiler 

length is important. Mr. Mooney stated that the widths don’t vary, but the length of the boiler always does. Mr. 

Mooney stated that, as a general rule of thumb, the smaller the generating unit capacity (in megawatt (MW)), 

the smaller the boiler. 

Additionally, we discussed some differences between the remote SFC and the SFC. CBDD stated that the 

remote SFCs are designed for the existing pipelines in the system and operate as a batch process (based on the 

existing sluice rate in gallons per minute (GPM)). Additionally, very few projects are currently looking to install 

the remote SFC, however, more plants are considering the option because of space constraints underneath the 

boiler. For the remote SFC, bid proposals include the design and supply operation and the installation costs. 

Additionally, the remote SFC has potential cost savings because of multiple unit synergies. Meaning, because 

the unit is sluicing to a remote SFC, multiple units could sluice to the same conveyor.

Alternately, SFC systems are continuous removal systems. Each unit at the plant has its own designated SFC 
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system because it is located directly under the boiler. Simply multiplying the cost per SFC by the number of 

units at the plant will underestimate the cost because each system is specific to a unit. CBDD stated that the 

SFC has potential cost savings because there are no pumping costs. 

Further, we discussed the maintenance required for each system. CBDD stated that with the SFC, there are big 

slag falls from the bottom of the boiler directly onto the drag chain, resulting in need to replace the drag chain. 

However, with the remote SFC, there are no concerns with falling slag resulting in less maintenance and a 

longer drag chain life.

ERG and EPA also discussed the differences in costs for a tank-based complete recycle system with CBDD. 

Mr. Mooney and Mr. Fleming explained that high costs are necessary for this system for the steel fabrication of 

two dewatering bins, a surge tank, and a settling tank. These cost estimates could include installation and/or 

demolition when taking into to account what the plant is currently doing. 

CBDD stated that the design life of remote SFC or SFC systems is twenty years minimum; however, 30 to 40 

years is also very common. For the remote SFC, CBDD stated that the system uses the existing sluice pipelines 

and costs are estimated using flow rates. Further, the addition of a clarifier to remove additional total suspended 

solids (TSS) and control pH is optional for the system. 

The pump requirements for an SFC is approximately 50 horsepower (HP) for the continuous operations 

underneath the boiler; compared to the 250 HP pumps required for the remote system because of the batch 

process. However, CBDD stated that the chain life of the remote SFC is longer because large pieces of boiler 

slag are not falling on the conveyor chain like the SFC system located directly underneath the boiler.

Currently, CBDD is working on bids for the remote SFC for the spring of 2013. This system is being considered 

where there is no room under the boiler or a liner in a pond is about to give away.