Fuel Tech, Inc.

27601 Bella Vista Pkwy 

Warrenville, Illinois 60555 

630.845.4500 

www.ftek.com

Wheelabrator Saugus Inc. 

WTE Units 1 & 2 

Two 750 TPD MSW Combustors 

SNCR Optimization

Report 

Prepared for: John T. O’Rourke 

Project #: 470S 

January 29, 2010 

Copies To: 

Wheelabrator: Timothy J. Porter, John T. O’Rourke, Scott Manning, William Hoen 

Fuel Tech: Bill Cummings, Alex Dainoff, Dave Kieffer, Brad Gieseke, Project File 

100 Salem Turnpike 

Saugus, Massachusetts 01906-1899 
Wheelabrator Saugus, Inc. Service Report 

WTE Units 1 & 2 January 29, 2010 

-CONFIDENTIAL - Page 1 -DO NOT DUPLICATE1.0 EXECUTIVE SUMMARY

Fuel Tech performed furnace gas temperature profiling and conducted SNCR optimization 

testing at the Wheelabrator Saugus J.V. waste to energy (WTE) facility in accordance with the 

NOx Control Optimization Program submitted to MADEP for Best Available Retrofit 

Technology (BART). The overall objective was to try and achieve lower NOx emissions while 

minimizing ammonia slip levels below the current permit limit of 10 ppm (dry, 7% O2). 

Phase I- Furnace Temperature Profiling January 18 to 22, 2010

Furnace gas temperature profiling was done on Units 1 and 2 using the SpectraTemp Gas 

Temperature Monitor with data logger. These data were then analyzed with boiler operating 

data taken from the boiler distributive control system (DCS) process data historian to 

determine present operating conditions of the furnace and NOx control. 

Phase II- SNCR Process Optimization January 25 to 29, 2010

The SNCR system configuration and operating conditions were then changed to the extent 

allowed by the available furnace injector points and number of operating injectors to 

determine the capability of reducing the NOx emissions while minimizing ammonia slip. 

Present and alternative SNCR injector arrangements (location and number of injectors in 

service and reagent feed rates were adjusted to determine the best SNCR system 

configuration to achieve and sustain lower NOx emissions. 

Four and six injectors were tested on Saugus Units #1 and #2 and six injectors were tested on 

Saugus Unit #2 at reagent feed rates of 0, 5, and 10 gallons per hour and results show a 

capability of reducing NOx consistently down to 185 ppmv (dry, 7% O2) with loads at or above 

150,000 lbs/hr steam flow. Based on these tests it was determined that: 

• Injector locations are near the lower end of the optimum SNCR operating range at normal 

boiler operating conditions. 

• There was no significant performance difference between in utilizing 4 or 6 injectors in 

each furnace 

• Baseline NOx varied between 240 and 280 ppm (dry, 7% O2) 

• A reduced NOx setpoint of 185 ppm (dry, 7% O2) was achieved on both units even at 

higher NOx baselines 

• Increasing reagent feed rates from 5 to 10 gph did not appreciably lower NOx 

Therefore, the present injector configurations may be maintained and reagent flow increased to 

reduce NOx emissions to a target of 185 ppm (dry, 7% O2) at loads above 150,000 lbs/hr. 
Wheelabrator Saugus, Inc. Service Report 

WTE Units 1 & 2 January 29, 2010 

-CONFIDENTIAL - Page 2 -DO NOT DUPLICATE2.0 Table of Contents

1.0 Executive Summary 1 

2.0 Table of Contents 2 

3.0 Unit Description 3 

4.0 SNCR System Description 4 

5.0 Furnace Temperature Measurements 6 

6.0 SNCR Optimization Testing 11 

7.0 Conclusions 15 
Wheelabrator Saugus, Inc. Service Report 

WTE Units 1 & 2 January 29, 2010 

-CONFIDENTIAL - Page 3 -DO NOT DUPLICATE3.0 Unit Description

The Wheelabrator Saugus J.V. waste-to-energy (WTE) facility has two Riley Stoker boilers rated 

for 650 psig operating steam pressure at 850 degrees F. both driving a 56 MWg turbine/generator 

which is operated at approximately 35 MWg. The generator rating was originally sized for three 

units but only two units were installed. MSW is fired on early Von Roll (“L” style) grates 

designed for a maximum firing rate of 750 tons per day of municipal solid waste or refuse. Each 

unit is fit with two auxiliary oil fired burners for preheating the furnace prior to refuse 

combustion. The boiler, furnace and grate combustion system represent the earliest Von Roll 

design (circa 1975) and still are reflective of current WTE European designs where tail end 

boilers dominate. 

Primary air is fed underneath the fuel bed through individually controlled air plenums in each of 

three (3) grate zones. Secondary air is added just above the fuel bed via front and rear wall 

headers in the lower furnace. Total combustion air flow is split between primary air and 

secondary air to optimize air penetration, turbulence and air-to-fuel mixing, to ensure low flame 

height and to minimize fly ash carryover to the boiler convection sections. 

Combustion testing this past year has led operators to run a minimum rate of overfire air with 

enough rear wall pressure to keep the combustion path towards the front furnace wall. Operators 

use fan amps as a guide to minimizing overfire air flow from day-to-day. This ensures more 

radiant cooling in the furnace thus minimizing attemperating water flow and lowering radiant 

tube metal temperatures. These adjustments also appear to have succeeded in minimizing 

combustion-generated NOx. 
Wheelabrator Saugus, Inc. Service Report 

WTE Units 1 & 2 January 29, 2010 

-CONFIDENTIAL - Page 4 -DO NOT DUPLICATE4.0 SNCR System Description

The Fuel Tech urea-based NOxOUT® SNCR Systems were supplied by Wheelabrator Air Pollution 

Control. The Systems were installed in 2000 to meet the USEPA’s Maximum Achievable Control 

Technology (MACT) limit of 205 ppm (dry, 7% O2) required by the 1990 Clean Air Act. The 

original System was designed so that up to eight ports per furnace with air-atomized injectors could 

be utilized to achieve the 205 ppm limit. Each injector had individual injector air pressure control 

with four injectors located on one distribution module for each furnace sidewall (four distribution 

modules in all). 

The original injectors were replaced this past summer by improved new injectors sold by DeNOx 

Technologies (DNT). These injectors are capable of higher liquid flows with larger droplets, have 

more open liquid internals and are therefore less subject to plugging than the original injectors (the 

plant uses service water as the supply). The new DNT injectors also have an Inconel atomizing 

spray tube eliminating the need for a shield (the original injectors had ceramic coated 300 series 

stainless steel 3⁄4” tubing shields). These new injectors improve the overall system performance and 

reliability while minimizing injector maintenance. Operators have found that only four of the new 

injectors need be operating on each boiler with settings of 0.5 gpm liquid flow per injector and 40 

psig air pressure (originally eight were used) to ensure compliance with the 205 ppm limit. The 

typical urea consumption for this compliance level averages between 2 and 4gph per unit. 

The new DNT injectors allowed the replacement of the original individual injector air pressure 

regulators from the distribution modules with a single upstream air pressure regulator to control the 

air to all four injectors on each distribution module. With the improved performance of the new 

DNT injectors only two injectors need to be operated on each distribution module. 

The injector ports are located on the sidewalls of the units as shown below in Figure 1. Due to 

relative differences in furnace temperature and combustion conditions between the two furnaces, 

operators have been locating the injectors on Unit 1 with more of a mixed arrangement than on Unit 

2. 
Wheelabrator Saugus, Inc. Service Report 

WTE Units 1 & 2 January 29, 2010 

-CONFIDENTIAL - Page 5 -DO NOT DUPLICATE24' 24'

inj inj inj

4' 4'

Port 2A Port 2B Port 1B Port 1A

5.9' 5.9'

inj inj inj inj

4' inj

5' 5'

3.3'

EL. 62' EL. 62'

(Darkened Ports are Capped) (Darkened Ports are Capped)

FACING EAST

Burners

FACING WEST

HEAVY ASH HEAVY ASH

NORTH

UNIT #1

WHEELABRATOR SAUGUS INJECTOR PORT ARRANGEMENT

32' 32'

Burners

NORTH

FACING EAST FACING WEST

UNIT #2

Figure 1 SNCR Injector Ports and Furnace Temperature Monitoring Locations

The original injector port locations were determined during the SNCR system design phase based 

on furnace temperature profiling. Because of the short furnace height and tail end boiler the 

optimum SNCR temperature window of 1650 to 2100 deg F in the furnace is relatively narrow and 

access to the furnace for SNCR injector installation is limited. 
Wheelabrator Saugus, Inc. Service Report 

WTE Units 1 & 2 January 29, 2010 

-CONFIDENTIAL - Page 6 -DO NOT DUPLICATE5.0 Phase 1 FURNACE TEMPERATURE MEASUREMENTS

Phase I furnace temperature measurements were obtained using a Spectratemp monitor. The 

Spectratemp monitor is an optical based pyrometer designed to continuously monitor average 

furnace flue gas temperature across the entire furnace width. The Spectratemp senses light 

radiated from ~30 μm diameter ash particles (these particles come to equilibrium temperature 

with the flue gas very quickly) in three differing wavelengths to determine the flue gas 

temperature. Energy levels seen in these wavelengths are proportioned to find the gas 

temperature. The measurement principle of the Spectratemp ensures that temperature readings 

are not biased by water wall temperatures or radiant heat. A Spectratemp monitor was used in 

the original furnace temperature profiling during the SNCR design phase in 2000. 

Furnace temperature data were utilized to evaluate current injector locations relative to the 

optimum operating temperature window for SNCR. By properly selecting the zone of injection 

based on flue gas temperature, the SNCR process can be optimized with regard to NOx 

reduction, chemical flows, and ammonia slip. Furnace temperature monitoring was conducted 

using two test ports located opposite the auxiliary oil burners on each unit just above the injector 

locations as follows: 

 Start Stop 

Unit 2A port: 1/20/10- 15:42 1/21/10- 08:01 (Boiler outage Jan 11-16, 2010) 

Unit 2B port: 1/21/10- 14:02 1/21/10- 15:15 

Unit 1A port: 1/21/10- 16:29 1/22/10- 08:18 (Shutdown for water wash Jan 27, 2010) 

Unit 1B port: 1/22/10- 08:53 1/22/10- 13:09 

The Port designations are Boiler Number (1 or 2) and front/rear wall (A for front; B for rear- see 

port layout in Figure 1 above). Furnace temperatures were monitored with both boilers operating 

at normal load between 145 to 155 klb/hr steam flow. Longer term furnace temperature data was 

obtained by leaving the Spectratemp in Test Port A overnight. Hourly average boiler conditions 

are shown in the tables following the temperature plots. A summary of the gathered data 

follows: 

 Port #1A Port #1B Port #2A Port #2B 

 Average 1666.0 1653.0 1677.7 1744.6 Deg.F. 

 Maximum 1889.4 1835.0 1908.1 1850.6 

 Minimum 1563.8 1551.9 1560.0 1652.5 

 Standard Deviation 32.5 55.5 49.2 44.6 

The temperatures on both ports for Unit #1 were found to be generally lower than the 

temperatures on Unit 2’s ports even though Unit 1 was a few days away from a scheduled water 

wash. The optimum temperature window for SNCR is between 1700-2100 degrees F. The 

furnace temperature monitoring data indicate that available injector ports are located near the 

lower end of the optimum SNCR operating temperature window of 1650 degrees F. 
Wheelabrator Saugus, Inc. Service Report 

WTE Units 1 & 2 January 29, 2010 

-CONFIDENTIAL - Page 7 -DO NOT DUPLICATE- 

.

Saugus Unit 1 A Port

Jan 21 to 22, 2010

1500

1550

1600

1650

1700

1750

1800

1850

1900

1950

2000

16:19 17:19 18:19 19:19 20:19 21:19 22:19 23:19 0:19 1:19 2:19 3:19 4:19 5:19 6:19

Time

Temperature (deg F)

Saugus Unit 1 B Port

Jan 22, 2010

1500

1550

1600

1650

1700

1750

1800

1850

1900

1950

2000

8:13 9:13 10:13 11:13 12:13 13:14 14:14

Time

Temperature (deg F)
Wheelabrator Saugus, Inc. Service Report 

WTE Units 1 & 2 January 29, 2010 

-CONFIDENTIAL - Page 8 -DO NOT DUPLICATESaugus Unit 2 A Port

Jan. 20 to 21, 2010

1500

1600

1700

1800

1900

2000

15:21 16:21 17:21 18:21 19:21 20:21 21:21 22:21 23:21 0:22 1:22 2:22 3:22 4:22 5:22 6:22 7:22

Time

Temperature (deg F)

Saugus Unit 2 B Port

Jan 21, 2010

1500

1550

1600

1650

1700

1750

1800

1850

1900

1950

2000

13:12 14:12 15:12 16:13

Time

Temperature (deg. F)
Wheelabrator Saugus, Inc. Service Report 

WTE Units 1 & 2 January 29, 2010 

-CONFIDENTIAL - Page 9 -DO NOT DUPLICATE1/20/2010

TIME STEAM BLR FEED E FEED W MAIN I MAIN W IN NOX

START FLOW MSTR SPD SPD SPD SPD PRESS FLOW CURRENT FLOW DUCT FRONT BACK CURRENT O2 AVG.

12:00 AM KLB/HR % % % % % inWC KCFM AMPS KCFM PRESS FLOW PRESS FLOW PRESS AMPS % PPM A B

0:00 FI201

#2_BLR_M

AST_OUT SC230 SC240 SC231 SC241 PI208 FI208 II251

#2_SEC_AI

R_FLOW PI209 FI2122 PI2114A FI2114 PI2114B II252 AI2201 AI6264B TI264 TI265

1:00 153.10 37.90 28.86 24.86 32.86 34.86 3.76 41.48 11.74 33.98 27.97 23.27 11.01 10.24 15.04 55.34 7.13 179.22 857.13 754.90

2:00 154.20 34.98 25.94 21.94 29.94 31.94 3.90 40.53 11.65 33.95 27.98 23.24 11.02 10.25 15.02 55.37 6.91 188.39 859.31 760.23

3:00 153.66 38.56 29.57 25.57 33.57 35.57 3.92 39.02 11.27 33.96 28.01 23.23 11.00 10.25 14.98 55.35 7.13 190.67 854.82 750.24

4:00 153.09 39.86 30.84 26.84 34.84 36.84 3.78 39.75 11.36 33.96 28.03 23.17 11.01 10.24 14.98 55.33 7.17 186.98 867.99 753.41

5:00 153.71 35.17 26.17 22.18 30.17 32.17 3.77 38.62 10.83 33.97 28.05 23.25 11.03 10.25 15.01 55.32 7.04 178.55 866.49 755.94

6:00 153.72 41.12 32.13 28.13 36.13 38.13 3.67 38.86 10.71 33.98 28.03 23.25 11.01 10.23 14.98 55.35 6.99 187.58 868.10 752.99

7:00 152.99 43.72 33.67 30.09 38.74 40.74 4.05 36.58 10.32 34.01 28.00 23.23 10.99 10.26 14.99 55.15 6.68 204.95 854.80 750.03

8:00 154.50 50.10 37.07 34.41 45.08 47.10 3.87 37.75 10.46 37.02 28.01 23.91 11.01 12.57 23.27 56.75 7.51 208.29 822.17 743.20

9:00 153.86 54.92 41.15 34.80 48.09 51.84 3.83 38.37 10.50 37.76 28.00 24.15 11.00 13.15 25.27 57.20 7.83 207.55 818.32 737.14

10:00 153.57 52.22 36.06 30.38 43.73 48.31 3.90 37.81 10.40 38.05 27.97 24.41 12.02 13.18 25.25 57.52 7.33 203.16 819.33 734.32

11:00 152.87 53.44 35.27 30.43 42.43 49.40 3.68 37.96 10.35 38.33 27.99 24.70 12.98 13.19 25.27 57.80 7.70 191.36 823.70 739.23

12:00 147.22 59.16 40.15 32.48 44.30 53.11 3.57 37.66 10.28 38.40 28.00 24.70 12.93 13.20 25.28 57.68 7.71 191.36 815.53 728.25

13:00 152.76 58.53 39.36 30.14 41.38 51.52 3.60 39.17 10.46 38.36 28.00 24.67 12.93 13.21 25.27 57.66 7.60 191.36 825.93 738.06

14:00 153.18 53.24 32.97 26.27 34.49 46.21 3.71 38.30 10.43 38.43 28.00 24.72 12.92 13.21 25.27 57.65 7.69 197.71 831.34 736.02

15:00 153.41 56.94 34.84 30.83 36.65 48.57 3.63 38.66 10.41 38.40 28.00 24.75 12.85 13.21 25.27 57.58 7.66 208.68 831.48 738.84

16:00 148.18 61.60 39.55 35.55 39.61 51.66 3.54 39.60 10.68 38.50 28.00 24.77 13.22 13.21 25.26 57.73 8.14 201.26 827.22 733.10

17:00 153.15 66.69 45.50 40.94 44.12 56.12 3.48 39.61 10.58 38.50 28.00 24.81 13.35 13.20 25.26 57.80 8.09 205.12 833.86 737.86

18:00 145.86 67.59 47.57 40.80 46.86 58.77 3.57 39.80 10.74 38.34 28.00 24.62 12.96 13.23 25.24 57.69 8.45 202.09 828.94 733.14

19:00 141.54 60.27 41.56 31.85 60.17 70.20 3.82 41.20 11.95 38.47 28.00 24.74 13.39 13.22 25.25 57.92 8.45 196.68 829.00 729.47

20:00 149.68 55.35 38.39 25.39 55.39 65.39 4.03 41.04 12.27 38.41 27.99 24.66 13.34 13.23 25.25 58.01 7.53 198.82 843.32 735.51

21:00 144.80 51.69 34.72 21.73 51.72 61.72 3.89 41.29 12.11 38.39 27.99 24.62 13.29 13.22 25.26 58.09 8.49 203.96 834.72 733.20

22:00 148.72 65.26 48.01 35.01 65.01 75.01 3.44 42.68 12.08 38.30 28.00 24.62 13.31 13.24 25.25 58.28 8.26 198.70 839.82 737.33

23:00 147.32 65.74 48.71 35.72 65.71 75.71 3.98 40.63 12.12 38.33 28.00 24.61 13.31 13.25 25.26 58.41 7.80 198.52 847.46 738.10

0:00 144.64 48.12 31.09 21.31 48.09 58.09 4.24 38.51 11.55 38.36 28.00 24.54 13.39 13.25 25.25 58.53 8.06 200.56 832.56 732.41

TOTAL 150.82 52.17 36.63 29.90 43.71 50.79 3.78 39.37 11.05 37.01 28.00 24.19 12.30 12.32 22.18 57.06 7.64 196.73 838.89 740.96

PRIMARY AIR SECONDARY AIR

BOILER 2

1/20/2010

 SH OUTLET

 GAS TEMP

TIME STEAM BLR FEED E FEED W MAIN I MAIN W IN NOX

START FLOW MSTR SPD SPD SPD SPD PRESS FLOW CURRENT FLOW DUCT FRONT BACK CURRENT O2 AVG.

12:00 AM KLB/HR % % % % % inWC KCFM AMPS KCFM PRESS FLOW PRESS FLOW PRESS AMPS % PPM A B

0:00 FI201

#2_BLR_M

AST_OUT SC230 SC240 SC231 SC241 PI208 FI208 II251

#2_SEC_AI

R_FLOW PI209 FI2122 PI2114A FI2114 PI2114B II252 AI2201 AI6264B TI264 TI265

1:00 152.87 52.42 35.38 32.38 52.38 62.38 4.09 39.25 11.68 38.34 28.00 24.55 13.43 13.25 25.25 58.67 7.41 209.32 844.61 739.48

2:00 157.49 54.26 37.26 34.27 54.26 66.24 4.21 38.54 11.62 38.34 28.00 24.56 13.44 13.25 25.24 58.75 7.00 194.28 854.77 747.63

3:00 158.09 43.72 26.72 23.70 43.72 58.70 4.31 37.99 11.53 38.31 28.00 24.57 13.44 13.26 25.25 58.82 6.92 195.73 859.69 746.95

4:00 148.48 62.35 45.32 42.32 62.32 77.32 4.06 39.45 11.78 38.29 28.00 24.53 13.44 13.26 25.24 58.92 7.49 199.46 836.56 742.32

5:00 148.49 45.69 26.48 18.47 45.31 59.81 3.78 40.80 11.92 38.23 28.01 24.47 13.25 13.26 25.26 58.88 7.73 194.22 842.94 739.30

6:00 146.39 60.78 40.68 20.68 55.68 65.68 3.84 47.02 16.04 38.17 28.00 24.42 12.93 13.26 25.25 58.76 8.50 204.27 846.90 742.26

7:00 143.60 68.50 49.24 28.50 63.13 73.04 4.16 45.81 15.56 38.14 28.01 24.44 12.88 13.26 25.24 58.67 8.67 229.87 850.02 740.48

8:00 154.21 63.13 43.60 26.42 54.89 63.90 4.62 48.60 18.21 38.15 28.00 24.37 12.97 13.27 25.25 58.72 8.04 183.66 883.10 748.66

9:00 148.39 62.79 41.58 27.79 50.82 61.81 4.42 46.57 16.57 38.26 28.00 24.45 13.40 13.27 25.26 58.82 8.90 188.26 852.60 742.92

10:00 152.69 61.77 39.74 26.74 47.74 58.75 4.25 46.05 15.86 38.39 28.00 24.63 13.36 13.33 25.23 58.66 8.36 203.15 877.35 748.14

11:00 151.43 76.51 54.47 41.48 61.40 72.46 3.69 44.12 13.67 38.44 28.00 24.52 13.13 13.40 25.19 58.46 8.58 197.32 859.01 746.13

12:00 147.76 63.20 41.17 28.17 46.35 59.17 3.72 42.60 12.76 38.43 28.00 24.53 12.81 13.41 25.17 58.21 8.24 195.12 849.87 739.42

13:00 148.35 75.82 53.87 40.87 58.87 71.87 3.70 43.58 13.38 38.50 28.00 24.61 13.08 13.40 25.16 58.18 8.11 201.52 852.77 739.38

14:00 157.50 58.47 35.89 22.92 41.46 53.22 3.92 43.10 13.60 38.68 28.00 24.81 13.32 13.41 25.18 58.18 7.91 207.22 866.73 749.95

15:00 149.07 66.53 45.15 32.06 52.31 60.38 3.83 43.57 13.59 38.55 28.01 24.68 12.91 13.41 25.17 57.97 8.81 203.14 850.65 739.16

16:00 156.68 59.66 43.19 30.20 57.00 50.98 4.23 43.31 14.21 38.58 28.00 24.72 12.96 13.40 25.16 57.94 8.09 207.79 861.54 748.73

17:00 156.92 61.83 50.28 42.88 58.96 52.81 4.31 44.77 15.27 38.59 28.00 24.72 13.29 13.41 25.18 58.13 8.33 193.66 873.71 749.96

18:00 152.03 73.05 62.96 62.95 71.96 63.96 4.37 45.66 15.96 38.52 28.00 24.61 13.28 13.39 25.17 58.12 8.15 196.50 876.08 747.20

19:00 145.65 58.95 47.69 56.61 51.52 46.27 4.06 46.87 16.39 38.46 28.00 24.57 13.29 13.40 25.18 58.24 8.79 199.90 874.31 739.95

20:00 154.20 56.54 46.58 58.74 52.74 52.25 4.45 42.96 14.59 38.48 28.00 24.46 13.29 13.42 25.17 58.46 7.94 205.44 861.96 748.67

21:00 157.71 40.88 35.87 35.89 40.88 40.89 4.53 39.90 12.97 38.37 28.00 24.49 13.36 13.42 25.18 58.62 7.77 200.61 861.22 748.62

22:00 157.73 45.29 40.28 40.31 45.28 45.31 4.28 38.84 12.01 38.31 27.99 24.37 13.36 13.44 25.17 58.84 7.74 192.64 862.53 749.88

23:00 157.84 38.52 33.52 33.52 38.52 38.51 4.24 36.77 10.99 38.28 28.00 24.36 13.37 13.44 25.17 58.93 7.34 191.31 861.64 748.13

0:00 158.16 38.40 31.42 31.40 38.40 38.40 4.20 36.98 11.05 38.31 28.00 24.42 13.37 13.44 25.17 59.03 7.32 206.92 862.79 749.32

TOTAL 152.57 57.88 42.02 34.97 51.91 58.09 4.14 42.63 13.80 38.38 28.00 24.54 13.22 13.35 25.20 58.54 8.00 200.06 859.31 745.11

1/21/2010 1/21/2010

BOILER 2

PRIMARY AIR SECONDARY AIR SH OUTLET

 GAS TEMP

Unit 2 Boiler Operating Data for January 20th and 21st
Wheelabrator Saugus, Inc. Service Report 

WTE Units 1 & 2 January 29, 2010 

-CONFIDENTIAL - Page 10 -DO NOT DUPLICATE1/21/2010

TIME STEAM BLR FEED E FEED W MAIN I MAIN W IN NOX SH OUTLET

START FLOW MSTR SPD SPD SPD SPD PRESS FLOW CURRENT FLOW DUCT FRONT BACK CURRENT O2 AVG.

12:00 AM KLB/HR % % % % % inWC KCFM AMPS KCFM PRESS FLOW PRESS FLOW PRESS AMPS % PPM A B

0:00 FI101

#1_BLR_M

AST_OUT SC130 SC140 SC131 SC141 PI108 FI108 II151

#1_SEC_AI

R_FLOW PI109 FI1122 PI1114A FI1114 PI1114B II152 AI1201 AI6164B TI164 TI165

1:00 145.02 64.16 59.19 64.19 97.19 62.19 4.39 60.00 12.80 31.65 30.00 23.51 11.02 7.51 16.12 50.39 8.80 199.34 813.10 856.22

2:00 142.48 72.65 65.51 68.04 105.66 75.76 4.18 59.60 12.87 31.98 30.01 23.85 11.01 7.53 16.11 50.44 8.73 191.68 809.46 852.77

3:00 144.69 65.22 58.65 57.19 98.19 70.19 4.00 61.19 13.60 32.21 30.01 24.04 11.02 7.52 16.12 50.49 8.89 185.66 814.56 852.36

4:00 138.63 55.04 49.02 47.02 78.47 55.62 4.32 58.66 12.35 32.22 30.00 24.06 11.00 7.51 16.12 50.54 9.50 177.30 812.28 848.95

5:00 148.79 55.54 48.80 45.51 38.63 39.34 4.06 58.90 12.22 32.65 30.00 24.47 11.01 7.47 16.13 50.55 9.38 179.34 837.83 865.94

6:00 133.54 67.92 57.99 56.98 48.99 43.99 4.51 62.22 16.26 32.80 30.01 24.57 11.01 7.53 16.13 50.55 10.11 201.89 797.97 848.07

7:00 136.75 71.89 60.00 59.35 52.66 47.46 4.38 62.11 15.55 32.68 30.00 24.53 10.98 7.42 16.13 50.46 9.90 222.52 802.15 855.35

8:00 135.04 70.59 58.61 56.26 49.33 43.38 5.13 60.88 15.69 32.72 29.99 24.47 10.99 7.51 16.13 50.50 9.72 190.42 799.56 851.05

9:00 139.64 59.73 47.53 43.99 37.21 32.66 5.17 63.37 17.66 31.62 29.99 23.51 10.99 7.46 16.13 50.44 9.71 199.83 804.97 851.49

10:00 144.73 75.33 62.27 60.27 50.27 47.27 4.42 62.33 15.44 31.22 29.99 23.02 11.01 7.49 16.13 50.32 9.76 208.20 811.04 854.88

11:00 146.69 70.39 57.36 55.36 45.36 42.36 4.35 61.29 14.34 31.22 30.00 23.01 11.02 7.48 16.14 50.19 9.45 204.45 814.35 860.51

12:00 140.65 71.91 58.86 56.86 45.87 42.84 4.24 61.52 13.92 31.39 30.00 23.20 11.00 7.49 16.14 50.08 9.67 202.91 806.90 849.79

13:00 149.99 71.66 58.70 58.11 44.70 41.70 4.10 61.00 13.34 31.14 30.00 22.92 11.02 7.55 16.13 50.02 9.02 203.36 820.65 860.26

14:00 147.09 67.72 54.77 54.77 40.05 37.77 4.02 61.22 13.33 30.84 30.00 22.57 10.99 7.56 16.13 49.95 9.27 199.39 815.80 856.31

15:00 146.22 73.46 62.15 62.13 45.49 43.49 3.93 60.88 12.95 31.22 30.00 22.97 10.99 7.55 16.13 49.88 9.40 203.79 812.25 857.19

16:00 152.16 56.46 55.96 55.96 28.07 26.05 4.36 59.67 12.72 31.06 30.00 22.74 11.01 7.59 16.14 49.85 9.06 200.58 816.11 865.78

17:00 156.80 54.28 56.06 56.06 25.26 23.26 4.75 59.97 13.58 31.20 30.00 22.94 11.00 7.55 16.14 49.91 8.87 197.69 824.47 872.05

18:00 145.58 67.05 73.59 73.60 38.07 36.07 4.95 58.72 13.68 31.41 30.00 23.17 11.01 7.50 16.13 49.90 8.53 204.01 823.99 856.74

19:00 147.59 38.39 45.41 45.41 9.41 7.41 4.94 58.66 13.82 31.54 30.00 23.34 11.01 7.55 16.13 50.00 9.09 195.10 808.39 865.58

20:00 153.23 45.13 52.15 52.19 16.44 14.69 4.88 59.29 13.96 31.26 30.00 23.13 10.99 7.50 16.14 50.14 8.58 200.19 818.34 872.07

21:00 153.68 29.79 24.90 24.85 29.83 29.76 5.00 57.66 13.30 31.43 30.00 23.13 11.01 7.53 16.15 50.26 8.68 200.07 815.45 872.98

22:00 152.67 43.28 38.32 38.32 43.32 43.32 4.61 57.79 12.30 31.60 30.00 23.50 11.02 7.50 16.15 50.44 8.68 201.18 811.68 871.97

23:00 154.75 36.09 31.09 31.09 36.09 36.09 4.83 53.54 10.88 31.98 30.00 23.78 11.00 7.53 16.14 50.53 8.10 199.97 818.91 864.35

0:00 153.80 36.45 29.46 29.47 36.45 36.45 4.78 54.54 10.96 32.31 29.99 24.13 10.99 7.50 16.13 50.60 8.18 204.31 820.81 863.02

TOTAL 146.26 59.17 52.76 52.21 47.54 40.80 4.51 59.79 13.65 31.72 30.00 23.52 11.00 7.51 16.13 50.27 9.13 198.88 813.79 859.40

BOILER1

PRIMARY AIR SECONDARY AIR

 GAS TEMP

1/22/2010

TIME STEAM BLR FEED E FEED W MAIN I MAIN W IN NOX

START FLOW MSTR SPD SPD SPD SPD PRESS FLOW CURRENT FLOW DUCT FRONT BACK CURRENT O2 AVG.

12:00 AM KLB/HR % % % % % inWC KCFM AMPS KCFM PRESS FLOW PRESS FLOW PRESS AMPS % PPM A B

0:00 FI101

#1_BLR_M

AST_OUT SC130 SC140 SC131 SC141 PI108 FI108 II151

#1_SEC_AI

R_FLOW PI109 FI1122 PI1114A FI1114 PI1114B II152 AI1201 AI6164B TI164 TI165

1:00 154.12 50.21 42.13 42.13 50.13 50.13 4.43 57.03 11.30 32.55 30.00 24.31 11.01 7.55 16.14 50.64 8.20 200.25 827.29 862.35

2:00 145.93 69.89 58.84 58.66 72.37 72.37 4.36 57.77 12.01 32.64 30.00 24.56 11.00 7.45 16.14 50.66 8.27 195.85 822.43 851.14

3:00 149.86 43.52 27.35 27.11 46.63 46.63 5.10 62.32 16.76 32.61 30.00 24.41 11.00 7.53 16.13 50.63 8.26 194.96 829.77 857.76

4:00 148.54 51.92 34.94 34.94 54.94 54.94 4.46 63.53 16.93 32.57 30.01 24.44 10.99 7.48 16.14 50.58 9.24 198.38 820.60 859.77

5:00 148.01 68.12 51.09 48.09 71.09 71.09 4.07 61.64 14.42 32.62 29.99 24.48 11.02 7.48 16.13 50.63 8.97 208.90 826.91 860.49

6:00 147.01 53.42 34.80 30.77 56.51 56.51 3.90 60.13 12.26 32.43 30.01 24.14 10.98 7.51 16.14 50.63 8.66 198.97 821.93 849.55

7:00 150.52 71.64 56.30 50.65 74.65 74.65 3.67 59.87 11.93 32.35 30.00 24.22 10.98 7.47 16.14 50.57 8.77 225.31 836.60 856.77

8:00 148.08 44.12 32.13 26.13 47.10 47.10 2.31 52.52 7.06 32.51 29.36 24.37 10.97 7.51 15.72 50.76 10.26 173.14 816.72 875.53

9:00 157.85 58.02 49.62 41.44 61.02 61.02 3.72 60.39 11.83 32.70 29.99 24.51 11.02 7.48 16.12 50.71 8.79 200.41 832.55 872.49

10:00 157.19 61.22 52.93 38.34 61.53 61.53 3.59 59.88 11.71 32.65 30.00 24.46 11.03 7.54 16.14 50.48 8.70 200.04 846.82 867.49

11:00 157.96 63.34 79.94 58.17 61.37 61.37 3.47 59.79 11.40 31.92 29.99 23.73 10.97 7.46 16.14 50.28 8.63 190.37 837.86 868.30

12:00 158.42 45.10 66.32 43.27 43.10 43.10 3.65 58.77 10.89 31.59 30.01 23.27 10.99 7.60 16.14 50.04 8.24 193.28 837.74 870.90

13:00 158.50 34.67 54.32 31.29 32.67 32.67 3.82 57.93 10.68 31.13 30.01 22.89 11.02 7.59 16.13 49.93 7.81 198.65 840.68 868.59

14:00 156.11 33.19 49.40 26.35 31.18 31.18 3.98 56.84 10.63 31.18 29.99 22.94 11.00 7.57 16.12 50.00 8.07 208.92 834.59 869.99

15:00 153.90 30.72 35.53 13.06 28.73 28.73 3.91 57.38 10.71 31.25 30.01 23.13 11.01 7.55 16.13 50.07 8.36 199.95 825.59 863.55

16:00 152.04 58.02 60.97 38.93 56.05 56.05 3.66 59.32 11.29 31.34 30.00 23.25 10.98 7.52 16.13 50.12 8.99 206.00 818.75 866.39

17:00 154.48 40.78 57.74 37.14 38.72 38.72 3.94 58.83 11.46 31.30 30.00 23.08 11.01 7.52 16.13 50.15 8.64 194.57 827.45 868.53

18:00 153.84 34.82 49.50 36.38 33.59 34.41 4.24 57.32 11.23 31.31 30.00 23.13 11.01 7.53 16.14 50.09 8.73 198.33 824.61 871.97

19:00 153.71 34.60 34.61 38.64 34.64 36.64 4.42 57.35 11.16 31.36 30.00 23.05 10.99 7.58 16.14 50.11 9.11 196.96 826.04 872.11

20:00 153.63 39.58 39.58 43.58 39.58 41.58 4.18 58.69 11.36 31.45 30.00 23.26 11.00 7.51 16.12 50.25 9.10 202.18 815.64 886.51

21:00 153.99 32.89 32.89 36.63 32.89 34.89 4.46 56.58 11.18 31.73 30.00 23.67 11.03 7.48 16.13 50.32 8.71 199.24 818.70 877.52

22:00 153.57 31.00 25.70 25.63 31.85 33.88 4.53 56.50 11.18 32.01 30.00 23.75 10.99 7.50 16.13 50.40 8.60 204.42 821.08 876.78

23:00 152.54 40.41 26.85 26.72 44.16 45.28 4.15 58.98 11.52 32.20 30.00 24.06 11.00 7.50 16.13 50.47 8.99 200.56 816.47 880.36

0:00 152.99 54.66 40.66 40.66 58.73 59.73 4.00 60.40 12.13 32.45 30.01 24.38 11.02 7.50 16.14 50.50 8.65 204.83 825.94 873.22

TOTAL 153.03 47.74 45.59 37.28 48.47 48.92 4.00 58.74 11.79 31.99 29.97 23.81 11.00 7.52 16.12 50.38 8.70 199.77 827.20 867.84

 GAS TEMP

BOILER1

1/22/2010

PRIMARY AIR SECONDARY AIR SH OUTLET

Unit 1 Boiler Operating Data for January 21st and 22nd
Wheelabrator Saugus, Inc. Service Report 

WTE Units 1 & 2 January 29, 2010 

-CONFIDENTIAL - Page 11 -DO NOT DUPLICATE6.0 Phase 2 SNCR Optimization Testing 

Phase 2 optimization tests were performed on Units 1 and 2 on Tuesday, January 26th, 2010 and 

on Unit 2 on Wednesday, January 27th, 2010. Tests on Tuesday were comprised of running 

reagent pumps manually with approximately 0, 5, and 10 gallons of reagent an hour to each unit 

for enough time to gather hourly average performance data. Unit #1 went into a water wash 

outage on Wednesday, so two new style injectors were borrowed from Unit #1 and mounted in 

Unit #2 making use of three injectors in each sidewall on Unit 2 (see following detail). Reagent 

pump rate tests of 0, 5, and 10 gallons per hour were repeated for comparison to Tuesday’s 

performance. The following tables summarize the performance observed: 

Test Injector No. of Steam Heat Urea Dilution Injector NOx NOx NOx

No. Location Injectors Flow Input Flow Flow Type @ 7% O2 Baseline Reduction

[Klb/Hr] [Mmbtu/hr] [GPH] [GPM] [ppmvc] [ppmvc] [%]

1 See 4 153.2 248.9 4.4 2.0 DNT 174.7 240.7 27.4%

2 Sketch 4 153.7 249.8 5.1 2.0 DNT 177.1 240.7 26.4%

3 Page 6 4 153.1 248.8 5.1 2.0 DNT 180.4 240.7 25.0%

4 4 150.9 245.3 5.1 2.0 DNT 190.6 240.7 20.8%

6 4 155.7 253.1 0.0 2.0 240.7 240.7 0.0%

8 4 153.8 250.0 10.7 2.0 DNT 166.1 240.7 31.0%

9 4 151.8 246.6 10.7 2.0 DNT 164.0 240.7 31.9%

Wheelabrator Saugus

Unit #1

Test Injector No. of Steam Heat Urea Dilution Injector NOx NOx NOx

No. Location Injectors Flow Input Flow Flow Type @ 7% O2 Baseline Reduction

[Klb/Hr] [Mmbtu/hr] [GPH] [GPM] [ppmvc] [ppmvc] [%]

1 See 4 153.6 249.6 4.4 2.0 DNT 189.0 268.0 29.5%

2 Sketch 4 153.5 249.4 4.7 2.0 DNT 192.7 268.0 28.1%

3 Page 6 4 153.1 248.8 4.7 2.0 DNT 195.0 268.0 27.2%

4 4 153.0 248.7 4.8 2.0 DNT 185.7 268.0 30.7%

5 4 154.4 250.9 0.0 2.0 268.0 268.0 0.0%

6 4 151.1 245.5 10.3 2.0 DNT 185.5 268.0 30.8%

7 4 153.7 249.8 10.3 2.0 DNT 175.4 268.0 34.6%

8 6 153.7 249.7 4.9 2.0 DNT 210.6 280.0 24.8%

9 6 155.0 251.9 5.1 2.0 DNT 204.6 280.0 26.9%

10 6 158.7 257.9 5.2 2.0 DNT 186.4 280.0 33.4%

11 6 157.7 256.3 9.9 2.0 DNT 181.3 280.0 35.3%

12 6 158.0 256.7 10.1 2.0 DNT 156.4 280.0 44.1%

13 6 156.0 253.5 0.0 2.0 DNT 280.0 280.0 0.0%

Note: Added one injector towards rear wall same level

Unit #2

Wheelabrator Saugus
Wheelabrator Saugus, Inc. Service Report 

WTE Units 1 & 2 January 29, 2010 

-CONFIDENTIAL - Page 12 -DO NOT DUPLICATE24'

Added

Injector

inj inj

4'

Port 2A Port 2B

Added

5.9' Injector

inj inj

4'

5'

3.3'

EL. 62'

32'

Burners

NORTH

FACING EAST FACING WEST

UNIT #2

HEAVY ASH

(Darkened Ports are Capped)
Wheelabrator Saugus, Inc. Service Report 

WTE Units 1 & 2 January 29, 2010 

-CONFIDENTIAL - Page 13 -DO NOT DUPLICATENote: Added injectors in service on Unit #2 for second set of tests on January 

27

Saugus Unit #1

150.0

200.0

250.0

300.0

0.0 2.0 4.0 6.0 8.0 10.0 12.0

Urea Flow (GPH)

NOx (ppmv, 7%)

Saugus Unit #2- 4 Injectors

150.0

200.0

250.0

300.0

0.0 2.0 4.0 6.0 8.0 10.0 12.0

Urea Flow (GPH)

NOx (ppmv, 7%)
Wheelabrator Saugus, Inc. Service Report 

WTE Units 1 & 2 January 29, 2010 

-CONFIDENTIAL - Page 14 -DO NOT DUPLICATESaugus Unit #2- 6 Injectors

150.0

200.0

250.0

300.0

0.0 2.0 4.0 6.0 8.0 10.0 12.0

Urea Flow (GPH)

NOx (ppmv, 7%)

The results show a small incremental increase in NOx reduction and decrease in NOx emissions 

by doubling reagent flow from 5 to 10 gallons per hour. This marginal improvement in NOx 

removal and NOx reduction at twice the reagent flow rate is indicative that the injectors are 

located at the lower end of of the SNCR operating window where potential for ammonia slip 

generation is highest due to limited reaction time in SNCR operating window. It should be noted 

that there was an extremely heavy rainfall the weekend before these tests and that due to the wet 

refuse, higher than normal primary air flow was needed for the combustion; the baseline NOx 

was therefore higher during these tests than typically found on these units, but baselines which 

can be expected during the course of the year. 
Wheelabrator Saugus, Inc. Service Report 

WTE Units 1 & 2 January 29, 2010 

-CONFIDENTIAL - Page 15 -DO NOT DUPLICATE7.0 SNCR Optimization Test Conclusions

Four and six injectors were tested on Saugus Units #1 and #2 and six injectors were tested on 

Saugus Unit #2 at reagent feed rates of 0, 5, and 10 gallons per hour and results show a 

capability of reducing NOx consistently down to 185 ppmv (dry, 7% O2) over a 24 hour average 

with loads at or above 150,000 lbs/hr steam flow. Based on these tests it was determined that: 

• Because of furnace configuration, there was no significant performance difference 

between in utilizing 4 or 6 injectors in each furnace using the DNT injectors. 

• Baseline NOx varied between 240 and 280 ppm (dry, 7% O2) 

• A reduced NOx setpoint of 185 ppm (dry, 7% O2) was achieved on both units even at 

higher baselines 

• Increasing reagent feed rates from 5 to 10 gph did not appreciably lower NOx or increase 

NOx reduction. 

• This marginal improvement in NOx removal and NOx reduction at twice the reagent flow 

rate (5 gpm to 10 gpm) indicates that the injector locations are the lower end of the 

SNCR operating window where potential for ammonia slip generation is highest due to 

limited reaction time in optimum SNCR operating window. 

Therefore, a reduced NOx emissions target of 185 ppm (dry, 7% O2) at current boiler operating 

loads of approximately 150,000lbs/hr may be achieved with the existing SNCR system 

configuration and an increase in reagent feed rate from 2-4 gpm to 4-6 gpm. Long term 

operation at this lower NOx target should be evaluated with ammonia slip testing to verify the 

current limit of 10 ppm 7% O2 is consistently achieved..