~HATCH~ 

United States Steel- Minntac Iron Ore Pelletizing Operation 

NOx Reduction Analysis 

Appendix A 

Indurating Process Flow Diagram 

ISO 9001 

PR332002-0t US Steel Minntac- Nox Reduction 

Technology Report.Doc 

"7"V WorkingTogether V SAFELY 

, Rev. 0, Page 17 

e Hatch 2006/03 X 
n 

Dryer D1 

G) 

Waste Gas 

Stack 

Gas Side Analysis 

Waste Gas 

Fan 

1. Gas Flow Rates: 

- actual: (acfm 

2. Mass Flow Rates: 

- dry gases: (lbs/min) 

- water vapor: (lbs/min 

3. Gas Temp.: (deQ F) 

4. Gas Densl_ty:_(lbs/ft3) 

5. Static Pressure: ("wg) 

Pellet Analysis 

6. Pellet Temp* (deg F) 

• estimated pellet temperature 

Dryer D2 

Scrubber 

System 

G) 

Waste Gas 

Stack 

550,000 

32,000 

2,600 

120 

0.063 

0.5 

Dryer D1 

100 

Preheat 

0 

Preheat 

Air 

(1A& 18) 

550,000 

19,003 

148 

600 

0.035 

-15.2 

Dryer D2 

650 

Exhaust 

Fan 

1A& 1B 

0 

Recoup 

Flow 

412,468 

7,619 

143 

1,630 

0.018 

-0.6 

Preheat 

1100 

@ 

Cooler Vent 

Stack 

270,580 

7,580 

100 

930 

0.027 

0.3 

Rotary/Kiln 

2450 

@ 

Cooler Vent 

Stack 

Inputs: I /':;'\ -Biomass \11 - Natural 

Gas 

- Fuel Oil 

Cooler 

Zone 1 

Exhaust 

Fan 3A 

® 

Cooler 

Zone2 

0 

Cooler lndraft Air 

Zone 1 Zone 2/3 

(FAN 3A) (FAN 38) 

167,470 199,220 

12,378 14,724 

129 154 

69 69 

0.072 0.072 

-2.1 -2.1 

Cooler 1 Cooler 2/3 

800 250 

Exhaust 

Fan 38 

Cooler 

Zone3 

US Steel Minntac - Line 5 

Hatch Project No. 332002 

SK1 - Process Flow Diag. 
~HATCH~ 

ISO 9001 

PR332002-0l US Steel Minnlac- Nox Reduction 

Technology Report.Doc 

United States Steel- Minntac Iron Ore Pelletizing Operation 

NOx Reduction Analysis 

Appendix B 

Line 5 Operating Data 

"'V'f:: WorkingTogether V SAFElY 

1 Rev. 0, Page 18 

o Hatch 2006/03 X 
""~ c: " ..,_ 

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"" "' """ I ~~~~····· <PC!l I """ ~ "'- 0 LL ca -':.:. -~x· :-:,;_ _v_ "'{ -, ii: "' ~ -~a; " 

C!lz 

0 -~-----:: .... \- :......:..;:;, .. \~- --~7:-ii:.;;,..._;;, 

9/15/2007 

Date 
~HATCH'" 

United States Steel - Minntac Iron Ore Pelletizing Operation 

NOx Reduction Analysis 

Appendix C 

Budgetary Specifications and Vendor Proposals 

ISO 9001 

PR332002-01 US Steel Minntac- Nox Reduction 

Technology Report.Doc 

~ WorkingTogether V SAFElY 

, Rev. 0, Page 19 

o Hatch 2006/03 X 
USS Minnesota Ore Operation 

NOx Reduction Technologies 

lngulrv: H·332002·M·01 

NOX EMISSION CONTROL SYSTEM 

INDURATING FURNACE OPERATION 

US STEEL MINNTAC -IRON PELLETIZING PLANT 

MT.IRON, MN 

1. Background Information 

SPECIFICATION 

Section 00 1119 

Summary of Work 

Rev. 0. Page 1 

US Steel operates an iron ore pelletizing plant at their Minnesota Ore Operation (Minntac) 

facility, including five pelletizing lines designated as Nos. 3, 4, 5, 6 and 7. US Steel is 

currently investigating the feasibility of reducing NOx emissions from the indurating process 

dedicated to the pelletizing operations, focusing initially on Line No.5. NOx emission 

controls would be installed on the other lines once the technology proves to be effective. 

As part of this investigation, US Steel is requesting budgetary proposals covering applicable 

NOx reduction technology for the indurating process. If applicable, US Steel would also like 

to consider conducting CFD modeling and/or pilot testing of any/all promising NOx reduction 

technologies. Bidder shall utilize the existing emission control system to the extent possible 

to be utilized in conjunction with the proposed NOx reduction technology and equipment. 

2. Applicable Codes and Standards 

All work shall be carried out in accordance with the latest edition of all applicable standards 

and codes initiated and issued by the following organizations 

AIST 

ANSI 

ASCE 

ASME 

ASTM 

AWS 

OSHA 

SMACNA 

SSPC 

Association of Iron and Steel Technology 

American National Standards Institute 

American Society of Civil Engineers 

American Society of Mechanical Engineers 

American Society of Testing and Materials 

American Welding Society 

Occupational Safety and Health Administration 

Sheet Metal and Air Conditioning Contractors National Association, Inc. 

Society of Protective Coatings 

3. Line No. 5 Indurating Process Operations 

The indurating process at Line No.5 is a "grate-kiln" type system, which employs a traveling 

grate, a rotary kiln and an annular cooler. The green pellets are dried and heated in an 

oxidizing atmosphere at an incipient fusion temperature of approx. 2400-2600 deg F 

depending on the type of pellet. Acid pellets are generally heated to the lower end of the 

temperature range, while flux pellets are heated to the higher end of the temperature range. 
~HATCH~ 

USS Minnesota Ore Operation 

NOx Reduction Technologies 

lnguirv: H·332002·M·01 

SPECIFICATION 

Section 00 11 19 

Summary of Work 

Rev. 0. Page 2 

• 

Drying of the green pellets and partial induration occurs at the grate, while final induration is 

finished in the rotary kiln. The pellets are cooled in an annular cooler that is designed to 

operate with counter-current cooling air flow. Refer to attached SK1 • Process Flow 

Diagram for typical indurating process concept and operating parameters. 

Emissions generated from the indurating process include solid particulates, mercury, S02, 

as well as combustion products such as CO, C02, and NO.. The existing emission control 

system includes wet scrubber system for particulate removal. 

Line No.5 -Indurating Process Design Basis: (typical flux pellets) 

1. Indurating Grate Feed Rate: 

2. 

3. 

4. 

Average Rate 

Maximum Rate 

Iron Pellets Produced: 

Average Rate 

Maximum Rate 

Fuel Input: (average) 

Natural Gas 

Biomass Fuel 

Total Fuel 

NO, Emissions: (typical) 

Average Rate 

Maximum Rate 

450 tonnes/hr 

530 tonnes/hr 

370 tonnes/hr 

440 tonnes/hr 

170 x 1 06 Btu/hr 

120 x 1 06 Btu/hr 

290 x 1 06 Btu/hr 

470 lbs/hr 

1,230 lbs/hr 

Note that all production rates quoted in tonnes per hour are long tons . 

4. Scope of Work 

The Bidder shall provide budgetary proposal covering the design, fabrication and supply the 

NO, emission control system as specified herein. Bidder shall identify the overall efficiency of 

their proposed system in reducing the NOx emissions outlined above. The equipment furnished 

shall be capable of meeting the indicated performance requirements and where possible, shall 

be the Equipment supplier's standardized design. 

Bidder shall utilize the existing emission control system to the extent possible, minimizing 

equipment modifications and downtime to install the additional NOx control system equipment. 

US Steel is also interested in developing and/or validating the proposed NOx reduction system 

technology via computational fluid dynamic (CFD) modeling or by installing a pilot unit. Bidder 

shall include an optional price to provide the either or both of these services. 
~HATCH~ 

USS Minnesota Ore Operation 

NOx Reduction Technologies 

Inquiry: H-332002-M-01 

SPECIFICATION 

Section 00 1119 

Summary of Work 

Rev. 0. Page 3 

4.1 Bidder shall identify the expected NOx emissions from their proposed system. 

4.2 Bidder shall identify whether this NOx reduction system technology has been previously 

installed in this type of pellet plant, and shall provide NOx emission data, if available. 

4.3 Bidder shall identify how the NOx reduction system will be monitored and controlled, including 

adjustments required based on varying process parameters and NOx emissions rates. 

4.4 Bidder shall offer as an option the engineering services required to provide a CFD model to 

develop the proposed NOx reduction system technology prior to full-scale installation. 

4.5 Bidder shall offer as an option a pilot type unit capable of validating the proposed NOx 

reduction system technology prior to full-scale installation. 

4.6 Bidder shall identify the proposed NOx reduction technology, including all key operating design 

parameters, operating costs, utility consumption, injection chemical usage, NOx reduction 

efficiency, etc. 

4. 7 Bidder shall identify whether the technology is expected to be capable of reducing any other 

emissions typical of this application such as SOx, mercury, or carbon monoxide. 

4.8 Bidder shall provide a preliminary project schedule for completing the NOx emission system 

upgrades, including any and all CFD modeling and pilot system installation. 

4.9 Bidder shall provide budgetary costs covering the proposed NOx emission control system, 

including proposed CFD modeling and/or pilot testing. 
Dryer D1 

(!) 

Waste Gas 

Stack 

Gas Flow Rates: 

Waste Gas 

Fan 

- actual: (acfm 

Mass Flow Rates: 

- dry gases: (lbs/min 

- water vapor: (lbs/min 

Gas Temperature: (deg F) 

Gas Density: (lbs/ft3) 

Static Pressure: ("wg) 

Dryer D2 

Scrubber 

System 

(!) 

Waste Gas 

Stack 

550,000 

32,000 

2,600 

120 

0.063 

0.50 

0 

Preheat 

Air 

(1A& 18) 

550,000 

19,003 

148 

600 

0.035 

-15.2 

Exhaust 

Fan 

1A& 16 

0 

Recoup 

Flow 

412,468 

7,619 

143 

1,630 

0.018 

-0.55 

0 

Cooler Vent 

Stack 

270,580 

7,580 

100 

930 

0.027 

0.26 

,Inputs: 

.. Biomass 

- Natural 

Gas 

- Fuel Oil 

Cooler 

Zone1 

Exhaust 

Fan 3A 

® 

0 

Cooler 

Zone2 

0 

0 

Cooler lndraft Air 

Zone 1 Zone 2/3 

(FAN 3A) (FAN 38) 

167,470 199,220 

12,378 14,724 

129 154 

69 69 

0.072 0.072 

-2.1 -2.1 

0 

Cooler Vent 

Stack 

Cooler 

Zone3 

Exhaust 

Fan 36 

US Steel Minntac- Line 5 

Hatch Project No. 332002 

SK1 - Process Flow Diag. 
~HATCH~ 

USS MINNESOTA ORE OPERATIONS 

NOx REDUCTION TECHNOLOGIES 

INQUIRY: H-332002-M-01 

1. Technical Questionnaire 

Name of Bidder/Proposal No.: 

Date of Proposal: 

Contact's Name: 

Contact's Phone Number 

Contact's E-Mail Address 

Type of NOx emission reduction technology proposed. 

Expected NOx reduction efficiency(%). 

Preliminary list of capital equipment included in proposal. 

Preliminary cost of capital equipment included in proposal. 

Estimate of equipment installation cost included with proposal. 

Estimate of operating cost, incl. chemicals included in proposal. 

Annual maintenance cost included with proposal. 

Operational improvements resulting from the installation of NOx 

emission reduction equipment detailed in the proposal. 

Reduction of other emissions resulting from the installation of 

NOx emissions reduction equipmeint. 

-SOx 

-CO 

-Mercury 

- Other (specify) 

Should low NOx burners be consided in addition to NOx 

emissions reduction equipment? 

Details of proposed pilot system included in proposal. 

Details of proposed CFD modeling outlined in proposal. 

Preliminary Project Schedule included with proposal offering. 

1509001 

US Sleel Minnlac · Seclion 00 43 40 10 Technical 

Ouastion.Doc 

'1\7::,1 Wo!klngTogelher ~ SAFUY 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Specification 

SECTION: 00 43 40.10 

TECHNICAL QUESTIONNAIRE 

REV. 0, PAGE: 1 

% 

No 

No 

No 

No 

No 

No 

% 

% 

% 

% 

No 

No 

No 

No 

©Hatch 2006/03 X 
US Steel Minntac 

Hatch Project No.332002 

November 2, 2008 

Urea Usage Requirements: 

Urea Usage: 

2NOx + (NH2J,CO + %02 = 2N2 + 2H20 + C02 

470 lbs NOxlhr 

7805 hrs/yr 

3,668,350 lbs NOxlyr 

1834 Ions NOxlyr 

60 lbs urea/lb mole urea 

31.6 lbs NOxllb mole NOx 

2 lb moles NOxllb mole urea 

Urea; 470 lbs NOxlhr I (31.61bs NOxl mole NOx) I (2 moles NOxl mole urea) • 60 lbs urea/ mole urea 

Urea Solution: 

NOx Removal: 

NOx Removal Costs: 

; 446.2 lbs urea/hr 

50 % urea solution (by weight) 

1.14 specificgravity 

9.5 lbs total/gal 

4.8 lbs urea/gal 

93.9 gal/hr 

1.6 gal/min 

732,595 gal/yr 

50% NOx removal efficiency (expected) 

470 lbs NOx/hr (average level) 

235 lbs NOxlhr removed 

917 lons/yrremoved 

$1.25 per gal urea (50% solution) 

$915,744 peryear 

$999 per ion NOx removed 
NALCO 

Mobotec~ 

U.S. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

Mt. Iron, Minnesota 

Nalco Mobotec Proposal 08-0437 Preliminmy Budgetary 

NALCO 

Mobotec~ 

November 21, 2008 

U.S. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

Mt. Iron, Minnesota 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

Proposal No. 08-0437 

N alco MobotecSystemTM 

For 

NOx Reduction 

November 21,2008 

PRELIMINARY BUDGETARY 

Physical Address: 

2540 Camino Diablo, Suite 200 

Walnut Creek, California 94597-3933 

Page 1 of 19 

.. Confidential & Proprietary Information .. 

Mailing Address: 

Post Office Box 2025 

Orinda, California 94563 

This information is proprietary and confidential and shall not be copied, disclosed or shared with parties other than those addressed without specific written 

authorization by Nalco Mobotec. All state and federal laws governing such information, copy writes, and trademarks shall apply. All rights reserved. 
NALCO 

Mobotec~ 

US. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

MI. Iron, Minnesota 

Nalco Mobotec Proposal 08-0437 

The Nalco Mobotec Solution 

Preliminary Budgetmy November 21, 2008 

Nalco Mobotec is currently preparing to perform a CFD modeling study of the Minntac 

pelletizing line #5. This preliminary budgetary proposal outlines the mostly likely solutions for 

optimum NOx reduction for the pelletizing line. Testing or modeling of the unit has yet to 

begin. Without performing the initial HVT testing as a minimum, the solutions outlined in this 

proposal are extremely preliminary and subject to change after testing and modeling. 

This proposal outlines the likely Nalco Mobotec Systems required to meet the NOx reduction 

goals at Minntac. Include are brief descriptions of the Rotamix System and ROFA System, as 

well as expected performance. A preliminary general arrangement ofthe Nalco Mobotec System 

is included as Exhibit 1. A proposal for a mercury capture demonstration test using MerControl 

and a combination ofMerControl and Activate Carbon Injection (ACI) is included in Exhibit 2. 

The Nalco Mobotec Rotamix Description 

The Rotamix System for NOx reduction consists of a reagent delivery system including a liquid 

concentrate urea storage tank, urea transfer pump skid, urea dilution (batch mixing) tank, urea 

metering pump skid, and delivery lines. The delivery lines traverse the kiln up to the Rotamix 

injection lances. The dilution water and reagent are mixed inside the Rotamix urea dilution tank, 

and the diluted urea is delivered to the injection lances through the urea metering pump skid. All 

urea tanks and piping shall be heat traced and insulated. The Rotamix injectors consist of 

delivery air, cooling air, humidification water, and diluted reagent mixture. 

Through automation and on-site tuning, the Rotamix System preferentially introduces reducing 

chemicals where the temperature is most favorable for pollution reduction. This considerably 

reduces chemical consumption and lowers chemical slippage by increasing the efficiency of 

reactivity through mixing. Relative to other SNCR systems, Rotamix can decrease recurring 

chemical costs by up to 50%. The Rotamix System is sufficiently flexible to utilize ammonia 

and/or urea for NOx control. 

The Nalco Mobotec Rotamix (SNCR) System is designed to run year around. Minor 

maintenance may be required, such as keeping the injection lance nozzles clean, but shut downs 

will not be necessary to keep the system operational. Some of our customers that operate our 

Rotamix System year round schedule their major unit outages once every eight years. Annual 

maintenance cost is expected to be minimal. 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

Physical Address: 

2540 Camino Diablo, Suite 200 

Walnut Creek, California 94597-3933 

Page 2 of 19 

••Confidential & Proprietary Information** 

Mailing Address: 

Post Office Box 2025 

Orinda, California 94563 

This Information Is proprietary and confidential and shall not be copied, disclosed or shared with parties other than those addressed without specific written 

authorization by Nalco Mobotec. All stale and federal laws governing such information, copy writes, and trademarks shall apply. All rights reserved. 
NALCO 

Mobotec~ 

U.S. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

Mt. Iron, Minnesota 

Nalco Mobotec Proposal 08-0437 Preliminary Budgetary November 21, 2008 

The major equipment for the urea concentrated reagent feed, metering, dilution, distribution, and 

kiln injection system are: 

Rotamix Fan - The Rotamix fan is sized to use a small amount of ambient air to deliver the 

reagent into the furnace and requires a small motor. The Rotamix fan shall be approximately 15 

HP. 

Urea Injection Devices - The urea injection lances are used to inject urea and water into the 

preheater. Location of the lances is determined by CFD modeling. 

Urea Tank- The urea storage tank would be an open vented tank of FRP construction. 

Urea Dilution Tank- The dilution tank would be an open vented tank ofFRP construction. 

Urea Transfer Pumps - The urea pumps are multi-stage centrifugal pumps for transfer the urea 

from the urea storage tank to the urea dilution tank. 

Urea Metering Pumps - The urea pumps are multi-stage centrifugal pumps for transfer the urea 

from the urea storage tank to the urea dilution tank. 

Urea and Water Filters- The filter elements are polypropylene with a I micron rating. The filter 

housing is constructed of stainless steel. 

Water Pumps -There are two multi-stage centrifugal pumps on each skid for dilution and 

humidification water. 

The utility requirements are: 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

• Air: 80-100 psig supply pressure (clean, dty, oil free) 

• Electrical (typical): 

o Fan Motor, 480 V, 3 phase, 60Hz 

o Pump Motors, 480 V, 3 phase, 60 Hz 

o Pump Motors, 230/460 V, 3 phase, 60 Hz 

o Damper Motors, 120 V, Single phase, 60 Hz 

o Instrument, 110 V, Single Phase, 60Hz 

o Heat tracing, 110 V, Single Phase, 60 Hz 

o Enclosures: NEMA 4 

Physical Address: 

2540 Camino Diablo, Suile 200 

Walnut Creek, California 94597-3933 

Page 3 of 19 

••eonfidenUal & Proprietary Information** 

Mailing Address: 

Post Office Box 2025 

Orinda, California 94563 

This information is proprietary and confidential and shall not be copied, disclosed or shared with parties other than those addressed without specific written 

authorization by Nalco Mobotec. All slate and federal laws governing such information, copy writes, and trademarks shall apply. All rights reserved. 
NALCO 

Mobotec~ 

U.S. Steel Minnesota Ore Operations 

Minnlac Iron Pelletizing Plant 

Mt. Iron, Minnesota 

Nalco Mobotec Proposal 08-0437 

• Urea: 

Preliminmy Budge/my 

o 40%-50% (wt) Urea 

o 2.5-4gpm 

• Demineralized water for dilution 

• Service water for humidification 

Nalco Mobotec ROFA System 

November 21, 2008 

Rotating Opposed Fired Air, or ROFA, is a state-of-the-art furnace staging and NOx reduction 

system. The bulk flow upward through the furnace is set in rotation with custom-designed 

strategically placed air nozzles. The overall effect is increased turbulent mixing and bulk rotation 

in the entire furnace. This improves gas temperature distribution, species distribution, heat 

absorption, CO oxidation, and particle burnout in the upper furnace. 

Mixing and rotation prevents bulk laminar flow and enables the whole volume of the furnace to 

be used more effectively for the combustion process, as well as the sorbent mixing process. The 

ROFA swirl reduces maximum reaction temperature, reduces NOx formation, bums out carbon 

more efficiently, and increases convective heat absorption, which in combination may improve 

the overall kiln efficiency. By mixing the combustion air more effectively, ROFA also reduces 

the need for surplus excess air. This results in less cooling of the furnace due to unused 

combustion air, further increasing heat absorption efficiency. 

The ROFA boxes are strategically placed along the furnace walls to optimize NOx reduction and 

combustion intensity. Ultimately, the performance and functionality of ROFA System works in 

conjunction with and is dependant on the overall furnace geometry and operation. The ROFA 

air is thereby injected in a manner which creates a rotational flow in the combustion zone. The 

ROFA System results in the following combustion improvements: 

1> Reduced oxygen availability in the primmy combustion zone, reducing the opportunity for NOx 

formation. 

1> Turbulent mixing in middle and upper firrnace region allowing completion of the combustion 

process in this secondary zone, reducing LOI and CO levels 

1> More uniform temperature profile and heat distribution in the middle and upper firrnace, 

reducing thermal stress and improving kiln efficiency. 

1> Evening offirel-air distribution reducing pockets of low 0 2 and high CO/combustibles, allowing 

the unit to be operated at/ower levels of excess 02 for improved efficiency. 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

Physical Address: 

2540 Camino Diablo, Suite 200 

Walnut Creek, Caiirornia 94597-3933 

Page 4 of 19 

uconfidential & Proprietary lnformationu 

Mailing Address: 

Post Office Box 2025 

Orinda, California 94563 

This information is proprietary and confidential and shall nol be copied, disdosed or shared with parties other than those addressed without specific written 

authorization by Nalco Mobotec. All state and federal laws governing such information, copy writes, and trademarks shall apply. All rights reserved. 
~~6£~c~ U.S. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

Mt. Iron, Minnesota 

Nalco Mobotec Proposal 08-0437 Preliminmy Budgetary November 21, 2008 

ROFA Fan- the ROFA fan(s) are sized to deliver the approximate equivalent of 10% of the total 

air flow. The ambient air supply to the ROFA fan is controlled by an inlet vane or louver 

damper, and the air to the burners will be subsequently reduced via the control system to ensure 

that equivalent total air flow remains constant. The ROFA design may entail mounting of the 

fans on the kiln. 

ROFA Nozzles 

The ROFA nozzles are designed and engineered by Nalco Mobotec. The boxes are designed to 

minimize pressure drop throughout the dueling system, and deliver high velocity air into the kiln. 

The ROFA boxes are located on the kiln based on furnace geometry and CFD modeling. Nalco 

Mobotec expects approximately 4-8 ROFA nozzles. 

The utility requirements are: 

• Electrical (typical): 

o Fan Motors, 480 V, 3 phase, 60 Hz 

Nalco Mobotec Burner Modifications 

Nalco Mobotec shall investigate the potential for modifying the existing burners for further NOx 

reduction through staging. This will be studied during the CFD modeling stage. Burner 

modifications are not included in the cutTen! performance and pricing; however, the expectation 

would be to achieve another 10% NOx reduction with minimal cost (in comparison to the overall 

project costs). 

Nalco Mobotec System Expected Performance 

Nalco Mobotec expects to reduce NOx emissions significantly. The numbers below represent 

our expected performance, subject to change during testing and modeling. 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

Nalco Mobotec System Expected % Reduction 

Rotamix System 35-55% 

ROFA System 10-20% Additional 

Physical Address: 

2540 Camino Diablo, Suite 200 

Walnut Creek, California 94597-3933 

Page 5 of 19 

'*Confidential & Proprietary Information*" 

Mailing Address: 

Post Office Box 2025 

Orinda, California 94563 

This Information is proprietary and confidential and shall not be copied, disclosed or shared with parties other than those addressed without specific written 

authorization by Nalco Mobofec. All slate and federal laws governing such information, copy writes, and trademarks shall apply. All rights reserved. 
NALCO 

Mobote-c~ 

US. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

MI. Iron, Minnesota 

Nalco Mobotec Proposal 08-0437 Preliminary Budgetary 

Nalco Mobotec System Expected Schedule 

November 21, 2008 

The functional activities listed below may be performed concurrently in many cases. Overall 

project length is expected to take 8-12 months upon completion of CFD modeling. 

Engineering and Design -

Equipment Supply -

Installation -

Commission/Start-up 

Tuning & Optimization 

20-26weeks 

26-30 weeks 

4-8 weeks 

2-4weeks 

4-6 weeks 

Nalco Mobotec System Costs 

N alco Mobotec offers the following pricing for the engineering, equipment, controls, guarantee, 

and startnp of the Nalco Mobotec System. Equipment installation is not included in the Nalco 

Mobotec scope of supply. Nalco Mobotec pricing is subject to all terms listed in the "Proposal 

Notes" section that follows this proposal. All pricing is per unit. 

Nalco Mobotec Rotamix System 

Mechanical Installation, budgetary 

Nalco Mobotec ROFA/Rotamix System 

Mechanical Installation, budgetary 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

Physical Address: 

2540 Camino Diablo, Suite 200 

Walnut Creek, California 94597-3933 

Page 6 of 19 

••eonfidenUal & Proprietary Information*" 

Cost 

$1,327,620 

$ 325,350 

Cost 

$2,227,332 

$ 599,850 

Mailing Address: 

Post Office Box 2025 

Orinda, California 94563 

This information Is proprietary and conftdential and shall not be copied, disclosed or shared with parties other than those addressed without specific written 

authorization by Nalco Mobolec. AU state and federal laws governing such information, copy writes, and trademarks shall apply. All rights reserved. 
NALCO 

Mobotec~ 

U.S. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

MI. Iron, Minnesota 

Nalco Mobotec Proposal 08-0437 Preliminary Budgetary November 21, 2008 

Exhibit 1: General Arrangement of N alco Mobotec System 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

Physical Address: 

2540 Camino Diablo, Suite 200 

Walnut Creek, California 94597-3933 

Page 7 of 19 

*'Confidential & Proprietary Information** 

Mailing Address: 

Post Office Box 2025 

Orinda, California 94563 

This Information is proprietary and confidential and shall not be copied, disdosed or shared with parties other than those addressed without specific written 

authorization by Nalco Mobotec. All state and federal laws governing such information, copy writes, and trademarks shall apply. All rights reserved. 
(Preliminary) 

Rota mix 

Urea Transfer 

Pump Skid 

~otamix Damper --------

Diluted 

Urea 

Tank 

Rota mix 

Fan 

Pump Skid 

Rotamix Ports (x24, 3 walls) 

lAFan 

Waste 

Gas 

r ;: Ustack 

ROFA NOZZLES (x8) 

18 Fan 

ROFA FAN (x2) 

Kiln Mounted 

Cooler Zone 1 I Cooler Zone 2 I Cooler Zone 3 
NALCO 

Mobotec~ 

US. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

MI. Iron, Minnesota 

Nalco Mobotec Proposal 08-0437 Preliminary Budgetary November 21, 2008 

Exhibit 2: Nalco Mobotec MerControl/ACI Demonstration Test 

Nalco Mobotec proposes the demonstration of two mercury capture technologies, MerControl 

and MerControll ACI, to determine the optimum combination for achieving a high level of 

mercury capture at U.S. Steel Minntac. 

MerControl Technologv 

MerControl is a method of capturing mercmy, which includes injecting a molecular halogen or 

thermolabile molecular halogen precursor, such as calcium hypochlorite or calcium bromide, 

able to decompose to form molecular halogen at flue gas temperature. The molecular halogen 

converts elemental mercury to mercuric halide, which is absorbable by alkaline solids such as 

sub bituminous or lignite coal ash, alkali fused bituminous coal ash, and dry flue gas 

desulphurization solids, capturable in whole or part by electrostatic precipitators (ESPs), 

baghouses (BHs), and fabric filters (FFs), with or without subsequent adsorption by a liquid such 

as a flue gas desulphurization scrubbing liquor. In essence MerControl is a patented technology 

(exclusively licensed to Nalco Mobotec) that covers the injection of an oxidizer into the furnace 

to aid mercmy oxidation, increasing formation of particulate mercury and subsequent capture 

rates across the existing ESP. 

Activated Carbon Injection 

The U.S. Environmental Protection Agency recognizes Activated Carbon Injection as the most 

widely used and widely studied method of capturing mercury. Powdered Activated Carbon is 

injected into the correct temperature zone prior to the gas reaching the backend particulate 

collection device. The carbon binds with the mercury in the gas in the duct and in the 

particulate collection device. Used in combination with MerControl, Nalco Mobotec expects to 

achieve a high level of mercury capture at U.S. Steel Minntac. 

Description of Proposed Demonstration 

The mercmy capture demonstration will be separated into three distinct testing phases, with each 

test lasting two weeks in duration. The first test will establish the baseline mercmy capture. 

After the baseline testing, the equipment required for the MerControl and ACI injection systems 

shall be installed. 

In order to minimize the costs for this demonstration test, N alco Mobotec proposes to utilize our 

temporary test equipment for the storage, transfer and injection of the MerControl and ACI into 

the kiln. This temporary equipment will be removed upon the completion of the test program. 

The halogen that will be used for testing is calcium bromide. The system would be 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

Physical Address: 

2540 Camino Diablo, Suite 200 

Walnut Creek, California 94597-3933 

Page 9 of 19 

uconfidentlal & Proprietary lnformationH 

Mailing Address: 

Post Office Box 2025 

Orinda, California 94563 

This Information is proprietary and confidential and shall not be copied, disclosed or shared with parties other than those addressed without specific written 

authorization by Nalco Mobolec. All state and federal laws governing such information, copy writes, and trademarks shall apply. All rights reserved. 
~~~£~c~ U.S. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

Mt. Iron, Minnesota 

Nalco Mobotec Proposal 08-0437 Preliminary Budgetary November 21, 2008 

commissioned, tuned, evaluated and tested over a demonstration period of four weeks, two 

weeks for MerControl and two weeks for MerControl and ACL 

Demonstration Test Goals 

1. Demonstrate Mercuty Capture 

The mercury emission level will be determined by EPA Method 30B carbon trap sampling 

during the test period and the analysis will be performed by Nalco Mobotec. The input 

mercury level will be determined by the coal mercury content in ppmw as determined by an 

independent laboratmy combined with the calculated fuel input and the mass & energy 

balances for the unit obtained from plant data. 

2. Kiln Operation 

Demonstrate no adverse effects on current kiln operations due to MerControl and ACI 

injection into the furnace. 

Nalco Mobotec Demonstration Tasks 

The following list of tasks is intended to provide a snapshot look at the major tasks to be 

accomplished by Nalco Mobotec and U.S. Steel during the mercury capture demonstration. 

A. Two weeks of baseline mercury capture testing. 

B. Furnish the temporary equipment for halogen storage, transfer and injection. 

C. Install ACI device in duct prior to the scmbber. 

D. Furnish the temporary equipment for Activated Carbon (AC) storage, transfer, and 

injection. 

E. Furnish and deliver the halogen to the site. 

F. Furnish and deliver ACto site. 

G. Perform system start-up, tuning and optimization. 

H. Conduct mercury capture testing for two weeks of MerControl. 

I. Conduct mercury captme testing for two weeks ofMerControl/ACI. 

J. Submit a technical report of the results. 

Nalco Mobotec Demonstration Schedule 

N alco Mobotec is prepared to begin the demonstration project immediately. The first step is the 

baseline testing at the plant, which will be schedule as soon as practical after notice to proceed. 

Baseline Testing 

Engineering 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

2 weeks 

4weeks 

Physical Address: 

2540 Camino Diablo, Suile 200 

Walnul Creek, California 94597-3933 

Page 10of19 

**Confidential & Proprietary Information•• 

Mailing Address: 

Post Office Box 2025 

Orinda, California 94563 

This information is proprietary and confidential and shall not be copied, disclosed or shared with parties other than those addressed without specific written 

authorization by Nalco Mobotec. All state and federal laws governing such information, copy writes, and trademarks shall apply. All rights reserved. 
~t~~t~c~ U.S. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

MI. Iron, Minnesota 

Na/co Mobotec Proposal 08-0437 Prelimina/y Budgela/y 

Installation (mechanical and electrical) 

Commission MerControl 

MerControl Testing 

Commission ACI 

MerControl/ACI Testing 

Report and Technical Presentation 

1-2 weeks 

1 week 

2 weeks 

1 week 

2 weeks 

4 weeks 

Scope of Supply and Division of Responsibility 

November 21, 2008 

The following list of deliverables is intended to convey the scope of supply that is included in the pricing 

for the mercmy capture demonstration. 

Item Description 

Engineering 

P&ID 

Temporary equipment arrangement drawings 

Temporary equipment electrical requirements 

Prepare and submit a technical report upon completion of demonstration 

Mobotec-furnished equipment 

Temporary set of test equipment that includes: 

Temporary halogen (Ca8r2) storage tank 

Temporary halogen (Ca8r2) metering pumps and piping 

Halogen (Ca8r2) for the defined demonstration period 

Temporary AC storage silo 

Temporary AC feed and injection system 

AC for the defined demonstration period 

Field instrumentation 

Onsite support 

Job trailer onsite 

Demonstration test manager onsite 

Equipment functional testing 

System tuning and optimization 

On site mercury measurement via EPA 308 carbon trap sampling 

On site mercury analysis during baseline, tuning and optimization of 

system 

Coal and ash analysis sample collection for mercury content during 

baseline, tuning and ootimization 

Items furnished by others 

I Halogen unloading from truck to tank 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

Physical Address: 

2540 Camino Diablo, Suite 200 

Walnut Creek, California 94597-3933 

Page 11 of 19 

uConfidential & Proprietary lnformaUon*" 

Furnished by 

Nalco Mobotec 

Nalco Mobotec 

Nalco Mobotec 

Nalco Mobotec 

Nalco Mobotec 

Nalco Mobotec 

Nalco Mobotec 

Nalco Mobotec 

Nalco Mobotec 

Nalco Mobotec 

Nalco Mobotec 

Nalco Mobotec 

Nalco Mobotec 

Nalco Mobotec 

Nalco Mobotec 

Nalco Mobotec 

Nalco Mobotec 

Nalco Mobotec 

Nalco Mobotec 

US Steel Minntac 

Mailing Address: 

Post Office Box 2025 

Orinda, California 94563 

This information Is proprietary and confidential and shall not be copied, disclosed or shared with parties other than those addressed without specific written 

authorization by Nalco Mobo!ec. All slate and federal laws governing such Information, copy writes, and trademarks shall apply. All rights reserved. 
NALCO 

Moootec ~ U.S. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

Mt. Iron, Minnesota 

Nalco Mobotec Proposal 08-0437 Preliminary Budgetary 

Item Description 

AC unloading to storage silo 

Coal and ash analysis for mercury content during demonstration testing 

On site mercury measurement via EPA 308 carbon trap sampling during 

performance testino 

Mercury continuous emission monitor (if elected) 

Mechanical installation of temporary piping 

Electrical installation of temporary injection system equipment 

Electrical equipment and service (MCC, starters, disconnects, wire, 

conduit, etc.·) 

Modifications to power system if required to accommodate new motors 

Refractory 

Configuration and programming of existing DCS if required 

Provide site area for equipment receiving and storage prior to installation 

Coal and ash sample collection during demonstration testing 

Plant historical data for demonstration period 

November 21, 2008 

Furnished by 

US Steel Minntac 

US Steel Minntac 

US Steel Minnlac 

US Steel Minntac 

US Steel Minntac 

US Steel Minntac 

US Steel Minntac 

US Steel Minntac 

US Steel Minntac 

US Steel Minntac 

US Steel Minntac 

US Steel Minntac 

US Steel Minntac 

1. Nalco Mobotec will furnish and deliver to the U.S. Steel Minntac the defined predetermined 

supply of halogen required for the full length of the demonstration. 

2. Nalco Mobotec will furnish and deliver to the U.S. Steel Minntac the defined predetermined 

supply of AC required for the full length ofthe demonstration. 

3. During the baseline testing, system tuning and optimization, and demonstration testing N alco 

Mobotec will provide EPA Method 30B carbon trap sampling and analysis to measure 

mercury levels. During the initial weeks of the demonstration, the carbon trap analyzer will 

be setup on site to allow prompt feedback of results during tuning and optimization of the 

system. Once the system is optimized, carbon trap samples will be taken periodically on the 

stack at a location similar to that of a mercury analyzer. These traps will be analyzed on site 

by Nalco Mobotec. 

4. The performance goals for this demonstration test are based on the percentage of mercury 

capture from the input levels of the fuel-bound mercury. Thus whenever carbon traps are 

being taken it will also be necessary to capture coal and ash samples representative of the 

current operating conditions. These coal and ash samples will be sent out to an independent 

laboratory to analyze their mercury content. If U.S. Steel wishes to include continuous 

mercury monitoring during the demonstration, Nalco Mobotec will assist in processing the 

data collected by the CEMS. We caution, however, that the available CEMS technology 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

Physical Address: 

2540 Camino Diablo, Suile 200 

Walnut Creek, California 94597-3933 

Page 12 of 19 

**Confidential & Proprietary Information*' 

Mailing Address: 

Post Office Box 2025 

Orinda, Calirornia 94563 

This Information Is proprietary and confidential and shall not be copied, disclosed or shared with parties other than those addressed without specific written 

authorization by Nalco Mobotec. All state and federal laws governing such Information, copy writes, and trademarks shall apply. All rights reserved. 
NALCO 

Mobotec~ 

U.S. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

Mt. Iron, Minnesota 

Nalco Mobotec Proposal 08-0437 Preliminary Budgetary November 21, 2008 

requires a high-level of attention to assure proper functionality. A trained CEMS technician 

would need to be assigned virtually full time for such data to be useful for perfonnance 

evaluation. Even if a mercury-CEMS is in place during the demonstration, evaluation of the 

halogen system performance for testing confirmation purposes will be based on the data from 

the carbon trap analysis and corresponding coal sample analysis. 

Nalco Mobotec System Costs 

Nalco Mobotec pricing is subject to all terms listed in the "Proposal Notes" section that follows 

this proposal. 

Cost 

Nalco Mobotec Mercmy Capture Demonstration $298,679 

Note: Final installation of the MerControl System shall require a licensing agreement between 

U.S. Steel and Nalco Mobotec. 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

Physical Address: 

2540 Camino Diablo, Suite 200 

Walnut Creek, California 94597-3933 

Page 13 of 19 

uconfidentlal & Proprietary Information** 

Mailing Address: 

Post Office Box 2025 

Orinda, California 94563 

This Information Is proprietary and confidential and shall not be copied, disclosed or shared with parties other than those addressed without specific written 

authorization by Nalco Mobotec. All stale and federal laws governing such Information, copy writes, and trademarks shall apply. AU rights reserved. 
~~~~t~c~ U.S. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

Mt. Iron, Minnesota 

Nalco Mobotec Proposal 08-0437 

Proposal Notes 

Pre/iminmy Budgetary November 2 I, 2008 

1. All prices quoted are in USD, and do not include sales tax nor any special or extraordinary 

taxes, permits, fees, or applicable duties. 

2. All pricing terms of this proposal shall remain valid for 60 days from the date of this 

proposal. Nalco Mobotec reserves the right to include escalation costs if incmTed during this 

time period. Any breakdown of pricing following this proposal shall be for accounting 

purposes only and not for line-item sale. 

3. Nalco Mobotec System pricing is subject to escalation, utilizing 50% via Producer Price 

Index 3312, Steel Product Manufactured From Purchased Steel, and 50% via Producer Price 

Index 54133, Engineering Services. The start of escalation will be determined based on the 

project schedule. The base index will consist of the three month average beginning in the 

month the escalation starts. Escalation will continue until the month in which the last piece 

of major equipment is purchased for the project. The ending index will consist of the three 

month average ending with the month in which the escalation ends. The contract price will 

be adjusted using the simple percentage method: Original Contract Value for Nalco Mobotec 

System x (Ending Index/Base Index). The index will be not be adjusted seasonally. The 

index adjustment shall use the latest version of the PPI data published as of the date the 

escalation ends. The price adjustment to account for escalation shall be made following the 

181

h day of the month preceding the end of escalation. Index data shall be as per the Bureau 

of Labor Statistics PPI indexes noted herein, and as published on the BLS website 

(www.bls.gov/ppilhomelhtm). In the rare case that the index drops, pricing shall remain 

unchanged. Escalation will be invoiced net 30 days, after the final escalation cost is 

determined. 

4. Perf01mance guarantees and pricing are based on stated and available information as 

described herein. Nalco Mobotec reserves the right to adjust guaranteed and expected 

performance prior to commencement of equipment procurement and installation and prior to 

completion of modeling and preliminary engineering analysis. 

5. U.S. Steel Minntac shall provide all temporary trailer power and power sources for use at 

site. 

6. U.S. Steel Minntac shall supply office space and temporary toilets for Nalco Mobotec on-site 

personnel. 

7. Design and specification ofNalco Mobotec System shall be by Nalco Mobotec. 

8. Nalco Mobotec does not recommend operating equipment, existing or new, above the 

manufacturer's nameplate rating. The Nalco Mobotec technology is designed to operate 

within acceptable design parameters. 

9. Nalco Mobotec System installation may block some walkways. Walkways will be relocated 

where reasonably feasible. Additional platforms are not included in this proposal. 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

Physical Address: 

2540 Camino Diablo, Suite 200 

Walnut Creek, California 94597-3933 

Page 14 of 19 

**Confidential & Proprietary lnformatlonH 

Mailing Address: 

Post Office Box 2025 

Ortnda, California 94563 

This information is proprietary and confidential and shall not be copied, disclosed or shared with parties other than those addressed without specific written 

authorization by Nalco Mobotec. All state and federal laws governing such information, copy writes, and trademarks shall apply. All rights reserved. 
~~~~~c~ US. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

Mt. Iron, Minnesota 

Nalco Mobotec Proposal 08-0437 Preliminary Budgetary November 21, 2008 

10. Kiln outer casing cutouts will be limited to no more than one foot outside the line of Rotamix 

box installation. 

11. All foundations assume a 3-foot re-enforced slab foundation. 

12. If Nalco Mobotec furnishes a process control system to control the Nalco Mobotec Systems, 

Nalco Mobotec's scope of supply includes the control system hardware, software, application 

programming and wiring diagrams. Installation and wiring of the control system is excluded. 

13. The Nalco Mobotec-furnished process control system (PCS) (if selected) will require 

interface to existing kiln control system. The PCS can be interfaced via hardwired signals or 

a Modbus data communication link. Nalco Mobotec to provide all necessary infmmation for 

integration with existing control system and equipment. Owner to make available the 

required signals and perform any necessary integration I tie-in work with existing plant 

controls and instrumentation. Typical signals required include kiln steam flow as a load 

index, combustion air flows, wind box pressure, 02 and unit-specific emissions data (CO, 

NOx, S02, PM, and opacity). 

14. Control and instrumentation devices needed shall be as identified and furnished by Nalco 

Mobotec. 

15. Electrical: Nalco Mobotec's proposal does not include electrical engineering, design, 

equipment and installation. Nalco Mobotec will furnish electrical requirements and details 

for all Nalco Mobotec-furnished equipment, and will provide technical assistance to U.S. 

Steel Minntac for electrical design and installation issues. 

16. Hazardous materials handling, removal or abatement and paint removal to be provided by 

others. 

17. Duct supports to be tie rods with strategically located sway bracing. Flexible fabric and metal 

expansion joints and /or spring hangers will be used where determined necessary by Nalco 

Mobotec and as detailed by Nalco Mobotec. 

18. Nalco Mobotec will perform duct layout and routing. All routings will be done in the most 

efficient manner possible over the shortest distance possible to avoid significant pressure 

loss. Although Nalco Mobotec will endeavor to avoid interferences, obstructions or conflicts 

may occur. Design and re-location of interferences is not included in this proposal and shall 

be by others. 

19. N alco Mobotec has not included new access platforms or modifications to existing access 

platforms as part of this proposal. 

20. Structural members and ductwork provided by Nalco Mobotec shall be furnished painted. 

Equipment skids I equipment to be furnished with standard factory finish. Touch up paint, 

including duct field weld areas, is excluded. 

21. Nalco Mobotec has not included Rotamix manual valves, fittings, tubing, and piping. 

Rotamix manual valves, fittings, tubing, and piping shall be field run and provided by others. 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

Physical Address: 

2540 Camino Diablo. Suile 200 

Walnut Creek, California 94597-3933 

Page 15 of 19 

uconfidential & Proprietary Information*' 

Mailing Address: 

Post Office Box 2025 

Orinda, California 94563 

This Information is proprietary and confidential and shall not be copied, disclosed or shared with parties other than those addressed without specific written 

authorization by Nalco Mobotec. All state and federal laws governing such information, copy writes, and trademarks shall apply. All rights reseiVed. 
NALCO 

Mobotec~ 

U.S. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

Mt. Iron Minnesota 

Nalco Mobotec Proposal 08-0437 Preliminary Budgetary November 21, 2008 

22. All existing kiln systems and equipment are assumed by Nalco Mobotec to be in proper 

operating order. Nalco Mobotec shall not be responsible for equipment not supplied by Nalco 

Mobotec. 

23. Nalco Mobotec will require a shutdown for a minimum duration of 3 weeks for kiln tie-in 

work. 

24. Nalco Mobotec system tuning will require operation at various loading conditions over short 

time durations. Tuning will require estimated three to six week duration per kiln. Additional 

tuning time beyond six weeks duration due to schedule impacts, delays or changes caused by 

others will be charged to U.S. Steel Minntac at an additional $16501 technician day. 

25. In the event that one or more U.S. Steel Minntac kiln systems are not performing in 

accordance with manufacturers recommendations Nalco Mobotec System testing and 

completion for retention acceptance shall be performed at the most reasonable I stable I 

recordable operating level. Upon completion of testing, retention monies shall be paid as if 

all work is complete. Work remaining for tuning at other loads, if still necessary, will be 

rescheduled in accordance with contract te1ms. 

26. Nalco Mobotec will establish the testing protocol for performance acceptance testing. U.S. 

Steel Minntac to provide testing services to confirm final results and performance. N alco 

Mobotec and U.S. Steel Minntac to jointly review and approve all fuel to be used for testing 

purposes. 

27. Should Nalco Mobotec not meet guarantees during the performance test, Nalco Mobotec 

reserves the right to correct any shortfalls discovered during testing and re-mn the test. One 

re-test will be permitted without penalty. 

28. Changes to kiln operation (02 curve, bruner flows, mill biasing, etc) shall not be made 

between baseline and Nalco Mobotec Systems "ON" without input from Nalco Mobotec 

personnel. 

29. In the event that other U.S. Steel Minntac system changes I revisions are implemented 

concurrent with Nalco MobotecSystem improvements the following conditions shall apply: 

Unstable or incorrect unit operation necessitating additional Nalco Mobotec tuning time shall 

be compensated in accordance with the terms identified. Unstable or incorrect unit operation 

extending beyond Nalco Mobotec's identified tuning period shall void all penalty te1ms. 

30. U.S. Steel Minntac is to review all Nalco Mobotec drawings for acceptance. 

31. CEMS S02, NO., CO meters and kiln 0 2 analyzer are required to be operational during unit 

tuning. This equipment or further additional emissions monitoring equipment is not included 

in this proposal. 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

Physical Address: 

2540 Camino Diablo, Suite 200 

Walnut Creek, California 94597-3933 

Page 16 of 19 

'*Confidential & Proprietary Information** 

Mailing Address: 

Post Office Box 2025 

Orinda, California 94563 

This information is proprietary and confidential and shall not be copied, disclosed or shared with parties other than those addressed without specific written 

authorization by Nalco Mobolec. All slate and federal laws governing such Information, copy writes, and trademarks shall apply. All rights reserved. 
NALCO 

Mobotec~ 

U.S. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

Mt. Iron, Minnesota 

Nalco Mobotec Proposal 08-0437 Preliminary Budgetary 

General Terms and Conditions 

Nalco Mobotec, Inc. ("Contractor") 

November 21, 2008 

I. THE PROGRAM: Contractor shall be responsible for reasonable diligence and care in providing its services 

( 11 Services") and equipment, materials, products, parts, components and other items (

11Equipment") set forth in the 

Agreement. Customer acknowledges that the ultimate success of the Services set forth in the Agreement is 

dependent upon the Customer fulfilling its obligations under the Agreement and in accordance with Contractor's 

instructions. Contractor shall not be liable for any failure to fulfill Contractor's obligations including any warranties 

and/or performance guarantees caused by Customer's lack of diligence or failure to follow Contractor instructions. 

2. ACCEPTANCE: Customer accepts all of the terms and conditions set forth in this Agreement, and agrees that 

any additional or different terms or conditions contained in Customer's purchase orders or other documents shall not 

modify this Agreement, notwithstanding any acknowledgment or acceptance of such documents by Contractor. 

3. PRICE AND PAYMENT: (a) if pricing is not set forth elsewhere in this Agreement, then the price for any order 

shall be the price in effect on the date of acceptance of the order by Contractor. 

(b) Payment te1ms shall be net 30 days unless specifically changed elsewhere in this Agreement, and payment shall 

be in lawful money of the United States, without deduction or offset. Past due invoices are subject to a late fee 

equal to the lesser of one and one-half percent per month or the highest rate permitted by law. 

4. FREIGHT. TITLE AND TAXES: Unless othenvise specified in this Agreement, Equipment shall be shipped 

F .O.B. Customer's facility, and title and risk of loss or damage shall pass to Customer upon Contractor's tender of 

the Equipment at Customer's facility. Shipping and delivery dates are approximate and subject to confirmation. 

Prices exclude and Customer shall pay any applicable sales, use, excise, VAT, GST, export and import taxes, 

assessments and similar fees. Customer shall make any necessary arrangements for importation of the Equipment 

into a count1y other than the United States. 

6. FORCE MAJEURE AND SHORTAGES: Neither party shall be liable for any failure or delay in performance 

(other than payment) which is due, in whole or in part, to any cause of any nature beyond the reasonable control of 

the party affected. If there are Equipment shortages for any reason, Contractor may allocate the available supply of 

Equipment among itself, its affiliates and its customers on whatever basis it deems practical. 

7. WARRANTIES AND LIMITATION ON LIABILITY: 

(a) Contractor warrants that equipment manufactured by Contractor and supplied hereunder shall be free from 

material defects in workmanship and materials for a period equal to the lesser of 15 months from the date of 

shipment or 12 months from the date of installation. Contractor's liability under this warranty is limited to 

repair or replacement of items proven to be defective. Equipment, which is not manufactured by Contractor, is 

subject to the original manufacturer's warranty. 

(b) Contractor warrants that Services provided will be performed in a good and workmanlike mmmer. Contractor 

will perform such Services in accordance with sound generally accepted practices in effect at the time of 

performance. 

(c) Contractor warrants that the Equipment and Services itself does not, at the time of delivery, infringe any patent 

of the United States. Customer shall give Contractor prompt written notice of any patent infringement suit or 

claim, Contractor shall control the defense or settlement of same, and Customer shall cooperate in such defense. 

Contractor's liability under this warranty is limited to such defense, and, if sale or use of the Equipment or 

Services is enjoined, refund of the price paid by Customer for such Equipment or Services (less a reasonable 

charge for use, damage and obsolescence). Contractor makes no warranty against patent infringement arising 

out of Customer's particular use of the Equipment, alone or in combinat~on with other materials; any equipment 

resulting from such use; any equipment or product manufactured for Customer according to Customer's 

specifications; or any equipment (including components and ingredients) manufactured by other than 

Contractor. 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

Physical Address: 

2540 Camino Diablo, Suite 200 

Walnut Creek. California 94597-3933 

Page 17 of 19 .. Confidential & Proprietary Information•• 

Mailing Address: 

Post Office Box 2025 

Orinda, California 94563 

This information Is proprietary and confidential and shall not be copied, disclosed or shared with parties other than those addressed without specific written 

authorization by Nalco Mobotec. All state and federal laws governing such information, copy writes, and trademarks shall apply. All rights reserved. 
~~G;t~c~ US. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

Mt. Iron, Minnesota 

Nalco Mobotec Proposal 08-0437 Preliminary Budgetary November 21, 2008 

(d) Because many factors affect Equipment application and performance and quality of Services, Contractor will be 

relying on information provided by Customer concerning its facility, operations and systems to provide 

Services. Customer shall be responsible for the accuracy of the information provided to Contractor, and 

Contractor assumes no liability or obligation for any technical advice, services or products provided by 

Contractor based on inconect information from Customer. Customer is responsible for designating appropriate 

places in its facilities and processes for delivery, storing and installing Equipment and conducting related testing 

activities. 

(e) Contractor shall not be liable for any incidental, consequential, indirect or special damages, including, but 

not limited to, lost profits and lost production, whether arising under breach of warranty or contract, 

negligence, strict liability or other tort, indemnity or any othe1· the01y of liability. In any event, Contractor's 

liability for any and all claims, damages and causes of action arising out of the sale, use, storage, delive1y or 

non-delive1y of any Equipment, performance of any Services or any warranty shall be limited to the price 

(including freight charges if paid by Customer) paid to Contractor for such Equipment or Services. In no 

event shall Contracto1·'s liability for any liquidated damages exceed 10% of the price under the Agreement. 

(f) EXCEPT FOR THE TITLE WARRANTY, THE FOREGOING WARRANTIES ARE EXCLUSIVE AND 

CONTRACTOR MAKES NO OTHER WRITTEN, ORAL, EXPRESS OR IMPLIED WARRANTIES. 

CONTRACTOR SPECIFICALLY DISCLAIMS THE WARRANTIES OF MERCHANTABILITY AND 

FITNESS FOR A PARTICULAR PURPOSE. CUSTOMER'S REMEDIES FOR BREACH OF ANY 

WARRANTY SHALL BE LIMITED TO THOSE REMEDIES DESCRIBED ABOVE. 

8. CONFIDENTIALITY: Customer shall not: (a) disclose to any third party and shall prevent third parties from 

obtaining or becoming aware of the composition, design, operation or application of the Equipment or any Services 

and the contents of this Agreement (collectively, the "Proprietary Information") without in each instance securing 

the prior written consent of Contractor; or (b) use the Proprietary Information for any purpose other than the purpose 

for which Contractor provided the Proprietary Information to Customer. Customer shall not be liable for the use or 

disclosure of information that: (a) is already in the public domain at the time of the use or disclosure; (b) becomes 

part of the public domain through no fault of CUSTOMER; (c) is disclosed to Customer by a third party having the 

right to make such disclosure; or (d) is in the possession of Customer at the time of disclosure by Contractor. 

9. INDEMNIFICATION: Contractor shall indemnify and hold harmless Customer for all losses, liabilities, costs 

(including, but not limited to, reasonable attorneys' fees), expenses and claims for personal injury or death, or 

tangible property damage (collectively, the "Claims"), to the extent proximately caused by the negligence or willful 

misconduct of Contractor. Customer shall indemnify and hold harmless Contractor for all Claims to the extent 

proximately caused by the negligence or willful misconduct of Customer. In the event of a Claim arising out of the 

joint negligence or willful misconduct of Customer and Contractor, Customer and Contractor shall be liable to each 

other and to any damaged third party in proportion to their relative degree of fault. 

10. INSURANCE: 

(a) Contractor agrees to procure and at all times maintain, for the duration of the contract, policies of insurance of 

the types and in the minimum amounts as follows: 

I. Statutory Workers' Compensation or its equivalent and Employers Liability with minimum limits of 

$2,000,000 U.S. in full compliance with all federal, province, state and/or local laws. 

2. Occmrence based Commercial General Liability Insurance with a minimum limit of $2,000,000 U.S. 

Coverage shall include broad form property damage, product/completed operations, independent 

contractors liability, blanket contractual liability, personal injury and employees as additional insured. 

3. Automobile Liability Insurance covering owned, non-owned and hired vehicles with a minimum limit 

of $2,000,000 U.S. 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

Physlcal Address: 

2540 Camino Diablo, Suite 200 

Walnut Creek, California 94597-3933 

Page 18 of 19 

uConfidential & Proprietary lnformationu 

Mailing Address: ' 

Post Office Box 2025 

Orinda, California 94563 

This Information Is proprietary and confidential and shall nor be copied, disclosed or shared with parties other than those addressed without specific written 

authorization by Nalco Mobotec. All state and federal laws governing such information, copy writes, and trademarks shall apply. All rights reserved. 
~~~~~c~ U.S. Steel Minnesota Ore Operations 

Minntac Iron Pelletizing Plant 

Mt. Iron, Minnesota 

Nalco Mobotec Proposal 08-0437 Preliminary Budget my November 21, 2008 

(b) Upon request, Contractor shall provide Customer with a certificate of insurance confirming the insurance 

coverage described above. All such Contractor certificates of insurance shall be submitted to Customer prior to 

the start of the Services at the Customer's site. Each certificate shall contain a statement that such policies will 

not be materially changed or canceled without at least thirty (30) days prior written notice to Customer. 

(c) Should Contractor subcontract any work, Contractor is obligated to ensme that each subcontractor, at a 

minimum, meets the above insurance requirements. 

11. COMPLIANCE WITH LAWS: Contractor shall comply with all applicable national and state laws and 

regulations, and all amendments thereto, including, where applicable, the Fair Labor Standards Act of 1938. 

Customer shall not resell Equipment without Contractor's prior written consent, and shall not resell, divert, 

transship, export or re-export the Equipment to any country, except in accordance with applicable national, state and 

United States laws and regulations. Customer is responsible for compliance with all environmental, health and 

safety regulations regarding its facility, operations, and equipment, including any registrations applicable to use of 

storage tanks at its facilities. 

12. TERMINATION: Either party may terminate this Agreement if (a) the other party fails to perform or meet a 

material obligation under this Agreement and (b) such default is not cured within 45 days after written notice of the 

failure. Each delivery under this Agreement shall be considered a separate and independent contract. If Customer 

fails to make a payment when due or Customer's financial condition becomes unsatisfactory to Contractor, then 

Contractor, at its option, may (a) withhold future performance until Customer cures the default or improves its 

financial condition to Contractor's satisfaction; (b) require payment in advance; or (c) terminate this Agreement. As 

a condition of termination of this Agreement for any reason Customer shall pay Contractor the applicable amount set 

forth in the Termination Schedule in the Agreement. 

13. MISCELLANEOUS: 

(a) This Agreement shall be governed by the Uniform Commercial Code and other laws of Illinois, and not by the 

United Nations Convention for the International Sale of Goods. Customer agrees that the com1s in the State of 

Illinois have exclusive jurisdiction for the resolution of disputes with respect to this Agreement. 

(b) Customer shall inform Contractor of any special or unusual safety precautions that should be taken because of 

conditions in Customer's plant or process. 

(c) Failure by either party to require strict compliance with any provision hereof shall not be construed as a waiver 

of that provision or any other provision. If any competent authority holds that any provision hereof is wholly or 

partially void or unenforceable, this Agreement shall be deemed modified to conform to applicable law and 

shall continue to be valid. 

(d) All prior and contemporaneous proposals, negotiations and agreements, written and oral, with respect to the 

transactions contemplated herein are merged into this Agreement, which constitutes the entire agreement 

between Customer and Contractor with respect to such transactions. This Agreement may not be altered, 

modified or amended except pursuant to a writing signed by both Customer and a senior executive of 

Contractor. 

(e) Contractor shall be an independent contractor with respect to the services to be performed under this 

Agreement. Contractor, its subcontractors and their respective employees shall not be deemed to be the 

servants, employees or agents of Customer. 

(f) Contractor shall be entitled to subcontract portions of the work to be performed under this Agreement provided 

that the subcontractor shall be acceptable to the Customer. 

(g) Customer consents to casual references that may identify Customer on Contractor's website or promotional 

materials, provided that Customer's participation will be sought before formal disclosures such as press releases 

which identify Customer are issued. 

(h) The Agreement may not be assigned without the express written consent of the other party. 

Nalco Mobotec 

Ph: 925.935.2500 

Fax: 925.935.2583 

Physical Address: 

2540 Camino Diablo, Suite 200 

Walnut Creek. California 94597-3933 

Page 19of19 

'*Confidential & Proprietary lnformationu 

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This Information Is proprietary and confidential and shall not be copied, disclosed or shared with parties other than those addressed without specific written 

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( E J A) Energy Systems Associates 

Proposal to Supply NOx Emission Controls for 

USS Minnesota Ore Operations 

Line No.5 

INQUIRY H-332002-M-01 

Submitted to: 

HATCH, Ltd. 

Pittsburgh, Pennsylvania 

Submitted by: 

ENERGY SYSTEMS ASSOCIATES 

Pittsburgh, Pennsylvania 

ESA Proposal No. ESA 08-2017 

October 2008 

One Veterans Way, Suite 204, Pittsburgh, PA 15106 (412) 429·2713 
TABLE OF CONTENTS 

1.0 INTRODUCTION ....................................................................................... 1 

1.1 Background on ESA ............................................................................... 1 

2.0 TECHNOLOGY OVERVIEW ...................................................................... 3 

2.1 Low NOx Combustion Modifications ....................................................... 3 

2.2 SNCR Technology .................................................................................. 4 

2.3 SCR Technology .................................................................................... 6 

2.4 NOx Oxidation/Wet Scrubbing ................................................................ 6 

2.5 ESA's Technical Recommendation ........................................................ 7 

3.0 SCOPE OF WORK/SUPPLY ..................................................................... 8 

3.1 Task 1: Baseline Testing/Evaluation ...................................................... 8 

3.2 Task 2: SNCR Demonstration Test ....................................................... 9 

3.3 Task 3: System Design with CFD Modeling ........................................ 10 

3.4 Task 4: Low NOx Combustion System Supply ..................................... 14 

3.5 Task 5: SNCR System Supply ............................................................. 15 

4.0 SCHEDULE ............................................................................................. 20 

5.0 COST ESTIMATE .................................................................................... 21 

5.1 Estimated Installation Cost ................................................................... 21 

ESAOS-2017 
1.0 INTRODUCTION 

US Steel operates an iron ore pelletizing plant at their Minnesota Ore 

Operation (Minntac) facility that includes five pelletizing lines. US Steel is 

currently investigating the feasibility of reducing nitric oxide (NOx) emission from 

the indurating process Line No. 5. Line 5 is a "grate-kiln" type system that 

employs a traveling grate, a rotary kiln and annular cooler. Line No. 5 averages 

approximately 290 million Btu's per hour of heat input consisting of about 60% 

natural gas and 40% biomass fuel. The average NOx emission rate is about 470 

pounds per hour. This is equivalent to about 1.6 lbs of NOx per million Btu of fuel 

fired. This is a very high NOx emission rate in comparison to steam boiler 

combustion systems which typically have uncontrolled NOx emission rates in the 

range of 0.4 to 0.8 lbs/MMBtu. 

Energy Systems Associates (ESA) of Pittsburgh, Pennsylvania is pleased 

to provide the following budgetary proposal for the design, fabrication and supply 

of a nitric oxide (NOx) emission control system for Line No. 5 at the US Steel 

Minnesota Ore Operation Facility in Mt. Iron, Minnesota. 

1.1 Background on ESA 

Energy Systems Associates (ESA) is an engineering and consulting firm 

giving special emphasis to helping industry with energy and environmental 

related problems including combustion engineering, air pollution control 

technology, and energy conservation and utilization. The company was founded 

in 1981 and is headquartered in Pittsburgh, Pennsylvania. 

Members of the professional staff of ESA have many years of consulting 

engineering experience with a variety of organizations. Examples of their 

collective experience include: 

1 ESAOB-2017 
• Boiler and emissions testing. 

• Computational Fluid Dynamics Modeling 

• Design and implementation of over fired air systems 

• Design and implementation of flue gas recirculation systems 

• Low NOx burner design and implementation 

• Gas reburn system design and implementation 

• Selective non-catalytic NOx reduction system design and installation 

• Evaluating and recommending modifications for fuel switching. 

• Developing new technologies for NOx reduction. 

• Utilizing renewable energy sources. 

• Utilizing opportunity fuels 

• Experimentally investigating combustion processes. 

• Developing emission monitoring programs. 

ESA's broad capabilities extend from providing consulting and testing 

services to performing detailed engineering, design, procurement, construction 

management, and start up services for projects. These projects have included 

retrofit and facilities design, new construction, and detailed design and 

installation of equipment for plant additions or modifications. Many of these 

projects include working with combustion technologies from their birth as a 

research concept, development at pilot scale, implementation at full scale, and 

optimization through several generations of installation at multiple locations. 

2 ESAOB-2017 
2.0 TECHNOLOGY OVERVIEW 

There are a variety of technical approaches that would be capable of 

reducing NOx emissions from the combustion system at the US Steel Minntac 

facility. As with NOx technology selection in other applications, the optimum 

control approach will depend primarily on the targeted NOx emission rate and the 

capital and operating expenditure. Table 1 provides a general overview of the 

suitable NOx control options for USS Minntac along with the expected NOx 

removal efficiency and the relative capital and operating cost of each technology. 

Table 1. NOx Option Summary 

NOx Reduction Cost 

Technology (%) Capital Operating 

Combustion modifications 20% to 30% $ $ 

SNCR 25% to40% $$ $$ 

SCR 75% to 90% $$$ $$$ 

NOx oxidation/wet scrubbing >90% possible $$$$ $$$$ 

2.1 Low NOx Combustion Modifications 

Combustion related modifications such as reduced excess oxygen 

operation, staged combustion, low NOx burners, overfire air and/or flue gas 

recirculation are proven techniques for reducing NOx emissions by 20% to 50% 

from most combustion systems. These combustion related modifications usually 

require relatively low capital cost investment and have very low operating costs. 

For this reason, some form of combustion related control is usually the "front line" 

in almost all NOx emissions control strategies. 

The indurating process combustor at USS Minntac is not ideally suited to 

off-the-shelf retrofit low NOx burners for several reasons. First, the indurating 

3 ESAOS-2017 
process requires large volumes of air for drying which makes reduced excess 

oxygen operation impractical and off-stoichiometric combustion staging more 

difficult to achieve. Second, the use of both natural gas and biomass fuel 

presents certain combustion and NOx related challenges to most commercial low 

NOx burners. ESA engineers are not aware of any low NOx burners currently 

available for taconite kilns. 

Despite these constraints, ESA is confident that some low NOx features 

can be incorporated into the existing combustion system design that will result in 

NOx emission reductions of 25% or more from current levels. ESA's approach to 

redesigning the existing burner system to achieve lower NOx formation 

characteristics will be through the use of computational fluid dynamic modeling 

(CFD) validated by on-site baseline testing. This approach is discussed in 

Section 3.3 of this proposal. The expected control cost associated with low NOx 

combustion modifications, expressed in dollars per ton of NOx removed, would 

typically be about $500 per ton of NOx removed or less. Based on the very high 

baseline NOx level at USS Minntac, the effective control cost would likely be 

much lower. 

2.2 SNCR Technology 

The next option for reducing NOx emissions would be through the use of 

selective non-catalytic reduction (SNCR) technology. This technology is typically 

capable of reducing NOx emissions by 20% to 50% depending on the flue gas 

temperature and residence time characteristics and the final unreacted ammonia 

(ammonia slip) level. SNCR technology is typically used in conjunction with low 

NOx combustion modifications resulting in overall NOx emission reductions of 

50% to 70% from uncontrolled baseline levels. 

The SNCR process is a well-proven technology for reducing NOx emission 

from fossil fired systems through the injection of ammonia or urea into the 

4 ESAOS-2017 
combustion effluents. The technology was invented and patented in the United 

States in the 1970s. The technology came into commercial use on oil and gas 

fired power plants in Japan in the middle of the 1970s. In Western Europe, 

SNCR systems have been used commercially on coal-fired power plants since 

the end of the 1980s. In the US, SNCR systems have been used commercially 

on gas and oil-fired units since the 1980s and on coal-fired power plants since 

the early 1990s. 

In SNCR systems, a reagent is injected into the flue gas in the furnace 

within an appropriate temperature window. The NOx and reagent (ammonia or 

urea) react to form nitrogen and water. A typical SNCR consists of reagent 

storage, reagent injection equipment and associated control instrumentation. 

The temperature window for efficient SNCR operation typically occurs 

between 1650 oF and 2000 oF depending on the reagent and condition of SNCR 

operation. When the reaction temperature increases over 1800 °F, the NOx 

removal rate decreases due to thermal decomposition of ammonia. On the other 

hand, the NOx reduction rate decreases below 1800 oF and ammonia slip may 

increase. The longer the reagent is in the optimum temperature window, the 

better the NOx reduction. Residence times in excess of 1 second yield optimum 

NOx reductions. However, minimum residence time of 0.30 second is desirable 

to achieve moderate SNCR effectiveness. 

Ammonia slip from SNCR systems occurs either from injection at 

temperatures too low for effective reaction with NOx or from over-injection of 

reagent leading to uneven distribution. Controlling ammonia slip in SNCR 

systems is sometimes difficult since there is no effective feedback to control 

reagent injection. The reagent injection system must be able to place the 

reagent where it is most effective within the boiler because NOx distribution 

varies within the cross section. 

5 ESAOB-2017 
The control cost for SNCR technology would be in the range of $1000 to 

$2000 per ton of NOx removed. Generally the capital cost of the SNCR process 

are relatively low and the primary operating cost is the purchase of ammonia or 

urea. 

2.3 SCR Technology 

Selective Catalytic Reduction (SCR) is a catalyst-based NOx control 

technology that can reduce NOx in the oxygen-rich exhaust from combustion 

processes. Like SNCR technology, SCR technology employs the use of a 

reductant such as ammonia to facilitate the catalytic NOx reduction process. 

However, unlike SNCR technology which depends on furnace gas temperature 

characteristics to support the kinetic NOx destroying reactions, SCR employs a 

catalytic reactor containing a vanadium based catalyst to support the reaction 

kinetics. As a result, the SCR process is capable of achieving very high levels of 

NOx removal depending on the volume of catalyst provided. Typically SCR's will 

achieve NOx reductions of 75% to 90%. Where possible, low NOx combustion 

systems are typically used to reduce the SCR inlet NOx concentration thereby 

reducing catalyst volume and chemical reagent requirements. SCR technology 

is much more expensive to install and to operate than SNCR technology but 

achieves much higher levels of NOx control. On large utility units where SCR 

technology is most prevalent, the operating costs are around $3,000 per ton of 

NOx removed based on the reagent and catalyst replacement cost. On relatively 

small units such as the USS Minntac indurating furnaces, the combined capital 

and operating cost of SCR technology would be very high. 

2.4 NOx Oxidation/Wet Scrubbing 

Several companies have developed technologies for reducing NOx 

emissions that involve the oxidation of NO to form water soluble compounds that 

can be removed from the flue gas by wet scrubbing. The oxidizing chemicals 

6 ESAOB-2017 
include ozone (generated on-site from pure oxygen), hydrogen peroxide and 

other more complicated techniques to form oxidizing compounds. Some of these 

process also require a catalytic reactor. 

In general, these technologies are capable of very high levels of NOx 

reduction and other pollutants as well. ESA participated in one of the first pilot 

scale demonstrations of a technology that involves NO oxidation using ozone. 

While the technology proved technically capable (at a pilot scale) of achieving 

almost 100% NOx removal, the process was not commercially viable or remotely 

cost effective in comparison to the other option presented here. In general, it is 

ESA's belief that such processes have a niche after low NOx combustion 

modifications and perhaps SNCR technology have already been implemented 

but additional levels of NOx reduction are still needed. 

2.5 ESA's Technical Recommendation 

Based on ESA's detailed understanding and experience with the technical 

solutions to NOx control, as well as our current understanding of US Steel's 

needs, ESA recommends a NOx control strategy incorporating the following 

components: 

1. Low NOx combustion modifications to the existing burner system. 

2. SNCR Technology. 

It is ESA's belief that combination of these techniques can reduce the NOx 

emissions by 50% or more from baseline levels while maintaining emission 

control cost-effectiveness that is comparable to other industries. 

7 ESAOB-2017 
3.0 SCOPE OF WORKISUPPL Y 

ESA proposes to design, fabricate, supply, startup and test a low NOx 

combustion system for Line No. 5 at USS Minntac. ESA scope of work and 

supply shall include the following tasks: 

3.1 Task 1: Baseline Testing/Evaluation 

ESA proposes to perform a brief test project on the unit. The objective of 

the baseline testing will be to document existing operating and emissions 

characteristics of Line No. 5 in order to develop the understanding and data 

necessary to design a NOx control system. ESA desires to obtain performance 

and emission data while firing gas and biomass fuel. ESA will provide personnel 

and test equipment to fully document the temperature, flow and emission levels 

as various locations within the grate-kiln system. In addition, ESA's engineers 

would like to obtain a first hand understanding of the process and the NOx 

characteristics as a function of various operating adjustments. 

The burners employed in US Steel's kilns have multiple passages for 

introducing atomizing and cooling or biomass conveyance air streams, as well as 

an adjustable gas tip. This allows for various possible operating conditions that 

may effect NOx emissions. During the baseline testing, systematic variation of 

each air stream will be conducted and the NOx emission measured. This will 

develop a parametric set of NOx measurements that determine a NOx emissions 

envelope for the current burner design 

The baseline test information serves two important purposes: (1) it 

provides necessary data for construction and validation of a computational fluid 

dynamic model and (2) it acquaints ESA engineers with the normal operating and 

emission characteristics of the unit. The spatial data on NOx, CO, 02, and 

temperatures leaving the kiln are critical to developing an accurate CFD model. 

Balance of plant issues can be directly observed during the testing. 

8 ESAOB-2017 
ESA will supply testing equipment consisting of a mobile emissions 

laboratory for analyzing the flue gas for NOx, 02, and CO species, water-cooled 

probes for collecting flue gas temperatures and gaseous species. 

3.2 Task 2: SNCR Demonstration Test 

After completing the baseline testing as described above, ESA 

recommends the performance of a short-term (3 day) SNCR demonstration test. 

The objective of this demonstration would be evaluate the effectiveness of the 

SNCR process at reducing NOx emissions from Line 5 using available 

observation or test ports. The demonstration would serve to provide a rough 

idea of the effectiveness of the technology at reducing NOx, identify any potential 

negative impacts and provide a better technical basis for designing a permanent 

system. ESA scope of work for this project would include the following: 

• ESA will supply and setup an SNCR test system consisting of all pumps, 

transmitters, valves, hoses, spray lances or other components necessary to 

convey and inject about 1 to 2 gallons per minute of urea solution. 

• ESA will supply and operate an extractive ammonia sampling system at the 

stack or other process location for determination of ammonia slip levels. The 

ammonia sampling procedure shall conform to the EPA Condition Test 

Method 27. 

• ESA will supply all labor necessary to operate, test and optimize the SNCR 

system over a thee (3) day test period during normal work hours. Most 

testing will occur under full load operating conditions for the unit. The 

objective of the effort will be to evaluate the potential for a somewhat 

simplified SNCR system to achieve cost-effective NOx reductions. 

• ESA be responsible for supply a urea batch tank and procurement of urea 

necessary for the test. 

• ESA will prepare a brief report documenting the SNCR system performance 

as a function of urea utilization including NOx emissions reductions and 

ammonia slip levels. The report will include recommendations for a more 

permanent system as well as anticipated performance. 

9 ESA08-2017 
3.3 Task 3: System Design with CFD Modeling 

The objective of Task 3 is to develop a CFD model of the unit to aide in 

the design of low NOx combustion modifications and the SNCR system. The 

CFD modeling would encompass two parts: a model of the kiln for design of 

modifications to the burner system, and a model of the preheat section to assist 

in the design of the SNCR system. 

ESA engineers recently employed CFD modeling to evaluate the gas 

burner for US Steel's Minntac Line 3 kiln. Sample output is shown below, which 

compares the peak temperature produced by the gas kiln burner at two different 

combustion air settings. This model will be used as the starting point for 

simulating changes to the kiln burner. 

Peak T(F) 

2000. 2375. 2750. 3125. 3500. 

ESA proposes to extend the existing CFD model of Minntac line 3 kiln to 

line 5 to provide detailed analysis of NOx production and the potential for 

reduction by altering the combustion process. By extending the CFD model to 

NOx predictions, detailed information about how the current combustion 

processes inside the kiln generate NOx can be determined. This information can 

be employed to quantify improvements in NOx generation that might be expected 

from changes to the kiln burner. 

10 ESA08-2017 
ESA's NOx subroutines employ reduced chemical kinetics to predict NOx 

generation from the reaction of atmospheric nitrogen (thermal NOx routes), and 

combustion of fuel bound nitrogen (fuel NOx routes). Fuel nitrogen routines 

include fuel bound nitrogen in the form of HCN (predominant in coal) and NH3 

(predominant in biomass). The reduced chemical kinetic set is integrated with the 

turbulent mixing and combustion of the CFD model to ensure accurate prediction 

of NOx emission. The model will be compared to test data to ensure accuracy of 

the NOx predictions and then will develop a comprehensive set of baseline NOx 

predictions. 

CH4 

.1.00 

0.75 

0.50 

0.25 

0.00 

An example of the CFD model of one of the burners employed in US 

Steel's kilns is shown above. It has been constructed with multiple inlets for 

introducing atomizing and cooling (or conveyance) air streams, to allow it to 

simulate the various possible operating conditions. The kiln model will be run 

using the fuel and air conditions measured during baseline testing and NOx 

emissions will be predicted. The NOx model predictions will be compared to the 

baseline testing measurements to ensure that the model is accurately 

representing current NOx emissions. 

11 ESAOB-2017 
After simulation of the normal operation, variation of each air stream 

(atomizing and cooling) will be conducted to match the baseline testing matrix. 

The graphic visualization produced by the CFD model will allow the development 

of an understanding of where and why NOx emissions are produced by the 

current burner design. Some parameters of interest to NOx formation are 

expected to be: 

1. Because both cooling and atomizing are ambient air streams, the effect on 

NOx formation of the total amount of ambient air used in the burner will be 

determined. 

2. Some effect of the central, atomizing air on flame shaping has been 

observed in the previous CFD modeling; the baseline modeling will 

determine if this has any effect on NOx formation. 

3. The effect of biomass combustion on extending the flame and possibly 

limiting the formation of NOx will be calculated. 

To address these and other issues, the formation of NOx from each 

baseline run will be plotted to allow determination of how and where NOx is 

generated by the burner, and how it responds to changes in the air supplied 

through atomizing or cooling regions. 

After completion of the baseline modeling, design changes to the burner 

for reducing NOx emissions will be discussed with US Steel engineers and tested 

in the CFD model. These alterations will be based on the relation of NOx to 

operating parameters developed in the baseline modeling, and will likely include 

replicating some combination of the usual components of a traditional low NOx 

burner. In general, a low NOx burner includes the some combination of the 

following elements to control NOx formation: 

• Multiple fuel streams, to allow controlled introduction of the fuel to the 

combustion zone. 

• Multiple air streams, to control the mixing of air into the fuel streams, 

allowing further control of the combustion zone. 

• Swirl on the air streams, to entrain furnace gases to reduce the oxygen 

concentration and improve flame holding of the extended flame. 

12 ESAOB-2017 
• Forced flue gas recirculation, to reduce the local oxygen content in the 

combustion zone. 

In a low NOx burner, these functions are achieved through the use of swirl vanes, 

blockages, splitters, or other fabricated parts. Each of these features will be 

replicated in the CFD model to test their function in reducing NOx. Because of 

the high temperatures and high 02 process air present in the indurating air, and 

into which the kiln burner fires, some of these low NOx burner elements may not 

be possible or may not function to reduce NO,. The design modeling will provide 

information about the extent to which that occurs, allowing assessment of which 

design features successfully reduce NOx. 

To assist with the design of SNCR, ESA will construct and validate a CFD 

model of the preheat section of the processing line to provide an additional tool 

for the design of a permanent SNCR system. Values of 0 2, NH3, and NOx will 

be extracted from the model and compared to test measurements from the field 

trial. If the multiple point comparisons of the CFD model match the test 

measurements, it can reasonably be assumed that the modeled conditions are 

the same as the real preheat furnace. 

The validated model provides two important benefits for the design of a 

permanent SNCR. The first benefit is a visual indication of where the 

combination of temperature, 02, and NOx is suitable for SNCR reagent 

application, and how that region moves under different operating conditions. 

The second benefit is that reagent distribution from all possible injector locations 

can be simulated, not just the limited set of locations available to the field trial. 

Combined, these two benefits provide the knowledge of where the best location 

of SNCR reagent application is, and how to target it with injectors. 

Using the CFD modeling, a process design will be developed for a 

permanent SNCR system, which determines the number and location of 

13 ESAOB-2017 
chemical injection nozzles, the amount of chemical use and the spray distribution 

required from each nozzle. 

3.4 Task 4: Low NOx Combustion System Supply 

ESA proposes to supply the required equipment and services to convert 

the existing burner to low NOx operation. To a large extent the precise nature of 

the equipment to be supplied will depend upon the results of the CFD modeling 

conducted in Task 3, therefore, this list a best estimate of the components 

required 

3.4.1 Equipment Supply 

QTY 1 Modified Burner Tip 

It is expected that some combination of swirl vanes and/or splitter 

vanes will be retrofit to the existing burner to achieve lower NOx. 

The precise nature of the modification parts will result from the CFD 

modeling task. Since ESA's intention is to modify the current 

burner rather than completely replace it, ESA's preliminary 

expectation is to combine the required splitter/swirl vanes into a 

modified tip that can be retrofit onto the current burner. 

3.4.2 Engineering Services 

ESA will perform the following engineering services to complete the scope 

of work: 

• Field verification of existing burner dimensions and design 

• Conversion of CFD conceptual design to detailed design drawings for 

fabrication of replacement tip components. 

• Installation Drawings for replacement components 

• On-site installation support 

14 ESAOS-2017 
• Burner commissioning and Startup 

• Operator training 

• Burner optimization testing 

3.4.3 Scope of Work by Others 

• Removal of current burner. 

• Installation of ESA supplied modified tip onto current burner. 

• Reinstallation of burner. 

3.5 Task 5: SNCR System Supply 

ESA proposes to supply the following process equipment and services. In 

general, ESA's scope will include all equipment such as tank, process skids, 

transmitters, pumps, valves, flex hoses and PLC control system. Excluded from 

process equipment supply is interconnecting piping, electrical conduit, electrical 

cable, access platforms or stairs (if necessary). 

3.5.1 

QTY1 

SNCR Equipment Supply 

15.000 Gallon Insulated FRP Urea Storage Tank 

The FRP tank will be filament wound, flat bottom, vertical side, and 

closed dome tanks. The tank will be rated for atmospheric 

pressure conditions. The tank will consist of premium grade 

Derakane 441-400 vinyl ester resin in the corrosion barrier and 

isophthalic polyester resin in the structural layers. The tank will be 

insulated with 2" polyfoam insulation and over wrapped with FRP 

and coated with an UV inhibitor barrier. The tank will include two 

manholes for tank entry with a safety ladder and cage for accessing 

the top manhole. The tank will also have thermostatically controlled 

heating panels to maintain 75° F. along with the necessary fittings 

15 ESAOS-2017 
QTY1 

and connections for pump suction lines, recirculation and fill lines 

with down tubes, ventilation, level and temperature indication, and 

tank drains. The tanks will be constructed to an 80 MPH wind load 

and Seismic Zone 0 rating with the appropriate snow load. The 

urea usage for the proposed system is estimated at 1500 gallons 

per day. The 15,000 gallon tank will provide approximately 10 days 

of storage capacity. 

Urea Circulation System and Outdoor Equipment Enclosure 

One urea circulation system will be used to deliver pressurized urea 

from the urea storage tank location to the SNCR process flow 

control skid. 

The urea circulation system will contain redundant centrifugal 

pumps for the circulation loop between the urea storage tank and 

the SNCR process skid located inside the plant. The urea 

circulation system will include an in-line heater and heat traced and 

insulated stainless steel piping to prevent the urea from 

crystallizing. The circulation heater will be a 20 kW electric heater 

with 304 SS wetted parts. The electric heater controls will be 

housed in a NEMA 4 rated box and will require 480V/3 Ph/60 Hz. 

The circulation pumps, in-line heater, strainer, valves, and 

instrumentation will be skid mounted and installed within an outdoor 

enclosure building. All skid piping will be Sch. 40 304 SS, all valves 

will be 316 SS, and instrumentation will have wetted 316 SS parts. 

The enclosure will be constructed of fiberglass reinforced 

isophthalic plastic resin with a laminate composite, UV inhibitors, 

and flame retardant additives. The heated enclosure with have a 

polyurethane closed cell foam core in the walls and roof. The 

enclosure will house the electrical breaker panels with circuits and 

16 ESAOB-2017 
QTY1 

QTY4 

transformers designed for the tank heaters, containment area 

lighting, circulation loop in-line heater, circulation equipment and 

instrumentation, pipe heat tracing, and the enclosure lights, outlets, 

and heater. The enclosure will be mounted on a concrete pad. 

The enclosure will be rated for 150 MPH wind load and 40 lb per 

square foot snow load. 

SNCR Process Flow Control Skid 

ESA is proposing to build one SNCR process flow control skid. The 

urea/dilution water flow control skid will contain the equipment 

required to monitor and maintain the proper urea injection rates for 

the SNCR systems on each unit independently. The skid mounted 

equipment will include a vertical stage centrifugal pump for 

controlling dilution water supply pressure, pressure and flow 

transmitters for urea and water supply, urea flow control valves, 

water pressure control valves, urea and water automatic isolation 

valves, multiple purge/fill connections, strainers, and a NEMA 4X 

junction box for power and control wiring connections. The skid will 

consist of 304 SS piping and fittings with a stainless steel dip pan. 

Piping and valve connections will be ANSI150# RF flanges. 

SNCR Injection Lances and Insertion/Retract Assemblies 

The unit will utilize four (4) injection assemblies and two (2) 

independent injection zones. The SNCR injection assemblies will 

include an injection lance and nozzle, manual and automatic 

isolation valves, a dual acting limit switch, flexible braided steel 

hose, and a dual acting pneumatic actuator. All wetted parts will be 

304 SS or 316 SS. The automatic insertion/retract mechanisms 

can be operated remotely through the control system or locally 

17 ESAOB-2017 
QTY1 

through a field mounted junction box with insertion and retraction 

switches. 

SNCR PLC System 

The SNCR system will be controlled by an Allen Bradley PLC 

system. Each skid will contain a dedicated controller and 1/0 cards 

to monitor and control the operation of the skid mounted equipment 

and any field installed equipment located near the skid. The PLC 

equipment will be mounted in NEMA 4 or 4X junction boxes and will 

include power supply filters, voltage transformers, and climate 

control systems. The skid mounted PLCs will be connected by 

Ethernet cables and linked to an operator interface located in the 

boiler control room. 

3.5.2 Engineering Services 

ESA will perform the following engineering services to complete the scope 

of work described in this proposal: 

• Equipment Specifications 

• P&ID Drawings 

• General Arrangement Drawings 

• Tank Foundation Drawing 

• Skid Arrangements Drawings 

• Electrical Schematic Drawings 

• Electrical Interconnection Drawings 

• Single Line Power Distribution Drawing 

• PLC Software Programming 

• On-Site Installation Support- 15 man days of on-site support services 

during equipment installation. 

18 ESAOB-2017 
• Equipment Commissioning and Startup Services- Manpower as 

necessary. 

• Operator Training 

• Operation and Maintenance Manuals - 3 printed copies plus electronic. 

• SNCR Process Optimization Testing. The SNCR optimization testing 

will require about 1 weeks per unit to complete. ESA will supply all 

personnel and test equipment to tune the system the system and 

measure ammonia slip levels. The results of the testing, together with 

input from the station, will be used to establish the operating set points 

for the system. 

3.5.3 Scope of Work by Others 

• Installation of ESA supplied equipment. 

• Foundation for Urea Tank and Transfer System/Outdoor Enclosure. 

• Interconnecting piping and instrument air. 

• Interconnecting Cat-5 Ethernet cabling between the PLC control 

system and remote Flex 1/0. 

• Interconnecting electrical cabling. 

• 480 power supply to process skids. 

• Filter water supply - 10 gpm. 

• Supply of Nalco water hardness suppression chemical -should be 

about 30 to 60 gallons per month depending on water hardness and , 

operating hours. 

• Instrument air. 

• Installation of stairs, platforms, handrails, interior/exterior lighting, 

eyewash stations or safety shower. 

19 ESAOB-2017 
3.5.4 SNCR System Operating and Maintenance Cost 

The primary operating cost of an SNCR system is the cost to purchase 

urea (or ammonia). The system will require periodic replacement of spray 

nozzles and repairs or replacements to pumps, flex hoses or other equipment but 

these cost are relatively insignificant in comparison to the reagent cost. The 

system will use about 1 to 3 gallons per minute of filtered station water for 

dilution. 

Urea at 50% by weight is a commodity that current costs about $1.00 to 

$1.25 per gallon delivered. The expected flow rate for Line No.5 is about 60 

gallons per hour. The anticipated NOx reduction is about 150 lbs per hour or 

greater. Therefore, the operating cost would be in the range of $800 to $1000 

per ton of NOx removed. 

4.0 SCHEDULE 

The proposed project could be completed within about 6 to 8 months. The 

baseline testing and SNCR demonstration test would only require about 1 - 2 

weeks to complete but completion of the CFD model and low NOx burner design 

will require about 12 weeks. 

Tasks 3 and 4 would be performed in parallel requiring about 3 to 5 

months to complete after Task 1 if finished. 

20 ESAOB-2017 
5.0 COST ESTIMATE 

The budgetary prices to develop and supply a low NOx combustion 

system for USS Minntac, Line 5 is detailed below according to the 

described scope of work. 

Task Work Task Price 

1 Baseline testing $30,000 

2 Optional SNCR short term demonstration test $45,000 

3 CFD modeling and low NOx system design $50,000 

4 Engineer, fabricate, supply and test low NOx $175,000 combustion modification 

5 Engineer, fabricate, supply and test SNCR $550,000 System 

TOTAL $850,000 

5.1 Estimated Installation Cost 

The estimated installation cost of the proposed low NOx combustion 

system including burner modification and SNCR system installation is detailed 

below by labor scope. 

Work Scope Installation Cost 

Civil -Tank foundation/containment $75,000 

Pipe fitting/ tank erection/ mechanical $125,000 

Electrical $60,000 

Insulation I refractory $15,000 

Burner modification installation $15,000 

TOTAL $290,000 

21 ESAOS-2017 
I 

BACT PROCESS SYSTEMS, INC. 

3345 N. ARLINGTON HEIGHTS RD. SUITE E 

ARLINGTON HEIGHTS, IL 60004-1900 

(847) 577-0950 

FAX: (847) 577-6355 

E-MAIL: bact_process@sbcglobal.net 

November 18, 2008 

To: 

Attn: 

From: 

Re: 

cc: 

HATCH 

Chester Dietrick 

N. Balakrislman, BACT PROCESS SYSTEMS, INC. 

NOx Emission Control System for U.S. Steel 

BACT File No. 0870 

Ron Tomcik 

Chester, our recommendation is for you to consider a selective non-catalyst (SNCR) 

process for reduction ofNOx for this application. Based on our experience with cement 

plants, a system could be designed to inject urea solution to the gas stream. The ideal 

temperature is 900 degree C to II 00 degree C. We are attaching technical information on 

the SNCR system. 

The injunction nozzles could be installed down stream of the rotary kiln. The injunction 

nozzles could be designed after CFD to assure a uniform mixing of gas and reagents. 

Typically, you could get 60% removal efficiency. Based on 470 lbs/lu· NOx the urea 

usage will be 262 PI-L 

Compressed air usage: 1200 SCFM @75 psig. 

I. BACT will design, furnish and supply one SNCR denox system for this project. 

2. Denox shall be based on urea. 

3. We assume that the space requirement for atomization of the reagents is very limited. 

I. Our scope of supply is as follows: 

- CFD modeling 

BEST AVAILABLE CONTROL TECHNOLOGY 
-2-

2. Equipment: 

(a) Urea Storage: 

One 15,000 gallon FRP tank complete with inlet flange, outlet flange, 

level probe flange and Delta T temperature maintenance system with 

insulation. 

The tank has a dimension of 14'-0" dia x 28'-0" height. The tank is 

capable of receiving 50% urea solution. 

(b) Pump Skid: 

To pump urea solution from the storage tank to the day complete with 

pump, TEFC motor, pump spared and valved for manual switchover. 

(c) Urea day tank, 5000 gallon capacity- polyethylene 

(d) Water tank- polyethylene- 5000 gallon 

(e) Two (2) pump skids with necessary valves and instruments for water 

and area solution to the atomizing nozzles. Pumps are spared. Four 

installed with one warehouse spare. 

(f) Urea injunction nozzles and lances complete with control valves. Pressure 

transmitter in each nozzle. 

(g) Material suitable for high temperature. Barrier air system is included. 

(h) A control panel, NEMA 12 with Allen Bradley micro-processor and 

touch screen and NOx monitor. 

(i) All required piping to inter-collllect the pump skid with the nozzles. 

Compressor: By others 

Field installation: By others 
-3-

SELL PRICE: 

Budget price for engineering, equipment and start-up: 

Field installation (inter-connecting piping 

and electrical wiring): 

Cost for CFD modeling: 

Delivery: 

6 months after receipt of order 

$850,000 

Later 

$80,000 

Chester, the information presented here is very preliminary. We have already sent you a 

users list from our licensing partner. 

We would like to meet with you to discuss our approach at your convenience. If you 

have any questions please do not hesitate to contact us. 

Kind regards, 

N. S. Balakrislman, President 
• • 

• • • • 

0 I ' • • 

- • • 

BACT PROCESS SYSTEMS, INC. 

3345 N. Arlington Heights Rd .. Suite E 

Arlington Heights, Illinois 60004-1900 

1'-847/577-0950 

F-847/577-6355 
Applications SCR-system 

NO.reduction in flue gases from: With the SCR method the 

• cement industry 

• oil, gas and coal combustion 

• waste incineration plants 

• gas/diesel engines 

• gas turbines 

• wood incineration plants 

General description 

For NOx reduction in flue gases 

usually two Industrial procedures 

are used: 

• selective catalytic reduction 

SCR 

• selective non-catalytic reduction 

SNCR 

Both procedures convert the 

nitrogen oxides harmful to the 

environment Into nitrogen and 

water by adding a reducing 

agent. As a reducing agent 

ammonia or urea solution can be 

used, as they react selectively 

with NO •. 

nitrogen oxides are reduced to 

molecular nitrogen using a 

catalyst. The reducing agent is 

Injected at temperatures from 

2oo•c to 45o•c. In order to 

guarantee a homogeneous 

distribution In the flue gas a static 

mixer is mostly foreseen after the 

injection. 

Very important for a successful 

operation is the atomislng 

technology. 

CALDYN has more than 1 0 years 

of experience in this field and 

provides the necessary atom ising 

lances as well as the respective 

engineering. CALDYN guarantees 

the complete evaporation of the 

Injected liquid before the gas 

reaches the catalyst resp. the 

static mixer. Thus extremely short 

evaporation distances are 

achieved while smallest channels 

can be used. 

SNCR-system 

With the SNCR method the 

reducing agent Is directly 

injected into the hot flue gases 

at temperatures from 900 ·c to 

1100 •c. The water in the solution 

Is evaporated and the reducing 

agent reacts with NO to water 

and nitrogen. At temperatures 

exceeding 11 00 •c the added NH3 

is increasingly oxidized. At 

temperatures below 900 •c the 

reduction velocity decreases 

leading to an increased 

ammonia slip. 

As no static mixers can be used 

due to the high temperatures a 

homogeneous distribution of the 

reducing agent in the flue gas Is 

necessary. In order to observe 

the legal limits an optimum 

dimensioning and regulation of 

the system Is essential. 

For this method CALDYN 

provides the complete atomlsing 

technology with engineering as 
well as the pump and regulating 

station including the programmable 

control. 

Advantages of the SNCR system 

• low capital investment 

• no additional apparatus in the 

flue gas system (direct spraying 

into the boiler, reheating 

chamber, ... ) 

• no pre-dedusting 

• quick retrofitting 

• no catalyst necessary 

It depends on the spraying I 

... 

I 

·~ 

-~-~~ 

Fig.2 Working principle of the 

CALDYN nozzle CSL 

Nozzle CSL was developed by 

CALDYN and has been proven as 

a very robust and economical 

spraying technology over the past 

years. Liquid and gas are mixed 

at low velocities in a mixing 

chamber and accelerated to the 

sonic velocity of the two phase 

mixture. The atomlsatlon is 

achieved by the pressure jump at 

the outlet of the nozzle when the 

mixture Is expanded In a gas 

atmosphere (see Fig. 2 and resp. 

Technical information CSL 9801 

CALDYN nozzles). 

The atomising system is the most 

Important component of the 

SNCR system. Especially the 

evaporating distances and the jet 

throw of the nozzles have to be 

considered when dimensioning 

the SNCR system. The nozzles 

have to penetrate the flue gas 

without causing lump formations 

and damage due to incomplete 

evaporation. Our engineers 

use a CALDYN dimensioning 

software for optimum results. 

Characteristics 

CALDYN nozzles CSL generate 

a defined and narrow droplet size 

distribution. A variation of the jet 

throw and the droplet size 

distribution can be achieved by 

changing the liquid flow rate and 

the gas pressure. The liquid flow 

rate can be regulated from zero 

to maximum design flow rates 

(see Fig. 3 Jet velocity profile of 

a CALDYN nozzle). 

Especially for the NO, reduction 

CALDYN developed a nozzle with 

a flat jet throw called CSL_flat 

providing a wide spread spraying. 

The combination of single 

nozzles in a cluster or several 

nozzles In line allows an optimum 

adaptation to different duct or 

tower diameters. 

Regulation 

Depending on the contents of 

NO, in the clean gas the spraying 

system is automatically and 

continuously adjusted to the 

varying parameters. For 

changing temperatures in the flue 

gas several levels of nozzles are 

installed. For each range of 

temperature the respective level 

is used. Thus operating costs and 

ammonia slip are reduced. 

0 

0.15 

s: 

' 0 ~· 

:;;, 

..(), 15 

0 0,1 0.2 0.3 0.4 0.5 

Fig.4 CALDYN lance with 3 

nozzle tips CSL (SCR) 

--------------------~ 

Design 

The lances are made of heat 

resistant stainless steel. An 

additional cooling system is 

usually not required. When 

needed the lances can be 

operated with protection tube 

and barrier air. 

[mls} 

5 10 15 20 25 30 

0.6 0.7 0.8 0.9 

distance from nozzle outlet [m) _. I 

~ 

Fig.3 Calculated jet velocity profile of a CALDYN-nozzle CSL I ____ _......... ....... ~=_...~_.._....,. "~"""""-·----' 
Advantages ofthe CALDYN system: 

• low energy consumption • no additional lance cooling 

• efficient use of reducing agent • little maintenance required 

• wide range of regulation • long wearing and plugging-free nozzles 

• steam can be used instead of pressure air • easy installation I retrofitting 

Scope of Supply 

The CALDYN scope of supply Includes the engineering, delivery of lances with nozzles CSL, atomising 

systems with special design on customer's request for DeN Ox-systems as well as complete plants. 

Detailed information is available for further applications of the CALDYN nozzle CSL (quenching systems, 

spray absorber, evaporation of waste water, aerosolenlargement, etc.). 

References 

CALDYN delivered atomislng systems or DeN Ox-systems to: 

@) Clments Calcia 

I!J!cerrer.li G:o:.1p 

"--

. . . 

ll•KOCH-GLITSCII 

LLAFARGE 

HWH 

' ' I o_ 

SIEMENS· 

0 ";:. > -~ \ r '' 

STEl"LlER 

AJ\I.IQf'APUtt. GmhH .\Co, KG 

BACT PROCESS SYSTEMS, INC. 

3345 N. Arlington Heights Rd., Suite E 

Arlington Heights, Illinois 60004-1900 

P·847/577·0950 

F-847/577·6355 

- I ........ I V L..o~"lll 1~""'11 

Tel. ++49-7243/5403-0 

Fax ++49-7243/5403-99 

E-mail: info@caldyn.de /Internet: http://www.CALDYN.de 
~WJM Apparatebau GmbH 

Dok: Referenzliste DeNOx Stand 2008 

List of Companies using CALDYN CSL System 

for NOx-Reduction in SNCR & SCR plants 

Company Conntry NOx-target 

(mg/Nm') 

Mliquld 

(kg/h) 

Temp. Gas Flow Rate 

(° C) (Nm'lh) 

SNCR-Systerns in cement plants 

Cirnents Calcia SNCR France < 800 240 950-1100 48.000 

Lafarge SNCR Germany <500 80 1050-1150 24.000 

Lafarge SNCR Germany < 500 200 1050-1150 78.000 

Lafarge SNCR Getmany < 500 125 900-1050 51.000 

Lafarge SNCR Austria <500 800 900-1050 180.000 

ZKW Otterbein SNCR Germany <500 70 950-1050 96.000 

SNCR-Systems in other industries 

As exclusive contractor we made for Nalco Fuel Tech, Essen lances/nozzles for >70 SNCR 

plants for example: 

Plant Vojany 

Plant MV A Hamm 

Plant MVA Frankfurt 

Plants Standardkessel 

Slovaky 

Germany 

Germany 

Germany 

James Robinson SNCR Germany 

5.000 

4 

950-1050 

950-1050 

950-1050 

900-1100 

900 

500.000 

2.800 
SCR-Systems 

Deutsche Babcock, Germany 890 

Knifeld SCR 

Siemens AG, Redwitz Germany 5-440 

> 300 plants SCR 

(now Argillon) 

Steinmiiller SCR Germany 1.600 

2.600 

H+H Umwelttechnik Germany 5-250 

> 300 plants SCR 

Steuler Germany 5-950 

> 30 plants SCR 

Integral Austria 5-200 

> 20 plants SCR 

Envirgy Austria up to 330 

> 10 plants SCR 

MAGUINSCR France 

Conversion factors: I ° C = I ,8° F; I Nm'/h = 0,59 scfin 

SCR = Selective catalytic reduction 

SNCR = Selective non catalytic reduction 

100 

~WIM Apparatebau GmbH 

400-160 7.200 

430-240 

280-170 26.000 

280-190 52.000 

450-250 

430-250 up to 227.000 

350-250 up to 160.000 

315-280 up to 4.500 

260-300 65.000 
SCHEME 

Urea solution injection system SNCR-plant 

·------------------------------~ 

I .-----------------~: : I r---------~ I I 

1 I I 1 I I 

1 I ..L. 1 I I ~-----------------------~ ' ' ' ' 1 I I 

)-__ _._l __ r:Xl(] I I I r::J<J---l><l I I I I I I ± I 

pressure air>-I><J I· 1 1 

:~ .. 'l ' ' ' . ' 

5,5borg 1 II 

LS 

Water 

tank 

" 

Urea 

tank 

1 I I 

I II 

I I I -------, I I I r----- r---.--=--:...-:...-:..-r =...:-..:-.;-i I I I l I I 

,l, : : :I ~- , '~~t;cl bo~ I I I Q I ltl 

I ltl 

I It I 

I It I 

11 I 

I' I 

II I 

tit .---r==~-=--=--=---=_J I 

I 1 r---' 

I ~ I 

I 

y 

4 lances with nOZZles CSL 

' ' ' ' 

Section •e• ··::~;~~;~~(~ 

flue gas 

"Inl 

: 4 X l ______________________ _ 

Scheme SNCR-system 

Injection of ta'ea sollltion for 

NOx-Reducticn 

~ I SNCR02E.DCD-02-2HOOO , •• ~q 

~d! 
Hatch 

BUDGET PROPOSAL FOR 

Low NOx Burner System for USS 

Minntac 

OG**,DRAFT 

November 18, 2008 

20 Stirling Street 

Thebarton 

SA 5031 

AUSTRALIA 

Tel: +61 8 8352 9999 

Fax: +61 8 8352 9988 

FCT, Inc. 

Draft 

Checked 

Approved 

5 Great Valley Parkway 

Malvem 

PA 19355 

USA 

Tel: +1 610 725 8840 

Fax: +1 610 725 8846 

www.fctintemational.com 

SD 
TABLE OF CONTENTS 

I. INTRODUCTION ............................................................................................................................................... 2 

2. BACKGROUND ON FCT .................................................................................................................................. 3 

3. SCOPE OF SUPPLY ........................................................................................................................................... 3 

3.1 PHASE 1: BURNER REPLACEMENT WiTH LOW NOX DESIGN ................................................................................. 3 

3.2 PHASE 2: PILOT PLANT TESTING TO OPTIMIZE NOX REDUCTION ........................................................................ .4 

4. BUDGET PRICES ............................................................................................................................................... 5 

4.1 SiTE SERVICES ...................................................................................................................................................... 5 

5. TERMS AND CONDITIONS ............................................................................................................................. 5 

6. SPECIAL CONDITIONS OF SALE ................................................................................................................. 5 

6.1 PRICE BASIS .......................................................................................................................................................... 5 

6.2 VALIDITY .............................................................................................................................................................. 6 

6.3 DELIVERY ............................................................................................................................................................. 6 

7. TERMS OF PAYMENT ..................................................................................................................................... 6 

8. LIMITATIONS OF LIABILITY AND CONSEQUENTIAL LOSSES .......................................................... 6 

9. EXCLUSIONS ..................................................................................................................................................... 6 

10. OWNERSHIP OF INTELLECTUAL PROPERTY CREATED IN PROJECT ........................................... 7 

11. INSURANCES ..................................................................................................................................................... 7 

APPENDIX 1: FCT GYROTHERM BURNERS ........................................................................................................ 8 

APPENDIX 2: FCT PILOT BURNER SYSTEMS ................................................................................................... 11 

Contact: Sanjiv Dhanja1 

Cell: +I (484) 919-2029 

- 1 - OG** DRAFT, Nov. 20, 2008 
1. INTRODUCTION 

US Steel operates an iron ore pelletizing plant at their Minnesota Ore Operation (Minntac) facility. 

They have fives pelletizing lines, numbered 3-7, and are investigating the feasibility of reducing NOx 

from the indurating process. Focus is initially on line 5. 

Line 5 consists of a travelling grate dryer/preheater, rotary kiln and annular cooler. Pertinent data for 

line 5 is tabulated below. 

Indurating Feed Rate 

Iron Pellet Production 

Fuel Input 

J> Natural Gas 

J> Biomas Fuel 

J> Total 

NOx Emissions 

Units 

Tonnes/hr 

Tonnes/hr 

Btulhr 

lblhr 

Ave. 

450 

370 

170 

120 

290 

470 

Max. 

530 

440 

1,230 

FCT is ideally suited this project. FCT specializes in design and supply of rotary kiln burners, having 

worked on hundreds of kilns tluoughout the world. Through proprietary designs and modeling 

techniques, FCT is able to match the rotary kiln flame to the process. 

In this case FCT proposes the Gyrotherm bumer. Gyrotherm has been shown to reduce NOx 

emissions in rotary kilns. While not used in an iron pellet kiln, FCT is undertaking extensive pilot 

scale tests to verify its NOx reducing capability in such kilns. FCT therefore has a clear 

understanding of Minntac's requirements and the critical elements of such an iron pellet plant, i.e. 

NOx, production rate and product quality. 

Our proposed approach comprises the following phases: 

l. Replacement of the burner with a Gyrotherm low NOx dual fuel bU'mer. A NOx reductions of 

30% or more is expected, at current production. 

2. Pilot plant work, to optimize wood chip injection and fuel mixing, and aerodynamic modeling to 

optimize kiln hood design. Our experience in these types of kiln has shown that aerodynamics can 

impact significantly on combustion performance. 

3. Should it be necessary, post treatment with SCR or SNCR to remove NOx at the end of the 

process can be investigated. As this is a costly exercise, a decision on how to proceed will depend 

on the outcomes from Phases l and 2. 

Contact: Sanjiv Dhanjal 

Cell: +1 (484) 919-2029 

-2- OG** DRAFT, Nov. 20, 2008 
2. BACKGROUND ON FCT 

FCT is a combustion and process specialist company operating mainly within a variety of industries 

including such as pulp and paper, cement, limestone and alumina. The group consists of FCTCombustion and FCT-ACTech. 

FCT Combustion uses its broad range of experience in the design, operation and maintenance of 

plants to deliver benefits to its customers through optimizing the equipment it provides from a total 

plant perspective. For example, combustion modeling is a key part of the FCT burner design process, 

giving some predictability of outcomes and reduction in risk to projects. 

FCT-ACTech is an on-line analysis and control company. The company offers an on-line XRD 

analyzer, COSMA, which provides a continuous mineral phase analysis of a material stream as it 

passes through the analyzer. The information from the analyzer allows operators to see the quality of 

the product in real time, rather than a few hours later, thereby allowing them to make process changes 

in the most timely manner for plant and product control purposes. 

With over 50 kiln burner installations, FCT has vast experience in designing robust equipment that 

requires minimum maintenance. 

3. SCOPE OF SUPPLY 

3.1 Phase 1: Burner Replacement with Low NOx Design 

In Phase 1 FCT will provide a new low NOx GyroTherm burner to USS Minntac for the rotary kiln in 

line 5. Included in the scope are all technical services to ensure that the design is suitable, such as site 

survey, physical modeling, mechanical design and auxiliary equipment. The scope consists of: 

3.1.1 Combustion Design using Physical Modeling 

The process will include a visit to the plant site by two FCT engineers for approximately one week to 

collect data, take plant measurements with FCT site equipment and gather drawings required to 

produce a scale model of the kiln. It is anticipated that a site engineer will assist the process for the 

FCT engineers to gather all necessaty information. 

The data gathered from site will be used to prepare a basic mass and energy balance and gain further 

insight into the process. It will also be used to design, manufacture and test of a scale model of the 

kiln and hood in our laboratories in Adelaide. The model will investigate the combustion 

performance using acid/alkali techniques. Once the combustion and flame characteristics have been 

determined, FCT will attempt altered operating conditions and burner designs and positions to 

improve kiln conditions. 

The modelling provides the critical design parameters for the new burner. 

Contact: Sanjiv Dhanjal 

Cell: +1 (484) 919-2029 

-3- OG** DRAFT, Nov. 20, 2008 
3.1.2 Mechanical Design and Supply of Dual Fuel Natural Gas and Biomass GyroTherm Burner 

FCT will design, manufacture and supply a new kiln burner. The burner will be rated at 85MW (290 

MMBtu/h) and consist of: 

>- Central gas pipe with GyroThetm gas nozzle 

>- Annular channel for Biomass 

>- Air cooled annular channel for auxiliary guide pipes 

>- Guide pipe for pilot burner 

>- Guide pipe for main flame scanner 

>- Additional axial gas nozzles, if needed 

>- Outer channel for axial cooling air 

>- Points for overhead suspension or floor mounted support 

A burner of this size is likely to have a 600mm (24") NB outer pipe. 

3.1.3 Main Flame Scanner 

UV Main flame scanner for mounting on rear of hood 

3.1.4 Automatic Pilot Ignition System 

FCT will design and supply our spark ignition system. The system will be rated at 90 MW (300,000 

Btu/h) liberation. It will include: 

>- Pilot gas burner 

>- Pilot valve train and control box for safe and automatic ignition. 

>- HT ignition box with 1Oft of cable 

>- Flame amplifier relay to indicate flame presence with 10 ft cable 

3.1.5 Installation, Commissioning, Evaluating and Training 

FCT offers installation and start up assistance at our normal daily rates. The level of assistance is site 

dependant on site requirements, but is expected to be 10-15 days. Included is training for plant 

personnel on operation and maintenance of the new burner and auxiliary equipment. 

In addition, FCT engineers will conduct detailed process testing and fine tuning to ensure the NOx 

levels are minimized and production and quality are optimized. This exercise is expected to be 2-4 

weeks. 

3.2 Phase 2: Pilot Plant Testing to Optimize NOx Reduction 

Contact: Sanjiv Dhanjal 

Cell: +I (484) 919-2029 

-4- OG** DRAFT, Nov. 20, 2008 
Hatch for forLowNOx 

FCT offers to further investigate the operation of the pelletizing kiln using a pilot scale plant. The 

pilot scale plant is rated at 1 MW (3 MMBtu/hr) and is located at our head office. The plant is 

operated in conjunction with the University of Adelaide. 

The work will include assessment of flames and emissions using actual fuels to be used at USS 

Minntac. 

While the details of this phase will be somewhat dependant on the outcomes of Phase 1, pilot scale 

trials include the following scope 

• Pilot plant burners design and manufacture: 

• Design and manufacture of current and alternative hood: 

• Operating pilot plant including sourcing fuels and reporting of results: 

4. BUDGET PRICES 

Item Number Description Number BUDGET Price 

3.1 New Gyrotherm Kiln 1 US$200,000 

burner 

3.2 Pilot Plant Trials 1 US$200,000 

4.1 Site Services 

A daily rate ofUS1,300/day for each engineer would apply to site services. All costs such as air travel 

(business class air travel from Australia to Canada), cost of hire car, accommodation and living 

expenses, and out of pocket expenses would be charged to the customer at cost plus 10% for supply of 

above site services. However these costs aren't applicable if the customer chooses to provide these to 

FCT during site services. 

5. TERMS AND CONDITIONS 

This quotation and any ensuing contract is subject to the standard FCT, Inc. terms and conditions of 

contract unless otherwise agreed in writing except for the terms and conditions outlined in Section 6 

of this quotation. 

NOTE: All prices are based on the current exchange rates. Should this change significantly from this 

by the time an order is placed, FCT reserves the right to adjust the final price. 

6. SPECIAL CONDITIONS OF SALE 

6.1 Price Basis 

Contact: Sanjiv Dhanjal 

Cell: +I (484) 919-2029 

- 5 - OG** DRAFT, Nov. 20, 2008 
Prices are in US Dollars ex-works and exclude all applicable taxes and duties. 

6.2 Validity 

This quotation is for BUDGET purposes 

6.3 Delivery 

Typical butner delivery is 26 working weeks. Should this proposal be successful, then FCT will 

develop a project schedule based on the installation date required. 

All delivery periods are conditional upon receipt by FCT of full and complete information allowing 

design and engineering to proceed, and timely payment of progress payments. 

7. TERMS OF PAYMENT 

All payments to be made net 14 days from invoice date by check or electronic transfer to FCT Inc. 

Payment Schedule for Item 3.1 

l> 30% on placement of purchase order 

l> 60% on delivery of equipment 

l> 10% on commissioning 

Payment Schedule for Item 3.2 

l> 30% of contract value on placement of order 

l> 30% of contract value on completion of intermediate pilot plant trials and modeling 

l> 40% of contract value on provision of final report. 

8. LIMITATIONS OF LIABILITY AND CONSEQUENTIAL LOSSES 

FCT's limitation of liability shall not exceed the total contract value. FCT will not accept any claims 

for consequential losses howsoever arising. 

9. EXCLUSIONS 

The following items and services are excluded from the scope of supply of main kiln butner in this 

quotation: 

l> Any design, engineering, equipment supply or site installation services not specifically mentioned 

in this quotation. 

l> Site installation work. 

l> General plumbing or electrical equipment installation is to be done by others. 

l> No allowance has been made for any local duties and taxes which will be to customer's account. 

Contact: Sanjiv Dhanjal 

Cell: +1 (484) 919-2029 

-6- OG** DRAFT, Nov. 20, 2008 
> All necessary licences and approvals for installation would be obtained by the customer. 

> Delivery is ex-works, delivery, off-loading at site, civil works, site installation and electrical 

wiring are by others. 

10. OWNERSHIP OF INTELLECTUAL PROPERTY CREATED IN PROJECT 

Any Intellectual Property created during the Project will be owned by FCT. 

FCT will provide to the Customer an in-evocable, royalty free, licence in perpetuity for the use of the 

Background Intellectual Property and the Created Intellectual Property by the customer for the 

application the subject of this proposal. 

11. INSURANCES 

FCT will obtain and maintain insurances which it considers to be adequate for the Project, for the 

duration of the Project only (a period of one month after the successful installation of the equipment 

or completion of supply of the service). 

Contact: Sanjiv Dhanjal 

Cell: +I (484) 919-2029 

-7- OG** DRAFT, Nov. 20, 2008 
APPENDIX 1: FCT GYROTHERM BURNERS 

The economic performance of a rotary kiln is significantly influenced by the performance of its 

burner. This burner will influence the fuel consumption, production rate, product quality, refractory 

life and gaseous emissions for that plant. It is often surprising to calculate the extent to which the 

return on investment of the whole plant can be affected by such a relatively minor and low cost item 

such as the kiln burner. 

The most effective design of a kiln burner has to account for the aerodynamics of the environment in 

which the burner will operate, in addition to mechanical considerations to convey the fuel and ensure 

the burner withstands the harsh kiln environment. Another key factor is that the burner must operate 

within the range of kiln operation. 

A kiln flame and its heat transfer characteristics are directly dependant on the mixing process for air 

and fuel, and this in tum depends equally on the airflow patterns around the burner as much as the 

burner design itself. Most burners utilize the phenomenon of turbulent jet diffusion to ensure efficient 

fuel and air mixing. This includes axial and swirl flows, mechanisms that are public domain 

knowledge. FCT also offers "precessing jet" flow, where gas exits in a stirring type (precessing) 

action. This creates a naturally staged flame, which has enhanced flame emissivity. 

Figure I: Cross Section Diagram of Precessing Jet Nozzle 

The FCT Gyro Thetm burner incorporates a precessing jet to create an efficient burner, with high heat 

transfer and low emissions. To allow for maximum control the Gyro Therm burner also includes a 

number of standard axial gas nozzles. These help to make the flame narrow and long. By adjusting 

the ratio of gas through the precessing nozzles and axial nozzles, the flame can be made longer or 

shorter. This means flame adjustment can be carried out with little change in primary air. 

Contact: Sanjiv Dhanjal 

Cell: +1 (484) 919-2029 

- 8- OG** DRAFT, Nov. 20, 2008 
In some cases flame modeling is utilized. FCT utilizes various types of modeling to design an 

optimum burner. Some of these teclmiques are shown below. 

Contact: Sanjiv Dhanjal 

Cell:+ I (484) 919-2029 

-9-

Figure 2. Flame Modeling Techniques employed 

byFCT 

Figure 3: Multi Fuel Gyro-Therm rotary 

kiln burner design 

OG** DRAFT, Nov. 20, 2008 
for USS Minntac- for Low NOx Burner 

Swan Portland NOx Emissions 

~ 400 

~"' ~0 300 

u,. 

E~ 200 0.~ 

.sS 100 ~ 

... • • • • • 

• • • •• •• • • • +Swan Swirl 

•Gyro-Therm 

0 0 z 

950 1000 1050 1100 

Burning Zone Temperature (° C) 

Stack NOx emissions 

Type II clinker, Tyres, Oil and Gas 

1200 

• 37% Reduction 

- 1000 • 

E 

a. 

Eo 

s 

... 

0 

~ 

@) 

~ 

0 

z 

BOO 

600 

400 

200 

• 0 

' I ' 

10-Jul- 11-Jul- 12-Jul- 13-Jul- 14-Jul- 15-Jul- 16-Jul- 6-5ep- 7-5ep- 8-5ep-

% % % % % % % % % % 

Date 

" Gyro-lhenn • Old bumer 

Figure 4 and 5: Benefits Achieved with GyroTherm Burners 

Contact: Sanjiv Dhanjal 

Cell: +I (484) 919-2029 

- 10- OG** DRAFT, Nov. 20, 2008 
APPENDIX 2: FCT PILOT BURNER SYSTEMS 

Contact: Sanjiv Dhanjal 

Cell: +1 (484) 919-2029 

Figure 6: FCT Pilot Burner Front End 

Figure 7: Example of Pilot Control Station 

- 11- OG** DRAFT, Nov. 20, 2008 
~HATCH~ 

ISO 9001 

PR332002-01 US Steel Minntac- Nox Reduction 

Technology Report Doc 

United States Steel - Minntac Iron Ore Pelletizing Operation 

NOx Reduction Analysis 

Appendix D 

Cost Summary 

~ WorkingTogether Q SAFElY 

, Rev. 0, Page 20 

e Hatch 2006/03 X 
US Steel Minntac Iron Ore Pelletizing Plant - NOx Reduction 

Hatch Project No. 332002 

Cost Estimate(+/- 50% Order of Magnitude) 

Energy Systems Associates 

1. Burner Upgrades/Process Changes Scope of Services Installed Costs 

a. CFD Modeling Testing incl. below 

b. Pilot Plant Trials Demonstration Test incl. below 

c. Bumer Replacement Modified Bumer Tip 300,000 

d. Combustion Air Upgrades - - e. Misc. Field Testing $30,000 

f. Estimated NOx Reduction(%) 25% NOx Reduction 

2. Selective Non-Catalytic Reduction (SNCR) 

a. CFD Modeling CFD Modeling $50,000 

b. Pilot Plant Trials Demonstration Testing $45,000 

c. SNCR Upgrades SNCR Upgrades $900,000 

d. Misc. 

e. Estimated NOx Reduction(%) 35% NOx Reduction 

3. Selective Catalytic Reduction (SCR) 

a. SNCR Upgrades not viable $4000/ton NOx 

b. Estimated NOx Reduction(%) 80% NOx Reduction 

4. Low Temperature Oxidation (lo-TOx) 

a. Lo-TOx Equipment Upgrades not viable $5000/ton NOx 

b. Estimated NOx Reduction(%) 90% NOx Reduction 

Nalco Mobotec BACT Process Systems FCT, Inc. 

Scope of Services Installed Costs Scope of Services Installed Costs Scope of Services Installed Costs 

Testing incl. below - - Pilot Plant Trials (lab) $200,000 

- - - - - - - GyrotherTI'I Bumer $400,000 

ROFA $2,000,000 - - N/A N/A 

- - - Field Testing $50,000 

15% NOx Reduction - 30% NOx Reduction 

CFD Modeling submitted to USS Testing/CFD Modeling $80,000 

not included not included - Rotamix (SNCR) $2,000,000 SNCR Upgrades $1,700,000 

45% NOx Reduction 60% NOx Reduction 

- - -

- - -
Gateway View Plaza, 1600 West Carson Street, Suite 1 

Pittsburgh, PA, USA 15219 1031 

Tel (412) 497 2000 • Fax (412) 497 2212