# Bottom Ash Handling Conversion Operating Characteristics and Conversion

Costs

The PDF documents EPA’s conversations with Clyde Bergemann Power Group (Previously

Delta Ducon).

From: "Elizabeth Sabol" <Elizabeth.Sabol@erg.com>

To: < CraigF@deltaducon.com>, <GaryM@deltaducon.com>

Cc: <jordan.ronald@epa.gov>, "Deborah Bartram"

<Deborah.Bartram@erg.com>, "Thomas Finseth" <Thomas.Finseth@erg.com>

Date: 06/23/2011 07:06 AM

Subject: Bottom Ash Handling

- Follow Up

Gary/Craig

,

Thank you again for your time on the phone this morning. As discussed, EPA

is requesting the following system information and cost items for the

ASHCONTM and SSC bottom ash handling systems.

ASHCONTM: Please provide cost data for ASHCONTM systems bas ed on the sluice

flow rate (gpd) for the wet sluicing bottom ash handling system currently

operated at the plant. Additionally, we have the following follow

- up

questions from our discussion this morning:

1. Is the overflow of the ASHCONTM system the sa me as the sluice flow rate

entering the system?

2. What is the maximum sluice flow rate that one ASHCONTM system can handle

(i.e., at what flow rate do you need to install a second ASHCONTM system)?

3. What is the standard clarifier used for applicable bids requesting the

additional clarifier option?

4. What is the typical pH of the overflow from the ASHCONTM system? To what

pH level does the overflow need to be adjusted in order to reuse the water

for sluicing the ash? What is the typical chemical used to adjust the pH?

5. What size motors are used to operate the ASHCONTM system? If the size

of the motor varies depending on the size of the system, please provide a

relationship between the sluice r ate and the size of the motor.

SSC: Please provide cost data for SSC systems based on the length of the

boiler (proportional to the unit MW). Additionally, we have the following

follow

- up questions from our discussion this morning:

1. What size moto rs are used to operate the SSC system? If the size of

the motor varies depending on the size of the system, please provide a

relationship between the boiler length (or MWs) and the size of the motor.

2. What is the typical overflow flow rate of an SSC s ystem?

In an effort to develop our model for bottom ash handling as soon as

possible, we ask that you provide the above cost data by Friday, July 1,

2011. If the responses to any of the requested data contain confidential

business information (CBI), p lease do not send a response via e

- mail.

Instead, please mail it hard copy to the address listed below (Attention:

Elizabeth Sabol).

14555 Avion Parkway, Suite 200

Chantilly, VA 20151

Please let me know if you have any questions.

Thanks,

Elizabeth

Elizabeth A. Sabol

Environmental Engineer

Eastern Research Group, Inc.14555 Avion Parkway, Suite 200

Chantilly, VA 20151

elizabeth.sabol@erg.com

Phone:703

- 633

- 1659

>>> <CraigF@deltaducon.com> 6/27/2011 1:58 PM >>>

Elizabeth, as a follow

- up to your Em ail, please find the attached Bottom

Ash Conversion Pricing.

Best regards,

Craig

Craig H. Fleming

Sales Engineer

Clyde Bergemann Delta Ducon

-----------------------------------------------------

>>CLEAN ENERGY SOLUTIONS<<

-----------------------------------------------------

Phone: 610

- 695

- 9700

Cell: 610

- 551

- 0856

Fax: 610

- 695

- 9724

Direct: 610

- 695

- 9726

Email: cfleming@clydebergemann.com

Internet: http://www.deltaducon.com

Clyde Bergemann Delta Ducon | 33 Sproul Road | Malvern | PA | 19355

From: <GaryM@deltaducon.com>

To: "Elizabeth Sabol" <Elizabeth.Sabol@erg.com>

CC: "Deborah Bartram" <Deborah.Bartram@erg.com>, "Thomas Finseth" <Thomas.Finseth@erg.com>,

<jordan.ronald@epa.gov>, <CraigF@de ltaducon.com>, <RonG@deltaducon.com>

Date: 6/27/2011 4:54 PM

Subject: Re: Bottom Ash Handling

- Follow Up

Elizabeth et al: In addition to the pricing we sent earlier, here are the

additional answers you requested:

ASHCONTM:

1. Is the overflow of the ASHCONTM system the same as the sluice flow rate

entering the system? Yes

2. What is the maximum sluice flow rate that one ASHCONTM system can handle

(i.e., at what flow rate do you need to install a second ASHCONTM system)?

We can design an ASHCONTM for any flow rate but in practice the

most flow we generally see is 3800 GPM in 12" pipes. In a 14" pipe

system, the flow would be about 6000 GPM.

Since multiple Boiler Units can send their slurry to one ASHCONTM,

an other "limit" is up to four to five Boiler Units per ASHCONTM since most

Boiler Units convey bottom ash in one to two hour cycles.

Most plants design around an 8 hour shift schedule so 4 to 5

Units would sequence one at a time into one continuou sly operating ASHCON

TM

As we discussed on the phone, additional SPARE ASHCONTMs are

common.

3. What is the standard clarifier used for applicable bids requesting the

additional clarifier option? A "contact" clarifier as supplied by

Infilco

- Degr emont or WesTech.

4. What is the typical pH of the overflow from the ASHCONTM system? To what

pH level does the overflow need to be adjusted in order to reuse the water

for sluicing the ash? What is the typical chemical used to adjust the pH?

The pH of sluice water is a function of the coal chemistry. Higher

sulfur content coals lead to an acid, low pH water slurry while lowsulfur

- high calcium coals like PRB lead to higher pH water.

Any pH control system merely tries to reach the neutral level of 7

but a range of 6

- 8 is fine.

The contact clarifier people supply pH control as part of their

design. Sodium hydroxide is common to raise pH and sulfuric acid can

lower it.

5. What size motors are used to operate the ASHCONTM system? If the size

of the motor varies depending on the size of the system, please provide a

relationship between the sluice rate and the size of the motor.

We have used a range of 50 HP (37 KW) to 75 HP (55 KW).

Yes, the motor size varies with the storage volume in the ASHCONTM

. There is not a significant cost difference across sluice rates.

SSC:

1. What size motors are used to operate the SSC system? If the size of

the motor varies depending on the size of the system, please provide a

relationship between the boiler length (or MWs) and the size of the motor.

We have used a range of 50 HP (37 KW) to 75 HP (55 KW).

Yes, the motor size varies with the storage vo lume in the SSC.

There is not a significant cost difference across MWs.

2. What is the typical overflow flow rate of an SSC system?

The main loss of water is the 20% water by weight that leaves with

the continuously removed bottom ash. For 6 TPH of ash, the water carried

out is 6 GPM.

Add in evaporation and the typical over flow average is 35 to 50

GPM.

Often, the water fill is intermittent and when a low water level

is detected, a valve opens to supply 200

- 400 GPM for a short period.

Also, when the pyrites are sluiced in from the surrounding

pulverizers, the incoming sluice water is 400

- 600 GPM.

Best regards,

Gary D. Mooney

Sales Engineer

Clyde Bergemann Delta Ducon

---------------------------------------------------------------------------

>> CLEAN ENERGY SOLUTIONS <<

___________________________________________

Phone: 610

- 560

- 4302

Fax: 610

- 695

- 9724

Email garymooney@clydebergemann.com

Inter net: www.deltaducon.com

Clyde Bergemann Delta Ducon | 33 Sproul Road | Malvern | PA | 19355

From: "Elizabeth Sabol" <Elizabeth.Sabol@erg.com>

To: <CraigF@deltaducon.com>, <GaryM@deltaducon.com>

Cc: <RonG@deltaducon.com>, <jordan.ronald@e pa.gov>, "Deborah Bartram"

<Deborah.Bartram@erg.com>, "Thomas Finseth" <Thomas.Finseth@erg.com>

Date: 06/30/2011 07:39 AM

Subject: Re: Bottom Ash Handling

- Follow Up

Craig/Gary,

Thank you for providing cost information and responses to our questions

for the bottom ash handling systems discussed during our call last week.

I do have one additional question regarding the cost basis for the ASHCONTM

system. During the call, we dis cussed that the ASHCONTM system is sized to

accommodate the existing ash sluice flow rate at the plant; however, thecosts provided for the system are based on the megawatt of a generating

unit. Because we have the existing sluice information, we would l ike to

obtain ASHCONTM costs based on sluice flow rate if that is the information

used to size these systems.

Additionally, if there is a correlation between sluice rate and megawatt

of generating unit that we can apply to the existing cost informatio n,

please let us know.

Thanks,

Elizabeth

From: <GaryM@deltaducon.com>

To: "Elizabeth Sabol" <Elizabeth.Sabol@erg.com>

CC: <CraigF@deltaducon.com>, "Deborah Bartram" <Deborah.Bartram@erg.com>, <jordan.ronald@epa.gov>,

<RonG@deltaducon.com>, "Thomas Finseth" <Thomas.Finseth@erg.com>

Date: 7/1/2011 8:14 AM

Subject: Re: Bottom Ash Handling

- Follow Up

- ASHCON Design

Elizabeth:

We had already incorporated our estimates for sluice rate into our

estimates for MW size.

Be careful though. We need/use the maximum instantaneous sluice rate INTO

the ASHCON at any time during the day. Not any average water usage such

as gallons per day.

One Customer wants us to size for two 12" conveying lines from Unit #1

plus one 6" overflow line from another Unit #2 all going into one ASHCON

for one hour every 8 hours.

That design sluice rate approaches 7000 GPM.

That would be an extreme case for our general Cost Information as follows;

MW Sluice Rate (GPM) (Assumed Line

Size)

<150 900

- 1200 6"

150

- 300 1200

- 1800 6"

300

- 500 1800

- 2800 8"

500

- 700 2800

- 3800 10"

700

- 900 3800

- 4800 12"

Enjoy your 4th of July!

Best regards,

Gary D. Mooney

Sales Engineer

Clyde Bergemann Delta Ducon

---------------------------------------------------------------------------

>> CLEAN ENERGY SOLUTIONS <<

_________________________________________ __

Phone: 610

- 560

- 4302

Fax: 610

- 695

- 9724

Email garymooney@clydebergemann.com

Internet: www.deltaducon.com

Clyde Bergemann Delta Ducon | 33 Sproul Road | Malvern | PA | 19355

From: <gary.mooney@us.cbpg.com>

To: < Deborah.Bartram@erg.com>, <Elizabeth.Sabol@erg.com>, <Alicea.Jezebele@epamail.epa.gov>,<Thomas.Finseth@erg.com>, <jordan.ronald@epa.gov>

CC: ron.grabowski@us.cbpg.com <ron.grabowski@us.cbpg.com>

Date: 10/9/2012 11:09 AM

Subject: CBPG Revised Chart for E PA/ERG

Attachments: EPA

- BA CONVERSION ANALYSIS 6

- 27

- 11

- UPDATED.pdf

Good Morning, All: Here is our Revised Chart with the "CONFIDENTIAL"

removed.

Thank you again for your continued interest in our quality designs and

equipment.

Regards,

Gary D. Mo oney

Product Manager, Ash Technology

Clyde Bergemann Malvern

-----------------------------------------------------

>>CLEAN ENERGY SOLUTIONS<<

-----------------------------------------------------

Phone: +1 610

- 560

- 4302

Fax: +1 610

- 695

- 9724

Em ail: gary.mooney@us.cbpg.com

Internet: www.cbpg.com

Clyde Bergemann Malvern | 33 Sproul Road | Malvern | Pennsylvania | 19355EPA - BA CONVERSION ANALYSIS 6-27-2011MWASHCONTMDRYCONTMSSCBUDGET PRICE / UNIT$ IN MILLIONS<150 $4 $6 $7150 to 300 $6 $8 $9300 to 500 $9 $12 $13500 to 700$11$15$17500to700700 to 900 $15 $20 $22Pricing given reflectsfully erected and commissioned systems including equipment,controls, foundations and field labor.controls,foundationsandfieldlabor.DRYCONTM:Pricing reflects a complete system from boiler throat to a single dry bottom ash silowithin 200 feet distance.SSC:Pricing reflects a complete system from boiler throat to a single semi-dry bottom ash silowithin 200 feet distance.ASHCONTM:Pricing reflects a complete system from the discharge of an existing bottom ash slurryPricingreflectsacompletesystemfromthedischargeofanexistingbottomashslurryline into a singleASHCONTMRemote Submerged Scraper Conveyor. TheASHCONTMRSSC conveyor shalloverflow into a single sump pit where it would be pumped back tothe boiler area for recycling. Water treatment system is not included.The estimated prices areapproximate as each plant site will vary in layout.6/27/2011