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 based 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 same 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 rate 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 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.

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

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), please 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 Email, 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@deltaducon.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, 

another "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 continuously 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-Degremont 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 low 
sulfur-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 volume 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

Internet: 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@epa.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 discussed that the ASHCONTM system is sized to 

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

unit. Because we have the existing sluice information, we would like 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 information, 

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 EPA/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. Mooney

Product Manager, Ash Technology

Clyde Bergemann Malvern

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

>>CLEAN ENERGY SOLUTIONS<<

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

Phone: +1 610-560-4302

Fax: +1 610-695-9724

Email: gary.mooney@us.cbpg.com

Internet: www.cbpg.com

Clyde Bergemann Malvern | 33 Sproul Road | Malvern | Pennsylvania | 19355
EPA - BA CONVERSION ANALYSIS 6-27-2011

MW ASHCONTM DRYCONTM SSC

BUDGET PRICE / UNIT

$ IN MILLIONS

<150 $4 $6 $7

150 to 300 $6 $8 $9300 to 500 $9 $12 $13

500 to 700 500 to 700 $11 $15 $17700 to 900 $15 $20 $22

Pricing given reflects fully erected and commissioned systems including equipment, controls, foundations and field labor. controls, foundations and field labor.DRYCON

TM:

Pricing reflects a complete system from boiler throat to a single dry bottom ash silo within 200 feet distance.SSC:Pricing reflects a complete system from boiler throat to a single semi-dry bottom ash silo within 200 feet distance.ASHCON

TM:

Pricing reflects a complete system from the discharge of an existing bottom ash slurry Pricing reflects

a complete system from the discharge of an existing bottom ash slurry

line into a single ASHCON

TM Remote Submerged Scraper Conveyor. The ASHCON

TM

RSSC conveyor shall overflow into a single sump pit where it would be pumped back to the boiler area for recycling. Water treatment system is not included.The estimated prices are approximate as each plant site will vary in layout.

6/27/2011