# Development of Chemical Precipitation Purchased Equipment

Costs:

Filter Presses

Purchased Equipment Costs are the sum of the following cost elements:

(1) Pump Costs

(2) Tank Costs

(3) Chemical Feed System Costs

(4) Mixer Costs

(5) Clarifier Costs

(6) Filter Press Costs

(7) Sand Filter Costs

Each cost component includes the cost of freight and associated ancillary equipment such as piping, valves, and

controllers.

Th e following emails support EPA’ s development of cost element (6 ) by documenting EPA's communication

with a vendor regarding purchase costs for filter presses used in the Steam Electric cost model.Project No.: 0172. 08 .02 9 .0 4 4 DISTRIBUTION

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Project Name: Steam /Cost/Compliance Modeling

TELEPHONE CALL RECORD

Outgoing Call Date: 04/5 / 2011 Time: 11:15 a m EST

Company Name: Andritz Separation Contact Name: Bill Perron

Phone No.: ( 817 )

- 419

- 1772

Email address: bill.perron@andritz.com

Name: Kavya Kasturi ERG

GENERAL SUBJECT: Vendor cost request for filter presses for a chemical precipitation wastewater treatment system.

TOPICS DISCUSSED AND ACTION TAKEN

On April 5 , 20 1 1 at 11:15 a m I contacted Mr. Bill Perron . I explained to M r

. Perron that we are working

on conceptual level costing of a chemical precipitation wastewater treatment system to treat FGD (flue gas

desulfurization) wastewater fr om steam electric power plants and a s a part of this project, we are trying to

collect cost information on different components or units of a chemical precipitation system

.

I told Mr. Perron that we would like to obtain purchase costs (including ancillary equipmen t), power

requirements and any available marketing material or brochures for recessed plate and frame filter presses for

wastewater flow rates ranging from 7 gpm to 700 gpm

.

Mr. Perron was familiar with FGD wastewater treatment. He said the cost of the fi lter press will vary by the size

of the machine and the options chosen. He stated that filter press plates can range in size from 470 mm to 2.4 m.

He stated the number of chambers formed by the plates could be between 2 chambers and 100 chambers.

Mr. Perr on stated that for FGD wastewater, the most common plate sizes used are 1500 mm, 2000 mm, and 2.4

m. He said that these are usually for wastewater flowrates of 500 to 1,500 gpm. He said the cost of these filter

presses may range from $300,000 to $1,000,000 . The cost is impacted by whether high or low pressure is used

and whether a cloth washer is included. If membrane squeeze or recessed plates are used, approximately

$150,000 can be added to the cost.

I asked Mr. Perron for more details on the specific costs. Mr. Perron directed me to send him an email with

additional details to which he could respond. I sent an email to Mr. Perron on April 5, 2011 at 11:29 am . After

no response was received, I emailed Mr. Perron again on April 18, 2011 at 4:44 pm . Mr. Perron then direct ed

my email to Mr. Alex Yaz dj erd.Project No.: 0172.08.029.044 DISTRIBUTION

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Project Name: Steam/Cost/Compliance Modeling

TELEPHONE CALL RECORD

Outgoing Call Date: 04/22/2011 Time: 10:00 a m EST

Company Name: Andritz Separation Contact Name: Alex Yazdjerd

Phone No.:( 817)

- 375

- 4493

Email address: alex.yazdjerd@andritz.com

Name: Kavya Kasturi ERG

GENERAL SUBJECT: Vendor cost request for filter presses for a chemical precipitation wastewater treatment system.

TOPICS DISCUSSED AND ACTION TAKEN

Mr. Yazdjerd attempted to contact me by phone and email. On Friday, April 22, 2011 at 10 am, I contacted Mr.

Yazdjerd. I explained my request to Mr. Yazdjerd as I had previously to Mr. Perron.

Mr. Yazdjerd indicated he was familiar with FGD wastewater. I asked if special materials were required due to

the high chlorides levels. Mr. Yazdjerd stated that the plates are made out of polypropylene which is appropriate

for FGD sludge. He stated that the unit itself may need special piping and valves to accommodate FGD sludge

.

Mr. Yazdjerd stated that underflow rate from the clarifier is needed to cost filter presses. He stated typically a

filter press runs 8 hpd, 5 days per week but can run up to 12 hpd, 7 days per week. Also, if sludge is stored for

processing, more cycles may be necessar y.

The largest size filter press is the 1.5 x 2

. The plates are 1.5m square. The depth of the plate recess is 16 mm

yielding a 32 mm cake. The maximum pressure that can be applied without damaging the plates is 100 psi. A

positive displacement, progressiv e cavity pump should be used. A fast fill pump may be used for large presses.

Typically in such cases, a fast fill pump (high volume, low pressure, e.g., high gpm, 30 psi) would be used first

and then a feed pump would be used to top off the press. Mr. Yaz djerd stated that for FGD applications, it was

likely that only a feed pump would be required. Mr. Yazdjerd stated an animation of the filter press operation

was available on the Andritz website, www.andritz.com.

A cycle takes approximately 1 hour and an additional half an hour is required to get ready for the next cycle,

yielding a total cycle time of 1.5 hours. At the start of the cycle, the pump brings sludge in. No operator is

needed until the filtration cycle is complete. Then the press is opened to r emove the cake. Once the cycle is

complete, the cake has 40

- 50% moisture.

The feeds solids typically range from 8

- 12%. Mr. Yazdjerd said 10% solids is a reasonable assumption. Mr.

Yazdjerd described that the size and number of filter presses could be calc ulated using the volume of the press

and the flow rate of sludge in the system. For example, a small size press has a capacity of 10 0 cubic feet which

translates to approximately 748 gallons. The press is filled in 5

- 6 minutes. By dividing 748 by 6, the sl udge

flow rate can be found.

Mr. Yazdjerd recommended using multiple presses instead of one large press due to shipping constraints and

having redundancy.