Alternative Fuels Can Significantly Reduce Costs

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1 2006 Forum on Energy: Immediate Solutions, Emerging Technologies May Appleton, WI Alternative Fuels Can Significantly Reduce Costs Three Case Studies Presented by: David F. Seitz, P.E. Project Director RMT, Inc.

2 The Three Case Studies Heat Input (MMBtu/Hr Boiler Type Stoker Stoker Fluidized Bed Age (years) New Current Fuels Medium sulfur Bituminous Coal Low sulfur Bituminous Coal Wood Waste Mill Sludge Alternative Fuels Other Options Natural Gas Propane Upgrade for MACT Limit Use Discontinue Retrofit for NG Add SO2 Control PRB Coal Western Bituminous Illinois Bituminous Other coal Add SO2 Control Blending of Fuels TDF Other Wood Waste Coal Mill Rejects Mill Sludge TDF Wood Waste Carpet Waste BFB CFB Existing NG Boiler

3 Case Study 1 50 MMBtu/hr Boiler Normal Operating Conditions: Normal Steam Demand = 50% Capacity Peak Demand = 75% Capacity Operate at Steady Load/Blow off Excess Steam Over-sized 90 MMBtu/hr gas boiler available

4 Case Study 1 50 MMBtu/hr Boiler Existing Emission Controls: PM SO 2 NOx Multi-Clone Sulfur Limit in Coal None

5 Case Study 1 50 MMBtu/hr Boiler Driver for Change #1: Ease of Operation Lack of Experienced Operators Nuisance of Fuel and Ash Handling Opacity Limits in Boiler MACT

6 Case Study 1 50 MMBtu/hr Boiler Driver for Change #2: Boiler MACT Actual Emission Rate Lb/MMBtu Emission Limits Lb/MMBtu Unlimited Use Limited Use PM TSM Hg 0.13 x x 10 6 NA HCl NA CO NA NA

7 Case Study 1 50 MMBtu/hr Boiler Options Considered: Continue to Use Coal-fired Boiler Use 90 MMBtu/hr NG Boiler as alternative Modify boiler to use Hi Sulfur Coal Retrofit Boiler to burn NG Replace Boiler with NG Boiler

8 Case Study 1 50 MMBtu/hr Boiler Option Requirements NPV of Cost Status Quo Opacity Monitor $510,000 Limited Use Opacity Monitor > Use of NG Boiler $4.25 Million Use NG Boiler None $4.54 Million Higher Sulfur Coal SO2 Control PM Control Chemicals $2.25 Million Retrofit to NG Boiler rebuild $5.01 Million Replace w/ NG New NG Boiler $6.39 Million

9 Case Study MMBtu/hr Boiler Normal Operating Conditions: Normal Steam Demand >100% Capacity Gas-fired Boilers to handle peak and swing loads Redundant Capacity in Gas-fired Boilers

10 Case Study MMBtu/hr Boiler Existing Emission Controls: PM SO 2 NOx 3-Stage ESP Sulfur Limit in Coal None

11 Case Study MMBtu/hr Boiler Drivers for Change: Increasing Cost for NSPS Sub-Compliant Coal (<1.1 Lb SO 2 /MMBtu) Sulfur Level in Coal Fuel Feed System Restrictions Boiler MACT

12 Case Study MMBtu/hr Boiler Options Considered: Increased Use of Wood Waste Western Bituminous Eastern Bituminous Western Sub-Bituminous (PRB) Tire Derived Fuels Pelletized Paper

13 Case Study MMBtu/hr Boiler Indicative Coal Market Pricing Coal Type Size Sulfur content Indicative Price ($/ton delivered) $/MMBtu Current Coal Stoker 1 1/4x1/4 Sub compliance 1.12 lb SO2/MMBtu) $110 $4.40 Central Appalachian Stoker 1 1/4x1/4 Compliance 1.2 lb SO2/MMBtu $95 $3.80 Central Appalachian 2x0 Compliance 1.2 lb SO2/MMBtu $80 $3.20 Colorado 2x0 <1.2 lb SO2/MMBtu $80 $3.28 Colorado Stoker 1 1/4x1/4 <1.2 lb SO2/MMBtu $95 $3.90 Illinois Seam 2x0 2.5 lb SO2/MMBtu $70 $2.92 PRB 1 2x0 <1.2 lb SO2/MMBtu $40 $2.27 PRB 2 2x0 <1.2 lb SO2/MMBtu $48 $2.73

14 Case Study MMBtu/hr Boiler Economic Analysis Coal Type Capital Costs Reduction in Operating Cost ($/yr) Payback (years) Current Coal $0 $0 Base Condition Central Appalachian 2 x 0 Central Appalachian Stoker Coal Colorado 2 x 0 Colorado Stoker Coal $1 Million $1.8 Million 1/2 $0 $500,000 Immediate $1 Million $1.8 Million 1/2 $0 $500,000 Immediate Illinois Seam $7 to $12 Million $700,000 >10 PRB $2.5 to $7 Million $2.0 to $2.5 Million 1 to 3

15 Case Study MMBtu/hr Boiler Other Considerations: Compliance Coals exceed permitted sulfur limit - need to be offset by increased use of wood waste Market for wood waste not favorable Western Bituminous Coal delivery constrained

16 Case Study 3 New 380 MMBtu/hr Boiler Facility Steam supplied by: 1-10 year old MMBtu gas-fired boiler Normal Operating Conditions: Normal Steam Demand = 90% Capacity Annual Capacity Factor > 80% No Back-up Capacity

17 Case Study 3 New 380 MMBtu/hr Boiler Driver for Change: Cost for Natural Gas Cost for electricity

18 Case Study 3 New 380 MMBtu/hr Boiler Solution: System to supply Steam and Electricity 280,000 lb Steam per hour 8 MW electricity

19 Case Study 3 New 380 MMBtu/hr Boiler Preferred Technology: Circulating Fluidized Bed Bubbling Fluidized Bed

20 Case Study 3 New 380 MMBtu/hr Boiler Fuels: Coal eliminated due to emissions Wood/Wood Waste Pre-consumer carpet waste TDF Mill Sludge Mill Rejects Natural gas

21 Case Study 3 New 380 MMBtu/hr Boiler Select Fuel Characteristics Fuel Moisture (%) Sulfur (%) Ash (%) Cl2 (ppm) Heat Content (Btu/lb as burned) Natural Gas N/A N/A N/A ND 1,000 Btu/cf Carpet ,900 Bark/Wet Wood ND 4,500 Dry Wood ND 7,900 Paper Sludge ND 3,900 Heavy Rejects ND 7,100 TDF ,700

22 Case Study 3 New 380 MMBtu/hr Boiler Environmental Issues: Ozone Non-attainment Area BACT for NOx (SNCR and SCR?) NOx Offsets Minor Increase for VOC SO 2 Control includes polishing scrubber NSPS (proposed) Boiler MACT (new source standard)

23 Case Study 3 New 380 MMBtu/hr Boiler Maximum Criteria Pollutant Emissions Pollutant Maximum Emissions (tpy) Equivalent Average Value* (lb/mmbtu) CO < NOX < PM/PM SO2 < VOC

24 Case Study 3 New 380 MMBtu/hr Boiler Economic Considerations: Capital Costs: $50 Million Fuel Savings: $12 Million per year Electricity Savings: $2 Million per Year

25 PRESENTED BY David F. Seitz, P.E. Project Director RMT, Inc. Thank You

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