aalities

again IIAZARdOUS
ational
. Also, WASTE
)re ap-
INCiNERATiON
If it is
;s rath-
Example of pART 5
. If the
r agree
;ion. If
or, the
incinerator
recent
:whose
cost estimation
volun-
dition, indicated by the dotted une). At 180°F, the flowrate is
The cost of a rotary-kiln incinerator
annual 1.14 X 106 actual ft3/h. The water vapor content at 180°F
doing. is estimated to illustrate the is 50% (from Fig. 3, Part 1). Therefore, the total flowrate
would of saturated fluegas downstream of the scrubber =
application of the cost-estimating
anage- [(1.14 x 106 actual ft3/h) X 1.51/(60 s/min) = 28,500 ac-
method and information presented in tual ft3/min.
Foam Estimate the volume of the primary combustion cham-
the previous articles of this series.
.ful for ber (rotary kiln) from the thermal input and the desired
ations. Gregory A. Vogel, The Mitre Corp., and heat release rate. In this case, the entire thermal input is
ilitator Edward J. Martin, U.S. Environmental Protection Agency assumed to enter the kiln; therefore the volume =
le the [34.8 x 106 Btu/h]/[30,000 Btu/(h)(ft 3)] = 1,160 ft3.
issues Compute the volume of the secondary chamber from
The example rotary-kiln incinerator is equipped with
oyees' the combustion-gas flowrate, in std ft 3/h, obtained from
an afterburner, energy-recovery boiler, venturi scrubber
rer the Fig. 1 (Part 1), corrected to actual flowrate at 2,200°F,
and packed-tower absorber.
used it and for the 2-s residence time: (880,000) [(2,200 +
The following are the incinerator's operating charac-
it. I've 460)1492] [2/3,600) = 2,700 ft s .
teristics: waste feedrate-5,000 lb/h; operating schedule-
-ations (For a more extensive discussion of the sizing of com-
24 h/d, 300 d/yr (7,200 h/yr); afterburner temperature-
bustion chambers, refer to Part 1 of this series.)
2,200°F; excess air usage-150%; residence time (after-
Noryl
burner)-2 s; heat release rate (rotary kiln)-30,000 Combustion chamber costs
, ndous
Btu/(h)(ft 3); auxiliary fuel—No. 6 fuel oil. Saturated
)ective fluegas leaves the scrubber (a once-through, lime-addi- Estimate refractory costs from the following firebrick
e con- tion type) at 180°F; the venturi pressure drop is 55 in. thickness and chamber area information:
back I Firebrick thickness (both chambers) = 6 in.
water-gage.
r since Insulating firebrick thickness: primary = 2 in.;
The waste feed's heating value is 6,000 Btu/lb. It con-
it how secondary = 4 in.
tains 21% water, 6% chlorine and 8% ash.
e bes t Primary combustion chamber area = 5.7
:aff by Sizing the combustion chambers (1,160)0 ' = 651 fe.
er." Secondary combustion chamber area = 5.76
Estimate the auxiliary fuel requirement by means of
a very (2,700)067 = 1,147 ft2.
an approximate heat balance:
re and Heat input = heating value of waste X waste Next, estimate refractory material and installation
team. costs.
feedrate = (6,000 Btu/lb)(5,000 lb/h) = 30 X 106 Btu/h.
r, Editor In primary chamber:
Heat output = fluegas enthalpy (from Fig. 1, Part 1) +
water-vapor enthalpy (from Fig. 2, Part 1) + radiation Material cost for 60%-alumina firebrick =
loss (5% of heat input) = (31 x 10 6 Btu/h) + (2.3 x 10 6 (6 in.)(651 ft2)[$2.411(ft2)(in.)] = $9,41$
6 Btu/h) = 34.8 x 10 6 Btu/h. Btu/h)+(1.5x0 Material cost for insulating firebrick
letal Auxilialy fuel requirement = heat output – heat input (2,000°F) = (2 in.)(651 ft 2)[$1.251
astics
(413) = 4.8 X 106 Btu/h. (ft2)(in.)] = $1,628
hology For the total thermal input of 34.8 x 10 6 Btu/h, the In secondary chamber:
an
fichigan, flowrate of dry fluegas resulting from the combustion is Material cost for 90%-alumina firebrick =
itions. 880,000 std fts/h, as estimated from Fig. 1 (Part 1; as
ing an (6 in.)(1,147 ft 2)[$10.25/(ft2)(in.)] = $70,540
na Pan 1 (Sept. 5, 1983, p. 143) of this series dealt with sizing equipment in integrated Material cost for insulating firebrick
incineration facilities as a prelude to estimating equipment costs, asid with estimating (2,600°F) = (4 in.)(1,147 ft 2)[$1.90/
the overall facility costa; Pan 2 (Oct. 17, p. 75) covered the costa of waste-storage and
-Ioading systems asid of combustion chambers; Part 3 (Nov. 28, p. 87) took up costa (ft2)(in.)] = $8,717
I Soc. of energy-recovery, air-pollution-control and fluegas-handling systems, and pre-
t'Id the sented adjustment factors for deriying the cost of an installed, operating plant; Pan 4 Total material cost $90,300
(Jan. 9, 1984, p. 97) presentad information for estimating direct operating costa and
a method for figuring steam credit; Pan 5 concludes this series. The estimate of the total installed cost depends on an

CHEMICAL ENGINEERING FEBRUARY 6, 1984 121

 COST FILE

Estimation of capital cost

of example incinerator

Combustion chambers:
Refractory
Shell
Burners
Itero

Waste-storage system (two 10,000-gal tanks)

Waste-feed system (screw feeder)
Table I

Cost, $

207,700
200,000
80,000
118,000
10,000
each of the two incinerator combustion chambers is sum-
marized as follows:
Two waste burners (each 20 million Btu/h) = 2 X
$35,000 = $70,000.
Two fuel burners (each 5 million Btu/h) = 2 X
$5,000 = $10,000.
(For cost data on combustion chambers and a more
detailed treatment of the cost-estimating procedure,
refer to Part 2 of this series.)
11
Ash-handling system 60,000
Energy-recovery boiler
Air-pollution control system (quench chamber,
scrubber and absorber)
290,000

410,000
Ash generation rate
An idea of the rate at which ash will be generated is
1
needed in order to estimate the capital cost of the ash-
Blower [of 304 stainless steel, operating at
handling system (Part 2) and effluent-disposal operating
45 in. w.g.; cost adjustment for 28,000
actual ft 3 /min at 30 in. w.g. = (45 - 30) costs (Part 4). The rate depends on the ash content of the
(0.015)(8100,000) + $100,0001 122,500 waste and the waste feedrate: (0.08 lb ash/lb waste)(5,000
Stack (carbon steel, 90 ft at $90/ft) 8,100 lb waste/h)(7,200 h/yr) = 2.88 x 10 6 lb ash/yr.
Breeching (refractory-lined, 30 ft at $300/ft) 9,000
Total equipment cost 1,515,300 Consumption of utilities and chemicals
Installation (50% of total equipment cost) 757,600 Water, power and chemical consumptions must be es-
Startup (10% of total equipment cost) 151,500 timated in order to arrive at operating costs.
Spare parts (8% of total equipment cost) 121,200
Water consumption in the quench chamber, venturi
Engineering (7% of total equipment cost) 106,100
scrubber and packed-tower absorber per 1,000 std ft 3 of
Instrumentation (20% of total equipment cost) 303,100
Total capital cost
combustion gas is estimated as follows (the relationships
2,954,000
for estimating water consumption in the quench cham-
ber and venturi scrubber are presented in Part 4):
Quench chamber 5.3 gal/1,000 std ft 3
Estimation of annual operating cost Venturi scrubber 328.6ga1/,0stdf
for example incinerator Table II Absorber 315.0ga/,stdf
Real Cost, $/yr Total 348.9gal/1,0stdf
Personnel (1 supervisor at $26,400; 2 operators
Total water consumption = (48.9 ga1/1,000 std
at $22,200 each; 4 yard - crew workers at
$15,000 each; 1 secretary at $15,000) 145,800 ft3)(880,000 std ft 3/h)(7,200 h/yr) = 3.10 x 10 8 gal/yr.
Electricity (473 hp)(7,200 h/yr)($0.037) 126,000 Power consumed by the blower motor is estimated
Water (3.1 x 10 8 gal/yr)($0.80/1,000 gal) 248,000 from the total pressure drop across the incinerator sys-
Auxiliary fuel: tem (70 in. w.g.) and the volumetric flowrate of saturated
Startup (10)18 h)(10 x 10 6 Btu/h)($5.62/10 6 Btu) 4,500 fluegas at the blower: Motor horsepower = (70 in.
Operating ($12/10 6 Btu))4.8 x 10 6 Btu/h) ter
w.g.)(28,500 actual ft 3/min)/4,464 = 448. The power
(7,200 h/yr) 414,700
consumed by the pump is estimated from the water an
Chemicals (2.25 x 10 6 lb lime/yr)($0.0167/1b) 37,700
consumption rate: Pump horsepower = (717 up
Effluent disposal:
Scrubber liquid (3.1 x 10 8 gal/yr)($1.20/1,000 gal) 372,000 gal/min)(0.036) = 25.
Ash (2.88 x 10 6 lb/yr)($0.005/1b) 14,400 Hydrated lime consumption depends on the waste fi)
Laboratory 60,000 feedrate and its chlorine content: (0.06 lb chlorine/lb tra
Maintenance (10% of total equipment cost) 151,500 waste)(5,000 lb waste/h)(7,200 h/yr)(1.04 lb lime/lb to
Refractory replacement ($207,700/8-yr life) 26,000 thE
chlorine) = 2.25 x 10 6 lb lime/yr.
Direct operating cost 1,600,600 mc
After these preliminary calculations have been done,
Value of recovered steam (Fig. 4, Part 4) (1,200,000)
the estimation of capital and operating costs is straight- zo
Net operating cost 400,600
forward. The few additional calculations remaining are ne
indicated in Tables I and II. pr
J. Matley, Editor
sp
installation factor of 2 and a freight factor of 0.3:
pr
($90,300)(2 + 0.3) = $207,700.
The cost of the incinerator shell and burner system The authors lE
must be added to the total refractory cost in order to Gregory A. Vogel, a technical staff member of the Environmental Engineering and
Hazardous Waste Dept. of The Mitre Corp. (1820 Dolley Madison Blvd , McLean,
arrive at the total cost of the combustion chambers. As- VA 22102), is a technical consultant to the U.S. Environmental Protection Agency,
suming that the shells of both the rotary kiln and after- Office of Solid Waste, for the development of hazardous-waste management regula-
tions. Holder of a B.A. in chemistry and an M.S. in chemical engineering from the
burner chambers are of carbon steel, the costs of the University of Virginia, he is a member of AIChE and the American Soc. for Testing FO
shells are estimated as follows: and Materials. rec
Rotary kiln (primary combustion chamber) = 651 Edward J. Martin, as Regulations Program Manager for the U.S. Environmental
ft2 x $175/ft2 = $114,000. Protection Agency (Office of Solid Waste, 401 M St. S.W., Washington, DC 20061), is \N`
responsible for developing hazardous-waste management regulations. Holder of a
Afterburner (secondary combustion chamber) = B.S. in civil engineering and an M.S. in sanitary engineering from Case Institute of lz
1,147 ft2 x $75/ft2 = $86,000. Technology, and a Ph.D. in environmental engineering from Rensselaer Polytechnic Ph
Institute, he is a member of many organizations, including the National Soc. of
The cost of one waste burner and one fuel burner in Professional Engineers and the American Soc. of Civil Engineers.

122 CHEMICAL ENGINEERING FEBRUARY 6, 1984