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NIAGARA Development seeks buyer of “On-Site Power Generation and Utilities”!

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With the various economic incentives, prospective manufacturers, possibility of supplying electricity behind the meter, or with a complete rebuild to sell electricity to the grid (using one of the many BIO-Fuels benefit programs), one could quickly negotiate with NIAGARA Worldwide to get the recently shut down facility, bought, leased or managed.


Contact us today to set up a site walk and process review:
Eric J Spirtas – President NIAGARA Worldwide LLC – 314.780.3742 – eric.spirtas@niagaraworldwide.com


Steam Production

The New Page mill has (4) four 75,000 lb per hour coal fired power boilers (located in building 45) that produce process steam for drying paper, heating water, heating the buildings and producing power. Coal is delivered by truck from the Escanaba lakefront dock to an on-site storage yard, which has a 10,000 ton storage capacity.  The coal is then processes through a crushing and screening system (located in building 97), where it is sized for use dependent on the boiler being supplied (stoker or pulverized coal fired).  Two of the four boilers also have the ability to burn wood waste as a supplemental fuel.  Wood waste is produced on-site in the PGW fiber pulping process and also purchased locally.  All four boilers are ducted through a common state of the art electrostatic precipitator (building 90) and electrostatically enhanced baghouse to control particulate emissions.  The baghouse was installed in 2006 at cost of 7.5 million dollars and is considered the best available control technology (BACT) for particulate matter control.


Filtered Water

The Menominee River
is the main source of water for the paper mill. A pumping station (located in building 57) draws water from the river and pumps it to the water filtration plant (located in building 56) where it is treated for suspended solids and color.  The plant capacity is approximately 7.2 million galloons per day.


Waste Water Treatment

Waste water is treated by means of two different processes.  An aerobic facility (buildings 89, 93, and 104) treats low BOD process waters at a maximum average capacity of 8 million gallons per day.


Waste Water Treatment
(Continued)

An anaerobic treatment facility (building 99) pre-treats high BOD process waters at a rate of 1.5 million gallons per day.  Solids from the treatment facility’s are concentrated using two Andritz presses (building 103) and then spread on local farming land.

Utility Department Process details

Steam Generation

Typical Monthly Totals

Total steam produced:  132.4 mm lbs.

Boilerhouse auxiliary:  12.4 mm lbs.

Steam turbines:  24.3 mm lbs.

Process:  95.7 mm lbs.

#1 Boiler

1939 combustion engineering water tube boiler

Steaming capability

75,000 lb/hour 80% efficient (coal)

450 lb. steam @ 675 deg.

Fuel used – pulverized coal

15,000 tons of coal per year

2 – CE Raymond 372 bowl mills

New Ro type burners in 1996

6” wide x 10’ long x 8’ tall dutch ovens that burn 14,250 tons of bark per year

Bark produces 30 to 35 K/Lb/hour

wood waste:  70% efficient

2 five million BTU natural gas ignitors for lighting off the coal

#2 Boiler

1939 combustion engineering water tube boiler

Steaming capability

75,000 lb/hour 80% efficient

450 lb. steam @ 675 deg.

Fuel used – pulverized coal

15,000 tons of coal per year

One CE-Raymond 453 bowl mill

Installed in 1997

New Ro type burners in 1996

2.6’ wide x 10’ long x 8’ tall dutch ovens that burn 14,250 tons of bark per year

Bark produces 30 to 35 K/Lb/hour

Wood waste:  70% efficient

2 five million BTU natural gas ignitors for lighting off the coal

 

#3 Boiler

1948 combustion engineering water tube boiler

Steaming capability

75,000 lb/hour 85.5% efficient

450 lb steam @ 675 deg.

Fuel used – pulverized coal

27,000 tons of coal per year

CE Raymond 453 bowl mill

DCS Bailey Infi 90 installed in 1999

2 five million BTU natural gas igniters for lighting off the coal

#4 Boiler

1963 Babcock & Wilcox Detroit roto-grate stoker

Steaming capability

75,000 lb/hour 86.1% efficient

450 lb steam @ 675 deg.

Fuel used – 1 ¼” x 3/8” stoker coal

Coal fed into boiler by three Detroit roto-grate stokers

23,000 tons per year  

Controls

All boilers and auxiliaries are controlled by a Bailey DCS system

#2 boiler in 1997

Auxiliaries in 1998

#1 boiler in 1998

#4 boiler in 1998

#3 boiler in 1999

Coal Crusher

Designed to run 50 tons per hour of run of mine coal (6” x 0” or 5” x 3/8”)

Gunlach Machine Company double stage crusher

Coal crusher building

Crushes the coal into two categories (2” x 1 ¼” and 3/8” x 0”)

All coal is sent to a double deck vibrating screen where the sizing takes place

Stoker coal 1 ¼” to 3/8” goes to #4 boiler

Coal 2” to 1 ¼” and 3/8” to 0” goes to pulverized coal boilers #1-2-3

Stocker coal pile – 8,724 tons

Stoker coal is stored in a 60 ton silo until use

Coal storage area can hold 10,000 tons of coal

 

Coal Specifications

Heating value – 13,000 BTU/lb. (min 12,500 BTU/lb)

Ash content – target 7.5% maximum 8.5%

Moisture – 5% maximum

Sulpher range – 0.8% to 1.8%, 2% maximum at 13,000 BTU/lb.

Grind – 50 to 55 HGI

Volatile matter – 35% to 38% based on fuel specification

Fixed carbon – 19% to 52% based on fuel specification

Ash fusion – target 2,300 Deg. F ID

 

Bark Handling System

Drag type conveyor system that handles 14 tons of bark per hour

All of the woodbark (15,000 tons/year) that is blown to us, plus what we receive from an outside supplier (42,355 tons/year)

All wood waste is burned in boilers #1 & 2 dutch ovens

Produce 30 to 35 K/Lb/hr in each boiler from wood wastes

3.15 pounds of steam per pound per bark

Ash Handling System

Two ash silos

South silo

Unloader is rotary drum type (1962)

Collects ash from all 4 boilers

Bark furnaces back end and fly ash

Dry ash handling system

North ash silo

Unloader is from United Conveyor Model 1535/45 twin paddle mixer

Ash comes from the precipitator, ash hoppers under each field

Dry ash handling system

All ash hauled to a company owned solid landfill site

Precipitator

1974 electrostatic precipitator with one common stack from all four boilers

Four fields have weighted wires in the first three fields

Fourth field installed in 1997 with riged discharge electrodes

Controlled by a precip-tech SQ-300 automatic voltage controllers

Efficiency is 99.8% at zero opacity

Baghouse

GE Max 9 baghouse installed in 2006

Electrostatic enhanced

First of its type in operation

Nine modules, 1188 bags

Maximum temperature is 500 degrees F

300,000 Acfm gas volume

Clarage #173 5450 RHW ID fan

86 ½” diameter

300,00 CFM, 20” S.P. 450 degrees F

1250 HP, 1200 RPM ID fan motor with spare

Variable hydraulic Gyrol drive with spare

Howden size 315 class 4

Internal pump geared for 1200 RPM


Power Generation

The FERC hydro project number 2536-009 has been sold to Northbrook Energy

Raw Water Supply System

Basin Capacities

Quick mix basin – 24,000 gallons

Flocculation basin – 80,000 gallons

Settling basin – 2,000,000 gallons

Clearwell – 600,000 gallons

Six filter beds – 392 ft2 each

Raw Water Supply Pumps

Primary – Two vertical 3500 GPM pumps per 250 HP motors

Backup – One pump, 7500 GPM

Chemical Feed Systems

40-80 ppm alum at raw water pump discharge – dosage dependent on river water quality and temperature

0-2.0 ppm coagulant polymer (alum replacement) at raw water pump discharge

0-2.0 ppm flocculent polymer at discharge of quick mix basin

10:1 ratio NaOC1:NaBr added at feed to filter beds – closed loop ORP control to 780 target

Chemical Storage Tanks

Filter plant

850 gallon flocculent polymer

2 tanks 2500 gallons each – sodium hypochlorite

2 tanks 1500 gallons each – sodium bromide

Pump house

1500 gallons coagulant polymer

8000 gallons alum

Powerhouse

1500 gallons coagulant polymer

Sludge Removal

DCS operated zone valves remove sludge from settling basin to sludge pit

40 HP sludge pump empties sludge pit to effluent plant sewer

Each filter bed backwashed once per day

50,000 gallons per filter

Backwash recycled automatically to quick mix basin – 300,000 gallons per day

Process Description

The process is controlled by the Bailey DCS

The primary pumps are supplied from a 40,000 tank located under the powerhouse – Two sources supply this tank

In winter, warm water from #2 turbine condenser (8000 gpm) is reclaimed for heat value

Any additional makeup (100% during summer months) is provided by a 20” line from the penstock

Alum and coagulant polymer are added at the pump discharge for good mixing

The raw water is pumped through a 16” heat traced line to the quick mix basin at the filter plant

A flocculent polymer is added at the discharge of the quick mix basin as the water enters the flocculation basin

Solids settle in the settling basin and the water is disinfected as it enters the filter beds

From the filter beds, the water enters the clear well for distribution to the mill

Each filter is backwashed once per day for approximately five minutes at 10,000 gpm

In-line meters track the turbidity before and after the filters

Disinfection is controlled by an ORP controller

Filters

Leopold underdrain with Integral Media Support Cap

10” silica sand

14” filter anthracite

Air scouring headers on 4 of 6 filters

Environmental

Anaerobic Pre-Treatment Facility

Purpose:  To treat high BOD process waters

Neutralization tank (175,000 gallons) – combination of high BOD waste waters and waste-activated biosolids from the aeration system

Two anaerobic reactors (2,450,000 gallons each)

Degas tank (34,800 gallons)

Gravity clarifier (734,000 gallons)

Settled biosolids aer split into two streams, one stream is sent to the dewatering plant (80 gpm) and one stream is returned to the anaerobic reactors (600 gpm)

Effluent from clarifier is sent to aerobic treatment facility (1,500,000 gallons per day)

Biosolids Dewatering Plant

Purpose:  To concentrate biosolids for use in the Niagro program or for landfill

Two Andritz presses (400 gpm maximum capacity each) – settled biosolids from the anaerobic plant clarifier are combined with underflow solids from the primary clarifier in the aerobic treatment facility

Average production:  250 gpm, 30 dry tons per day

Aerobic Treatment Facility

Purpose:  To treat low BOD process waters, effluent from the anaerobic plant and effluent from the dewatering plant

Primary clarifier (2,460,000 gallons)

Average flow into clarifier 6,500,000 gallons per day (5.5 million in winter and 7.5 million in summer)

Underflow solids sent to dewatering plant

Overflow sent to aeration tanks

Two aeration tanks (40,000 gallons & 871,000 gallons)

Two rectangular secondary clarifiers (945,000 gallons & 1,081,000 gallons)

Settled solids are split into two streams, one stream is sent to the anaerobic plant (250 gpm) and one stream is returned to the aeration tanks (9200 gpm)

Effluent is sent to the Menominee River (6,000,000 gallons per day average)


Contact us today to set up a site walk and process review:
Eric J Spirtas – President NIAGARA Worldwide LLC – 314.780.3742 – eric.spirtas@niagaraworldwide.com

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