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30 YEARS OF EXCELLENCE Providing Utility and Industrial Services Coal Combustion Residuals Flue Gas Desulphurization Limestone Handling Coal Handling Landfill Design and Operations Logistics Equipment Maintenance Construction Management

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Page 1: 30 YEARS OF EXCELLENCE Providing Utility and Industrial ...flyash.com/data/upfiles/resource/HPS Kit.pdf · 30 YEARS OF EXCELLENCE Providing Utility and Industrial Services ... Wet-to-dry

30 YEARS OF EXCELLENCE Providing Utility and Industrial Services

Coal Combustion Residuals

Flue Gas Desulphurization

Limestone HandlingC

oal H

andl

ing

Landfill Design and Operations

Logi

stic

s

Equipment Maintenance

Construction Management

Page 2: 30 YEARS OF EXCELLENCE Providing Utility and Industrial ...flyash.com/data/upfiles/resource/HPS Kit.pdf · 30 YEARS OF EXCELLENCE Providing Utility and Industrial Services ... Wet-to-dry

Safe and Efficient Management of

Non-Core Site Operations

HEADWATERS PLANT SERVICES PROVIDES

COMPREHENSIVE MATERIALS MANAGEMENT

AND DISPOSAL SERVICES TO UTILITIES

AND INDUSTRIAL FACILITIES OF ALL SIZES.

Page 3: 30 YEARS OF EXCELLENCE Providing Utility and Industrial ...flyash.com/data/upfiles/resource/HPS Kit.pdf · 30 YEARS OF EXCELLENCE Providing Utility and Industrial Services ... Wet-to-dry

Your core business is generating electricity or manufacturing products. Our core

business is managing the raw materials and byproducts related to your core busi-

ness. Headwaters Plant Services Inc. offers the experience, vision, and capabili-

ties to create optimal programs for each client’s non-core site functions – so you

can focus on the business that’s most important to you.

An Ever-Changing World

Operating utility and industrial facilities becomesmore complex every year. Environmental, healthand safety regulations become more stringent on aregular basis. New technologies are deployed toreduce emissions, changing the character ofbyproducts and sometimes creating new byproductstreams altogether. Handling large volumes of rawmaterials and byproducts becomes a majorenterprise.

That’s where Headwaters Plant Services comes in.

A Constant Partner

Headwaters Plant Services is there every step of theway to help our clients find and implement theoptimal strategies for handling site services issues.

HPS is the largest disposal contractor in UnitedStates for Coal Combustion Residuals. We have over30 years experience at over 100 utility siteshandling all types of CCRs, plus other service

projects such as coal and limestone handling. Weare not a local contractor that sidelines in CCRhandling or disposal. We provide plant services asour core business.

Headwaters Plant Services provides a full suite ofservices for our utility and industrial clients.. Thestatistics speak for themselves:

• On-going projects at 25 utility and industriallocations

• Under contract to dispose of more than 15million tons of CCR annually

• Operate and maintain Flue Gas Desulphurizationdewatering plants

• Construct new or expand existing landfillsmeeting any and all regulatory requirements

Headwaters Plant Services also offers unique insightwhen planning for the future. No other companypossesses the historical perspective, national scale,operating experience and political and regulatoryexpertise that reside within the company. There isno better partner to assist you in when it comes toplanning your byproduct management.

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PermittingHPS can perform permitting for Storm water,wetlands, air, stream alteration, solid waste, and landfills.

R&DHPS laboratories have the capabilities to developMSDA sheets, product and characterizationtesting, OA/OC and as well as CCR research.

Engineering and DesignLandfill design – Wet-to-dry ash handlingconversion – Bulk storage facilities design –Material handling system design (bulk, powder,sludge, liquid) – Material processing system design(screening, pug-milling, jet-milling, pelletization,briquetting) – Site planning – Rail facilities – Scalefacilities – O&M procedures development – Landfillclosure and post-closure planning

ConstructionContract administration for Landfills – Materialhandling systems – Material processing systems– Bulk storage systems – Rail facilities – Scale facilities

Operations and LogisticsAsh marketing – Landfill management – Wet-to-dry ash handling conversion – Pond cleanoutsand closures – Landfill closure – Structural fill –Mine reclamation – Waste stabilization – Coal yardmanagement – Limestone management Railscheduling – Truck scheduling – Rolling stockmaintenance – Grounds maintenance

Headwaters Resources also performs evaluationsof existing landfills and disposal operations toassist clients in identifying emerging issues.

A DIVERSE MENU OF SERVICES

From individual services to turnkey operations, Headwaters Plant Services provides a range of options toutility and industrial facility managers. For each client, Headwaters Plant Services designs a custompackage that draws from these capabilities:

Page 5: 30 YEARS OF EXCELLENCE Providing Utility and Industrial ...flyash.com/data/upfiles/resource/HPS Kit.pdf · 30 YEARS OF EXCELLENCE Providing Utility and Industrial Services ... Wet-to-dry

10653 S River Front Parkway, Suite 300, South Jordan, Utah 84095 • PHONE 801.984.9400 • www.HWPlantServices.com

HPS – New Name, Decades of ExperienceHeadwaters Plant Services was formed to focus expertise where clients need it most today.

Many people know Headwaters Resources as aprominent marketer of coal ash for beneficial uses.Many people are not aware that the company alsohas a long history of providing management anddisposal services for coal combustion residuals andother industrial byproducts.

Enter Headwaters Plant Services.

As the complexity of managing residuals increasesbecause of changing regulatory demands, Headwatersoffers the vision, experience, and capabilities to createcomprehensive disposal and marketing programs forutilities and industrial facilities of all sizes. HeadwatersPlant Services was formed to focus exclusively on utilityand industrial services such as coal ash managementand disposal.

HPS is comprised of personnel from Headwaters’existing utility and industrial services practice. The teamhas more than three decades’ experience designing,permitting, constructing, operating and closing solidwaste disposal operations for coal-fueled utilities andother industrial clients.

While many engineering firms are qualified to designsafe and compliant disposal facilities, only HPS canoffer unparalleled expertise in ensuring that newfacilities are designed in a way that maximizes efficiencyfor both operations and potential recycling activities.Furthermore, HPS offers decades of experience actuallyoperating disposal facilities – freeing clients to focus ontheir core businesses of generating electricity ormanufacturing products.

HPS has extensive experience designing andconstructing residual management facitilites,conducting landfill operations and pond cleanouts,converting disposal operations from wet to dry handling,

designing and managing systems for handling flue gasdesulphurization materials, deploying systems forimproving coal ash quality to make it suitable formarketing, and more.

With on-going projects at more than 100 utility locationsand more than 15 million tons of coal combustionresiduals under management annually, Headwaters isthe largest manager of coal ash resources in the UnitedStates. Headwaters Resources is also responsible formore than half of the nation’s total sales of coal fly ashfor use in concrete applications – an importantcontributor to reducing greenhouse gas emissionsassociated with concrete construction.

Page 6: 30 YEARS OF EXCELLENCE Providing Utility and Industrial ...flyash.com/data/upfiles/resource/HPS Kit.pdf · 30 YEARS OF EXCELLENCE Providing Utility and Industrial Services ... Wet-to-dry

10653 S River Front Parkway, Suite 300, South Jordan, Utah 84095 • PHONE 801.984.9400 • www.HWPlantServices.com

Coal Combustion Residuals DisposalChanging regulatory requirements for coal ash disposal make a trusted partner more important than ever.

One thing is certain in the changing worldof Coal Combustion Residuals: Regulatoryrequirements will make disposal requirements morestringent and complex in coming years than they haveever been in the past. A partner whose core businesshas focused on CCR management for decades can beinvaluable in that evolving environment.

Headwaters Plant Services is the undisputed leader incoal combustion residuals management. Through itsaffiliates and predecessor companies, HPS has moreexperience than any other company in managing CCRsof all types. Services are tailored to the need of individualclients, ranging from managing specific aspects of CCRdisposal to providing complete turnkey operations andmaintenance services that handle all aspects ofoperations, from CCR collection to final disposal.

Leadership By the Numbers

Coal Combustion Residuals management is not asideline activity for Headwaters Plant Services. It is,and always has been, the company’s core business.The numbers tell the story:

• More than 15 million tons of material under contractfor management annually

• More than 100 utility locations served

• Experience constructing material handling facilities ofall sizes, up to four million tons of CCRs annually

• Experience constructing and operating landfills of allsizes up to 200 acres

Unparalleled Capabilities

More important than size, though, is HPS’ experience indeveloping and using industry best practices to ensureregulatory compliance and cost-effective operations.For instance, HPS utilizes the most advanced GPSequipment to ensure that disposal facilities areconstructed according to plans and at least cost.

HPS also maintains strategic relationships that ensureaccess to the most up-to-date equipment, includingpartnering agreements with two national heavyequipment suppliers and a partnering agreement with aleading national truck supplier.

Finally, no other company offers the capabilities HPShas already demonstrated for completing projects thatwill become increasingly common in the coming years,including conversions from wet to dry disposal methodsand developing integrated programs to increasebeneficial use of CCRs as an alternative to disposal.

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10653 S River Front Parkway, Suite 300, South Jordan, Utah 84095 • PHONE 801.984.9400 • www.HWPlantServices.com

FGD Management ServicesExperience makes a difference in getting the most from Flue Gas Desulphurization operations.

Headwaters Plant Services boasts 35 years of diverseexperience in FGD operations – experience that has shownthat the most costly facility is not always the one that iseasiest or most economical to operate and maintain.

HPS offers its expertise to ensure that its clients get themost from their FGD systems. From helping to designsystems that are best suited for each unique facility toperforming operations and maintenance services in themost cost-effective manner, HPS is a valued partner forany FGD installation.

Extensive ExperienceHPS staff experience includes design and constructionof 39 FGD facilities and engineering design services forfive plants.

HPS currently operates all aspects of a process facilityfor a major utility where HPS personnel havemaintained a presence for 25 years.

Technologies SupportedHPS has experience with calcium sulfate, calciumsulfite, dual alkali systems, and all equipment requiredfor these operations. Equipment experience includesoperation and maintenance of belt filters, rotary drums,segment filters, plate and frame, centrifuges, tanks,pumps, mixing systems, controls and instrumentation.

Project locations served by HPS staff range from thelargest to the smallest electric service providers in thenation, from Arizona to the East Coast.

Services OfferedThe HPS staff has a long and diversified history ofinvolvement in FGD processing. HPS staff memberswere at the forefront of conceptual design, engineering,construction, procurement and operations of FGDprocessing plants and equipment.

HPS offers the following services to plants operating wetor dry scrubbers:

• Conceptual design for dewatering equipment• Construction management • Consulting services in FGD• Operations and maintenance of FGD process

facilities and equipment• Operation of limestone preparation equipment and

material handling of limestone• Material handling

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Construction Management ServicesFrom concept to start-up, an experienced partner brings additions to your plant online more efficiently.

Headwaters Plant Services has the experienceand capabilities to provide construction managementservices for any capital projects on your plant site. HPShas special expertise in overseeing design andconstruction of facilities related to handling byproductsand waste materials, including fly ash, bottom ash,sulfite FGD sludge, synthetic gypsum, CFB bed ash,and waste water treatment sludge. HPS also managesdesign and construction of landfills and impoundmentsused to dispose of those materials.

HPS and its affiliates have handled coal combustionresiduals at more than 100 utility sites in the UnitedStates. No other company has the breadth ofexperience that HPS can provide when it comes toprojects involving CCRs.

Scope of Work

Probably the most important service that HPS canprovide is the establishment of the Scope of Work forany project. HPS can utilize its unparalleled experienceto ensure that each project will not only do what isrequired, but will also allow the utility to meet otherpossible needs in the future. For example:

• In the design of a new fly ash handling system, HPSwill design the system not only to allow for thedisposal of the fly ash, but also to allow the utility tomaximize the beneficial re-use of the fly ash. In somecases this has eliminated all disposal costs for ourutility clients.

Page 9: 30 YEARS OF EXCELLENCE Providing Utility and Industrial ...flyash.com/data/upfiles/resource/HPS Kit.pdf · 30 YEARS OF EXCELLENCE Providing Utility and Industrial Services ... Wet-to-dry

10653 S River Front Parkway, Suite 300, South Jordan, Utah 84095 • PHONE 801.984.9400 • www.HWPlantServices.com

• In selecting equipment types, HPS can draw fromdecades of hands-on experience operating andmaintaining almost all types of material handlingequipment in all regions of the country. From fly ashconditioning units, fly ash silos, pneumatic systems,and vacuum filters for FGD dewatering to almost anyother bulk materials handling system, our experiencewill ensure that the equipment chosen for the job willbe the right choice.

• HPS also operates numerous landfills across theUnited States, giving us insight that ensures landfilldesigns that not only meet all regulations, but alsoprovide operational efficiencies that contribute tocost effective operation of the landfill and lowerdisposal costs.

• A full time staff of regulatory professionals alsoensures that HPS provides advice that is timely andcomplete for every Scope of Work project. Correctlydefining regulatory requirements as part of the designprocess ensures compliance in the most cost-effective manner possible.

Design Overview

HPS frequently works with national engineering firms toensure that final designs not only meet requirements ofthe Scope of Work, but also that the designs are carriedout in a cost-effective manner. Decades of operationalexperience allow HPS to determine when systems are“over-designed” or when they are unlikely to meet therequirements of the project. Either of these conditionscosts plant owners money.

HPS maintains alliances with three of the largestengineering firms in the United States and is availableto review project designs on an as-needed basis fromany other engineering firm.

Construction Management

HPS also provides dedicated, on-site staff tosupervise construction projects and ensure timely,correct completion of projects. Examples ofconstruction projects HPS has managed in the pasttwo years alone include:

• Conversion of a wet fly ash disposal system to dryhandling

• Construction of a multi-million-dollar coal ash rail totruck transfer facility that is designed to handle morethan four million tons of coal combustion residualsannually

• Construction of the largest coal combustion residualslandfill in the United States, consisting of more than200 acres of development

All of these projects were completed on time and at orbelow budget.