THE HONEYWELL PROJECTGoing Where No Pipeline Has Gone Before

MILESTONES

• 23 miles in length

(believed to be the longest dedicated landfill gas pipeline in the world).

• Links one of the Largest East Coast Landfills with one of the largest natural gas consumers.

• Required the approvals of 3 municipalities and 7 agencies in order to be built.

• When built-out will have ability to flow 14,000+ SCFM

• LFG is utilized in direct LFG-fired engines to turn LFG screw compressors at the landfill.

Thank you - Team1. Honeywell International Inc. 1. The Governor’s Energy 2. Waste Management, Inc Office 3. Sussex County 2. The LMOP Team 4. Prince George County 3. The VA Legislature 5. The City of Hopewell 4. EPA Durham, Reg.3 6. John Hancock 5. VA DEQ 7. Arthur J. Gallagher

6. VA DOTFinancial8. ISCO 7. VA SCC 9. Polypipe 8. VA Marine & Wildlife 10. SCFM 9. VA Dept. Conservation 11. Flora Surveying 10. SCS 12. Diamond K 11. Michael’s Pipeline 13. Gas Control Engineering 12. Armstrong Electric 14. Dawn Pipeline 13. Paul Tower 15. Jericho Construction 14. CTS Eng.16. Lee Supply

15. Engineering Sales 16. Bill Melton, Tiny & Slasher

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Pipelines • Have the legal

authority to selllandfill gas

• Change NSPS • Contractors • Public Relations• Federal Codes • S.C.C. • D.O.T. • D.C.N.R. • Restoration

The Challenges

Pipelines Permits & Authorizations

1. VASCC - Qualified welders, qualified procedures 2. VDOT Encroachment permit 3. Landfill air emissions permits 4. Local building permits for plant 5. Certified VA Land Disturbers for VADCR 6. Wetlands disturbance 7. Individual Land Owner Easements 8. Local approval of the board(s) 9. Local land disturbance permits 10. Local zoning -- special use permit 11. City of Hopewell franchise agreement

Pipelines Connecting Industry

• This pipeline connects Waverly,VA to the industrial Mecca of Hopewell, VA

• There are seven major industries and three large co-generation plants in town

• This line is connected to Honeywell’s Hopewell site. The plant manufactures ammonium sulfate and caprolactam (a base building block of nylon)

Pipelines Atlantic Waste Landfill

Connecting Industry

Pipelines Connecting Landfills

• Connecting large landfills is difficult. • The sites are generally remote. • There are usually some geographical

connection challenges (swamps, rivers, rock, sand).

• The WMI Atlantic Site is a major rail intake facility.

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Compression Skid

Pipelines Directional Boring

1. Directional Boring needsengineered calculationsprior to boring.

2. DB needs weak links. 3. DB needs support

equipment (i.e. mudreclaimer, hoe, support trucks for rods, water truck(s), vac truck(s).

4. DB was fully supported on swamp mats.

5. DB should be pigged andpressure tested

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• (2) Small 40,000 lbrigs shot underdriveways for pullsunder 350’.

• (5) Larger 80 x120 rigsmade the 400’ to 1400’ shots.

• The first number is thrust and the second number is pull-back.

• Pullbacks are continuouslymonitored

Directional Rigs

Pipelines Biblical Rains

1. 3 consecutive months above 20” of precipitation.

2. Record Days withoutsunshine.

3. Finally July, August,and September hadhot days and hotnights to keep theconstruction activities going.

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Pipelines Historical Areas

1. Went by one signer of the Declaration of Independence.

2. Followed the old – Confederate Highway.

3. Passed a Confederate Hospital.

4. Went along ‘TheBeefsteak Raid’ Route.

5. Had many fielddiscussions with local historians.

6. Souvenir hunters with metal detectors following equipment.

Pipelines Cleanup

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Building Roads in Swamps

Factors for Consideration

• Developers need to know right of wayissues. No rights of condemnation.

• Pipeline training 1. Federal 191 & 192 Regulations2. Having qualified and approved plans for

welders, drillers, fabricators, operations,and maintenance.

3. Time to educate -- transmission, distribution, or service line ?

4. How many customers can be served?

About the Hopewell, Virginia Plant:

• Located about 23 miles SSE of Richmond, VA • Constructed in 1915 >> DuPont munitions plant• Today >> World’s largest single-site producer of

caprolactam and ammonium sulfate • 6.8 billion pounds of materials produced annually • Caprolactam is the monomer for nylon polymer • Nylon used in carpet fibers, engineered plastics,

and films • Ammonium sulfate used in fertilizers

• Employees 750 people Sulf-N®

Ammonium Sulfate

Fast Facts about the LFG project:

• Talks began in 1999 • Supplier contract signed in 2002 • Pipeline construction completed in 2004 • Started flow of LFG on January 23, 2004 • Zero capital project for Honeywell • 23 mile pipeline • LFG displaces portion of NG fuel to Reformer • 15-year supply contract with Waverly Gas Producers

• NOx reduction of 60 tons per year • Equivalent to planting 5544 square miles of trees • Equivalent to not burning 1.2 billion gallons of oil

About the Honeywell Team:

• Safety • Legal • Environmental • Construction Management • Process Engineering • Maintenance • Design Engineering • Quality Assurance • Reliability Engineering • Community Relations • Purchasing • Plant Management • Finance & Accounting • Corporate • Operations

About the LFG system:• Landfill site utilizes gas-fired compressors,

refrigeration, siloxane filtration

• Honeywell site utilizes compressor to boost pressure to 80 psig

• On-line analyses include O2, CH4, N2, CO2

About the LFG system:

• LFG is blended with fuel stream fed to Reformer

• System designed to receive all LFG that is available

• Natural gas control valve balances fuel requirement

LFGSpent H2 Gas

Natural Gas

About the Reformer process:

• Ammonia manufacturing plant • Reformer makes hydrogen from methane and steam

• CH4 + H2O => 3H2 + CO • Reaction is endothermic; heat input required • Heat input provided by NG fuel • Reaction occurs inside catalyst-packed tubes • NG fired downward from ceiling, between rows of

tubes • 154 burners configured in 14 rows

• 8000 scfm NG burned in Reformer- 12,000 MMbtu/day

PRIMARY REFORMER

Gas

Spent H2 Gas

LFG

Natural

Process for Utilizing LFG in Reformer

Purchase and Receive LFG

Pressure Gas Blending

Fuel Combustion

Flue Gas to Stack

Control

�Safety �Air Emissions �Reliability �Yield �Operations �Cost

Failure Mode and Effects Analysis

• Identifies possible failures • Identifies potential effects • Rates the severity of the effects • Identifies potential causes for the

failures • Estimates frequency of causes/failures • Ranks failures and effects • Facilitates recommendations

Important factor identified and addressed:

• Oxygen content in LFG • Blending with high hydrogen spent gas stream • Performed explosion limits analysis • Established oxygen limit set points • Installed redundant oxygen analyzers with system

interlocks • Installed fuel stream temperature sensors with

interlocks • Installed natural gas purge system

Important factor identified and addressed:

• Siloxane content in LFG • Application in high temperature furnace • Flue gas passes across multiple heat exchanger

coils • Coils are tightly packed tubes, some with fins • High potential for coil fouling >> efficiency losses • Installed siloxane removal system at landfill site • Implemented siloxane sampling/analysis protocol

Where are we today?

• Successfully burning LFG in the Kellogg Reformer

• Displacing about 15% of the NG fuel requirement for the site

• Eliminating/minimizing flaring of LFG at landfill site

• Reducing the region’s air emissions

• Conserving a valuable natural resource

Where are we headed with our LFG project?

• Planning, designing, implementing additional modifications to enable increased flow of LFG

• Considering additional applications for the LFG

• Evaluating the potential for CO2 separation • Will reduce the impact of inert gases • Will recover and use CO2 gas in an internal plant

process