PROJECT PROFILE

SOLID FUELS CONVERSION RESEARCH FACILITY

Waak Engineering, Inc. Process Plant Consultants 1111 E. Touhy Avenue, Suite 100 Phone: 847-390-9069

Des Plaines, Illinois 60018 Fax: 847-390-9641

PROJECT PROFILE

SOLID FUELS CONVERSION RESEARCH FACILITY This 12.5 million dollar facility is a test plant for converting various types of solid fuels, including coal and biomass, into low and medium BTU gaseous fuel. This flexible facility will evaluate process performance under different operating parameters using both air and oxygen blow gasification. The plant is designed to allow flexibility in handling various feedstock materials and accommodate various test equipment to be installed in the future. Waak Engineering, Inc provided both preliminary and final engineering, procurement of process equipment, instruments and construction subcontracts, and provided construction management and owners representative services during construction. Project Highlights:

• The five-story combination process and utility/services building with structural steel frame and masonry and sided walls is supported on 105 steel pipe piles.

• A 450 HP process air compressor is housed in a separate one story pre-engineered building

• Fuel and ash are fed and removed from the gasifier utilizing 3 separate lock hopper systems

• The process area is served by a freight elevator with a 16,000# capacity for moving vessels and equipment.

• Building safety features include continuous monitoring of LEL, oxygen and carbon monoxide. An emergency building exhaust system, interlocked with the process, will purge the building in the event of a leak

• The entire building is protected by a combination of dry pipe sprinkler systems, deluge system, and FM-200 fire suppression system

• Process monitoring and control is via a distributed control system (Delta V) with multiple operator stations with large screen plasma display

Waak Engineering, Inc. Process Plant Consultants 1111 E. Touhy Avenue, Suite 100 Phone: 847-390-9069

Des Plaines, Illinois 60018 Fax: 847-390-9641

Waak Engineering provided the following services and deliverables:

• Prepared zoning variance application, participated in public meetings and presented the project to the City Council.

• Prepared documents for building permit application • Negotiated with the State of Illinois and prepared Illinois air permit

application • Prepared a detailed, appropriation grade, cost estimate • Project was designed with the aid of a 3-dimensional computer model

that was created using Rebis AutoPlant AutoCAD based database software

• Prepared requisitions for approximately 50 process equipment items that included: two bucket elevators, six screw conveyors, two hoppers, two bin dischargers, a dust collector, three rotary feeders, bin vent filters, two high temperature heat exchanges, 14 pressure vessels, 450 horsepower air compressor, instrument air compressor, 600# electric steam boiler, packaged start up heater, high pressure and temperature refractory lined gasifier system, 3 cyclones, 4 solids handling spherical valves and an elevated enclosed flare.

• Prepared requisitions for 332 instrument items including: 24 control valves, 27 on/off auto valves, 13 relief valves, 15 flow orifices with transmitters, 36 thermocouples, 34 pressure transmitters, 25 rotameters, 9 nuclear level devices, 10 gas detectors, 6 weigh systems, 2 ultrasonic level switches and 4 conductivity level switches.

• Prepared subcontract bid packages for the following: steel pipe piles, concrete foundations, underground utilities, underground electrical, structural steel, testing services, fire protection, mechanical HVAC, building siding, pre-engineered stairs, masonry, doors and hardware, painting, asphalt paving, misc. metals, process mechanical erection, building electrical, process electrical, process instrumentation, compressor building framing, overhead doors, plumbing, roofing, process piping, and thermal insulation.

• 389 drawings for the project were prepared: 20 General Arrangement, 2 Process Flow Diagrams, 22 Piping and Instrumentation, 9 Civil, 21 Structural, 5 Plumbing, 16 Architectural, 7 Mechanical HVAC, 11 Fire Protection, 48 Electrical, 10 Instrument, 8 Piping Plan & Section and 210 Isometric Piping Drawings w/BOM.

Waak Engineering, Inc. Process Plant Consultants 1111 E. Touhy Avenue, Suite 100 Phone: 847-390-9069

Des Plaines, Illinois 60018 Fax: 847-390-9641

Waak Engineering, Inc. Process Plant Consultants 1111 E. Touhy Avenue, Suite 100 Phone: 847-390-9069

Des Plaines, Illinois 60018 Fax: 847-390-9641

Waak Engineering, Inc. Process Plant Consultants 1111 E. Touhy Avenue, Suite 100 Phone: 847-390-9069

Des Plaines, Illinois 60018 Fax: 847-390-9641

Waak Engineering, Inc. Process Plant Consultants 1111 E. Touhy Avenue, Suite 100 Phone: 847-390-9069

Des Plaines, Illinois 60018 Fax: 847-390-9641

Waak Engineering, Inc. Process Plant Consultants 1111 E. Touhy Avenue, Suite 100 Phone: 847-390-9069

Des Plaines, Illinois 60018 Fax: 847-390-9641

Waak Engineering, Inc. Process Plant Consultants

1111 E. Touhy Avenue, Suite 100 Phone: 847-390-9069

Des Plaines, Illinois 60018 Fax: 847-390-9641

Waak Engineering, Inc. Process Plant Consultants 1111 E. Touhy Avenue, Suite 100 Phone: 847-390-9069

Des Plaines, Illinois 60018 Fax: 847-390-9641

Waak Engineering, Inc. Process Plant Consultants 1111 E. Touhy Avenue, Suite 100 Phone: 847-390-9069

Des Plaines, Illinois 60018 Fax: 847-390-9641