Sample Projects
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Stove Waste Heat Recovery System
Fairfield, Alabama
Project: FEL3 Engineering on Stove Waste Heat Recovery System
Summary of Scope of Service
ATSI, Inc. provided detailed engineering, procurement, construction support and startup services for the Stove Waste Heat Recovery System on a blast furnace.
It was based on an energy study performed by ATSI that determined that a significant energy cost reduction could be realized from installing a waste heat recovery (WHR) system on the Fairfield No. 8 Blast Furnace stoves. This system would reclaim energy from the stove stack and utilize it to reduce stove firing natural gas requirements. Recovery of the stove stack energy via preheating of the firing gas or combustion air reduced the stove firing requirements. Preheating led to high enough flame temperatures to eliminate the need for most, if not all, of the natural gas used for enrichment.
Stove simulation modeling were done to determine the benefits from the WHR system. The stove model runs confirmed that there would be significant energy savings from the WHR system. It was calculated that the annual natural gas reduction would be 929,000 MMBTU. Blast furnace gas consumption would increase by approximately 587,000 MMBTU resulting in a net energy reduction of 342,000 MMBTU.
Bio Facility Upgrade
Kenton, Ohio
Project: Bio Facility Upgrade
Features: Control System Upgrade
Summary of Scope of Service
ATSI provided engineering services to evaluate and upgrade the Waste Water Bio Facility operations. The goal of this project was to improve current operations by improving system information, and eliminate the need for weekend operators. The control system consisted of a Modicon 984 PLC with WonderWare Intouch used for the operator interface.
The Modicon 984 PLC was replaced with a Quantum PLC to allow Ethernet communications, and a Modicon Momentum PLC system was added with wireless Ethernet communications for the monitoring of remote storage tanks. Control system improvements were made in the areas of sand filter operation, polymer addition, and turbidity monitoring. WonderWare SCADAlarm was also added to the HMI system for remote alarm notification during unattended operation.
Services Provided
- Evaluated existing control system
- Revised existing P&I Diagrams
- Prepared all control wiring drawings
- Supplied equipment specifications for all newvinstrumentation
- Revised PLC and HMI programming
- Provided start-up assistance
Hypo Recycle Project
Niagara Falls, New York
Project: Hypo Recycle
Features: Final Detail Design
Summary of Scope of Service
ATSI was selected to complete the final design of a sodium hypochloride destruction process to be integrated into their existing chlorine and caustic production facility. The new process reduced operating costs by producing a low strength raw bleach using material that was previously discarded at a recurring cost. The new process involved two areas; a sparge tank area and a raw bleach area.
Services Provided
- Process flow diagram including mass and material balance for the new process
- Design of all equipment and vessel internals
- Piping and instrument diagrams defining line and valve numbers, instrument loops, tie pointsvto existing equipment and equipment sizes
- Layouts of all equipment
- Design, and specifications for new MCC, including existing building installation drawings
- Tie point list with coordinated digital photos to support construction
- Instrument data sheets for bid and purchasing
- Process specifications for all support equipment were prepared for procurement specifications
- Equipment fabrication specifications for the following:
- Titanium Sparge Tanks—API 650
- Hand Lay-Up FRP Tanks—ASME RTP-1
- Rubber Lines Scrubber—API 650
- Chlorine Knockout Pot—ASME
- Civil design and construction packages of all foundations and containment dikes
- Prepared all piping drawings for contractor fabrication and installation, line and valve lists
- Process description for development of control logic and process safety reviews
Blast Furnace Scrubber Upgrade
Project: Blast Furnace No. 8 Gas Cleaning Scrubber Upgrade
Features: Gas Cleaning Improvements
Summary of Scope of Service
ATSI provided engineering services to evaluate and upgrade the main scrubber on U.S. Steel’s Blast Furnace No. 8 in Fairfield, Alabama. The initial scrubbing element was badly worn and ineffective, as were other portions of the scrubber. ATSI provided engineering to replace the upper fixed venturi throat with a counter current spray chamber replacing other warn scrubber parts, as well as adding a chevron blade mist eliminator to the final stage.
Services Provided
♦ Evaluated gas cleaning system
♦ Provided process information and required design upgrades
♦ Prepared all installation drawings
♦ Updated record drawings
♦ Supplied equipment specifications for all new equipment
♦ Provided expediting and shop inspections
♦ Provided construction management assistance
♦ Provided start-up assistanceInstead of replacing the entire scrubbing system which would have been a large job (likely over $10 million USD with a 30+ day outage), ATSI recommended modifications and upgrades to their existing scrubber for considerably less capital and a shorter outage, costing approximately $2.8 million USD which was implemented in a 12 day outage.
Fairfield Coal Injection Facility
Fairfield, Alabama
Project: Fairfield Coal Injection Facility
Summary of Scope of Service
U.S. Steel Group selected ATSI to engineer, procure, construct, and start up a coal injection plant to inject granular coal into a blast furnace. This was a turnkey project performed on a “partnering” basis with U.S. Steel Group. Total project value was $22 million.
Services Provided
♦ Overall project management of all companies
♦ Two 100 TPH pneumatic railroad unload systems
♦ Three 800-ton silos for storing dry, granular coal, designed in accordance with NFPA68
♦ Nitrogen tank farm
♦ New railroad track spur (2000 feet)
♦ New structures and buildings to house injection and electrical equipment
♦ PLC/PC-based control system consisting of three nonredundant Allen Bradley PLC 5/60s and four PCs with Wonderware InTouch software
♦ PLC programming (PLC I/O count included 942 digital and 312 analog points)
♦ HMI screen development (HMI consisted of 36 main screens and 71 pop-up screens)
♦ Complete system commissioning services for checkout, startup, and acceptance testing.
“S” Area RRT APL Treatment Facility
Niagara Falls, New York
Summary of Scope of Service
Plant addition to neutralize and separate suspended solids and organics from contaminated groundwater. Installation engineering including civil, piping, electrical and control disciplines.
Services Provided
♦ Review of process and instrumentation diagrams.
♦ Equipment arrangements, neutralization and storage tanks, sand filter, filter press, several stages of carbon bed tanks, carbon service truck drive through.
♦ Hazardous construction.
♦ Heating and ventilation system.
♦ Exhaust system with carbon adsorbers.
♦ Detailed piping drawings.
♦ Single lines, schematics, interconnection and loop drawings, panel drawings, physical location drawings.
♦ New 5,000 ft2 plant. One block and steel building, one steel building, both buildings on piles.
♦ Construction support.
“S” Area RRT Leachate Storage and Handling Facility
Niagara Falls, New York
Project: “S” Area RRT Leachate Storage and Handling Facility
Summary of Scope of Service
Plant addition for a tank farm to store contaminated groundwater for further treatment. Installation
engineering including civil, piping, electrical and control disciplines.
Services Provided
♦ Review of process and instrumentation diagrams.
♦ Equipment arrangements, compressor, storage tanks, pumps, control building, power station,
and control panel.
♦ Hazardous construction.
♦ Full containment.
♦ HVAC system.
♦ Vent system with carbon adsorbers.
♦ Detailed piping drawings.
♦ Single lines, schematics, interconnection and loop drawings, panel drawings, heat trace
drawings, physical location drawings.
♦ New 12,000 ft2 plant. Five decanter tanks, one NAPL storage tank, two APL storage tanks, one
concrete block building.
♦ Construction support.
Fuel Cells
Lewiston and Colden, New York
Project: Fuel Cell Demonstration Project
Features: Engineering, Installation, and Project Management
Summary of Scope of Services
ATSI performed engineering, project, and construction management for the installation of two residential Proton Exchange Membrane (PEM) fuel cells in Western New York. ATSI performed daily monitoring, telemetry data review, and on-site maintenance/troubleshooting. ATSI initiated a technology transfer program to educate the general public and local building departments about fuel cells and their installation requirements. ATSI’s responsibility included fuel cell decommissioning following the 12-month demonstration project.
Services Provided
♦ Specification and purchase of installation and support equipment.
♦ Acquisition of permits in the respective localities.
♦ Coordination with the utilities to establish grid connection requirements.
♦ Subcontracting for the respective installation contractors.
♦ Monitoring of the fuel cells and review of telemetry data.
♦ Maintenance of the fuel cells and performance of troubleshooting as necessary.
♦ Transfer of technology to educate the general public and local building departments.
♦ Reporting of activity and fuel cell performance on a monthly basis.
♦ Decommissioning and post-project evaluation with the manufacturer.
