Rockwell International, Corp. has achieved a major energy breakthrough at its Marysville, Ohio plant. The company now uses combustible trash to fuel its heating and air conditioning system.
The heart of the system is a Kelley Pyrolytic Furnace and Energy Recovery Unit. It converts waste into hot water which is used to heat the plant in cool weather or channelled through an absorption chiller for air conditioning in the summer.
Because this unique system is now providing major portions of its heating and air conditioning needs, this Rockwell plant is no longer solely dependent on outside energy sources. According to William Smith, Superintendent of Facilities,
"With this installation, we could conceivably increase the size of the plant 50 percent and still live within our present gas allocation."
Rockwell estimates that the system will carry a return on investment of 21.50 percent. The list of companies installing Kelley Energy Recovery Systems is impressive: John Deere Co. at its Horicon. Wisconsin plant uses trash-generated heat for a paint drying operation resulting in an annual savings of $52,000. Xerox Education Center in Columbus, Ohio converts paper waste into heating fuel, saving $38,000 annually. K.W. Muth in Sheboygan heated an entire 90,000 sq. ft. plant last winter with a Kelley System. To date over twenty-five major corporations have purchased Kelley energy recovery equipment.
Each of these progressive companies is converting combustible trash into energy, not only to save substantial amounts of money each year, but also to reduce dependence on future supplies of natural gas and fuel oil. Look into a Kelley Energy Recovery System for your company right away.
Summary:
Rockwell Installation
Location: Marysville, Ohio
Time of Operation: 1970's- 1990's
Industrial
For nearly 20 years, Mr. Hoskinson teamed with Mr. Kelly to design and deliver hundreds of industrial and hospital gasification combustors.
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Xerox Education Center in Columbus, Ohio, will stay in full operation, no matter what happens to future gas and oil supplies, simply by using its own combustible trash as fuel for heating.
The key to this remarkable process is the unique Kelley Pyrolytic Furnace and Energy Recovery System, which has been in operation at Xerox since 1976.
Not only does the company save some 60,000 gallons of fuel oil each year (at an average cost in Ohio during 1977 of 39¢ per gallon), but it eliminates most of the $15,000 annual cost formerly paid a hauling service to truck away the combustible waste.
According to Nicholas J. Masucci, Manager of Engineering and Support at Xerox... "The company is saving about $38,000 per year in hauling and fuel costs. At that rate, the unit will pay its installation cost in about three years. Our accountants estimate a return on investment of 35% per year for the life of the equipment, and with fuel costs sure to go up in the future, the return could be even higher."
Summary:
Xerox Education Center
Location: Columbus, Ohio
Time of Operation: Completed in 1976
Industrial
Below are images from Industrial Installations in the 1970's
This installation was commissioned in 1996 and was primarily used to gasify some of the most noxious industrial waste in Daejeon City, Korea. It also proved out the scalability of Hoskinson application of modular panelized construction of up to 200 tons per day per unit.
Prior to its initial testing for emission control the weather didn't cooperate and it rained for 3 weeks. The waste dedicated for the test runs was as a result, immersed with water. Mr. Hoskinson insisted that the trials begin and within 20 minutes, the water-logged waste was being consumed effectively by his machine at temperatures greater that 1,100°C without using any auxiliary fuel!
The testing engineer was incredulous, and the Hoskinson's gasifier passed all environmental tests.
Summary:
Korea Installation
Location: Daejeon City, Korea
Time of Operation: Completed in 1996
Industrial
This plant was constructed in Korea and was commissioned to get rid of industrial waste. The resulting bottom ash was less than 5% of the the total volume of waste introduced into the plant.