Subscribe
Share
Share
Embed
Powering the Process℠ is a podcast for engineers, plant managers, and operations leaders focused on industrial systems, plant optimization, and manufacturing efficiency. Hosted by ProcessBarron experts, each episode delivers practical insights on material handling, air and gas systems, industrial equipment, and reducing downtime.
Powering the Process — Waste-to-Energy
Host: Jen Little
Guest: Ashley Doyal, Vice President – South Region & Central and South America, ProcessBarron
00:00:00:07 – 00:00:31:20
Jen Little:
This podcast is brought to you by ProcessBarron — handle everything better.
Welcome to Powering the Process, the podcast focused on the real work behind industrial manufacturing. Each week, your host, Jen Little, dives into the systems, equipment, and strategies that keep plants running efficiently. From everyday operational challenges to emerging engineering solutions, we’re here to share practical insights that help you keep your process moving.
00:00:31:23 – 00:00:35:18
Jen Little:
Let’s get started.
00:00:35:21 – 00:00:54:10
Jen Little:
What if the garbage we throw away every day could actually power our homes tomorrow? Welcome to Powering the Process, where we uncover the innovations shaping the future of industry. In this episode, we’re diving into waste-to-energy — a technology that turns trash into a valuable resource.
00:00:54:12 – 00:01:11:00
Jen Little:
ProcessBarron plays a critical role in making this transformation possible. From designing and installing systems that move fuel and ash efficiently to optimizing air and gas flow, they help waste-to-energy plants operate at peak performance.
00:01:11:03 – 00:01:31:00
Jen Little:
It’s all about reducing landfill waste, generating clean energy, and creating a more sustainable future. Today’s guest is Ashley Doyal. He’s been with ProcessBarron for nearly 32 years and currently serves as Vice President of the South Region and Central and South America. Thanks for joining us, Ashley.
00:01:31:05 – 00:01:33:16
Ashley Doyal:
Thank you for having me.
00:01:33:17 – 00:01:46:07
Jen Little:
I’m so glad you’re here today. We’re going to talk about waste-to-energy and the role ProcessBarron plays in that industry. Let’s start with a few general questions.
00:01:46:10 – 00:01:51:25
Jen Little:
What are the environmental benefits of waste-to-energy compared to traditional waste disposal?
00:01:51:27 – 00:02:18:26
Ashley Doyal:
Traditional waste disposal is primarily landfilling. Roughly 50% of municipal waste goes to landfills. By using waste-to-energy to produce electricity, you significantly reduce the amount of garbage going into landfills. You also reduce greenhouse gases, because landfill decomposition produces methane and CO₂, which contribute to climate change.
00:02:18:29 – 00:02:23:10
Jen Little:
What misconceptions do people tend to have about waste-to-energy plants?
00:02:23:13 – 00:02:50:03
Ashley Doyal:
The biggest misconception is that waste-to-energy plants are harmful to the environment. These facilities are heavily regulated. About 99.9% of what exits the stack is oxygen, nitrogen, and water vapor. When air pollution control systems are properly maintained, waste-to-energy plants are very safe and dramatically reduce landfill waste.
00:02:50:06 – 00:02:59:03
Jen Little:
What specific equipment or solutions does ProcessBarron provide for this industry?
00:02:59:05 – 00:03:47:01
Ashley Doyal:
We offer a wide range of equipment, starting with air-handling systems. Boilers require balanced airflow — forcing oxygen into the furnace using FD fans and pulling exhaust gases out using ID fans. We also provide air pollution control equipment, including spray dryer absorbers, separators, and baghouses. In addition, we design and maintain ash handling systems to manage both bottom ash and dry ash and ensure it’s removed efficiently from the site.
00:03:47:12 – 00:03:53:10
Jen Little:
What are the biggest operational challenges in waste-to-energy plants?
00:03:53:12 – 00:04:24:06
Ashley Doyal:
One major challenge is getting the waste into the boiler — it’s labor-intensive and complex. Maintenance is another big factor, especially maintaining air pollution control equipment to stay within emissions regulations. Building a new waste-to-energy facility is also a major investment, typically costing between $500 and $600 million.
00:04:24:08 – 00:05:21:26
Jen Little:
When we talk about burning garbage — often called garbage burners in the industry — trash is the fuel. Is there a limit to what can be burned? Are we talking household waste, construction debris, or everything people throw away?
Ashley Doyal:
Large appliances like refrigerators are removed beforehand, but most household and office waste goes directly into the furnace unprocessed — plastics, glass, and other materials. Glass doesn’t burn, but it still moves through the system. The average person generates about five pounds of garbage per day. That adds up to more than 290 million tons annually in the U.S. A plant burning roughly 2,200 tons per day can generate 40–60 megawatts of electricity, enough to power about 15,000 to 20,000 homes.
00:06:01:12 – 00:06:25:19
Jen Little:
Are these facilities typically owned by municipalities?
Ashley Doyal:
It’s a mix. Some are municipally owned, while others are owned or operated by larger waste-to-energy companies under long-term contracts with municipalities.
00:06:25:22 – 00:07:22:09
Jen Little:
At one point, Florida had the highest concentration of these facilities. How has that changed over time?
Ashley Doyal:
Florida still has a high concentration, along with much of the East Coast. Population density drives it. Transportation costs also matter — moving waste long distances is expensive, especially for hazardous materials.
00:07:22:11 – 00:08:38:26
Jen Little:
How does ProcessBarron address issues like corrosion, especially when the fuel content can’t be tightly controlled?
Ashley Doyal:
The system is designed for mass burning. Large items are removed early, but plastics, metals, glass, and batteries still enter the boiler. Corrosion is addressed through material selection, specialized coatings, and stainless steel components in air-handling systems.
00:08:38:28 – 00:09:40:15
Jen Little:
Looking ahead, how do you see waste-to-energy evolving over the next decade? Could it become a major contributor to the circular economy?
Ashley Doyal:
It needs to be. Facilities are focusing on recovering metals and reusable materials from ash. Given how much waste the U.S. produces — more than any other country — more waste-to-energy plants will be required.
00:09:46:18 – 00:10:27:29
Jen Little:
So unlike traditional incinerators, waste-to-energy actually converts waste into usable power.
Ashley Doyal:
Exactly. It controls emissions while producing energy. Steam from the boiler drives a turbine and generator, producing electricity that offsets power from fossil-fuel plants.
00:10:28:02 – 00:11:21:23
Jen Little:
What makes ProcessBarron’s solutions unique in this space?
Ashley Doyal:
It’s our integrated approach — engineering, air pollution control, fans, baghouses, and system upgrades. In one Florida project, we improved a fan’s efficiency from 35% to over 70%, significantly reducing energy consumption.
00:11:21:25 – 00:12:45:14
Jen Little:
So these facilities are largely self-sufficient?
Ashley Doyal:
Yes. They generate enough power to operate and also supply electricity to the grid. Municipalities evaluating waste-to-energy need to consider land availability, transportation costs, and long-term waste management strategies.
00:12:45:16 – 00:13:17:04
Jen Little:
How does waste-to-energy reduce landfill dependency?
Ashley Doyal:
Burning waste reduces volume dramatically. Ash represents about 10% of the original waste volume, and some ash is reused in products like asphalt.
00:13:17:08 – 00:14:41:27
Jen Little:
What steps are taken to minimize emissions?
Ashley Doyal:
Facilities use spray dryer absorption systems, baghouses or precipitators, and continuous emissions monitoring systems. Everything is heavily regulated and continuously monitored.
00:14:41:29 – 00:15:55:25
Jen Little:
Ashley, thank you for being here and helping educate us on waste-to-energy and ProcessBarron’s role in the industry.
Ashley Doyal:
My pleasure. Thank you very much.