DANIEL
MAHR, P. E.
Project Manager
Master of Science, New Jersey Institute
of Technology.
Bachelor of Science in Mechanical Engineering, New Jersey
Institute of Technology.
Registered
Professional Engineer: States of Colorado, Missouri, New Jersey, and
North Carolina.
Mr. Mahr is a
specialist in the engineering and design of dry bulk material handling systems.
He is an expert in the supply, handling, blending, and processing of a wide
range of bulk materials ranging from alumina to wood chips. Mr. Mahr is
experienced in ports and terminals, the power, transportation, mining, steel,
and process industries. He has managed large or technically demanding
projects handling bauxite, coal, biomass, minerals, and other bulk
commodities. As president, Mr. Mahr is responsible for all corporate
activities of Energy Associates.
Expert Witness
Mr. Mahr has provided
technical services in instances for breach of contract, dispute resolution,
equipment failure, fatal accidents, and litigation investigation.
* Confidential
Client. Commissioning and operating problems for the iron ore handling system of
a major concentrates plant.
* Continental Casualty
Company. Mediation technical support, for the Wawa, Ontario Canada,
pellet plant.
* Confidential Client. Non-fatal,
tractor-trailer dump truck unloading accident.
* Great American - Specialty E
& S Division. Fatal accident investigation, frac
sand train unloading using a mobile unloader.
*
Quarles & Brady, LLP. Advised and assisted in Salt River Project’s
dispute with BRUKS Rockwood Materials Handling alleging breach of contract concerning
the supply of two (2) stacker scraper reclaimers at
the Springerville Unit No. 4 coal-fired power plant.
Project Manager
As a project manager,
he was responsible for the schedule, budget, and technical aspects of the
following projects.
* NST Transloading.
Provided technical services preparing bid specifications, proposal reviews, EPC
Contractor reviews for compliance with the Contract for a frac
sand terminal in East Fairview, ND.
* Atlantic Power. Prepared
concept drawings and reports for the addition of a used railroad tie handling
system to be added to the biomass handling system of the Williams Lake Power
Plant.
* NIRAS Ports and Maritime.
Provide technical support for Sable Mining Africa’s plan for an iron ore export
facility at the Port of Buchanan, Liberia with a transloading
operation from Panamax to Cape vessels, including the use of dedicated
self-unloaders.
* Mott MacDonald. Reviewed
fuel quality issues, studies, and submittals of the ash handling and landfill systems
for Jordan Oil Shate Company’s plans for the Attarat Power Plant.
* CH2M HILL. Samalaju Industrial Port, Sarawak, Malaysia. EPC tender
documents for a complex, multi-dry bulk commodity, conveyor belt system, with
four dry bulk berths, multiple ship unloaders, shiploader,
stackers, reclaimers, truck loading terminal,
multiple paths, and interface with Industrial Park’s distribution conveyor belt
system.
* Sirois
E&C. Examined coal washing technologies that would work to reduce the
ash content of a Brazilian coal, so it might used in
a PC boiler with a different, design basis coal.
* Ingetec,
S.A. Investigated issues for the pre-feasibility study expansion of the Cerrejón Coal Mine in Colombia, South America from the
current 32MTPA capacity up to 60MTPA, assessing both the existing Central Plant
and a new Satellite Plant.
* PPL. Investigated problems being
experienced with the OSHA Dust Control project at the 1483MW Brunner Island and
1552MW Montour coal-fired power plants.
* Halcrow,
Inc. Prepared a desktop study for a Useful Life Assessment of the Bay
Side Coal Pier, Baltimore, MD, which considered functional suitability,
capacity/utilization, cost/efficiency, safety/compliance, and siting
* Sigma Energy Solutions. Sulcis Plant, Sardinia, Italy. Investigated fuel
feeding problems for ENEL’s 350MW, Unit No. 2, CFB boiler and developed a
variety of options to address the issues and retrofit improvements.
* Mott MacDonald/Drax Power. Developed concepts, system arrangements,
and bid specifications for the fuel feed systems for both the Heron and Ouse,300 MW biomass power plants.
* Longview Power. A/E
responsibilities (concept development, bid drawings, specifications, foundation
design, technical evaluations, etc.) for three (3) fuel systems with an
approximate value of $100 million for a greenfield, 700MW plant; including the
plant’s coal handling system, an adjacent coal-blending yard, and a 4.5 mile
overland conveyor system with a surge stacking/reclaim system.
* Bechtel Power Corporation.
Failure analysis for the scraper/reclaimer at
Wisconsin Electric’s Elm Road coal-fired plant.
* Consumers Energy. Provided
technical and support consulting services for the coal and bulk handling for an
Advanced Supercritical Pulverized Coal Plant at the Weadock
& Karn Plants
* Halcrow.
Assessment of existing bulk export/import facilities for bauxite, manganese,
and clinker for the Port of Takoradi, Ghana.
* AES Cayuga. Responsible
for the feasibility study and detail design of a unique feeder/conveyor
addition to the 50-year old AES Cayuga coal-fired plant.
* Sigma Energy Solutions.
Investigated area classification for Madison Gas and Electric’s Blount Power
Plant, which was the subject of an OSHA inspection/notice of a pending
citation.
* Sigma Energy Solutions.
Investigated the system modifications for the receipt/handling of delayed
petroleum coke at GWF’s five (5) FBC plants near Pittsburgh, California.
* Ingetec,
S.A. Reviewed the bulk material handling and blending plans for three (3)
plant expansion programs for Argos Cement, Columbia, South
America.
* Prairie State Energy Campus:
Technical consulting related to the development of a new “Greenfield”, mine
mouth 2 x 800 MW coal fired generating station with supercritical steam cycle.
* LS Power. Reviewed and
commented on technical documents associated with the coal handling system for
the Plum Point Power Plant.
* Sigma Energy Solutions.
Investigated biomass handling problems which was adversely impacting combustion
for the Detroit Stoker hydrogate at GWF’s Tracy Power
Plant, California.
* Han-Padron Associates.
Investigated design options for bulk commodities import/export facilities in
support of planned steel mill, aluminum smelter, and miscellaneous enterprises
for Port Khalifa, major new infrastructure, Abu Dhabi
* Ameren Services Company, Meramec
Rail Receiving. Responsible for the feasibility study and mechanical/structural
detail design for a $64 million coal handling system addition to the Meramec
Plant.
* Ingetec,
S.A. Provided consulting services for expansions of coal handling
facilities at the Port of Santa Marta and the Cerrejon
Mine in Colombia, South America
* Ameren Energy Generation
Company, Coffeen Crusher House Chutes.
Responsible for the total redesign of surge bins, chutes, and skirtboards at the Coffeen Plant.
* Tri-State Generation &
Transmission. Responsible for the detail engineering of a rotary coal
breaker addition to 110 MW Nucla Station, Nucla, Colorado
* Ameren Services Company.
Responsible for the engineering investigation for additions to coal handling
system to support fuel changes at the Sioux Plant.
* Bechtel Power Corporation.
Providing engineering review services for the lignite and limestone
handling/preparation systems at the AFBC plant - Red Hills Generation Project,
Mississippi.
* Union Electric Company.
Responsible for the engineering investigation for upgrading the coal handling
system to support fuel changes at the Meramec Plant.
* Foster Wheeler USA.
Responsible for coal handling engineering services to support their proposal
efforts on the Lagisza Power Project in Poland.
* Union Electric Company.
Responsible for the detail engineering of the relocation of the take-up for the
South No. 6 conveyors at the Labadie Plant.
* Foster Wheeler USA.
Responsible for coal handling engineering services to support their proposal
efforts on the Duburi Power Project in Orissa and the
Ghogha Project in Gujarat, India.
* Han-Padron Associates / American
Commercial Barge Lines (ACBL). Responsible for material handling
engineering services in support of ACBL’s Orinoco multi-bulk terminal,
Venezuela.
* Foster Wheeler Mt. Carmel.
Responsible for the engineering investigation of improvements to solve
anthracite culm handling problems at the 40 MW Mt. Carmel Plant, Pennsylvania.
* Tri-State Generation &
Transmission. Responsible for the engineering of improvements to the
in-plant coal handling system of the 110 MW Nucla
Station, Nucla, Colorado
* Union Electric Company.
Responsible for preparing a coal pile procedures guideline for managing
stockpiling and reclaiming operations of the rotary plow system.
* Foster Wheeler Power Systems
(FWPS). Provided consulting services on the fuel handling system for the
100 MW IGCC unit, at the Tracy Station of Sierra Pacific
* Union Electric Company.
Responsible for the detail engineering of the retrofit of six self-cleaning
magnetic separators to the Labadie Plant.
* CMS Energy. Assisted in
the sourcing of coal and the draft contract for importing coal and reviews of a
coal unloading, stacking, and reclaim system for a new 2x300 MW power plant to
be constructed at Batangas, Philippines.
* Han-Padron Associates /
International Marine Terminals (IMT). Investigated improvements and
operations at IMT's coal export terminal near New Orleans to service a direct
reduced iron (DRI) processing plant.
* Fine, Kaplan, and Black.
Assisted in research and analysis of the existing and potential market for
oil-in-water emulsion fuels.
* Union Electric Company.
Responsible for an investigation of improvements to the Labadie Plant's coal
handling system to solve plow feeder tunnel washout problems and develop
improved coal blending procedures.
* Tri-State Generation &
Transmission. Responsible for an investigation of improvements to the
coal handling system of the 110 MW Nucla Station, Nucla, Colorado
Vice President and Project Manager
As a vice
president, Mr. Mahr was responsible for negotiating client contracts,
establishing a new engineering office, and engaging consulting services.
As a project manager, Mr. Mahr was responsible for the commercial and technical
aspects of his assigned projects. His assignments include:
* Central Termica
San Nicolas (CEA/AES/CMS/ORMAS Consortium). Responsible for an
investigation of improvements to the coal handling system of the 650 MW San
Nicolas Plant, Argentina.
* Tampa Electric Company.
Responsible for an investigation of short and long term improvements for the
coal handling, fuel feeding systems of the Gannon Station.
* EPRI. Responsible for the fuel,
sorbent, and bed material sections of EPRI's AFBC Balance-of-Plant Guidelines.
* Electricity Generating Authority
of Thailand. Responsible for a coal sourcing study that examined
candidate sources of coal and transportation alternatives for the Ao Phai Power Plant.
* EPRI, NYSE&G, Severud. Responsible for the fuel system
investigation of the Jennison Station Fabric Structure Study.
* Electricity Generating Authority
of Thailand. Responsible for the feasibility of a 2x150 MW, fluidized bed
plant for the Mae Moh lignite mine
* Electricity Generating Authority
of Thailand. Responsible for a mining training and orientation program as
part of a 2 x 150 MW fluidized bed feasibility study for Mae Moh.
* Community Energy
Alternatives. Provided consulting services the design requirements for
the fuel and limestone systems on a fluidized bed boiler.
* Electrical Generating Authority
of Thailand. Responsible for the feasibility of a 4x700 MW pulverized
coal fired plant and a study comparing oil/coal as the plant's primary fuel.
Principal Engineer
As a Principal
Engineer in the Energy Systems Technology Division, Mr. Mahr was responsible
for the management of engineering and design on his assignments. This includes
direct supervision of the engineering team, budget, and schedule.
Assignments completed by Mr. Mahr at Burns and Roe include:
Cogentrix, Inc. Responsible for the design
and specification of the coal handling system for Cogentrix's
150 MW reference plant and its application to sites in the USA and Puerto Rico
(2 x 150 MW).
Florida Power
& Light. Investigated system requirements to convert the Sanford
Plant from oil to orimulsion.
Korea Power
Engineering Co. Provided engineering services for the coal handling
system on Poryong Units No. 3 and 4 (2 x 500 MW).
Mecca,
California Power Plant. Responsible for the design and specification of
the fuel handling system of the 49 MW Colmac
Plant. The fuel consists of waste wood chips, baled straw, and various
waste agricultural products that are custom blended by the fuel system.
Florida Power
& Light. Responsible for a coal transportation and terminal study to
move four million tons annually from candidate ports within the State to
several potential plant sites. The study examined barge, rail, truck, and
slurry pipeline modes of transportation. It included the conceptual
design of the transshipment terminal and the calculation of all freight rates.
New England
Power. Responsible for a coal shipping alternates cost study for
delivering coal to the Brayton Point and Salem Harbor Stations. The
marine facilities and unloading systems were examined for several vessel/barge
configurations.
Rail India
Technical and Economic Services (RITES). Responsible project manager and
shipping/port handling expert for the U.S. technology input on a coal
transportation study. The study examined the 50 million TPY
transportation of coal to 13 power plant/port locations via rail, barges,
oceangoing vessels, and slurry pipelines. Conceptual designs of all
transportation modes and facilities were developed. Freight rates and
facility capital/operating costs were estimated. RITES was responsible to
India's Central Electricity Authority for the overall study.
Consolidated Edison.
Responsible for the fuel oil handling facilities' inspection program at 12
plant locations that receive oil via vessel or barge. The investigation
included modernizing or repairing marine structures, fire protection, electric,
oil spill prevention, and communication systems. In addition, technical
data on a leak detection system was reviewed.
Electricity
Generating Authority of Thailand. Responsible for the bankable
feasibility report that consolidated the previous investigations for a 2,400 MW
coal-fired power plant at the Ao Phai
Site. Coal will be received via ocean going vessels up to 120,000 DWT in
size.
Korea Power
Engineering Co., Inc. Provided feasibility design review and analysis of
the coal receiving and handling systems of an eight unit, 4,000 MW coal-fired
power plant at the Sao San site.
China
International Water and Electric Corp. Provided design and cost analysis
of the coal receiving and handling system for the coal conversion study of two
125 MW units at the Zhabei Power Station. Coal
is received via ocean going coastal vessels.
Taiwan Power
Company, Hsinta Plant. Provided input to the
coal blending investigation for the Hsinta Power
Plant. A variety of designs using stacker/reclaimers,
silos, and tunnels were investigated.
Taiwan Power
Company, Talin Plant. Responsible for the coal
blending investigation of the 2400 MW Talin Power
Plant. A variety of designs were investigated and evaluated on the basis
of capital cost, operating cost, and features/benefits. The blending system
was designed to improve boiler performance by maintaining coal quality (from numerous suppliers) within pre-selected ranges.
Taiwan Power
Company, Lin Kou Plant. Responsible for the coal blending portion of an
air quality control (FGD) investigation of the 650 MW Lin Kou Plant. The
coal blending system was designed to improve fuel reliability and maintain
sulfur levels within the limits allowable for a dry scrubber system.
China
International Water and Electric Corp. Prepared the commercial bid documents
for the Changshan Coal Conversion Project which will
be financed through ADB.
Lansing Board
of Water & Light. Responsible for an ash handling study at the 155 MW
Erickson Station. Eight options were investigated to separate bottom
ash/pyrites from fly ash to increase their marketability to the construction
industry.
Consolidated
Edison. Responsible for the 60-Day Coal Burn Plan for the Ravenswood
Station, Unit 30. This provides a pre-planned program for reconverting
this unit to coal in an emergency, including lay-up maintenance and
re-conversion construction. The program included coal handling, burner,
ash handling, precipitator, water treatment, and electrical equipment.
Project Manager and VP of ORTRAN
Mr. Mahr joined
ORBA Corporation as a Project Engineer and was promoted in 1979 to a Project
Manager. In 1980, he was given the additional responsibility of Vice
President for ORTRAN, a joint venture subsidiary. This subsidiary was
responsible for the operation and maintenance of Detroit Edison's Superior
Midwest Energy Terminal. Plant improvements during this period included the
extension of utilities, foundation and structural repairs, expansion of the
office and shop, pile spray system addition, increases in production rates,
updating of the controls to PC logic, and a computerized maintenance
program. As a Project Manager, Mr. Mahr was responsible for a number of assignments
including:
Virginia Power
Co., Chesterfield, Portsmouth, Possum Point, and Yorktown Power Stations.
Feasibility study of the barge delivery of coal. Preliminary engineering
for $50 million in plant additions.
Utility Fuels,
Inc. (Houston Lighting & Power), W.A. Parish Plant. Asset
evaluation program to identify the current/retirement value of the coal
handling facilities.
Union Electric
Company, Labadie Plant. Design and arrangement for retrofitting a coal
blending system. The system is designed to reduce SO2
emissions and minimize fuel cost.
Williams
Pipeline Company, Tulsa, Oklahoma. Coal Export Terminal at Wilmington,
N.C. Site selection, feasibility study, and engineering for a $70 million
facility.
Bethlehem Steel
Corp., Sparrows Point, Maryland. Feasibility studies and bid
specification for a $12 million plant addition.
Energy
Terminal, Inc., Port Richmond, Philadelphia, PA. Problem solving and
plant revisions for a coal export terminal.
Tampa Electric
Company, Big Bend Station. Preliminary design of the coal yard
expansion/blending facilities. The final installation used this plan.
Jersey Central
Power and Light Co. (with Dames and Moore), Unnamed Plant. Planning study
of waste disposal for a major coal-fired plant. Five plant sites with 25
disposal sites.
Union Electric
Company, Labadie Plant. Design optimization for a $15.4 million coal
blending facility.
CILCO, E.D.
Edwards Station. Coal blending study to solve boiler fouling and slagging
problems.
Ohio Edison,
Bruce Mansfield Station. Short and long-term plant improvement studies
for the coal and lime handling systems.
Pennsylvania
Power Co., Bruce Mansfield Station. Operating Procedure and an Equipment
Identification Program for the coal and lime handling systems.
Detroit Edison
(with PBQ&D), Unnamed Plant, Rubicon Township Site. Conceptual
design of a high capacity dock/overland coal receiving facility.
Williams
Brothers Urban Ore, Tulsa, Oklahoma. Conceptual engineering for an RDF
waste processing facility.
Foster Wheeler
Corp., Coal Gasification Plant, Duluth, Minnesota. Responsible for the
design of the gasifier's automated poke rod system.
Mechanical Engineer
As a Mechanical
Engineer, Mr. Mahr was responsible for mechanical engineering calculations,
equipment selection, drawings, purchasing, and expediting. He worked on a
variety of assignments including:
Perini
Corporation, Greater Lawrence Sewage Treatment Plant, North Andover, Mass.
Design and supply of the ash, grit, and sludge systems. Also served as
construction representative.
Caulim de Amazonia, Ltd., Kaolin Port, Munguba, Brazil. Design of the plant and shiploader equipment to load vessels up to 50,000 DWT.
American
Cyanamid, Fort Lonesome Plant, Florida. Design and supply of a phosphate
handling and rail loading facility.
Oiltanking of Texas, Aragonite Port, Jacintoport, Texas. Design and supply of 4,000 TPH
aragonite handling equipment.
Exportadora de Sal, Baja, California, Mexico. Design and supply of a mobile solar salt harvester.
Marcona Ocean Industries, Savannah, Georgia and
Ocean Bay, Bahamas. Design and supply of port facilities.
Charles
Schaefer Sons, Elizabeth, N.J. Design and supply of rail salt receiving
facilities.
National Bulk
Carriers, Manguba, Brazil. Design of the raw
material (limestone, salt, sulphur, etc.) and hog
fuel systems.
Marcona Ocean Industries, Marcona Conveyor. Design and supply of the self-unloading system for a 74,000
vessel.
Gotaas Larsen, New York, New York, MV Don
Segundo Sombra, Hapag Lloyd
Shipyard, Bremerhaven, Germany. Design and supply of the self-unloading
system for a 15,300 DWT vessel. Also served as construction representative.
American Society of Mechanical Engineers
– Life, Fellow Membership Grade
* Current Member of the B20 Safety
Committee – Safety Standard for Conveyors and Other Equipment
* Dedicated Service Award, 2000
* Newsletter editor, FACT Division
(1998 to 2004)
* Past Representative the Coal
Utilization & Fuels Systems Conference
* Past Chair, FACT Division (two
years) and past representative to the Energy Conversion Board
* Past Chair of the Fuels
Handling, Transportation, and Storage Technical Committee, FACT Div.
Society of Mining Engineers
* Minerals Processing Division
* Coal Division
National Society of Professional
Engineers
N.J. Society of Professional Engineers
Mr. Mahr has authored
articles on biomass, coal, and power plants for the following magazines and
conferences:
* Power Engineering International
* Power Engineering
* Combustion Engineering
* Mechanical Engineering
* Coal Age
* Bulk Solids Handling
* Skillings
Mining Review
* Industrial Fuels and Power
* American Power Conference
* ASME Power
* Electric Power
* Internatiional
Joint Power Generation Conference
* Industrial Power Conference
* Ports 80 Conference
* Power-Gen Conference
* EPRI's Coal and Ash Handling
Conference
*
Western Coal Great Lakes Conference
Mr. Mahr has
also contributed a chapter to ASME's Materials Handling Handbook and is the
editor of seven ASME publications: 1) Coal Sampling, 2) Coal Quality
Control, 3) Handling Low Grade Coal, 4) Fuel
Strategies - Coal Supply, Dust Control, and Byproduct Utilization, 5) Fuel
Strategies - Conventional and Unconventional Fuels, 6) Recent Fluidized Bed
Projects, 7) FBC and AFBC Projects and Technology