v>EPA
/nited States Industrial Environmental Research EPA-600/7-78-052b
Environmental Protection Laboratory July 1978
Agency Research Triangle Park NC 27711
EPA Industrial
Boiler FGD Survey:
Second Quarter 1978
Interagency
Energy/Environment
R&D Program Report
-------
RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories were established to facilitate further development and application of en-
vironmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields
The nine series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7. Interagency Energy-Environment Research and Development
8. "Special" Reports
9. Miscellaneous Reports
This report has been assigned to the INTERAGENCY ENERGY-ENVIRONMENT
RESEARCH AND DEVELOPMENT series. Reports in this series result from the
effort funded under the 17-agency Federal Energy/Environment Research and
Development Program. These studies relate to EPA's mission to protect the public
health and welfare from adverse effects of pollutants associated with energy sys-
tems. The goal of the Program is to assure the rapid development of domestic
energy supplies in an environmentally-compatible manner by providing the nec-
essary environmental data and control technology. Investigations include analy-
ses of the transport of energy-related pollutants and their health and ecological
effects; assessments of, and development of, control technologies for energy
systems; and integrated assessments of a wide-range of energy-related environ-
mental issues.
EPA REVIEW NOTICE
This report has been reviewed by the participating Federal Agencies, and approved
for publication. Approval does not signify that the contents necessarily reflect
the views and policies of the Government, nor does mention of trade names or
commercial products constitute endorsemeht or recommendation for use.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
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EPA-600/7-78-052b
July 1978
EPA Industrial Boiler FGD Survey:
Second Quarter 1978
by
J. Tuttle, A. Patkar, N. Gregory, and M. Eckstein
PEDCo. Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
Contract No. 68-02-2603
Task No. 36
Program Element No. EHE624
EPA Project Officer: R. Michael McAdams
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
-------
NOTICE
This report, (prepared by PEDCo Environmental, Inc.,
Cincinnati, Ohio under EPA Contract No. 68-02-2603, Task No. 4)
is provided as an information transfer document. Data in this
report are supplied voluntarily by industry representatives;
flue gas desulfurization (FGD) system designers, vendors, and
suppliers; regulatory personnel; and others. Neither EPA nor
the designated contractor warrants the accuracy or completeness
of information contained in this report.
Initial distribution of the report is limited to organization
and individuals indicating a specific interest in the field of
FGD technology. Additional copies of this report and succeeding
issues can be purchased from National Technical Information
Service, Springfield, Virginia 22151.
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TABLE UF CONTENTS
SECTION PAGt
NOTICfc
EXECUTIVE SUMMARY iv
1 INTRODUCTION l
2 LIST UF INDUSTRIAL BOILERS WITH FtD SYSTEMS i
A SUMMARY UF ALL INSTALLATIONS BY NAME, LOCATION, STARI-UP DATE, Alvl)
CURRENT STATUS.
3 SUMMARY OF FGD SYSTEMS UN INDUSTRIAL BOILERS ^
A BRIEF SUMMARY UF THE SOURCE CHARftCTEN 1STICS, THE CONTROL PROCESS AI\D
CONTROL SYSTEM SUPPLIEw, AND IMFOftMA I IJN ON RECENT SYSTEM PEKFuRMNCe .
4 SUMMARY BY VENDOR OF FGO SYSTEMS UN INOUS1RIAL ttUlLERS 1-5
A LIST OF THE CONTROL SYSTEMS SUPPLIED BY EACH SYSTEM VENDOR OR MANiJF SCTURER.
5 OPERATIUNAL FGD SYSTEMS ON INDUSTRIAL BOILERS 1*>
6 UNDER CONSTRUCTION FGD SYSTEMS UN INDuSIRiAL BOILERS 19
7 PLANNED F&D SYSTEMS ON INDUSTRIAL BUILERS 2u
8 SUMMARY OF DISPOSAL PRACTICES FUR FGD SYSTEMS ON INDUSTRIAL BOILERS ai
9 PERFORMANCE DESCRIPTION FOR OPERATIONAL F&D SYSTEMS ON INDUSTRIAL BUILERS 35
AN IN DEPTH DATA PRESENTATION FOR THE UPEhATIUNAL CONTROL SYSTEMS. THIS
SECTION PRESENTS BACKGROUND INFORMATION, OPERATING EXPERIENCE, ECONOMIC
DATA , DESIGN DATA, DISPOSAL PRACTICES, AND ANY OTHER RELE V ANT IiMF.uRf>.ft (ION
AVAILABLE CQrMC-ERWING THE FbD SYSTEMS AT THE VARIOUS INSTALLATIONS.
10 DESIGN INFORMATION FOR UNDER CONSTRUCTION FGD SYSTEMS ON INDUSTRIAL BulLEkS 9b
SAME AS SECTION 9, FOR CONTRUL SYSIEMS UNDER CONSTKlJCTION.
11 DESIGN INFORMATION FOR PLANNED FGO SYSTEMS ON INDUSTRIAL BOILERS 101
SAME AS SECTION 9, FUR PLANNED CONTROL SYSTEMS.
18 DESCRIPTION OF INDUSTRIAL BOILER FGO SYSTtMS NOT OPERATING lUb
SAME AS SECTION t, FOR CON1ROL SYSTEMS WHERE FOR SOME REASON, 1HE SYSTEM
IS NOT OPERATING.
13 PROCESS DIAGRAMS FOR INDUSTRIAL BOILER FGO SYSTEMS 11"?
iii
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EXECUTIVE SUN'r-ANY
1.1E FIRST FULL-SCALE UMTEP STATES APPL1CATICN OF FLUE GAb OFSULFUR I 7 A T I ON (FGD) TECHNOLOGY TO
['•.'OUST* I Al. FtOTLFRS WAS AT 1 HE GENERAL MOTORS PLAiiiT IN ST. LOUIS, MISSOURI WHERE TWO FGD SYSTEMS WERE
1NSIALLED ON Tea) COAL.-F IREu BOILERS IN 147,;. ]M THIS
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HIGHLIGHTS FKOM THE CURRENT INDUSTRIAL PUILEK FGD aURVtY AKF GlVf. BEI. Uft:
ALYE'SKA PIPELINE SERVICF CU, HAVE BfEN OPERATING A FMC SODIUM nYORUXIDE SCKIIttHlNG SYSTEM AT VALUEZ.
ALASKA SINCE JUNK 1977. THE" FbD SYSTFM KFMOVKS 9f-X UF SO? GENERATED BY FIRING OIL WITH U.l% SULFUR.
UllhlNG THE REPORT PtRIUO, THE AC ID i C L 1 KlnlM COLLECTED BY THE M1SI ELIMINATOR HAS CAUSED CO"IRUb ION .
I HE PRUHLFM HAS BFtN ALLEVIATED BY I NC URPOK A I ING HYPkrtZTNF SH&AYS AT THE BuTT'l.vi OF THE DEMISIER.
ARCO/PtJLYMERS, INC. HAVE AWARDED A CONTRACT TO FMC FOR A OUUBLL ALKALI FGO SYSTEM TO Bt INSTALLED AT
THE MOMACA, PENNSYLVANIA PLAMT BY JIJN'F 1980. THE THREE IDENTICAL BOILERS (. 30u,000 LBS/HR STEAM )
WILL HAVE SEPARATE SC.KUBBEKS WITH A COMMON REGENt R A T I (MM SYSTtM. THE TOTAL INSTALLED COST OK THE FGD
SYSTEM IS REPORTED TO BE Sb.U MILLIONS.
C.A.M.t A JOINT VENTURE OF UNION CARB10F, AMOCUf AND MONSANTO, HAVE ANNOUNCED PLANS TO INSTALL A CO-
GENEkATIQN FACILITY NEAR HOUSTON, TEXAS. THE PROPOSED huO M« (FHUIVALENT) POWER PLANT WILL GENERATE
ELECTRICITY AND PROCESS STEAM FOR THE EXCLUSIVE USE OF NEARBY PLANTS OF THE THREE COMPANIES. THE
TYPE (IF COAL TO BE USED HAS NOT SEEM DECIDED YET. HOWEVER A FliD SYSTEM IS DEFINITELY UNDER
CONSIDERATION. THE PLANT IS SCHEDULED TO GO ONSTREAM BY LATE 1983.
CATERPILLAR TRACTOR CO. CONTINUED OPERATIONS OF THE FGD SYSTEMS AT JOLIET AND MOSSVILLE, ILLINOIS
HLANIS. THF OPERAIIONAL PROBLEMS HAVE BEEN HEAVY FILTER CLOTH ATTRITION, AND EXCESSIVE WEAR OF IHE
FGO SYSTEM EQUIPMENT AT THE TWO PLANTS RtSPFCT 1 VEL Y .
CATERPILLAR TRACTOR CO. REPORTED THAT <4 FMC DOUBLE ALKALI FGD SYSTEMS WERE STARTED UP AT E. PEORIA,
ILLINOIS IN APRIL 1978. THE SYSTEMS ARE DESIGNED TO REMOVE 90* OF S03 FROM THE FLUE GASES GENERATED
BY BURNING 3.2% SULFUR COAL. FGD OPERATIONS PROCEEDED FOR THIRTY DAYS BEFORE THE BOILER PLANT WAS
SHUT DOWN FOR SUMMER.
CHEVERON U.S.A. INC. HAVE REPORTED THE STARTUP OF 3 FGD SYSTEMS AT THE BAKERSFIELD, CALIFORNIA OIL
SHE IN JUNE/JULY 197B. THE SODIUM CARRONATE SCRUBBING SYSTEMS WERE SUPPLIED dY KOCH ENGINEERING AT
A TOTAL COST OF » 2.6 MILLIONS. EACH SYSTEM TREATS FLuF GASES FROM 6 IDENTICAL OGILERS, WHICH HAVE
A TOTAL RATING OF iOO MM 8TU/HR. THE STARTUP HAS BEEN SUCCESSFUL.
AT THE FIRESTONE TIRE AND RUBBER cu. IN pension, PENNSYLVANIA, THE FMC DOUBLF ALKALI
PLANT CONTINUED OPERATIONS. THE SYSTEM COMPONENTS, ESPECIALLY THE F.D. FAN AND THE SCKUbHER
INTERNALS, HAVE EXPERIENCED SEVERE FLYASH ABRASION. DURING THE REPORT PERIDO, A NEW FAN HAS PUT IN
WITH A HOUSING METAL1ZED 8Y 31b SS. THE MILD STEEL SPRAY hiOoS WE9E REPLACED I1Y 316L So.
THE FMC SODA ASH PLANT IN GREEN RIVER, WYOMING REPORIEu THAT SuS REMOVAL EFFICIENCIES uF 87-9'U
ACHIEVED DEPENDING UPON THE L/G RATTO, AND REC IRCUL A T ING LIQUOH PH. PH VARIATIONS, AND LEAKS IN Tup
WERE THF MAIN OPERATIONAL PRUBLPKS DURINi., THE KF.POiVI Pt^IOD.
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S C"kWtf"LV W**n«l PSD SYSUM5 AT FlVt INSTALLATIONS AKO.J.MD THE UNI1EO STATES.
ALLOWING UPUAIt INFURMAITUN WAS PrfOVIOFO HY PArtl-'A, 0,110 M)R THt UOUPLF ALKALI FGD SYSTEM:
SYSTEM H*° AN ^^^ITY ^ ™*. ^ ^cu^ AND LiM
J^, THE F6D SYS, EH
BUNNKEH MILL- IWIANA kFpOhiTED PLANS FOR A DOUBLE ALKALI FGD SYSTEM, WHICH
«ILL TKEAT FLUE GASES FROM £ EXISTING ANU i PROPOSED BOILERS. THE BIOS ARE UNUEW EVALUATION, AND
IHt SYSTEM IS SCHEDULED TO STARTUP IN AUGUST
IH TRUN*' C*^^*""!* * SODIUM CARtiONATE SCRUBBING SYSTEM WAS STARTED UP
AlOMGwiTH THE NFft l.i flM TONS/YR SuOA ASH PLAWT. THE FLUE GASES FHOM T«0 ig-M« COKE, COAL, AND OIL-
FTkEu dOILERS ARfc SCKUbBED 8Y THE SODA ASH END-LIHUOrt IN TnO SC^UdflEKS SUPPLIED rtY COBUSTIUN EOT.
IHt MAJOR STARTUP PROBLEM «AS WEAKENING OF THE PUL YPkOP YLEHE SIEVE TRAYS, WHICH WILL BE REPLACED BY
ilhL SS OR A HIfiHb'i< GRADE ALLOY.
C°* KEPOI
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StCTTUN 1
INTKOUUCTIOU
IriJS REPORT ADDRESSES THE APPLICATION UF FLUE GAS OF rillLF (IR 1 / A T I ON (FGD) TECHNOLOGY TU INDUSTRIAL
i:lf)ll.t.*b. THt NRtl) FU« SuCH A DOCUMENT HAS AKlSEu AS A RESULT UF MOKE STRINGENT EMISSION REGULATIONS
UHblG"EO TU REDDLE SULFUR DIOXIDE. ISO?) tMlSSIUNS. IN VIEW l)F THF DEVELOPMENTAL STATUS OF FbD TECH-
,MI:LI.H,Y, EPA'S INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY IN RESEARCH TRIANGLE PARK is ESTABLISHING
A PERIODICALLY UPDATED ENGINEERING APPL 1C A T 1 UN/IiMFuRMA T TON TRANSFER PROGRAM FOR INDUSTRIAL USE OF
bfld LtlNTROL TECHNOLOGY.
FI«ST ISSUED IN DECEMBER 197? AS A COMPREHENSIVE 9UO-PAGE RFPOKT ON S0£ CONTROL SYSTEMS ON ALL
CUMbUSTlOlM AND PHUCLSS SOURCES, THE CURRENT StRIFS, in THE INTEHFST OF tCUNOMY, AOOKESSES
TMDUSIRIAL HOlLErt APLICAT10MS OF KGD TECHNOLOGY. THE FIRST ISSUE OF THIS SEKIES, ENTITLED "EPA
IMiMJSTnilAL HOILER FGD SURVEY: FIRST JUARTER l^rfl", PRESENTED DETAILED TECHNICAL INFORMATION ON
INDUSTRIAL BOILERS F&D INSTALLATIONS. THE INFORMATION WAS OBTAINED BY A SURVEY OF PLANT PERSONNELr
CONlKOL SYSTEM VENDORS, REGULATORY AGENCIES, AND ENGINEERING FIRMS.
1ME CURRENT REPORT REPRESENTS AN EXPANSION OVER THE FIRST UUARTEK 1978 REPORT WITH RESPECT TO
BOTH IHE NUMBER OF 1NSTALLA1 IljNS, AND THE INFORMATION PRESENTED FOR EACH INSTALLATION. THE DATA
ARE GTVF.M IN TWO TYPES OF TABLES: ONE GIVFS SUMMARY INFORMATION; THF OTHER, UFTAILED INFORMATION.
SUMMARY TABLES PRESENT INFORMATION AS FUNCTIONS OF TYPE OF CONTROL PROCESS, CONTROL SYSTEM VENDOR,
OISPuSAL TECHNIQUES AND OPERATIONAL STATUS (OPERATIONAL, UNDER CONSTKUCTICiN, PLANNED, OR NOT OPERAT-
ING). .MUMBEHS, OPERATIONAL STATUS, AND OVERALL CAPACITY OF THt FGD SYSTEMS ARE SUMMERIZED IN THE
tXtCUTIVE SUMMARY. UETAILtD INFORMAITuN INCLUuES: CONTROL SYSTEM DESIGN PARAMETERS, OPERATING EXPE-
RIENCE, ECONOMICS, PROBLEMS AND SOLUTIONS, WASTE DISPOSAL TtCHNIUUES, AND MAINTENANCE PRACTICES.
Tut INFORMATION IN THlb REPORT WILL BE PERIODICALLY UPDATED AND EXPANDED BY MEANS UF TELEPHONE
AND MAR SURVEYS, AND PUBLISHED EVERY UUAKTEK. IN FUTURL REPORTS, THE DATA BASE ON SELECTED PLANTS
nILL BE EXPANDED BY UN-SITE SURVEYS. INDIVIDUAL SURVEY REPORTS WILL ALSO BE PUBLISHED FUR THE
wESPfcC I IVE PLA.MTS.
CERTAIN ENGINEERING SYMBOLS AND TERMS ARE USED VERY FREOUENTLY IN THE FIELD OF FGD TECHNOLOGY.
TABULATED BELOtt ARE THE DEFINITIONS OF PERTINENT SYMBOLS AND TERMS USED IN THIS REPORT.
SYi'hOL/TtRM DEFINITION
ACFM ACTUAL CUBIC FEET PER MINUTE, UNIT OF GAS FLOW RATE fEASURFD AT ITS ACTUAL
TtMPErtA IllKE ANT) F'RESSURE
AVAILABILITY HOURS THE FbO SYSTEM WAS AVAILABLE (WHETHER OPERATED OR NOT) DIVIDED BY HOURS IN
PERIOD, EXPRESSED AS PERCENTAGE
F DEGREES FARENHEIT, UNIT OF TEMPERATURE
F.n. FuHCEiJ DrtAFI
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SYMBOL/TERM
GP>"
I.D.
L/G
OPERABILITY
PSIG
RELIABILITY
SCFM
T
rtli
0/XX
DEFINITION
GALLONS PER MINUTE
INDUCED DRAFT
EXPRESSED
LIaU1° FL°" °mDED BY 1ME
PERJOD,
POIIIMDS PER SQUAKF INCH, UNIT OF PkESSURE
EXPKESSEO Is°PEKCStNTAGES
*' HOURS IT «S CALLED UPON TO OPERATE,
UF GAS FLOW HAIE "tAsu«ED AT 70 F ANU i ATM.
TEMPERATURE
WATtR GAUGE, UNIT UF PRESSUKE DKHP EXPRESSEU AS INCHES UF f.ATER
WHEN IHt EXACI MONTH OF A STARTUP DATt iS NUT AVAILABLE IT IS INDICATED BY A ZERO
ANYONE DESIRING TO RECEIVE THE [lUAKTtRL* UPDATED VERSIONS OF THIS REPORT FREE OF COST, MAY
HEUUEST ADDITIUN OF HIS OR HfcR NAME IU THE MAILING LIST BY CONTACTING THE EPA PROJECT OFFICER UR THE
CONTRACTOR.
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US! uF iNtJOSTRlAu r.OHERS /, I T H tuD SYSIEHS
blATuS Ab UF 0//3
-------
5t 1. T ION ? (COM INUEl))
L1S1 OF INDbSlRlAL bOlLEkb ,< I 1 H Fblt SYS1EMS
STATUS AS OF 07/30/78
INSTALLATION NAME
GKEAT WESTERN SUGAR
GREAT WESIEKN SUGAR
GrtEAT lut.SIERN SUGAR
GKEAT lit SI EKM SUGAR
GKFAT ASTERN SUGAR
GrtrAT WESTERN SuGAR
GKloSuw AIR FORCE HASE
HAHKIa MINING CO.
TIT RAYONIER, INC.
KERR-MCGEE CHEMICAL CORP.
MtAu PAPERBOAKD CO.
MINN-OAK FARMER'S COOPERATIVE
MUHIL OIL COMPANY
MublL UIL COMPANY
NEKOOSA PAPERS, ItMC.
TUAuIfY MILLS, INC.
RICKfcNBACKEK AIR FORCE BASE
SHELLtR GLObE CORP.
SI. JUE ZINC CO.
sr. REGIS PAPER co.
TtXACO INCORPORATED
TtXACU 1MCORPORATEQ
TtXASbllLF
TKAfcSCO TEXTILES, IMC.
il.S. GYPSUM CORP.
LGCATiUN
FREEMON1,UHJO
GERlNb, NEBRASKA
GREEIEY, COLOkAlid
LUNGMuMl, COLORADO
LOVELAND, Cul UPADO
SCOI1S DLUFF, NESitAbKA
BUWKEh HILL, INDIANA
SPRUCE PINE, NORTH CAROLINA
FtHNANDlNA bEACH, FLORIDA
TKONA, CALIFORNIA
SlEVtNSUN, ALABAMA
HAHPEION, NOK'IH DAKOTA
BUTTOiMWlLLOw, CALIFORNIA
SAN AKDO, CALIFORNIA
ASHOOtvN, ARKANSAS
MI. AIRY, NORTH CAROLINA
COLUMBUS, OhIU
NORFOLK, VIRGINIA
MUNACA, PENNSYLVANIA
CANTONMENI, FLORIDA
SAN AROO, CALIFORNIA
SAN AROO, CALIFORNIA
GRANGER, YiYOMiNb
AOGUS1A, UEORUIA
OAKMONT, KEfiNSYLVAM A
START-UP
DATE
10-7B
10-75
10-75
10-73
10-73
10-75
9-79
0-73
0-75
6-78
0-75
b-7 I
9-78
0-74
2-7b
5-70
3-7fa
0-75
10-7b
0-73
11-73
,-7b
3-75
0- 0
STATUS*
2
1
1
7
1
1
5
7
1
1
1
1
2
1
1
7
1
1
2
1
1
1
7
7
PAGE NUMBER*
9/( 9,14,19,22)
&7( 9,14,17,23)
69( 9,14,17,23)
107( 9,14, 0,23)
70( 9,14,17,23)
Vd( 9,14,17,23)
105(10,14,20,21)
108(10,15, 0,24)
74(10,13,18,23)
76(10,13,18,22)
78(10,13,18,21)
80(10,14,18,23)
98(10,14,19,22)
82(11,14,18,22)
83(11,13,18,21)
109(11,13, 0,22)
85(11,15,18,22)
88(11,15,18,24)
99(11,13,19,22)
89(11,13,18,23)
91 (12,13,18,23)
100(12,13,19,24)
93(12,15,18,23)
110(12,14, 0,23)
111(12,13, 0,21)
* STATUS CuDES
0 - STAluS NOT DEFINED
1 - UPEWAT10NAL
a - CO.MSTRUCTluNAL
3 - PLANNED-CONTRACT
5 - PLANNEO-REfJUESl ING/EVALUATING RIDS
6 - PLANNED-CONSIDERING so? CONIROLS
7 - TtRhlNAIF.ly
B - luOEFllMITt'LV SH01 DOWN
- PLANNED-LEU fcR 01- I MEM SIGNED 9 - NEVER S1AKTEP-UP
+ FOK COMPLETE INFURNAIIOK ON I HE INDICATED FGU SYSTEM REFER TO URSI PAGE LISIEU.
THE INSlALLAIIuN APPEArxS IN uTrlEh SUMMARY bECTIOl.S ON THE PAGES IN PARENTHESES.
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STATUS AS UF 07/30/78
SECTION ?
bUMMAhY UF FGO SYS1EMS UN INDUSTRIAL BUILEKS
CU''1'A;MY TNFURMA1 ION
AlYtS'vA PIPELINE SERVICE CO.
vAi.iiF/, ALASKA
FK: F ,\iVlRuNMENT AL F.UUIPMENT
FiifL UTL CO. 05% - 0.1X SULFUR)
•jO.Ully SCFM (DESIGN 1-iAXlMUM)
MUK 1-up 6/77
SuniU.1-. HYDROXIDE bCKUbtUMG
SIATIIb - UPERATIUNAL
tCArJ THREAD CU.
dN, NORTH CAROLINA
K.:. bLY MANUFACTURING CU.
CIIAL (0.8% SULFUR): H\TERRUPTIBLE NATURAL GAS
Iti.jOO SCFM (T01AL - c TOILERS)
S1AK1-HP U/73
CAllsTIC-WASTE STREAK
SIA1US - OPERATIONAL
AKCG/HOLYMERS, IMC.
MUNACA, PENNSYLVANIA
F«iC ENVIRONMENTAL EQUIPMENT
COAL li.O* SULFUR)
aih,oon SCFM (TC1AL - 3 BUTLERS)
SIART-UH 6/80
IHHIi-jLE ALKALI (CONCENTRATED)
STAIUS - PLANNED-CONTRACT ArtARDED
ARMCU STEEL
M10ULETOWN, OHIO
KOCH ENGINEERING
CUAL IU.8* SULFUR)
HU.uOO bCFM (TOTAL - i. BOILERS)
S1AKT-IIP 0/7b
LIME bCKUBBING
STAIMo - OPERATIONAL
HUNIStf INC.
CAIhC. ILLINOIS
OKAvO CURP./NAT'L LIMb ASS'M
COAL I'ii SULFUR)
44,iHiU bCFM (TOTAL - d dOlLtRS)
S1AKT-UP 9/ 0
Ll"it SCKUH6ING
STAlilH - TERMINATED
C.A.M.fCARBlDE-AMOCU-N.ONSAMTOj
lIUHSTON. Tt'XAi
n. u T StLbCTEO
NuT StLtCTED
1 ,<>UO, (i00 SCFM (1 BOILER)
SrAhT-UP 10/83
MUT SELECTED
SIAllia - PLANNEU-COIMSIDERIWG $0^ CONTROL
SU"'-
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STATUS A3 UF 07/4U/7B
SECTION 3 (CONTINUED)
SUMMARY OF FGD SYSTEMS ON INDUSTRIAL BOILERS
COMPANY INFORMATION
SUMMARY OF KECENT OPERATIONS
CARBORIJMDUM ABRASIVES
BUFFALO, ME^ YORK
CARBORUNDUM ENVIR. SYS. LTD.
COAL 12X S AVERAGE, S.iJX S DESIGN MAX)
36,000 ACFM 3 3bO F
SIAKT-UP O/ U
LIMt SCRUBBING
STATUS - PLANNED-CONTRACT AwARDhO
NO DEFINITE PLANS HAVE BEEN MADE FOR THE CONTnOL
Oh S02 EMISSIONS FROM THIS BOILER. THF FUTuRf UF
THE CONTROL SYSTEM WILL Bt DETERMINER BY A REGU-
LATORY AGENCY DECISION EXPECTED NEAR THE END uF
197t>. THE CURRENTLY OPERATING vENTURI (L/G = 10)
CONTROLS ONLY PARTTCOLATE, BUT TIE-INS HAVE BEEN
PKOVIOED FOR A LIME SCRUBBING SYSTEM USING
A 6-siAGE SPRAY TO. BOILERS)
SIAKT-UH 9/7K
DOIioLE ALKALI (DILOIE)
STATUS - OPERATIONAL
THE FGO SYSTEM CONSISTS OF AN INDEPENDENT
SCR08BING TRAIN ON EACH OF TrtO COAL-FIRED BOILERS.
THESE BOILERS HAVE BEEN OPERATIONAL EACH HEATING
StASON SINCE OCTOBER 1974. SINCE THAT OATE,
SCRUBBER AVAILABILITY HAS BEEN AVERAGING ao-s^x.
SEVERAL PROBLEMS PLAGUED 1977-1978 OPERATIONS:
UNRELIABLE 305 MONITORS, HIGH EROSION OF FILTER
CLOTH, AND PLUGGED PIPELINES. SLUDGE FREEZING
WAS ALSO A PROBLEM AREA.
CATERPILLAR TRACTOR Co.
MAPLF10N, ILLINOIS
FwC ENVIRONMENTAL EQUIPMENT
COAL 13.2X SULFUR)
li>7,UUO SCFM (TOTAL - 3 BOILERS)
START-UP 10/78
DuilbLE ALKALI (CONCENTRATED)
STATUS - CONSTRUCTION
AT THE CATERPILLAR MAPLETON PLANT, FMC CONCENTRA-
TED MODE DOAL ALKALI TECHNOLOGY KILL BE UTILIZED
TO CONTROL S02 EMISSIONS. [HREE SCRUBBER SYSTEMS
WILL START-UP IN OCT. 1978, CONTROLLING EMISSIONS
FROM THREE COAL-FIRED BOILERS. CONSTRUCTION
DELAYS, PRIMARILY On [HE STEAM GENERATION SIDE,
HAVt DELAYED SYSTEM START-UP BACK TO THE 1978-79
HEATING SF.ASON. BY THE EARLY i980's THERE >VILL
Bt 8 FMC FGD SYSTEMS AT TriE TrtO MAPLETON SITES.
CATERPILLAR TRACTOR CO.
MiiMlOw, ILLINOIS
7URr, INDUSTRIES
COAL (3.ax SULFUR)
«U,OOU SCFM (TOTAL -<2 BOILERS)
STAKT-UP 1/78
DOUBLE ALKALI (UILUTF)
STATUS - OPERATIONAL
THE CATERPILLAR MORION PLANT UTILIZED ZORN INDUS-
TRIES' DILUTE MODE DOUBLE ALKALI TECHNOLOGY
TO CONTROL EMISSIONS FROf THE STEAM PLANT.
FGD SYSTEM START-OP OCCURRED AT THE BEGINNING
OF 19/8. OPERATIONS CONTINUED 10 BE PROBLF
DURING THIS REPORT PERIOD. SOME BOILER-RELATED
PROBLEMS HERE EXPERIENCED.
CATERPILLAR TRACTOR CO.
MuSSVlLLE, ILLINOIS
FISC ENVIRONMENTAL EUUIPMENT
COAL (3.ax SULFUR)
140,000 SCFM (TOTAL - 4 BOILERS)
STAKT-UP 10/7S
DOIIHLE ALKALI (CONCENTRATED)
STATUS - OPERATIONAL
THE CATERPILLAR MOSSV1LLE PLANT HAS UTILIZED AN
FMC CONCENTRATED MODE FGD SYSTEM EACH HEATING
SEASON SIlMCE OCT08F.R 1975. THERE A«E FOUR COAL-
FIRLD BOILERS EACH bEING TREAIED BY A SEPARATE
scROBBiuG TKAIN. OPERATIONS FOK THE 1977-78 HEAT
SEASON WFRE MARKED BY EROSION IN Tut SCRUBBER
LINING, PIPING, PUMPS, AND CONTROL VALVES.
CnFvtKOivi U.S.A. INC.
flAMiiVSFiELt), CALIFORNIA
NUT SELECTED
OIL U.1I SULFUR)
14h,000 SCFM (TOTAL - 1 £ BOILERS)
SlAhT-UP 4/79
SODIUM CARBONATE SCRUBBING
STAillS - PLANNEO-RFtJUcSTING/EVALUATING BIDS
CHEVERON U.S.A. IS PLANNING TO INSTALL TWO MORE
FGD SYSTEMS A[ BAKERSHIELO OIL SHE. IHESfc WtLL RE
OivCt.-THROUGH, SODIUM CARBONATE SCRUBBING SYSTEMS
AND ARE SCHEDULED TU GO Om-STREAM BY APxIL 1979.
-------
STATUS AS OF U7/30/7tt
af-cTHi.* < icn:.i INHJFJ)
SUMMARr UF-' Fbl) SYSTEMS '"• INDUSTRIAL "BOILERS
IllFORMAl ION
SijV'iARY IH- RFCt'NT ''PFRATTUNS
CHFVRUN U.S.A. IMC.
SAKtRSFlELU, CALIFORNIA
KOCH ENGINEERING
OIL (l.U SULFUK)
2«tt,00i> SCFM ITuTAL - Id bOiLtRSl
START-UP 7/7h
SODIUM CARBONATE SCRUBBING
STATUS - OPERATIONAL
CriK l/RUN U.S.A. HAS PURCHASED IHwFE FRO SYSTEMS
FROM KOCH E.iGINcFR I ^G. THt SOOIuf CAHiiOivAIF SLrfn-
rUil.M'^ SYSTEMS JU.M oN-STREAM IN JUNE/JULY 197n.
TnF STARTUP HAS BEE.M SUCCESSFUL. THt SYSTtMS ARE
<'tS lGijf',J Kl REDUCE SOc c;'ISSluiMS BEi-O* 7U PHM.
FIRESTONE TIRE AND KUoBER CO
PUTISTO.MN, PFNNSYUVANIA
FIV.C ENVIRONMENTAL EUUIPMENT
?.5-.i.OX SULFUR CUAL
B07U SCFM (13(OUO ACFh aj 3(")
S1AKT-UH 1/7S
DOllttLt ALKALI (CONCF.NTRATEDJ
- uPERATIOiXiAL
F)
THt FbO SYSTEM AT FIRtSKlNF-POTTSlOivrM CONSISTS UF
AN FML UOU6LE ALKALI DUAL THUOAT VF.IMTUKI SCKUBBtR.
Into 30e CONTROL SYSTtM nAS BulLT AS A OFMOivSIKA-
T|f)r< HRiUECI F-U.'jDtn BY FlKFSlUNt. TM? SYSIFM OPt«-
AlEl) rtllri AIM AVAIl.AblLTTY VALUF. OH 91 'I. IN THE FALL
UUAnTtW UF 19/7. Int" MA.lOtt PKUBLtM AHKA .lAii
PK05ION OF FAN AND SHiVAY NOZZLES aY FUVASH. ThE
FAN AiMO SHRY KODS KtSt KFPLACen KM APRIL 1 <* IA.
FMC (SODA ASH PLANT)
GKF.tN RIVER, WYOMING
FrtC ENVIRONMENTAL EUUIPMENT
CliAL (1% SULFUR)
4«b/UUO SCFM [TUTAL - 2 BOILERS)
START-UP 5/76
SUIHUM CARBONATE SCRUHBiMG
STATUS - OPERATIONAL
THE FGO SYS1EM CONSISTS fiF TftO FMC SODILJN1 SCRufl-
HlNb UMTS TO Rt^OVh SULFUR UIOxIOE A.MlJ HARTICU-
LATh HATTtR FROM 1Ht FLUF GAS OF I WO BOILERS.
SCRUBBER UIKROSION HAS KFtfM A PROBLEM. PLANT
PERSONNtL FtLt THAT THE LINING rtAS IMPRuPERLY
APPLIED. FOAMING AND SEDIMENTATION HAS OCCURED
IN I HE SCRUBBER DUE TU ICPURI TIES IN tlifc LluUOR.
Ph VARIATIONS AND DAMPER LEAKS ARE OTHER PRuBtEMS.
GENERAL MOTORS CORPORATION
DAYTON, OHIO
ENTOLETER, INC.
COALfO.7% - 2.OX SULFUR)
36,000 SCFM (TOTAL - d BOILERS)
SIART-UP 9/71
SUDItlM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
THF FGI.) SYSTEM CONSISTS OF IWU ENTOLtlhR SODIOM
HYDROXIDE SCRUBBING UNITS. THE UNITS HAVE BEEN
UPHKATIONAL SINCE SEPTEMBER H7t. 1 Ht AVERAGE
OPFKABILIIY OF THE SYSTEM IS S5*. THE ORIGINAL
31hL SS MIST ELIMINATORS ARE SEvERLY CORRODED, AMU
'ULL bF. REPLACED BY HAS1E ALLOY-G. PLUGGING OF RF.-
CIRCULATTON LINES, CAUSED BY FLYASH, HAS BEEN A
SERIOOS PROBLEM.
GENERAL MOTORS CORPORATION
PARf.A, OHIO
Gl'l ENVIRONMENTAL
CuAL (H.5X SULFUR* 7.1* ASH«
1^8,100 SCFM a) 70 F (TOTAL -
START-UP V71
DuubLE ALKALI (OTLUIE)
SVATUS - OPERATIONAL
l?,^b(i BTU/LB)
1 BOILERS)
THE FGO SYSTEM CONSISTS OF 4 GM-DESIGNED DUUBLE
ALKALI SCRUBBERS UPERATIO.MAL ON a BOILERS. THE
SCRU8BEKS HANDLE A I01AL d1d,00o ACFM OF FLUE GAS.
THF SCRUBBF.RS HAVE BFEN OPERATIONAL SINCE MARCH
1974. THE SYSTEM HAD AN AVAILABILITY OF 78*
DURING THIS REPORT PERIuD. FILTRATION EQUIPMENT
AND LIME SLURRY FEEU PUMPS rtlLL BE REPLACED.
GENERAL MOTORS CORPURATION
PUNTIAC, MICHIGAN
PEABUUY ENGINEERING
CUAL (0.84% SULFUR)
Iu7,300 SCFM (TuTAL - F K'FHEAT.
-------
STATUS AS OF 07/30/78
bf.CTIOr-. 5 (CONTINUED)
SUMMARY oh rb n SYSTEMS ON INDUSTRIAL BUILERS
INFORMATION
SUMMARY OF RECENT OPERATIONS
I'ft.KAL MOTORS CORPORATION
TliMljAAr.i[,A, |\,Fft YOKK
FM; F\V1RONMFNTAL EljUIPMEiMT
COAL. (1.3% SIILFuR)
3e,,M)l) aCFM (TOTAL - '4 HOILERS)
START-UK h/7b
Sol/Ill:1-' riYORUXlOE SCRUBBING
SI ft [lib - OPERATIONAL
THE Flit) SYSTEM CONSISTS OF FOOR GM SOOIOM SCRUR-
rtlM, UNITS FOR THE REMOVAL UF PARTICULATES AND
SULFUR DIOXIDE FROM FOUR COAL-FIRED BOILERS.
IMF. SCRUBBERS ARE EQUIPPED WITH VENTURI SCRUBBERS
FUR PARTICULATE REMOVAL. UNSTABLE PH CONTROL,
PIPE EROSION AND STACK CORRISION ARE MAIN PROBLEM
ARFAS. REPLACEMENT OF CONTROL SENSORS, PIPING
Awn RELINI.MG OF STACK ARF. THE CORRECTIVE ACTIONS.
PAPER co.
L'KiisSt T I , ARKANSAS
' IKPI'L INDUSTRIES
^Arvis A..JU OIL UR COAL u* - i.i% SULFUR)
2,000 SCFM (1 BOILER)
SFART-UP 0/7!i
CAUSTIC WASTE STREAM
STATUS - OPERATIONAL
THE FGD SYSTEM CONSISTS OF AN AIR-POL CAUSTIC
SCRUBBING UNIT TO REMOVE SULFUR DIOXIDE AND PAR-
UCULATE MATTER FROM THE FLUE GAS OF A COAL/BARK
OK UIL/BARK POWER BOILER. [HE SYSTEM IS PRECEDED
BY CYCLONES FOR PARTICULATE REMOVAL. DURING THE
REPORT PERIuD No MAJOR PROBLEMS OCCURRED. THE
BOILER-SCRUBBER HAS BEEN OFF-LINE A TOTAL OF ABOUT
Ib OAYS SINCE JANUARY. GLASS LININGS IN THE
SCHuBdEK ARE REPLACED AS THEY FAIL.
GETTY OIL COMPANY
r»AKhPSFlELO, CALIFORNIA
Fi-.C ENVIRONMENTAL EuUlPMENT
CuAL (1.1% SULFUR)
7d,uO(l SCFM (TOTAL - fe BOILERS)
S1AKT-UH b/77
SuI'lUw CARBONATE SCRUBBING
STATUS - OPERATIONAL
THF SODIUM CARBONATE SCRUBBING FGD SYSTEM WAS
RETROFITTED BY FMC IN JUNE 1977. THE SYSTEM HAS
S02 REMOVAL EFFICIENCY OF 9UX. THE MAJOR MODIFI-
CATIONS HAVE BEEN REPLACEMENT OF MESH DEMISTER BY
CHEVRON TYPE AND ADDITION OF A KOCH FLEXITRAY IN
TOP SECTION. SEVERAL TYPES OF PH CONTROLLERS ARE
CURRENTLY UNDER TESTING. MILD STEEL RECYCLE PIPES
WILL BE REPLACED BY 316L SS.
BETTY OIL COMPANY
>)AKERbFIELO, CALIFORNIA
PiVOPKl AT ARY DESIGN
CRUDl- UiL (1.1% SULFUR)
99?,7bO SCFM CTUTAL-72 BOILERS)
SIART-IIP 12/78
SODIUM CARBONATE SCRUBBING
STATUS - CONSTRUCTION
GETTY OIL COMPANY HAS DESIGNED •* MORE SODIUM
CARBONATE SCRUBBING FGD SYSTEMS IN-HOUSE. EACH
SYSTEM, ONLIKE THE OPERATING UNITS, WILL HAVE A
SCR08BFR PURCHASED FROM KOCH CONTAINING 3 FLEXI-
TRAYS AND i FLEXTMESH DEMISTER. EACH SCRUBBER
MILL TREAT GASES FROM 8 ROILERS. CONSTROCTION IS
IN PROGRESS AND STAKTUP IS DUE DECEMBER 197b.
GKF.AT SOUTHERN PAPER CO.
CtOAR SPRINGS, GEORGIA
AiSHOL INDUSTRIES
tURK ANu COAL OR OIL (l.OX-a.UX SULFUR)
'Jc'O.OuO SCFI«! (TuTAL - 2 BUILERS)
STAKT-tJP 0/7b
CAUSTIC WASTF SfREAM
SIAIliS - OPERATIONAL
THE FGD SYSTEM CONSISTS OF TWO AIR-POL CAUSTIC
SCRUBBERS TU CONTROL PARTICULATE AND SULFUR DI-
OXIDE FROM TWO POWER BOILERS. THE PRIMARY FUEL
IS BARK/COAL (BARK/OIL IS FIRtD OCCASIONALLY).
THE FoLLOnliMG PROBLEMS HAVE BEEN ENCOUNTERED!
EROSiuN AND PLUGGAGE OF THE PH PROBES, INTERNAL
WEAR ON PUMPS, AMD EROSION IN THE RECIRCULATION
LINES.
SI
ntSTFRN SUGAR
GS, MuNTAiMA
EAT me. STERN SUGAR
10. TU SULF'u&J
,UUU bCFM H 70 f
Ai
-------
STATUS AS UF 0?/iO/7a
SEL.T IPi\ 5 (CO.-1 ItMUFD)
SUMMARY OF FbD SYSIFHS UN INDl'STHlAL HuILFRS
ClJ"t>ANY INFORMATION
SuMWAKY Of RFCENT OPFRATtuNb
b«f AT .vcSTFRN SUGAR
FiilH -iiiKGAN, COLORADO
Rht-AT •JtSIERfJ SUGAR
CoAL I 1.2% SULFUR, AVERAGE)
hti.cio SCFM UOIAL - 2 BOILERS)
STARf-UP 10/7b
ANKUNIA-LADtN PROCFSS WATER
8 I AIIIS - uPtRAT IONAL
ThF VENTUKY SCRUBBER «AS DESIGNED FOR PARTICIPATE
CONTROL AND si ANTED IN ociVft. rut CONOENSATE
PKMCESS WATtW USE l) HAS A HUiH PH 18.7) AHiCH
WtMUVhS SuMt S(V. TnK PARIICULATE AND SU? CON1RUL
EFFICIENCIES AKL 4fe* AML) 4SX r(EbHtC T I V F. L Y .
KhFAT v.tSIFKN SUGAR
FHFt-'ONI ,UH1U
lirftAT AtSTEKN SUT,A«
CulL I U SlILFUH)
Uu.uOu SCFM 'ulM»-LADEN PROCFSS WATtR
SI AIDS - UPERATIONAL
GRFAT WESTERN SUGAR IISFS CONOENSATE PROCESS WATER
PRIMARILY FOR PARTICOLATF CONTROL. THE WATER
HAS A HIGH PH (a.7) BUT THE SYSTEM HAS A LOW soa
REMOVAL. THE SCRUBBERS wFRE INSTALLED IN OCT'7«.
PLANT OPERATES OMLY DORING IHE FALL QOARTER.
Rwt-AT WESTERN SUGAR
hLi>nb LlLUFF, P»
r,RFttr ''VtSTEKfJ SUGAR
CuAL U.2X SULFUR, AVtRAGt)
h'j.e'iu SCFM (TOTAL - d bOlLfcRS)
olAnT-UP 10/7b
AM'-uJNIA-LADEN PROCESS ,-*ATtR
SIAIUS - OPERATIONAL
THF PLANT OPERATES ONLY OORING FALL UOARTER OF
EACH YEAR. I HE. VENTuRI SCRUBBER WAS DESIGNED FOR
PARIICULATE CONIROL AND WAS SIANEO IN OCT'7S. THE
PAKTICULATF AND Su
-------
STATUS AS OF 07/40/7H
SEcTlOM 3 (CONTINUE!))
SUMMARY uF FGO SYSTEMS DIM INDUSTRIAL BOILERS
COMPANY INFORMATION
GRISSOM AIR FORCE BASE
BDfv'RfR HILL, INDIANA
NUT SELECTED
CuAL (0.9% - 4.6% SULFUR)
?d,ooo SCFM (TOTAL - i BOILERS)
S1AHT-UP 9/79
DOUBLE ALKALI (CONCENT RATED)
STATUS - PLANNEO-REUUESTING/EVALUATING BIDS
HARRIS MINING CU.
SPRuCt PINE, NORTH CAROLINA
W.to. SLY MANUFACTURING CO.
COAL 10.at SULFUR)
1,000 SCFM (TOTAL - Z BOILERS)
STARI-UP 0/7JS
WATtP SCRUBBING (NA.NH3 OPTN.j
STATUS - TERMINATED
SUMMAKY OF RECENT OPF_RAIIUNS
THE AIR FURCE HAS INITIATED A PROJECT HHICH WILL
ADO OIME Nt« COAL-FIXED BOILER TO THE EXISTING
SIFAM PLANT. A PORTION OF IHE PROJECT INCLUDES SIM
FGD SYSTEM FOR IHE NEW BOILER AiMO ffiCI EXISTING
UMTS. THF A-E FIRM, FOSOICK AND HILMER, HAS
SPECIFIED A CONCENTRATED DflOHLE ALKALI FGD SYSTEM,
A.MO BIDS ARE CURREMLY sFING EVALUATED. PROJECT
COMPLETION IS SCHLDOLED FOR AOGUST JO, 1979.
THE FGD SYSTEM CONSISTS OF A «.«. SLY IMPINJET
SCRUHBEK CURRENTLY BEING USED STRICTLY AS A PAR-
TICuLATE CONTROL DEVICE. THE SYSTEM HAS THE
CAPABILITY OF SCROrtBIiMG WITH AMMONIA OR CAOSTIC
IF NECESSARY. HOfttVER, AS LONG AS CURRENT
LOK'-SJLFUh COAL SUPPLIES LAST, THERE IS No NEED
FOK soi CONTROLS.
ITT RAYONIEH, INC.
FLf/.MANDINA BEACH, FLORIDA
AIRPOL INDUSTRIES
BARK AND OIL (?x - d.b* SULFUR)
201,000 SCFM (TOTAL - Z BOILERS)
STAkT-DP 0/7b
SODIUM HYDROXIDE SCRObBING
STAIOS - OPERATIONAL
AT FERNANDIIMA BEACH, ITT RAYONIER FIRES BARK
AND OIL IN TWO OF THF FuUK PROCESS STEAM BOILERS.
PARTICOLATE AND SO? EMISSIONS AXE CONIROLLED IN
TwO AIRPOL SCRUBBING TRAINS. THE PLAmT HAS PERMA-
NtNTLY CONVERTED FRuM WASTE STREAM CAUSTIC SCRUB-
BING TO A SODIUM HYDROXIDE CONTROL. APPROXIMATE
SCRUBUER OPERA8ILITY SINCE JAN. HAS BEFN 95x.
KERK-wCGEE CHEMICAL CORP.
TRONA, CALIFORNIA
CoHoUSTIOiM EQUIPMENT ASSOC.
CuKE, COAL, OIL (O.b% - 5X SULFUR)
7db,000 ACFM a) 320 DEGREES F
STAHT-IIP 6/7fl
SODIUM CARBONATE SCRUBBING
STATUS - OPERATIONAL
THE FGO SYSTEM CONSISTS OF A COMBUSTION EQUIPMENT
(CEA) SUOA ASH SCRUBBING SYSTEM WHICH REAVES FLY-
ASH AND SOLFOR DIOXIDE FROM THE FLUE GAS OF TWO
COAL-FIRED BOILERS. THE SYSTEM WENT uM STREAM IM
JUNE. THE BOILERS HAVE USED UP To bO< COAL FEED,
AND 100% UIL FEED. PULYPROYLENE 1RAYS rtILL BE
REPLACED BY 316L SS OR A HIGHER GRADE ALLUY.
MEAD PAPERBOARD CU.
STEVFNSUN, ALABAMA
AIRPOL INDUSTRIES
OIL (l.b% - in SULFUR)
100,1100 ACFM al 450 F (TOTAL - 2 BOILERS)
SIAwT-up 0/7b
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
AIRPOL INDUSTRIES HAS SUPPLIED A PARTICULATE
AND so? CONTROL SYSTEM FOR THE TUQ OIL-FIRED
BulLEKS AT THIS MEAD PULP MILL. DUKliNG A JONE
POLP HILL SHUTDOWN, THE RUBBER LINER IN THE
ABSORBER WAS REPAIRED. ALSO, MODIFICATIONS WERE
IMPLEMENTED AT THE ABSORBER MOOOLE INLET WITH THE
INTENT OF PREVENTING FLY ASH ERROSION IN THE
MODULE. FGO SYSTEM OPFRABlLlTY WAS REPORTED TO
PE 100%.
MINN-DAK, FARMER'S COOPERATIVE
WAHPFTON, NORTH DAKOTA
KOCH ENGINEERING
LIGNITE (1.0% SOLf-UR)
160,000 ACFM a) 450 F (TOTAL - t BOILERS)
STAKT-UP b/77
A;lMuNIA SCRUBBING
SIATOS - OPERATIONAL
KOCH ENGINEERING HAS SUPPLIED TmO AMMOM A-B ASED
S02 CONTROL SYSTEMS FUR THESE COAL-FIREO BOILERS.
EACH YEAR THE PLANT ONLY PRODUCES SOGAR DURING THE
SEPT. - Ft*. PEKIOD. THEREFORE, THE SCRUBBER DID
NOT OPERA1E DURING THIS REPORT PERIOD. THE PLANT
HAS MADE SOME FGO PROCESS MODIFICATIONS DURING THE
SCHEDULED SHUTDOWN.
MOHIL OIL COMPANY
BOT10,M«ILLOH, CALIFORNIA
HtATER TECHNOLOGY
OIL (1.1% SULFUR)
Id,000 SCFM (TOTAL - 7 BOILERS)
SIAWT-UP 9/78
SuOlUM CAWBONATE SCKUBB1NG
SIAIuS - CONSTRUCTluN
MOBIL OIL HAS PURCHASED SEVEN EUUCTOR SCROHBERS
FROM HEATER TECHNOLOGY FOR THE CONTROL OF
EMISSIONS FROM I STE4M GENERATORS! d5 MM 8TO/HN).
EACH SYSTEMS CONSISIS OF A VENTURI SECTION, A
RECYCLE T«NK, AND AN OUTLET OuCT HIIH A MIST
ELIMINATOK. START-UP IS SCHEDULED FOR SEPT. 1978.
10
-------
STATUS AS UF i)7/3u/7b
SECTION 5 (COMT if(UF'J)
SUMMARY UF Fb') SYS I EKS OIM INDUSTRIAL BOILERS
COMPANY INFORMATION
SUVMARY OF RECENT OPEhAITUNS
'•'OBIL OIL COMPANY
SAN AROO, CALIFORNIA
MutUL OIL COMPANY
OIL C2.0X - 2.?S% SULFUR)
182,000 SCFM (TOTAL - JO bOlLEHS)
START-UP 0/7<4
SODIUM HYDROXIDt SCRUBBING
S1AIUS - OPERATIONAL
MUBll HAS ntSIGNFl) THt H-U) SYSTtM BY IN-HOUSE
FmfilNtF.Klnl'. ri«Sti> ON A PAH«|TE.U SODIUM HYDHUXIDE
SCRUBBING PROCESS. CUWKi'lSIJN OF MST FLlM.MATQR
ANIl l.n. FAN BLAOES HAVt BE'tN ThE MAJOR PrtOltLEM
Awe AS. TrlF Su3 REMOVAL EFFICIENCY IS CHANGED BY
ADJUSTING Irifc PH OF IM.hr LIQUOri.
NtKOMSA PAPERS, INC.
ASHOOM, ARKANSAS
AIRPfJL INDUSTWItS
COAL (U-l.bX SOLFUHI
211,000 SCFM a) JS55 ^ (TOTAL - 1 HUILEK)
STAH.T-UP 2/lb
CAUSTIC SCRUBBING
STATUS - OPERATIONAL
IMF. FGI.1 SYSTEM CONSISTS OK TWO AIK-POU CAUS1IC
•SLiioduF.KS CONl ROLL INS KLYASH ANu SUuFOR DIOXIDE.
TME PLAN! aePOKTEu NO MAJOH HsoaLtMS FIIK
Pt^IOi). SCKOriflLi* HuUKS vATLritil FJUlLF.rf
(vAS OPERATING AT
f>OX CAPACITY.
QOALIIY MILLS, INC.
Ml. A1WY, NORTH CAROLINA
COMMEKCIAL FABRICATION & MAC
FuEL OIL
STAKT-UP 5/70
WATEW SCRUBBING
STATUS - TERMINATED
THIS SMALL INOU3TKIAL BOILES UTILIZED A
CUMMEKICAL FAdWICATIOiM AND MACHINE ICFM) SCKUB-ATK
SYSTF.i-l TO CO^frtOL EMISSlil.vS FSOM 1HE COAL-FIRED
SUILEW FROM MAY 1S7U It) DtCEMbdH 1973.
AI 1HAT TIMt IHEY CONVEKftn TO FINING LOW-SOLFUk
OIL, REMOVING Trib NtFO TO CONTROL EMISSIONS.
RICKENBACKEK AlK FOkCt BASE
COLUMIIS, OHIO
RtSEAHCH-COTTkELL/BAHCO
COAL (1.0X SLILFUS)
50,000 SCFM (1 bOILEHJ
START-UP 3/7b
LIMtSTONE SCRUBBING
STAIUS - OPERATIONAL
THIb KESFARCH-COTTRELL/BAHCO LIME FGD UNIT
WAS FIRST PLACED IN SERVICE ^ARCH 11, 197b.
ThF. SYSTEM rtAS SWITCHED OVER 10 LIMESTONE IN APRIL
1*7?, AND HAS REGAINED IN THAT OPERATING MODE Tu
DATE. DURING THE SECOND QUARTER OF 1^78, THE FiiD
SYSTEM HAS DEMONSTRATED AN OPERABILITY OF 100%.
THF PLANT REPORTS NU REMAINING PROBLEM AREAS.
SHELLER GLOBE CORP.
NORFOLK, VIRGINIA
W.W. SLY MANUFACTORING CO.
COAL (.LESS THAN 1X SULFUR)
8,000 SCFM (TOTAL - I BOILERS)
START-UP 0/75
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
AFTER SYS1EM WE3IART IN OCTOBER 1S77, THERE HAVE
BEEN NO PKOHLEMS RESULTING FROM EITHER BOILER OR
SCRUBdFR UPtRATIONS. THE PLANT UNOtri wtNT A
VIRGINIA EPA INSPECTION AND WAS FOUND TO BE IN
COMPLIANCE rtlTH THE PARTICULAR EMISSION REGULA-
TIONS.
ST. JOE ZINC CO.
MONACA. PENNSYLVANIA
BUREAU UF MINES
COAL (i?.5%-4.5X SULFUR)
10-4,000 SCFM (TOTAL - 1 BOILER)
S1AHT-UP 10/78
CITRATE PROCESS
STAIUS - CONSTRUCTION
.CONSTRUCTION CONTINObS ON Trit CITRATE PROCESS
SCHUBrilrtG SYSTEM WHICH rtlLU CONTROL So? EMISSIONS
FROM A bO-Mrt (NOMINAL PtAK CAPACITY) COAL-FIRED
POWER GtNERATING UNIT. STARTUP WILL Be OCT'78.
.THIS SYSTtM WILL riF ALSO r(FPORTtD IN I HE EPA/PEUCO
LIIILTTY FliD SUSVEY, blwCE INFORMATION WILL BE
GATHERED UURING THE ONE YtAK DEMONSTRATION PtKlon
BY FOLLOWING A TYPICAL UTILITY OPERATING LOAD
PROFILE.
ST. REGIS PAPER CO.
CANlONMtNT, FLORIDA
AIRPOL INOUSTKlfeS
BARK AND GAS OR OIL (LESS THAN 1% SULFUK)
115,000 SCFM (1 80ILE«)
START-UP 0/73
CAUSTIC SCRUBBING
STAIUS - OPERATIONAL
AIR-POL HAS SUPPLIED THt CAUSTIC SCKIMBING KG I)
SYSlErt TO kEMOVt PArtTICdLAIc AND S>Ui_FOK OIOxIoF
FrIOM THt FLOE GAS OH A HAWK BOlLEKi WHICH CAN ALSO
FIRE NATURAL GAS AND JlL. PLANT HAS NOT YET
THt FtED i-.ATEK SOuRCF TO ALuflVlATE PROrtLEMS OoF
TO FlttFRS PLUbGINo LluFS AND MloT FL I.'ilNO I OR.
PLANT INDICATED THAT THIS RtPoRT HAD PREVIOUSLY
RtPORlhi) 1 HO HIGH A FUEL SULFurf CuNlK.MT.
-------
STATUS AS OF 07/iO/78
. SECT ION i (COIMT INutU)
SUMMARY UF Fl,P> SYSIFMS'OiM i NljUSTh f Al_ BOILERS
CO'-IPANY TNFORhAT ION
1EXACU INCUKPURATED
SA«i ARDu, CAt IFliRiMA
CEILCdTt
OIL U./Z SULFUR)
ieh,ciuo SCFM (TOTAL - 2(4 BOlLtRSl
SIA.RT-i.JP. 11/73
SODIUM HYDROXIDE SCKUbBlNb
SI ft HIS - OPERATIONAL
TEXiiCu INCORPORATED
SAN AKIIU, CALIFORNIA
DuCuM COMPANY
"IL (1.7% SULFUR)
117,000 SCFM (TOTAL - 9 BUILERSJ
STAKT-Up 3/79
SuDUlH CARBONATE SCRUBBING
-SIATlib - CONSTRUCTION
lEXASbULF
GRA,,RtP.f WYOMING
Snh-iCU INC.
dJL (1.1X SOLFUR)
ltd,000 SCFM (TOTAL - Z BOILERS;
S 1 A R T-11P 9/76
SU01U", CARBONATE
SIAtUS - OPERATIONAL
TSAKiscn TEXTILES/ INC.
AUGUSTA, GEORGIA
FwC ENVIRONMENTAL EQUIPMENT
FOF.L OIL (.?.% MAX. SULFUR)
SO.oOO ACFM
SIAKT-IIH i/7b
SODIUM CARBONATE SCRUbSING
STATUS - TERMINATED
SUMMARY OF RECENT OPERATIONS
EACh FGl) SYSTEM CONSTSlb JF A riORi^UNIAL, HACKEO-
RtD SCROBMFR FtIR tACH OH THE OlL-HREO bOILERS.
POOR oCKUBBlNii LI.JUOR QUALITY CAUSES PLUGGING OF
PAC^ElJ isEuS AMD SPRAY NOZiLES. THE SYSTEMS HAVE
HIGH MAINTENANCE REUtilREMENTS AND RELATIVELY LOW
SO? REMOVAL (73*). TEXACO IS PLANNING TO PHASE
HUT THIS (,KOUP OF SCHOHBF.RS BY LATE 1979.
TEXACO is PLANNING TO PHASE OUT THE EXISTING FGD
SYSTEMS AT THEIR SAN AROO, CALIFORNIA OIL SITE.
AS THE FIRSl STEP OK Trit PROGRAM, 9 OF THE PRESENT
31 SCrtUbBtKrs UN 50 MM BTU/HR STEAM GEiMERATORS ARE
BtlivG RtPLACEO bY A MtW SYSTEM, SOPPUIEO 8Y DUCON
COMPANY. THE Ntw'FGI) SYSTEM WILL CONSIST OF THREE
TRAINS OF A VENTURI SCROHHER/SPRAY ABSORBER COM8I-
NATIOiM. THE SYSTEM IS UNOER CONSTRUCTION.
THTS SOUIUM CARHONATE SCRUBBING SYSTEM WAS DESIGN-
ED 6Y SrvEMCU. SOd ABSORPTION OCCURS IN THE
QJfc-,«CHfR ANO THE SIEVE-TRAY AdSORBER MODULE. AN
iNTtRtSTING FEATURE IS AN INTERNAL OANPER WHICH
ALLOWS A n TO i TURNDOWN RATIO. INITIAL PROBLEMS
INCLUDED PLUGGING CAUSED aY FLYASH, AND CORROSION
Iiv RECIkCOLATlON PIPING, CAUSED BY THE SLIGHTLY
ACIDIC SCRUBBING LIUIJOR.
THE Fan OPERATIONS HAVE BEEN TERMINATED FOR AN
INDEFINITE PERIOD. THE PLANT BURNS NUMBER 6 FUEL
OIL AND THE SULFUR oiuxine EMISSIONS ARE 5
-------
STATUS AS UF 07/.*(>/7 8
SECTION 4
SUMMARY BY VF.NIH'R Of- FGu bYbltMb UN INHUSTH1AL
vFhJ'UH
rt.li. I JTTLt
INDUSTRIES
BUREAU OF MINES
CARBORUNDUM ENvTR. SYS. LTD.
CEILCOTF
COMBUSTION EQUIPMENT ASSUC.
COMMERCIAL FABRICATION * MAC
L'WAVU CORP./NAT'L LIME ASS'N
ullCON COMPANY
bfvlOLtlER, INC.
F-'-*C ENVIRONMENTAL EQUIPMENT
INblALLATTuN NAMt / LOCAIIUN
GFNFhAL M01OKS CORHOHATIllN
SI. LdOlbt M1SSOUKI
bf UfblA-PACIHL HAPt.K CO.
CHuSbt I T, AK^AwSAS
liKLAl bOUTnt-KN PAPtR CU.
CEUAK SPKll>gRS, GtORGIA
IT! KAYOhlEW, INC.
f-FKNANDIlvA RtACH
Mt AD PAPtRBDARU CO,
STtVtNSON, ALABAMA
PAPEKS, INC.
ASrlilOWIMf AKKANiiAS
ST. Ktblb PAPEK CO.
U.b. GYPSUM COKP.
UAHMUNT, PENNSYLVANIA
bT. JOE ZINC CU.
MONACA, PENNSYLVANIA
CARBORUNDUM ABKASIVES
dllFFALOr NtW YUKK.
TF.XACO INCOKPOKA1FU
SAIM ARDO, CALIFORNIA
KERR-MCGEE CHEMICAL CORP.
TRUNAr CALIFORNIA
QUALITY MILLS. TNC.
,-lT. AlHY, ,\'(JKTh CAROLINA
ttUNRt. INC.
CA1KU, iLLlMlIb
TEXACO IwCORPOKATEO
SAh AROO, CALIFORNIA
UENF.hAL N:U10KS COHf'ORATIUN
UAYTUN, OHIO
ALYFSKA PIPELINE SERVICE CO.
VALDEZr ALASKA
ARCO/PDLYMt RS, INC.
MONACA, PENNSYLVANIA
LA.XlluN TEX1 ILES
CANTUN, bEORbIA
CA1FKPILLAR TRACTOR CO.
tAST PtURlA, ILLINOIS
CATERPILLAR TRACTOR CO.
MAPLtTUN, ILLINOIS
CATERPILLAR TRACTOR CO.
N'OSSVILLE, ILLINUIS
FlKFSTuNt TIRE Ai\i[) RUHBER CO.
POITSTUWN. PENNSYLVANIA
CONTROL SYSTEM PROCESS
SODIUM HYDROXIDE SCRUBBING
CAUSTIC -vASTE STREAM
CAUSITC rtASTE STREAM
SOOIUM HYDROXIDE SCRUBBING
SODIUM HYDROXIDE SCRUBBING
CAUSTIC SCRUBBING
CAUSTIC SCRUBBING
DOUBLE ALKALI (.DILUTE)
CITRATE PRuCESS
LIME SCRUBBING
SODIUM HYDROxlUE SCRUBBING
CARBONATE SCRUBBING
WATER SCRUBBING
LIME SCRUBBING
SODIUM CARBONATE SCRUBBING
SODIUM HYOROXIDE SCRUBBING
SODIUM HYOROXIDF SCRUBBING
DOUBLE ALKALI CCONCEN T K ATED)
CAUSTIC- WASTE STREAM
DOUBLE ALKALI (.CONCENTRATED)
DOUBLE ALKALI (CONCENTRATED)
DOUBLE ALKALI (CONCENTRATED)
DOUBLE ALKALI (CONCENTRATED)
13
-------
STATUS AS OF U7/io/7a
SECTION 4 (CONTINUED)
SUMMARY RY VENDOR OF FGu SYSTEMS UN IM)USIR1AL BOILERS
VENDOR
FMC ENVIRONMENTAL EQUIPMENT
GM ENVIRONMENTAL
GREAI WESTERN SUGAR
HEATtW TECHNOLOGY
KOCH FIMGINEEKING
MOttTL UIL COMPANY
SELECTED
INSTALLATION MAMt / LOCA1IUN
FMC (SODA ASH PLANT)
GREEN klVEk, WYOMING
GENERAL hOTOHS CORPORATION
TONOnAftiDA, Nth YORft
GE 1 TY uIL COMPANY
BAKERSF icLo, CALIFORNIA
1RANSCU TEXTILES, IMC.
AUbUSTA, GEORGIA
MOTORS CORPORATIuM
PAHMA, OHIO
GRtAl WESTERN SUbAk
rtlLLINbS, MONTANA
GRtA f rtESTtrffM JiUGAK
FIMDLAY, OrilU
GREAI WESTERN SLIGAk
KJKT MORGAN, COLORADO
GREAI wESTfcRN SUGAk
FRtEM()NT,()HIO
URtAT
GEklNG,
GREAT WESTtRN SUGAR
bRtELEY, COLORADO
bRtAT nESTEKN SUGAR
LONGHOMT, COLORADO
GREAT AESTtRN SUGAR
LOvtLAivD, COLORADO
GREAT ftESTtRiM SUbAk
SCOTTS HLUI-F, NEBRASKA
MOtfTL UIL COMPANY
bUTTUNwlLLOrt, CALIFORNIA
ARMCU STtEL
HIDOLEIOwN, OHIO
CHtVRON U.S.A. INC.
BAKERSF IELL), CALIFURUTA
MIIMN-OAK FARMER'S COOPERATIVE
rtAHPtTON, iMORTh DAKOTA
PEAHUDY ENGINEERING
uIL COMPANY
SAN ARDO, CALIFORNIA
C.A.h.(CARmuF-AMOCO-MUNSANTU)
ttnUSTON, TtXAS
CHtVtRljN U.S.A. INC.
riAKE'RSFltLD, CALIFORNIA
bRISSOi'l Alk MlkCE HASE
HUNKER HILL, INDIANA
GENERAL hOIOKS CORKURATIUM
KINTIAC, MICHIGAN
CONTROL SYSTtM PROCESS
SODIUM CARBONATE SCRUBBING
SDDIIJW HYDROXIDE SCRUBBING
SOUIUI' CAkitONATE SCRUHblNR
soDiut-- CARBONATE SCRUHHING
DOURLE ALKALI (DILUTE)
AMMONIA-LADEN PROCESS WATER
SODIU^ CARBiJNAIE SCRUBBING
AMMOiJIA-LADEni PROCESS rtAlER
SODIUK CARdOiMAlE SCRUBBING
AMMONTA-LADEN PROCESS WATER
AMMONIA-LADEN PROCESS WATER
AMMONIA-LADEN PROCESS WATER
AMMONIA-LADEN PROCESS WATER
AMMdmlA-LADEN PROCESS WATER
SODIUM CARoUHAiE SCRURBING
LIME SCRUBBING
SODIUM CARBONATE SCRUBBING
AMMONTA SCRUbHINb
SODIUM HYDROXIDE SCRUBBING
NOT SELECTED
SODIUM CARBONATE SCRUBBING
DOUBLF ALKALI (CONCENTRATED)
SO.DIU"1 HYOKllXlDE SCRUBBING
-------
SIATUS Ab UF Il7/i-'ljHI3IiMG
CAUS I IC-rt4b ft
IVAIF.K 3Ct*UHrtING CNAriMHi
U!» HYOKUXIDE
ALKALI (DILUTE)
DOUBLE ALKALI (DILUTE)
-------
STATUS A3 OF 07/30/78
OPERATIONAL t-Ko ;>Y;jlt.N!, DM INDUSTRIAL BOILERS
("U"HA;.!Y/L
Mb-.*/
tTKUFT T
UNIT !UZL
(SCI M)
PRUCESb/VFNDuR
START-UP
MO/YR
ALYtSKA PIPELINE bERVICE CO.
VALUE/, ALASKA
FUF|_ UTL (O.Oi*. - O.U SULFUR)
N R ft
bO,000
SODIUM HYDROXIDE SCRUBBING
EMC ENVIRONMENTAL EQUIPMENT
6/77
AMfxTLAN THREAD CU. RETROFIT
'•iAKiOu, NORTH CAROLINA
CbAL Id.8i SULFUR); INTERRUPT1BLE NATURAL GAS
1 fl , 5 0 0
CAUSriC-.«ASTt" STREAM
n.r,. SLY MANUFACTURING cu.
0/73
AKMCC STE-EL
MlDi)LbTOWNf OHIu
CUAu (0.8Z SUL^UR)
HETRuFIT
84,000
LIME SCRUBBING
KOCH ENGINEERING
0/75
CANTON TEXTILES RETROFIT
CAiVniiW GEORGIA
CoAL ((1.8* SULFUR); INTERRUPTI8LE NATURAL GAS
d5,000
CAUSTIC- WASTE STREAM
FMC ENVIRONMENTAL EQUIPMENT
6/77, 000
DOUBLE ALKALI (DILUTE)
ZURN INDUSTRIES
9/7 MISSOURI
CuAL (}.?.'/. SllLFuR)
WETROFIT
64,000
SODIUM HYIlRnxiDE SCRUBBING
A.u. LITTLE
o/^^
.JcNtRAL MuTORb CORPORATION
'ihY[(ii\i, OHIO
C..iAL(il.7X - a.Oz SULFUR)
RFIRUFIT
36,000
SODIUM HYOkOXIUE SCRUBBING,
tNIOLFTER, i«C.
9/74
-------
STATUS AS OF 07/30/78
SS-CT10N 5 (CONTINUED)
OPERATIONAL FGO SYSTtr"b UN I.NfHISFRlAL BOILERS
RfcTKflF IT
UNIT SI7E
(SCFM)
PROCESS/VENDOR
START-UP
MO/YR
KEMERAL MOTORS CORPORATION
Tli''iu.-.A")UA, Nf.ft YORK
Cl'AL 11.2X SULFUR)
REIRUFIT
V2.000 SOUIUM HYUROXIDE SCRUBBING b/75
FMC ENVIRONMENTAL EQUIt-MENT
fefltl'AL MUTORS CORPORATION RETROFIT
PARMA, OHIO
CUAL li?.5X SULFUR* 1.1% ASH* 13,3bO Rlll/Lb)
128,aoo DOUBLE ALKALI tnuuTt)
liM fc.MVIKJNMENTAL
MOTORS CORPORATION
Pli"l T AC, MICHIGAN
CI,AL ift.84% SULFUR)
.SHOD, PAPER, AN!) CARDBOARD.
107,iOO SOUIUM HYDROXIDE SCRUBBING
PEABOOY
4/7b
GcOKBlA-PACIFIC PAPtR CU. N£«Y
CtOISSfcTT, ARKANSAS
^^Arf^ AND OIL OR COAL (1% - 1.5X SOLFOR)
-------
STATUS AS OF (I7/JO/7H
SECTION 5 (CONTINUED)
OPERATIONAL FGD SYSTtMb UN INDUSTRIAL BOILERS
COMPANY/LOCATION/FUEL
ITT RAYUNIER, INC.
FERNANDINA BEACH, FLORIOA
8ARK AND OIL (2X - d.b% SULFUR)
NEW/
RETROFIT
Rt TKUFIT
DMT SIZE
(SCFMJ
PROCESS/VENDOR
t?01,uOC SODIUM HYDROXIDE SCRUBBING
AIRPGL INDUSTRIES
bTARI-UH
NO/Yh
O/
KERR-MCGEE CHEMICAL CORP. N
TKOlMA, CALIFORNIA
COKE, COAL, OIL (O.bX - 5% SULFUR)
7?b,OOU SODIUM CARBONATE SC^UhBIIVG b/7»
COwBUSTIUN Eul)lHHF.,NiT ASSuC.
MtA.U PAPERBUARO Cu.
STFVEIMSON, ALAHAMA
OIL tl.5% - 31 SULFUR)
Nfcrt
100,000 SODIUM HYDROXIDE SCKUbblMG 0/7b
AlKPOL INDUSTRIES
MINN-DAK FARMER'S COOPERATIVE
WAHPElOiM, NORTH DAKuTA
LIGNITE Cl.OX SULFUR)
RETROFIT
160,000 AMMONIA SCRUBRINr,
KOCH ENGINEERING
b/77
MUH1L OIL COMPANY
SAN Awr>0, CALIFORNIA
OIL Id.OX - 2.P5X SULFUR)
RETROFIT
SODIUM HrnRoxiuE SCRUBBING 0/74
MOolL UIL COMPANY
NEKUOSA PAPERS, INC.
ASHUdAN, ARKANSAS
COAL tix-i.sx SULFUR)
NErt
•ill,000 CAUSTIC SCRUBBING
INDUSTRIES
RICKENHACKFR AIR FORCE BASE
COLUMBUS, OHIO
COAL (i.M SULFUR)
RETROFIT 50,000 LIMESTONE SCRUBBING
KESEARCH-COTTRELL/dAHCU
3/7b
SHEuLtR GLOBE CORP.
NORFOLK, VIRGINIA
COAL ILESS THAN IX SULFURJ
RF1RUFIT B,000 SOuIUM HYDROXIDE SCRUBBING
W.rt. SLY MANUFACTURING CO.
SI. REGIS PAPER Cu. RETROFIT
CANTOIMMENT, FLORIOA
BARK AND GAS OR OIL (LESS^HAN IX SOLFLIR)
115,000 CAUSTIC SCROBBIMb
AIHPOL INDOSIRIES
0/7i
TEXACO INCORPORATED
SAN ARHO, CALIFORNIA
OIL (1.7X SULFUR)
RE TRUFIT
366,000 souiuM HYDROXIDE SCRUBBING
CE1LCOTE
TtXASGIJLF
GRANGER, WYOMING
UIL (1.1X SULFUR)
I«0,o0u SODIUM CARbONAIE SCRUBBING q/7b
INC.
1H
-------
STATUS Ab OF 07/30/7(1
SF.U If)hi h
CONSTRUCTION FuO SVSTtMS Oi\ 1NDUSTKIAL HOILFkh
COMPANY/LOCATJON/FOtl
Mt«/
ETwOFIT
UNIT SIZt
lAKT-UP
Ml/Yk
CATEkPTLLAW IrtACTOR Co.
^APLF.ION, ILLINUIS
CuAu (3.2% SULFUR)
1-57,000 IJOUBLE ALKALI lCo^CFf^.^Kf» IEO) 10/7B
GtTFY OIL COMPANY
BAKERSFIELD, CALIFOkNIA
CRUDE OIL (1.1X SULFUR)
Kt IRUFIT
993,750 SODIUM CARBONATE
PRuPRIATARY OE81UN
12/7b
GREAT WESTERN SUGAR
FrtEfcMONT.OHIQ
COAL C3X SULFUR)
RETROFIT
4 0 , 0 0 0
SODIUM CARBONATE SCRUBblNG
bR£AT WESTERN SUGAR
10/7b
MOBIL OIL COMPANY
BuTTONWILLOn, CALIFORNIA
OIL d.ix SULFUR)
RETROFIT
,000
SOuIUM CARBONATE SCRUBBING
HEATER TECHNOLOGY
9/78
ST. JOE ZINC CO.
MONACA, PENNSYLVANIA
COAL U.5X-4.SX SULFUR)
RETROFIT
10<4,00u CITRATE PROCESS
bUREAU OF MINES
10/7S
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
U1L (1.7X SULFUR)
RETROFIT
117,000 SODIUM CARBONATE SCRUBBING
DUCQN COMPANY
3/79
-------
STATUS AS OF 07/40/78
SFuTiOiM 7
K;U hYbTfb uN InHuSFRlAL dOILERS
1 I
' M T S 1 7 E
PROCESS/VENDOR
START-UP
Ml/YR
Awro/POLYMERS, INC.
^uNACA, PENNSYLVANIA
CuAL tl.O/S SULFURJ
KETRQFIT
uouaLE ALKALI (CUIVCENTRATEU)
FMC tNVlKUNMENTAL tQUIPMENl
6/80
CARtUlKUNPUM AtiRASIVtS KFTRUFIT
rtuFFAL'l, ,MEW YORK
CL)AL UX S AVERAGE, 3.8« S DESIGN MAX)
3fi,000
LIMF SCRUBBING
CARriORUMDUM ENVIR. SYS. LTD.
O/ 0
CiiEVFRON U.S.A. INC.
rtAKfcWSFIELO, CALIFORNIA
OIL (1.1% SULFUR)
KETRUF1T
116,000 SODIOM CAR80NAIE SCR08SING 1/79
NOT SELECTED
M AIR FORCE BASE
tiUNKhn HILL, IiMDIANA
CiiAL (0.9* - 4.fa)C SULFIIrt)
1 NE« £ KETRuFiTia,000
DOUBLE ALKALI (CONCENTRATED)
MOT SELECTED
9/79
C.A.M.lCAKBIOE-AMUCG-MOiMSANTO)
HOUSTON, TEXAS
MuT SELECTED
NEW
l,dOO,000 NOT SELECTED
IMO] SELECTED
10/83
-------
STATUS AS OF 07/30/78
SECTION R
Oh inSPuSAl. PRACTICES FJR FGP SYSTF-.HS 0,M INUUSTklAl BOILERS
INSTALLATION NAMt / LOCATION
STATUS/CuMMElvTS
Al.,\ALliME SULHTt/msoLU ie KtCYCUtl) ID PULP PHUCtSS
i.lFAl) PAPEHbOARD CO.
&TF-VHNSOiMi ALABAMA
PAPERS, INC.
ASnr>i>''M, ARKANSAS
OPERATIONAL
RECOVERED SOLUTION USED AS MAKE-UP TO COOKING LIUUOR IN PULP
MILL.
OPERATIONAL
SDiJ KE'COvEn'F.D HP.OM SUOIUh SDLFITE/SULF ATE LIQUOR AND RE-
LYCLtD TU PULPING PKJCESS.
SLURWY Tu LANDFILL
AKCd/PJLYMERS, INC.
PENNSYLVANIA
bUNGE, INC.
, ILLINOIS
t.» IfKPiLLAM TRACTOK CO.
tAbT PtOi«IA, ILLINOIS
CATcnPILLAK TWACTOK CO.
i-ilJSSV ILLtf ILLINOIS
CAIEKPILLAR FRACFOK CO.
JOLlcT, ILLINOIS
CATI-NPILLAK TRACTOR CO.
MOKTUN, ILLINOIS
CAIFHPtLLAR TRACTUK CO.
("APLclON, ILLINOIS
TIRE AND RUBHEH CO.
HOiTaTowi\i, PENNSYLVANIA
uf.iMEKAL MOTORS CORPORATION
NtW' YORn
CiFiMKKAL MOTORS CURPOKATIUN
t'Ai,^A, OnIO
MOTORS CORPORATION
KO«TIAC» MICrilbAlM
AIR FORCt b«SE
HJLL»
U.S. (iYPSUH CO«P.
PLANNED-CONTRACT AWARDED
FLYASH AUDITION TO OEWATERtn CAS03/CASUa FILTER CAKF.,
THEN TU LANDhILL.
TERMINATED
OPERATIONAL
60+% SUL1DS CCASoa) SLUOUE DIRECTLY TO LANDFILL
OPERATIONAL
bO + X SOLIDS CCASU«) SLUOb'E DIRECTLY TO LANDFILL
OPERATIONAL
OPERATIONAL
CONSTRUCT ION
bO+% SOLIDS ICASO
-------
STATUS AS OF 0//3U/7B
SECTION 8 (CONTINUED)
SUMMARY OF DISPOSAL PRACTICES FOR FGD SYSTEMS ON INDUSTRTAL BOILERS
INSTALLATION NAME / LOCATION STATOS/COMKENTS
HOLDING POiMD FOR EvAPOxAIIuN "
^i""?* ASH..^A?T1 OPERATIONAL
!;»"»« «»>«•« TO COLLECT PUND - NO PRIOR
LANDFILL IN THE FUTURE
GETTY OIL COMPANY OPERATIONAL
10 GPM BLEEDOFH TO A BLO^U^N , ANK . THE BL0«OO.N IS THEN
TO A .DISPOSAL PUNu ONCE A WEEK.
KEKR-MCG.EE CHEMICAL COWP. OPtRATlOivAL
CALIFORNXA «KUHB« EFFLUEN, IS CLAKtFItO ANO THE, PUT INTO A MINERAL
UP.RATZONAL
OIL COMPANY CONS1PHC1 ION
INlERMiHE.T B.LO.DONN TO ,ASTE DISPOSAL S!rE.
NOIM-FIXATEU SLURRY To LINED POM) " ----- " ----------------
CANTON TEXTILES OPERATIONAL
CANTON, GEORGIA WA SU3/SU LIQUOR UISPOStD TO LINED HOLDING PONDS
RICKENUACKER AIR FuRCE BASE OPERATIONAL
COLUMrtUS, O.HIO UNSTA8IL1ZEO C»Sy3/SU/l SLOuGE TO LINED POND
KEbENEHABLE - ELEMENTAL SULFOR PKOUUCT " ""' " ------------------
ST. JOE ZINC CO.
MJNACA, PENNSYLVANIA
(VASTEWATER TREATMENT AND IHSCHARtt To CITy'sEWEH
MOTORS CORPORATION OPERATIONAL
ST. LOOIS, MISSOURI '???y"L°X '°!ZEl) '° NA2bt"*' PH ^^TRALIZED AW DISCHARGED TO
LI IT bfcWhW SYSfFNi
GENFKAL MOTORS .COHPOSATION
3, GP, ,0 ON-SirE CLARIFICA T ION AND
GEORGIATPACIFI.C PAPER go. OPEWATIOMAL
CRuSSETT,
GREAI WESTERN SUGAR OPERATIONAL
FINDLAY, OHIO bLEED-OFI- STREAM TO HOLDING TANK
CHEAT WESTtRN SUGAR CONSIRUCHUN
Fh'tFMONT.OHIO
UMAL1FY MILLS, INC. TERMINATED
MT. AIRY, NORTH CAROLINA SCABBING LIUHUR DISCHARGED TO Nt U F R AL I I AT 1 1)>4 POND
-------
STATUS AS UF 07/.50/7B
SECT ION 8 (CO. ! if-uMj]
SUMMARY OF DISPOSAL HnALTJCKS FUK FI;|I SYSTEMS
I \ijlJSTK I Al tt.JILEl™»»«™™^™»" — •» — — ™"~™™™~'"~~~~ — "~~~"
OPERATIONAL
CONSTRUCTION
CHEVRON U.S.A. INC.
tiAKERSFIELDr CALIFORNIA
GETTY OIL COMPANY
bAKERSFIELO, CALIFORNIA
ITT KAYONIEW, INC.
FERNANDINA BEACH, FLORIDA
OPERATIONAL
WASTEWATER TREATMENT
ALYESKA PIPELINE SERVICE CO.
VALDE/, ALASKA
CHEVERON U.S.A. INC.
BAHERSFIELD, CALIFORNIA
MINN-DAK FARMER'S COOPERATIVE
HAhPETON, NORTH DAKOTA
ST. REGIS PAPER CO.
CANTONMENT, FLORIDA
TEXACO INCORPORAIEU
SAN ARUO, CALIFORNIA
OPERATIONAL
iMASSU3/HSOi AF.kATEU TO NAi2S01 AND TRANSFERRED TO WASTEWATER
TREATMENT PLANT AT A RATt UF lu GPM. IT 13 MIXED WITH ABOUT
10,000 GHM OF BALLAST HAIEK FROM TANKERS IN HOnT VALDEi.
CLEANED ft'AIEK IS TMEln OlbCHAreGEO IwTO PORT VALuEZ.
IMG/EVALUATING BIDS
TEXAbGULF
OPERATIONAL
BLEED STKEAM GUES TO AN ACTIVATF-D SLUDGE SYSTEM a lb(J GPM
OPERATIONAL
EFFLUENT IS TREAIFU IN Aw uN-SlTt SEmAGF TREATMENT PLANT
OPERATIONAL
HALF OF IHt SCRUdBER UNDERFLOW IS TREAIFU AND RECYCLED AS
BOILER FEEuWATtR; THE uTrIEK nALF GOFS 10 WASTEwATEK
l/ISPOSAL wtl LS.
OPERATIONAL
WYOMING
-------
STATUS AS OF
SFlTJOiM a (CUrjTllvuFOl
HUILEKS
SUMMARY OF OISHOSAL HKAUTICtS FOR F«D S, STEMS ON JNUUSTKIAL
INSTALLATION NAME / LOCAIIuN STATUS/COMMENTS
uvtRFLuW Tu StntR/SLiiDbt Tu LAfMDFlLL
GLO«t CORP.
NtlKFuLn. VIRGINIA
UtaPOSAL TtCHNIOuE NOT KNOnN
HLANNFO-CONSZOtRlNU 802 CONTROL
HARRIS MINING to. TERMINATED
SPRUCE PINE, NORTH CAROLINA itKMJNATEO
SCHIIoBER EFFLOENT DISPOSED OF IN
IEXACO INCORHORATfO CONSTRUCTION
SAn ARUO, CALIFORNIA
-------
STATUS AS UF 07/JO/7H
SECTION 9
PERFORMANCE DESCRIPTION FOR uPtRftllONAL KGl) SYSTtMS ON ' IUPuS1R1AL BOILERS
INSTALLATION NAME
I'MSTALLAIIUN LOCATION
SOul'Ct CHARACTERISTICS
SHIlkCF HATING
MJi-:titR OF SEPARATE FUO UNITS
SOURCF CAPACITY
LOiMTtVOL SYSTEM VENDOR
CO,\TRUL PROCESS
wtn / RETROFIT
START-UP DATE
CONTROL SYSTEM S1AIIIS
Slid EFFICIENCY
PAKTICULATfc EFFICIENCY
AA1F.R MAKE-UP
SI.UDbF OK BY-PRODUCT DISPOSAL
ALYEbKA PIPELINE SERVICE CO.
VALOEZ, ALASKA
t-ufcL OIL (u.ojx - u.i* SULFUR)
50,01/0 SCFIW (DESIGN MAXIMUM)
1
25 Mft (FUUIVALENT)
FMC tNVIWONMENTAL EQUIPMENI
SOOlOM HYDKOXIUE
CONTROL SYSTEM COST
JIIME, 1977
OPERATIONAL
<»6 + % (15U-160 PPM oi INLET)
PAKT1CULATE EMISSIONS MEET NSPS.
10 GPM - OHEN LOOP
V.ASTEHATER TREATMENT
NAdSOi/HSOi AEKATEO TO NA2S01 AND TRANSFERRED TO WASTEWATEk
fREAIMEN'l PLANI AT A RATE OF lu GPM. IT IS MIXEO rtlTH ABOUT
10,000 GPM OF bALLASl rtATER FROM TANKERS IN PORT VALDEZ.
CLEANED HATER IS THEN 'OISCHAKGtD INTO PORT VALOEZ.
LAPIIAL: PLANT PERSONNEL no NOT HHEAK our FGU SYSTEM COSTS
OVERALL PiPtLiNt PROJECI
: PLANT ALCOUNTING OOES NOT KEEP OPERATING COSTS
FUR THE INERT GAS (FGD) SYSTEM.
bACKGKUOND INFORMAIION
AI THE VALOEZ TERMINAL OF THE ALASKAN OIL PIPELINE, ALYESKA PIPELINE SERVICE COMPANY OPERATES
IHt OIL STORAGE AND TRANSFER FACILITY. OIL FLOWING IN FROM THE PIPELINE IS (EMPuRARILY STORED IN
BE\/FKAL HUGE TANKS, THEN TRANSFERRED FROM int TANKS TO OIL TANKER SHIPS IN NEARBY PORT VALOEZ.
ALYEbkA i\iEtOtD NEUTRAL BLANKET AIR FOR THE OIL SIORAbE TANKS, A LOW OXYGEN CONTENT BEING PARTICULAR-
LY ntSlRABLE. II WAS UEfExMlNED THAT UN-SITE bOILER FLOE GAS nOJLO HAVE THE REUUIWED LOW OXYGEN
co«TtM . CORROSION PREVENTION IN THE OIL STORAGE TANKS OICTATED THE NEED FOR sod CONTROLS.
THAT IS, THE DEVICE WAS NOT INSTALLED TO MEET AN EMISSIONS REGOLATION. NEVERTHELESS, THE
"Uif'KT I^AS" SYSTEM IS BASICALLY A SOOIOM HYDROXIDE FGD SYSTEM AMO WAS DESIGNED AND INSTALLED BY
h"C rJWVTRONMENT AL EQUTPMENT OIVTSIUN.
Tut BOILERS DO NOT OPERATE AT STEADY STATE CONDITIONS. THIS IS OUE TO THE FACT THAT WHEN OIL
IS RE"ui/tI) FROM Tht TANKS AT A FASTER RATE THAN IT IS bFiNG FED ttY THE PIPELINE, AN ADDITIONAL INERT
-------
STATUS AS OF 07/.50/78
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL KC-D SYSTEMS ON INDUSTRIAL bORERS
ALYESKA PIPELINE SERVICE CU.; VALDtZ, ALASKA (CONTINUED)
AIR BLANKET IS NEEDED. THIS REuOIRES INCREASING ,Ht UOILtR LUAU FROM THE NORMAL LEVEL OF PLANT
PO-ER PRODUCTION TO RUN THE COMPRESSORS AND PRODUCE ADDHIONAL GAS FOR BLANKET PRODUCTION.
if THE TANKS ARE FILLING EASIER THAN THEY ARE BEING EMPTIED, THE AI. FORCED OUT br THE INCOMING
OIL WILL BE INCINERATED.
THE BOILER PLANT AT THE VALUE* TERMJNAL CONSISTS OF THREE 250 MM BTU/HR OIL-FIRED BOILERS,
MANUFACTURED BY COM8US,ION-FNG,NEERING. THE OIL BEING USED IN ,hE BOILERS PRODUCES A VERY LOW
PARTICULATE GRAIN LOADING. AN0 HAS A, EXTREMELY LOW SOLFOR CONTENT WHICH RANGES FROM 0.0« TO O.U.
THERE .IS NO PAKTICULATt CONTROL OTHER IHAN WHA, OCCURS I, THt H,C SO, ABSORBER MODULE.
THE MAXIMUM DESIGN CAPACITY OF THE SCRUBBER MODULE IS 50,000 SCFM, *HICH REPRESENTS ABOUT 2S»
UF THE TOTAL FLUE GAS GENEHAIED. THE 50i CONTKOL SYSTEM Is DESTINED ,£TH 10o% REDUNDANCY, I.E.,
fHEPE ARE TWO MODULES IN PARALLEL, ONLY ONE uF WHICH IS IN USE AT ANYTIME.
CAUSTIC (SODIUM HYDROXIDE, IS USEO AS REAGENT MAKE-UP. DESIGN PH CONTROL WAS AHOUT 6.5, BUT
OPERATIONS HAVE INUICA,Eu ,HAT A HIGHEK PH IS ,0,E DESIRABLE, ,0 CON,KOL PH IS NO, AttOoT 8.0.
A BLtEU STREAM OF SOD.OM 8ISOLFITE/SOLFI,F GOES TO AN AERATOR AT A RATE OF ,0 GPH. AF.ER COMPLETE
OXIDATION TO NAB504.. TnE WASTE STREAM GOES To A hASTthATtR TKEATMENT AHEA «HtRE IT IS MlXEu .IIH
10,000 GPM OF BALLAST «A>EK FROM THF TANKERS I,, , HE PORT, AND DISCHARGED INTO THE PORT.
OPERATING HISTORY
3RD UUARTEK-I977 CORROSION HAS OCCURRED IN 'I HE PIPING FOR THE WATER RECIRCULAT ION SYSTEM.
AT THE TIMt OF THIS REPORT, ,HE CAUSE «A3 NOT KNOWN. ALYESKA TESTS HAVE DEMONSTRATED ABOUr
5 PPM S0d/803/80a AT THE ABSOfiuFri OUTLET. INLET Su2 CONCENTRATION RANGES FHOM ISO Tj 160 PPM.
THE SYSTEM WAS THEREFORE REMOVING ABOUT 96% OF THF INLET SoLFUR OXIDES. AT THE ,IME OF THIS REPORT,
THfRE WAS NO CONIINOOOS bO«e MONITOR ON THE SYSTEM.
«TH UUAR1EH-1-177 THE CONTROL SYS,EM OPERATED NEARLY PRUBLEM-FREE, WITH NO DOWNTIME
BEING ASSIGNED TO THE SO* REMOVAL SYSTEM. THE CURRENT LOAD IS APPHOXIMAIELY ->U* OF DESIGN
CAPACITY. THIS IS A RhSULT OF OIL FLO» BEING LO.AT PRESENT. PLANS ,£RE *ti^ MAOE To DEAL WITH
THE WET AREAS CORROSION PRORLEM HY TlJ TKODIIC ING NEUTRALIZING AMINE SPRAYS.
1.ST UUARTEK-1978 DURING THIS PERIOD, THE CORROSION PROBLEM WAS ALLEVIATED RY SPRAYING HYDRAZINF
!NTO THE SYSTEM UPSTREAM .OF THE MIST ELIMINATOR. ,'HIS MEASORE RAISED FRoM 4 TO b.S THt PH OF tHE
LIUUOR RECOVERED BY I HE MIST ELIMINATOR. CYCLoHEXAMJNt MAY bE TESTED iN PLACF OF THE HYORAZlNE.
THE PLANT WAS NOT YET AWARE UF THE CAUSE OF THE CORROSION, ALTHOUGH .H£Y SOSPFCTtD CARBON, SULFUR,
AMD NITROGEN ACID GASES. CHLORIDES HAVE VIRTUALLY BEEN RULED OUT AS THE SOURCE OF THE CuRKOSION.
^ U..AR,EH-m« .Ht FMC FGD SYSTEM CUMUNUED TO OPERATE ON A CONTINUOUS HASIS, BEING RfSPONSl-
BLfc l-nn NO DOWNTIME. ANY MAIN.ENANCE OPERATIONS ,ERE tFFECTED WHILE THE SYSTFM ,vAS OPERATIC.
-------
STATUS A3 UF U?/iO/76
bFCUOiv 4 (COhiT INJEij)
PERFUNMANCE uEbCRIt-THJN KUK OPt XA I lO.'i AL HIS,) .YSTtMa UN I ivOUS T-< 1 AL HlULtMS
INSTALLATION NAMt
INSTALLATION LOCATION
SOURCt CMARACTtRISI KS
SOURCE RATING
NUMBER Oh SEPARATE FGD UNITS
SQUhCE CAPACITY
AMtKlCAN T H rt t 4 i) CO.
MAKlUN, i\lOhTH CAROLINA
LOAL (O.rtX SULFUR); INT KrtHUPT I&LF- inATUKAL i.AS
i«,5oo SI:FN CTUTAL - 2 HUTLFKS)
Mft (EuUlVALtM); TOTAL - ^
CONTROL SYSTtM VtNOUK
COivTxOL PROCtSS
NEW / HEIRUFJT
bTART-UP UATt
CONTROL SYSTEM STATUS
SOi EFFICIENCY
PAKTICULATt EFFICIENCY
SLUObF. OR iJY-PWODlJCT DISPOSAL
n.tt. SLY MANuFACrilKluG CU.
CAuST IC-WA6Tt aTKEAM
KE IRUFIT
197 J
UPtRATlONAL
1QX.
CONTROL SYSTEM COST
HOLDING POMO FOR EVAPOKATION
THE SOUIUM SULFITE/SULFAfE WASTE LIQUOR IS PUMPED TO
A KEU CLAY LINtO ASH 8ASI>M. LEACHING OF THE SOLUBLE SODIUM
SALTS IS THEKtiiY PREVENTEO.
CAPITAL: $i3«,ooo tis/a). THIS is TOTAL INSTALLED COST.
OPtRATINt.: $lh,?00/Yk 11977). THIS FlbUftE iNCLUuES i
FlbEKGLAiS LININGS IN UUCTwORK AND ON FAi\iS Awl) OIHER
OPERATING LABOR AND MATERIALS.
OPERAIING HISTORY
PLANT KEPOHTS THAT IT IS STILL EXPERIENCING SChUbBtR 1.0. KAN PROBLEMS HUE Tu VloRATIOiM AND
CORROSION. TO OVERCOME THIS PHOriLEM, PLANS ARE HE1NG MADE TO ELIMINATE THE 1.0. FANS ON THE
SCRUBBER AND UPGRADE bUlLEH ID FANS.
OTHER PROBLEMS HAVt flEtN AS FOLLOWS:
1. VIBRATION CKACKb IN PVC PIPING.
2. FAILURE OF PUMP RUBBER LINING.
1. THE NEED TO ORAIN THE RtClWCULAHuN TANK AMU PAINT IT WITH tPOXr PAINT TO ALLEVIATE
CORROSION PROULEMS.
-------
STATUS A3 OF 07/30/76
SECTION 9 (CONTINUED)
PFRFURMA,,Ct DESCRIPTION R)K OPERATIONAL F6,.) SYSTEMS UM INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LUCATldm
sooRuf CHARACTERISTICS
SrtlJkCt RATING
ullMRER OF SEPARATE FbD UNITS
COivTKOL SYSTEM VENDOR
CONTROL PROCESS
I'jF-tv / RETROFIT
STARf-uP DATE
CONTROL SYSTtM STATUS
aOc> fcFKICItNCY
SLuObE OK BY-PRODUCT DISPOSAL
ARMCU STtEL.
i"lIOOLEIO«N, UH10
COAL Id.oZ SULFUR)
8i,ooo SCFM (TOTAL - a BOTLERSJ
dOO.OOO L8/HR STtAM (TOTAL)
1
KOCH ENGINEERING
LIME SCRUBBING
19/b
OPERATIONAL
NOT AVAILABLE
hOLOINb POND FUR EVAPORATION
BACKGROUND 1NFOKMATION
THE SCRUBBER UNIT SERVES Two MULTI-RETuRT. UNDERFEED STOKER, COAL-FIRED BOILERS, EACH *ITM A
CAPACITY OF 100,000 LBS/HR STEAM. THE COAL BURNtD IS TYPICALLY 0.7 TO 0.9 PERCENT SULFUR
AMD d% TO 10% ASH. NORMALLY THE RulLERS ARE OPERATED IN THE WINTER MONTHS ONLY, HOWEVER FOR THE
PAST TWO YEARS, uPERAT HNS HAVE BEEN YtAR-ROUNU WITH REDUCED CAPACITY DURING THE SUMMER.
IHE CONTROL SYSTtM CONSISTS OF A VARI AdLt-1 H«OAT VEMIIRI SCRUBBER .(IfH A PRESSURE DROP CONTROLLED
AUJUdTABLF PLUG. IMMEDIATELY uOwNaThEAM FROM I HE VENTuRI IS An ABSORBER MODULE 17 FEET IN
DlAMtTLR WITH THREE GAS SCRUBBING TRAYS, A S-TYPt CHEVRON MIST ELIMINATOR AND A 106-INCH DIAMETER
STUB STACK. THE SYSTEM IS DESIGNED TO HANDLE 1
-------
STATUS AS OF 07/iO/78
SECTION 9 (CONTINUED)
PF.RFURM*i\lCt UESCKTHTION FOR UPt« A T JON AL FGl) SYSTEMS ON INDUSIRIAL BOILERS
AHi-i;u STEEL; MIDllLtTlcMMf OHIO ICuMT Iin
PIPT'.r; ]N ItUS SYSTEM rtAb MTLO STFtL ANO HAS StVtRLY ABRADED CAUSING NUMEROUS LEAKS.
1Ht SYSTEM HAS RtF.iM 1-iUOIFItD Tu A uiMCt -T HRUUGH OPERATION AND THE ABRASION HAS CEASED.
SHRIUHS ABRASION PRObLt^S f,ERE ALSO tNCOuNIEKEli IN 1,2-INCH STEEL PIPING CARRYING P1KTY WATER FROM
Irtt IWAY3 10 THE RECYCLE TANK AS rttLL AS IN IHt PUMPS. THE PROBLEM «AS SOLVEH BY KEPLACINu THt
HlKl-jf- -ITH KUBBEH HUSfc, RUR6EK LTIMtO ELBIMS, ANO RUhHER LINED POMPS. IN ADDITION, PUMP SPEED WAS
KKiyllCfcU FROM 1780 TO 1180 KPM AND FLANbEU T-SECTlOwS «bRE INSTALLED ON THE SUCTION SIDE OF THE
SLUIibE POMPS AND RtClRCULATION PUMPS. THIS MA1ERIAL HAS rtlTHSTHOI) ABRASION HETTEK THAN ANY OTHER
,-iAIFKIAl. TRIED TO DAtF.
A LIME BUILD OP PROBLEM WAS EXPECTED ON THt ABSORBER TRAYS AT LOW GAS FLOU RATES. THIS
PROBLEM HAS NOT YET OCCURRED A[ SUSTAINED PH LtVtLS OF h-6.5.
THt LIME SLURRY SYSTEM HAS ALSU PRESENTED A PROBLEM. CLOGI.ING OF THE LIME SLURRY LINE is
ATlRlnuTtD TO ITS EXCESSIVE LENGTH. LIME ADOHIuN RATt IS A PROBLEM WHICH CAN BE RESOLVED WITH
IHt INSTALLATION OF A PROPORTIONAL LIME sLAKER.
OPEKAIING HISTORY
4TH UiUARTER-l1)?? ThE PLANT WAS NOT ABLE TO SUPPLY EXIENSIVE OPOATE INFORMATION FOR THIS REPORT
HFkTui), ALTHOUGH REPORTED IHAT RECENT OPERATIONS HAVE UFEN RELATIVELY PROBLEM-FREE. THE SCRUBBER
rtAb DO. KM IN FEBRUARY 1S7B AS A RESULT OF THE POWER SHORTAGE OHIO IS EXPERIENCING.
PLANT HAS INDICATED THAT II WILL SoPPLY MOnE DETAILED INFORMATION FOR IHt ,MEXT REPORT
PF.KTuli.
dnu UUARTER-1978 IvO INFURMAIIUN flIAS OBTAINED FOR THIS UPDATE.
-------
STATUS AS OF 07/30/78
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS UN INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PARTICULATE EFFICIENCY
rtAIER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CANTON TtXIILES
CANTON, GEORGIA
COAL (O.rtX SULMIR); IiMTERRUP T IBLE .\iATURAL GAS
.55,000 SCFM (1 BOILER)
1
10 Mrt (EQUIVALENT)
FMC tNvIRONMENTAL EQUIPMENT
CAUSTIC- WASTE STREAM
RETROFIT
JUNE, 1974
OPERATIONAL
70* (500 PPM H INLET)
BOX - >>0% (5.9d L6/MM BTU AT INLET)
UPtN LOOP
NON-FIXATED SLURRY TU LINED POND
ivA S03/SU4 LIUUOR DldPOStn TO LINED HOLDING PONDS
CAPITAL COST IS FOR AM INSTALLED SYSIEM.
BACKGROUND INFORMATION
CANTON TEXTILE MILLS IN CANTON, GEORGIA HAS A 10 MW (EQUIVALENT) STEAM BOILER WHICH FIRES COAL
I-RUM OCT. TO' MAY AND INERUPTABLE NATURAL GAS THE REMAINDER OK THE YEAR. THE BOILER IS A COMBUSTION
ENGINEERING (C-E) VERTICAL UNIT EQUIPPED WITH A CYCLUNIC RUST COLLECTOR. THE DUST COLLECTOR
CAPTURES APPROXIMATELY 75 10 100 POUNDS UF FLY ASH PtR HOUR. THE TYPICAL COAL BORNEO HAS A SULFUR
CONTENT OF 0.8 PERCENT AND AS RECEIVED HEAT VALUE UF 13,faOO BTU PER POUND COAL. SULFIlK DIOXIDE
CONCENTRATION IN FLOE GAS IS 1500 PPM WITH A PARTICIPATE LOAulNG UF 3.92 LB/MM BTU.
THE HGU SYSTEM CONSISTS UF A FMC MEDIUM ENERGY, VENTURI-TYKE SCRUBoER. CAUSTIC DYEING WATER
WASTE CONTAINING SODIUM HYDROXIDE AND SOOIOM SULFATE WITH A PH OF APPROXIMATELY 11 To U IS THE
SCRUBBING LIQUOR. THF SCROBUING LIQOlU IS INJECTED INTO THE FLUE GAS STREAM THROOGH SPRAY NUZZLES
AHEAD OF THE VENTURI THROAT. THE WASTEWATER IS COLLECTED IN AIM EQUALl^ATIUN BASIN. DEPENDING ON
IHt DESIRED DEGREE OF NEUTRALIZATION, THE »vASTL«ATtR IS THEN RECYCLED TO THE SLRUBHER OR PUMPED TO
THE rtASTEWATER TREATMENT FACILITY.
bl-VFRAL OPERATIONAL PROBLEMS WERE ENCOONTERED UPuN INITIAL STARTUP. A SEVERE PLUGGING PROBLEM
.VAS ENCOUNTERED IN SEVtRAL PJMPS DOE To THE PRtSENCE OF COTTON KIBERS IN THE ftAS TErtA TEit. 4 SCixEtN
rtASKtT AROUND THE INITIAL SCRUBBER SYSTFM INTAKE PIPE IN THE DYE COLLECTION MANHOLE IS BEImG USED
11-hPul'AKU.y UNTIL FURTHER INVESTIGATION IS COMKLE1ED. SURF ACE-AC TI Vt AGENTS IN THE DYtl.MG OASTE-
.MAIFRS VHICH PRODUCE FOAMING IN THL scRUbHER PUMP «ERE DETECTED AND A DEFOAMER ADDITIVE is NOW
INJECTED INTO THE SCRIIBBtR FEED FROM THE DYE RETENTION BASIN. FOOLING OF THE PH PROSES AND SULFUR
-------
STATUS At, UF 07/30/7H
SECTION 9 (UO.jT It'JUFU)
CE DESCRIPTION FO* UPtRAT lfK»AL KGu SYSTEMS UN INOuSTKtAL dUILtrtS
CANTUN TEXTILES? CANTdur GtOriGIA (CONT INilF.i) >
ANU MIST GENERATION ARE UTHtK KWUHUKM AWtAS THAT HAVt HF.tN INVt S T ! G A F EU.
UPEKAI I-NiG HISIOnV
3RD UUAIUER-1977 MO OPtWAllOiMAL HRUBLEMiJ WtKt iVFKUkltO DURING THIS SukvFY PEHIUD. THF. PLAiMT
KEHORTS THE SYSTEM IS rtOKKINii bA TI bFAC I OK H Y . ThF. PuANT HAS HtEiM dllKNlNG iMAfll^Ai. GAS bUT EXPtCTS
TO RETURN TO COAL DUKTwG THE HEA1ING StAbON (OtCtMBEH-ilA 1) .
4TH UlJARIEH-1977 I>(E PLANT STAKltO HURnlMG CuAu AMU OPERATING SCHUiiHER 100 PtRCEmT OP (HE TIME
IN MID-OCTOBEK. NO OPtMA T iU.MAL PRUHLEMS HAVt BEEN £M JIJ.U EKEO DuBI'MU IHIS PEhlOO.
1ST QDARTEH-1978 THE SCWllbBtR OEMONSTRATEO AN OPfKABlLlTY OF 100X.
£NQ QUARTEK-1978 THE SCKIJttBtR WAS SHlJTDOrt.M IN MID-MAY WHEN GAS FINING HESUHEO FW SUMMEH. COAL-
FIRING WILL RESUME IN MID-OCI. OUHTNG CUAL-HKED OPERATIONS IN 1977 AND 1470, THE SCNUBHE* WAN AT A
100X IJPEKABILIIY.
-------
STATUS AS OF 07/.30/7B
StLTKliv 9 (CONTIMJFLJ)
P£RFU«i,AMCt DESCRIPTION FOK OPERATIONAL FRu SYSTEMS UN INDUSTRIAL BUILERS
INSTALLATION NAME
INSTALLATION LUCAT10I-:
SliuRLfc CHARACTERISTICS
SOuKCE HATING
OF SEPARATE Fi,D UMTS
CAPACITY
L SYSTEM VENDOR
PROCESS
i»E« / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOd EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
AK TRACIOK c:o.
cAST PEOKIA, ILLINOIS
COAL (i.d% SULFUK)
e!lO,OOu-3CFM (IOIAL - 4 BOILERS)
aO,OOfl ACFM ol i5o F, FUH EACH OF « FSD SYSTEMS
u
100 MW (EQUIVALENT); TOTAL - 4 ROILEKS
FHL ENVlKOiv^tNTAL EUUIPMENT
DOUBLE ALKALI CCONCEINTKATEU)
£ NEft,a KEIRUFIT
APi
-------
STATUS AS OF 07/30/7B
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR uPLk A I 10<\ AL FGu SYSltM& UM INDUSTRIAL HOil-tRS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTtRlSTICS
SOuP-CE RATING
f«Oi«.htK Oh SEPARATE FGO ONUS
snuPLE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
i-iEft / RETROFIT
STAPt-oP OATt
CO.JTKOL SYSTEM STATUS
S0
-------
STATUS AS (IF 07/40/78
SECTION 9 (CONTINUEU)
PERFORMANCE DESCRIPTION FOR OPERATIONAL. FGD SYSTEMS UN INDUSTRIAL BOILERS
CATERPILLAR TRACTOR CO.; JULIET, ILLINOIS (CCiNI INUED)
THE UNITS WERE ULTRASONICALLY 1ESTEU Awn RESULTS ShOrt 1HAT THE SYSTEMS AWE UN IHt HIGH
SIDE OF IOLERANCE LEVELS. A M1NUR LEAK WAS DElECltO AS A RESULI OF A FAULTY fttLu.
tTM UUAR1ER-1977 F&D SYSTEM RESTART UCCUKREO AT THt BEGINNING UF THE HtATTiMb SEASON.
PLANT HAO INITIATED A PROCESS OF DETAILEu (JECUKO KEEPING HuT ftftS ST TLL *UKK 1 Nr,
ON THE INTERNAL INFORMATION TRANSFER PROCESS. PLANT HAS IwRI.CATfcO THAI A SUMMARY OF THESE
RECORDS WILL BE AVAILAbLE TO THIS REPORT IN IHt NF.AH FUTURE.
1SI UUARTER-1978 FILTER CLOTH PRUBLEMS CUNTlNUED WITH KEPLACtMtNT BEING KEUl'lRtO EVERY 8-.1 hEEKS.
THE SYSTEMS WERE OOrtN IN MARCH BECAUSE OF HLUGtEu
2ND LHIARTER-1978 UNRELIAbLt SOi MQNIIORS WtRt A KRuBLEM DURING THIS PERIOD. Ht.AV Y ' ATTKI F ION OF
FILTER CLOTHS CONTINUED.
-------
STATUS Ah OF
SELIUiN 1 (LONTINiUFIj)
PERFORMANCE DESCRIPTION M)« UPtKATIONAL FGU SYSTEMS UK INDUSTRIAL oOJLEKS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMrtER 01- SEPARATE FGO UNITS
SOORCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOd EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CATESP1LLAK IRACfOK CO.
MORTON, ILLINOIS
COAL li.i* SULFUR)
40,000 t>UFI»i ITUT«L ~d ttOlLERS)
S
20 Mn Ifijll IVALtNU ; TOtAL - TECHNOLOGY. THE TrtO BulLERS AND THE TrtO SCRUBBING TRAINS AND t»OST ANCILLARY
EQUIPMEM ARE WITHIN TnE BOILER rtOUSE.
THE SYSTEM AT MORTON IS VERY SIMILAR TO THAI AT THE CATERPILLAR JOLIET PLAf T, WHICH HAS BtEN
OPERATING EACH HEATING SEASON SINCE OCIOBER 1971. WHENEVER POSSIBLE, PROBLEM AREAS AND
SOLUTIONS IDENTIFIED IN JOLIET OPERA] IONS HAVE BtEN IMf-LtMENTEli TO IMPROVE THE SYSTEM DESIGM
AT MORTON. SPECIFIC AREAS IN WHICH MOUIF 1C AT IUNS TO DESIGN HAVE BtEN MAUE ARE WATER BALANCE,
HUMPS, PH MONITORING, PIPING, LIME S10RAGF:, AND COLD AtATHtR PROTECTION.
OPERATING HISTORY
1ST UUARTER-1978 SYSTEM START-UP OCCURRED AT THE BEGINNING UF JANUARY. INITIAL OPERATIONS WERE
PROBLEM-FREE. THROUGH JANUARY AND PART OF FEBRUARY, ZURin PERSONNEL WERE TKAIMNG THt bOlLER PLANT
PERSONNEL IN THE OPERATION OF THE FGi) SYSTEM. OPERA I TufMAl EXPERIENCES A1 jOLItT AND MOSSVILLE HAVE
SHOWN IHAT THE BOILER OPERATORS CAM BE EFFECTIVELY TRAINED Tu uPtRATE AND MAIMAIN THE Fbl) SYSTEMS.
CURRENT PLANS CALLED FOR ACCEPTANCE TESTlNb IN THE SPKINo, BuT TnE CUAL SITUATION MAY UELAY THE IFST
PER1UO.
rf
-------
STATUS AS OF 07/30/78
SECT 10., 9 (CONTINUED)
OESCrflPTiOr. Kit. OPERATIONAL hGu SYSTEMS UN IM>USIMAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
Si'URCE CHARACTtRlSUCS
SOURCE RATING
MIi-irtcR Oh SEPARATE Flil) UNITS
SOURCE CAPACITY
LOi.TROL SYSTEM VENDOR
LOiVTHOL PROCESS
-------
STATUS AS OF 07/iO/7t>
SECTION 9 (CONT INUED)
PERFORMANCE DESCRIPTION (-OR OPERATIONAL FGl) SYSTEMS ON TNDUSTKIAL BOILERS
CAIFitPlLLAK IRACTOK CO.; MOSSVILLE, ILLINOIS ICONTINuEO)
AriuVt PrfuCtSS LIQUID
SL'Jufit HANDLING - SLOdGt IS TRANSPORTED FKOM THt VACUUM FILTERS TU THE LOADING AREA ON A BELT
CCihVtYuR. SEVERAL STRATEGIES, ALL IfcVOIvIiMG SCRAPING OR PLUrtliMG THE DEAATERtD SLUDGE UFF I Ht BFLT,
KfcSllLTtO IN tXCESSIVE rtEAR Oh EITHER THE BtLTS OK I Ht HLUWS. THE PRESENT APPROACH SIMPLY OUNiPS
IHt HAItxIAL OFF THE f-NO OF 1HE HEU INTO UINS. THE PUS1T10IM UF THt BELT' IS CHANGEABLE SO ThAF
ElbHI -41NS CAN BE FILLtO BEFORE THEY MUSI BE EMPTIED. A FUkThiEK MODIFICATION HAS A DUAL POSITION
CHuTt uNOEK EACH HtLT tMO POSITION, SO THAT A lOTAi. OF 16 blfcS CAN BE PLACED ON IT AT A IIME.
SLUICE BINS ARE THEN LOADEO HYIJRAULICALLY INTO TRUCKS AND nAuLEO TO THE SANITANT LANDFILL AREA.
ANuTrtEK HR08LEM, COLD AEATHEM ICING ON THE SLUUGE LOADING AREA, rtAS SOLVED BY ENCLOSING THE AREA.
INSTRUMENTATION - Ohi^tMAL DESIGN PLANS CALLED FOK GONTKOL BY THE MONITORING OF THE so3/sot
KAflO AND SODIUM ION CONCElMTKATION. THE CONTROL RANGE WAS FOUND TO BE TOO SMALL AND THE PRESENT
APPROACH IS PH CONTROL (6.5) AND CLEANING UF ThE PROBES EVERY OTHER DAY.
ORIGINAL DESIGN DID NuT MONITOR S02 CONCENTRATION BUT A COMPLETE MONITOR SYSTEM WAS INSTALLED
PRIDK 10 THE 1977-78 SEASON.
PIPING - MODIFICATIONS HAVE BEEN MADE WHICH FACILITATE CLEANING OK SCHEDULED REPLACEMENT.
OPERATING HISTORY
<4TH UOARTEW-1977 CATERPILLAR BEGAN A PROCtOUHt OF DETAILED RECORD KEEPING, BUT THE FLOW OF
INMIKMATION rtAS NOT YET SULH THAT IT WAS AVAILABLE TO THIS REPORT.
dfJO UMARTER-l<'7ft NUMEROUS BOILER-RELATED PROBLEMS HAVE COMPOUNDED FGD SYSTEM PROBLEMS. MAJOR
KGii PKGBLEM AREAS WERE AS FOLLOWS!
tWuSlON OF SCRUBBED LINER MATERIAL.
EXCESSIVE «EAR OF PIHING, PUMPS, AND CONTROL VALVES.
SLUOGE FKEEZE-UP ON IHE CONVEYOR BELT PLUGGED SLUOGE CHUTES.
-------
STATbS AS UF l)7/30/7b
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOK OPERATIONAL FGD SVSTtMS ON INDUSTRIAL BOILERS
INSTALLATION NAMt
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-OP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM CuSI
CHtVRON U.S.A. INC.
BAKEkSFIELU, CALIFORNIA
UIL 11.1% SULFUR)
c>Ub,OOo SCFM (TOTAL - 1* BUILERS)
150,1/00 ACFM ;i 500F, FOR EACH UF 5 FGD SYSTEMS.
3
90U MM HTU/HK (TUTAL - 18 BOILERS; fc BUILEkS/ FGD SY.STtMj .
85 M« (EQUIVALENT); VOo MM B1U/Hh: luTAL - le flOILERS
l?i> hW (EQUIVALENT), TuTAL - 1 tt BOILERS
KOCH ENGINEERING
SODIUM CARBONATE scRuRtsiNG
RETROFIT
JULY, 1978
OPERATIONAL
90* (7U PP^: at OUTLET)
HASTEWATER TREATMENT AND DISCHARGE TO TAILINGS POND
CAPITAL:^,BOO,ooo (1979). THIS is TOTAL INSTALLEU COST
OF THE FGD SYSTEM, INCLUDING SITE PKEPATION.
OPERATING: APPROXIMATELY $90o/oAY PER SCRUBBER ti97b) .
THIS CORRESPONDS TO A TOTAL OF * 9dO,OuO/YR K'R ALL -THE
SYSTEMS a/ i«0 UAYS/Yk. THE COST INCLUDES ELECIRICITY, SUOA
ASh, AND MAINTENANCE (LABOR AND MATERIALS ).
BACKGROUND INFORMATION
CHEVERON U.S.A. HAS AN UIL SITF AT b AK EkSF I ELU , C AL 1 1- ORN I A . THERE ARE ABOUT bl) STEAM GENERATORS
6URN l.U SULFUR CRUDE OIL. EACH GENERATOR IS RATED AT 50 MM BTU/HK. THE STEAM Is USE!' 1 u HEAT
OIL ANu hACILITATE ITS FLOn UPWARDS ^UM THE OIL WELLS.
KuCH ENGINEERING HAS COMMISSIONED THREE FGO SYSTEMS IN JUNE/JULY 19/8. THE SODIUM CARuONATE
SCRUhMNG PROCESS IS USED, WITH EACH SCWUHBFk TREATING FLUE GASES FRON b GENEf-'AlURS WITH A TuTAL
FLOW RATE OF 150,000 ACFM AT 5uO F. THERE ARt 3 MICH FLEX I fk AYS AND A KOCH FLEXlMESH DfcMlSIER IN
tALh SCRUBBER. THE SPENT LKJUOk IS MIXED !«' 1 1 H f-RESn SOuIUM CARBONATE IN THE uOITOM OF THE SCRUBBER.
A CONTiNuOOS BLEED OFF STREAh, IS TAKEN Tu D I SPOS AL POND , .'.HLREAS KEST OF i Ht LTuUuW IS KE C IkCUL A TtO .
A PH OF b-b.5 IS MAINTAINED AT THE TUP T * A Y AND A L/li RATIO UF S GALLON'S/ 1 000 ACF IS USEcJ. THERF Is
iMO REHtA) FACILITY BUT THE SCROBuFR LAN bE BYPASSED. TnE BulLEK l.D. FANS WILL HE UPGRADED TO OFFSeT
-------
bTATUS A6> OF 07/jtl/?U
PERFORMANCE UF.SCKIP1 lOiv F- ON uPfc R A T i flNAL F-Gu SYb'tMb UK I iMPuS I l> 1 AL BDllekM
CHEVRON U.S.A. liMC.; rtAKLRSF ItLO, CALlhtlKfjIA (CUM iNotn)
THt HHESbUKE DKOP UF 1 IN. ftU. TuE hLKUBHEKh AKE PtSlGnF.- 10 Rf-uVt >*IU UF SUH Auli MAINTAIN t. X i 1 Su2
COivCENTRATlbN BELOW 7U PPM. tACH SCKUBtsEH IS 1 h . •s FT.LT P1A. ANu ^5 FtM HIGH. I Ht HflKuT INCLUDES
IHAT OF A STUB STACK SITjATEi) UM TOP Oh tALK SCRUHSEh.
THE SCWUBbEKS AM) Tt
-------
STATUS AS OF 07/30/7d
PFRFURfcANCE DESCRIPTION H>k OPERATIONAL
SYSTEMS UN TNUUSrRIAL UOILERS
INSTALLATION NAME
i'MST ALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
ivUmfitR OF SEPARATE FGD UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CO, 300 FJ
1
i Ml* (EQUIVALENT)
f MC tNVIKOiMMENl AL EQUIPMENT
DOUBLE ALKALI CCUNCEuTKATED)
RETROFIT
JANUARY, 147b
OPERATIONAL
90.5% CluOO PPM ol INLET)
97.4% CS Lb/MM BIU S INLET TO MECHANICAL COLLECTOR.)
DFnATEWED SLURRY TO LANDFILL
CAPITAL: $163,uoo us7t). THIS COST INCLUDES EQUIPMENT>
ENGlNEERINli, AMD STARTUP. THE CUSI UOES NOT INCLUDE
LAbOK AND MATERIALS K)H ELECTRICAL SYSTEM, PIPING,
OR STRUCTURAL ANU FOUNDATIONS ERECTION.
OPERATING: sbO,ooo/YR (1977). THIS COST INCLUDES
LABOk, F.LECTRIUI IY, DISPOSAL, MATERIALS, AND LAB WORK.
BACKGROUND INFORMATION
THE FIRFSTONt TIRE AND RUBBER CO. LOCATED IN POTTSHHvN, PENNSYLVANIA HAS BEEN OPERATING A FGO
SYSTEM SINCE JANUARY 1975 AS A DtHUNSTKA11UN-SLALE PLANT, DESIGNED TO TEST THE FEASIBILITY OF FGO
UN INDUSTRIAL BOILERS. THE UNIT is DEMONSTRATING ^o PHRCE.MT Sue REMOVAL EFFICIENCY «ITH AN
AVAILABILITY OF 90 PERCENT AND A FLUE GAS CAPACITY Oh 12!,000 ACFM OR EQUIVALENT OF 3.0 Mw. THIS
FLO« REPRESENTS APPROXIMATELY 1 /.4 THE TOTAL OUTPUT OK UNE 120,000 LB/HR STEAM BOILER. THE SULFUR
uluxii.t EMISSIuM REGULaTHJN FOR THE KLANT IS O.«b Lhb /"I I LI. I UN ulu OF HtAI OUTPUT.
THt PLANT IS USING THE CONCENTKATEu OOOHLE ALKALI PROCESS PATENTED BY FMC CORPORATION. THE LOAD
CAPACITY f)F THE bOILER Oi\, fiUlCti THE SCKUdfltK IS jPERATINb IS APPROXIMATELY ID rtW. IN UCIObER 1976,
int. oUiLtR WAS CONVERTED FROM BURNING KEStOUAL FuEL ulL 12.354 s) TO COAL (<».S-i.OX S) .
IKE vENTURl SCRUHBER IS SPKAYEO rtllH ALKALINE LIUUUR WHEkE THK FLUE GAS ENTERS. THE FAN AND
u*i..PtK UPSTREAM OF VtlMHJRI CONTROL THE FLMc bAt> KEtO. SCRuBblur, LIQUOR hLUWS FROM THE VENTURI TO
THE M'lTTUM OF CYCLONE DEMlbThR AND THE'M 1N T (1 THE htC 1RCHL A TI ON TANK. DROPLETS OF SCRUBBING LIQUOR
A*c ,iPjr» DOT IN THt CYCLONE AND RON tiACK OOIMM IN i HE RtC I RCUu A TI UN, TANK. THE SCRUBBING LlJUOR IS
PAf,TLY RECIRCULATEO TO THE VEiMUIKl THUS LUhPLETlNU THE SCRuHoIuG CYCLE. ACCUMULATION OF SULU3LE
-------
STATUS AS OF U7/30/7B
SECTION •» (CONTINUED)
PERFORMANCE DESCRIPTION K)K OPERATIONAL FGU SYiTEMS ON IiMHUSTWIAL BOILERS
FI-*.
4TM JHAHTEH-J976 IN OCTOBER. THE SYSTEM UPEKAfED AT A RELIABILITY INDEX OF IOOX, UNTIL THE UNIT
*AS CONVtMTEu TO COAL FIRING U.5 - i.0% SULFUR). THF SYSTEM OPERATED FOR AN ADDITIONAL 511 HOURS,
OF THE «6 H£UUIkEO, OEMUNSTRATHMG A RELIABILITY IiMDtX VALUE OF 97.2X. IN NOVEMBER AND DECEMBER,
IHE SYSTEM OPERATED F0n 1172 HOURS AGAINST THF. REQUtrtEMEiMT OF 1211 HOURS. THEREFORE, THE AVERAGE
RELIABILITY INllEX FOR IHE TrtO MONTHS WAS 9b.7%.
1SI uiUAKlEK-1977 SYSTEM OPERATED 1193 HuUkS, flAS kEUUIREO Tu UPERATE FOR 14b9 HOURS, YIELDING A
Ktl. IAH1L1TY 1NUEX VALUE OF 81. CX. SYSTEM WAS DEalbNtO FOR A MUCH LOWER PARTICULAR LOADING THAN
til
-------
STATUS AS OF 07/30/78
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FUR OPERATIONAL fSO SYSTEMS UN INDUSTRIAL BOILERS
FIRESTONE TIRE AND Ru«bER CO. ; POTTSTUWN, PENNSYLVANIA CCuNTiNUtO)
THAT ACTUALLY ENCOUNTERED ON CUAL FTKING. THE HIGH GRAIN LOADING CAUSED ABNORMAL «EAR AND DOWNTIME
UF THE F.D. FAN.
dNO u.UARTER-1977 SYSTEM OPERATED 139fl HOURS, WAS RETIRED Tu OPERATE 1690 HOURS, YIELDING A
RELIABILITY INDEX VALUE OF 8
-------
STATUS AS Ul- 07/30/7B
SECT 10 IV •?• tClli.T IMOKO)
PERFORMANCE OFSCRT('T I»IM I- Ol< Ol't R A F I fi .. « L K(i,j SY.iTcMb J.v I '< I AU
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUnRER OF SEPARATE FbO UNITS
SOURCE. CAPACITY
CONTROL SYSTEM VENDUK
LllNTHOL. PROCESS
ME in / RETROFIT
START-UP DATE
CONTKOt SYSTtM S'lAHJS
SOI EFFICIENCY
PARTICULATE EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
(•ML l5t(l)A ASH HI. AND
l,KEFIM n'lvtKt 'AYUMlNG
LllAL (I'/- Slll.nJ'O
'»ae,uoo SCFM (loiAL - d
c>.S(j Mw ItUUltf AUh'iJTJ : TOTAL - c1 1-UJlLfcRS
FML ENVlKUlMMtNT AL EMUlPMtNf
S'lOIUM CAKnOmATF SCRUHtflM5
Nfcrt
MAr , I47h
UPtHATlOMAL
9S* IBOO PHH AT INLET)
REMUVEIJ bY PRFCF.UING FSP (49. 5«)
OPEN LUDP* L/6 - lb-c!0 GAL/1000 ACF
HOL01NG POND FOR EVAPORATTUN
fMAriSOJ/Soa L1HJOK DISPOSED TO COLLECriUN PONU - MO PKIU*
AEKAIIUiM. LANDFILL IN ThF. FOToRL
CAPITAL COST INCLUDES tSP
BACKGROUND 1NFOKMATION
FMC CHEMICAL CORP. HAS A SODA ASH PLAN1 IN GKELM RIVtR, nYOMIiMli. THE PLANT HAS TWU COAL-FIRtD
POWER BOILERS WHICH BURN 1.1 PERCENT SULFUR COAL. THE FLUE GAS HRUM EACH BOILER (330,000 ACKM AT
320 F) IS TREATED 8Y A HUTSIDE FSP WITH 2flh r-'LATCS Ai\D A PARTICULAR HEMutfAl. cKFICIEiMCY uF 99.5 %.
THE FLUE GASES ARE SCRUBBED BY THE PLANT ENO-LIOuOR IN TWO SCRUBBERS, EACH WITH THKEt PAIRS OF
DISC-AND-OONUT THAYS. THE SCRUBBERS AND 1 HE DISCS A«E LINED WITH CEILCOfE Io3 rtHEnEAS THE DONUT
PAKTS OF THE TRATS ARE MADt FRUM IMCUNEL 8cb. THE StKUfibtrt LIuUoH IS MAINTAINED Al A PH OF 6.3 ANu
IS RECIRCULATED AT A RATt OF 10 - IS GALLONS/1 oOl) ACF OF FUJt bAS. A PAKT OK FHt REcIRCULAT ING
LIQUOR IS CONTINUOUSLY PURGED 10 REMOVE SULFITES AND SuLHAItS FUrtMEll BY IHt rttACTIUN OF oOa .HFH
SODA ASH. THE RECIRCOLATING PUMPS AND THE RELATED PIPING IS RUHBER LIiMFU. A HESH TYPE uEMlsTfc'R 15
USED IN EACH SCRUBBER. THE bASES ARE REHEATED BY OTRELT FlRi,Mb OF NATURAL GAS Al IHc EXIT UF IHE
SCRUBBERS. THE REHEATED FLUE GAS IS MIXED 'U1H HYPAoStt) GAS BcFjRt bUliMG TO THE STACK AT ArtulIT
180 F .
AUTOMATIC CONTROLS MAINTAIN SOLUTION LEVEL If- IHt bCRUBHER BASIN. THE HRIrtAWY SOURCE OF
MAKE-UP IS PROCESS WASTEwAlFn nHICn iS CHANNELED Tu A MAKt'-up IA,gK. I(- MilKF f'AKt-oP IS REuilI
WIVER WATER IS TAPPED. IHE SCKUI3&EK BLEED STREAM IS PIScHAKliEli in A WASIF PUM) »T IHH SITt.
DAMPERS «ITH REMOTE CONTROLS REGULATE IHE (-LOW OF OFF tiAS fHKOUGH AND AhuUnD 1 HE SCRUHBEnS.
APPROXIMATELY 5>OI OF loTAL FLUE GAS IS ROM THKlUbH TnF SCRofluFKS.
-------
STATUS AS UF 07/30/7a
SF.CMOu f ICIIivT llMUf L>)
PERFURNANCt UFbr^THUdN Ff,K ,.Pt R A . I Hiv AL h Gl, SY^TtMb UN I,,DUSl«tAL BUILEHS
(SUI.» ASH PLAN!); (,H|tF.N Klvt(v, ,,Yl-)Mm, (u
UPFnA, Fur; HIS I DRY
JRD uUAR.ER-1,77 M,»E PROBLEMS HAVE OCCuKKED «I,H TnF SuRUflBKK LINING AS A RESULT OF FAULTY
INFLATION. THE POSSIalLl.Y OF RHNNIN, ,HE SYSTtM W1TM Nf, RtH£AT IS RtlN6 !.VESTIGATEO.
,TH HUA,IE«-1977 THt SCKUB8ERS HA«E CoK'ROUEU AS A RtSULT UF FAULTY INSTALLATION OF THE LINING.
IHt IMPURITIES IN THE SCRUBBING LIUUUR CAUSE FOAMING AND SEDIMENTATION ON THE TRAYS.
IS, UUARIE«.,,78 PIPELINE FREE7UPS. AND LEAKS FROM I HE VANE HAMPERS WERE THE MAIN PROBLEM AREAS.
«*u UUARIEft-197e IHt DEMISTER ,AS PLUGGED, ANU , HE RFCIRCULAUON PUMP WAS DOWN FOR SOME PERIOD.
PH CUMKUL IS N01 VERY EFFEC.IVE, CAUSING PH ExCtRSION, ,0 A.OuT ,.». THIS HAS CAUSED SCALING IN
InE PIPELtNES AND IN THE TO.VER. F,C TESIS HAVE MEASURED S02 REMOVAL EFFICIF.Cr IN IHE RANGE OF 87%.
^1%, flEPtNuING ON L/b AND PH.
-------
AS uF
sf uT ION <> (LONT
PERFORMANCE INSCRIPTION FOR UPt R A T 1 ON A I FGu bYbTtMb UN I IMllUS f WI Al. BOlLtRS
1'iSIAI.LATlON NAME
IUN LOCATION
CHAKACURIS1 U.S
RA11NO,
INIMHEP OF SEPAkATE FbD UMIIS
aiii)Wi.E CAPACITY
bEiMEkAL HOIHRS CORHOHA riurj
DAYTON, OHIO
CUAL10.7* - cJ.uX SULHIRJ
ih,l)00 SCFM UOTAL - .TrN bYPASS THE GASES TO IHE ATMOSPHFi-E IN CASE OF A SCRUBBER
MALFUNCTION; OR IT CAN MIX AMBIENT AIR MIH IHE FLUE PASES IN CASE OF LO« LOAD IN OROER 10 MAINTAIN
CO,\SFAi\iT AIR FLO»* 10 TnE SCKUbbER FAN.
THt hCKUHBER CONSISTS OF THE F.NTULETEW "VA^E-CAGb" (b Fl. I) IA. X <, FT. HIGH) rtHlCH IS HOUSED IN
-------
STATUS AS UK
SECTION g (CONTINUED)
PERFORMANCE DESCRtPTIO, FOR OPERATIONAL FGO SYSTEMS UN INDUS, RIAL BOILERS
GENERAL MOTORS CORPORATION; DAYTON, UHIO (CONTINUED)
A CONICAL BOTTOM SEC.ION (» FT. DIA. X 5 FT. H1&H), AN TNTERMEDIATE 8ECT,ON („ FT. DIA. X
5 FT. H,6H)f AND A DISENGAGEMENT ZONE do FT. UTA. X 1, FT. MlliHJ. THE FLUt (,AS (i4,0u0 ACFM
- 50UFJ ENTF.RS THE BOTTOM SECTION TANGENT I ALLY . RtCIRCULATIuG LIQUOR IS SPRA,tU FROM THE rOP OF
!HE VANE CAGE SECTXON, WHICH CAN BE MOVED VERTICALLY TO VARY THE PKFSSORE URuP ACRUSS THE ttc»U88tH
A PRIMAL UEMISTER IS LOCMED ABOVE ,Ht PREVIOUSLY MENTIONED I.TERMEUUTE SECTION ANO A SECO^OARV
UE.ISTER IS LOCATED ATOP THE OI8£N«BtMEMT ZUNt. IHE G4b , HtN PASStS .HKOJGH A ,TuH STACK Tu THt
AT.nSPHFRE. SCRUBBING LIOUOR IMH,NRtS ON , Ht b01TOM OF THt VA,,£ CAGt ANU A SPKAr CHAMbE, tFFFCT
H«UV1,,£S THE S02 REMOVAL. SCRUBS UNUFKFLO-, CONTAINING PARTICULAR ANO A ,^SoVSu< SOLUTION IS
SENT TO ,HE RECYCLE TANK, HHtRE HAKEOP ,ATt, AT A RATE OF ,0 GPM IS ADOC,,. RECYCLE PUMPS TAKE
LIUHOR FROM THE IOP OF THE RECYCLE TANK, ALONG WiTH ,HE CAUS.Ic STREAM A.OLD Tu TH, FEED LINE, ANO
KEdKCOLATE IT TU ,HE TOP OF THE VANE CAGE AT A RATE OF ,00 BPM. THE L/G ,75 THt DAMPERS ANO OAN.PER CONTROL SYSTEMS WERE MAJOR PROBLEMS. THREE SETS OF
EXPANSION JOINTS HAD Tu BE INSTALLED BEFORE ACHIEVING PROPER FL0« CONTROL.
MU yUARTEK-i47i A FAN BEARING HAD .0 BE kEPLACEO THRtE TIMES.
iRD ^OARTEK-1975 INSTRUMENTATION AND CONTHOL PROBLEMS PkOHPTEo WIRING REVISIONS.
«TH UUARTER-1976 T HE FGD SYSTEM DEMONSTRATED AN AVAILABILITY OF 93 PERCENT.
IS, UUARTER-1977 MECHANICAL PROBLEMS WITH THE VANE CAGE DRIVE. THE ACCESS OOOR DEVELOPED LEAKS
AND .HE LIQUOR CORRODED THE OUTER SURFACE OF THE INLET ,,UC , AROUuD THE ACCES, DOOR.
4TH UIIARTER-14J7 COKROSION AND PLUGGING PnObLEMS CONTINUED 10 HAMPEK SCKUUHtH OPERATIONS.
HO.FVER, USUALLY WHEN A SCRUBBER IS UO»N, THE uTHEK .OILER IS FIHEu OP «H,LE ..PAIRS AKt: MADE TO THF.
UtJrtNtl) UNIT.
isi
THE PRIMARY UEMTSTER WAS SEVERELY CORRODED OOF TO ACID DROPPING UU*N ONTO IT
-------
STATUS AS OF 07/30/78
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOK OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
GENERAL MOTORS CORPORATION; DAYTON, OHIO (CONTINUED)
FROM THE UPPER DEMISTER.
2ND QUARTER-1978 THt FOLLOWING SYSTEM MODIFICATIONS WERE BEING PLANNED: THE IIMTERMEOIATE SECTION
WILL BE REMOVED, THE PRIMARY DEM1STER WILL Bt REPLACED BY A SIMILAR VANE-TYPE HASTELLOY-G DEMISTER,
THE SECONDARY DEMISTER WILL BE REPLACED ttY A RADIAL VANE HASTELLUY-G DEMISTEH, AND A CONVEX
IMPINGEMENT BAFFLE PLATE OF HASTELLUY-G rtILL BE INSTALLED ABOVE IHb PRIMARY DEHISTER TO ASSIST IN
RAPID DRAINAGE OF THE ACID DROPLETS.
-------
STATUS AS OF 07/30/7a
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOd EFFICIENCY
PARTICULATE EFFICIENCY
WATER MAKE-UP
SLUDSE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GENERAL MOTORS CORPORATION
HAKMA, OhIU
COAL C2.bX SULFUR* 7.1% ASH* 13,350 8TU/L8)
128,400 SCFM 51 7U F ITuTAL - 4 HOILEKS)
320,000 LBVHR STtAM (TUTAL)
1
32 Mi*. (EQUIVALENT); TOTAL - 4 bOILERS
GM ENVIRONMENTAL
DOUBLE ALKALI (DILUTE)
RE1ROFJT
MARCH, 1974
OPERATIONAL
90% 1800-1300 PPM a INLET)
63X (AT INLET: UNITS 1&2 - 1.75 LB/MIN* UNITS 3&4 - 1.32
LB/MIN)
CLOSED LOOP
DEWA1EREU SLURRY TO LANDFILL
50 + X SOLIDS (CASU3/SU4) SLUDGE TO DRYING POND AND LANDFILL
OPERATING COSTS ARE $643,500/Y« ol 55,000 TPY OF COAL
BACKGROUND INFORMATION
THE CHEVROLET PARMA PLANT OF GENERAL MOTORS IS LOCATEU NEAR CLEVELAND, OHIO. THE PLANT HAS FOUR
SPREADER-STOKER BOILERS FIRED BY TRAVELING GRATES, CAPABLE OF PRODUCING A TOTAL OF 320,000 L8/HR OF
STEAM OR APPROXIMATELY 32 MW OF EQUIVALENT ELECTRICAL CAPACITY. THE COAL FIRED IN THESE UNITS
ORIGINATES PRIMARILY FROM THE SOUTHEASIERN PORTION OF OHIO AND HAS THE FOLLOWING AVERAGE
CHARACTERISTICS: HEAT CONTENT OF 11,300 BTU/LB, SULFUR CUNTENT OF 1.7 TO 2.7 PERCENT, ASH CONTENT
OF 6.8 TO 14.8 PERCENT, AND A TOTAL MOISTURE CUNTENT OF 0.9 TO 7.8 PERCENT.
THE POWER BOILERS HAVE BEEN FITTED WITH AN EMISSION CONTROL SYSTEM CONSISTING OF MECHANICAL
COLLECTORS UPSTREAM OF A DILUU DOUBLE ALKALI SCRUBBING SYSTtM. THE FGD SYSTEM SCRUBBING MODULES
WERE SUPPLIED BY KOCH ENGINEERING. INSTALLATION WAS COMPLETED ON FEBRUARY 28, 1974. THE SYSTEM
CONSISTS OF FOUR SCRUBbERS OPERATING IN PARALLEL. EACH SCRUBBER CONTAINS THREE BUBBLE-CAP
ABSORPTION TRAYS AND A MESH MIST ELIMINATOR. THE FLUE GAS RATt IS 61,SOU ACFH AT 393 F FOR EACH OF
THE FIRST TWO SCRUBBERS AND THE OUTLET TEMPERATURE IS 137 F. THE INLET S02 CONCENTRATION IS 765
PPM. THE FLUE GAS FLOW RATE IS 58,600 ACFM AT 550 F FOR THE OTHER TrtO SCRUBBERS ANO T'HE OUTLET
TEMPERATURE IS 152 F. THE INLET S02 CONCENTRATION IS 800-1300 PPM. OUTLET CONCENTRATION VARIES
FROM 136-220 PPM FOR THE SCRUBBERS.
THE. SULFUR DIOXIDE CONTAINED IN THE BOILER FLUE GAS IS ABSORBED BY A REGENERATED CAUSTIC
48
-------
STATUS AS OF 07/30/78
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS UN INDUSTRIAL BOILERS
GENERAL MOTORS CORPORATION; PARMA, OHIO CCONTINUEO)
SOLUTION (0.1 MOLAR NAUH), FORMING A SOLUTION OF SOLUBLE SODIUM SALTS. THE SPENT CAUSTIC IS THEN
REGENERATED BY REACTING THE SODIUM SALT SOLUTION HlTn.SLAKED LIMt, RESULTING IN THE FORMATION OF
CALCIUM SULFITE/SULFATE SOLIDS, WHICH ARE SEPARATED OUT UF THE SOLUTION. NEXT, SODA ASH IS
ADDED TO THE SOLUTION IN ORDER TO MAKE UP FOR SODIUM LOSSES AND MINIMIZE THE SCALE POTENTIAL FROM
THE CALCIUM WHICH REMAINS IN SOLUTION. THE REGENERATED CAUSTIC FORMED IS THEN RECYCLED BACK TO THE
SCRU6BER FOR ADDITIONAL SULFUR DIOXIDE REMOVAL. THE CALCIUM SALT AND FLY ASH SLUDGE WHICH RESULTS
IS DEWATERED AND HAULEU AWAY BY TRUCK TO AN OFF-SITE LANDFILL.
EQUIPMENT SPECIFICATIONS
SCRUBBERS. EACH OF THE a SCRUBBERS IS 10.5 FT 01* X 22.5 FT HIGH X 11 GAUGE THICK AND CONTAINS 3
BUBBLE-CAP TRAYS. ALL THE SCRUBBERS AND TRAYS ARE MADE OF 316 L S3. THE SCRUBBERS HAVE A TURNDOWN
RATIO OF 3 AND ALSO HAVE A BYPASS DUCT. THE L/G RATIO HAS A DESIGN VALUE OF 30 GALLON3/ACF BUT IT
rtAY BE VARIED DURING OPERATION. THE PRESSURE DROP ACROSS THE SCRUBBER RANGES BETWEEN 8-9 INCHES WG.
DEMISTERS. ORIGINAL 316 S3 DEMISTERS WERE CORRODED DUE TO CONDENSATION AND ARE REPLACED BY FLEXI-
MESH TYPE POLYPROPYLENE ONES.
RECYCLE TANKS/PUMPS. ALL THE 4 RECYCLE TANKS ARE MILD STEEL WITH TAR TYPE RESIN COATING. THE PUMPS
(TUTAL 6, £ SPARE) ARE CENTRIFIGALS WITH MILD STEEL CASING AND HAVE RUBBER LINING. THE PUMP MOTORS
HAVE 40 H.P.
CHEMICAL MIX TANKS & AGITATORS. BOTH THE MIX TANKS ARE MILD STEEL WITH 5000 GALLONS CAPACITY. THE
DESIGN RESIDENCE TIME IS 7 MINUTES. NEW AGITATORS ARE PROPELLER TYPE. THESE ARE SPECIALLY DESIGNED
TO GIVE HIGHER FLOW SATE THROUGH THE BLADES. THE DRIVE RATINGS ARE 5 HP AND 45 RPM.
CLARIFIERS. BOTH THE CLARIFIERS (60 FT DIA X 14 FT LIQUID DEPTH) HAVE A CONICAL BOTTOM AND 300,000
GALLONS CAPACITY. THE DESIGN RETENTION LINE IS ABOUT 4 HOURS AT FLOW RATE OF 1300 GPM.
VACUUM FILTERS. BOTH THE VACUUM FILTERS HAVE 500 SO. FT. SURFACE AREA WITH 10 FT DRUM DIAMETER. THE
URUM DRIVE SPEED IS 0.5 KPM MAXIMUM.
FILTRATE TANK/PUMPS. THE TANK (4 FT DIA X 7 FT HIGH) IS MILD STEEL AND HOLDS 660 GALLONS OF
KILTRATE. THE PUMPS ARE MILD STEEL, CENTRIFIGAL AND HAVE A CAPACITY OF 300 GPM AT 15 FT. OF HEAD.
PROBLEMS AND SOLUTIONS
THE SYSTEM WAS STARTED UP ON FEBRUARY 28, 1974 AND BY APRIL 31, IT HAD OPERATED FOR 264 HOURS.
THERE WERE TWO SCHEDULED SHUTDOWNS DURING THIS PERIOD FOR EQUIPMENT INSPECTION. THE SECOND SHUTDOWN
REVEALED THAT SOLIDS WERE NOT BEING DISCHARGED FROM THE PRIMARY CLARIFIER RAPIDLY ENOUGH.
AS A RESULT, THE CLARIFIER RAKE JAMMED. A PIPING CHANGE WAS MADE TO BLEND THE CAUSTIC FEED
IN WITH THE RECYCLE LIdUOR. THIS HAS IMPROVED PERFORMANCE BUT NOT COMPLETELY ELIMINATED
-------
STATUS AS OF 07/30/76
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS ON INDUSTRIAL BOILERS
GENERAL MOTORS CORPORATION; PARMA, OHIO (CONTINUED)
THE PROBLEM. PREMATURE CAKE CRACKJNG IN THE VACUUM FILTERS RETIRED THE PRESENCE OF AN OPERATOR
DURING OPERATION. «.M. ANTICIPATES THAT THE CHANGE TO NrLON FROM POLYPROPYLENE WILL SOLVE THIS
PROBLEM. CAKE CASHING TO REDUCE LOSSES WAS NOT INITIALLY SUCCESSFUL BECAUSE THE SPRAY WATER
TENDED TO KNOCK THE CAKE OFF THE DRUM. ALTERATIONS IN SPRAY PATTERN AND OTHER MEASURES HAVE
APPARENTLY SOLVED THIS PROBLEM. THERE HAS BEEN NO EVIDENCE OF CORROSION OR ABRASION IN ,HE PUMPS
OR PIPING.
THE SYSTEM WAS SHUT DOWN FROM MAY 1 TO MAY 26, ,97,, BECAUSE OF UNEXPECTED BUILDUP OF SOLIDS IN
THE CLARIFIER, WITH SUBSEQUENT OVERFLOW INTO THE SCRUBbER. THE PROBLEM WAS SOLVED BY 1) USING
A POLYMERIC FLOCCULATION AGENT TO ATTAIN-BETTER SETTLING AND 2) WITHDRAWING SLUDGE FROM THE
CLARIFIER AT MORE FREOUENT INTERVALS. SYSTEM AVAILABILITY TU THE BOILER WAS 87 PERCENT IN APRIL
197*,, LESS THAN 10 PERCENT IN MAY, AND 100 PERCENT IN JUNE, JULY, AND AUGUST AFTER THE SYSTEM WAS
RESTARTED. PLUGGING BY GYPSUM DEPOSITS IN THE OVERFLOW LINE BETWEEN THE CLARIFIERS AND IN THE
LINE FROM CLARIFIER NO. a TO THE M!X TANKS WAS CORRECTED BY RELOCATING A CHEMICAL FEED LINE AND
REPLACING SOME PIPING. THE SYSTEM WAS DOWN THROUGH JULY AND AUG. 1975 FOR REPLACEMENT OF GRAVITY
FLOW LINES WITH AN OPEN FLUME THAT CAN BE EASILY CLEANED. ADDITIONAL MODIFICATIONS TO THE DESIGN
AND OPERATION OF THE F60 SYSTEM HAVE CONTINUED. THE OPERABILITY !NDEX FOR THE FGD SYSTEM HAS
INCREASED SIGNIFICANTLY THROUGHOUT THE COURSE OF 1976. THE MAJOR PROBLEM ANO SOLUTION AREAS,
PLUS MODIFICATIONS IMPLEMENTED TO THE SYSTEM ARE HIGHLIGHTED BELOW IN THE SYSTEM PERFORMANCE TABLE.
OPERATING HISTORY
OPERATION HOURS
MONTH BOILER FGD SYSTEM OPERABILITY (X)
THE SYSTEM WAS RESTARTED AND PARTICULATE TESTS WERE CONDUCTED IN MAY. THE SYSTEM WAS SHUT DOWN DUE
TO PLUGGED CHEMICAL FEED LINE TO THE CLARIFIER AFTER RESTART. AROUND JUNE 10, THE SYSTEM WAS
SHUTDOWN BECAUSE OF SIMILAR PLUGGING IN ANOTHER PART OT THE LINE. THE UNIT RAN FOR ABOUT TWU WEEKS
IN JUNE.
THE FGO SYSTEM WAS DOWN IN JULY AND AUGUST FOR REPLACEMENT OF GRAVITY FLOW LINE WITH AN OPEN FLUME.
OCT. 75 2331 1848 79
THE FGU SYSTEM RESTARTED ON SEPTEMBER 8, AND OPERATED DURING THIS PERIOD AT AN AVAILABILITY FACTOR
OF 80 PERCENT. THE FIGURES GIVEN FOR UCT08ER REPRESENT THE OPERATION HOURS FROM SEPTEMBER 8 TO
NOVEMBER 9.
DEC. 75 2135 U50 59
THE FGO SYSTEM OPERATED WELL DURING THE REPORT PERIOD EXCEPT FOR A SCHEDULED HOLIDAY SHUTDOWN FROM
OECEMflER 23 TO JANUARY a, 1976. BECAUSE OF PROBLEMS WITH SOLIDS AND SOLIDS CARRY-OVER, G.M. CON-
DUCTED STREAM TESTS DURING DECEMBER TO DETERMINE WHETHER THE CARRY-OVER OF SOLIDS WAS DUE TO A HIGH
50
-------
STATUS AS OF 07/30/7*1
SECIlOiv 9 (Cl)iiU'JUF.i))
PEHFliRMANCt UESCKTHTJON FUK DPL •< ^ T I.J'« * L KGi; SY.ittu5i uN INDUSTRIAL MUlLt^b
GENFKAL MOTDHS CllHPOKATIUN; PArtMA, (JHtl) ( C ON T I r.ltt !'l )
OPERATION HOURS
MONTH rifULER FGIJ SYSTEM UPLRAHILITY 1%)
SOLIDS RECIRtULATIUN RATe. Irit Mil) SYSTL"' AAS DurtN HOST OF DELFMER BECAhSF OF IHtSfc TESTS, ftHlCH
CAUSED TriF LOW UPERABILITY FACTOR.
Ffc'tf. 76 .£9^7 119f> 10
G.M. HAS FOUND SOLIDS CONCtMT RA TI On IN THh Cl.AklFItW TOO HIGH K1K t'FFICTtNT SYSTEM ORF.K Al ION. A.D.
LITTLE INAS SCHEDULED TO CO'MOOCI TESTS OM THE S»Sie*t IN APKJL AS PAfi T Or Ai\ FHA EVALUATION PKUGHAK).
hAH. 7fa U79 dH(l /
APK. 76 10«« tt«7 78
THt LOrt UPE«ABIL1TY INDEX OUklNG THE MONTH n^ NArtCh nESULTtD FKUM EXTENSIVE MODIF 1C AT IONS PEhFORtoFl)
ON THF SYSTEM bY 6.M. OOWTNG THIS PERIOD THE SLMOH6FK 6Lu«HuOwN Ai\iO SCrtOUciEK FLOW lull) ICAT ION SYSTEM
rtAS hEVISEO. FHOM APRIL 11 10 THE t.MD OF I Ht MOi\,Tn 1 HE SYSTtM fliAS OPtHAdLt 100%. OURlfiG THIS
PEWIOO ALL SYSTEM MODIFICATIONS WEKt COMPLETED AiMD ALL MAJOR PK08LEM ArtEAS CuRSECTED.
MAY 76 Ua9 lu«£ 91
JUIM. 7o 9
-------
STATOS A3 UF 07/30/76
SECT KIN 9 (Cni'iTIMuPo)
HFKFURMANCE DESCRIPTION Km UPt k«T l,l,-.«L FG,, SYSTEMS ON INDUSTRIAL BOILERS
GFivEKAL MlirOKS CORPORATION; HAKMA, (JHlu ICON I IhillEO)
OPERATION HOUWb
MUivTM uCHLER FGO SYbTEM UPLHABILITY U)
REPLACEMENT OF Ut.MISTfcR PADS.
AliUATOH PROBLEMS.
• HE SYSTEM WAS RETURNS ,0 SERVICE THE SECOND KFEK ,N OCI03ER. F«0 BORERS AND THEIR CORRESPONDING
.CK.mHtKS -EKE PUT BACK IN tHF. GAS STREAM. PRu^MS ENCUUNTtRED STEMMED PRIMARILY FROM A MECHANICAL
COLLECTOR MALFUNCTIONING HtSoLIINS IN EXCESSIVE PARTICULATt LOADING IN THE MODULES ANO EVENTUALLY
LAuSINb WIDESPREAD PL.lbGINU UF Ht LO.ER BUBBLE-CAPt TRAYS. SHUTDOWN AND CLEANOUI OF MODULES PLUS
rtfcHAlKS TO THE MtCHANJCAL COLLECTOR WERE REUUIKED. SYSTEM RES.ART OCCURRED NOVEMBER 8.
«AJOK HOtllFICATIONb FFRFORMEU TO ThF DOUBLE ALKALI SYSrFM DUKlNG THE PERIOD INCLUDED THE INSTAL-
LATION OF A GREAT LAKES PH MONITOR AND CONTROL UNIT FOR THE REGULATTUN OF LIME FEED TO THE RE6EN-
NATION REAC10R-CLAR1FIER UNIT. THIS UNIT EMPLOYS A DIGITAL READOUT AND HAS SCHEDULED FOR OPERATION
SUhETI*E IN NOVEMBER. SUPERIOR CRYSTAL GROWTH OF THE CALCIUM SULFITE/SULFATE SALTS RESULTED BY
KiMNINtt A SEEDING LINF SACK TO THE RfcAC TOR-CLARIFIER UNIT.
NOV. 76 13dl 787 60
uFC. To I5b<) i4<» ?_£
OUKING THE LATTER PART OF NOVEMBER ANO EARLY DtCEMaER, THE SCRUBBERS .ERE TAKEN OUT OF THE FLUE GAS
PATH BECAUSE OF CONTINUED SOLIDS BUTLDUP IN THE MU rA«K. IN ADDITION. SOME PIPING ARRANGEMENTS
-EKE MU()IFIED AND 1 Ht oEAR REDUCER IN THE HlX TANK HAD TU UE RtPLACED. THE FBI) FIGURES REPORTED FOR
THt HO«TH UF DtCtMbEK ARE NO, FULLY HEHREStNT AT IVE BECAUSE IT IS PART OF THE LOCAL UA* CONTRACT THAT
ONLY t,A« PtRSONNtL CAN OPERATE THE FGD SYSTEM ANu mt»tFuRE THE SCRUBBERS COULD NOT BE OPERATED.
JAN. 77 18!>a oOB 3^
FEB. 77 1462 ac<<; bl
THEHt. «AS A FAILURE UF THE AGITATORS AT THE MIX TAUKS. THEY WtRE LATER REPLACED WITH NEW ONES.
fMt PLAN! «AS SHUTOOWN FOR SOME PEKTOl) DUE To CUTBACK UF NATURAL GAS SUPPLY ANO REQUEST TO CURTAIL
fcLECl^ICAL CuNbUMPTIUhl.
APK. 7V 13(JO 11 SB 89
"•'AY II I'ZtZ Hlo q£
bl'ILtC HUUKS WfcRt LOt, UUt TO LUHER I.UAU IN SUMMER.
JU'>l. 77 1180 1'lOi <)U
JI'L. 77 7(lg
-------
STATUS A3 OF 07/50/70
SECT JON "J (CO'iT INuEO)
'JCE DESCRIPTION r()R U P t * A T 1 ON 4 L VGD bY.SItMS DM INDUSTRIAL rtUlLtRS
I:,H.FK<\L .-minus CURPOKA MUM; PAKMA, I.IMIU ICUNI livjtD)
OPfc WAT 10.-1 HOURS)
t-iduTri (JlHLtP KJO SYSTtM OPERABU1TY U)
UtlrlNK THIS LOW-LOAD PtRIOO THt LlMt FEED HUMP A,Ml) LIME FEED LINtS WbRE CLEANF.J. GENERALLY, EVEHY
3IJI-MLK A,M ANiMUAL Ft,D Ol/Et
-------
STATUS AS OF 07/30/7B
SECTION 9 (CONTINUED)
PERFURMANCE DESCRIPTION FUR OPERATIONAL FGO SYbTEMS UN INDUSTRIAL BOILERS
INSTALLATION NAMt
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
COinTKOL PROCESS
NErt / RETROFIT
START-HIP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PARTICIPATE EFFICIENCY
nATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GENERAL MUTORS CuRPORATION
^ONTIAC, MICHIGAN
COAL (O.B1X SULFUR)
ALSO WUUD, PAPER, AND CARDBOARD.
107.300.SCFM (TOIAL - 2 BOILERS)
350,000 LB/HR STEAM (TOTAL - 2 HOILERS).
LB/HR i>T£AM (TOTAL - g BUlLtRS)
2
VO M«v (EUUH/AI.ENT) ; TOTAL - a BOILtRS
PEA800Y ENGIiMFtRING
SOOIuM HYDRUXIuE SCRUBBING
NEn
APRIL, 197b
bYSTLM OPExAFEu TWU MONTHS IN EARLY 1973.
UPERATIUNAL
NOT DETERMlNtD
65X
UPtN LUOP; 50 iiPM
DErtATEKEO SLURRY Tu LANDFILL
5X SuLins SLURRY DEWATtRtD AND TU .L-AUOFILL
CAPITAL: SbOo,uoo imra). THIS is THE"-TOTAL
INSTALLED COST.
BACKGROUND INFORMATION
1HE GENERAL. MOTORS TRUCKS AND COACH PLANT LOCAIED AT PONTIC, MICHIGAN OPERATES TnO BOILERS TU
GENERAIE STEAM FUR PROCESS REQUIREMENTS. BuILEh ,MO. b, INSTALLtD IN 1972 BY ERIE CITY, 13 RATED AT
186 «l" HTU/HR UR IbO.OuO LBS/HK uF STEAM. tJOILtR NO. 8, INSTALLED IN 197d BY RILtY, IS RATED A! 250
MM Htll/Hrt OR200.000 LHS/HR OF STtAM. THt 1-UbL USEu IS CUALtu.Ol X SULFUR), AMD SULID KE"KUSE (PAPER
ANu CARDBOARD). THE PAR TICULA I E EMISSIONS ARE CUNTRULLElJ BY MLCHA.MICAu COLLECIORS SUPPLIED BY ZuRIV
INOUSTKlcS, DESIGNED Tu UPtRAlh AT 93 * EFFUItNu Y, nlTri A PRtSSURE DROP OF ABOUT 3 IN. KIG.
PF.AHUDY ENGINEERING SUPPLIED Two *ET SCRUBBERS IN APRTL 1976, PRIMARILY FOR ADO I T IUNAL PARUCULA1E
CONTKOL. tACH SCRURbEKC Id FEET DIA.X 21. 5 FELT HIGH) CONTAINS 5 IMP I NGF .IE-NT TRAYS AND OPERATES
rillH A L/6 OF b GAL/lOud «LF . I HE SCwimntR EFFLUtNT IS MIXED 1 1 T H CAUSTIC AND MAKEUP «ATER IN A
HUL.J 1 AUK, AND PUHPLO TU A CLARIFIFK. THE UVFRF(.UA IS RECYCLED TO THE SCRUBBER, THUS SIGNIFICANT
SO 2 CONTROL IS -ACHIEVtO. THE UNDERFLDw IS SEnjT Tj A ,,ASTc I RL A T F.,1ENT PLA.MT, AHERE I HE FLYASH IS RE-
MOvhu AMU LANDFILLED. THE EFFLUEiMT 0 1 SC H A Wbt "FKOM IHt rtASTt TRtATMENT PLANT IS 10-23 GPM.
-------
3TAIUS A3 UF
PEKKui'MAfJCt DFSCKHMUH Fl)K UHc H A F I U.iHL Hii) aYjltMS UN I,«UUSI«IAL l
t-El^FRAL rtOTOKS C URPUK A'l I U'M ; POiMTlAC, MICHIGAN ICu.'-f I I rtllcl) )
THE SCKUd8ERS» THAYSr AMD MlaT r u TM TM IOKS I ^<«jIAL VANt FYHF) A^h ALL MADE UK 31bL SS.
DPEKA I I.Vli H1S1 (IKY
2ND UIIARTEH-19/b IliMSIAULt PH CUMlKuL AND rttAh nP WLCHAi\IICAL tUUlPEwENr HANliLINU IHt I-LTASH SLURRY
WE«E MAJOR STARTUP PirOtlLEMS.
3i
-------
STATUS AS OF 07/30/70
SECTION
-------
bTATUS AS UF 07/3U/78
SECTION 9 (COiMT 1-NUED)
JESCHTKUdN I-OK OPERATIONAL FGU SYSTEMS UN INDUSTRIAL BOILERS
l!i,->TALLATUIN NAMt
INbT AULATIuN LUCAT1DN
b-ilURLr CHARACTERISTICS
SOURCE RATING
OH SEPARATE F60 UNITS
E CAPACITY
CONTROL SYSTEM VENDOR
LOlvTRDL PROCESS
HF.V / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOd EFFICIENCY
PART1CULATE EFFICIENCY
rtAIFK MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
COmT-ROL SYSTEM CUST
GENERAL MOTORS CORPORATION
TUNOAA,\DA, .\t>\ YufiR
COAL (1.2X SUI.FllK)
4i?,()UO SCF'1 CTUTAL - 4 BUTLEHS)
36,000 ACFM a «0fa F, FJR EACH OF 3 FGD SYSTEMS
^9,600 ACFM ol iSO F, FOR 1 FGD SYSTEM
jau.uOU L8/HW bTEAM (TOTAL - t BOILEKS)
a
65 MW (EQUIVALENT); TOTAL - 4 dOILERS
FMC ENVlKOivlMENTAL EQUIPMENT
bODIUM HYDROXIDE SCRUBBING
WETRUFIT
JUNE, 1975
OPERATIONAL
90X-V5X (1,000 PPM S INLETJ
*OJt 11.0 LU/HM 8TU AT INLET)
OPEN LUOP
OEnATEriEU SLURKY TO LANDFILL
FLY ASH AND NA£SU3/S01 WASTE LIUUOrt DEWATEKED AND THEN TO
SAUITArtY LANOFILL
CAPITAL: $^,aoo,ooo ti97t)
INFORMATION
THE CHEVROLET DIVISION OF GENERAL MOTORS HAS A MOTOR PROUOUTION PLANT AT TONAWANUA, NEH YORK.
ARE i cuAL-Fiwbo BOILERS AT THE FACILITY WHICH RUKN 1.16 PERCENT SULFUR COAL WITH A HEATING
VALUt OF la,b50 HTU/L'a. TUP TOTAL COAL FfctD RAtt IS 17 TONS/HH WHICH IS F.UUIVALENT TO «12 MM BTU/HR
UF htAf INPUT U« 540,DUO LoS/HR uF STEAM. THE HUILERS ARE RATED AT A TOTAL OF 3£ MW.
uwt SCRUDStR HANULtS 3^,000 ACFM AT 350 t- wHERtAS EACH OF I HE OTHER THREE 36,000 ACFM AT aub F.
IHLHE IS A CYCunNE btFuPE ANU AFIF.K SCRIIBHtR FuR MUST COLLECTION AND MIST REMOVAL PURPOSES, RESPEC-
TIvELY. THF VARIAbLt InROAT VENTURI SCHOBriERS WERt SUHPLltO BY FMC CORP. ThE PH OF RECYCLE
SCRilniiLH LIQUOR IS CuNTRULLED AT 7.0 Ami) A L/S RATIO OF dO GALLONS/1UOU ACF IS USED. PRESSURE DROP
ACrtMbS FACH SCWDBHER IS 10 TIM. /Iti. CAOSTIC bOUA IS ADOEU TO THE SPENT LIQUOR IN A SEPARATE RECYCLE
I AUK. THE BLEED OFF RATE FROM THF RECYCLE TAN* VARIES FROM 25 - 100 GP^. THE DISCHARGE CONTAINS
H. YASH AMD SODIUM SOLFATt. THE FI.YASH IS CONTROLLtO AT LESS THAN U SUSPENDED SuLlDS. THE EFFLUENT
is DISCHARGED TO THE /VASTE TKEAT.»IF.NT PLAI\T AFTER AERATUM. THL AVERAGE INLET CONCENTRATIONS ARE
u.OI l.n/MM 13TO UF SUt AND 1 L8/MM nTu OF PARTICULATE. ThE EFFICIENCY OF S02 REMOVAL IS 90« WHEREAS
IriAT ill- FARTICllLATt KKl-UWAL IS 8UX-9aX.
-------
STATUS AS OF U7/30/78
SFCTIOn 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOK OPERATIONAL FGU SYSTEMS UN INDUSTRIAL BORERS
GENERAL MOTORS CORPORA I ION; IONOWANOA, NEW Yu*K (CONTINUED)
EACH SCRUBBER AND THE CYCLONIC OEMISTEK IS MADE UF 316L SS. PLUME REHEAT IS NUT INCORPORATED
IN THE SYSTEM. THE ENERGY HEQUIREME*TS FOR THE SYSTEM ARE ABOUT 3 - 5 * OF THE FoEL aURNED.
OPERATING HISTORY
3RU ULIARTERM977 AVERAGE OPERABILITY OUKlNS TnlS PERIOD WAS REPORTED TO BE 10UX.
1TH UUARTER-1977 MAJOR PROBLEMS HAVE dEEN PH CONTROL ANO RECYCLE PIPE EROSION. CONTROL
SENSORS/MODULATING MIXER VALVE REPLACED FON PH CONTROL AND CAST IRON PIPE «A5 USED TO
REPLACE SS RECYCLE PIPING. DURING NOV - DEC CONDENSATION FOLLOWING THE OEMIbTER
HAS CORRODED THE STACK LINING. A DECISION HAS BEEN MAOF TO RELlNE THE STACK.
1ST dUARTER-1978 THt STACK, rtAb ,\or RELlNEO.
^NU UI.ARTER-197» ONE MORE CYCLONE WILL BE RETROFITTED AFTER EACH BOILER IN ORDER 10 REDUCE THE
PAKTICULATt LOADING TO THE SCRUflriERS.
-------
STATUS « J UF U7/30/76
bf-CTlOivl ° ( !.(>.•-! T I Will- u)
PERFORMANCE I'JF.SCRIPT lOiv FM* uPr..n AT I'1n«L KJ\I SYSTEMS ili\, IMJUSIRIAL
INSTALLATION NAMt
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
SOURCE CAPACITY
CONTROL SYSTtM VENDOR
CONTROL PROCESS
NEW / rtF.IROFIT
START-UP DATE
CONTROL SYSTtM STATUS
802 EFFICIENCY
PARTICULAR EFFICIENCY
WATER MAKE-UP
SLUnSE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
l,FuRt.I A-PALlF 1C PAPE« CO.
!, K u b 3 E I T i AKl\AnSAS
L-,Ar
-------
STATUS AS OF 07/30/78
SECTION 9 (CDriT 1MUEU)
PERFORMANCE UESCrfrPTIO',. K)K uPEKATIUNAL HGu SYSTEMS ON INDUSTRIAL BORERS
INSTALLATION NAME
INSTALLATION LOCATION
S'luRLE CHARACTERISTICS
d'liiKCe RATING
MjMrttrt OF SEPARAIE FliO UNITS
SHuWCE CAPACITr
LG.Ui?<)L SYSTEM VENDOR
UONTKOL PRUCcSS
nlErt / rJFlROFIT
STAk'T-UP DATE
CONTROL SYSTEM STATUS
SOU EFFICIENCY
SLUDGE nw BY-PRODUCT DISPOSAL
SYSTEM COST
GETTr ulL COMPANY
IJAKF.RSl-" ItLO. CALIFORNIA
COAL (1.1% SULHUiV)
'2,000 SLFM (TOTAL - 6 BUTLERS)
1
30 MA (EQUIVALENT); t> BOILtRS, EACH a) 50 MM 6TU/HR.
FMC tNVlKONHENIAL EOUIHMEMT
SOOIUM CARUO.MATE SCRUBBING
hETROFIT
JUNE, 11n
UPtRATiONAu
90 + X (600 PPM al INLET)
HOLOIN6 PONO FOR EVAPOKATION
10 GPM BLEEDOFF TO A BLOHOOrtlM TANK. THE SLOWDOWN IS THEN
SENT Tu A DISPOSAL POiMD ONCE A WEEK.
CAPITAL: $aoo,ooo (1977). THIS COST INCLUDES THE ABSORBER
MUOHLE, SODA ASH TANK, PUMPS, ANO PIPING. IT DOES NOT
INCLUDE THE STAC*, DUCTING, ENGINEERING. OR OVERHEADS.
OPERATING: «59o,ooo/YR lot 510 OAYS/YW). THIS COST is
EQUIVALENT Tu iO.lb/NM Bill ANO HMCLUuES THE COST FOR
SODA ASH, ELECTRICITY, AND SCRUBBER MAINTENANCE.
BACKGROUND INFORMATION
>,ETTY OIL COMPANY HAS AN OIL SITE NEAR 8 AKE «SF i ELD, CALIFORNIA WHICH OCCUPIES ABOUT 15 SQUARE
MILES. THERE ARE t 3b STEAM GENERATORS; 100 AllH A HtAT rtATE OF 50 MM BTU/riR AND 36 WITH A HEAT
*ATfc OK dO MM bTo/.IR. THE FuEL USED IS CRUDE OIL WITH l.U SULFuR AND A HEATI.MG VALUE OF 6.4 MM
rtTu/bBL. STEAM IS DISTRIBUTED THRUIIGHUlll I HE OIL FIELD BY INSULATED PIPELINES; ANO INJECTED INTO
lilt ulu «ELLS. LONOLNbAIIuN Oh IHt STEAM KEoUCES I ML VFSCJSIH OF THE OIL, WHICH FLOWS FREELY TO
Iht S'lKFACE ALONG WITH THE «AT(;R. THE OIL IS SEPARA.EO FROM WATER BY OECANTATION IN SETTLING TANKS,
A'H) KlIRlHtD BY DISTILLATION IF REUIUREO.
IHc rLUE GAStS (150,000 ACFM fl 500 f) FROM SIX LARGE BOILERS (50 MM BTU/HK) ARE MANIFOLDED
IMO A TRAY ABaORHtR (13.5 FEET DIA A 55 FEET HIGH) AHICH rtA3. RETROFITTED IN JUNE 1977 BY FMC,
Lf.VlKt.'.riLNIAL EliUlPMtNi DIVISION. THE PRJLHSS USE,; IS SoDiUM CARBONATE SCRUBBING. THE LUUOR IS
.•lAiMAi,.tD Al A PH Ol- b.», AND REC IRCIJL A T ED ,V I] H A I./G RATIO Of b.
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STATUS AS Of 07/i()/7B
SFCTIOlM 9 (CU.JT J.XJFM)
PfKFuRMANCt DESCRIPTION t-0* uPt X AT I [j.\, AL FUO SYbTt^S ON IM'JSTHIAL BOILERS
IJMTY J!L COMPANY; *AH AiMO LtVtL CONTROLLFwS.
4Th i,'!.IAKIEK-1977 TtiF. FAN ROToR *AS S T Rt NliT HEnEu AiviO CLEANED JF THE SCALES. THE FAiM BEARING BURNED
UP. II WAS REPLACED AND THE FAN WAS REALIGNED.
1SI uli«KIEk-197» HlbH SIACK DISCHARGE VtLUCITY ihO FPS) CAOb.FO BY SMALL STACK DIAMETER; AND POOR
LUCA1IO-J OF MIST ELIMNATOK Cl 00 CLOSE To bTACK TRAMSIIION SECTION) RESULTED IN HIbH ENTRAINMENT OF
URUPLFfS. THF STACK Awn TOP SECTTUM 01- I'Ht SCRUrilttH WERE REDESIGNED.
c!'Mli UIIARTFR-197U THt MESH OLMISTEn ftILL BE REPLACED BY A MUUTEHS CHEVERON TYPE MIST ELIMINATOR.
A MiLM F-LFXITRAY WILL BE INSTALLED AoOvf THF PK£bEi\lT 3RD TKAY IN JKDtR Tu IMPROVE S0£ REMOVAL
tF-r TCItA-'CY, PAKilCOLARLY DURING IiJKNuOnN CoNIjTIIuNS. IHt PH PROBES ARE FOOLED FREljUENILV. SEVERAL
lYpfc OF CONTROLLERS ARr. PWtStNtLY tiUNi, IFSTtD FOR HIGH RELIABILITY. THE MlLO STEEL REC I HCUt AI ION
LliMFb rtFKE EKOuEU, AND WILL BE RtPLALFu oY 31hL SS. THE AIR BUBBLtR IN SOOA ASH TANK LEVEL
CdiMlKOLLtK IS OFIEN PLOGUEl). IT ill U L BF. RtPLACEO BY A DIAPHRAGM TYPt LEVEL CONTROL DEVICE. THE
ril. urti;0,i|i-' TANK OUTLET LINE nAj OEVELOPEO SCALING. A POSITIVE DISPLACEMENT PUMP WILL 8E INSTALLED IN
MIS I. IVt, AND flN !NhIBITO« MAY UE AlJDtH IN THt I ANK LIOUOK.
bl
-------
STATUS AS OF 07/30/70
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL EGu SYSTEMS UN .INDUSTRIAL BOILERS
INSTALLATION NAMt
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
HllMHEW OF SEPARATE FGD UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NF.w / RETROFIT
START-UP DATE
CONTROL SYSTEM S1AT.I.IS
S0£ EFFICIENCY
PART1CULATE EFFICIfcMCY
rtATER MAKE-UP
SLUDGE" OR BY-PROOUCT DISPOSAL
CC/NTROL SYSTEM CUST
GREAT SOUTHERN PAPER CU.
CEOAR SPRINGS, GEORGIA
tiARK AND CuAL UR OIL C1.OX-2.0* SULFUR)
420,bOu SCEM (TOTAL - i BOILERS)
S
100 MW (EQUIVALENT); TOTAL - 2 TOILERS
AIRPUL INDUSTRIES
CAUSI1C AA3TE STREAM
RETROFIT
1975
UPERATIONAL
85Jt-^Oi! (1,000 PPM AT INLET)
99.1% (DESIGN: a.5 GR/SCF AT INLETJ
UPEN LOOP; 3iO - auO GPM PEK AriSuRdER
rtASTErtATER TKEATilENT AND DISCHARGE Tu KlVER
CLARIFICATION FOLLOWED 8Y PONDING ANO DISCHARGE TO RIVER
CAPITAL: sooo.ooo (1974). THIS is THE EQUIPMENT CUST FOR
THE TWO SCRUBBER MODULES.
UACKGKOUNu INKOKMATION
THE FGD SYSTEM AT GREAT SOUTHERN PAPER AT CtOAR SPRINGS, GEORGIA CONSISTS OF TWO AIRPOL SODIUM
SCRUBBING -TRAINS CONTROLLING EMISSIONS FROM I Wu COAL-FIRED BUI|_ERS, EACH RATED AT 50 Mw
(EUUIVALENT) AND EACH PROOUCINb bOO.OOO LB/HR STEAM. THE FUELS f IREU IN THE 80ILEHS TYPICALLY HAVE
THE FOLLOWING SULFUR CONTENTS: CUAL - l.b% , OIL - 1.5*. AND BARK - d.0%.
THE STAINLFSS STEEL SCRUBbERS HANDLE A COMBINED TuTAL OF VOO.OOO ACFM AT 42b DEGREES F. THE
PRESSURE DROP ACROSS A SCRUrtilER IS AHPROX IM A TEL Y 7 INCHES rt.G. WITH db To 90% SULFUR DIOXIDE
REMOVAL EFFICIENCY. THE SULFUR CONC t N T R AT I ON OF THE FLUE bAS IS 1000-1200 PrK A^D-THE PARIICULATE
LOAD ING IS 4.5 GR/SCFD.
THE SCRUBBER UNDERFLOW IS CUMPOSEO OF FLYASH ANu SODIUM SULF I r E/ SULM TE SoLUTIUN. SOLIDS
CONTENT tFLYASH) IS IYPICALLY i TO S X BY HEIGHT. SCRuBdE'R WASTE «ATEK fllfH AN AVERAGE PH OF 4.5
IS PuMOEU ANO CLARIFIED WATER IS RETURNED TO THE RIVER.
OPERATING HISTORY
•4TH IJIIARIFH-1977 THE EXPANSION JOINT 6F.lrtc.KN 1 HE EXISTING STACK AND SCRUHrtER HAD TO HE REPLACED
IN SEPIFMBtK. SOME iNIE'RNAL WEAR ,-, A S UFltCItO On I Mr. PMMPo DUE TO TnE ASH CUMTEivT.
ERUSKMv ANU PLUGGAGE PROBLEMS rtlTH THE PH HROBhS HAVE BHEN ENC UJN T t RED . THE PLANT WAS IN
THt PROCESS OF CHANGING IHE CONTROL PH AND MUVING THE PKOBES. IAMKS AMD NECESSARY
-------
STATUS AS JF U7/JO/7S
SECTION ft HH T I ll.J AL hRu SYi'L-tS ON IM1USIW1AL
bHtAT SOUTHERN PAPfH CO.; tl-liAK bPi
-------
STATUS AS OF 07/30/78
HF.kFllR.'IAnCt UE.j
l'Jbl ALLA I IljN NAMt
IMSTALl-ATIliN LOCATION
£>oi)f.R TREATMENT AND DISCHARGE TO RIVER
-------
STATUS AS OF 0?/Ji)/7S
ShCTlON 9 ICHitTINUFl))
PERFORMANCE DESCRIPTION FOR OPERATIONAL FRiJ SYiiTtMS
I'JDUS|RI»L TOILERS
INhTAI LAI IUN NAMt
Pi.STALi.AT ION LuCATl(nX thua PPM n) INLLT)
90X
«ASTt«ATtR TREATMENT AND DISCHARGE TO CIIY SEWER
bLtEu-UFF STKEAM TO HOLDING TANK
CAPITAL: $^2.4,000 (tvr.4). THIS is THE TOTAL INSTALLED COST
OF THE FbD SYSTEM.
OPERATING: sio,2uo/YK. THIS INCLUDES ELECTRICITY.
MAI,\llENt'.Ct, LA8UR, AND MAIFKTAI.3.
BACKGROUND INhOKMATlOM
THt GREAT •rtESTER^ SUGAR COMPANY HAS two COAL-HRtn BUILEKS AT THE FIIMDLAY, OHIO PLANT. EACH
iJfilLtK IS RATFU AT bO.OOu LBS/hR nh STtAM; AND BURNS COAL rtlTH 1.2 PERCENT AVERAGE SOLFUH, 9.2
PthfENT AVERAGE ASH, AND A HEATING VALUE (IF 1 2 , 7 1 b RTII/Lb. THE SUGAR FACTORY IS OPERATIONAL ONLY
i MONTHS OF EVERY YEAR, UURINb THE FALL UUAKTE'K.
TnF Fi,0 SYS1EM »iAS REMOFlTIEl) IN OCT. 19V« AS A PROPRIETARY DESIGN PRIMARILY FOR PARTICOLATE
Cl.iNlKdL. THE FLUF GAStS FROM TWu BdlLtWS I 1^0,000 ACFM at bib F) PASS THROUGH rtUL T ICLONES , *i»D THEN
AWE strrjT THROUGH A VENIORI SCRUB«EK, WHICH OHEKAIES WTIH A PRESSURE DROP OF ? IN. OF WG AND L/G
VALOt
-------
STATUS AS UF 0 I /la/7 a
SFtTIUM g (CONTINUED)
PERFORMANCE DESCRIPTION FUK OPERATIONAL. HGU bYSTEMS ON INO.JSIKIAL HQtLEKS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FbD UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
•Mfrt / RETROFIT
START-OP DATE
CONTROL SYSTEM SI AT US
S02 EFFICIENCY
PAKTJCULATE EFFICIENCY
SLUDGE Ok bY-PROOUCT DISPOSAL
CONTROL SYSTEM COST
GREAT WESTERN SUGAR
FONT M,uRGAl\i, COLORADO
COAL (i.c;x SULFUR, AVKRAGEJ
65,230 SCFM (TUTAL - 2 BUILERSJ
100,uoo AChM EACH nj aoo ^ (TOTAL - a BOILERS;
25u,600 LHb/MR STEAM ((OTAL - d UOILERbJ.
?
38fa MM HTU/HR, 31 MW (cQIJH/ALEI»T; ; TOTAL - 2 BOILERS
bRtAT WFbThRiM SUGA'K"
A'MMDMA-LAUEN HRuctSb «ATPK
R'EIKOFll
OCIObER,' 1^76
OPERATIONAL
481 I3ot)-tf00 PPM a)
V5% (750 I.BS/Hri
WASTEWATtR TKtATMEfJT AND DISCHAHbE TO
CAPITAL: S7o?,ooo iis?o.). THIS is TOTAL INSTALLED COST
OF THE ?UD SYSIEM*
UPERATlMt,: $8H,200/YK THIS INCLUOfiS ELECTRICITY, STEAM,
MAlNTEUEiMCtv LrtHOR, AMU.. MA TE,R TALS .
fiACKGROUNu INFORMATION
THE GREAT WESTERN SUK«R COMPANY HAS Iwu COAL FIRED BuILEftS AT TH£I« FORT MORGAN, COLORADO PLANT,
EACH HUILER IS HATEU Al i8si000 LBb/HR OF STfcAM; Am. BURNS CUAL «ITH 0.5a PERCuNT AVtRAGt 3ULFUR,
8.7 PERCENT AVERAGE ASH, AND AN AVERAGE HEATING VALUE OF 10,17D dTU/LB. THE SJG«R FACIOrfY IS OPER-
ATIONAL ONLY 3 MONTHS, OF EVERY YEAK, DURING THE FALL QUATEK.
IHt ,-Gl) SYSTEM WAS RETROFTTTEO TN Off. '76 AS A PHOPHIETARr UESiliN PRIMARILY FOR PARTIC04.ATE
CONTKOL. THE FLUE GASES FKOM EACH HOILER UOO.fluO ACFn a) 400 (- ) PASS THROUGH ,-IUL T ICLO,.£S, AM) THEiM
Ai?L SfNT THROUGH A VENIURI SCRUHBFR, WHICH OPERAIES rtliH A PRESSURE IJROP OF b IN. OF *G ANO L/G
VALUt OF » GAL/1000 ACh. The SC«UbHERb ARE MlLLO-VtD RY A COMMON VESSEL «H1CH CONTAINS A SlNGLt-
PASS, THREE. StAGE CHEVtRON OEMlSffK. *ASH WATtR KLOB ,n TnE DfcMIstEK IS 120 SHM. nITH A FhtoUtNCY
OF tb MFNUTES EVERY 8 HOuRS. 1 HE PKhSSUKt OhOf ACROSS OtHISTEK IS 0.5 l«. OF *s. A CONSTANT dLtEu-
UFK STREAM OF bOU GPM FROM EACH SCRUtiHtR IS SENT To A POND, WHICH OVERFLOWS INTO ANOTHER HOLDING
pown.
(HE VENTURl SCRUbhER, [HE PLUG, liEMISTfcK VESSEL, AW. THF. DtMlSIFK ARE ALL MAUE OF i t oL SS.
-------
STATUS AS OF U7/30/7B
SFCTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION F OK uPK RA TI O.MAL KUU SYbTEMS UN INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHAKACTERIST1CS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
SOURCE CAPACITY
GRtAI WfcSTtRm SUbAR
GF-KlNG, NEoRAStsA
COAL (l.dX SULKIJR, AVERAGE)
110,OOU SCFM (TOTAL - 2 BOILERS)
97,000 ACFM EACH 3 4bO F (TOTAL - 2 BOILERS)
205,000 LBS/HR S1EAM (TOTAL - 2 BOILERS)
2
«!Q.5 Mft (TUTAL 1 - 15, 1 - 5.5 BOILER)
21B MM RTU/HK (TOTAL), 21 MW (EQUIVALENT); TOTAL - 2 BUILF.RS
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-OP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GREAT WESTERN SUGAR
AMMONIA-LAOEIM PROCESS HATER
RETROFIT
OClOfaEK, 1975
OPERATIONAL
70% IfeOO PPM o") INLET)
WASTEWATER TREATMENT AND DISCHARGE Tl) RIVER
EFFLUENT TO HOLDING POND
CAPITAL: $613,000 cms). THIS is TUTAL INSTALLED COST
UF THE FGD SYSTEM.
OPERATING: i3«,6oo/YK THIS INCLUDES ELECTRICITY,
CiAIMlENENCE, LABOR, AMU MATERIALS.
BACKGROUND INFORMATION
THE GREAT WESTERN SUGAR COMPANY HAS TWO COAL FIRED BOILERS AT THEIR GEN ING, NEBRASKA PLANT.
BOILER *i IS RATED AT 150,000 LBS/HR OF STEAM AND WAS SUPPLIED BY ERIE CITY IN 1963, WHEREAS BOILEH
#2 IS RATED AT 55,000 LB/HR OF STEAM AND WAS SUPPLIED BY ERIE CITY IN 195
-------
STATUS AS UP 0//iO/7
llM u UOM JMJtU)
HF.hFUPl..«MCt UFbrMPTION K)h l.PtRATlONAL HJI) SYSThMS ,)M INDUSTRiAL bORERS
ii«tA| rtFiTtftlv. bUoAk! GtWlMb, l\itBKA.SK», I f Ul\i I IMtt i) J
IHt SGKiltiBfcR fFF-LUtNl, 700 GPH FhOH tAtH SCPUHbFk iS Stt-iT TO A HuMU.
IHt VENTUK1 SCKUBBtHS,, VARIAnLt uT.MEUR PLUbbr LtHlbTtK VbSSfL. AN[) THE DtMISTF.H Akt ALL MADE
UF 3U'. 1. SS. Tht IOIAL- 1MSIALLEU CO&T Of IHt. vEMUPI bCkUbBER SYSTEM *AS 46<.3fOuO 1 ,M !975 DOLLARS.
IHt UPtSAT-ItoK COST F0(- THE SYSTH-I IS S3«,by(i /YR.
-------
STATUS AS UF
SECTION <) CCONT1NUEU)
PERFORMANCE INSCRIPTION FOR OPERATIONAL FGO SYbTtMS UN INDUSTRIAL bUILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
MJwhER OF SEPARATE FGO UNITS
COMTKOL SYSTEM VENOOh
LONTKUL PROCESS
!M£n / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S0
-------
• ST«TUS AS UF (ty/jl)/7a
SFCTJON 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOK UPtkAUGNAL Ffiu SYSTEMS UN TNDUblhMAL UOiLtHS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
CUNTKUL SYSTEM VENDOR
CONTROL PROCESS
NEK / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOd EFFICIENCY
n/UEK MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GREAT AtbTtKW SUGAh
LOvELAMJ, COLORADO
COAL u. dx SULFUR, AVERAGE)
l£l,faOO SCFM (IOIAL - d BOILERS)
100,000 ACFM FACh a) nil) F
100,000 LBS/Hf. STFAM (TOTAL - d
GREAT WESTERN SUGAh
AMMOMA-LAUEtN HRuCtSb WATER
kFTROFIT
OCTOBER, 197i
OPERATIONAL
30i (.95 Ld/MM BTll i) TNLETJ
BOO GPM (PROCESS CUNUEuSATE hAIFK, HH=O.7, L/G=flJ
wASTtwATtR TREATMENT AND DISCHARGE TO RIVER
EFFLUENT STREAM 10 HULUING POND
TOTAL UlbTALLEU COST fijK THE TnO SCkUBBFKS, NEW BREECHING,
CAPITAL: sijo.ioo 11974). THIS is TOTAL INSTALLED COST OF
THt F60 SYSTEM, l.D. FANS, AND WATER SYSTEM
THE FGU SYSTEM.
'OPtR*TlJ»b: »b«,fl-oO/Yh THIS INCLUDES ELECTRICITr, STEAM,
MAINTENENCE, LABOR, ANU MATERIALS.
BACKGROUND INFORMATION
THE GREAT WESTERN SUGAR COMPANY HAS Twu cOAL FIRED BOILERS AT THEIR LOvELAND, COLORADO PLANT.
EACH HolLER IS RATED AT 12i,000 LBS/HR OF STEAM; AND BURNS COAL WITH 0.5d PERCENT AVERAGE 5IILFUH,
•».-* PEKCENT AVERAGE ASH, AND AN AVERAGE HEATING VALUE uF 10,i«b BTU/LB. TnE SUGAR FACIORY IS OPER-
ATIONAL ONLY 3 MONTHS UF EVERY YEAR, DURING 1 HE FALL OUAKTER.
THE FGD SYSTEM WAS RETROFITTED TN OCT. '7« AS A PROPRIETARY DESIGN PRIMARILY FOR PARTICIPATE
CONTROL. THE FLOE GASES FROM EACH BulLER 1100,000 ACFh tf alo F) PASS THROUGH CYCLONES AND ARE MIXED
IN A COMMON DUCT, AND IH£N SENT THROUGH IKU VENTuRJ bCRUbBERb, WHICH OPERATE WITH A PRESbURt PROP
OF 7 I,,. OF KG AND L/G VALUE OF 7.i GAL/1000 ACF. THE OPERATING GAS VELOCITY AT THE VtMUKl IM.ET
IS Hi HPs. THE SCRUBBERb ARE FOLLOWED BY A UEMSTER VES&FL WHICH CONTAINS AN ONE-PASS, i-HKEE STAKt
LHtVERON OEMISTER. ftASH WATER FLUn 1C) THE PEMlSIfk IS ItO GHM, ftlTH A FkEUUENCY OF Ib MIN'UTh.b EVERY
« HOURS. THE .PRESSURE DROP ACROSS PEMISTEk IS O.S -I |v. C)F f,G. THE EFFLUEM STREAM FkUI. EACH SCf-'UH-
UER, 7iO GPM, IS SENT TO A PuNu, WHICH (WERFLOwS INTO ANOTHER HOLDING PONP.
70
-------
STATUS AS OF 07/30/78
SECTION 9 (CONTINUED)
PERFORMANCE OESCKIPTION FOX OPERATIONAL F6D SYSTEMS ON INDUSTRIAL BOILERS
GREAT nESTERN SUGAR; LUVELANu, COLORADO (CONTINUED)
THt VENTURI SCRUBBERSi VARIABLE DIAftTER PLOGS, DEMISTER VESSEL. AND THE ['EMlSTEk ARE ALL MADE
UF 31h L SS. THE TOTAL INSTALLED COST OK THE VENTURI SCKUbSER SYSTEM WAS SliO.SOO IN 197fl DOLLARS.
THE OPERATING COST FOR THE SYSTEM IS $8«,1UO/YR.
-------
STATU? AS UF 07/30/78
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTtMS UN INPUSTRIAL BQILfckS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE F6D UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEft / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PArtTICULATE EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GREAT WESTERN SU6AK
SCOTTS BLUFF, NEBRASKA
COAL U.2X SULFUk, AVERAGE)
65,230 StFM (TOTAL - 2 BUILEKS)
130,000 ACFM tACH al «00 F (TOTAL - ? BOILERS)
300,(iOO LBS/HR STEAM (TOTAL - f BOILERS)
a
30 MIN (TOTAL 2 - BOILERS)
315 MM BTU/HR (TOTAL), 31 Mfc (EQUIVALENT); TUTAL - 2 BOILERS
GREAT WESTERN SUGAk
AMMONIA-LADEN PROCESS WATER
RETROFIT
OCTOBER, 1975
OPERATIONAL
35% («00 PPM a INLET)
-------
STATUS AS OF U7/M>/7b
SECTION 9 (CONTINUED)
DESCRIPTION FOR OPERATIONAL KH> SYSTEMS Ofo IM'UST (• IAL BUlLfcRS
^Rcftl .,'F-bTtRN SUbAk; SCOTTs ciLUFF, MtC'KASKA iCbNTTNUtD)
IHfc VENTURI SCHDBHtRS, VARIABLE DIAMETER PLUGS, UEMISTER VESSEL, AND THE PEMIS1EK AKt ALL MADE
OF 316 L SS. THE TOTAL INSTALLED COST OF THE VENTUR1 SCkUBBER SYSTEM ftAS $7t«,000 IN 197tt DULLAKS.
THE uP£«ATIN6 COST FOR THE SKSTEn IS $108,100/V«.
-------
.STATUS AS UF 07/JO/7B
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGU SYSUMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEn / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PARTICIPATE EFFICIENCY
IVATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTtM COST
IT1 RAYOMER, INC.
FERNANDINA BEACH, FLORIDA
BARK AND OIL (£* - 2.5% SULFUR)
201,001) SCFM (TOTAL - £ BOILERS)
a
100 MW TOTAL - « BOILERS; EACH BARK BOILER HAS A SCRUBBER
AIRPOL INDUSTRIES
SODIUM HYDHOXIDF SCRUBBING
RETROFIT
1975
OPERATIONAL
80% - 85% (I,?00 PPM A'l INLET)
97X (1.7 GK/SCF AT INLtT)
OPEN LOOP
rtASTEWATER TKEATMENT AND DISCHARGE To TAILINGS POND
DUCTWORK, AND STACKS.
CAPITAL: $500,000 tmb), CUST is FUR s SCRUBBERS,
DUCTWORK, AMD STACKS.
BACKGROUND INFORMATION
ITT RAYONIER OPERATES AN AMMONIUM-BASED SULFITE PULP MILL IN FERNANDIMA BFACH, FLORIDA.
THERE ARE FOUR PROCESS STEAM BOILERS OPERATING IN THE FOLLOWING MAiMIMtR:
NO. 1 - 100,000 LB/HR STEAM- FIRES FUEL OIL (NO. 6)
NO. 3 - 1 USE IT
FOR THtlK SODA BASE. LONDdNSATE STEAM Is BF.ING RtCYCLtD AND USEu FOR SCRUbRHG HURPUSES.
-------
STATUS Ab UF D7/jU/7b
-------
STATUS As OF Oi/SO/Ttt
SECTION 2<> MM IS FOR POLLUTION CONTROL
EQUIt-rtENT, AND S16 MM OF THAI IS FuR POfctR PLANT WITH ITS
KELATEO POLLUTION CONTROL APPARATUS.
BACKGROUND INFORMATION
KEKR-MCGEE CHEMICAL CORP. HAS A NEW l.J MM TuN/r* SOOA ASH PLANT AT 1RONA, CALIFORNIA. THE
PLANT, LOCATED ALONG THE SHORE OF SEARLES LAKE, IS TnE LARGEST Y£T BUILT TO YIELD SUUA ASH BY DIRECT
CAhrtONATION OF BRINE AND ^AS CUMMIbSlONEo IN JUNE 1978. THt PROCESSING HVNUVATIONS, tvHICH
HAVE IMPROVED THE PLAM EFFICIENCY, INCLUDE CAR80NATION UNDER 13.5 L8/56. IN. PRtSSUKE, USE OF
A COAL-FIRED PO«tR PLANT, AND RECOVERY OF CO* MOM THE FLUE GASES.
THE PLANT HAS uo BOILERS, EACH RATED AT ^ Mft. «HTCH PROUOCE PROCESS SIEAM AND ELECTRICITY.
EACH BOILER PROOOCES 6^0,OuO LdS/HK OF STEAM AT 1SOO PSI AND 8oRNS A *[XTUKE OF WESTERN COAL
(0. ! PERCENT SULFUR) A.^0 PETROLEUM COKt (l.b PfeRthNT SULFUR). THE HItH SULFOf- CoKE IS MIXED IMTH
IHL CI.AL I:. OROER TO I«PKOVE TnE PART1CAL IGNUAtluN A,vO IN TORN FLY-ASH COLLECTION IN THE ESP
.'.MiCri OPERATES ON THE uOLD SIDE OF THE P*FHEATER AT 98.5 PtRCENT EFFICIENCY AMJ iOO F. THE FLUE
bAS HLO. RATt FRUM EACH BOILER IS 363,u«u ACFM A) 3^0 f AM, MAY CONTAIN SOc' bMNLEN i3b TO 5985 PPh
7fc
-------
STATUS AS UF 07/30/76
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOk OPERATIONAL FGu SYSTEMS ON INDUSTRIAL BOILERS
KFRR-MUGtE CHEMICAL COKP.; TrtONA, CALIFORNIA (CONTINUED)
UEHEMHNG UPON THE FUEL. THE AIM POLLUTION REGULATIONS DICTATE THAT EACH BOILER MAY RELEASE NOT
wtjKh TnAi\ 10 LbS/HR PARTICULATE, 200 LBS/HK OF SU2 AND IflO LbS/HR OF NOX.
IHt FLUE GASES ARE SCRUBBED bY THE END LIQUOR FRuM THE SODA ASH PLANT IN TWO SCRUBBERS
130 FT DIA X Ji FT HICH EACH] WHICH ARE MILD STEEL VESSELS KITH FLAKE LINING AND POLYPROPYLENE SIEVE
TKAY8. THE TOP TRAY RECEIVES PLAIN WATEK WHEREAS THE SECOND T*AY RECEIVES THE RECIRCULATING LIQUOR
AT CM OF 6 - 6.5. THE SPENT L13UOR FROM THE BOTTOM OF THE SCRUBBERS IS HEC IwCULATED BY RUBBER
LINED PUMPS TO A MILD STEEL SURGE TANK WHERE FRESH END-LIQUOR IS ADDED TO IT WITHOUT AGITATION. A
BLEED OFF STREAM IS CONTINUOUSLY TAKEN BACK TO THE SALT PONDS.
THE BOILER 1.0. FANS (1600 HP.) FORCE THE GASES THROUGH THE SCRUBBERS AND EXPERIENCE 6 IN. WG
PRESSURE DROP. THE FANS HAVE MILD STEEL CASING. 1 HE DOWNSTREAM DUCTWORK IS MILD STEEL WITH FLAKE
LINING WHEREAS THE STACK IS CONCRETE WITH FRP LINER. AMdIENT AIR IS HEATED IN AN EXTERNAL
STEAM HEATER AND MIXED WITH THE EXIT FLUE GASES TO INCREASE THE TEMPERATURE FROM 125 F Tu ABOUT
175 F. AT MAXIMUM LOADING, THE SCRUBBERS HAVE A SU8 REMOVAL EFFICIENCY OF 9B PERCENT. THE SCRUBBED
FLUE RASES WILL 13E PROCESSED THRUUUH TWO MONOET HANOLAMINE (MEA) PLANTS FUR EXTRACTION OF C02. EACH
PLANT WILL PRODUCE 300 TONS/DAY OF C02 AND WILL BE THE MAIN SOURCE OF MAKEUP C02 IN THE CARBONATION
PLANT.
OPERATING HISTORY
1ST QIIARTER-1978 THE MAJOR CONSTRUCTION WORK (VAS OVER. PRECOMMISSIONING ACTIVITIES V»ERE UNDERWAY.
THE PLANT WAS PROJECTED TO GO OlMSTRtAM tiY APRIL 1. 1978.
2ND UlllARTER-1978 THE FGD SYSTEM WAS COMMISSIONED DURING THE REPORT PERIOD. THE BOILERS WERE RUN
TO FULL CAPACITY WITH 100 X OIL FEED. COAL AND COKE WERE USED UP TO 80 X OF THE FUEL. 1 HE MAJOR
STARTUP PROBLEM WAS FRAY TIEOOrtN. THE POLYPROPYLENE SIEVE TRAYS WERE NOT STRONG ENOUGH TO TAKE THE
LOAD OF INVENTORY LlUUIO. THESE WILL BE REPLACED BY 31faL SS OR A HIGHER GRADE ALLOY. ThE PRESENCE OF
CHKOK.ATE IONS IN THE MAKtUP WATER CAUSED SOME CONCERN.
77
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•STATUS AS OF 07/30/76
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGu SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENOOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S0£ EFFICIENCY
PARTICIPATE EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
MEAD PAPERBOARO CO.
STEVENSON, ALABAMA
OIL (1.5* - 3X SULFUR)
100,000 ACFM 3 450 F (TOTAL - 2 BOILERS)
1
SO M(V (EQUIVALENT); TOTAL - TfcO BOUtRS
AlkPOL INDUSTRIES
SODIUM HTDKOXIDE SCRUBBING
NEW
1975
OPERATIONAL
95* (1,500 PPM S INLET)
90%
ALKALINE SULFITE/BISULFITF. RECYCLED TO PULP PROCESS
RECOVERED SOLUTION USEj AS MAKE-uP TO COOKlNb LIuUOR IN PULP
MILL.
CAPITAL: $173,000 (197*1). THIS *AS THE ORIGINAL
EQUIPMENT ANU INSTALLATION COSI. SINCfc IHfcN EXTENSIVE
MODIFICATIONS HAVE BtEiv REQUIRED. ANOTHER 173,000 WAS SPENT
FOR REPAIRS ANU UPGRADING IN 1976. UVER THE SCRUBBER PLANT
LIFE, AN ADDITIONAL 136,000 HAS BEEN SPENT, INCLUDING:
35,000 (RUBBER LINERS), 51,000 (STAINLESS STEEL LINERS),
AND 47,000 (GENERAL REPAIRS).
OPERATING: s
-------
STATUS) *S OF G7/31I/7B
SFCTIOlv 9 ICONTlMjFti)
PERFORMANCE DESCRIPTION F OK OPERATIONAL H-u SYSTtMS UN TivDUfrT >• 1 AL BOILERS
MEAD PAPtRSOARO CO.; STEVENSON, ALAHAMA (COM li'vUtl'J
THE ABSORBER SECTION AND PASSES UP -THROUGH THREE V UBBLt-C AH TR* Yb. A SClilU^ CARbONAlE SOLUTION IS
INTRODUCED THROUGH A BANK OF 1.5 INCH NOZZLES W> SPIM VANtS. IhF GAS FXI1S THROUGH A FIBERGLASS"
STACK. SCRU3BER EFFLUtN] 1600 6PMJ , MuSTLY SOuIuM SuLFITE, IS ScNT 10 ThF MILLS PULPING OPERATION'S
FOR EVENTUAL USE IN 1HE DIGESTERS. PH IS CONTROLLED Al 7.U-b.i> IN THF. REC IRtMLAT ION 1AMK.
THE S02 SCKUBtJlNG SYSTEM WAS DOftN FKOM MAnCrt IHKOUGH JULY 197fe DUE 10 AtikASJO^ PROBLEMS. TnE
A8KASION WAS CAUSED PARTIALLY &Y HIGH STKEAM VELOCITY IHKOU&M THE tXISIEM VEMOKl PARIltULAH
SCRUBBER I«TO THE S02 SCKOUBER. SODIOfi LAr-BONATE AM) CAKROfc PAKTICLES THAT HAD NOT KONt IMl) SOLU-
TION ALSO WERE VERY ABRASIVE TO THE. SO? SCRUBBER HN1MU. IN AOniTION. THE ORIGINAL bLASS-FlAKEO
LINER (5 MM THICK) WAS EXPERIENCING STRESS ChACKlf.b.
THE HIGH VELOCITIES IMTWOUUCEu BY THE VENlUkI hERh ELIMINATED BY kFMOVING THE PAR11C.ULA1E
VENTURI SECTION OF THE SYSIEM. THE KLASS-FLAKtD LINING WAS HAIChED wIlH SbO.DUO WURTH OF
CAKPtNTEH 20 LINER. THESE CORRECTIVE ACTIONS HELPED FOR A WHILE, 8UT AS II 1URNtP OUT, THE CARPEN-
TER <>0 rtAS NOT INSTALLED PROPERLY AMU SOLU1IUN WAS GETTING BETWEEN IT AND THE MILD STEtL SHELL. IT
WAS FINALLY DECIDED TO INSTALL NEW RUBBER LINING INSIDE THE ENTIRE SCRUBBER, INCLUDING THE SPIN
VANES, AT A COST OF *15>0,000. TO PREVENT ANY HEAT PROBLEMS, ADDITIONAL NU2ZLFS WERE 1NS1ALLEO. TO
UATE, NO MAJOR PROBLEMS HAVE OCCURRED KITH THE RUBBER LINING.
OPERA!ING HISTORY
-------
STATUS AS OF 07/30/78
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION F()K OPERATIONAL FGu SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE F60 UNITS
SOURCE CAPAClTr
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NErt / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOd EFFICIENCY
HATER MAKE-UP
SLUO&F OR bY-PROOUCT DISPOSAL
CONTROL SYSTEM COST
MINN-DAK FARMER'S COOPERATIVE
ftAHPETUN, NORTH DAKOTA
LIGNITE 11.OX SULFUR)
160,000 ACHM 5) 3bO F (TOTAL - d BOILERS)
?
ba Mh (EQUIVALENT); TOTAL - 2 BOILERS
1WO BOILERS, EACH id 275,000 LBS/HR STEAM (£50 PSIG - 155 F)
KOCH ENGINEERING
AMMONIA SCRUBBING
RETROFIT
JUNE, 1977
OPERATIONAL
TESTS INCONCLUSIVE.
200 GPM POND WATER
WASTEWATER TREATMENT . .
BLEED STREAM GOES TO AN ACTIVATED SLUDGE SYSTEM a) 160 GPM
CAPITAL: $300,oou (1977). TOTAL EQUIPMENT COST.
BACKGROUND INFORMATION
MINN-OAK FARMER'S COOP. HAS A SUGAR FACTORY AT WAHPElOu, NORTH OAKOTA. THERE ARE TWO BOILERS,
EACH WITH A CAPACITY OF £75,000 LBS STEAM/HR AT dSu PSIG AND «bS F. THE FUEL BURNED IS 1% SULFUR
LIGNITE. SULFUR DIOXIDE REMOVAL IS EFFECTED BY AMMONIA ADDITION TO THt RECIRCULA T ING SCRUBBER
LIQUOR.
KOCH ENGINEERING HAS SUPPLIED TWO SCRUBBERS FOR THE BOILERS EACH OF WHICH GENERATES 135,000 ACFM
OF FLUt GASES AT 350 F. T ME SCRUBBER SYSTEMS ftE.MT ONSTREAM IN JOIME 77. EACH SCRUBBER IS A VARIA8LE
THROAT VENTURI WITH OPLN ENDED PIPE INLETS FOR LIHUID ANo WAS PR1MARLY DESIGrtEU FOR PARTICULATE
CONTROL. THE SCRUBBER LK4UOR IS RECIRCULA1ED AT A RATE OF 800 GPM AND THE BLEED-OFF RATE GOING TO
THt ACTIVATED SLUDGE SYSTEM IS IbO GPM. THE MAKEUP PO.MO WATER FLOW KAIE IB dOO (,P«. THc PRESSURE
DROP ACROSS A SCRUBBER IS 11 IN. WG. IHERE IS Oh.E CUMMON CHEVERuN TYPE UEMISltR AND ONE STACK.
I HE INLF.1 CONCEN1RATION KANGES ARE 76-193 LBS/HR OP M^ ANu .3-.4 GR/SCF OF PARTICULATE. THE OUT-
LET CONCENTRATION RANGES ARE 10-37 LWS/HK AND .027-.030 GR/SCF RESPECTIVELY.
THE SCRUBBERS ANu I HE LluUuR INLET PIPtS ARE MAUL uF ;
-------
STATUS AS OF 07/30/78
SECTION 9 (COM 1NUFD1
PEKFURMANCt UESCKIPTION H>k UPtRATlOuAL F'Gu bYSTtMS ON INDUSt^IAL BlJILtKS
MT^N-DAK FARMER'S COUF't«ATlVt ; (VAHPtTur
-------
•STATUS AS OF 07/30/78
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGu SYSTEMS UN INDUSTRIAL BOlLfcRS
INSTALLATION NAMt
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOa EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
MOBIL OIL COMPANY
SAni ARDO, CALIFORNIA
OIL (2. (1% - 2.d« SULFUR)
182,000 SCFM (TOTAL - 30 BOILERS)
8000 ACFM a 470F, FOR tACH OF d'd FGD SYSTEMS
18,000 ACFM oi <470F, FOR tACH OF b FGD SYSTEMS
30
60 Mn CEUUIVALtNI); btO MM BTU/HR: TUTAL - 3U BOILERS
MOBIL OIL COMPANY
SOUIUM HYDROXIDE SCRUBBING
RE1RUF1I
1971
OPERATIONAL
tOU tlbOo PPM
-------
STATUS Ay UF 07/il'/7u
btLTION 9 (LONT If>uEu)
PERFGRMANCt DESCRIPTION MlK OPfcRATlOKAL hfcii SYSUMS UN 1 NDuh 11-i AL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMMER OF SEPARATE FGO UNI IS
SOURCE CAPACITY
CONTKOL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
STARI-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PARTICuLATE EFFICIENCY
WATER MAKE-UP
SLOOGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
NEKOUSA PAPERS, INC.
AShDGWN, AhKANSAb
LOAL (1X-1.VA SULFlik)
ell,UUO sCfl" Si 3bb F (TOTAL - 1 BOHERJ
I
10U H.W (LfOUlVALFNT) ! DESIGN - bOu,0(!0 LB/HK bTEAH
AlkPCL INni'SIMFS
LAuSTIC bCKUBBiNU
FEbRUARY,
OPERATIONAL
90 + X (600 HPM ill INLET)
9B% - 99* 11.42 GR/SCF Al INLET)
OPEN LIUip
AL^ALINE SULKITE/B1SULFITE RECYCLED TO PULP PROCESS
S0£ RECOVERED FROM SODIUM StILF I TE/SHLFATE LIUUOR AND RE-
CYCLED TO PULP1NU PROCESS.
CAPITAL: Sc?50,ooo 11973). THIS is THE EQUIPMENT COST.
BACKGROONi) INFORMATION
THE NEKOOSA-EDWARDS PAPER PULP MILL IN AShDOrtN, AfiRANSAS HAS TWO AIRPOL SCRUBBERS ON A 50-Mrt
EQUIVALENT STEAM 801LEK FIRED WITH COAL OR FUEL OIL. THE VENlURI SCRUBBERS ARE UESIIiNED TO REMOVE
BOTH SULFUR DIOXIDE AND PART ICULATES. THE IMENI OF NEKOOSA-EDnARDS ftAS TO MAKE, FROM THE SCRUBbFK
EFFLUENT, SALTCAKE WHICH WOULD BE USED AT THE MILL. I HE COAL HAS 1-1.5* SULFUR AND A HEATING VALUE
OF 12,000 BTU/LB. IT IS BURNED AT A RATE OF 27 TONS/HR.
THE SCRUBBER HANDLES 325,000 ACF« AT 355 DEGREES F. SCRUBBER INLET S02 CONCENTRATION
IS TYPICALLY 600 PPM WITH A PART1CULATE LOADINb UF 1.U2 &K/SCFM. RECIRCULATtD WATER IS dLED
OFF AT lbO-250 GPM. REAGENT MAKE-UP AMOUNTS Tu 1 ? LC/hlN OF SODIUM HYDROXIDE. SCRUBBER UlMUERFLUW
CONSISTS OF FLYASH AND A SOLUTION OF SODIUM SULFllE/SULFATt. THE ASh SLUkRY G'UES TO A SETTLING
POND.
THE PREDOMINANT DIFFICULTIES WITH THE FGD SYSTEM HAVE BEEN IwO-FOlD. FIRST, THE PLANT HAS BEEN
UNABLE TO DEVELOP AN ADEQUATE PH CONIROL MECHANISM. THE PH CONTROL SYSTEM MONITORS THE AMOUNT Uh
CAUSTIC AGENT, I.E., SODIUM HYOROXlOfc, WHICH GOES INTO THE RECYCLE TANK, KEEPING THE PH OF THE
SCRUBBER SOLUTION AT A NONCO«ROSIVE LEVEL, THE PLANT HAS BEEN PLAGUED KITH PROBLEMS ii\
OPERATING THE PH CONTROL SYSTEM AND HAS SUFFERED A GREAT DEAL OF CORROSION. THE SECONO PROBLEM
CONCERNS THE CHEMICAL REGENERATION PORTION OF 1 HE SYSTEM. THE INTENT OF THF PLANT WAS TO SEPARATE
THE FLY ASH FROM THE SCRUBBER LIQUID AND TARE THE SCRUbBER LIQUlu THROUGH A SERIES OK EVAPORATORS
-------
STATUS AS UF 07/30/78
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOh OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BORERS
«EM.)USA PAPERS, INC.; ASHDOWN, AKKAMSAS (CONTINUED)
-HtRE SOUIUM SULFAIE, I.t., SALTCAKE. WOULD BE GENERATED. THE PLANT HAS BEEN UNABLE TO OPERATE THE
FLY ASH SEPARATION SYSTEH PROPERLY, AND THERE IS NOT ENOUPH EVAPORATION CAPACITY FOR THE PLANT TO
PROCESS THE SCRUBBER EFFLUENT AT FULL OPERATIONAL CAPACITY.
IN SPITE OF THE OPtRATIONAL PROBLEMS, THE SoLFUK DIOXIDE AND PARTICULATE REMOVAL EFFICIENCIES
UF THE FSD SYSTEM ARE 90 AND 99 PERCENT, RESPECTIVELY, ACCORDING TO 1 HE PLANT ENGINEER. THE WASTE
PRODUCT FROM THE SCRUBBER IS NOT RECYCLED, AT PRESENT, AND IS PUMPED 10 IHE HASTENATER TREATMENT
PLANT. CLEANED WASTEwATER IS RETURNED Tu THE RIVEK.
UPON STARTUP, PROBLEMS OCCURED MTH THE PIPING AND VALVES MICH WERE CONSTRUCTED OF CARBON
STEEL. THE CARBON STEEL SYSTEM WAS REMOVED AND REPLACED WITH STAINLESS STEEL VALVES AND PIPING.
SfME PIPING LEAKS OCCURRED AND WERE REwELDED. SuME CORROSION OF DUCT DAMPERS OCCURED AND WERE RE-
LIEVED 8Y ADJUSTING THE PH OF THE SCRUBBING LIQUOR. THE PH IS MAINTAINED BETWEEN b.5 - 6.0.
THE SCRUBBER SYSTEM OPERATES WITHOUT REHtAT, EXHAUSTING TO A FIBERGLASS COATED STACK. PARTIC-
ULARS ARE CONTROLLED WITH CYCLONES AND TWO VARIABLE THROAT VENTURI SCRUBBERS WITH AN AVERAGE PRES-
SUKE DROP OF 14 TO Ib INCHES W.G.
OPERATING HISTORY
3RD QUARTER-1977 NO MAJOR PROBLEMS HAVE BEEN REPORTED.
CO,
-------
STATUS AS uF 07/30/7B
SECTION 9 (CONTINUED)
PERFORMANCE OESCKIPT ION FOR OPERATIONAL FGO SYSTEMS UN INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMPtfl OF SEPARATE FGD UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
COfcTrtOL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SClc. EFFICIENCY
(-ARTICULATE EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
RICKtNBACKER AIR FORCE BASE
COLUMBUS, OHIO
COAL (i.bX SULFUR)
30,000 SCFM (1 BOILER)
1
20 Mft (EQUIVALENT)
RESEARCH-COTTRtLL/BAHCU
LIMESTONE SCRUBBING
RETROFIT
MARCH, 1976
OPERATIONAL
90* (AVERAGE)
98%
OPEN LOOP - 2.b 6PM/hl» (MAX)
NON-FIXATED SLURRY TU LINED POND
UNSTABIL1ZED CAS03/S04 SLUDGE TO LINED PONU
CAPITAL: $
-------
'STATUS AS OF 07/J50/7B
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGu SYSTEMS 0* INDUSTRIAL BORERS
RICKENBACKER AIR FORCE BASE? COLUMBUS, OHIO (CONTINUED)
SCRUBBER TOWER, LIMESTONE STORAGE AND HANDLING SYSTEM, CLARIFItR, BOOSTEK FAN AND ASSOCIATED DUCT-
WORK, PUMPS, CONTROLS, AND A SLODGE DISPOSAL POND.
SOLID PARTICULATE AND SULFUR DIOXIDE-LADEN FLUE GAS TAKEN FRUM EACH UF THF EXISTING SFVf.N
STACKS IS FED THROUGH A COMMON HEADER AND INTO A MECHANICAL COLLECTOR .HERE PRIMARY PAKTICULATE
REMOVAL TAKES PLACE. 1 HE MECHANICAL COLLECTOR HAS A DESK,,, REMOVAL EFFICIENCY OF ,0 PERCENT AND
WAS INSTALLED PRIMARY TO RtDUCE FAN .EAR. THE .PARTLY CLtANEu GAS THEN FLO.S JNTO THE BACHO ,0WER
WHERE ADDITIONAL PARTICULATE AND PRIMARY SULFUR DIOXIDE REMOVAL TAKES PLACE.
THE BACHO SCRUBBING VESSEL IS A VERTICAL TOWER CONSISTING UF T*0 SCRUBBING STAGES. GAS FLOWS
THROUGH THE TOWER «H£RE IT IS CONTACTED WITH A LIMESTONE SLURRY. AFTER PASSING THROUGH THE
FIRST SCRUBBING STAGE, ENTRAINED MOISTURE IS REMOVED BY A CYCLONIC TYPE MIST FLIMINATOR. THE
GAS THEN PASSES THROUGH A SECOND SCRUBBING STAGE AND A SECOND CYCLONIC MIST ELIMINATOR. THE
CLEANEU GAS IS DISCHARGED TO THE ATMOSPHERE THROUGH A STUB STACK ATOP THE ABoORBER ToWLR.
FINE MESH LIMESTONE IS EMPLOYED AS THE REAGENT IN THE SCRUBBING SYSTEM. THE SCRUBBING SLURRY IS
THEN PUMPED TO THE ABSURBER WHERE IT IS CONTACTED W!TH THE FLUE GAS IN A CUUNTERCURRENT FASHION.
THE SPENT SCRUBBING SOLUTION IS DISCHARGED TO THE THICKENER WHERE THE WASTE SOLIDS SETTLE OUT.
THICKENER OVERFLOW IS RETURNED TO THE NIx/HOLO TANK. THICKENER UNDERFLOW IS DISCHARGED TO A 5-
ACRE HYPALON-LINED DISPOSAL POND. THIS POND IS LOCATED APPROXIMATELY «0o FEET FROM ,HE ABSORBER
TO.ER. CLEAR WATER FROM THE POND IS RETURNED TO THE PROCESS AS MAKE-UP MTEK JN THE SLUKRY 1ANK.
OPERATING H1SIORY
THE SYSTEM WAS INITIALLY PLACED IN SERVICE MARCH U, ,976. INITIAL OPERATION PROCEEDED IN AN
OPEN WATER LOOP MODE BECAUSE THE THICKENER WAS NOT YET COMPLETELY INSTALLED. SULFUR DIOXIDE IN-
LET CONCENTRATIONS WERE IN THE 1800 TO 2000 PPM RANGt. HIGH OXYGEN CONCENTRAT!ONS ALSO EXIST IN
THE FLUE GAS BECAUSE THESE OLDER. INEFFICIENT BOILERS OPERATE AT IbO TO 160 PERCENT EXCESS AIR
RATES. SULFUR DIOXIDE REMOVAL EFFKIENCY HAS BEEN !N THE LOW 90 PERCENT PLUS RANGE. EARLY
PROBLEMS WERE PRIMARILY UF A MECHANICAL NAIURE USUALLY ASSOCIA.ED WITH START-UP. THE MAJOR START-
UP PROBLEMS WERE AS FOLLOWS:
1. ELECTRICAL CIRCUITS AND SYSTEM CONTROL PANEL.
2. PUMP MALFUNCTION-SPARE PARTS SHIPMENT DELAY.
3. SEDIMENTATION BUILDUP IN THE SCRUBBER VESSEL (THIS WAS (HIE PRIMARILY TO OPERATION AT
HIGHER THAN DESIGN SOLIDS CONCENTRATION IN THE SCRUBBING SOLUTION BECAUSE IHt THICKENER
WAS NOT YE1 IN SERVICE PLUS GRIT GETTING THROUGH THE LIME SLAKER RKII REMOVAL STEP).
«. FAMILIARIZATION OF THE OPERATING STAFF WITh IHE MECHANICS OF THE PROCESS.
5. I.D. BOOSTER FAN PROBLEMS. ADDITIONAL BRACING, AND EPOXY GROUT I Ml WAS REQUIRED TO STOP
THE ELEVATED FAN CONCRETE SUPPORT FROM VIBRATlNb WHILE IHE FAN AAS OPERATING.
Bfe
-------
.STATUS AS UF" U7/30/7M
SECTJt'1-J "9 ICOf-Jl 1 MJFU)
OESC>< TFT 10i\ FOR OPt .RA I 1 Ut.»L FGu SYSTEMS UN INDUSTRIAL BOH.tKb
RICKfcNbACKER AIR FuRCt SASt! CuLJMbUS, Onlu (Ci,i\ I 1 Mil tfi J
,MOv/. 76 IHROUGH JUN. 77 DUWNTIf'f ft*S LESS THAT, 6%. OPERATING PRObLtKS HAVb BEEN rFCHANlCAL AUO
CONTROL RATHER THAM PROCE SS-HEL A IE U. FAN-RELATED PRuBLEMS ACCOUNTED FUR I VtR 75* uF THE ACTUAL
DOWN-TIME. THIS RESULTED FROM EXCESSIVE FAN VJ8RATTUNS CAUSED BY BEARING, SUPPORT, AND INSTRUMENT-
ATION UIFFICULTIES. IN APRIL 19/7. I Ht FAiv viHlF.L DEVELOPED A (.RnCx, IN Tut Rir AITKIBI1TLO T (I
FAlTbllc FROM RESUNAMT VIBRATION. THE FAN ftAa S,E,,T B«Cn TO THE' MANUF ATI IJKFK, AMERICAN STANDARD, wHU
MADE THE REOUIKED.MODIFICATIONS. Tht UPIGINAL FAN AAS RADIAL oLADE WTIh KIMb, A,JD A MAJUR MuniFI-
CATION WAS CHOPPING THE .VIMS OFF, ThcRtwv KELiiciivt THE HIAMEIEU. int FAH WAS KFTUKNEU IN EARLY MAY
AMI) IHE VIBRATION PROBLEM WAS SOLVED. OTHER OF'EKAT I ufci, ir.ERF RtLATlVLLY PRuPLF M-F REE. THfcKE WERE
NO CORROSION, EROSIOK, SCALINK, OR PLUbGlNfe PROBLEMS. THE SYSTEM bF.GAN RIIIMNlNt; UN LIMESTONE IN
APRIL, A3 PART OF THE fcPA TEST PKd&KAM. LIMESTONE PtRFOtjD NO. 3 WILL BE ON bTANuiJY. IIE-IN WAS COMPLtTEH IU JUME.
AUG. 77 THE ARMS BHOnE OFF IN THE £5-FOOT U1AMF..TER THICKENLR TANK, CAUblNfi A 3U DAYS DOWNTIME.
Sgp. 77 A MAKE-UP nATER BOOSTER PUMP HAD Tli bF FJEPLACED.
OCT. 77 THE MOTOR DRIVE ON THE SLAKE.R BELT HAD Tu BE REPAIRED. ALTHOUGH THE SLAKF.R IS NO LDNGtR
USED WITH THE LIMESTONE REAGENT, THE BELT IS USED TO CONVEY IHt LIMFSTONE TO THE DISSOLVING TANK.
1ST UUARTER-1978 IT WAS DISCOVERED 1HAT wlTh A &TUICH10METR1C RATIO OF 0.75 THE KfcUuIRED oEGMhE
UF SO?. REMOVAL CAN BE ACHIEVED. THE CURRENT REGULATION LIMITS EMISSIONS Tu ->.d LBS/MM OTU HtA I
INPUT. DURING THE JANUARY BLIZZARD, SUMt FREE/E-ilP HRuRLEi-iS HERE ENCOUNTERED.
DURING JANUARY THE BOILERS OPERATED 744 HOUKb AND THE EGO SYSTEM UPERATEU b9b HOURS YIELDING OPER-
ABILITY AND AVAILABILITY INDEX VALUES UF SOX. ALL OUKiMTiME rtAb A T f R1 SOT ABLE TO f REFTZE-UPS DURING
BLIZZARD CONDITIONS. DURING FEBRUARY, THE BOILERS OPERATED b7i HOURS AND THE COwTKOL SYSTEM OPERA-
TED 16H HOORS. HOWEVER THE FGU SYSTEM WAS AVAILABLE Sb) HuURS. THEREFORE THE OPERAblLI'Y INDtX WAS
e!5% WHILE, THE AVAILABILITY WAS 8i%. THE AbSURBER LlNEb ftEivE TIIArtEu uUT FEBRUARY b, BUI DURING
FEBRUARY, THE GOVERNOR OF OHIO TEMPORARILY SHELVED PuLLUTluN CONTROL REGULATIONS. THEREFORE THE
FGD SYSTEM WAS NOT OPERATED ALTHOUGH II ftAS AVAlLABLt FOK OPERATION. THE SYSTEM WAS SHUIDUWN UN
FEBRUARY 13 AND DID N01 OPERATE DURING MARCH.
£Nu utlARTER-1978 SYSTEM wAb RESTARTED APRIL 10 AIMF> ^AS REPORTED TO HAVh RUi-J rtl TH luu% UPF.RA-
blLIlY INDEX VALUE FOR THE REMAINING PtKIOD. F'LANl REPOklfcll THAI ALL PRcVlOUS PROULLMS HAVE
bEt.N CORRECTED. DURING IHE LAST PURTJuN OF I Hi. eNU JUARIE'R 1 Ht BOILER LOAD DKUPPED fU T IS SUMMER
LEVEL, ABOUT 30 MM STU/HR, AS OPPOSED 10 THE MAXIMUM COLO SEASi.N LOAD OF IbO I'M HTU/HR.
-------
STATUS AS OF 07/30/7a
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION KIR OPERATIONAL FGU brsiEMS UN INDUSIRIAL BORERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOti EFFICIENCY
PARTICULATE EFFICIENCY
SLUDGE OK BY-PROOUCT DISPOSAL
SHELLER GLOBE CORP.
NORFOLK, VIRGINIA
COAL CLESS THAN u SULFUR)
6,000 SCFM (TOTAL - tL bOILERS)
1
4 hW (EQUIVALENT); TOTAL - 2 BOILERS
W.K. SLY MANUFACTURING CO.
SODIUM HYDROXIDE SCRUBBING
RETROFIT
1975
OPERATIONAL
NOT DETERMINED
NOT DETERMINED
OVERFLOW TO SEWER/SLUDGE TO LANDFILL
BACKGROUND INFORMATION
IN NORFOLK, VIRGINIA, SHELLtR GLOBt CORPORATION OPERATES THE MITCHELL SMITH DIVISION PLANT,
WHERE THE PRIMARY PRODUCT IS CORK RUBBER GASKET MATERIAL. PROCESS (AUTOCLAVE) AND HEATING STEAM
ARE SUPPLIED BY A BOILER RATED AT 350 BOILER HP (ABOUT 3.5 MW EQUIVALENT). STEAM CONDITIONS ARE
125 PSI AT 325 F. THE BOILER WAS ORIGINALLY ERECTED IN 1939, BUT UNDERWENT A COMPLETE OVERHAUL IN
1977. BOILER TUBES, REFRACTORY BRICK, GRATE, AND SOOT BLOWERS WERE REPLACED DURING THE OVERHAUL.
THE BOILER FIRES COAL SUPPLIED BY GENERAL COAL - NOMINAL SIZE IS 1.2b X 0.25 INCHES. COAL
CHARACTERISTICS ARE AS FOLLOWS. HHV=li,200 faTU/LB, ASH=6X, ANU SULFUR IS LESS THAN IX.
THE EMISSIONS CONTROL SYSTEM AT SHELLER GLOBE CONSISTS OF A W.W. SLY WINJET SCRUBBER
WHICH REMOVES PARTICULATE AND S02 FROM THE FLUE GAS. THE SYSTfcM USES A SODIUM HYDROXIDE MAKE-UP
FOR SOd CONTROL. RECYCLE TANK SUPERNATANT IS FH NEUTRALIZED AMD IS DISCHARGED To CITY StWERS.
FLYASH AND SEDIMEN] ARE SUMPEO OUT AND HAULED 10 A SANITARY LANDFILL.
OPERATING HISTORY
2ND UUARTER-J978 DURING THE REPORT PERIOD THE UNIT UNDER WENT A VIRGINIA EPA CERTIFICATION
INSPECTION, AND WAS FOUND TO BE IN COMPLIANCE. NO SCRUBBER-RELATED PROBLEMS HAVE OCCURRED.
-------
STATUS AS OF 07/it.)/7tt
SECTION « (CONTlNUfO)
PERFORMANCE DESCRIPTION FOR UPt RAT KmAL FGu SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE MATING
NUMBER OF SEPARATE FbO UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-OP DATE
CONTROL SYSTEM STATUS
bOd EFFICIENCY
PASTICJLATfc EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
ST. REGIS PAPER LO.
LANTuNMENT, FLORIDA
rtAhK AM) GAS OK OIL UESS THAN U SULFURJ
lib,000 SCFM (1 bOILhHJ
1
60 Mh (EQUIVALENT); DESIGN - 300,000 LB/HK STEAM
AIKPOL INDUSTRIES
LAUS1IL SCRUBBING
RETROFIT
1973
OPERATIONAL
80* - SOJi
94.5X 1400 LB/HR AT INLET)
OPtN LOOP; 300 GPM-250 GPM SCRUBBING LIHUOK FEED
WASTfcWATtK TREATMENT
EFFLUEixiT IS TRtATEO IN AN ON-SITE SEWAGE TREATMENT PLANT
CAPITAL: sioo.ooo (I97i). COST is FOR ABSORBER ONLY.
BACKGROUND INFORMATION
THE SCRUBBER SYSTEM AT SI. REGIS PAPER LOCATED AT CANTONMENT, FLORIDA «AS MANUFACTURED HY
AlRPOL. THE UNIT IS CONSTRUCTED OF JlfaL STAINLESS SIFKL AND HANDLES A TOTAL FLOE GAS VOLUME OF
175,000 ACFM. PARTICIPATES ARE CONTROLLED WITH CYCLONES PRECEEDING THE SCRUBBER. SCRUBBER PRESSURE
OROH Is APPROXIMATELY 10 INCHFS rt.G. *vlTH bO TO 90X SULFUR DIOXIDE REMOVAL EFFICIENCY. THE SCRUBBER
IS FOLLOWED BY A CHEVEkON-TYPE M1SI ELIMINATOR.
THt dOILtR IS RATED AT h(l MW AND PRODUCES 300,000 LBS/HR STEAM. THE TYPICAL SULFUR CONTENT
OF THF FUEL IOIL OR BAKK, NATURAL UAS TS LESS THAN 1%.
SCRUBBER UNDERFLOW CONSISTS OF ASH AND A SODIUM SULF1TE/SULFATE SOLUTION. THE SLUDGE IS OIS-.
CHARdEU TO AN ON-SITE SEftAUE TRFATMENT PLANT.
OPERATING HISTORY
IKi) ijMARTER-1977 KiOUP FIBERS FROM BARK WERE CLOGGiNli SEPARATORS AND CONTROL VALVES. INSPECTION
BIAS tiAue AND SOLUTION 10 PROBLEM is BEING INVESTIGATED.
4Tn ullARTER-1977 AFtER INVESTIGATION OF THE CLOGGING PROBLEM IT WAS DECIDED TO CHANGE THE MAKE-UP
UP WATER SOURCE. WATER is NOW OBTAINED FROM A CLEANER PORTION OF THE PROCESS LOOP.
PLAiil RbPOkTS SATISFACTORY OPERATTuNS WITH NO OTHER MAJOR PROBLEMS.
UMARTER-197B
PLUGGING DUE TO FTnERS I Iv THE SCRUBBER FEEDrtAIER REMAINED TO BE AN UNRESOLVED
-------
STATUS AS OF 07/30/78
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SY5TEMS UN INDUSTRIAL BOILERS
ST. RESIS PAPER CO.; CANTONMENT, FLORIDA (CONTINUED)
PROBLEM DURING THE REPORT PERIOD. PLANT HAD NOT YET CHANGED THE SCRUBBER LIUUUR FEED SOURCE. IN
THE JANUARY THROUGH MAY PERIOD, THE BOILER OPERATED 3473 HOURS. SCRUBBER RELIABILITY INDEX WAS NEAR
100 X. THE PLANT INDICATED THAT THIS REPORT HAD BEEN REPORTING TOO HIGH OF A SULFUR CONTENT IN THE
FUEL (2-3 X), AS COMPARED TO THE CORRECT VALUE OF LESS THAN IX.
SO
-------
STATUS AS OF 07/30/7d
SECTION <> (cnuTiNUEi))
PERFORMANCE DESCRIPTION FOR OPERATIONAL FKI) SYSTEMS UN INfliiSlRIAL d'HLERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NFrt / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOd EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
IF.XACO INCuRPORAIED
SAN AHDO, CALIfORNIA
OIL 11 .7* SULFUR)
ihhfOOU SCFM (TOTAL. - da HUILERSJ
dh,000 ACFM n oOOF, FO* EACH OF d£ FGO SYSTEMS
00,000 ALFH a) bOUF, FOR tACH OF d FGD SYSTEMS
d<(
140 MW (EQUIVALENT); 14&0 MM BTU/HH: TOATL - it BOILERS
CFILIOTF;
SODIUM HYDROXIDE SCRUBBING
RETROFIT
NOVEMBER, 1973
OPERATIONAL
73% 11000 PPM o) INLET)
wASTtwATtR TKFATMEMT
HALF OF 1HE SCRUBBER UNDERFLOW IS TREATED AND RECYCLED AS
BOILER FEF.DWATER; THL OTHEK HALF' GOES TO WASfErtATER
DISPOSAL WELLS.
BACKGROUND INFORMATION
TEXACO USES SEVERAL OIL FIRED BOILKftS AT ThE SAN ARDU, CALIFORNIA SITE. THE STEAM IS INJECTED
IN OIL WELLS TU FACILITATE OIL FLOW. THERt ARt TWu DIFFERENT SIZES l»F THE BOTLEWS: 180 MM ti TU/HR
(2 NOS), AND 50 MM BTU/HK 131 NOS) . THF FUEL OIL HAS A TYPICAL SULFUR CONTF.iMT OF 1.7*.
THE FLUE GASES (BO,000 AND db.OOO ACFM FROh EACH BuTLErf b) bOo F) ARE SCRUHtSED BY A FGO SYSTEM
SUPPLIED BY CE1LCOTE COMPANY IN NOV. '73. EACH riOILER TS FOLLOWED HY A UUENCHIIMG CHAMBER ANi) A
SCwUBBER. THE StRUBbEkS, WHICH ARE HORZONIAL lOrtFRS PACKED wIlH 2 IN. TELLEKAFE PACKINGS ARe OF
SIZES: 15 FI X 15 FT X 2(1 FT IE NUS) , AND 15 FT X t5 FT X 9 I/a FT (2
-------
STATUS AS UF 07/30/78
SECTION '» (i;(JNTINUElJ)
PERFORMANCE UESCKlPTiUN Hh< UPtkAT lUWAL hG.l SYilTtMS ON INDUSl«IAu BOILERS
fFAALO IrfCOKHUkAlfcu; S«N ARPU, CALIFORNIA ICU.M I tNUfcD J
OPEKA1 I Mi HIS fORY
IHt MAJOR OPERATIONAL PROBLEM AREAS ARb:
1. THfc UUENCHER SkCUON HAS SUFFERED SEVF.KE CORROblurj DUE Tu ACID ATTACK.
?. F^P LINEK OETfklUATES DUE 10 MECHANICAL ABrtASION n.WING LLtANING OHErtAFIONS. IT NEEOS
OCCASIONAL RESURFACING.
3. THE. PACKED BEOS AKE FrttOUENTLY PLUGGED «r HLYASH. THE OIL TN THE NAf.lHAL LIQUOR HAS CAUSED
FullLINR OF THE PALKEO BEDS.
«. OCCASIONAL OVERTNJECTION OF CAUSTIC HAS RESOLTEH IN PLUGGING OK SPRAY NOZZLES dY SCALES.
!ST gUARIEH-1978 DUE 10 THE LOW S02 REMOVAL AND HIGH MAINTENANCE COST OF THE ABOVE DESIGN, TEXACO
HAS UNDERTAKEN A TEST PROGRAM t,HICH, IF SUCCESFUL, MLL PHASE UUT THE PRESENT SCRUBBERS BY THE END
OF 1,79. FOR MORE INFORMATION ON THfc PROGRAM SEE THE OTHEK TEXACO, SAN ARDO BACKGROUND INFORMATION
tNTWY IN SECTION 10 OF THIS REPORT.
MO yUARTER-1978 THE AVAILABILITY OF EACH FGD SYSTEM MAS APPROXIMATELY S4 X. ON AN AVERAGE, ONE
SYSTfcM WAS SHUTDOWN 1 rtil DAYS A MONTH FOR HA INTtNANCF.
If.
-------
STATUS AS OF 07/30/7B
SECTION 9 (CONTINUED!
PERFuRMANCE DESCRIPTION KOR OPERATIONAL FGJ SYSTEMS UN INOOSIRIAL BOILERS
INSTALLATION NAMt
INSTALLATION LOCATION
bOuRCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
SOORCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEft / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOi! EFFICIENCY
PARTICULATE EFFICIENCY
SLUDGE OK bY-PROOUCT DISPOSAL
TEXASGULF
GRANGER, WYOMING
OIL 11.IX SULFUR)
140,000 SCFM (TOTAL -
-------
•STATUS AS OF 07/i0/78
SECTION Q (CONT1NUFD)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGU SYSTEMS UN INDUSTRIAL TOILERS
TEXASGULF? GRANGER, WYOMING (CUNT INUEO)
EACH ABSOR6FR IS DIVIDED VERTICALLY INTO TWO SECTIONS, ONE OF WHICH HAS A DAMPER AI THE TOP.
THIS PERMITS CURTAILMENT OF GAS FLOW THROUGH HALF OF THE UNITS AT LOW LOADS. THE ABSORBER,
THEREFORE, CAN OPERATE AT THE DESIGN EFFICIENCY rtHLN THE BuILEK PRODUCES FKU« *5l 10 luOX OF US
RATED OUTPUT. THE ABSORBER BYPASS ALLOWS UPTO 25% OF THE INCOMING HOT FLUE GAS 10 BE DIVERTED.
TYPICALLY, TtXASGULF USES THE BYPASS TO KEEP THE FL.Jt GAo IN THE STACK 10 F rtArtMEK THAN fHAT AT THE
SCRUBBY OUTLET. THE SCRUBBERS ARE MADE OF 31b L SS, THE TKAYS ARE UOOEHULM 904-L, THC POMP TANKS
ARE FRP AND THE STACK i7.5 FT ID X 1 bO FT HIGH) IS OUUbLE-rtALL. INSULATE,, STEEL TYPE «ITH FLAKtLINE
COATING 6Y CEILCOTE COMPANY.
OPERATING HISTORY
1ST QUAKTER-1978 THE OUTLET DUCTWORK, WHICH IS CORRODED DOE TO ACID COMPENSATE, WILL BE REPLACED.
THE SYSTEM OPERATED WITHOUT ANY MAJOR PROBLEMS.
-------
STATUS A3 Or 07/3U/78
SEC U DIM 10
DESIGN INFORMATION FOR uNDtK LUuSIRUCIION FGI) SYSTEMS UN INUUSUIAL
INSTALLATIUN NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FED UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATt
CONTROL SYSTEM STATUS
802 EFFICIENCY
SLUOUE OR BY-PRODUCT DISPOSAL
CATEkPILLAK fRACIOR CU.
MAPLtfUN, ILLINOIS
CUAL (i.
-------
STATUS AS UF 07/iU/7a
oH. ITOlM in (COuT ir.ijKu)
OKSIGN INFORMATION FUK ,,N,»K LON-S IKUC UN* K(,l, SVSIfHS 0* INDUSTRIAL
INSTALLATION NAME
INSTALLATION LUCATJlMj
SIHJWCF CHARACTERISTICS
SOURCE. RATING
iJUKHER OF SEPARATE F(,[) UNITS
SduwCF CAPAClIr
UONTHflL SYSTEM VENuflK
CB^TKOL PHuCh.SS
ME« / KETRUFIT
START-uP DATE
COiviTHOL SYSTEM STATUS
Sn<: tft- ICItNCY
SLunGt OK dY-pRODUcT DISPOSAL
COAiTwOU SYSTEM CuST
1>F1 i Y U1L LOMPAMY
bAKEKSHcl.u, CALIFUHUIA
LRUDfc JIU U.l* SiJLFuRJ
'i^.S./'^u oC.t-H (KUAL-/!? BUTLERS)
y FGU SYSTEMS, EACH THtAriMG 300,000 ACFM a) 500 F
9
360U MM itTU/HR, 310-Mrt EQUIVALENT CTOTAL-7£ BOILERS)
LALH HillLEH KAiEU AT '43,000 L3S/HR SfEAM
PRuPKTATARr iJtSIbN
SiHHUM CAKbOHA Tf SCKUBI3ING
KFTRUFJT
UFCFMBEK, 1^78
CUNSTKUCTTUM
">h* I 10 PPM SUc? AT OUTLET J
wASTlrWATtW THHATi-it.NT AfMD DISCHARGE TO TAILINGS POMU
LAPITAL: s 500,000 (19/8) FOR LACH SYSTEM. THIS INCLUDES
COST (IF SCKUHHEM.SUUA ASH T AlMK , PIPING, AND PUMPS. THE COST
DOES NOT INCLUDE STACK, DUCTWORK, OVERHEADS, AND ENGINEERING
hTo OR » SJJO.OOO/YK FOR EACH SYSTEM.
THIS 1,'i nASF.u ON 340 HAYS/YR. 1 HE COST I.MCLUuES ELECTRICAL,
SCKUhBtR MAINTENANCE, AND SODA ASH.
-------
STATUS AS OF 07/30/78
SECTillN 10 (CONTINUED)
DESIGN INFORMATION FDR UNDER CONS IHUC1 ION Flil) SY.STFMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE F6D ONITS
SYbTtM UENDOk
PROCESS
iMEA / RETROFIT
START-UP DATE
COwTHUL SYSTEM STATOS
S0£ tFFICIENCY
SLJDGF OR BY-PRODUCT DISPOSAL
GREAT WESTERN SUGAR
FRtEMONT.OrllO
COAL (iX SULFUR)
40.0UO SCFM a) 70 F (TOTAL - I BOILERS)
140,000 LB/HK STEAM (TUTAL - 2 BOIuERS)
a
GREAT WESTERN SUGAR
SODIUM CARbONATE SCRUBBING
KETROFIT
OCTOBER, 1978
CONSIRUCrluN
WASTEWATER TREATMENT AND DISCHARGE TO CITY SEWER
97
-------
STATUS A3 OF 07/30/78
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCTION FGD SYSTEMS UN INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE F6D UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
nEw / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
MOBIL OIL COMPANY
BUI TuNhiLLow, CALII-OKNIA
OIL 11.IX SULFURJ
42,000 3UFI»i (TOTAL - T BUTLFRS)
I FGU SYSTEMS, FACH TREATING U,<400 ACFM ,OOO us78). THIS COOT I.MCLUUES ABSORBER
MODULES, RECYCLE TANKS, STACK, DEMISTExS, PUMPS, AND PIPING.
IT OuEb NOT INCLUDE CAUSTIC TANK, FEED PUMPS, UR FfcEO PIPES.
BACKGROUND INFORMATION
MOBIL OIL HAS PURCHASED SEVEN HEATER TECHNOLOGY EDUCTOR bCKUWHER SYSTEMS FUR THE CONTRUL OF SOd.
-------
STATUS AS OF 07/30/78
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNoER CONSTRUCTION FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PRUCtSS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
ST. JOE ZINC co.
MONACA, PENNSYLVANIA
COAL C2.5%-«.5% SULFUR)
104,000 SCFM (TOTAL - 1 BOILER)
1
bO MW (MINIMAL PEAK CAPACITY)
BUREAU OF MINES
CITRATfc PROCESS
RETROFIT
OCTOBER, 1
-------
STATUS A3 UF 07/i(»/7a
DESIGN INFORMATION KIR
INSTALLATION NAMfc
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SFPARATE FGD UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
IM£» / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
li< 10 (CII..T1IHIED)
•ER tONSIKJCtluN FliD SYSTEMS ON INDUSTRIAL BOILERS
TEXALO INCORPORATED
SAN ARDO, CALIFORNIA
UlL (1.7* SULFUR)
11/,OOU SCHM CTOIAL - 9 BOILERS)
26,000 »LFM 00 F, FUR EACH UF 9 BOILERS.
3
50 MW (EQUIVALENT); bO MM BTU/HR/BOILER
DUCON COMPANY
SODIUM CARBONATE SCRUBBING
REIROFIT
MARCH, 1979
CONSTRUCTION
95% (1000 PPM g) INLET)
SCRUBBtR EFFLUENT DISPOSED OF IN WASTE rtELLS
BACKGROUND INFORMATION
TEXACO IS PLANNING TO PHASE OUT THE EXISTING FGD SYSTEMS AT THE SAN ARUO OIL FACILITY. AS THE
FIRST oTEP OF THE PROGRAM, 9 OF THE PRESENT 35 SCRUBBERS ON THE 50 MM BTU/HR STEAM GENERATORS ARE
BEING REPLACED BY A NEW SYSTEM.
THE NEK F6D SYSTEM IS BEING SUPPLIED BY DUCON COMPANY AND .ILL BE OPERATIONAL «Y MARCH 1979.
THE SYSTEM CONSISTS OF THREE TRAINS UF VENTURI SCRUBBERS AND HORIZONTAL SPRAY TOWERS. THE FLUE
GASES FROM 9 STEAM GENERATORS WILL BE MANIFOLDED INTO THE SYSTEM (2*4,000 «FM 3 600F). EACH TRAIN
CAN TREAT 50% OF THE DhSIGN LOAD AND CAN ESt ISOLATED FROM THE FLUE GAS STREAM. IT IS HOPED THAT
THIS SYSTEM DESIGN W1LL YIELD SIGNiF1CANTLY HIGHER AVAUABILITIES' THAN THE DESIGN CURRENTLY IN USE.
(FOR FURTHER INFORMATION, SEE THE OTHER TEXACO, SAN ARDO, BACKGROUND TNFURMAfTON ENTRY IN SECTION 9
OF THIS REPORT). THIS SYSTEM «ILL UTILIZE A SODIUM CARBUNATE .ECHNOLOGY FOR S02 REMOVAL.
THE COMPLETION OF THE PHASE-OUT PROGRAM IS CONTINGENT UPON ME OPERATING SUCCESS OF THE SYSTEM
AND ANY NOX REGULATIONS WHICH MAY HE PROMULGATED.
luo
-------
STATUS A3 OF 07/30/78
SECTION 11
UESI6N INFORMATION FOR PLANNED FSD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S0£ EFFICIENCY
PAKTICULATE EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
ARCO/POLYMERS, INC.
MONACA, PENNSYLVANIA
COAL (3.OX SULFUR)
236,000 SCFM (TOTAL - 3 BOILERS)
900rOOO LS/HR STEAM o) 70U PSI6 AND 7DO F.
3
118 MW (EQUIVALENT); TOTAL - 3 BOILERS
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
RETROFIT
JUNE, 1980
PLANNED-CONTRACT AWARDED
90* 12,300 PPM a INLET)
99.5%
DEWA1EREO SLURRY TO LANDFILL
FLYASH ADDITION TO 0£WfrTER£D CAS03/CA304 FILTER CAKE,
THEN TO LANDFILL.
CAPITAL! S8i000,000 (1978). THIS TOTAL INSTALLED COST
INCLUDES EQUIPMENT, INSTALLATION, DUCTWORK, STACK, PIPING*
COST OF THE FGO SYSTEM, ENGINEERING, START-UP, AND TESTING.
INSTRUMENTATION, ENGINEERING, AND OVERHEADS.
OPERATING: PROJECTED COSTS ARE NOT YET AVAILABLE.
lot
-------
•STATUS AS UF U7/iO/7«
SECTION 11 (CONTINUEDl
DESIGN INFORMATION FOR PLANNED FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOc! EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
C.A.M.lCARHIDE-AMOCO-MONs/ugTU)
HOUSTON, TtXAS
NOT SELECTED
1,200,000 SCFM Cl BOlLERJ
bOU MW (EQUIVALENT); 1 BOILER
1
NOT SELECTED
NOT SELECTED
NEW
OCTOBER, 1>*8J
PLANNED-CONSIDERING 802 CONTROL
NOT DETERMINED
DISPOSAL TECHNIQUE NOT KNU.i/N
BACKGROUND INFORMATION
UNION CARBIDE, AMOCO, AND MUNSANTO HAVE ENTERED INTO A JO!Nr VENTURE (C.A.M.), ,HICH WILL HAVE
A COGENERATION FACILITY NEAR HOUSTON,TEX AS. THE 60U-MW (EQUIVALENT) BOILER WILL PRODUCE ELECTRICITY
AND PROCESS STEAM FOR THE NEARBY PLANTS UF THE THREE COMPANIES.
•HE TYPE OF FUEL TO BE USED IS NOT FINALIZED. HOWEVER, A FbO SYSTEM IS DEFINITELY BEING
CONSIDERED. STARTUP FOR THE PO«FR GENERATING FACILITY IS SCHEDULED FUR LATE 1983.
102
-------
STATUS 48 UF 07/30/78
SECTION 11 (CONTINUED)
DESIGN INFORMATION FUR PLANNED Fbl) SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
SOURCE CAPACITY
COi\TROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CARBORUNDUM ABRASIVES
BUFF«LU, NEW YURK
COAL (a1/. S AVERAGE, 3.£% S DESIGN MAX)
38,000 ACFM nl 350 K
60,OUO - 85,000 LBS/HR STEAM (PROCESS AND HEATING STEAM)
1
10 Mh (EUUIVALENT)
CARBORUNDUM ENVIR. SYS. LTD.
LIME SCRUBBING
RETROFIT
PLANNED-CONTRACT AWARDED
9251
WASTEWATER TREATMENT AND DISCHARGE TQ CITY SEWER
BACKGROUND INFORMATION
NO DEFINITE PLANS HAVE BEEN MADE FOR THE CONTROL UF SU3 EMISSIONS FROM THIS BOILER. THE FUTURE
OF THE CONTROL SYSTEM WILL BE DETERMINF.D BY A REGULATORY AGENCY DECISION EXPECTED NEAR THE END OF
1978. THE CURRENTLY OPERATING VENTURI (1./G = 10) CONTROLS ONLY PARTICULATE, HUT TIE-INS HAVE BEEN
PROVIDED FOR A LIME SCRUBBING SYSTEM USING A b-STAGF SPRAY TOWER FOR S02 CONTROL.
2ND QUARTER-1978
OPERATING HISTORY
PLANT REPORTED NO CHANGE.
10?
-------
UFSIGN INFOKMA1
STATUS AS OF U?/30/7d
oFL TlOlv I 1 CC.ONI IMJFl) )
FOP PLANNtO f t,l) SYSrKMS d,J INDUSTRIAL
il»6TALLATJUN N'AME
ION LUCATIOI,
ChAKACTtKlSHtS
NlK'.RtR OF SFPAKATF Fun UNITS
•SOuMCE CAPACITY
COiViTwOL SVbTtM VtMuUK
NE'f, / RETROFIT
START-UP OATt
COKHKOu SYbTtM STA1US
S02 tFflCIENCY
SLUDGE OK BV-PKODUCT DISPOSAL
U.S.A. IMC.
LLU, CALIFORNIA
ulL ll.l/i bllLFUKJ
llbiOOO bCFM (TOTAL - 13 HOTLEr*Sj
d FGU SYbTtMS, EACH IHLATIuG IbU.OOO ACFM a) 500F.
2
60U MM 8IU/HK (TOTAL - Id WOILtRS; fa HOILEKS/FSI) SYSTEM)
IMOI SELtCTtD
SODIUM CARbOHAlE SCKOHBING
RETROFIT
APRIL/ 147S
PLANWEU-KEbUESTIUR/EVALUATING BIDS
SO* IftgO PPM oi iNLtTj
nAbTLWATtR TREATMENT
1 0"4
-------
STATUS AS OF 07/30/78
SECTION 11 (CONTINUED)
DESIGN INFORMATION FOR PLANNED FbO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTfcRISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S0£ EFFICIENCY
SLUDGE OR bY-PROOUCT DISPOSAL
CUNTRQL SYSTEM COS1
GR1SSOM AIR FORCE BASE
bUNKfcR HILL, INDIANA
COAL (O.SX - 1.6X SULFUR)
33,000 SCFM (TOTAL - 3 BOILERS)
15 Mh (EQUIVALENT); TOTAL - 3 BOILER.S
1
NOT SELECTED
DOUBLE ALKALI (CONCENTRATED)
1 NEW 3-HETROF1T
SEPTEMBER, 1979
PLANNEO-KEUUtSTING/EVALUATING BIDS
DEWATEREU SLURRY TO LANDFILL
CAPITAL: $i,dOo,ooo - sa,000,000 (1978). THIS is THE
PRUJECTED TOTAL INSTALLED COST.
BACKGROUND INFORMATION
AT GRISSOM AIR FORCE BASE NEAR BUNKEK HILL, INDIANA, THE AIR FORCE HAS INITIATED A PROJECT WHICH
INCLUDES THE ERECTION OF A NEW COAL-FIRED BOILER AND AN FGO SYSTEM FOR THE NEW UNIT AND TWO EXISTING
COAL-FIRED UNITS. THE AMOUNT OF CAPITAL ALLOCATED FOR THE EMISSIONS CONTROL SYSTEM IS IN !H£
$1.8 - $2.0 MILLION RANGE. THE NAVY IS THE MILITARY CONSTRUCTION AGENT FOR THE PROJECT. ARNOLD M.
DIAMOND HAS THE OVERALL CONSTRUCTION CONTRACT AND I-OSDICK AND HILMER (CINCINNATI) IS THE A-E FIRM
FOR THE FGD PORTION OF THE PROJECT.
THE A-E FIRM HAS SPECIFIED A CONCENTRATED DOUBLE ALKALI SYSTEM FOR THE CONTROL APPROACH. FLUE
GAS FROM EACH BOILER WILL PASS THROUGH A MECHANICAL COLLECTOR. I HE GAS FROM ALL THREE 8UILERS WILL
THEN Bt MANIFOLDED TOGtTrtER AND PASS THROUGH ThO PARALLEL ABSORBER TWAINS, EACH TRAIN CAPABLE OF
HANDLING SOX OF THE FLUE GAS. THE MAXIMUM FLOU RATE IS 33,000 SCFM (145,000 LB/HR OF GAS).
THE BOILERS FIRE APPROXIMATELY 40% EXCESS AIR. COAL MAY RANGE FROM 0.9X - 4.6% SULFUR AND WILL
HAVE AN AVERAGE HEATING VALUE OF 11,500 BTU/LB. THF A-E FIRM HAS SPECIFIED THAT THE MAXIMUM 802
OUTLET CONCENTRATION MLL b£ 1.2 Lb/MM B1U, AND THt MAXIMUM PAKUCULATE AT THE OUTLET WILL BE
0.171 Lrt/MM 6TU.
PROJECT COMPLETION IS SCHEDULED FOR AUGUST 30, 197B.
105
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STATUS AS UF 07/40/7(1
SECTION 12
DESCRIPTION OF INDUSTRIAL BOILER FGU SYSTEMS NOT
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
STARI-UP DATE
CONTROL SYSTEM STATUS
SOd EFFICIENCY
SLUDiiE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COS1
BUNGE, INC.
CAIRO, ILLINOIS
IOAL (4% SULHIR)
<4<4,000 SCFM tTOTAL - ?. BUFLFRS)
Bl »«i)0 ACFM at b2u F
1
ill Mn (EOUlVAl.tNF) ; TOIAL - £ HOILtHS
180,UOU LBS/HP. STEAM (TOTAL)
UWAVU tOKP./NAT'L LIME ASS'N
LIME SLPUBbfNR
RETROFIT
TERMINATED
<*«% 13700 PPM INLET)
UEnATERFLi SLORkY To LAignFILL
CAPITAL COST: 4i,ouo,ooo (is??). INCLUDES: TOTAL INSTALLED
COST OF THE FGU SYSTEM, ENGINEERING, START-UP, Aivil) TtSTIuG.
RACKGKOUNu INFORMATION
bONGE PORCHASEU THIS LIME SCRUBBING SYSTEM FOR US! ING PURPOSES. THE LEvKIS SCHUdHtR, WHICH IS
A HOKIZONT.AL RuTART VESSEL rtUh IMEkNAL MAINS, PFRFORMEl) VEKY >-,LLL DURING FriE TtSl t-9
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STATUS »S OF 07/30/76
SECTION 12 (CONTINUED)
DESCRIPTION OF INDUSTRIAL MOILEK FGD SYbTtMS NO I UPtRATING
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
502 EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
GRtAI WESTERN SUGAR
LONGMONT, COLORADO
COAL C0.7X SULFUR)
GREAT WESTERN SUGAR
AMMOMA-LADEN PROCESS WATER
RETROFIT
(JCTObER, 1973
TERMINATED
351 (300-
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STATUS Ab UF (J7/iO/76
SECTION If. IC
DESCRIPTION (,F iruuSlKlAL HIM LEU fGL; SYhltMS NO I
INSTALLATION NAME
INSTALLATION LOCATION
buuRCF. CHARACTERISTICS
bUuRtE RATING
NUMBtrt OF SEPARATE FbD LIMITS
SOURCE CAPACITY
CONTnf>L SYSTEM VENDOR
COcMTKfiL PROCESS
iMFrt / kETRUFIT
STAR1-UP DATE
CONTROL SYSTEM STATUS
SO* tFFICIENCY
(•ARTICULATE EFFICIEMCY
SLUDGE OR 8Y-PROUUCT DISPOSAL
SYSTEM COST
HARRIS MINlNb LCI.
SPKULF PiMfc, NURTH CAROLINA
COAL (U.ll% SULHIM1
«,ono bl^M II01AL - d HOILERS)
£
ii MW (EUUIVALEnTJ ; TOTAL - d HUILEKS
ft.W. SLY MANUFACTURING CU.
nAIER 5CKUUH1NG (NArNHi OPTN.)
RETROF1 I
l«/3
1 ERMINATtD
DISPOSAL TECHN10UE NUT KNOWN
CAPITAL: sji.ooo d9/3j. THIS is rut TOTAL INSTALLED co
BACKGROUND INFORMATION
IHE F6D SYSTEM AT THE HARRIS MIMING COMPANY LOCATED AT SPRuCt PINE, NORTH CAROLINA REMOVES FLY-
ASH ANO SULFUR DIOXIDE FROM IHE FLUt GAS OF A COAL FiREH BOILE*. THE SCRObBER IS A „.,,. SLY
IHHluetNT TYPE SCROBBER CONSTRUCTED OF 304 SlAINLfcbS 8IEEL. THE BOILER IS RATED 1.9 M*
ItuHlVALfcNT ^00 60ILER HORSEPOWER). COAL COMPOSITION IS TYPICALLY O.H* SULFuR AND 5* ASH. PRIMARY
INIfKEST IN FLUE GAS SCRUBBING IS IN FLYASh REMOVAL AND NO TESTS FOR SULFUR DIOXIDE REMOVAL EFFI-
CIENCY HAVE BEEN MADE.
OPERATING HISTORY
-------
STATUS AS OF 07/30/78
SECTION 12 (CONTINUED)
DESCRIPTION OF INDUSTRIAL BUILER F6D SYSTEMS NOT OPERATING
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUNBtR OF SEPARATE FGD UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTKOL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S0£ EFFICIENCY
PAKTICULATE EFFICIENCY
WATER MAKF-UP
SLUDGE OR BY-PRODUCT DISPOSAL
QUALITY MILLS, INC.
MT. AIRY, NORTH CAROLINA
FUEL OIL
5 MW (EQUIVALENT)* TOTAL - THREE BOILERS
52,000 Lb/HR STEAM
COMMERCIAL FABRICATION & MAC
WATER SCRUBBING
RETROFIT
MAY, 1970
TERMINATED
47X (600-800 PPM 9 INLET)
60X-95X (0.05-0.16 GRAIN/SCF a INLET)
40 GPM* OPEN LOOP
WASTEWATER TREATMENT AND DISCHARGE TO CITY SEWER
SCRUBBING LIQUOR DISCHARGED TO NEUTRALIZATION POND
109
-------
STATUS AS l)F U7/iU/7«
SECTION 12 (CONTINUED)
DESCRIPTION OF INDUSTRIAL BOILER FGO SYMEMS Mil OPERATING
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISlICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
HE*, / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOd EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
TRANSCU TEXTILES, INL.
AUGUSTA, GtORGIA
FLItL OIL (ex MAX. SULFUR)
50,000 ACFM
0
ao MH
FMC ENVIRONMENTAL EOUIPMtNl
SOUIUM CARbONAIE SChUBtalNR
NEW
MARCH, 1S75
TERMINATED
80X-65% tf.10 Lb/HR al INLET)
<4fl GPM* OPtN LOOH
WASTtHATfcR TREATMENT AND DISCHARGE TO KIVF.R
LIRuOK DISCHARGED Tu A HOLDING POND
1 1C
-------
STATUS AS OF U7/30/7»
SECTION 12 (CONTINUED)
DESCR1PUUN OF INDUSTRIAL HOILfK HGD SYSTtMS NOT OPERATING
INSTALLATION NAME
INSTALLATION LOCATION
SOuMCE CHARACTERISTICS
SOUftCF RATING
NUi«iBtH OF SEPARATE FGD UNITS
SOURCE CAPACITY
COiMTrtOL PROCESS
NF.w / RETROFIT
START-OP DATE
CONTROL SYSTEM STATUS
SO* tFlFICIENCY
PAKTJCULATE EFFICIfcNLY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
O.b. GYPbUM COKf.
UAKMON1* PENNSYLVANIA
C.OAL
1«»,300 SCFM (TOTAL - 1 BOILERS)
AIRHOL INOOS1R1ES
UOOBLE ALKALI (DILUTE)
NfcW
TtKMlNATEO
MEETS COUE
MEETS COUE
10 GHM* CLOSED LOOP
DEWA1ERED SLURRY TO LANDFILL
SLUDGE TO POND FOR DHY1NG. THEN TO LANDFILL.
Ill
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SECTION 13
PROCESS DIAGRAMS FOR
INDUSTRIAL BOILER FGD SYSTEMS
112
-------
A-l
Q-
F-l
T-l
h1
T-2
p-i
-A
P-2
L—Q-
P-3
RF-1
FIGURE 13-1. PROCESS DIAGRAM FOR CATERPILLER TRACTOR,
JOLIET INDUSTRIAL BOILER FGD SYSTEM
113
-------
F-l
L,
T-2
P-l
T-l
J
p-1
P-2
T-3
P-3
FIGURE 13-2. PROCESS DIAGRAM FOR GENERAL MOTORS,
DAYTON INDUSTRIAL BOILER FGD SYSTEM
EQUIPMENT LIST
Equipment no.
A-l
F-l
P-l
P-2
P-3
T-l
T-2
T-3
Name
Absorber
F.D. fan
Recirculation
pump
Caustic pump
Bleed off
pump
Recycle tank
Caustic tank
Bleed off
tank
_^____^^_
Size, feet
6 diameter x
35,000 scfm
200 gpm, 25
80 gpm
50 gpm
7 . 5 diameter
9 diameter x
6 diameter x
10 high
9 in. WG
head
x 12 high
18 high
6. 5 high
Material of construction
No.
316L SS j 2
Carbon steel
Carbon steel, rubber -lined
Carbon steel
Carbon steel, rubber -lined
316L SS
Carbon steel
316L SS
2
3
1
2
1
1
1
114
-------
H-l
— ©— ^
XNXS^
/n
A-l
1
F-l f.
J\
— 'i
c
S-l
>T" ~T^
r~! S"V \
.„, ,_ .^ T_ "t
*" ' -5 L»* T-4
n']M ^y^ ^^L^
^ P-3 RF-1 T'5 -~l
•5=4 — -vj- K-
P-l p.2
FIGURE 13-3. PROCESS DIAGRAM FOR GENERAL MOTORS,
PARMA INDUSTRIAL BOILER FGD SYSTEM
EQUIPMENT LIST
A-l
F-l
H-l
P-l
P-2
P-3
P-4
P-5
RF-1
S-l
S-2
T-l
T-2
T-3
T-4
T-5
T-6
Name
i Size, feet ; Material of construction i No.
Absorber 10.5 diameter x 22.5 316L SS 4
high
F.D. fan 200 hp, 12 in. KG Carbon steel ] 4
• 4
Reheater :
Recirculation Carbon steel, rubber-lined 4
pump l
Recirculation |
pump i
Underflow pump Carbon steel, rubber-lined 1
Underflow pump Carbon steel, rubber-lined 1
1
Filtrate pump
Rotary vacuum 500 square feet area Carbon steel, polypropylene 2
filter : cloth I
Lime silo . Carbon steel ', 2
Soda ash silo '. Carbon steel 1
Chemical mix 5000 gallons Carbon steel 1
tank j
Chemical mix 5000 gallons ] Carbon steel 2
tank
Clarifier 11 60 diameter x 14 high ' 1
Clarifier *2 ; 60 diameter x 14 high !
Filtrate tank ,4 diameter x 7 high ; Carbon steel , 1
Recirculation Carbon steel, tar coating 4
tank
115
-------
F-!
A-l
FIGURE 13-4. PROCESS DIAGRAM FOR KERR-McGEE,
TRONA INDUSTRIAL BOILER FGD SYSTEM
EQUIPMENT LIST
Equipment no.
A-l
F-l
H-l
P-l
T-l
Name
Absorber
F.D. fan
Reheater
Recirculation
pump
Recirculation
tank
Size, feet
30 diameter x 35 high
50°F reheat
125 gpm
Ma ter i
Carbon
lined
Carbon
Carbon
Carbon
steel, fiberglass
, 316L SS trays
steel
steel
steel, rubber-lined
No.
2
2
2
2
2
116
-------
F-l
T-1
A-1
Q-l
T-3
T-2
J
P-l
FIGURE 13-5. PROCESS DIAGRAM FOR TEXASGULF,
GRANGER INDUSTRIAL BOILER FGD SYSTEM
EQUIPMENT LIST
Equipment no.
A-1
F-l
P-l
Q-l
T-1
T-2
T-3
Name i Size, feet i Material of construction
Absorber
15.0 diameter x 20.5 ; 316L SS, trays Inconel 625
high ;
F.D. fan ;
Recirculation 550 gpm >? 15 psig
pump i
Quencher
Liquor head '
tank
Recirculation
tank
Head tank
No.
1
2
1
1
1
1
117
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1. REPORT NO.
TECHNICAL REPORT DATA
(flease read Instructions on the reverse before completing)
EPA-600/7-78-052b
2.
3. RECIPIENT'S ACCESSION NO.
EPA INDUSTRIAL BOILER FGD SURVEY: Second
Quarter 1978
5. REPORT DATE
July 1978
«. PERFORMING ORGANIZATION CODE
J. Tuttle, A. Patkar, N. Gregory, and M. Eckstein
8. PERFORMING ORGANIZATION REPORT NO
9. PERFORMING ORGANIZATION NAME AND ADDRESS
PEDCo. Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
10. PROGRAM ELEMENT NO
EHE624
11. CONTRACT/GRANT NO.
68-02-2603, Task 36
E AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Task Final; 4-6/78
ERL-RTP pr°iect
14. SPONSORING AGENCY CODE
E PA/600/13
Michael McAdams, Mail Drop 61,
of flue gas desulfurization (FGD) systems to industrial boilers. Design and operation
data has been obtained from 152 FGD control systems, with a capacity of
8.3 million acfm (2200 MW equivalent). An average of more than six FGD units
per year have come on line since 1972, indicating FGD to be a viable method of con-
trolling SO2 emissions. The information was obtained by a survey of plant personnel,
control system vendors, regulatory agencies, and consulting engineering firms. The'
data is given in two types of tables: one gives summary information; the other, de-
tailed information. Summary tables present information as a function of control pro-
cess, control system vendor, disposal techniques, operation status, start-up date,
and flue gas capacity. Detailed information includes: control system design, econo-
mics, operating experience, problems and solutions, waste disposal techniques, and
maintenance practices.
7.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS
c. COS AT I Field/Group
Pollution
Flue Gases
Desulfurization
Boilers
Waste Disposal
Maintenance
Pulping
Chemical Industry
Pollution Control
Stationary Sources
Industrial Boilers
13B
2 IB
07A,07D
ISA
15E
13H
STATEMENT
Unlimited
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
124
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2320-1 (9-73)
118
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