United States EPA-600/7-81-083 Environmental Protection Agency April 1981 Research and Development EPA Industrial Boiler FGD Survey--1979 Prepared for Office of Air Quality Planning and Standards Regional Offices 1 - 10 Prepared by Industrial Environmental Research Laboratory Research Triangle Park NC 27711 ------- 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 endorsement or recommendation for use. This document is available to the public through the National Technical Informa- tion Service, Springfield, Virginia 22161. ------- EPA-600/7-81-083 April 1981 DCN 81-203-001-13-16 SPECIAL REPORT EPA INDUSTRIAL BOILER FGD SURVEY - 1979 by Jay R. Hoover RADIAN CORPORATION 8501 Mo-Pac Boulevard Austin, Texas 78759 EPA Contract No. 68-02-3171, Task 13 Project Officer: J. David Mobley Industrial Environmental Research Laboratory Office of Environmental Engineering and Technology Research Triangle Park, North Carolina 27711 Prepared for: U.S. ENVIRONMENTAL PROTECTION AGENCY Office of Research and Development Washington, D.C. 20460 t!.f!. Emr-iroriental Protection Agency "v-xn 5, Lil-ary (5PL-16) >^JG ;*, Seaborn Scvoet, Loom 1670 Cliicaao, IL SC6C4 ------- ABSTRACT This Special Report presents the results of a project sponsored by EPA's Industrial Environmental Research Laboratory to survey vendors and operators of flue gas desulfurization (FGD) systems applied to industrial boilers for the 1979 calendar year. It was found that 123 FGD units were operated throughout 1979. Sodium systems (once through) accounted for 102 of these units and 74 of these sodium systems were applied to small oil- fired steam generators in the California oil fields. The second most prevalent FGD process was the dual alkali system typically used on large coal-fired boilers located primarily in Illinois and Ohio. In addition, there were 98 planned industrial boiler FGD units, most of which are once through sodium systems applied to oil field steam generators. The perfor- mance data (SOz removal) for once through sodium units is high, with all reporting systems achieving greater than 95 percent removal. The lime/ limestone units achieved 85 to 92 percent S02 removal, with the dual alkali units averaging greater than 90 percent 862 removal. Reported reliability for FGD units at seven sites averaged about 95 percent with sodium systems generally achieving greater than and lime/limestone systems less than 95 percent. ii ------- CONTENTS Abstract ii 1. Introduction 1 2. Results 3 2.1 Applications ' 3 2.2 Performance and Reliability 11 Appendix A Detailed Data Summaries 16 Appendix B Process Descriptions and Flow Diagrams 24 iii ------- FIGURES Number Page 1 Growth in number and installed capacity of industrial boiler FGD units, 1972-1979 4 B-l Sodium scrubbing FGD system 26 B-2 Dual alkali FGD system 28 B-3 Lime or limestone FGD system 31 B-4 Spray drying FGD system 33 TABLES Number Page 1 FGD System Applications to Industrial Boiler 5 2 FGD System Applications by Industry and State 7 3 Fuel/Capacity Breakdown for Existing FGD Units 9 4 Summary of Waste Disposal Practices by System Type 10 5 FGD System Vendors 12 6 Reported Performance Data for Existing FGD Units 13 7 Reported Reliability Data for Existing FGD Units 14 A-l Units Operating Throughout 1979 17 A-2 Units Planned, Under Construction, or Started Up in 1979 20 A-3 Units that Terminated Operation or Changed Status in 1979 23 ------- SECTION 1 INTRODUCTION The objectives of this project, sponsored by EPA's Industrial Environmental Research Laboratory in Research Triangle Park, North Carolina, are to: 1) survey vendors and operators of industrial boiler flue gas de- sulfurization (FGD) systems concerning performance and design data, and 2) evaluate and report the collected data for both operating and planned units. The information presented for each plant site includes 1) company name and location, 2) number of boilers and FGD units, 3) boiler fuel type and sulfur content, 4) FGD unit type, capacity and startup date, 5) FGD unit waste disposal practices, and 6) performance characteristics such as S02 removal capability and reliability. This report summarizes the results of the survey for the 1979 calendar year. The status of FGD units in operation throughout 1979 is reported and the FGD units that were purchased, under construction, started up, or terminated during the year are described. A series of quarterly reports on industrial boiler FGD systems was previously compiled for EPA by PEDCo Environmental, Inc. The last report published in that series was EPA-600/7-79-067b, April 1979. That series of reports has been replaced by a series of Special Reports which will present recent information in abbreviated form. These reports, prepared by Radian Corporation, will be updated annually. It should be noted that information regarding utility boiler FGD systems is presented in a separate report series (Reference EPA-600/7-80-029). To obtain the information contained in this report, vendors and operators of FGD systems were contacted. Vendors were asked to provide lists of new units which were started up or under construction in 1979. Operators of new facilities as well as operators of previously identified ------- units (whose names were provided by EPA) were also contacted. Information requested for both operating and planned units included: 1) location and status; 2) actual or projected startup date; 3) number of boilers and FGD units; 4) FGD system type and capacity; 5) type of boiler fuel and sulfur content; and 6) design SOa removal capability. In addition, actual performance data for SC-2 removal efficiency and system reliability were requested for the operating units. Thirty-eight out of fifty-nine companies (64 percent) contacted responded to the survey. For those companies not responding to the current survey, information presented in earlier surveys or in the open literature is reported where appropriate. EPA actively solicits updated information on the implementation and performance of industrial boiler FGD systems. Information for inclusion in future reports should be sent to Jay R. Hoover, Radian Corporation, Post Office Box 9948, Austin, Texas 78766, or J. David Mobley, U. S. Environ- mental Protection Agency, MD-61, Research Triangle Park, North Carolina 27711. ------- SECTION 2 RESULTS This section presents the results of the industrial boiler FGD survey. The trends in application of FGD technology to industrial boilers are dis- cussed in Section 2.1 while performance data (SC>2 removal efficiency and reliability) for operating units are presented in Section 2.2. All of the information collected during the survey is tabulated in Appendix A. The data for existing industrial boiler FGD units operating throughout 1979 are summarized in Table A-l. Table A-2 presents information on units planned, under construction, or started up in 1979, while Table A-3 sum- marizes information for units that terminated operation or changed status in 1979*. Appendix B provides brief process descriptions and flow diagrams for the more prevalent FGD processes, i.e., sodium scrubbing (once through), dual alkali, lime/limestone, and spray drying. 2.1 APPLICATIONS This survey identified that there were 123 industrial boiler FGD units that operated throughout 1979. In addition, 98 were either planned, under construction, or started up in 1979. Figure 1 illustrates the growth in the number and installed capacity of industrial boiler FGD units for the period 1972 through 1979. This figure shows that the average installed capacity per unit has increased significantly over this period. Several very large units (>100,000 scfm) installed on coal-fired boilers during 1977-1978 contributed to this trend. The breakdown between the different types of FGD processes applied to industrial boilers is presented in Table 1. This table shows that most of the existing and planned FGD applications to industrial boilers are once through sodium systems. The second most -'Compared to the listing in EPA-600/7-79-067b. This publication reported FCD unit status in the first quarter of 1979. 3 ------- -X H H O H CO W > H O 6000 I w 5000 o o o 4000 p 3000 2000 1000 I 1 J_ 200* H Pi w w 100 72 73 74 75 76 77 YEAR 78 79 Figure 1. Growth in number and installed capacity of Industrial Boiler FGD Units, 1972-1979. ^Includes only those units that were operating throughout 1979. Does not include units that were shut down prior to 1979. ------- TABLE 1. FGD SYSTEM APPLICATIONS TO INDUSTRIAL BOILERS System Type Sodium Scrubbing (once through) Dual Alkali Lime /Limes tone Spray Drying Ammonia Sulf-X Undecided Existing* Units 102 17 2 - 2 - - TOTALS 123 « Planned**Units 81 10 1 2 1 1 2 98 * Operating throughout 1979. **Planned, under construction, or started up in 1979. ------- prevalent type of FGD system used on industrial boilers is the dual alkali process. The use of FGD systems in industrial applications is not as widespread as Table 1 implies. Table 2 shows that most of the industrial boiler FGD applications are concentrated in a few industrial groups. For example, of the 123 existing FGD units identified, 74 are installed on steam generators used in California for thermally-enhanced oil recovery operations.* Sixty- seven of these are located at three oil field sites. Over 95 percent of these oil field applications are once through sodium units. The liquid waste from these sodium scrubbers is generally disposed of in evaporation ponds or by well injection. For many applications outside of the oil fields, the liquid waste will require more extensive treatment prior to disposal. There- fore, process complexity and cost may increase significantly and it is expected that once through sodium systems will not find the same widespread use in other applications. For non-oil field applications, General Motors and Caterpillar Tractor are leaders in demonstrating FGD technology for coal-fired industrial boilers, while the pulp and paper industry has experimented with using waste alkaline streams to achieve SOa removal in scrubbers designed primarily for particu- late removal. Experience with industrial boiler FGD technology is lacking in most other industrial sectors as there are only 17 operational FGD units out- side of the industry groups discussed above. Table 2 also shows the states that contain most of the industrial boiler FGD systems. Seven states have over 90 percent of the existing units. California has the largest number due to stringent environmental standards and the thermally-enhanced oil recovery operations. Illinois has the second largest number of units and Ohio ranks third. This is due in part to the high sulfur coal reserves in these states and the efforts of General Motors and Caterpillar Tractor to utilize this coal in an environmentally acceptable manner. Other states have less than five units each and many have no systems at all. *Steam is injected into producing zones to facilitate heavy oil production. Lease crude is fired in small steam generators and scrubbers are required for SOa control from new facilities. ------- TABLE 2. FGD SYSTEM APPLICATIONS BY INDUSTRY AND STATE Number of Units Industrial Groups Oil Companies TEOR Applications*** General Motors Caterpillar Tractor Pulp/Paper Chemical Companies Other Existing* 74 14 12 6 7 10 123 Planned** 80 - 5 4 4 5 98 Applications by State California Illinois Ohio New York Wyoming Arkansas Georgia Other Number of Units Existing* 79 13 7 4 4 3 3 10 123 Planned** 79 5 — 1 1 - - ^ 12 98 * Operating throughout 1979. **Planned, under construction, or started up•in 1979. ***Thermally-enhanced oil recovery. ------- Table 3 presents an analysis of existing industrial boiler FGD units by fuel type and capacity. This table illustrates several significant trends. The once through sodium system, which is the most prevalent, finds primary application to small oil-fired steam generators. Sodium hydroxide is used as the scrubbing medium for these units, while sodium carbonate is used for most of the larger sodium units. These units are less complex and therefore require lower capital investment than other FGD processes. However, chemical costs for sodium carbonate or sodium hydroxide are high. Therefore, for small capacity applications to boilers firing low-to-medlum sulfur fuels*, sodium systems will generally be preferred unless waste disposal costs are prohibitively expensive. -T Once through sodium systems, primarily sodium hydroxide, are also the most prevalent FGD processes applied to small coal-fired boilers. For large coal-fired boilers, dual alkali units are the most prevalent. The equipment required to regenerate the expensive sodium alkali in the dual alkali process can be economically justified for large-scale facilities (see Appendix B for descriptions of sodium scrubbing and dual alkali processes). Several once through sodium units on large coal-fired installations use a plant waste stream containing sodium to achieve SOa reduction. These units are typically particulate scrubbers with a waste alkaline liquor added for SOa removal. An example of this waste stream is the caustic stream from the pulp bleaching stage in pulp/paper mills. Most of these applications are in the pulp/paper industry. These installations typically recycle the waste stream to other plant processes or treat it prior to discharge. All of the existing or planned FGD systems produce a liquid or solid waste stream requiring disposal. Table 4 summarizes the waste disposal practices for the existing industrial boiler FGD units. The most prevalent disposal techniques for once through sodium units are evaporation in holding *The oil burned in steam generators typically contains 1-2 wt.% sulfur. Uncontrolled S02 emissions are about 1-2 Ib S02/106Btu. ------- TABLE 3. FUEL/CAPACITY BREAKDOWN FOR EXISTING* FGD UNITS Capacity Fuel Type Sodium Scrubbing (once through) Waste Stream NaOH Na2C03 Dual Alkali Lime /Limes tone Other < 32,000 scfm** Coal Oil 1 9 60 - 4 - - > 32,000 scfm** Coal Oil 5 4 3 . 4 16 13 2 2 * Operating throughout 1979. **32,000 scfm is the estimated volume of flue gas produced by firing approximately lOOxlO6 Btu/hr of coal or 145xl06 Btu/hr of oil. ------- TABLE 4. SUMMARY OF WASTE DISPOSAL PRACTICES BY SYSTEM TYPE* System Type/Disposal Practice Number of Existing**Units ONCE THROUGH SODIUM Holding pond for evaporation 45 Deep-well injection 29 Wastewater treatment and discharge to sewer, river or tailings pond 21 Alkaline scrubbing liquor recycled to other processes 3 Unknown 4 DUAL ALKALI Dewatered slurry to landfill 17 LIME/LIMESTONE Non-fixated slurry to lined pond 1 Dewatered slurry to landfill 1 AMMONIA Wastewater treatment 2 *Based on EPA-600/7-79-0676 **0perating throughout 1979. 10 ------- ponds, well injection, and wastewater treatment. All of the dual alkali systems use landfill for the dewatered slurry or sludge. This technique is also used for one of the lime/limestone units, while the other lime/limestone facility discharges the waste solids from the thickener to a lined disposal pond. The two ammonia scrubbing processes use wastewater treatment consist- ing of anaerobic digestion, followed by an open pond, followed by aerobic digestion. There are many vendors that license industrial boiler FGD systems. Table 5 lists the vendors which supplied/will supply the systems for the operating/planned indust-rial boiler FGD applications. 2.2 PERFOBMANCE AND RELIABILITY Few data concerning actual performance and reliability were obtained from operators during this survey. Table 6 presents the reported performance data while Table 7 summarizes the available reliability data. Reliability is defined as the hours the FGD unit was operated, divided by the hours it was called upon to operate. Actual performance data were reported or obtained for only 24 of the 123 existing units*. The data presented in Table 6 show that the SOa removal capability of the once through sodium units is high, with all reporting systems achieving greater than 95 percent removal. The two lime/limestone units achieved removals of 85 and 91.5 percent. The two dual alkali units achieved greater than 90 percent SO2 removal based on continuous monitoring tests. Reliability data were reported for only 20 of the 123 existing units. Based on these limited data, the following observations can be made: 1) the reliability reported for the 16 once through sodium units was high, *The reported performance data presented were obtained from either continuous on-line monitoring or wet chemical analysis (EPA Method 6). The continuous monitoring data were obtained by EPA in 1979-1980 to provide technical back- ground for the ongoing Industrial Boiler NSPS activities. 11 ------- TABLE 5. FGD SYSTEM VENDORS Vendor* A. D. Little Andersen CE Nat co Ceilcote Combustion Equipment Assoc. Ducon Company Entoleter, Inc. Flakt, Inc. FMC Environmental Equipment Heater Technology Koch Engineering Mikropul Corp . Neptune Airpol, Inc. Pittsburgh Environment & Energy Systems, Inc. Research-Cot trell/Bahco Wheelabrator-Frye/Rockwell Int. SWEMCO, Inc. Thermotics, Inc. W. W. Sly Manufacturing Co. Zurn Industries Carborundum Abrasives*** General Motors*** Getty Oil Co.*** Mobil Oil Co.*** Pfizer, Inc.*** Type of System** SS SS SS SS SS SS SS SS SS,DA SS SS,AM SD SS,DA,AM SX LS SD SS SS SS DA L SS SS SS L Number Planned 4 2 — - 6 . • - 1 8 52 6 1 7 1 - 1 -. 5 1 • 1 — 2 - - 98 of Units**** Operating 2 _ 1 29 2 - 2 — 17. 1 7 .— 8 - 1 ' - 2 1 - 4 — 6 11 28 1 123 * For units planned or operating throughout 1979 ** SS = Sodium Scrubbing (once DA = Dual Alkali SD = Spray Drying L = Lime LS = Limestone AM = Ammonia SX = Sulf-X thraugh) ***These companies have developed capabilities within their own organizations for FGD system desien. ****0perating means operating throughout 1979. Planned means planned, under construction, or started up in 1979. 12 ------- TABLE 6. REPORTED PERFORMANCE DATA FOR EXISTING* FGD UNITS Texas Gulf Chemicals Alyeska Pipeline Service Co. Getty Oil Co. Cat Caayon Field Minn-Dak Farmers Cooperative Kerr-McGee Chemical Corp. Pfizer, Inc. Getty Oil Kern River Field General Motors-St. Louis General Motors-Parma Mead Paperboard Number Total of FGD Capacity Units scfm 1 55,000 2 140.000 1 50,000 1 5,000 2 164,000 1 245,000 1 245,000 1 100,000 10 891.000 1 £4.000 1 38,000 1 16,000 1 100.000 Process Type** Limestone Waste soda ash Sodium hydroxide Sodium hydroxide Ammonia Sodium carbonate Sodium carbonate Lime Soda ash Sodium hydroxide Dual alkali Dual alkali Sodium carbonate Ib SO»/10'Btu Boiler at Fuel scrubber exit Coal 0 44 3.6% S Coal 0.01 0.75% S Diesel Oil 0.013 0.07% S Oil 0.07 4.0% S Lignite DNR 1.0% S Coke, coal, DNR oil: 0.5-5.0% S Coke, coal, DNR oil: 0.5-5.0% S Coal . 0.83 3.5% S Oil 0.04 1.0% S Coal 0.2 3.2% S Coal 0.33 2.5% S Coal 0.24 2.5% S Oil DNR 1.5-3.0% S Percent S02 Removal*** 01 ^a yi .D 99. 8b 9«.0b 98. Ob 95. Ob 99. lb 98. lb 85. Ob 97 .Ob 96. 0» 91. 3« 93. 8« 96. 0" * Units that operated throughout 1979. ** For once through sodium systems, the makeup sodium alkali is specified (where known) i.e., sodium hydroxide, sodiu carbonate, soda aah, etc. *** Method of determining performance: a « On-line continuous monitoring instrumentation. Data taken in 1979-1980. b - EPA Method 6 **** Continuous monitoring data was taken with lime being used as the sorbent. DNR - Data not reported. ------- TABLE 7. REPORTED RELIABILITY DATA FOR EXISTING* FGD UNITS Number Total of FGD Capacity Process Installation Name Rickenbacker Air National Guard Texas Gulf Chemicals Co. Minn-Dak Farmers Coop. Nekoosa Papers Kerr-McGee Chemical Corp. Pfizer, Inc. Getty Oil Co. Kern River Field *Units that operated Units scfm 1 55,000 2 140,000 2 164,000 2 211,000 2 490,000 1 100,000 10 891,000 throughout 1979. **For once through sodium systems, the hydroxide, sodium "''"Reliability data, carbonate, soda ash Type** Lime/ Limestone Waste Soda Ash Ammonia Caustic Waste Sodium Carbonate Lime Soda Ash makeup sodium , etc. Boiler Reliability*** percent Fuel 1234 Coal 3.6% S 98 94 96 25 Coal 0.75% S 100 100 100 100 Lignite 1.0% S 97.8 100 94.4 98. Coal 1.0-1.5% S 100 100 98 100 Coke, coal, oil 0.5-5.0% S 100 100 100 100 Coal 3.5% S 94.0 95.0 90.0 89. Oil 1.0% S 100 DNR DNR 98. alkali is specified (where known), i.e., Yr 78.3 100 5 97.7 99.5 100 0 92.0 9 98.9 sodium given for each quarter and the year, is defined as: the hours the FGD unit operated x 100% the hours the FGD unit was called upon to operate DNR - Data not reported. ------- generally greater than 98 percent; 2) the lime/limestone units reported 6 of 8 quarterly reliabilities of 90 percent or higher; 3) the two ammonia systems reported greater than 97 percent reliability for the year. No reliability data were reported for dual, alkali systems. 15 ------- APPENDIX A DETAILED DATA. SUMMARIES 16 ------- TABLE A-l. UNITS OPERATING THROUGHOUT 1979 Company Name and Location (Vendor) General Motors Corporation St. l.ouis, MO (A. II. Little) •Tezaco, Inc. San Ardo, CA (Ceilcote) •Mobil Oil Company San Ardo, CA (In~llouse Design) General Motors Corporation Parma. OH (GM Environmental) •Canton Textiles Canton, GA (FMC Environmental Equipment) Caterpillar Tractor Company Joliet. IL (Zurn Industries) General Motors Corporation Dayton, Oil (Entoleter, Inc.) •Firestone Tire and Rubber Company Potlstovm, PA (FMC Environmental Equipment) •Great Southern Paper Company Cedar Spring, GA (Neptune Airpol, Inc.) •ITT Rayonier, Inc. Fernandes Beach, CA (Neptune Airpol, Inc.) Mead Paperboard Company Stevenson, AL (Neptune Airpol, Inc.) • Based on EPA 600/7-79-067b ** For once through sodium systems. Number Number Start-Up of of FGD Capacity Date Boilers Units (scfm) 0/72 2 2 64,000 total 11/73 29 29 347,000 total 0/74 28 28 175,000 total 3/74 4 4 128.000 total 6/74 1 1 25,000 9/74 2 2 67,000 total 9/74 2 2 55,400 total 1/75 1 1 8,070 0/75 2 2 420,000 total 0/75 4 2 176,000 total 0/75 2 1 100,000 the makeup sodium alkali is specified (where Process Type" Sodium hydroxide Sodium hydroxide Sodium hydroxide Dual alkali (dilute) Caustic waste Dual alkali (dilute) Sodium hydroxide Dual alkali Caustic Sodium hydroxide Sodium carbonate known) , i.e.. Boiler Fuel Coal 3.2% S Oil 1.7% S Oil 2.0-2.25% Coal 2.5% S Coal 0.8% S Coal 3.2% S Coal 0.7-1.3% S Coal 2.5-3.0% S Bark, oil. Bark, oil 2.0-2.5% S Oil 1.5-3.0% S •odium hydroxide. Design SOa Removal Efficiency, % 90 73 $0 S 90 70 90 85 90.5 coal 85-99 85 95 (Continued) sodium DNR - Data not reported ------- TABLE A-l. UNITS OPERATING THROUGHOUT 1979 (Continued) oo Number Company Name and Location Start-Up of (Vendor) D«te Boilers General Motors Corporation 6/73 4 Tonowanda , NY (FHC Environmental Equipment) •Georgia Pacific 6/75 1 Crossett. AR (Neptune Airpol, Inc.) Caterpillar Tractor Company 10/75 4 Mossville, IL (FHC Environmental Equipment) Nekoosa Papers, Inc. 2/76 1 Ashdown. AS (Neptune Airpol, Inc.) Rickenbacker Air National Guard 3/76 7 Columbus, OB (Research Cottrell-Bahco) General Notora Corporation 4/76 2 Pontiac, HI (GH Environmental) FMC 5/76 2 Green River, WY (FHC Environmental Equipment) Tezasgulf Chemicals Company 9/76 2 Granger, WY (SWEHCO) Alyeska Pipeline Service Company 6/77 3 Valdez, AK (FHC Environmental Equipment) Getty Oil Company 6/77 1 Cat Canyon Field #8 Generator Santa Haria, CA (In- House Design) Number of FGD Capacity Units (scfm) 4 132,700 total 1 220,000 4 140,000 total 2 211.000 total 1 55.000 2 107.300 total 2 446.000 total 2 140.000 total 1 50.000 1 5.000 Process Type" Sodiun hydroxide Caustic waste stream DtTal alkali Caustic waste stream Limestone or Lime Sodium hydroxide Sodium carbonate Waste soda ash Sodium hydroxide Sodium hydroxide Design Boiler SO* Removal Fuel Efficiency. % Coal 90 1.2% S Bark, coal, oil 80 1.5-2.0% S Coal 90 3.2% S Coal 90+ 1.0-1.5% S Coal 90 3.6% S Refuse. Coal 90 0.84% S Coal 80 1.0% S Coal 90 0.75% S Diesel oil 96+ 0.07% S Oil 94 4.0% S • Based on EPA 600/7-79-067b ** For once through sodium systems, carbonate, soda ash, etc. DNR - Data not reported (Continued) the makeup sodium alkali is specified (where known), i.e., sodium hydroxide, sodium ------- TABLE A-l. UNITS OPERATING THROUGHOUT 1979 (Continued) Company Name and Location (Vendor) Wahpeton, Nl) (Koch Engineering) Caterpillar Tractor Company Morton, IL (/urn Industries) Kerr-McGee Chemical Corporation Argus Facility Trona, CA (Combustion Equipment Association) Caterpillar Tractor Company East Peoria, IL (FMC Environmental Equipment) •Kernridge Oil Company McKittrick. CA (Heater Technology) (Thermotics) (C-E Natco) "Chevron, USA, Inc. Bukerfield, CA (Koch Engineering) Pfizer, Inc. East St. Louis, IL (In-House Resign) Getty Oil Company Kern River Field Bakersfield, CA (In-House Design) • Based on EPA 600/7-79-067b ** For once through sodium systems. Number Number Start-Up of of FGD Capacity Date Boilers Units (scfm) 6/77 2 2 164,000 total 1/78 2 2 38,000 total 4/78 1 1 245,000 6/78 1 1 245,000 4/78 4 4 210.000 total 6/78 1 1 12.000 7/78 1 1 12,000 1/79 1 1 12,000 7/78 18 ' 3 248,000 total 7/79 12 2 146,000 total 9/78 3 1 100.000 12/78 87 10 891,000 total the makeup sodium alkali is specified (where Process Type" Ammonia Dual alkali (dilute) Sodium carbonate Sodium carbonate Dual alkali Sodium hydroxide Sodium hydroxide Sodium hydroxide Sodium carbonate Sodium carbonate Lime Soda ash known), i.e.. Design Boiler SO* Removal Fuel Efficiency, % Lignite 1.0% S Coal 3.2% S Coke, coal. oil 0.5-5.0% S Coke, oil 0.5-5.0% S Coal 3.2% S Oil 1.1% S Oil 1.1% S Oil 1.1% S Oil 1.1% S Oil 1.1% S Coal 3.5% S Oil 1.05% S sodium hydroxide, sodium DNR 90 98 98 90 DNR DNR DNR 90 90 95 96 DNR - Data not reported ------- TABLE A-2. UNITS PLANNED, UNDER CONSTRUCTION OR STARTED UP IN 1979 Number Number Company Name and Location Start— Up of of FGD (Vendor) Date Boilers Units Caterpillar Tractor Company 3/79 3 3 Mapleton, IL (FMC Environmental Equipment) San Ardo. CA (Ducon Co.) •Mobil Oil Company 4/79 7 7 Buttonwillow, CA (Heater Technology) •Inland Container Corporation 5/79 1 1 New Johnsonville, TN (Neptune Airpol. Inc.) Sun Production Company 9/79 1 1 Newhall. CA (C-E Natco) 9/79 1 1 Stratbmore Paper Company 8/79 1 1 Woronoco, MA (Mikropul Corporation) Mobil Oil Company Delivered 8/79 DNR 20 McKittrick. CA (Heater Technology) Atlantic Richfield 10/79 DNR DNR Ferndale, WA (FMC Environmental Equipment) Celanese Corporation 12/79 1 1 Cumberland, MD (Rockwell-Wheelabrator Frye) Boise Southern 12/79 2 2 DeRidder, LA (Neptune Airpol, Inc.) Getty Oil Company 12/79 2 2 McKittrick. CA (In-House Design) • Based on EPA-600/7-79-0«7b ** For once through sodium systems, the makeup sodium alkali ia specified ( Process Type" Dual alkali (concentrated) Sodium carbonate Sodium carbonate Ammonia Sodium hydroxide Sodium hydroxide Sprayer dryer- Lime Sodium hydroxide Sodium (once through) Spray dryer- Lime Sodium hydroxide Sodium hydroxide inhere known), i.e.. Boiler Fuel Coal 3.2% S f\l -m VI 1 1.7% S Oil 1.1% S Wood and spent liquor <3.0% S Oil 1.2% S Oil 1.4% S Coal, oil > 0.75-3.0% S DNR DNR Coal 3.2% S Primary fuel: wood waste Secondary Fuels: natural gas and # 2 fuel oil Oil 1.0-1.1% S sodium hydroxide, so Design SOi Removal Efficiency, % 90 95 . 85 90 85 85 75 DNR DNR 85 85% for #2 Fuel Oil 90-95 (Continued) dium carbonate, soda ash, etc. DNR - Data not reported ------- TABLE A-2. UNITS PLANNED, UNDER CONSTRUCTION OR STARTED UP IN 1979 (Continued) Company Name aud Location (Vendor) Sante Fe Energy Taft, CA (Heater Technology) •Carborundum Abrasives Buffalo, NY (Carborundum Environmental Systems. Ltd.) Caterpillar Tractor Company Hapleton, IL (FMC Environmental Equipment) Union Oil Company McKittricfc. Ca (Heater Technology) Shell Oil Company Coalinga, CA (Ducon Company) Chevron, USA, Inc. Maricopa, CA (Heater Technology) Mobil Oil Company Taft, CA (Heater Technology) Arco/Polymers Beaver Valley Plant, Honaca, PA (FHC Environmental Equipment) Union Oil Company McKittrick. CA (Anderson 2000) Texaco, Incorporated Santa Haria. CA (Thermotics, Inc.) Start-Up Date 12/79 3/81 7/81 0/80 1/80 1/80 3/80 6/80 7/80 11/80 3/80 7/80 6/81 Delivered 3/80 Delivered 7/80 8/80 8/80 7/81 10/81 8/80 Number of Boilers 8 3 1 2 2 1 2 2 2 1 12 DNR DNR 3 1 2 1 1 Number of FGD Units 1 3 1 1 2 8 3 1 2 3 4 1 Process Type** Dual alkali Sodium (once through) Sod inn (once through) Lime Dual alkali (concentrated) Sodium hydroxide Sodium hydroxide Sodium hydroxide Sodium hydroxide Dual alkali Sodium hydroxide Sodium hydroxide Design Boiler SO, Removal Fuel Efficiency, % Oil -1.1* S Oil -1.1* S Oil -1.1% S Coal 2.2% S Coal 3.2% S Oil 0.7-1.2% S Oil 0.6* S DNR DNR Coal 3.0% S Oil 0.7-1.2% S Oil 3.5% S 96 96 96 95 90 95 90 DNR DNR 90 95 98 (Continued) * Based on EPA-«00/7-79-0«7b ** For once through sodium systems, the makeup sodio carbonate, soda ash, etc. DNR - Data not reported alkali is specified (where known), i.e., sodium hydroxide, sodium ------- TABLE A-2. UNITS PLANNED, UNDER CONSTRUCTION OR STARTED UP IN 1979 (Continued) to 10 Company Name and Location (Vendor) Mobil Oil Company Bakertfield. CA (Heater Technology) Union Oil Company McKittrick, CA (Koch Engineering) Shell Oil Company Taft. CA (Neptune Airpol. Inc.) Chevron. USA. Inc. Bakersfleld. CA (Koch Engineering) Grisaon Air Force Base Bunker Hill. IN (Neptune Airpol, Inc.) Union Oil Company Ouadalupe. CA (Heater Technology) Shell Oil Company Bakertfield, Ca (Neptune Airpol. Inc.) Cranaton Print Works Fletcher, NC (W.W. Sly Manufacturing Co.) Grace Petroleum Corporation Pismo Beach, CA (Thermotics. Inc.) Commonwealth of Pennsylvania Harrisbnrg. PA (Pittsburgh Environment and Energy Sytema) St. Regis Paper Company Sartell. MN (Neptune Airpol, Inc.) Tenneco Oil Green River. WY (Flakt, Inc.) Start-Up Date Delivered 10/80 11/80 7/81 0/82 12/80 0/81 1/81 2/81 3/81 5/81 5/81 6/81 5/82 4/82 Number Number of of FGD Boilers Units DNR 8 1 1 4 2 3 1 DNS 2 3 1 1 1 8 1 1 1 4 4 1 1 1 1 J 1 Process Typ.«» Sodium hydroxide Sodium hydroxide Sodium hydroxide DNR Dual alkali (concentrated) Sodium hydroxide Sodium hydroxide Waste alkali Sodium hydroxide Sulf-X (iron sulfide slurry) Lime/ Soda ash Soda ash Design Boiler SO, Removal Fuel Efficiency, % DNR DNR Oil 95 0.7-1.2% S Oil 95 1.3* S DNR DNR Coal DNR 3.0% S Oil 95 2.2% S Oil 95 1.1% S Coal DNR 1.0-3.0% S Oil 98 1.18% S Coal 90 1.82% S Coal. bark. 90 sludge 0.45% S Coil 93 0.8% S * Based on EPA «00/7-79-Oo7b ** For once through sodium systems, the makeup sodium alkali is specified (where known), i.e.. sodium hydroxide, sodium carbonate. aod« ash, etc. DNR - Data not reported ------- TABLE A-3. UNITS THAT TERMINATED OPERATION OR CHANGED STATUS IN 1979* Company Name and Address C.A.M Houston, TX Double Barrell Oil Company Bakersficld, CA E. I. DuPont de Nemours & Company Athens, GA Northern Ohio Sugar Company Freemont, OH NJ OJ Phillip Morris, Inc. Chesterfield, VA Reichold Chemicals Pensacola, FL Western Correctional Institute Pittsburgh, PA Vendor Never Selected C-E Natco Never Selected Great Western Sugar Company Flakt, Inc. Neptune Airpol Pittsburgh Environmental & Energy Systems Process Typa Never Selected Caustic Never Selected Water (alkali addition capability) Sodium carbonate Sodium carbonate FeS; Sulf-X Status April 1979** End of 1979 Planned Cancelled Operating Shut down Planned Cancelled Operating See Comments Under Construction Cancelled Operating Shut down Planned Cancelled Comments Decision was made to not build cogencra tion facility. Went out of business. Boiler fires low sulfur fuels or natural gas. Used for particulate removal only; boiler currently burning low sulfur coal . Boiler fires low sulfur fuels or natural gas. Part of plant that uses FGD system shut down. Did not install FGD unit; decided to fire natural gas. Sulf-X system will be installed at a different site. » Compared to the status reported in EPA-600/7-79-067b "Reported in EPA-600/7-79-067b ------- APPENDIX B PROCESS DESCRIPTIONS AND FLOW DIAGRAMS 24 ------- APPENDIX B Brief process descriptions and flow diagrams for the most prevalent types of FGD processes identified in this survey are presented below. Sodium Scrubbing (once through) Sodium scrubbing processes are capable of achieving high SG2 removal efficiencies over a wide range of inlet SQz concentrations. However, these processes consume a premium chemical and produce an aqueous waste for disposal. A simplified process flow diagram is presented in Figure B-l. Sodium scrubbing processes currently being used in industrial boiler FGD applications employ a wet scrubbing solution of sodium hydroxide (NaOH) , sodium carbonate (NazCOs) or an alkaline waste stream to absorb SOa from the flue gas. The operation of the scrubber is characterized by a low liquid-to-gas ratio and a sodium alkali sorbent which has a high reactivity relative to lime or limestone sorbents. Additionally, the scrubbing liquid is a solution rather than a slurry because of the high solubility of sodium salts. The S02 absorption reactions which take place in the scrubber are: 2 NaOH + S02 — *Na2S03 + H20 Na2C03 + S02— *Na2S03 + C02 Na2S03 + S02 + H20—*2 NaHSOs Simultaneously, some sodium sulfite reacts with the oxygen in the flue gas to produce sodium sulfate: Na2S03 The scrubber effluent, therefore, contains a mixture' of sodium'' salts. 25 ------- REHEATER (OPTIONAL) STACK SCRUBBER FLUE GAS LIQUID WASTE TO TREATMENT OR DISPOSAL 70.1995-1 Figure B-l. Sodium scrubbing FGD system. 26 ------- Chemical storage and handling equipment are auxiliaries associated with sodium scrubbing systems. Sodium carbonate reagent handling require- ments include dry storage, usually in silos. A conveyor system is generally used to transport the reactant from the silo to a mixing tank, where the sodium alkali is dissolved to produce the scrubbing solution. The solution from the mix tank is pumped to a larger hold tank where it combines with the scrubber effluent. The majority of the hold tank liquor is recycled to the scrubber with a slipstream going to waste treatment and disposal. For small sodium hydroxide systems, especially in thfe California oil fields, sodium hydroxide solution is often trucked in and stored in tanks at the scrubbing site. Therefore, no solids handling equipment is required for these installations. Dual Alkali Process The dual alkali process, developed and utilized by industry in this country, uses a clear sodium alkali solution for SC-2 removal and produces a calcium sulfite and sulfate sludge for disposal. Although dual alkali pro- cesses produce a throwaway by-product, a regeneration step is employed to regenerate the active sodium alkali for S02 sorption. A simplified process flow diagram is presented in Figure B-2. The process can be divided into three principal areas: absorption, regeneration, and solids separation. The principal chemical reactions for a sodium/lime dual alkali system are illustrated by the following equations: Absorption 2 NaOH + S02 -^. Na2S03 + H20 Na2C03 + S02 —•* Na2S03 + C02 Na2S03 + S02 + H20 -^ 2 NaHS03 Na2S03 + 1/2 02 —*• Na2SOi» 27 ------- N3 00 SCRUBBER FLUE GAS WASTE CALCIUM SALTS TO DISPOSAL 70-1996 1 Figure B-2. Dual alkali FGD system. ------- Regeneration Ca(OH)2 + 2NaHS03 -^Na2S03 + CaS03-l/2H20 + 3/2 H20 Ca(OH)2 + Na2S03 + 1/2H20 — *• 2NaOH + CaS03-l/2 H20 Ca(OH)2 + Na2S(H + 2H20 — *• 2NaOH + CaS04'2H20 In the scrubber, S02 is removed from the flue gas due to reaction with NaOH and Na2C03. Because oxygen is present in the flue gas, sulfite oxidation also occurs. Most of the scrubber effluent is recycled back to the scrubber; however, a slipstream is withdrawn and reacted with slaked lime in the regeneration reactor. The presence of sulfate in the system is undesirable in that it converts active sodium to an inactive form, thus lowering S02 removal or increasing sodium consumption for a fixed S02 removal . The regeneration reactor effluent, which contains calcium sulfite and sulfate is sent to a thickener where the solids are concentrated. The thickener overflow is returned to the system, and the underflow containing the calcium solids is further concentrated in a vacuum filter (or other device) to about 50 percent solids or more. The solids are washed, to reduce the soluble sodium salts in the adherent liquor prior to disposal, and the wash water is returned to the system. Chemical storage and handling equipment are the principal auxiliaries associated with dual alkali systems. Receiving, storage, handling, and preparation facilities are required for both lime and the sodium alkali (either sodium hydroxide or sodium carbonate) . The types of facilities needed for the sodium alkali are described in the once through sodium process description. Lime facilities include silos for dry storage and a slaker. 29 ------- Lime and Limestone Processes The lime and limestone FGD processes use a slurry of calcium oxide or calcium carbonate to absorb S02 in a wet scrubber. A by-product calcium sulfite/sulfate sludge is produced for disposal. A simplified process flow diagram is presented in Figure B-3. The absorption of S02 from flue gases by a lime or limestone slurry involves both gas-liquid, and liquid-solid mass transfer. The chemistry is complex, involving many side reactions. The overall reactions are those of S02 with lime (CaO) or limestone (CaC03) to form calcium sulfite (CaSOa'1/2 H20) with some oxidation of the sulfite to form calcium sulfate (CaSOif*2H20). These reactions can be represented as follows: Lime S02 + CaO + 1/2 H20 — » CaS03'l/2 H20 S02 + 1/2 02 + CaO + 2H20 — Limestone S02 + CaC03 + 1/2 H20 ^ CaS03'l/2 H20 + C02 S02 + 1/2 O2 + CaC03 + 2 H2O — »• CaSO!t'2H20 + C02 The calcium sulfite and sulfate crystals precipitate in a reaction vessel or hold tank which is designed to provide adequate residence time for solids precipitation as well as for dissolution of the alkaline additive. The hold tank effluent is recycled to the scrubber to absorb additional S02. A slipstream from the hold tank is sent to a solid-liquid separator to re- move the precipitated solids from the system. The waste solids, which may vary from 35-60 weight percent solids, are generally disposed of by ponding or landfill. 30 ------- LIME 3 • WATER SOLID-LIQUID SEPARATOR LIMESTONE 70-1997 1 SOLID WASTE TO POND OR FILTER Figure B-3. Lime or limestone FGD system. ------- Auxiliary equipment associated with this process includes a reagent preparation system. Reagent preparation may consist of limestone grinding and slurrying or lime slaking. However, for most industrial boilers, due to their small size, preground lime and limestone may be purchased. There- fore, the feed preparation system will generally consist of storage silos and either lime slaking or limestone slurrying equipment. Spray Drying Process In a spray drying process, flue gas is contacted with a solution or slurry of alkaline material in a vessel (spray dryer) of relatively long residence time (5 to 10 seconds). The flue gas SOa reacts with the alkali solution or slurry to form liquid phase salts which are dried in the spray dryer to about one percent free moisture. The alkali is typically lime or sodium carbonate. The spent solids therefore contain either very soluble sodium compounds or relatively insoluble calcium compounds. Generally, the particulate matter is not removed upstream of the spray dryer. Therefore, the particulate collection device (ESP or baghouse) downstream of the dryer will remove both fly ash and the dry sodium or calcium compounds (unreacted sorbent plus sulf ite/sulfate compounds) formed in the dryer. For large capacity units and/or units treating flue gas with high S02 concentrations, recycle of the collected solids may be: economically feasible to increase sorbent utilization. A generalized flow diagram for a typical spray drying process is shown in Figure B-4. Reaction between the alkaline material and flue gas SOz proceeds both during and following the drying prolcess. The -mechanisms of the S02 removal reactions are not well understood. It has not been determined whether S02 removal occurs predominantly in the liquid phase, by absorption into the finely atomized droplets being dried, or by reaction between gas 32 ------- OR SODIUM LIME CARBONATE WATER WATER SOLID WASTE TO DISPOSAL 70-1998-1 Figure B-4. Spray drying FGD system. 33 ------- phase S02 and the slightly moist spray-dried solids. The overall chemical reactions for this process are shown below. S02 + Na2C03 —* Na2S03 + C02 or S02 + CaO + 1/2 H20 —* CaS03*l/2 H20 t In addition to these primary reactions, sulfate salts will be produced by the following reactions: Na2S03 + 1/2 02 —*• Na2S(K and S03 + Na2C03 —*• Na2S04 + C02 or S02 T- CaO + 1/2 02 + 2H20 —*• CaSO^*2H20 The combined particulate matter and sulfite/sulfate salts from the particu- late collection device are typically disposed of in a landfill. Highly- soluble sodium salts will, of course, require more sophisticated disposal techniques than calcium salts. Chemical receiving, storage, handling, and preparation equipment are the principal auxiliaries associated with spray dryer systems. These include facilities for dry chemical storage (silos) and sorbent preparation (slakers for lime and mix tanks for sodium carbonate). 34 ------- TECHNICAL REPORT DATA (Please read Instructions on the reverse before completing) 1. REPORT NO. EPA-600/7-81-083 3. RECIPIENT'S ACCESSION NO. 4. TITLE AND SUBTITLE EPA Industrial Boiler FGD Survey--1979 5. REPORT DATE April 1981 6. PERFORMING ORGANIZATION CODE 7. AUTHOR(S) Jay R. Hoover 8. PERFORMING ORGANIZATION REPORT NO 9. PERFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM ELEMENT NO. Radian Corporation 8501 Mo-Pac Boulevard Austin, Texas 78759 C9BN1B 11. CONTRACT/GRANT NO. 68-02-3171, Task 13 12. SPONSORING AGENCY NAME AND ADDRESS EPA, Office of Research and Development Industrial Environmental Research Laboratory Research Triangle Park, NC 27711 13. TYPE OF REPORT AND PERIOD COVERED Annual; 3/80-3/81 14. SPONSORING AGENCY CODE EPA/600/13 15. SUPPLEMENTARY NOTESIERL_RTP project officer is J. David Mobley, Mail Drop 61, 919/ 541-2915.EPA-600/7-78-052a, -b, and -c, and EPA-600/7-79-067a and -b are related reports. 16. ABSTRACT repOrt. giyes results of a survey of vendors and operators of flue gas desulfurization (FGD) systems applied to industrial boilers for the 1979 calendar year. A total of 123 FGD units were operated throughout 1979. Once-through sodium systems accounted for 102 of these units, of which 74 were applied to small oil-fired steam generators in the California oil fields. The second most prevalent FGD pro- cess was the dual alkali system typically used on large coal-fired boilers , primarily in Illinois and Ohio. In addition, there were 98 planned industrial boiler FGD units, most of which are once-through sodium systems applied to oil-field steam genera- tors. The performance data (SO2 removal) for once -through sodium units is high, with all reporting systems achieving greater than 95% removal. The lime/limestone units achieved 85 to 92% SO2 removal. The dual alkali units averaged greater than 90% SO2 removal. Reported reliability for FGD units at seven sites averaged about 95% with sodium systems generally achieving greater than and lime /limes tone sys- tems less than 95%. 17. KEY WORDS AND DOCUMENT ANALYSIS DESCRIPTORS b.IDENTIFIERS/OPEN ENDED TERMS c. COSATI Field/Group Pollution Boilers Flue Gases Desulfurization Pollution Control Stationary Sources Industrial Boilers 13 B 13A 21B 07A,07D 13. DISTRIBUTION STATEMENT Release to Public 19. SECURITY CLASS (This Report) Unclassified 21. NO. OF PAGES 39 20. SECURITY CLASS (Thispage) Unclassified 22. PRICE EPA Form 2220-1 (9-73) 35 ------- U.S. ENVIRONMENTAL PROTECTION AGENCY Office of Research and Development Center for Environmental Research Information Cincinnati, Ohio 45268 OFFICIAL BUSINESS PENALTY FOR PRIVATE USE. S3OO AN EQUAL OPPORTUNITY EMPLOYER POSTAGE AND FEES PAID US ENVIRONMENTAL PROTECTION AGENCY EPA-335 1ER004IOQ3JC 000045126001 001 USEPA REG V ENV ENG EDITHA M ARDIENTE 230 S DEARBORN ST CHICAGO IL 6Q604 If your address is incorrect, please change on the above label tear off; and return to the above address. If you do not desire to continue receiving these technical reports. CHECK A/ffffO, tear off label, and return it to the above address. Publication No. EPA- GOO/T-SI-OSS ------- |