United States Environmental Protection Agency Industrial Environmental Research Laboratory Research Triangle Park NC 27711 * Research and Development EPA-600/S7-81-012C Sept. 1981 Project Summary EPA Utility FGD Survey January - March 1981 M. Smith, M. Melia, N. Gregory, and K. Scalf This report, generated by a compu- terized data base system, presents a survey of operational and planned domestic utility flue gas desulf urization (FQD) systems, operational domestic particle scrubbers, and Japanese coal- fired utility boiler FGD installations. It summarizes information contributed by the utility industry, system and equipment suppliers, system design- ers, research organizations, and regu- latory agencies. It presents data on system design, fuel characteristics, operating history, and actual perfor- mance. Unit by unit dependability parameters are included. Problems and solutions associated with the boilers, scrubbers, and FGD systems are discussed. The domestic FGD systems are tabulated alphabetically by develop- ment status (operational, under con- struction, or in the planning stages), utility company, system supplier, process, waste disposal practice, and regulatory class. FGD system eco- nomic data, definitions, and a glossary of terms are appended to the report. Current data for domestic FGD sys- tems show 87 systems in operation, 35 systems under construction, and' 104 planned systems. Projected 1990 FGD controlled capacity in the U.S. is 108,612 MW. This Project Summary was develop- ed by EPA's Industrial Environmental Research Laboratory, Research Tri- angle Park, NC, to announce key findings of the research project that is fully documented in a separate report of the same title (see Project Report ordering information at back). Introduction This report is prepared quarterly (every 3 months) by PEDCo Environ- mental, Inc., under contract to the Industrial Environmental Research Laboratory/Research Triangle Park and the Stationary Source Enforcement Division of the U.S. Environmental Protection Agency. It is generated by a computerized data base system, the structure of which is illustrated in Figure 1 (see pages 6 and 7). Table 1 summarizes the status of FGD systems in the United States at the end of March 1981. Table 2 lists the units that have changed status during the first quarter 1981, and Table 3 shows the performance of operating units during this period. Current projections indicate that the total power generating capacity of the U.S. electric utility industry will be approximately 833 GW by the end of 1990.' (This value reflects the annual loss resulting from the retirement of older units, which is considered to be 0.4% of the average generating capacity at the end of each year.2) Approximately 370 GW or 44% of the 1990 total will come from coal-fired units. The distribu- tion of power generation sources, both present (December 1979) and future (December 1990) is shown in Table 4.1 Based on the known commitments to FGD by utilities as presented in Table 1, the percentage of electrical generating ------- capacity controlled by FGD for both the present (March 1981) and the future (December 1990) is shown in Table 5. In light of the revised New Source Performance Standards, actual FGD control is expected to be greater than what is reflected by the figures above. For example, about 40 to 50 systems representing approximately 20,000 to 25,000 MW of generating capacity presently fall into the uncommitted category. These are systems that cannot be included in the committed group at this time because information regarding their status is not ready for public release. Table 1. Number and Total Capacity of FGD Systems Status Operational Under construction Planned: Contract awarded Letter of intent Requesting/evaluating bids Considering only FGD systems No. of units 87 35 27 11 18 48 Total controlled capacity, MW* 32,717 14,835 13,796 8,235 10,191 28,838 Equivalent scrubbed capacity, MW'] 29,538 14,481 13,796 8,235 10,O75 28,850 Total 226 108,612 104,975 * The summation of the gross unit capacities (MWJ brought into compliance with FGD systems regardless of the percent of the flue gas scrubbed by the FGD systems. t The summation of the effective scrubbed flue gas in equivalent MW based on the percent of flue gas scrubbed by the FGD systems. Table 2. Summary of Changes—January - March 1981 In an effort to show general F usage and projected usage trends, Ta 6 gives a current (March 1981) an projected (December 1990) breakdo of throwaway product systems ven salable product systems as a percen the total known commitments to FGD of the end of the first quarter 1981. Highlights: January - March 1981 The following paragraphs highli FGD system developments during first quarter of 1981. Arizona Public Service announc that initial FGD operations at CholL commenced in March 1981. The 3 MW (gross) boiler fires pulverized c with an average sulfur content of O.E Flue gas flows through an ESP tc double-loop, spray-packed tower (f search-Cottrell design) which uses limestone slurry and treats 36% of 1 flue gas. The system operated 1 we and was shut down for a beari inspection. Basin Electric Power Coop announc that a contract was awarded to ~ Under Operational FGD status report Oecember31. 1980 No. 84 MW 28, 187" construction No. 34 MW 14.285 Contract awarded No. 30 MW 14,903" Letter of intent No. 10 MW 7,515 Requesting/ Considering eval. bids No. 16 MW 8,735 No. 49 FGD MW 29,640" Total No. 223 MW 103,26i Arizona Public Service Choi/a 4 Basin Electric Power Coop Antelope Valley 2 Cincinnati Gas & Electric East Bend 2 Colorado Ute Electric Assn. Craig 3 Iowa Electric Light & Power Guthrie Co. Jacksonville Electric Authority St. Johns River Power Park 1 St. Johns River Power Park 2 Kentucky Utilities Hancock 1 Hancock 2 Tennessee Valley Authority Widows Creek 7 Utah Power & Light Hunter 3 Hunter 4 Washington Water Power Creston Coal 2 Creston Coal 3 Creston Coal 4 West Perm Power Mitchell 33 126 -1 650 -1 +7 126 + 1 650 447 -7 440 447 -1 440 +1 720 -1 +1 +7 + 1 60O 600 650 650 -1 -1 -1 -1 720 600 600 650 650 +1 575 -1 + 7 + 7 + 7 575 400 400 300 -1 -1 -1 400 400 300 +7 +7 +7 570 +7 570 +7 570 +7 57C 57C 57C Total 87 29,538 35 14.481 27 13.796 11 8.235 18 10,075 48 28,850 226 104.97& 'Equivalent scrubbed capacity. "This value was modified slightly due to a MW correction. ------- Table 3. Performance of Plant Alabama Electric Tombigbee 2 Tombigbee 3 Amona Electric Power Apache 2 Apache 3 Arizona Public Service Cholla 1 Cholla 2 Cholla 4 Four Corners 1 Four Corners 2 Four Corners 3 Basin Electric Power Coop Laramte River 1 Big Rivers Electric Green 1 Green 2 Centra/ Illinois Light Duck Creek 1 Central Illinois Public Service Newton 1 Cincinnati Gas 4 Electric East Bend 2 Colorado Ute Electric Association Craig 1 Craig 2 Columbus & Southern . Ohio Electric Conesvilte 5 Conesville 6 Commonwealth Edison Powerton 51 Cooperative Power Association Coal Creek 1 Coal Creek 2 Delmarva Power & Light Delaware City 1 Delaware City 2 Delaware City 3 Duquesne Light Elrama 1 -4 Phi/lips 1-6 Gulf Power Scholz 1 Indianapolis Power & Light Petersburg 3 Kansas City Power & Light Hawthorn 3 Hawthorn 4 La Cygne 1 Kansas Power & Light Jeffrey 1 Jeffrey 2 Lawrence 4 Lawrence 5 Kentucky Utilities Green River 1-3 Louisville Gas & Electric Cane Run 4 Cane Run 5 Cane Run 6 FGD system caoacttv MW 179 179 98 98 119 264 126 175 175 229 570 242 242 416 617 650 410 410 411 411 450 327 327 60 60 60 510 408 20 532 90 90 820 540 490 125 420 64 188 200 299 Operational Units — January - FGD capacity on line Flue gas % scrubbed 70 70 50 50 100 too 33 too too 100 too too too 100 100 too 90 90 100 100 100 60 60 too too too 100 IOO N/A" 100 100 100 too 75 70 too too too 100 too too during No information period for this MW period. MW 179 179 98 98 119 264 126 175 175 229 570 242 242 416 617 650 410 410 411 411 327 327 60 60 60 510 408 20 532 90 90 820 540 490 125 420 188 200 299 March 1981 Shut down January 1981 throughout Dependability % pprinri MW AVL 100 too too 93 99 40 79 91 98 450 too 100 90 93 64 too 70 100 100 87 64 IOO 81 100 86 OPR 63 S3 95 92 90 48 78 86 92 44 57 90 93 64 75 69 too 100 too 81 100 83 REL IOO too too 96 IOO 48 78 85 92 90 93 64 77 95 too too 83 81 IOO 83 February 1981 '•' Dependability % UTL AVL OPR REL 63 100 11 100 46 100 27 100 92 100 95 100 92 91 92 99 90 100 95 tOO 38 9 8 9 78 66 66 66 77 94 92 92 92 92 85 85 0 44 83 53 57 100 57 90 86 84 84 93 96 96 96 64 88 88 88 75 97 82 82 69 95 69 73 74 85 100 67 67 5 tOO 5 68 99 100 99 • 0 100 81 0 0 89 82 77 77 so too too too March 1981 " Dependability %' UTL AVL OPR REL 11 100 54 100 27 79 24 53 85 100 99 100 9O 87 84 88 95 90 67 100 7 12 12 12 66 52 53 54 86 4-20 26 78 75 97 99 0 43 47 61 56 55 55 76 96 96' 96 96 S3 89 89 88 81 83 83 82 69 30 52 100 100 5 86 IOO 100 66 97 96 97 o too o too 100 too 59 tOO 46 46 72 IOO 34 34 :,• UTL 44 24 97 80 62 12 52 1 59 0 29 31 95 58 83 52 62 81 0 39 43 28 ------- Table 3. (continued) FGD system t Plant Mill Creek 1 Mill Creek 3 Paddy's Run 6 Minnesota Power ft Light Clay Boswell 4 Minnkota Power ft Light Milton ft. Young 2 Monongahela Power Pleasants 1 Pleasants 2 Montana Power Co/strip 1 Colstrip 2 Nevada Power Reid Gardner 1 Reid Gardner 2 Reid Gardner 3 Northern Indiana Public Service Dean H. Mitchell 1 1 Northern States Power Riverside 6,7 Sherburne 1 Sherburne 2 Pacific Power ft Light Jim Bridget 4 Pennsylvania Power Bruce Mansfield 1 Bruce Mansfield 2 Bruce Mansfield 3 Public Service Co. of New Mexico San Juan 1 San Juan 2 San Juan 3 Salt River Project Coronado 1 Coronado 2 South Carolina Public Service Authority Winyah 2 Winyah 3 South Mississippi Electric R.D Morrow, Sr. 1 R.D. Morrow, Sr. 2 Southern Illinois Power Coop Marion 4 Southern Indiana Gas ft Electric A.B Brown 1 Springfield City Utilities Southwest 1 Springfield Water, Light, ft Power Dallman 3 St Joe Zinc G f. Weaton 1 Tennessee Valley Authority Shawnee 10A Shawnee 10B Widows Creek 7 Widows Creek 8 Texas Power ft Light Sandow 4 Texas Utilities Martin Lake 1 Martin Lake 2 capacity. MW 358 442 72 475 185 618 618 360 360 125 125 125 115 110 740 740 550 917 917 917 361 350 534 280 280 14O 280 124 124 173 265 194 205 60 10 to 575 550 382 595 595 Flue gas % scrubbed IOO 100 too 85 42 100 100 100 100 IOO too 100 99 N/A" 91 91 100 100 100 IOO IOO IOO roo 80 80 50 too 62 62 100 IOO IOO 100 N/A' N/A' N/A' roo IOO 70 75 75 FGD capacity online Shutdown January 1981 February 1981 March 1981 during No information throughout Dependability %"* Dependability %°* Dependability %"•' nttnpff fnr f/lic nnrifirf MW' period, MW MW AVL OPR REL UTL AVL OPR REL UTL AVL OPR REL U 358 51 46 46 42 52 52 52 52 39 36 36 442 00 000 0111 72 IOO 0 100 0 100 475 100 95 100 95 100 82 100 81 100 92 100 185 84 94 100 84 95 100 100 95 88 95 100 618 618 360 96 97 360 98 97 125 85 85 85 85 43 54 54 43 76 73 73 ,25 97 96 97 84 93 90 89 75 100 98 98 ,25 99 99 99 99 100 IOO 100 100 89 67 67 115 IOO 0 0 100 0 0 100 0 110 740 too loo roo roo too 100. too 95 100 too 100 i 740 100 roo 100 roo too too 100 99 too wo too i 550 917 917 917 3S1 100 99 rOO 97 98 92 96 84 1OO 66 82 350 97 76 98 76 96 31 99 25 94 82 94 534 100 90 98 55 81 80 80 75 98 97 98 280 280 ,4O 99 99 99 99 97 97 97 97 IOO WO IOO 1 280 66 8O 80 66 86 88 88 82 85 WO 100 ,24 IOO 0 IOO 92 IOO 12 86 SO 80 ,24 89 98 98 87 IOO IOO 100 86 86 87 87 ,73 59 50 53 49 67 67 67 67 65 72 75 265 99 99 99 99 99 99 99 99 94 86 88 194 58 54 71 54 46 43 46 43 206 100 58 58 SB 50 48 95 40 50 46 46 60 00 000 000 10 10 575 550 382 595 595 ------- tie 3. Concluded FGD system Plant 'arlm Lake 3 'onticello 3 i/i Power & Light (inter 1 jnter 2 •jntington 1 "otal - MW 595 800 360 360 366 29.538 % scrubbed 75 too 90 90 86 FGD capacity on line during No information MW* period, MW 595 800 360 360 366 25,825 2.402 Shut down January 1981 throughout Dependability % MW AVL OPR REL 100 100 100 1.311 February 1981 '* Dependability % UTL AVL OPR REL 93 100 89 100 96 100 March 1981 " Dependability %" UTL AVL OPR REL UTL 95 100 31 96 1OO 99 1OO 100 94 uvatent scrubbed capacity s category includes the flue gas capacity being handled by the FGD system at least pan of the time during the report period ' percent figures listed are average values for all system scrubbing trains during the period. B gas % scrubbed for prototype and demonstration units is not applicable unless the system is designed to bring a unit into compliance with SOi emission standard. viability, operabilny. reliability, and utilization as defined in Appendix C of the full report nufacturing/Niro Atomizer for a e/spray drying FGD system to be tailed at Antelope Valley 2. The 440 V (gross) unit will fire lignite with an !rage sulfur content of 0.68%. Opera- is are scheduled to commence in ober 1985. 'he limestone FGD system operated Laramie River 1 of Basin Electric rver achieved 100% availability for first quarter of 1981. The system srated for the 3 month period with no jor problems reported. 'he dual-alkali scrubbing system tailed at Newton 1 of Central Illinois ilic Service achieved availabilities of %, 100%, and 90% during January, jruary, and March, respectively. No ijor FGD-related problems were iorted during the three months. nitial operation of the FGD system at st Bend 2 of Cincinnati Gas and ictric commenced in March 1981. e unit fires pulverized coal with an srage sulfur content of 3.0%. A hot- e ESP is followed by three lime FGD >dules, supplied by Babcock and Icox. The stabilized sludge from this >sed water loop system is disposed of an on-site landfill. The system erated in a shakedown/debugging ase during March. Colorado Ute Electric announced that nstruction of the Craig 3 FGD system gan during the first quarter of 1981. le lime/spray-drying system is being pplied by Babcock and Wilcox. The I5-MW (gross) unit will fire pulverized ibbituminous coal with an average ilfur content of 0.45%. A fabric filter ill be used to collect the flyash and the y calcium sulfite/sulfate paniculate alter (as well as any unused reagent). Table 4. Power Generation Sources; Present and Future Coal Nuclear Oil Hydro Gas Other GW (total) December December 1979 1990 39% 44% 9% 14% 25% 20% 13% 11% 13% 10% 1% 1% 603 833 Startup of the FGD system is expected in April 1983. Columbus and Southern Ohio Electric reported that the Conesville 5 FGD system achieved availabilities of 91% and 94% for January and February, respectively. The Conesville 6 FGD system achieved availabilities of 98% and 92% for the same period, respec- tively. No major FGD-related problems were reported for either system during the 2 months. March performance data were not provided. The 20-MW prototype dual-alkali/ limestone test program being conducted by Thyssen/CEA and Arthur D. Little at the Scholz station of Gulf Power was completed on March 28. The program was conducted to determine the feasi- bility of using limestone rather than lime as the source of calcium for regeneration reactions. The system reportedly achieved SOz removal ef- ficiencies of 96% and 97% during February and March, respectively. There are no current plans to continue operation of the prototype. The Elrama FGD system of Duquesne Light achieved availabilities of 100% for January and 97% for February. With the exception of some absorber module lining repairs during February, no major operational problems were encountered during the 2 months. Information for March was not provided. Iowa Electric Light and Power an- nounced that a letter of intent was signed with Combustion Engineering for the installation of a wet limestone scrubbing system on Guthrie County 1. The unit is rated at 720 MW (gross) and will fire pulverized subbituminous coal with an average sulfur content of 0.4%. An ESP will provide primary particulate matter control. Operations are scheduled to commence in October 1984. Jacksonville Electric Authority an- nounced that bids are being requested for wet limestone FGD systems to be installed at Units 1 and 2 at the St. Table 5. FGD Controlled Generating Capacity; Present and Future Coal-fired generating capacity controlled by FGD. % Total generating capacity controlled by FGD, % March 1981* December 1990 13.9 29.6 5.4 13.0 *The number of committed FGD systems is as of March 1981; however, the figure used for the total generating capacity and coal-fired generating capacity is based on the available December 1979 figures. ------- Boiler Stack Boiler Supp. Boiler Type Gas Flow Rate Stack Height Stack Liner Fuel Type Grade Heat Content Sulfur -% Particulate Matter Control 1 Mechanical Collector Type Supplier Removal Eff Design AP Quenchers/ Presaturators Type Supplier Design AP L/C Ratio ESP Type Supplier Removal Eff Design AP Fabric Filter Type Supplier Removal Eff Gas/Cloth Rat 1 Mist Eliminators Type Supplier Horn/Vert Stages Passes/Stage Absorbers Type Supplier Gas Flow Rate L/G Ratio Removal Eff \ FGD General Data Process Type Supplier New/Retrofit Start Date Status FOG Design information P 'articulate Matter Scrubber Type Supplier Gas Flow Rate L/G Ratio Removal Eff Fans Design Supplier Application Gas Flow Rate Reheaters Type Location Heading Med Flue Gas A T I Spare Component Index Absorber Fan Pump Spare Capacity Index Absorber Fan Pump Ductwork Location Configuration Dimensions Dampers Function Type Manufacturer Pilot Partict ProL Testr 1 Tanks Type Location Configuration Capacity Reagent Preparation Equipment Device Type Function Feed Capacity Pun Tyt Manufi Cape Ser I Recovt Prod Typ Quan Dispos r Figure 1. Computerized data base structure diagram. 6 Treatn Meth Device Inlet Cr Outlet C ------- _L Process Control and instrumentation Proc Stream Parameters -Chemical -Physical I Unit Performance Date Boiler Hours Boiler A vail Capacity Factor Removal Performance SOsREM -% Part REM -% I Literal Information Comments/ Abstract 'Ct '6 ity ition ------- Johns River Power Park. Each 500-MW (gross) unit will fire pulverized coal with an average sulfur content of 2.5%. Initial operations are scheduled for 1985 and 1987, respectively. Kentucky Utilities announced that bids are being requested for limestone FGD systems at Hancock 1 and 2. The 708-MW (gross) units will be located in Hawesville, Kentucky, and will fire Western Kentucky coal with an average sulfur content of 3.5%. ESP's will be used to control paniculate matter emissions. Operations are scheduled.to commence in 1988 and 1994, respec- tively. The FGD system at Clay Boswell 4 of Minnesota Power and Light achieved 100% availabilities during January, February, and March. No major problems were reported for the lime/alkaline flyash FGD system during the 3 months. Montana Power reported that the Colstrip 1 FGD system achieved avail- abilities of 96% and 97% for January and February, respectively. The Colstrip 2 FGD system achieved availabilities of 98 and 97% for the same 2 months, respectively. No major FGD related problems were reported for either system. March performance data were not provided. The limestone/alkaline flyash FGD systems installed at Sherburne 1 and 2 of Northern States Power achieved 100% availabilities for the first quarter of 1981. No major operational problems were reported for the 3 months. San Juan 1 of the Public Service of New Mexico achieved availabilities of 100%, 98%, and 100% during January, February, and March, respectively. San Juan 2 achieved availabilities of 97%, and 94% during the same period, respectively. No major FGD-related problems were reported during the three months. The limestone FGD system installed at Winyah 2 of South Carolina Public Service achieved availabilities of 99%, 97%, and 100% during the months of January, February, and March, respec- tively. An expansion joint problem in the quencher discharge pump was the only major problem reported during the 3 months. The FGD system installed at A.B. Brown 1 of Southern Indiana Gas and Electric achieved availabilities of 99%, 99%, and 94% during January, February, and March, respectively. Some minor pump and vacuum filter problems were reported during the 3 months; however. Table 6. Summary of FGD Systems by Process Percent of total MW March 1981 December 1990 Throwaway product process Wet systems Lime Limestone Dual alkali Sodium carbonate NA* °Dry systems Lime Sodium carbonate Salable product process Process 39.6 47.4 4.1 3.1 0.4 20.2 36.2 1.9 3.0 6.3 2.9 0.4 Byproduct Aqueous carbonate/ spray drying Citrate Lime Limestone Lime/ limestone Magnesium oxide Wellman Lord Wellman Lord Process undecided Elemental sulfur Elemental sulfur Gypsum Gypsum Gypsum Sulfuric acid Sulfuric acid Elemental sulfur Total — 0.2 — — — — 2.4 2.8 — 100.0 0.1 0.1 0.1 0.2 0.5 0.7 1.2- 0.7 25.5 100.0 Not available (these systems are committed to a throwaway product process; however, the actual process is unknown at this time). overall system unavailable time was minimal. Tennessee Valley Authority announced that initial FGD operations at Widows Creek 7 commenced in March 1981. The 575-MW (gross) unit fires pul- verized coal with an average sulfur content of 3.7%. The limestone spray tower absorber FGD system is preceded by an ESP and four variable-throat venturies for primary paniculate matter control. The system operated in a shake- down/debugging mode throughout March. Utah Power and Light announced that construction of the FGD systems at Hunter 3 and 4 began in March 1981. The 400-MW (gross) units are being constructed in Castledale, Utah, and will fire pulverized bituminous coal with an average sulfur content of 0.55%. GE Environmental Services, Inc. (formerly Chemico) is supplying the limestone FGD systems which are expected to begin initial operations in 1983 and 1985, respectively. Washington Water Power announced plans to construct Creston Coal 2,3, and 4 in Creston, Washington. Each 570- MW (gross) unit will use a limestone FGD system for S02 control. Construc- tion at this site is scheduled to com- mence in 1983, with initial operation of the units currently scheduled for 1987. West Pennsylvania Power announced that construction of the Mitchell 33 FGD system began in March 1981. This 300- MW (gross) unit is being constructed in Courtney, Pennsylvania, and will fire coal with an average sulfur content of 2.8%. The lime scrubbing process is being supplied by GE Environmental Services, Inc., and is designed for a 95% SOz removal efficiency. The system is expected to commence operation in August 1982. References 1. U.S. Department of Energy. Energy Information Administration. Office of Coal and Electric Power Statistics. Electric Power Statistics Division. 8 ------- Inventory of Power Plants in the United States, December 1979. Report No. DOE/EIA-0095 (79). Rittenhouse, R.C. New Generating Capacity: When, Where, and by Whom. Power Engineering 82(4):57. April 1978. M. Smith. M. Melia, N. Gregory, and K. Scalf are with PEDCo Environmental, Inc., Cincinnati, OH 45246. Norman Kaplan is the EPA Project Officer (see below). The complete report, entitled "EPA Utility FGD Survey, January-March 1981," (Order No. PB 81 -225 773; Cost: $23.00, subject to change) will be available only from: National Technical Information Service 5285 Port Royal Road Springfield. VA 22161 Telephone: 703-487-4650 The EPA Project Officer can be contacted at: Industrial Environmental Research Laboratory U.S. Environmental Protection Agency Research Triangle Park, NC 27711 US GOVERNMENT PRINTING OFFICE, '981 -757-012/7338 ------- 11 Is 00 8 ** i. t O - o f CD M O Z TO C 3T o o 2" C 3! m r ar • r T> r" :«3 m O •« -< fTi O o r m Un w< 01 ------- |