>EPA C f United States Environmental Protection Agency Industrial Environmental Research Laboratory Research Triangle Park NC 27711 Research and Development EPA-600/S7-81 -012e August 1982 Project Summary EPA Utility FGD Survey July—September 1981 M. P. Smith, M. Melia, and N. Gregory The report, generated by a computer- ized data base system, presents a survey of operational and planned domestic util- ity flue gas desurfurization (FGD) systems. It summarizes information contributed by the utility industry, system and equip- ment suppliers, system designers, re- search organizations, and regulatory agencies. It presents data on system de- sign, fuel characteristics, operating his- tory, and actual performance. Unit by unit dependability parameters are includ- ed and problems and solutions associ- ated with the boilers, scrubbers, and FGD systems are discussed. The FGD systems are tabulated alpha- betically by development status (opera- tional, under construction, or in the plan- ning stages), utility company, system supplier, process, waste disposal prac- tice, and regulatory class. FGD system economic data, definitions, and a glos- sary of terms are appended to the report. Current data for domestic FGD systems show 92 systems in operation, 42 sys- tems under construction, and 88 planned systems. Projected 1999 FGD controlled capacity in the U.S. is 107,197 MW. This Project Summary was developed by EPA's Industrial Environmental Re- search Laboratory, Research Triangle Park, NC, to announce key findings of the research project that is fully docu- mented in a separate report of the same title (see Project Report ordering infor- mation at back). Introduction The quarterly FGD survey report is generated by a computerized data sys- tem known as the Flue Gas Desulfuriza- tion Information System (FGDIS). A structure diagram of the FGDIS is illus- trated in Figure 1, which presents the in- formational areas addressed in the system and some representative data items con- tained in each. The design data contained in the system encompass the entire emission control system and the power generating unit to which it is applied. Performance data for the operational FGD systems include monthly dependa- bility parameters, along with service time and problem/solution descriptions. In addition to generating the survey report, the FGDIS is available for remote terminal access. Because the report is available only through purchase from NTIS, the data base is the most immedi- ate method for examining the data ac- quired under the survey program. Access to the FGDIS also enables users to obtain data that are too specific for inclusion in the quarterly report. Information con- cerning access to the FGDIS can be ob- tained from Walter Finch, NTIS, 5285 Port Royal Road, Springfield, VA 22161; (703) 487-4808. Custom searches of the FGDIS data can also be arranged. Executive Summary Table 1 summarizes the status of FGD systems in the U.S. at the end of Sep- tember 1981. Table 2 lists the units that have changed status during the third quarter 1981, and Table 3 shows the performance of operating units during this period. The units included in the fig- ures presented in Table 1 are identified in Table 4, and categorical FGD system cost data are presented in Table 5. ------- 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 TOTAL No. of units 92 42 16 11 10 51 222 Total controlled capacity, MW* 34,937 18,226 9,385 8,293 5,630 30,726 107,197 Equivalent scrubbed capacity, M Wt 31,738 17,457 9,169 8,235 5,630 30,398 102,627 * The summation of the gross unit capacities (MW) brought into compliance with FGD systems regardless of the percent of the flue gas scrubbed by the FGD system(s). t The summation of the effective scrubbed flue gas in equivalent MW based on the per- cent of the flue gas scrubbed by the FGD systemfs). Table 2. Summary of Changes July-September 1981 Under Contract Letter Operational construction awarded of intent FGD status report July 31, 1981 Requesting/ Considering eval. bids FGD Total No. MW No. MW* No. MW* No. MW* 88 30,158 40 15,887 21 11,599t>11 8,235 No. MW* No. MW* No. MW* 19 10,340 48 25,6/8*227 104,83 Arizona Public Service Four Corners 4 Four Corners 5 Basin Electric Power Antelope Valley 2 Laramie River 2 Central Illinois Light Duck Creek 2 East Kentucky Power J.K. Smith 2 Kentucky Utilities Hancock 1 Hancock 2 Nevada Power Warner Valley 1 Warner Valley 2 Northern States Power Wisconsin Coal 1 Pacific Power & Light Jim Bridget 1 Jim Bridget 2 Jim Bridget 3 Plains Electric G &T Plains Escalante 1 San Miguel Electric San Miguel 1 Seminole Electric Seminole 1 South Carolina Public Service Winyah 4 + 1 + 1 + 1 + 1 570 -1 755 -1 755 -1 440 -1 570 755 755 440 + / 233 - 1 233 + 1 400 -1 400 + 1 62O - 1 620 + 1 280 - 1 280 -1 -1 650 + 1 650 45O +1 450 -1 65( 1 65O 1 650 +1 650 295 295 -1 550 +1 550 +1 550 +1 -1 -1 670 -1 550 550 550 29i 29i 671 ------- ble 2. (continued) D status report July 31, 1981 Under Contract Letter Operational construction awarded of intent Requesting/ Considering eval. bids FGD Total No. MWa No. MW<> No. MW<> No. MW No. MW> No. MW* No. MW* 88 30,158 40 15,887 21 11,599° 11 8,235 19 10,340 48 28,61'8t>227 104,837'' uthern Illinois Power Aarion 5 nflower Electric Holcomb 1 ah Power & Light Naughton 3 *st Texas Utilities Oklaunion 1 -1 300 -1 300 + 1 347 - 1 347 + 1 330 - 1 330 + 1 720 -1 720 Total 9231,738 42 17,457 16 9,169 11 8,235 10 5,630 51 30,398 222 102,627 Equivalent scrubbed capacity. This value was modified slightly due to a MW correction. tbte 3. Performance of Operational Units July-September 1981 FGD capacity online FGD system during No information capacity, Flue gas period for this Plant MW % scrubbed MW-b period, MW labama Electric Tombigbee 2 Tombigbee 3 rizona Electric Power Apache 2 Apache 3 \rizona Public Service Cho/la 1 Cholla 2 Cho/la 4 Four Corners 1 Four Corners 2 Four Corners 3 tsin Electric Power Coop Laramie River 1 Laramie River 2 Big Rivers Electric Green 1 Green 2 Central Illinois Light \ Duck Creek 1 Central Illinois Public Service Newton 1 Cincinnati Gas & Electric East Bend 2 Colorado Ute Electric Association Craig 1 Craig 2 Columbus & Southern Ohio Electric Conesville 5 Conesville 6 Commonwealth Edison Powerton 5 1 179 179 98 98 119 264 126 175 175 229 570 57O 242 242 416 617 650 410 410 411 411 450 70 179 70 179 50 98 50 98 100 119 100 264 33 126 100 175 100 175 100 229 100 570 WO 57O 100 242 100 242 100 416 1OO 617 100 650 90 90 410 100 411 1OO 411 100 Shutdown July 1981 August 1981 September 1 98 1 throughout Dependability %<>•• Dependability %c-e Dependability%c-e MW AVL OPR REL UTL AVL OPR REL UTL AVL 100 91 100 91 100 40 100 36 100 100 69 100 69 100 100 100 100 62 1OO 95 100 95 97 96 100 92 100 96 69 1OO 68 1OO 98 96 96 96 95 93 93 85 85 94 89 89 77 97 94 94 86 100 72 63 75 54 75 74 76 74 89 70 99 68 100 82 WO 82 100 410 0000 0 0 O 0 0 0 0 0 0 33 34 34 33 51 100 10O 100 55 99 53 92 41 94 99 100 100 74 99 90 93 74 95 450 0 0 OPR REL UTL 99 100 99 63 62 62 94 100 25 82 WO 67 96 96 80 99 99 98 81 100 69 000 52 53 50 54 91 6 86 96 36 0 ------- Table 3. (continued) Plant Cooperative Power Association Coal Creek 1 Coal Creek 2 De/marva Power & Light Delaware City 1 Delaware City 2 Delaware City 3 Duquesne Light Elrama 1-4 Phillips 1-6 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 Mill Creek 1 Mill Creek 3 Paddy's Run 6 Minnesota Power & Light Clay Boswell 4 Minnkota Power & Light Milton R. Young 2 Monongahela Power Pleasants 1 Pleasants 2 Montana Power Co/strip 1 Co/strip 2 Montana-Dakota Utilities Coyote 1 Nevada Power Reid Gardner 1 Reid Gardner 2 Reid Gardner 3 Northern Indiana Public Service Dean H. Mitchell 1 1 FGD system CQOQCltV MW ' 327 327 60 60 60 510 408 532 90 90 820 540 490 125 420 64 188 200 299 358 427 72 475 185 618 618 360 360 440 125 125 125 115 FluG QQS % scrubbed 60 60 100 100 100 100 100 100 100 100 100 75 70 100 100 100 100 100 100 100 100 100 85 42 100 100 100 100 100 100 100 100 99 FGD capacity on line during No information MW-b period, MW 327 327 60 60 60 510 408 532 90 90 820 540 490 125 420 188 200 299 358 427 475 185 618 618 360 360 440 125 125 125 Shutdown My 1981 throughout Dependability %c.e MW AVL 37 42 99 77 99 99 74 100 96 97 64 100 73 46 57 76 63 72 100 100 29 100 99 97 115 100 OPR REL 37 37 99 99 77 77 99 99 95 99 72 73 100 100 80 95 100 100 100 100 100 100 75 75 74 74 86 100 32 33 99 100 97 99 96 97 0 UTL 99 77 99 95 72 52 49 54 0 73 46 57 72 63 0 75 29 95 78 93 0 August 1981 September 1 98 1 Dependability %c-» Dependability%c-e AVL 77 99 100 98 75 100 100 100 40 50 68 99 89 100 100 58 99 98 98 100 OPR 45 44 77 98 100 81 64 100 100 66 100 73 99 92 80 49 99 98 98 0 REL 77 98 100 98 70 66 100 73 99 92 100 50 99 98 98 UTL AVL 36 34 47 95 98 99 100 90 81 58 10 100 18 100 0 100 40 61 50 75 68 29 99 86 88 81 0 100 73 100 44 100 93 96 96 100 98 100 0 100 OPR REL UT < 60 60 95 95 95 96 96 8. 90 90 91 100 58 100 3 0 100 100 61 100 100 75 100 100 29 96 96 80 81 81 81 0 89 100 84 97 100 86 91 95 77 99 100 99 98 100 75 0 0 Northern States Power Riverside 6, 7 Sherburne 1 Sherburne 2 Pacific Power & Light Jim Bridget 4 Pennsylvania Power Bruce Mansfield 1 Bruce Mansfield 2 Bruce Mansfield 3 110 N/A" 740 91 740 91 550 917 917 917 100 100 100 100 740 740 917 917 917 110 550 97 97 99 ------- Table 3. (continued) FGD system capacity. Flue gas Plant Public Service Co. of New Mexico San Juan 1 San Juan 2 San Juan 3 Salt River Project Coronado 1 Coronado 2 San Miguel Electric San Miguel 1 Sikeston Board of Municipal Utilities Sikeston 1 South Carolina Public Service Authority Winyah 2 Winyah 3 Winyah 4 South Mississippi Electric R.D. Morrow, Sr. 1 R.D. Morrow, Sr. 2 Southern Illinois Power Coop Marion 4 Southern Indiana Gas and Electric A.B. Brown 1 Springfield City Utilities Southwest 1 Springfield Water, Light & Power Dal/man 3 St. Joe Zinc G.F. Weaton 1 Tennessee Valley Authority Shawnee 10A Shawnee JOB Widows Creek 7 Widows Creek 8 Texas Power & Light Sandow 4 Texas Utilities Martin Lake 1 Martin Lake 2 Martin Lake 3 Monticello 3 Utah Power & Light Hunter 1 Hunter 2 Huntington 1 Naughton 3 Total MW 361 350 534 280 280 400 235 140 280 280 124 124 173 265 194 185 60 10 10 575 550 382 595 595 595 800 360 360 366 330 31,738 % scrubbed 100 100 100 80 80 100 100 50 100 100 62 62 100 100 100 90 N/Ad N/Ad N/Ad 100 WO 70 75 75 75 100 90 90 85 1OO FGD capacity on line during No information period for this MW' b period, MW 361 350 534 280 280 400 140 280 280 124 124 173 265 194 185 60 10 10 575 382 595 595 595 800 360 360 366 330 25.228 4,614 Shut down July , 98 1 August 1 98 1 September 1 98 1 throughout Dependability %c. a Dependability %c- » Dependability1*"- • MW AVL OPR PEL UTL AVL OPK REL UTL AVL OPR REL UTL 100 97 100 96 100 100 100 100 100 75 90 32 93 80 86 80 100 54 100 43 69 19 19 19 98 96 97 96 86 86 86 86 97 32 32 31 235 000 89 93 96 44 98 98 98 98 96 98 96 88 88 83 84 82 82 84 82 70 98 96 98 86 100 99 99 94 100 100 100 100 99 99 99 98 100 97 100 93 100 100 100 96 98 98 98 98 74 74 94 74 52 47 60 47 91 84 87 84 92 89 89 89 98 97 90 90 97 93 96 93 98 87 90 87 89 78 85 76 54 44 44 42 0000 0000 00005555 55O O a O 1,896 ' Equivalent scrubbed capacity. b This category includes the flue gas capacity being handled by the FGD system at least part of the time during the report period. 0 The percent figures listed are a verage values for all system scrubbing trains during the period. d Flue gas % scrubbed for prototype and demonstration units is not applicable unless the system is designed to bring a unit into compliance with SO2 emission standard. e A vailability, operability, reliability, and utilization as defined in Appendix C of this report. ------- Table 4. Summary of Operational and Planned Domestic FGD Systems Company name/ unit name Alabama Electric Tombigbee 2 Tombigbee 3 Arizona Electric Power Apache 2 Apache 3 Capacity MW (gross) 255 255 195 195 Fuel % sulfur 1.15 1.15 0.50 0.50 FGD process Limestone Limestone Limestone Limestone FGD status 1 1 1 1 System supplier Peabody Process System Peabody Process System Research-Cottrell Research-Cottrell Arizona Public Service Cholla 1 119 Cholla 2 264 Cholla 4 375 Four Corners 1 175 Four Corners 2 175 Four Corners 3 229 Four Corners 4 755 Four Corners 5 755 Associated Electric Thomas Hill 3 730 Atlantic City Electric Cumberland 1 330 Basin Electric Power Antelope Valley 1 440 Antelope Valley 2 440 Laramie River 1 570 Laramie River 2 570 Laramie River 3 570 Big Rivers Electric D.B. Wilson 1 440 D.B. Wilson 2 440 Green 1 242 Green 2 242 Cajun Electric Power Chicot 1 562 Chicot 2 562 Chicot 3 562 Chicot 4 562 Oxbow 1 54O Oxbow 2 540 Central Illinois Light Duck Creek 1 416 Duck Creek 2 450 Central Illinois Public Service Newton 1 617 Central Maine Power Sears Island 1 600 Central Power & Light Coleto Creek 2 720 0.50 Limestone 0.50 Limestone 0.50 Limestone 0.75 Lime/alkaline flyash 0.75 Lime/alkaline flyash 0.75 Lime/alkaline flyash 0.75 Lime 0.75 Lime 4.80 Limestone 3.25 Process not selected 0.68 Lime/spray drying 0.68 Lime/spray drying 0.81 Limestone 0.81 Limestone 0.54 Lime/spray drying Limestone Limestone 3.75 Lime 3.75 Lime 1.70 Process not selected 1.70 Process not selected 1.70 Process not selected 1.70 Process not selected 0.60 Process not selected 0.60 Process not selected 3.66 Limestone 3.30 Limestone 2.25 Dual alkali 2.23 Process not selected 0.39 Process not selected 1 Research-Cottrell 1 Research-Cottrell 1 Research-Cottrell 1 GE Environmental Servic 1 GE Environmental Servic 1 GE Environmental Servic 2 United Engineers 2 United Engineers 2 Pullman Kellogg 6 Vendor not selected 2 Joy Mfg/Niro A tomizer 2 Joy Mfg/Niro A tomizer 1 Research-Cottrell 1 Research-Cottrell 2 Babcock & Wilcox 2 Pullman Kellogg 3 Pullman Kellogg 1 American Air Filter 1 American Air Filter 6 Vendor not selected 6 Vendor not selected 6 Vendor not selected 6 Vendor no t selec ted 5 Vendor not selected 6 Vendor not selec ted 1 Environeering, Riley Stoker 6 Vendor not selected 1 GE Environmental Services 6 Vendor not selec ted 6 Vendor not selected (continued) ------- Table 4. (continued) Company name/ unit name Capacity MW (gross) Fuel % sulfur FGD process FGD status System supplier Cincinnati Gas & Electric East Bend 1 East Bend 2 Colorado Ute Electric Craig 1 Craig 2 Craig 3 Columbus & Southern Ohio Electric Conesville 5 Conesville 6 Poston 5 Poston 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 Vienna 9 Deseret Generation & Transmission Bonanza 1 Bonanza 2 Duquesne Light Elrama 1-4 Phillips 1-6 East Kentucky Power J.K. Smith 1 Spurlock 2 Florida Power & Light Martin 3 Martin 4 General Public Utilities Coal 1 Coal 2 Coal 3 Coal 4 Seward 7 Grand Haven Board of Light & Power J.B. Sims 3 650 4.00 Process not selected 650 3.00 Lime 455 0.45 Limestone 455 0.45 Limestone 447 0.45 Lime/spray drying 411 4.67 Lime 411 4.67 Lime 425 Process not selected 425 2.50 Process not selected 450 3.53 Limestone 545 0.63 Lime/alkaline flyash 545 0.63 Lime/alkaline flyash 60 7.00 WellmanLord 60 7.00 WellmanLord 60 7.00 WellmanLord 550 2.50 Process not selected 410 0.50 Limestone 410 0.50 Limestone 510 2.20 Lime 408 1.92 Lime 650 1.50 Lime 500 3.50 Lime 800 Process not selected 800 Process not selected 625 3.50 Process not selected 625 3.50 Process not selected 625 3.50 Process not selected 625 3.50 Process not selected 690 Process not selected 65 2.75 Lime 6 Vendor not selected 1 Babcock & Wilcox 1 Peabody Process Systems 1 Peabody Process Systems 2 Babcock & Wilcox 1 Air Correction Division, UOP 1 Air Correction Division, UOP 6 Vendor not selected 6 Vendor not selected Air Correction Division, UOP 1 Combustion Engineering 1 Combustion Engineering 1 Davy McKee 1 Davy McKee 1 Davy McKee 6 Vendor not selected 2 Combustion Engineering 5 Vendor not selected 1 GE En vironmental Services 1 GE En vironmental Services 4 Babcock & Wilcox 2 Thyssen/CEA 6 Vendor not selected 6 Vendor not selected 5 Vendor not selected 6 Vendor not selected 6 Vendor not selected 6 Vendor not selected 5 Vendor not selected Babcock & Wilcox (continued) ------- Table 4. (continued) Company name/ unit name Hoosier Energy Merom 1 Merom 2 Houston Lighting & Power Limestone 1 Limestone 2 W.A. Parish 8 Indianapolis Power & Light Patriot 1 Patriot 2 Patriot 3 Petersburg 3 Petersburg 4 Iowa Electric Light & Power Guthrie Co. 1 Capacity MW (gross) 490 490 750 750 600 650 650 650 532 530 720 Fuel % sulfur 3.50 3.50 1.08 1.08 0.6 3.50 3.50 3.50 3.25 3.50 0.40 FGD process Limestone Limestone Limestone Limestone Limestone Limestone Limestone Limestone Limestone Limestone Limestone FGD status 2 2 3 3 2 6 6 6 1 2 4 System supplier Mitsubishi Heavy Industrie Mitsubishi Heavy Industrie Combustion Engineering Combustion Engineering GE Environmental Service Vendor not selected Vendor not selected Vendor not selected Air Correction Division, UO Research Cottrell Combustion Engineering Jacksonville Electric Authority St. Johns River Power 1 St. Johns River Power 2 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 Hancock 1 Hancock 2 Lakeland Utilities Mc/ntosh 3 Lansing Board of Water and Light Erickson 2 Los Angeles Department of Water & Power Intermountain 1 Intermountain 2 Intermountain 3 Intermountain 4 600 6OO 90 90 820 720 700 125 420 64 708 708 364 160 820 820 820 82O 2.50 2.50 0.60 0.6O 5.39 0.32 0.30 0.55 0.55 4.00 3.50 3.50 2.56 Limestone Limestone Lime Lime Limestone 0.79 0.79 0.79 0.79 Limestone Limestone Limestone Limestone Lime Limestone Limestone Limestone Process not selected Lime Lime Lime Lime 5 Vendor not selected 5 Vendor not selected 1 Combustion Engineering 1 Combustion Engineering 1 Babcock & Wilcox 1 Combustion Engineerin 1 Combustion Engineerin 1 Combustion Engineerin 1 Combustion Engineerin 1 American Air Filter 4 Babcock & Wilcox 6 Vendor not selected 2 Babcock & Wilcox Vendor not selected 6 Vendor not selected 6 Vendor not selected 6 Vendor not selected 6 Vendor not selected (continued) ------- able 4. (continued) Company name/ unit name ouisville Gas & Electric Cane Run 4 Cane Run 5 Cane Run 6 Mill Creek 1 Mill Creek 2 Mill Creek 3 Mill Creek 4 Paddy's Run 6 Trimble County 1 Trimble County 2 Capacity MW (gross) 188 200 299 358 350 427 495 72 575 575 Fuel % sulfur 3.75 3.75 4.80 3.75 3.75 3.75 3.75 2.50 4.00 4.00 FGD process Lime Lime Dual alkali Limestone Lime Lime Lime Lime Process not selected Process not selected FGD status 1 1 1 1 2 1 2 1 5 5 System supplier American Air Filter Combustion Engineering Thyssen/CEA Combustion Engineering Combustion Engineering American Air Filter American Air Filter Combustion Engineering Vendor not selected Vendor not selected ower Colorado River Authority Fayette Power Project 3 435 /larquette Board of Light and Power Shiras 3 44 Michigan South Central Power Agency Project 1 55 fiddle South Utilities Arkansas Lignite 5 890 Arkansas Lignite 6 890 Unassigned 1 890 Unassigned 2 890 Wilton 1 890 Wilton 2 890 Minnesota Power & Light Clay Boswell 4 554 Minnkota Power Milton R. Young 2 440 Monongahela Power Pleasants 1 618 Pleasants 2 618 Montana Power Co/strip 1 360 Co/strip 2 360 Co/strip 3 700 Colstrip 4 700 Montana-Dakota Utilities Coyote 1 440 Muscatine Power & Water Muscatine 9 166 1.70 Limestone Lime/spray drying 2.25 Limestone 2 0.50 Limestone 4 0.50 Limestone 4 0.50 Limestone 4 0.50 Limestone 4 0.50 Limestone 4 0.50 Limestone 4 0.94 Lime/alkaline flyash 1 0.70 Lime/alkaline flyash 1 3.00 Lime 1 3.00 Lime 1 0.77 Lime/alkaline flyash 1 0.77 Lime/alkaline flyash 1 0.77 Lime/alkaline flyash 2 0.77 Lime/alkaline flyash 2 0.87 Sodium carbonate/spray drying 3.21 Limestone Vendor not selected GE Environmental Services Babcock & Wilcox Combustion Engineering Combustion Engineering Combustion Engineering Combustion Engineering Combustion Engineering Combustion Engineering Peabody Process Systems Thyssen/CEA Babcock & Wilcox Babcock & Wilcox Thyssen/CEA Thyssen/CEA Thyssen/CEA Thyssen/CEA Wheelabrator-Fry/R. I. Research-Cottrell (continued) ------- I Paniculate Matter Control i : FGD General Data Process Type Supplier New/Retrofit Start Date Status Fuel Type Grade Heat Content Sulfur -% X Mechanical Collector Type Supplier Removal Eff Design AP ESP Type Supplier Removal Eff Design AP 1 Quenchers/ Presaturators Type Supplier Design AP L/G Ratio 1 Mist Eliminators Type Supplier Horiz/Vert Stages Passes/Stage Fabric Filter Type Supplier Removal Eff Gas/Cloth Rat Recoverab Product Type Quantity Disposition figure 1. Computerized data base structure diagram. 10 Treatmen\ Method Device Typ Inlet Chara Outlet Char, ------- Process Control and \strumentation Proc Stream Parameters -Chemical -Physical 1 Chemicals Function Name Consumption Removal Performance SOZ FtEM -% Part REM -% FGD System Performance Service Hrs Avail -% Oper -% Pel -% Util -% Problems Solutions Comments 9 ty tion 11 ------- Table 4. (continued) Company name/ unit name Nebraska Public Power District Fossil III 1 Capacity MW (gross) 650 Fuel % sulfur 0.36 FGD process Process not selected FGD status 6 System supplier Vendor not selected Nevada Power Harry Allen 1 Harry Allen 2 Harry Allen 3 Harry Allen 4 Reid Gardner 1 Reid Gardner 2 Reid Gardner 3 Reid Gardner 4 New York State Electric & Gas Somerset 1 Niagara Mohawk Power Charles R. Huntley 66 Northern Indiana Public Service Dean H. Mitchell 11 Schahfer 17 Schahfer 18 Northern States Power Metro Coal 1 Riverside 6-7 Sherburne 1 Sherburne 2 Sherburne 3 Pacific Gas & Bectric Montezuma 1 Montezuma 2 Pacific Power & Light Jim Bridget 1 Jim Bridger 2 Jim Bridger 2A Jim Bridger 3 Jim Bridger 4 Pennsylvania Power Bruce Mansfield 1 Bruce Mansfield 2 Bruce Mansfield 3 Philadelphia Electric Cromby 1 Eddystone 1 Eddystone 2 Plains Electric G&T Plains Escalante 1 Plane River Power Authority Rawhide 1 (continued) 500 500 500 500 125 125 125 250 625 100 116 421 421 200 110 740 740 860 mm 8OO 550 550 550 55O 55O 917 917 917 150 24O 334 233 279 Process not selected 6 Process not selected 6 Process not selected 6 Process not selected 6 0.50 Sodium carbonate 1 0.50 Sodium carbonate 1 0.50 Sodium carbonate 1 0.75 Sodium carbonate 4 2.20 Limestone 1.80 Aqueous carbonate/spray drying 3.50 WellmanLord 1 3.20 Dual alkali 2 3.20 Dual alkali 3 1.00 Lime 6 1.20 Lime/spray drying 1 0.80 Limestone/alkaline flyash 1 0.80 Limestone/alkaline flyash 1 1.0Q Lime 6 O.9Q Limestone 6 O.8O Limestone 6 0.56 Sodium carbonate 6 0.56 Sodium carbonate 6 0.56 Lime/sodium carbonate 2 0.56 Sodium carbonate 6 0.56 Sodium carbonate T 3.OO Lime 1 3.0O Lime 1 3.00 Lime 1 3.00 Magnesium oxide 2 2.60 Magnesium oxide 2 2.50 Magnesium oxide 2 0.80 Limestone 2 0.25 Lime/spray drying Vendor not selected Vendor not selected Vendor not selected Vendor not selected Thyssen/CEA Thyssen/CEA Thyssen/CEA Thyssen/CEA Peabody Process System Rockwell International Davy McK.ee FMC FMC Vendor not selected Joy Mfg/Niro Atomizer Combustion Engineering Combustion Engineering Vendor not selected Vendor not selected Vendor not selected Vendor not selected Vendor not selected Flakt Vendor not selected Air Correction Division, UO GE Environmental Services GE Environmental Services Pullman Kellogg United Engineers United Engineers United Engineers Combustion Engineering Joy Mfg/Niro Atomizer 12 ------- Table 4. {continued) Company name/ unit name Capacity MW (gross) Fuel % sulfur FGD process FGD status System supplier Public Service Indiana Gibson 5 650 Public Service of New Mexico San Juan 1 361 San Juan 2 350 San Juan 3 534 San Juan 4 534 Power Authority of State of New York' Fossil 700 Salt River Project Coronado 1 350 Coronado 2 350 Coronado 3 400 San Miguel Electric San Miguel 1 400 Seminole Electric Seminole 1 620 Seminole 2 620 Sikeston Board of Municipal Utilities Sikeston 1 235 South Carolina Public Service Cross 1 500 Cross 2 500 Winyah 2 280 Winyah 3 280 Winyah 4 280 South Mississippi Electric Power R.D. Morrow, Sr. 1 200 R.D. Morrow, Sr. 2 200 Southern Illinois Power Marion 4 173 Southern Indiana Gas & Electric A.B. Brown 1 265 A.B, Brown 2 265 Southwestern Electric Power Dolet Hills 1 720 Dolet Hills 2 720 Henry W. Pirkey 1 720 Soyland Power Soyland 1 500 Springfield City Utilities Southwest 1 194 3.30 Limestone 0.80 WellmanLord 1 0.80 WellmanLord 1 0.80 WellmanLord 1 0.80 WellmanLord 2 3.00 Process not selected 6 0.50 Limestone 1 0.50 Limestone 1 0.60 Limestone 6 1.70 Limestone 1 2.75 Limestone 2 2.75 Limestone 3 2.80 Limestone 1.80 Limestone 3 1.80 Limestone 2 1.10 Limestone 1 1.10 Limestone 1 1.70 Limestone 1 1.30 Limestone 1 1.30 Limestone 1 3.75 Limestone 3.35 Dual alkali 1 3.35 Process not selected 5 0.70 Limestone 3 0.70 Limestone 6 0.80 Limestone 3 3.00 Process not selected 6 3.50 Limestone Pullman Kellogg Davy McKee Davy McKee Davy McKee Davy McKee Vendor not selected Pullman Kellogg Pullman Kellogg Vendor not selected Babcock & Wilcox Peabody Process Systems Peabody Process Systems Babcock & Wilcox Peabody Process Systems Peabody Process Systems Babcock & Wilcox Babcock & Wilcox American Air Filter Environeering, Riley Stoker Environeering, Riley Stoker Babcock & Wilcox FMC Vendor not selected Air Correction Division, UOP Vendor not selected Air Correction Division, UOP Vendor not selected Air Correction Division, UOP (continued) 13 ------- Table 4. (continued) Company name/ unit name Capacity MW(gross) Fuel % sulfur FGD process FGD status System supplier Springfield Water, Light & Power Dallman 3 St. Joe Zinc G.F. Weaton 1 Sunflower Electric Holcomb 1 Tampa Electric Big Bend 4 Tennessee Valley Authority Paradise 1 Paradise 2 Shawnee 10A Shawnee Wb Widows Creek 7 Widows Creek 8 Texas Municipal Power Agency Gibbons Creek 1 Texas Power & Light Sandow 4 Twin Oaks 1 Twin Oaks 2 Texas Utilities Forst Grove 1 Martin Lake 1 Martin Lake 2 Martin Lake 3 Martin Lake 4 Mill Creek 1 Mill Creek 2 Monticello 3 Tucson Electric Power Springerville 1 Springerville 2 United Power Association Stanton 1A Utah Power & Light Hunter 1 Hunter 2 Hunter 3 Hunter 4 Huntington 1 Naughton 3 Washington Water Power Creston Coal 1 Creston Coal 2 Creston Coal 3 Creston Coal 4 (continued) 205 60 347 475 704 704 10 10 575 550 443 545 750 750 750 793 793 793 793 750 750 800 370 370 60 400 400 400 400 430 330 570 570 570 570 3.30 Limestone 2.00 Citrate 0.47 Lime/spray drying 2.35 Lime/limestone 4.20 Limestone 4.20 Limestone 2.90 Lime/limestone 2.90 Lime/limestone 3.70 Limestone 3.70 Limestone 1.06 Limestone 1.60 Limestone 0.70 Limestone 0.70 Limestone 0.80 Process not selected 0.90 Limestone 0.90 Limestone 0.90 Limestone 0.90 Limestone Process not selected Process not selected 1.50 Limestone 0.61 Lime/spray drying 0.61 Lime/spray drying 0.77 Lime/spray drying 0.55 Lime 0.55 Lime 0.55 Limestone 0.55 Limestone 0.55 Lime 0.55 Sodium carbonate Limestone Limestone Limestone Limestone 1 Research-Cottrell 1 Morrison & Knudsen/U.S.B. 2 Joy Mfg/Niro A tomizer 3 Research-Cottrell 2 GE Environmental Services 2 GE Environmental Services 1 Air Correction Division, UOi 1 GE Environmental Services 1 Combustion Engineering 1 Tennessee Valley Authority 2 Combustion Engineering 1 Combustion Engineering 3 GE Environments/Service 3 GE Environmental Services 5 Vendor not selected 1 Research-Cottrell 1 Research-Cottrell 1 Research-Cottrell 3 Research-Cottrell 6 Vendor not selected 6 Vendor not selected 1 GE Environmental Services 3 Joy Mfg/Niro A tomizer 3 Joy Mfg/Niro A tomizer 2 Research-Cottrell 1 GE Environmental Services 1 GE Environmental Services 2 GE Environmental Services 2 GE Environmental Services 1 GE Environmental Services 1 Air Correction Division, I/O 6 Vendor not selected 6 Vendor not selected 6 Vendor not selected 6 Vendor not selected 14 ------- Table 4. (continued) Company name/ unit name West Penn Power Mitchell 33 West Texas Utilities Oklaunion 1 Oklaunion 2 Capacity MW (gross) 300 720 720 Fuel % sulfur 2.80 0.34 0.34 FGD process Lime Process not selected Process not selected FGD status 2 3 6 System supplier GE Environmental Services GE Environmental Services Vendor not selected 1 Operational units. 2 Units under construction. 3 Planned - contract awarded. 4 Planned - letter of intent signed. 5 Planned - requesting/evaluating bids. 6 Planned - considering only FGD systems. Table 5. Categorical Results of the Reported and Adjusted Capital and Annual Costs for Operational FGD Systems Reported Adjusted Capital AH New Retrofit Saleable Thro wa way Alkaline flyash/lime Alkaline flyash/ limestone Dual alkali Lime Limestone Sodium carbonate Wellman Lord Range, $/kW 23.7-243.0 23.7-243.0 29.4-157.4 132.8-185.0 23.7-243.0 100.3-101.4 49.3-49.3 47.2-174.8 29.4-243.0 23.7-168.0 42.9-100.8 132.8-185.0 Average, $/kW 79.1 77.5 83.2 153.0 73.7 101.0 49.3 97.8 80.1 65.0 69.2 153.1 o 45.4 47.2 41.4 23.8 41.8 0.6 0.0 67.7 50.6 34.9 30.7 23.8 Annual Capital Range, Average, mills/kWh mills/kWh a Range, $/kW 0.05-13.02 0.05-5.52 0.46-13.02 13.02-13.02 0.05-11.32 0.53-2.97 0. 75-0. 75 1.30-1.30 0.92-11.32 0.05-7.76 0.23-0.46 13.02-13.02 2.64 1.84 4.54 13.02 2.35 2.16 0.75 1.30 3.65 1.78 0.38 13.02 3. 14 35. 1-258.9 1.84 35.1-242.1 4.64 57.5-258.9 0.0 233.6-258-9 2.65 35.1-242.1 1.41 133.8-142.9 0.0 94.4-94.4 0.0 80.6-242.1 3.02 57.5-192.7 2.54 35.1-148.7 0.13 79.9-138.5 0.0 233.6-258.9 Average, $/kW 113.5 103.8 132.3 249.1 104.2 136.8 94.4 134.6 105.1 93.4 101.7 249.1 o 54.6 43.3 69.4 13.6 42.5 5.2 0.0 93.1 39.1 42.5 28.0 13.6 Annual Range, Average, mills/kWh mills/kWh o 1.69-18.67 1.69-12.83 4.23-18.67 15.23-18.67 1.69-16.27 5.75-7.62 4.99-4.99 4.59-12.83 3.70-16.27 1.69-10.44 5.29-6.78 15.23-18.67 7.27 6.31 9.12 16.44 6.64 6.99 4.99 7.79 7.79 5.61 5.88 16.44 3.82 2.68 4.99 1.94 3.03 1.08 0.0 4.41 3.63 2.65 0.73 1.94 Current projections indicate that the total power generating capacity of the U.S. electric utility industry will be approx- imately 831 GW by the end of 1999.1 (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 373 GW or 45% of the 1999 total will come from coal-fired units. The distribution of power generation sources, both present (December 1980) and future (December 1999) is shown in Table 6.1 In light of the revised New Source Per- formance Standards, actual FGD control is expected to be greater than that re- flected by the figures above. For exam- ple, about 50 to 60 systems representing approximately 29,000 to 31,000 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 in- formation regarding their status is not ready for public release. In an effort to show general FGD usage trends. Table 8 gives current (Septem- ber 1981) and projected (December 1999) breakdowns of throwaway pro- duct systems versus saleable product systems as a percent of the total known commitments to FGD as of the end of the third quarter 1981. Highlights: July-September 1981 The following paragraphs highlight FGD system developments during the third quarter 1981. Arizona Electric Power reported that the Apache 2 FGD system achieved 100% availability for July, August, and September. The Apache 3 FGD system achieved 100% availability during July and August but dropped to 62% availa- bility during September as a result of damper problems. Arizona Public Service announced that construction began during the period on the lime FGD systems that are being retrofitted to control SO2 emissions from Four Corners 4 and 5. Both units are rated at 755 MW (gross) and burn coal with an average sulfur content of 0.75%. The FGD systems are being supplied by United engineers and are slated for initial start-up in December 1984. Basin Electric Power announced that construction of the lime/spray drying FGD system being installed on Antelope Valley 2 began during the third quarter. 75 ------- Table 6. Power Generation Sources: Present and Future Coal Nuclear Oil Hydro Gas Other GW (total) December December 1980 1999 41% 45% 10% 15% 24% 19% 12% 11% 12% 9% 1% 1% 616 831 Based on the known commitments to FGD by utilities as presented in Table 1, the per- centage of electrical generating capacity controlled by FGD for both the present (Sep- tember 1981) and the future (December 1999) is shown in Table 7. Table 7. FGD Controlled Generating Capacity: Present and Future Coal-fired generating capacity controlled by FGD, % Total generating capacity controlled by FGD, % September 1981* December 1999 13.8 28.7 5.7 12.9 * The number of committed FGD systems is as of September 1981; however, the figure used for the total generating capacity and coal-fired generating capacity is based on the available December 1980 figures. Table 8. Summary of FGD Systems by Process Percent of total MW September December 1981 1999 Throwaway product process • Wet systems Lime Limestone Dual alkali Sodium carbonate NA* •Dry systems Lime Lime/sodium carbonate Sodium carbonate Saleable product process 36.8 48.7 3.7 4.0 0.3 1.4 20.6 36.9 2.0 3.1 5.2 3.4 O.I 0.4 •Process Aqueous carbonate/ spray drying Citrate Lime Limestone Lime/limestone Magnesium oxide Wellman Lord Wellman Lord Process undecided •Byproduct Elemental sulfur Elemental sulfur Gypsum Gypsum Gypsum Sulfuric acid Sulfuric acid Elemental sulfur — 0.2 — — — — 2.3 2.6 — 0.1 0.1 0.1 0.2 0.5 O.7 1.2 0.8 24.6 Total 100.0 100.0 * NA - Not available (these systems are committed to a throwaway product process; however, the actual process is unknown at this time). This new unit will be rated at 440 M (gross) and will fire coal with an avera sulfur content of 0.68%. The FGD s tern is being supplied by Joy Manuf turing/Niro Atomizer and is schedul for initial operation in October 1985. The Laramie River 1 FGD syst achieved availabilities of 100%, 97 and 100% during July, August, a September, respectively. Corrosion c countered in the modular quencher s tions necessitated repairs during t period; however, overall system avail bility remained high as a result of spa module capacity. Initial operations of the Laramie Riv 2 FGD system of Basin Electric Row began during July. Laramie River 2 rated at 570 MW (gross) and fires c with an average sulfur content of 0.81 The limestone FGD system, which w supplied by Research-Cottrell, consis of five absorber modules and is preced by an ESP for primary paniculate matt removal. Availability of the FGD syste during August and September exceed 95%. Big Rivers Electric reported that t Green 1 FGD system achieved avail bilities of 98%, 95%, and 85% duri July, August, and September, respe tively. The availability dropped slightly i September due to the replacement of th chevron mist eliminators in both module; The Green 2 FGD system achieved avai abilities of 96%, 97%, and 100% ft the same 3 months with only mine problems being encountered. Plans for the installation of Unit 2 e the Duck Creek Generating Station hav been delayed as a result of current loa projections and economic conditions. A a result, the utility has temporarily sus pended requesting/evaluating bids fc an FGD system. Columbus and Southern Ohio Electri reported availabilities of 100%, 99% and 94% for the Cone^ville 5 FGD sys tern during July, August, and Septembei respectively. Conesville 6 achieved avai abilities of 99%, 99%, and 95% durin the same 3 months. Both units were re moved from service on September 19 a a result of low power demand. Deseret Generation and Transmissio announced during the third quarter tha Moon Lake 1 and 2 have been renamec The units are now Bonanza 1 and 2. East Kentucky Power announced tha plans for the installation of J.K. Smith : have been postponed indefinitely as a re suit of power demand not meeting utilit projections. In addition, initial start-up c 16 ------- .K. Smith 1 has been pushed back to ugust 1987. A letter of intent was signed during the eriod by Kentucky Utilities with Bab- ock and Wilcox for the installation of a nestone FGD system to control S02 missions from the planned Hancock 1. lis new unit is to be rated at 708 MW ross) and will fire coal with an average jlfur content of 3.50%. The FGD sys- tm is scheduled to begin initial opera- ons in April 1989. Plans for the installation of Unit 2 at le Hancock Generating Station have sen delayed and Kentucky Utilities has imporarily suspended requested/evalu- ing bids for the installation of an FGD rstem for S02 control. The unit, which to be rated at 708 MW (gross), is cur- intly scheduled for operation in 1994. Nevada Power announced during the sciod that plans for Warner Valley 1 and have been postponed indefinitely. Due > projected S02 emissions and the anned station location with respect to Class I area in Utah, the utility has been nable to obtain a permit from the EPA. he units were to be rated at 295 MW jross) and were slated for operation in une 1985 and June 1986, respectively. Plans for the installation of Wisconsin :oal 1 by Northern States Power have een postponed indefinitely. The unit i/as to be rated at 670 MW (gross) and i/as slated for initial operations in 1981. Pacific Power and Light hastemporari- i suspended requesting/evaluating bids or the installation of FGD systems at the ilanned Jim Bridger Units 1, 2, and 3 as i result of obtaining a modification in the :ompliance deadline for Unit 3. The jnits are to be rated at 550 MW (gross) tach and are scheduled for operation in . 988, 1990, and 1986, respectively. Construction began during the third quarter 1981 on the limestone FGD sys- em being installed on Plains Escalante 1 of Plains Electric Generation and Trans- mission. This new unit will be rated at 233 MW (gross) and will fire coal with an average sulfur content of 0.80%. The FGD system, which is being sup- plied by Combustion Engineering, is slated for initial operation in December 1983. Initial operations of the limestone FGD system installed on San Miguel 1 of San Miguel Electric began in August 1981 when one of the four absorber modules was placed in service. San Miguel 1 is rated at 400 MW (gross) and fires coal with an average sulfur content of 1.70%. The FGD system, which was supplied by Babcock and Wilcox, is preceded by a cold-side ESP for primary particulate matter control. Initial reports indicate that boiler problems have limited opera- tion of the FGD system. Construction of the Seminole 1 lime- stone FGD system of Seminole Electric began during the period. The 620 MW (gross) new unit will fire coal with an average sulfur content of 2.75%. The FGD system is being supplied by Pea- body Process Systems and will be pre- ceded by ESPs for primary particulate matter removal. Initial operation is scheduled for March 1983. Initial operations of the American Air Filter limestone FGD system installed on Winyah 4 began in July when one module was placed in service. Winyah 4 is rated at 280 MW (gross) and fires coal with an average sulfur content of 1.70%. A fire in the-second module 2 months prior to projected start-up has kept that module off line. Integrated operation of both modules is expected to begin in January or February 1982. South Mississippi Electric Power re- ported availabilities of 100%, 100%, and 99% for the R.D. Morrow 1 FGD system during July, August, and Sep- tember, respectively. The R.D. Morrow 2 FGD system achieved availabilities of 100%, 100%, and 98% during the same 3 months. No major FGD related problems were encountered during the third quarter. Southern Illinois Power has announced that plans for the installation of Marion 5 have been postponed indefinitely as a result of current load projections, eco- nomic conditions, and environmental concerns. The unit was to have been rated at 300 MW (gross) and was slated for operation in 1988. The A. B. Brown 1 FGD system of South- ern Indiana Gas and Electric achieved availabilities of 91%, 92%, and 98% during July, August, and September, respectively. Some pump liner problems were noted during the 3 months. Construction of the lime/spray drying FGD system being installed on Holcomb 1 of Sunflower Electric began during the third quarter. Holcomb 1 is to be rated at 347 MW (gross) and will fire coal with an average sulfur content of 0.47%. The FGD system, which is being sup- plied by Joy Manufacturing/Niro Atom- izer, is scheduled to begin initial opera- tions in September 1983. Initial operations of the sodium car- bonate FGD system retrofitted on Naughton 3 of Utah Power and Light began in early September. Naughton 3 is rated at 330 MW (gross) and fires coal with an average sulfur content of 0.55%. The FGD system was supplied by the Air Correction Division, UOP and is preceded by an ESP for primary partic- ulate matter control. The FGD system is currently in the start-up phase of opera- tions and is not required to be in full ser- vice until the end of the year. West Texas Utilities announced that a contract has been awarded to General Electric Environmental Services for the installation of a limestone FGD system to control S02 emissions from Okla- union 1. This new unit will be rated at 720 MW (gross) and will fire coal with an average sulfur content of 0.34%. FGD system start-up is scheduled for December 1986. References 1. U.S. Department of Energy. Energy Information Administration. Office of Coal and Electric Power Statistics. Electric Power Statistics Division. In- ventory of Power Plants in the United States, 1980 Annual. Publ. No. DOE/ EIA-0095 (80). 2. Berman, Ira M. New Generating Ca- pacity: When, Where, and by Whom. Power Engineering 85(4)72. April 1981. 17 ------- M. P. Smith, M. Melia, and N. Gregory 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, July-September 1981," (Order No. PB 82-231 150; Cost: $27.00, 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, NC27711 18 •&U. S. GOVERNMENT PRINTING OFFICE: I982/559-09^0487 ------- a w * «v CO 8 m > TJ n ?!M i j CD ^ w o o c W< S. 2 cn o s 3 5 S ------- |