United States
Environmental Protection
Agency
Air and Energy Engineering
Research Laboratory
Research Triangle Park NC 27711'
Research and Development
EPA600 S7-85/031b Sept. 1985
v>EPA Project Summary
An Evaluation of Full-Scale
Fabric Filters on Utility
Boilers: PP and L Brunner
Island Station Unit 1
John W. Richardson, John D. McKenna, and John C. Mycock
The objective of this program was to
evaluate and characterize the perform-
ance of full-scale fabric filter units in-
stalled on 100 MW or larger coal-fired
power plants. This document reports
the results of total mass and fractional
size paniculate emission tests at one
location. Operating and maintenance
data from this location are also in-
cluded. A separate report documents a
similar emission test on a second site.
Two series of tests were conducted
at Pennsylvania Power and Light's
Brunner Island Station Unit 1 on August
12-16, 1981, and September 2-4, 1982.
Five inlet/outlet total mass tests were
conducted in August 1981, and three in-
let/outlet total mass tests were con-
ducted in September 1982.
Emissions for Unit 1 are controlled by
a 24-compartment Carborundum bag-
house that has a designed gas flow of
1,200,000 acfm* at 330°F. Each com-
partment contains 264 bags, each mea-
suring 11.5 in. in diameter and 35 ft 4 in.
in length.
Average outlet concentrations for
both test series were higher than ex-
pected. Outlet emissions for the August
1981 tests averaged 0.037 lb/106 Btu,
and the average baghouse efficiency
was 99.7%. Average outlet emissions
for the September 1982 tests were
0.096 lb/106 Btu, and the average
'Readers more familiar with the metric system may
use the conversion factors at the end of this
Summary.
baghouse efficiency was 98.4%. The
allowable particulate emission rate for
this source stipulated by the Pennsyl-
vania Department of Environmental
Resources is 0.10 lb/106 Btu.
Two inlet/outlet and two blank cas-
cade impactor tests were performed
during the August 1981 program. The
impactor test series of September 1982
included 10 runs: 4 inlet, 4 outlet, and
2 blanks. Average mass mean diame-
ters were 13.4 pm at the inlet and 7.0
|tm at the outlet during the August
1981 tests, and 19.9 |im at the inlet and
9.0 |im at the outlet during the Septem-
ber 1982 tests.
This Project Summary was devel-
oped by EPA 'a Air and energy Engineer-
ing 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 or-
dering information at back).
Introduction
ETS, Inc., was funded by EPA to con-
duct a program to characterize the per-
formance of three full-scale fabric filter
units operating on large (>100 MW)
coal-fired power plants. The objective of
the program was to document the capa-
bilities and behavior of fabric filters ap-
plied to large utilities burning a range of
coals.
The purpose of the test series de-
scribed in this report was to determine
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Table 1.
Data Summary
(Test Series 1, PP&L Brunner Island, Unit 11
OUTLET EMISSION DATA
August 12-16, 1981
Run
&
Date
1
8 1281
2
81381
3
81481
4
8 1581
5
8 16/81
Paniculate Emissions
Ib 106 Btu
0.027
0.018
0.078
0.037
0.026
Ibhr
85.0
53.0
273
128
91
gracf
0.0085
0.0056
0.025
0.012
0.008
MW
Production
337
345
341
340
340
Flow
actm
dscfm
1170000
730000
1110000
680000
1250000
780000
1260000
780000
1330000
790000
Temp.
°F
294
289
280
282
289
Orsat
CO2 02 CO
12.2 6.0 0. 1
12.9 5.3 0.2
12.9 5.3 0. 1
13. 1 5.3 0. 1
13. 1 5.2 0.0
Stack
Gas
Moisture
5.7
7.8
7.6
7.6
6.8
INLET LOADING DATA
Run
&
Date
1
8 12/81
2
8/13/81
3
8/14/81
4
8/15/81
5
8/16/81
Baghouse
Col. Eff.
99.8
99.8
99.2
99.7
99.8
Paniculate
Ib/hr
52000
29000
37000
42000
45000
Loading
gr/acf
6.16
2.96
3.88
4.32
4.66
Baghouse
Diff. Pres.
in. H2O
8.0
8.1
7.9
8.3
8.5
Flow
acfm
dscfm
980000
600000
1 140000
710000
1 1 10000
690000
1 140000
710000
1 120000
690000
Temp.
°F
286
290
290
293
300
Orsat
CO2 O2 CO
13.1 5.4 0.0
12.7 5.4 0.0
12.1 5.7 0.0
13.0 5.3 0.0
13.1 5.2 0.0
Stack
Gas
Moistur
11.0
8.1
9.1
8.1
7.1
particulate emissions in pounds per mil-
lion Btu and to determine particle size
using cascade impactors at Pennsylva-
nia Power and Light's Brunner Island
Station Unit 1.
Two separate test programs were
conducted at the Brunner Island Station
during this research program from
November 1980 to October 1983. The
first test series was performed in Au-
gust 1981, and the second in August-
September 1982.
The particulate emissions at the inlet
to and outlet from the baghouse were
tested according to Federal Register
Reference Methods 1-5. Assembly and
use of the impacter train followed state-
of-the-art protocol and general
Method 5 sampling train procedures.
Five inlet/outlet particulate total mass
tests were performed during the 1981
test series, and three inlet/outlet partic-
ulate total mass tests during the 1982
test series. Summaries of these test
data are in Tables 1 and 2.
In addition to the two detailed test
programs conducted at the PP&L Brun-
ner Island Station, detailed operational
and maintenance data were recorded
for 2 years, from unit start-up, October
19, 1980, through September 31, 1982.
These data have been analyzed exhaus-
tively, and the results and recommen-
dations of this work appear in this
report.
Process and Control Device
Description
PP&L's Brunner Island Station Unit 1
consists of a tangentially fired Combus-
tion Engineering boiler, rated at 350
MW and 2,200,000 Ib steam/hr. Boiler
operating conditions are 2,500 psig and
1005°F at the superheater. Reheater de-
sign is 600 psig with an outlet steam
temperature of 1005°F.
Pulverized coal is supplied to the
boiler by five Combustion Engineering
Raymond bowl mills. The boiler is fired
with No. 2 fuel oil during start-up. Fuel
oil can also be used to supplement coal-
firing at any boiler load.
The flue gas from boiler 1 is directed
into a common stack that is shared with
Unit 2. Two induced-draft fans are in-
stalled on each unit. The I.D. fans for
Unitl were modified by PP&L to accom-
modate the baghouse.
Particulate emissions from Unit 1
were initially controlled by two parallel
electrostatic precipitators (ESPs). Ex-
tensive duct work runs and modifica-
tions were required to locate a full-scale
baghouse at the site. This baghouse
was designed, furnished, delivered, and
erected by the Carborundum Company.
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The newer ESP was blanked off and
retired in place, and all the gas flow was
directed through the original ESP. Only
the perforated plates were removed
from the original ESP.
The baghouse consists of 24 compart-
ments with 264 bags per compartment,
totaling 6,336 bags. Bag dimensions are
11.5 in. in diameter by 35 ft 4 in. in
length. Most of the original bags were
9.3 oz fiberglass with Teflon "B" finish.
Reverse air cleaning is used to periodi-
cally remove particulate which has col-
lected on the interior of the filter bags.
The baghouse can be cleaned either on
a continuous timed cycle or on a differ-
ential pressure basis. The baghouse has
a bypass damper designed for a flue gas
volume of 330,000 acfm at 300°F. The
standby heating system is an electrical
resistance type with controls to main-
tain the baghouse at 300°F after shut-
down.
Testing Methodology,
Sampling Equipment and
Procedures
Particulate emission tests were con-
ducted according to U.S. EPA Reference
Methods 5 and 17 procedures in con-
junction with Methods 1, 2, 3, and 4. An
Alundum thimble (Method 17) was used
Table 2. Data Summary
for testing on the inlet because the con-
centration of particulate matter in the
gas stream to the baghouse was very
high. The EPA contract specified
Method 5 sampling on the outlet. A Nor-
ton AN-899 retention Alundum thimble
was used in this test series to prevent
vacuum problems and reduce the extra
time required to change filters and
check for leaks. Subsequent laboratory
analysis supported this decision be-
cause no more than 6.5% of the total
outlet particulate catch was deposited
on the Method 5 filter during any of the
tests of the August 1981 test program.
Each test included a 49-point traverse
with a 5-minute sampling duration for
each point, resulting in a total test time
of 4 hours and 5 minutes.
The particulate sampling equipment
used is referred to as the "EPA Particu-
late Sampling Train," designed and de-
veloped by the U.S. EPA.
The apparatus used consisted of a
stainless steel sampling nozzle, an
Alundum thimble, a Method 5 filter
holder containing an 87-mm Schleicher
and Sherell #1-HV high-purity glass fil-
ter, a series of four Greenburg-Smith
impingers, a check valve, a leakless vac-
uum pump, a dry gas meter, and a cali-
brated orifice. The impingers and con-
(Test Series 2, PP&L Brunner Island, Unit 1)
OUTLET EMISSION DATA
necting tubes were Pyrex glass,
connected with glass ball-and-socket
joints. The probe was Type 316 stainless
steel.
Using a Type S pitot tube, a velocity
traverse was performed along each tra-
verse axis during each particulate run.
The velocity pressure at each sampling
point was measured, using an inclined
manometer. A thermocouple attached
to the pitot tube measured gas stream
temperature. Thermal potential was
measured with an Omega portable
potentiometer.
Before beginning a run, the sampling
train including probe and nozzle was
leak-tested by plugging the nozzle with
a rubber stopper and applying a vac-
uum of 15 in. Hg to the system. This
procedure was repeated at the conclu-
sion of each run. The maximum allow-
able leakage rate of 0.02 cfm was not
exceeded during any of the leak tests.
At the completion of each test, the
sampling nozzle, the inside of the probe,
the inside of the thimble holder, and the
front-half of the glass fiber filter holder
were washed with deionized water and
acetone. The washings were collected
in separate storage containers. The
Alundum thimble and the glass fiber fil-
ter were removed from their respective
September 2-3, 1982
Run
&
Date
1
9/2/82
2
9/3/82 '
3
9/3/82
Particulate Emissions
lb/106 Btu
0.071
0.104
0.114
Ib/hr
251
395
397
gr/acf
0.021
0.032
0.035
MW
Production
335
335
335
Flow
acfm
dscfm
1370000
820000
1440000
890000
1340000
820000
Temp.
°F
318
306
311
C02
%
13.0
12.6
12.5
Orsat
02
%
6.0
6.2
6.4
CO
%
0.0
0.0
0.0
Stack
Gas
Moisture
%
5.1
4.2
4.8
INLET LOADING DATA
Run
&
Date
1
9/2/82
2
9/3/82
3
9/3/82
Particulate Loading
lb/106 Btu
6.18
7.84
7.82
Ib/hr
17000
25000
24000
gr/acf
1.77
2.35
2.43
Baghouse
Diff. Pres.
in. H2O
8.2
8.0
8.2
Flow
acfm
dscfm
1 140000
670000
1230000
720000
1160000
690000
Temp.
°F
315
308
314
Orsat
CO2 O,
% %
13.0 6.0
12.8 6.0
12.5 6.3
CO
%
0.0
0.0
0.0
Stack
Gas
Moisture
%
11.0
11.1
9.2
Baghouse
Col. Eff.
%
98.6
98.4
98.3
-------
filter holders and stored in separate
storage containers.
Summary of Results for First
Brunner Island Test Series
Results for particulate total mass
emission tests performed August 12-16,
1981, at PP&L Brunner Island Unit 1,
steam-electric station are summarized
in Table 1. As shown in Table 1, the av-
erage particulate emission rate for
these five tests was 0.037 lb/106 Btu,
compared to a Department of Environ-
mental Resources' allowable emission
rate of 0.10 lb/106 Btu.
Six cascade impactor tests were per-
formed: two i.nlet, two outlet, and two
blanks. Average mass mean diameter
was 13.4 (xm at the inlet and 7.0 n-m at
the outlet.
Description of Second Brunner
Island Test Series
A second series of particulate tests
and impactor tests were conducted at
the Brunner Island Unit 1 station, Sep-
tember 2-4, 1982. The same objectives
were incorporated into the program as
for the test program of August 1981.
Test protocol, test port locations, and
sampling equipment were also the
same as those used in the first test pro-
gram.
Summary of Results—Second
Test Series
Results of the three inlet/outlet partic-
ulate total mass emission tests per-
formed September 2-4, 1982, are sum-
marized in Table 2. The average
particulate emission rate for the outlet
tests was 0.096 lb/106 Btu, more than
twice the emission rate of the August
1981 tests, yet still below the Pennsyl-
vania Department of Environmental Re-
sources' allowable emission rate of 0.10
lb/106 Btu.
The impactor test series included 10
runs: 4 inlet, 4 outlet, and 2 blanks.
Computer manipulation of these data
showed two peaks each for both the in-
let and outlet runs. Average mass mean
diameter was 19.9 urn at the inlet and
9.0 (Am at the outlet.
Metric Conversions
This Summary includes certain non-
metric units for the reader's conve-
nience. Those more familiar with the
metric system may use the following
conversion factors.
Nonmetric Times
Yields Metric
Btu
°F
ft
ft3
gr
in.
in.2
Ib
1.055
5/9 (°F-32)
30.48
28.32
0.065
2.54
6.45
0.454
kJ
°C
cm
1
g
cm
cm2
kg
J. Richardson, J. McKenna, andJ. My cock are with ETS, Inc., Roanoke, VA 24018.
Dale L. Harmon is the EPA Project Officer (see below).
The complete report, entitled "An Evaluation of Full-scale Fabric Filters on Utility
Boilers: PP&L Brunner Island Station Unit 1." (Order No. PB 85-235 521/AS;
Cost: $20.50, subject to change) will be available only from:
National Technical Information Service
5285 Port Royal Road
Springfield, VA 22181
Telephone: 703-487-4650
The EPA Project Officer can be contacted at:
Air and Energy Engineering Research Laboratory
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
United States
Environmental Protection
Agency
Center for Environmental Research
Information
Cincinnati OH 45268
Official Business
Penalty for Private Use $300
EPA/600/S7-85/031b
OC00329 PS
U S ENVIR PROTECTION AGENCY
REGION 5 LIBRARY
230 S DEARBORN STREET
CHICAGO IL <5Q*G4
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