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 ------- 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. ------- 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 ------- |