EPA-600/8-83-004
                                                April  1983
             POLLUTION  CONTROL  TECHNICAL MANUAL

                            FOR

           MODIFIED  IN SITU OIL SHALE  RETORTING
           COMBINED  WITH  LURGI SURFACE RETORTING
                   Denver Research Institute
                     University of Denver
                    Denver,  Colorado 80208
                   Cooperative Aqreement
                        OR 807294
            Program Manager:  Gregory G. Ondich
Office of Environmental Engineering and Technology (RD-681)
           U.S. Environmental Protection Agency
                     401 M Street, SW
                   Washington, DC  20460
             Project Officer:   Edward R.  Bates
 Industrial  Environmental  Research Laboratory - Cincinnati
                  Cincinnati,  Ohio  45268

-------
                                   TECHNICAL REPORT DATA
                            (f lease read Instructions on the reverse before completing)
1. REPORT NO.
                              2.
                                                           3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
    POLLUTION CONTROL TECHNICAL MANUAL FOR MODIFIED
    IN SITU OIL  SHALE RETORTING COMBINED WITH LURGI
    SURFACE RETORTING
              5. REPORT DATE
                February,  1983
              6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
                                                           8. PERFORMING ORGANIZATION REPORT NO,
    Denver Research  Institute
9. PERFORMING ORGANIZATION NAME AND ADDRESS
    Denver Research  Institute
    University of Denver
    Denver, CO  80208
              10. PROGRAM ELEMENT NO.

                N104 CZN1A
              11. CONTRACT/GRANT NO.
                                                              CR-807294
12. SPONSORING AGENCY NAME AND ADDRESS
    Industrial Environmental Research Laboratory
    26 W. St. Clair  Street
    Cincinnati, OH   45268
              13. TYPE OF REPORT AND PERIOD COVERED
                Final	L	
              14. SPONSORING AGENCY CODE
                                                              EPA/600/12
15. SUPPLEMENTARY NOTES
16. ABSTRACT
     The oil shale PCTM for Modified In Situ Oil  Shale Retorting combined with Lurgi
 Surface Retorting addresses the application of this  combination of technologies  to
 the development of oil shale resources in the western United States.  This manual
 describes the combined plant using Lurgi surface retorting technology (developed
 by Lurgi Kohle and Mineralotechnik GmbH, West Germany) and the Modified In Situ
 process (developed by  Occidental Oil Shale, Inc.)  proposed by Occidental Oil Shale,
 Inc. and Tenneco Shale Oil Company f-or use in the development of their Federal oil
 shale lease Tract C-b  in western Colorado.  Since details regarding waste streams
 and control technologies for the Lurgi process are presented in a separate PCTM, this
 document focuses principally on the Modified In  Situ process.

     This manual proceeds through a description of the oil shale plant, characterizes
 the waste streams produced in each medium, and discusses the array of commercially
 available controls which can be applied to the plant waste streams.  From these
 generally characterized controls, several are examined in more detail for each medium
 in order to illustrate typical control technology  operation.  Control technology cost
 and performance estimates are presented, together with descriptions of the discharge
 streams, secondary waste streams and energy requirements.  A summary of data limi-
 tations and needs for  environmental and control  technology considerations is presented.
 7.
                                KEY WORDS AND DOCUMENT ANALYSIS
                  DESCRIPTORS
                                              b.lDENTIFIERS/OPEN ENDED TERMS
                           c. COSATI Field/Group
 8. DISTRIBUTION STATEMENT
   RELEASE TO PUBLIC
                                              19. SECURITY CLASS (ThisReport/
                                                UNCLASSIFIED
                                                                         21. NO. OF PAGES
20. SECURITY CLASS (This page)
  UNCLASSIFIED
                                                                         22. PRICE
EPA Form 2220-1 (Rev. 4-77)   PREVIOUS EDITION is OBSOLETE
                                - -       411

-------
                                 DISCLAIMER


     The  information  in this document  has  been funded wholly or  in  part by
the United  States Environmental  Protection Agency under  Cooperative Agree-
ment CR-807294  to the  Denver  Research Institute, University of  Denver.   It
has been  subject  to  the Agency's peer  and  administrative  review,  and it has
been approved for publication as an EPA document.  Mention of trade names or
commercial products does not constitute endorsement or recommendation for use.

-------
                                  FOREWORD


     The purpose  of the  Pollution  Control Technical Manuals  (PCTMs)  is to
provide process,  discharge,  and  pollution control data  in summarized form
for the  use of permit writers,  developers,  and other  interested  parties.
The PCTM  series covers  a range  of  alternate fuel  sources,  including coal
gasification, coal  liquefaction by  direct and indirect  processing,  and the
retorting of oil shale.

     The series consists  of  a set of technical  volumes  directed at produc-
tion facilities based upon specific conversion processes.  The entire series
is  supplemented by  an appendix  volume which  describes the  operation and
application of approximately 50 control  processes.

     All PCTMs  are  prepared  on a base plant  concept  (coal  gasification and
liquefaction) or  developers'  proposed  designs  (oil shale)  -which  may not
fully reflect plants to  be built in the future.   The PCTMs present examples
of control  applications,  both  as individual process units and as integrated
control trains.   These examples  are taken in  part from  applicable permit
applications and,  therefore,  are reflective of specific plants.  None of the
examples are intended to convey an Agency endorsement or recommendation, but
rather are  presented for  illustrative  purposes.  The selection of control
technologies for application to specific plants is the exclusive function of
the designers and permitters who have the flexibility to utilize the lowest
cost and/or most  effective  approaches.   It  is  hoped that  readers  will be
able to relate  their waste streams  and controls to those presented in these
manuals to  enable  them to  better  understand the  extent to  which  various
technologies may control  specific waste streams and utilize the information
in making control  technology selections for their specific needs.

     The reader should be aware  that the PCTMs  contain  no legally binding
requirements or guidance, and that nothing contained in the PCTMs relieves a
facility from  compliance with existing or future environmental  regulations
or permit requirements.
                              Herbert L.. Wiser
                    Acting Deputy Assistant Administrator
                     Office of Research and Development
                    U.S. Environmental Protection Agency

-------
                                   ABSTRACT


     The   Environmental   Protection   Agency  (EPA),  Office  of  Research  and
 Development,  has undertaken  an extensive study  to determine synthetic  fuel
 plant  waste   stream   characteristics and  pollution  control  systems.    The
 purpose of this  and all  other PCTMs  is to  convey  this  information  in  a manner
 that is readily  useful to designers,  permit writers and the  public.

     The  oil   shale PCTM for  Modified  In Situ Oil  Shale Retorting  combined
 with Lurgi  Surface Retorting  addresses the application of this combination of
 technologies  to  the  development of  oil shale resources in the western United
 States.   This manual   describes the  combined  plant using Lurgi  surface  re-
 torting  technology  (developed by  Lurgi Kohle  und Mineralotechnik GmbH, West
 Germany) and  the Modified In  Situ  process  (developed by Occidental Oil Shale,
 Inc.)  proposed by Occidental  Oil  Shale,  Inc.  and  Tenneco  Shale Oil Company
 for  use in the  development  of their Federal  oil  shale lease  Tract C-b in
 western  Colorado.   Since  details  regarding waste  streams  and control tech-
 nologies for  the Lurgi process are  presented  in  a separate  PCTM, this docu^
 ment focuses  principally  on  the  Modified  In  Situ process.   In Situ plants
 proposed or built by  other developers  in the future can be expected to be
 similar in most aspects to the plant  described  in this document, but  each  can
 be  expected to  vary  in  some respects, such as mining methods,  selection of
 particular control technologies, methods for upgrading the raw shale  oil,  and
 the selection of a surface retorting technology,  if  any, combined with  the
 Modified In Situ process.

     This  manual  proceeds  through  a description  of  the  oil  shale plant,
 characterizes  the  waste  streams produced in each  medium, and discusses  the
 array  of  commercially available controls which can be applied  to the plant
waste  streams.  From  these  generally characterized  controls,  several   are
 examined  in  more  detail  for  each  medium  in  order  to  illustrate  typical
control  technology  operation.   Control   technology  cost  and  performance
 estimates are presented, together with descriptions of the discharge streams,
 secondary waste  streams  and energy requirements.   A summary of  data limita-
tions   and  needs  for  environmental and control technology considerations is
presented.

-------
                                  CONTENTS
Foreword	. .	i i i
Abstract	,	. .  .  . iv
Figures	,	. .  .  . viii
Tables .	 xi
Abbreviations	 xvii
Conversion Factors	xx
Acknowledgments	xxii
   1.  INTRODUCTION	,	1
       1.1  PURPOSE.  ........ 	  1
       1.2  APPROACH 	 .....  2
       1.3  DATA SOURCES	3
       1.4  STATE OF TECHNOLOGY DEVELOPMENT	4
            1.4.1   Modified In Situ Technology	4
            1.4.2   Lurgi-Ruhrgas Technology 	 ....  5
            1.4.3   Start-up Schedule	5
       1.5  ASSUMPTIONS.	  7
            1.5.1   Pollution Control and Performance Estimates	7
            1.5.2   Components of Pollution Control Cost Estimates ...  9
       1.6  UNIQUE FEATURES	, . .	  11
       1.7  ORGANIZATION AND USE OF THE MANUAL	17
   2.  SUMMARY OF STUDY FEATURES	  27
       2.1  PROCESS OVERVIEW 	  ............  28
            2.1.1   Site Description	  .  29
            2.1.2   Description of the Plant Complex	35
            2.1.3   Description of the Retorting Processes 	  35
       2.2  POLLUTION CONTROL CASE STUDIES	45
            2.2.1   Key Features of Pollution Control	45
            2.2.2   Pollution Control Case Studies .  .	46
       2.3  SUMMARY OF POLLUTION CONTROL TECHNOLOGIES AND COST 	  53
   3.  PROCESS FLOW DIAGRAMS AND FLOW RATES	  61
       3.1  STRUCTURE OF THE DIAGRAMS	•  •  •  •	61
       3.2  OVERALL PLANT COMPLEX.  ......  	  61

-------
                           CONTENTS  (cont.)


    3.3  UNIT PROCESS FLOW DIAGRAMS	.  .   64

         3.3.1   Mining, Rubblizing, Crushing, and
                   Transport of Raw Shale	64
         3,3.2   Lurgi-Ruhrgas Aboveground Retorting	  .   68
         3.3.3   Lurgi-Ruhrgas Oil Recovery 	   68
         3.3.4   Lurgi Lean Oil Absorber and Naphtha Stripper ....   70
         3.3.5   MIS Retorting and Oil/Water Separation 	   73
         3.3.6   MIS Absorber/Cooler	73
         3.3.7   Stretford Sulfur Process (Case Study B)	   75
         3.3.8   Phosam-W Ammonia Recovery Process	   75
         3.3.9   Power and Steam Generation	   78
         3.3.10  Flue Gas Desulfurization (Case Study A).  ......   81
         3,3.11  Water Management Schemes 	   81
         3.3.12  Solid Waste Management 	   85

4.  INVENTORY AND COMPOSITION OF PLANT
    PROCESS AND WASTE STREAMS	    91

    4.1  INVENTORY OF STREAMS.	    91

    4.2  MAJOR STREAM COMPOSITIONS	    117

         4.2.1   Material Balances	    117
         4.2.2   Raw Oil Shale	    119
         4.2.3   Processed Shale	    121
         4.2.4   Crude Shale Oil	    128
         4.2.5   Retort Gas. ........  	    130
         4.2.6   Flue Gas	    143
         4.2.7   Process Wastewaters	  .   147
         4.2.8   Steam Generation	   159

    4.3  POLLUTANT CROSS-REFERENCE TABLES	•  •  •  •  •  •  •   163

5.  POLLUTION CONTROL TECHNOLOGY.  ..................   171

    5.1  AIR POLLUTION CONTROL	  .  .	172
         5.1.1   Particulate Control.	   172
         5.1.2   Sulfur Control	  f  .   188
         5.1.3   Nitrogen Oxides Control	209
         5.1.4   Hydrocarbon Control	   216
         5.1.5   Carbon Monoxide Control	   223
         5.1.6   Control of Other Criteria Air Pollutants  	228
         5.1.7   Control of Noncriteria Air Pollutants	229

    5.2  WATER MANAGEMENT AND POLLUTION CONTROL ...  	   230

         5.2.1   Suspended Matter, Oil  and Grease ..........   230
         5.2.2   Dissolved Gases and Volatiles	243
         5.2.3   Dissolved Inorganics	   248
         5.2.4   Dissolved Organics	   267
         5.2.5   Water Requirements	  .   288
                                  vi

-------
                           CONTENTS  (cont.)


    5.3  SOLID WASTE MANAGEMENT  ...'..'	  296

         5.3.1   Disposal Approaches	  .  296
         5.3.2   Surface Hydrology Control Technologies 	  300
         5.3.3   Subsurface Hydrology Control Technologies	309
         5.3.4   Surface Stabilization Technologies 	  320
         5.3.5   Hazardous Waste Control Technologies 	  325

6.  POLLUTION CONTROL COSTS	 .	331
    6.1  ENGINEERING COST DATA	331

         6.1.1   Bases of Engineering Cost Data	  331
         6.1.2   Details of Engineering Costs	336
    6.2  COST ANALYSIS METHODOLOGY. ...  	 .......  336

         6.2.1   Overview of Cost Analysis Methodology	336
         6.2.2   Economic Assumptions Used in
                   Total Cost Calculations	342
         6.2.3   Solid Waste Management Costs 	 	  351
         6.2.4   Control Cost Example	353

    6.3  COST ANALYSIS RESULTS	 .  354

         6.3.1   Results for the Standard Economic Assumptions. .  . .  355
         6.3.2   Sensitivity Analyses	  362

    6.4  DETAILS OF COST ANALYSIS METHODOLOGY 	  378

         6.4.1   Cost Algorithms.	*.....  378
         6.4.2   Example Calculation of a Fixed Charge Factor ....  380
         6.4.3   Cost Levelizing Calculations	382

7.  DATA LIMITATIONS AND RESEARCH NEEDS .'.	  387
    7.1  .DATA LIMITATIONS	 ..............  387

    7.2  RESEARCH NEEDS .  .  .	389

8.  REFERENCES	  405
                                  vii

-------
                                   FIGURES

Number                                                                   £§
-------
                               FIGURES  (cont.)
 Number                                                                   Page
 3.3-16  Overall  water management scheme,  case study  A	  87
 3,3"17  Overall  water management scheme,  case study  B	  88
 3.3-18  Retort gas  condensate  and retort  water  treatment,
           case studies A &  B	89
 5.1-1    Particulate control technologies	  173
 5.1-2    Cost of  particulate control with  baghouses .	182
 5.1-3    Cost of  particulate control with  electrostatic precipitators  .  .  183
 5.1-4    Cost of  particulate control with  venturi wet scrubbers  . ...  .  184
 5.1-5    Cost of  particulate control with  spray  dryer/baghouse system  .  .  186
 5.1-6    Sulfur dioxide control technologies. .  . 	 .......  189
 5.1-7    Hydrogen sulfide control  technologies	195
 5.1-8    Cost of  flue  gas desulfurization with limestone scrubbers.  .  .  .  207
 5.1-9    Cost of  sulfur recovery with  Stretford  process	  208
 5.1-10   Nitrogen oxides control technologies 	  212
 5.1-11   Cost of ammonia removal with  absorber/cooler ...'...,...  219
 5.1-12   Hydrocarbon control technologies  	 ....  221
 5.1-13   Carbon monoxide control technologies .  . .  	  	  226
 5.2-1    Suspended matter, oil and grease control technologies.  . ,  .  .  .  232
 5.2-2    Cost of mine water clarification	  237
 5.2-3    Cost of oil/water separation  ........... 	  ,  240
 5.2-4    Cost of multimedia gravity filtration	  241
 5.2-5    Cost of equalization pond	  244
 5.2-6    Dissolved gases and volatiles control technologies .......  245
 5.2-7    Cost of retort water steam stripping	253
 5.2-8    Cost of ammonia recovery with Phosam-W process  	  ,  . .  254
 5.2-9    Dissolved inorganics control technologies	  255
 5.2-10  Cost of kettle evaporators	261
5.2-11  Cost of boiler feedwater treatment with  zeolite resin	264
5.2-12  Cost of cooling water treatment.	  266
5.2-13  Flow scheme for solar evaporation  treatment.  .	  268
5.2-14  Cost of solar pond	269
5.2-15  Dissolved organics control technologies	270

-------
                              FIGURES  (cont.)
Number                                                                   Page
5.2-16  Reverse osmosis process flow scheme. ...... 	  278
5.2-17  Cost of organics removal with reverse osmosis	 .  .  281
5.2-18  Carbon adsorption process flow scheme.	  282
5.2-19  Cost of organics control with carbon adsorption. . 	  285
5.2"20  Wet air oxidation process flow scheme	286
5.2-21  Cost of organics control with wet air oxidation	  289
5.3-1   Surface hydrology control technologies	  302
5.3'-2   Runon diversion costs	'....„•	  .  .  304
5.3*3   Typical runoff collection systems	i  .  .  306
5.3'-4   Runoff collection and channeling	307
5.3-5   Runoff collection costs	 . .	 ....  .  308
5.3"6   Runoff/1eaehate pond costs 		  310
5.3-^7   Runoff/I eaehate pond liner costs	311
5.3-8   Subsurface hydrology control technologies	  312
5.3-9   Liner costs	..'..'.	  316
5.3-10  Leachate collection costs	318
5.3-11  Groundwater collection costs	  319
5.3-12  Surface stabilization technologies . . 	  321
5.3-13  Dust control costs	  324
5.3-14  Reclamation and revegetation costs 	  326
5.3-15  Hazardous waste control  technologies ........  	  327
6.0-1   Interrelationships among various
          cost and economic terms	  332
6.3-1   Sensitivity analyses for case study A:
          total air pollution control costs. .	370
6.3-2   Sensitivity analyses for case study A:
          total water pollution control  costs. .............  371

-------
                                   TABLES





Number
1. 4-1
1.5-1

1.5-2
1. 5-3
1. 5-4

1. 6-1
1. 6-2

1.7-1
2.1-1

2.1-2
2.3-1
2.3-2
2.3-3
4.1-1
4. 1-2
4.1-3
4. 1-4
4. 1-5
4.1-6
4.2-1
4. 2-2
4.2-3
4.2-4
4.2-5

Production Data for MIS-Lurgi Project ...... 	
Performance Levels Estimated for Major
Pollution Controls 	 	 	
Components of Fixed Capital Cost Estimates 	 	 . .
Components of Direct Annual Operating Cost Estimates. . . .
Summary of Major Standard Economic Assumptions
Used in Control Cost Evaluations 	
Major Features of the Oil Shale PCTMs 	 . . . .
Pollution Control Technologies Examined
in the Oil Shale PCTMs 	 	
Composite List of Streams 	 	 . .
Major Parameters Defining the Size of the Commercial
Plant Complex 	
Shale Oil Production Schedule for the Start-up Period . . .
Summary of Pollution Control Technologies 	
Inventory of Major Pollution Control Technologies . . . . .
Pollution Control Cost Summary, . 	
Inventory of Gaseous- Streams. . . . . . . 	 • * •
Compositions of Gaseous Streams ....;... 	
Inventory of Liquid Streams . 	 	 . .
Compositions, of Liquid Streams. 	 	 	 .
Inventory of Solid Streams 	 , 	
Compositions of Solid Streams . 	 , 	
Gross Material Balance for MIS Retort 	 .'•...
Gross Material Balance for Lurgi Retort ..........
Composition of Raw Shale in MIS Retorts 	 	 .
Composition of Raw Shale for Lurgi Retorts 	
Laboratory Column Leachates from Some
Colorado Raw Oil Shales 	 ........
. . 6

. . 8
. . 10
. . 11

. . 12
. . 13

. . 15
. . 19

. . 30
. . 31
. . 54
. . 55
. . 58
. . 92
. . 97
. . 105
. . Ill
. . 115
. . 116
. . 118
. . 119
. . 120
. . 120

. . 122
                                     xi

-------
                               TABLES  (cont.)
Number                                                                   Page
4.2-6    Composition of MIS Processed Shale	  123
4.2-7    Composition of Lurgi Processed Moisturized Shale	123
4.2-8    Inorganic Analysis Of Lurgi Processed Shale . , 	 .  124
4.2-9    Physical Properties of Lurgi Retorted Shale 	  125
4.2-10   Concentrations of Dissolved Species in the
           Leachate from MIS Processed Shale	  126
4.2-11   Comparison of Concentration Range of Macro Ions Found
           in First Fraction of Leachates from Occidental's
           MIS Core Samples and Aboveground Retorted Shale 	  127
4-2-12   Analysis of Leachate from Lurgi Processed Shale	 .  128
4.2-13   Properties of MIS Crude Shale Oil .  ,	129
4.2-14   Properties of Naphtha-Free Shale Oil from
           Lurgi Retorting	. .	131
4.2-15   Composition of MIS Retort Gas	132
4.2-16   Composition of MIS Retort Gas After Absorber/Cooler 	  133
4.2-17   Composition of Lurgi Retort Vapors	  134
4.2-18   Composition of Lurgi Retort Gas After Middle Oils Scrubber. . .  135
4.2-19   Composition of Lurgi Retort Gas After Light Oils Scrubber . . .  136
4.2-20   Composition of Naphtha-Free Lurgi Retort Gas	  137
4.2-21   Reported Analysis of Naphtha-Free Lurgi Retort Gas.  ......  138
4.2-22   Composition of Lurgi Naphtha	  139
4*2-23   Composition of MIS Retort Gas After Stretford
           Precooler, Case Study B . . .	,	  140
4.2-24   Composition of MIS Retort Gas After
           Stretford Process, Case Study B 	 ........  141
4.2-25   Composition of Lurgi Retort Gas After
           Stretford Process, Case Study B	  142
4.2-26   Other Streams from Stretford Process,  Case Study B	  143
4.2-"27   Selected Sulfur Species in Retort Gas
           from Rio Blanco MIS Retort Zero Burn.	144
4.2b-28   Composition of Flue Gas from the Combined Retort
           Gases Before and After FGD,"Case. Study A	145
4.2-29   Retorted Composition of Flue Gas, Case Study.A.	146
4.2-30   Composition of Flue Gas from the Combined Stretford
           Treated Retort Gases, Case Study B	  147
                                     xii

-------
                                TABLES  (cont,)
 Number                        ;                                           Page
 4.2-31   Composition  of Flue  Gas  from Lurgi  Lift Pipes  ....  	   148
 4,2-32   Reported  Composition of  Lurgi  Flue  Gas.	   148
 4.2-33   Composition  of MIS Gas Condensate	   150
 4.2--34   Composition  of Lurgi  Gas  Liquor  .  .  .	151
 4.2-35   Composition  of Total  Feed to Phosam-W  Ammonia
            Recovery Process,  Case  Study A.	152
 4.2-36   Material  Balance Around  Phosam-W Ammonia
            Recovery Process,  Case  Study A.  .	   153
 4.2-37   Material  Balance Around  Lurgi  Waste  Heat Recovery
            Boiler, Case Study A	154
 4.2-38   Composition  of Total  Feed to Phosam-W  Ammonia
            Recovery Process,  Case  Study B.	   155
 4.2-39   Material  Balance Around Phosam-W Ammonia Recovery
            Process, Case Study B	156
 4.2-40   Material  Balance Around Lurgi  Waste  Heat Recovery
            Boiler, Case Study  B	   157
 4.2"-41   Composition  of Retort Water  for  MIS  Process	   158
 4.2"42   Other Properties of  Retort Water from  MIS Process 	   159
 4.2-43   Material  Balance for  the  Retort  Water  Around
            Steam Stripper	,	160
 4.2-44   Material  Balance for  Kettle  Evaporators, Case Study A  . . . .  .   161
 4.2-45   Material  Balance for  Kettle  Evaporators, Case Study B  	   162
 4.3"!     Pollutant Cross-Reference for  Gaseous  Streams .........   164
 4.3*2     Pollutant Cross-Reference for  Liquid Streams. ... 	   1S6
 4.3-3     Pollutant Cross-Reference for  Solid Streams ..........   1S9
 5.1-1     Key Features of Particulate  Control Technologies	174
 5.1-2     Particulate Control Equipment  and Design Parameters ......   179
 5.1-3    Major Items in  Electrostatic Precipitator 	 ....   180
 5.1-4    Cost of Particulate Pollution  Control	   181
5.1-5    Major Items in the Spray Dryer/Baghouse System	   185
5.1-6    Total Particulate Emissions  from the Plant.  .	187
 5.1^7    Key Features of Sulfur Dioxide Control  Technologies 	   190
5.1-8    Key Features of Hydrogen Sulfide Control Technologies  .....   196
5.1-9    Major Items in the Limestone FGD Process. .	203
                                    xvn

-------
                                TABLES   (cont.)
 Number                                                                   page
 5.1-10   Major  Items  in  the Holmes-Stretford  Process  	  204
 5.1-11   Cost of Sulfur  Pollution Control	206
 5.1^12   Total  S02 Emissions  from the  Plant*	210
 5.T*13   Key Features of Nitrogen Oxides  Control Technologies	213
 5.1-14   Major  Items  in  MIS Retort Gas  Absorber/Cooler	  217
 5.1-15   Cost of Nitrogen Oxides Pollution Control  	  218
 5.1-16   Total  NOx Emissions  from the  Plant.	,	220
 5.1"17   Key Features of Hydrocarbon Control  Technologies.  . .  . . . .  .  222
 5,1-18   Hydrocarbon Control  Practices  and Equipment	  223
 5.1-19   Cost of Hydrocarbon  Pollution  Control 	  224
 5.1-20   Total  Hydrocarbon Emissions from the Plant.  ....	  225
 5.1-21   Key Features of Carbon Monoxide Control Technologies	227
 5.1-22   Total  CO Emissions from the Plant	228
 5.1-23   Estimated Emissions  of Other Criteria Pollutants	229
 5.2-1    Key Features of Control Technologies for Suspended
           Matter, Oils  and Greases	233
 5.2-2    Design and Cost of Mine Water  Clarification	236
 5.2-3    Design and Cost of API Oil/Water Separator for
           Process Waters.	,	238
 5.2-4    Design and Cost of Multimedia  Gravity Filtration Unit  ...  .   .  239
 5.2->5    Design and Cost of API Oil/Water Separator for
           Runoffs and Leachate. .  .  •	242
 5.2-6    Design and Cost of Equalization Pond	  243
 5.2-7    Key Features of Control Technologies for Dissolved
           Gases and Volatiles .	246
 5.2-8    Design and Cost of Retort Water Steam Stripper	249
 5.2-9    Design of Phosam-W Ammonia Recovery System	250
 5.2-10   Cost of Ammonia Recovery by Phosam-W Process	   .  252
 5.2-11   Key Features of Control Technologies for Dissolved
           Inorganics	,   .  256
5.2-12   Design and Cost of Kettle Evaporators	  2(50
5.2-13   Design and Cost of Boiler Feedwater Treatment 	  .   .  263
5.2-14   Design and Cost of Cooling Water Treatment	265
5.2-15   Design and Cost of Solar Evaporation Pond	267

                                     xiv

-------
                               TABLES  (cont.)
Number                                                                   Page
5.2-16   Key Features of Control Technologies for Dissolved Organics . .  271
5.2-17   Composition of Stripped Retort Water Before
           and After Reverse Osmosis Treatment 	 ....  279
5.2-18   Design and Cost of Reverse Osmosis Treatment of
           Stripped Retort Water	....-.-. k -.,...  280
5.2-19   Composition of Process Waters Before
           and After Carbon Adsorption Treatment	  283
5.2-20   Design and Cost of Activated Carbon Adsorption for
           Process Waters. .... *	284
5.2"21   Composition of Stripped Retort Water RO Concentrate
           Before and After WAO Treatment. .	 ....  287
5.2-22   Design and Cost of Wet Air Oxidation of Stripped Retort
           Water RO Concentrate.	288
5.2-23   Steam Production, Uses and Boiler Feedwater Needs 	  291
5.2-24   Water Quality Parameters for Boiler Feedwater 	 ....  292
5.2-25   Plant Cooling Water Requirements	292
5.2"26   Water Quality Parameters for Cooling Tower Recirculation.  .  .  .  293
5.2-27   Water Requirements for Processed Shale Disposal and
           Dust Control	294
5.2-28   Pptable and Service Water Requirements	  295
5.3-1    Major Wastes Produced Over a Period of 30 Years	297
5.3-2    Key Features of Solid Waste Disposal Approaches ........  298
5.3^-3    Key Features of Surface Hydrology Control Technologies. .  .  .  .   303
5.3-4    Key Features of Subsurface Hydrology Control Technologies  .  .  .   313
5.3-5    Key Features of Surface Stabilization Technologies.  ......   322
5.3-6    Key Features of Hazardous Waste Control  Technologies.  .....   328
6.1-1    Detailed Engineering Costs for Air Pollution Controls .....   337
6,1-2    Detailed Engineering Costs for Water Pollution
           Controls, Case Study A.  .  .	   338
6.1-3    Detailed Engineering Costs for Water Pollution
           Controls, Case Study B	  .   339
S.IH'    Engineering Costs and Timing of Solid Waste
           Management Activities	  .   340
6.2-1    Summary of Standard Cost and Economic Assumptions 	   344
6.2-'2    Economic Assumptions that Vary from Control to Control	345
                                     xv

-------
                               TABLES  (cont.)
Number                                                                   Page
6.2-* 3    Fixed Capital and Direct Annual Operating Costs
           for Solid Waste Management	  352
6.2-4    Per-Barrel Cost Breakdown for Stretford System	353
6.3-1    Summary of Pollution Control Costs for-
           Standard Economic Assumptions 	  356
6.3-2    Pollution Control Costs, by Control Group,
           for the Standard Economic Assumptions	.  .	357
6.3-3    Control Groupings	  358
6.3-4    Details of Air Pollution Control Costs,
           Standard Economic Assumptions .  . 	  ........  360
6.3-5    Details of Water Pollution Control Costs,
           Standard Economic Assumptions 	 	  361
6.3-6    Details of Solid Waste Management Costs,
           Standard Economic Assumptions	  363
6.3-7    Assumptions for Sensitivity Analyses	364
6.3-8    Charge Rates for Sensitivity Analyses 	  365
6.3-9    Sensitivity Analyses Expressed as a Percentage
           of Shale Oil Value	366
6.3-10   Sensitivity Analyses by Control Group .....  	  367
6.4-1    Example of Fixed Charge Factor Calculation	  .  381
7.1*1    Data Limitations and Research Needs .  . .	390
                                     xv i

-------
                      ABBREVIATIONS
°API       — gravity (American Petroleum Institute)
ACF        — actual cubic feet
ACFM       — actual cubic feet per minute
ACRS       — accelerated cost recovery system
ADA        — anthraquinone disulfonic acid
ADR        — asset depreciation range
AMB        — ambient
BACT       — best available control technology
BOD        — biochemical oxygen demand
BP         — annual by-product credit
BPCD       — barrels per calendar day
BPSD       — barrels per stream day
CA         — carbon adsorption
CC         — total annual capital charge
CMLRB      — Colorado Mined Land Reclamation Board
COD        — chemical oxygen demand
CPB        — per-barrel control cost
CS/SS      — carbon steel/stain!ess steel
DCF        — discounted cash flow
DCF ROR    — discounted cash flow rate of return
DDP        — Detailed Development Plan
DEA        — diethanolamine
DGA        — diglycolamine
DIPA       — diisopropanolamine
DOC        — direct annual operating cost
DRI        — Denver Research Institute
ED         — electrodialysis
ESC        — annual extra start-up costs
                          xvn

-------
                 ABBREVIATIONS  (cont.)
ESP
FCC
FGD
FGR
fpm
gpm
gpt
HP
IBP
IOC
ITC
LHV
LTPSD
MDEA
MEA
MEB
MIS
MMBtu
MMSCFD
MSF
MTPSD
MW
MWt
pcf
pCi/1
PCTM
POM
ppmv
ppmw
PSD
psia
psig
RF
electrostatic precipitator
fixed capital cost
flue gas desulfurization
flue gas recirculation
feet per minute
gallons per minute
gallons per ton
horsepower
initial boiling point
indirect annual operating cost
investment tax credit
low heating value
long tons per stream day
methyldiethanolamine
monoethanolamine
multiple effect boiling
Modified In Situ
million British thermal units
million standard cubic feet per day
multistage flash
metric tons per stream day
megawatts
molecular weight
pounds per cubic foot
picocuries per liter
Pollution Control Technical Manual
polynuclear organic matter
parts per million, by volume
parts per million, by weight
Prevention of Significant Deterioration
pounds per square inch, absolute
pounds per square inch, gauge
fixed capital charge rate
                          xvm

-------
                 ABBREVIATIONS  (cont.)

RHC        — reactive hydrocarbons
RO         — reverse osmosis
RSH        — alkyl thiols, mercaptans
RW         — working capital charge rate
SCF        — standard cubic foot
SCFM       — standard cubic feet per minute
SCOT       — Shell Claus Off-gas Treating
SCR        — selective catalytic reduction
SEA        — standard economic assumptions
SNPA/DEA   -- Societe Nationale des Petroles d'Aquitaine/
                diethanolamine
SS         — stainless steel
STC        — annual severance tax credit
SWEC       — Stone and Webster Engineering Corporation
TC         — total annual control cost
TDS        — total dissolved solids
TIA        — annual property tax and insurance allowance
TOC        — total annual operating cost
TPCD       — tons per calendar day
TPM        — total particulate matter
TPSD       — tons per stream day
TPY        — tons per year
TSS        — total suspended solids
UF         -- ultrafiltration
USBM       — U.S. Bureau of Mines
VCE        — vapor compression evaporation
VOC        — volatile organic compounds
WAO        — wet air oxidation
WC         — working capital
WPA        — Water Purification Associates
                           xix

-------
                              CONVERSION FACTORS
 1 pound,  Ib


 1 ton

 1 inch,  in

 I foot,  ft


 1 mile, mi


 1 square  inch,  in2

 1 square  foot,  ft2

 1 square  mile,  mi2


 1 acre


 1 cubic inch, in3

 1 cubic foot, ft3

 1 gallon, gal


 1  barrel, bbl


 1  acre-foot

 1 pound/square inch, psi



1 pound/cubic inch,  lb/in3
 =  453.5924 grams, g
    0.4536 kilograms, kg

 =  0.9072 metic tons, tonnes
                                       !
 =  2.5400 centimeters, cm

 =  30.4800 centimeters,  cm
    0.3048 meters,  m

 =  1,609.3440 meters, m
    1.6093 kilometers, km

 =  6.4516 square centimeters,  cm2

 =  0.0929 square meters,  m2

 =  2.5900 square kilometers, km2
    258.9988 hectares, ha

 =  4,046.8564 square meters, m2
    0.4047 hectares,  ha

 =  16.3871 cubic centimeters,  cm3

 =  28.3161 liters,  1

 =  3.7853 liters,  1
    0.0038 cubic  meters, m3

 =  158.9828  liters,  1
    0.1590 cubic  meters, m3

 =  1,233.4818 cubic meters, m3

 =  70.3070 grams/square centimeter, g/cm2
    0.0680  atmospheres, atm
    0.3591 millimeters of mercury, mm of Hg

=   27.6799 grams/cubic centimeter, g/cm3
    27.6807 grams/milliliter, g/ml
                                     xx

-------
                         CONVERSION FACTORS  (cont.)
1 pound/cubic foot, pcf, lb/ft3  =
1 gallon per ton, gpt            =
1 barrel per day, BPO            =
1 gallon per minute, gpm         =
1 British thermal unit, Btu      =
   0.0160 grams/cubic centimeter, g/cm3
   16.0185 kilograms/cubic meter, kg/m3
   4.1726 liter/tonne, I/tonne
   0.1590 cubic meters/day, m3/d
   0.0631 liters/second, 1/s
   251.9958 gram-calories, g-cal
   1,054.1800 joules, J
1 million British thermal units,
    MMBtu
1 British thermal unit/pound,
    Btu/lb
1 British thermal unit/cubic
    foot, Btu/ft3
=  292.8750 kilowatt-hours, kW-hr
*  0.5556 gram^calories/gram, g-cal/g
=  8.8994 gram-calories/liter, g-cal/I
                                     xxi

-------
                               ACKNOWLEDGMENTS


     This Pollution  Control  Technical  Manual was prepared for the EPA by the
Denver  Research  Institute  (DRI),  University of  Denver, Denver,  Colorado,
under  EPA   Cooperative   Agreement  CR-807294.    Subcontractor  support  was
provided  to  DRI  by  Stone and Webster  Engineering Corporation  (SWEC)  of
Denver,  Colorado,  and Water  Purification  Associates  (WPA) of  Cambridge,
Massachusetts,  The project manager for DRI was Mr. Kishor Gala,  Chemical and
Materials Sciences Division.
                                   xx i i

-------
                                   SECTION 1

                                 INTRODUCTION
 1.1  PURPOSE
      Future U.S.  energy production envisions the development  of an environ-
 mentally acceptable,  commercial  synthetic  fuels  industry.  As  part of this
 overall effort, the Environmental Protection Agency (EPA), Office of Research
 and Development,  has  for the past several years undertaken extensive studies
 to  determine   synthetic  fuel  plant   waste  stream   characteristics  and
 potentially applicable pollution control systems.

      The purpose  of the  Pollution  Control Technical Manuals  (PCTMs)  is  to
 convey, in  a  summarized  and readily useful  manner,  information on synfuel
 waste  stream  characteristics  and  pollution  control  technology  as  obtained
 from studies  by  the  EPA  and others.   The  documents  provide  waste  stream
 characterization  data  and describe a wide variety of pollution controls  in
 terms of estimated  performance,  cost  and reliability.  The PCTMs contain  no
 legally  binding  requirements,  no   regulatory  guidance,  and  include  no
 preference   for  process  technologies  or  controls.   Nothing  within  these
•documents   relieves   a  facility  from  compliance  with  existing  or  future
 environmental  regulations or permits.

      The Pollution  Control  Technical  Manuals consist  of  a  set  of  seven
 discrete documents.   There are six  process specific  PCTMs and  a more general
 appendix volume which  describes over fifty pollution control  technologies.
 Application of  pollution,-:- controls  to  a  particular   synfuel   process  is
 described in each process specific  manual.   The  seven  manuals are:

      •    Pollution  Control Technical Manual  for Lurgi Based Indirect Coal
          Liquefaction and SNG

      •    Pollution  Control  Technical  Manual  for  Koppers-Totzek Based
          Indirect Coal  Liquefaction

      •    Pollution  Control Technical Manual  for Exxon Donor-Solvent Direct
          Coal Liquefaction

      •    Pollution  Control Technical Manual  for Lurgi Oil Shale Retorting
          with Open  Pit  Mining

     •    Pollution  Control Technical Manual  for Modified  In Situ Oil Shale
          Setorting  Combined  with Lurgi  Surface  Retorting

-------
     •    Pollution Control Technical Manual for TOSCO II Oil Shale Retorting
          with Underground Mining

     •    Control  Technology Appendices  for Pollution  Control Technical
          Manuals

     By focusing on specific process technologies, the PCTMs attempt to be as
definitive as possible on waste stream characteristics and control technology
applications.   This  focus  does  not  imply  any  EPA  recommendations  for
particular process  or control  designs.   Those described  in  the manuals are
intended  as  representative  examples  of  processes and  control technologies
that  might  be used.   The design  of  the PCTMs,  from process description
through waste  stream characterization and  control  technology evaluation, is
intended  to  provide  the  user  with  a comprehensive  understanding  of  the
environmental factors inherent in operating synthetic fuel  plants.

     Control technology  discussions  presented  in the PCTMs reflect pollutant
removal levels which  are believed to be achievable with currently available
control technologies  based  upon existing data.   Since there  are no domestic
commercial-scale synfuels facilities,  the  data base supporting this document
was  derived  from  bench-  and  pilot-scale  synfuel  facilities,  developer's
estimates,  engineering  analyses  and  analogue  'industries.   As  commercial
synthetic fuel plants are built, the EPA will continue conducting research in
order  to  develop  a  more comprehensive data base.   Based on  findings  from
these  future  studies, the  Agency  may  update  these documents  or promulgate
industry specific standards.   In  the interim,  the Agency encourages facility
planners,  permit officials,  and other interested parties to take advantage of
the information contained in these documents.

1.2  APPROACH

     The approach taken  in  developing this manual is to describe, in detail,
an  oil  shale  facility  which  has  been  proposed for  development  and  to
emphasize its pollution  control  aspects.   This facility is the basis for the
case studies  described   in  Section 2 "Summary of  Study  Features," Section 3
"Process  Flow  Diagrams  and  Flow  Rates,"  and  Section 4  "Inventory  and
Composition of  Plant  Process  and  Waste Streams."  The  process descriptions
and  control   technologies  presented  in  these  case   studies   are  based  on
documents   (identified in  Section 1.3) published  by  the  proposed  facility
developers and parallel, as  closely  as possible, the current thinking of the
developers.

     This   manual  examines  combined   Modified   In Situ  (underground)  and
Lurgi-Ruhrgas aboveground retorting processes as  proposed by Cathedral  Bluffs
Shale Oil  Company for development  of Federal  Lease Tract C-b in the Piceance
Basin  of   Colorado.   It should  be  noted, however,  that  the  company  is
currently  reassessing "the  project  due   to  increased  construction  costs,
reduced oil prices and  high interest rates, although activities required per
the Federal  lease agreement are being continued.

     In order to enhance the  flexibility of this manual, and since oil shale
development  plans  are   continually  changing,  Section 5 "Pollution  Control

-------
 Technology" expands  beyond  the description  of the  case  studies to  examine
 other pollution control  technologies and approaches that may be applicable to
 the waste sources identified  in  the case studies.   While  controls applied to
 major gaseous,  liquid,  and  solid  streams  described in  the  case study  are
 those which  have been  proposed  by the  developer,  Section 5 also  examines
 alternative pollution control technologies  on  a stream-by-stream basis.   For
 each stream receiving control, all  major control  technologies are discussed,
 while some example technologies  are analyzed in considerable  depth.   Stream
 flow rates and pollutant  characteristics  are  used  in  estimating the  size,
 performance,  and cost of the  controls,  and secondary streams  resulting  from
 the pollution  control  activities  are identified.

 1.3  DATA SOURCES

      This manual focuses  on  the  plans  that have  emerged over the past  few
 years for the development of  Federal  Lease Tract C-b.   The operation  of  the
 tract is  monitored  under  the Federal  Prototype Oil  Shale Leasing  Program
 through  the U.S.  Department of Interior's  Minerals  Management  Service.  Under
 this  program,   a  Detailed  Development Plan  (DDP),  modifications to the DDP,
 and extensive  environmental  information must be submitted on  a regular basis
 to  the  Minerals Management  Service by the lease operators.   The  DDP  and
 subsequent modifications to  the DDP  submitted  by the developers  of Tract  C-b
 were  the  principal data  sources used to  prepare the  case studies  described in
 Sections  2, 3  and 4 of this manual.

      The   first  commercial  development  plan,  or  DDP,  for  Tract  C-b   was
 published in 1976 (Ashland Oil, Inc.  and Shell Oil Co., February  1976).  This
 plan   called   for   the   production  of   approximately   45,000 barrels   of
 hydrotreated  shale  oil  per   day  using  the  TOSCO II  retorting technoloqy.
 (Essentially  the same  plan  has   been   analyzed   in  the  TOSCO II   PCTM.)
 Subsequent to certain issues raised  by the Area Oil Shale  Office  (now part of
 the  Minerals  Management  Service)  regarding the  original  plan,  the tract
 developers  submitted  a  modification to  the  DDP  (Ashland  Oil,  Inc.   and
 Occidental  Oil  Shale,   Inc.,  February 1977).   This  revised  plan specified
 Modified  In Situ (MIS)  retorting  technology  but  no  aboveground retorting.
 Finally,   a  third  plan  was  presented  in  the  Prevention  of  Significant
 Deterioration   (PSD)  permit  application  (Occidental  Oil  Shale,  Inc.   and
 Tenneco Shale  Oil Co.,  April  1981).  This  latest plan  is  based on using  MIS
 technology  in  conjunction  with  the   Lurgi-Ruhrgas  aboveground  retorting
 technology.

     These  three  documents  were   the  major sources used  in  deriving   the
 process,*  pollution control,  and other information  presented in this  manual,
with  the  PSD  permit application  being  the primary  source.    In  addition,
 several  supplemental  sources  were  used and they  are cited  throughout  the
manual.

     Where available,  actual   data  from  the various  scale operations  in oil
 shale  processing were   used.   It  is believed that  these  data accurately
 reflect  the  major  technical  features  which   will  be  encountered  in  a
commercial  oil  shale industry.    In  addition,  technologies  from  analogue
 industries  are transferred,  when  appropriate.   When  necessary,  engineering

-------
 analysis  and judgment provided by the authors of this  manual  (Denver Research
 Institute,  Stone and Webster Engineering Corporation and Water  Purification
 Associates)  and vendor information were  used.   In each  case,  all  assumptions
 required  to  carry  out the analyses  are  listed,  and areas lacking  hard  data
 are  identified (see Sections  1.5  and  7 for more  detailed discussions).

 1.4   STATE OF TECHNOLOGY  DEVELOPMENT

      The  processing plant considered  in  this manual  is  essentially the  same
 as  the one  in the latest plan proposed  for the Tract C-b development.  Two
 different retorting  technologies—the  MIS and Lurgi-Ruhrgas  processes—will
 be used simultaneously to produce a  total of 117,000 barrels per stream day
 (BPSD)  of crude shale oil.   The  MIS  process will produce 69,000 BPSD  of oil
 by  retorting the shale in place  underground.  Approximately 62,000 tons per
 stream  day (TPSD)  of raw shale will  need to  be  mined out to facilitate the
 underground   retorting.    The  mined   out  shale  will   then  be   processed
 aboveground   in  seven   Lurgi-Ruhrgas  retorts   to  produce  an  additional
 48,000  BPSD  of oil.  The shale left  in place will have  an average  oil yield
 of 26,7 gallons per ton (gpt)  based on  the modified Fischer assay and it  will
 be retorted  at an efficiency  equal to  60% of  the  assay.   The mined shale  will
 have  an average oil yield of  32.7 gpt  and it will be  retorted at 100%  of the
 Fischer assay efficiency.  (The  stream-day  rates are  the maximum,  24-hr/day
 rates   that   can  be   achieved;  however,   occasional   equipment   failure  and
 required  maintenance  can result in  a  reduced  production  efficiency.   To
 overcome  this  potential   problem,  Cathedral  Bluffs  has proposed  building
 oversized  processing  trains  and  including  spare, or standby,  equipment so
 that  maximum production  can  be maintained on a  long-term basis.   Thus, the
 plant  will  operate for 365 calendar  days per year at 100%  of its  capacity,
 i.e., the calendar^day rates  will be the  same as  the  stream-day rates.)  The
 current status of the  retorting technologies  is reviewed below.

 1.4.1  Modif i ed In  S1tu Techno!ogy

     Pilot MIS  retorts have  been  operated since  1976  in the Logan Wash  area
 of Piceance  Creek  Basin  in efforts  to bring the  technology  to  the  stage of
 commercial  development (Ashland  Oil,  Inc.  and  Occidental Oil  Shale,  Inc.,
 February 1977; Loucks, November 1979).  To date, six retorts of varying sizes
 have  been processed,  and a  variety  of rubblizing and  operating techniques
 have  been tested.   (Two  additional  retorts,  Rooms 7  and  8, were ignited
 during  the  spring  of 1982,  but  the  data are not yet available.)   The  last
 completed burn, Room  6,  experienced  difficulties at the beginning and end of
 operations, but it  also  had  an extended  period  of stable operations similar
 to what might be  expected in  a commercial facility (Loucks,  November 1979).

     The  retort  sizes and  rubblizing techniques  used  for Rooms 5  to  8
are  comparable to  those  planned for  the Tract  C-b  commercial  development
 (for  instance,  Room 6  measured   164  feet  by  164 feet  by  334 feet  high,
compared  to  the proposed size of 165 feet by 165 feet  by 290 feet  high for
the commercial  retorts),  but  the  commercial  development will  involve simul-
taneous processing  of 96  retorts.  Previous  experience  with  the  MIS retorts
has  involved only  single retort  firing  (although Rooms  7  and  8 have been

-------
 processed simultaneously); therefore, the firing of 96 retorts will present a
 tremendous scale-up in the necessary equipment and activities.

      It should be  noted  that the Logan Wash  site  differs significantly from
 Federal  Lease  Tract C-b.   The pilot  retorts  have  operated  on  shale  that
 yields about 15 gpt of ore when measured by  Fischer  assay.   The shale to be
 retorted  at Tract C-b   is  significantly  richer—an   average oil  yield  of
 26.7 gpt.   It is also suspected that the different mineralogy of the ore at
 th€> tract  may  produce a higher level  of sulfur  species  in the  retort gas
 (Sklarew,    etal.,   February 1981).     Furthermore,    Tract C-b   contains
 substantial quantities of  groundwater  (Ashland  Oil,  Inc. and Shell  Oil  Co.,
 February 1976), while  Logan Wash is  dry.   Although  aquifer dewatering will  be
 carried out through the project life at Tract C-b,  some infiltration problems
 may be anticipated,

 1.4.2   Lurgi-Ruhrgas Technology

     Small Lurgi-Ruhrgas  pilot plants  have  been operated by Lurgi  Kohle und
 Mineralb'technik  GmbH  in  West  Germany.  The  necessity to ship  ore to  West
 Germany  has limited  the  amount  of  available test  data.    To  date,   the
 experience relevant to this manual is limited to three  tests:   one in 1976  on
 shale  from  the  Colony  mine  in  Colorado,  and   two  in  1980  on  shales  from
 Tracts C-b and C-a,   The earlier (1976)  test was  run in a 5-ton/day pilot
 plant,  while the  1980 tests were performed  in a 25-ton/day plant.   Data  from
 the 1980 test on Tract C-b  shale, published  in the  PSD  permit  application for
 the Cathedral Bluffs project, were used in this  manual  (Occidental  Oil Shale,
 Inc.  and Tenneco Shale Oil Co., April 1981).   Tests  have been run on other
 shales  and  reported in the literature (Marnell, September 1976;  Schmalfeld,
 July 1975),  but substantially different results were obtained.

     A  Lurgi-Ruhrgas  demonstration  plant  processing 4,400 TPSD  of shale  on
 Tract  C-a  was  proposed (Rio Blanco  Oil Shale Co.,  February 1981), but these
 plans  were  suspended  indefinitely  during the  summer of 1981  in favor  of
 building  and operating  a  5-ton/day pilot  plant at Gulf Oil Corporation's
 research facility in Pennsylvania.

 1.4.3  Start-up Schedule

     Table 1.4-1 shows the start-up  profile  for  the MIS-Lurgi project based
 on  information  provided   by Occidental  Oil  Shale,  Inc.   The  shale which  is
 mined  in  creating the  MIS  retorts will be processed on the surface using the
 Lurgi-Ruhrgas  technology.   During  the first  year,  the  MIS  processing will
 have an average oil  production equal  to the amount which could be produced by
 burning two to three retorts at once.  Additional retorts will be added until
 a  full panel  of  96 retorts  can be  simultaneously operated  in  the seventh
year.  At  this point  the  retort design will  be  changed,  allowing the number
 of retorts operating to be decreased to 48; each retort will be substantially
 larger (more than twice  the size of the smaller retorts), increasing the oil
 output.  As  the scale  of  the MIS operation increases,  surface facilities for
 handling the MIS retort gas and for retorting the mined shale  will be brought
 on stream.

-------














&
UJ
a.
i
•-*
E
ae
£
I
S
t—t
1
CL
7"
«r
rH


S
1-






























O
en
cb



!"•



to




in





en





CM








rH




















S-
m
a>
r» r-
m oo to CM
CM en


P^ CM
tn co to to
CM CM


i^. en
m oo to'"*
CM CM




r» o
in to to en
CM CM
l»- 03
^* *1* IO rH
CM CM


P» tO
en CM to o
CM CM



^

CM rH US 
CM rH






r-*

CMrH tgr;.



•*•>

*—
S
o

-4-*
m

0}
a.
o
(fl ^S.
C 4-*
•*— <1> '""l* O.
at % 4J cn
s- m a.'w
>— TD U O>

4-» UJ cn o>
i. V) S-  S.
O S- >-* 3 r- HI 3
+J tO E — 1 «3 E -J
01 O) -C

o o
UD O



So
o



o o
U) O
r-H



O O
10 O

O O
to o



o o
10 O





§1








§1















0
*" 4?
g" S?"~'

•>-> D>
fc. .CO t.
O M 3
*> E-l
01

O O
en in
i-Tci"
totn

||

rH CM
to in

cn o
CO 00
CrTrH"
in in

o o
r- o
*r en

o o
tn in
CM en
en o"
CM CM



o o
o r»
rH





O O
CO «S-
to cn_
to in






S cn
in o









•a
c; *~*
r- 0
•a co
c a.
•S ^t
CJ^ O ^
«— tn cj
fO O_ U)
J= Ir- V)

f- 30
O) to Sv
t- cc ex
3
— J








































C
_O
4J
U
3



a.



O

IS
a

ra
m
s.
0)

O O
3.8.
cn oo
to -a-

0 0
co «r

in" 03"
m en

co in
rH to
in" ii. ^
tA t> eo
rH 3
E -J


3
1

O CMI
o ^-1
CM in)
in rM
CM I-H|

SSI
rH rH|
CM rH|

O Oil
*.*J
O CM]
CM rH|

If)
"H
O CO
CM 1

co r-l
p» ol
u»*|
S'1'!



§31
o oil
an





ssl

en rH|






O rHI
oo its-
en «*•!














S"°
o
a rH


O)
r-l 3
Z-l

CM
«!•
CM
•a-

5
CM
S

3
pi
CM"
en

1
03"
CM

1
S



CO
00
<7l
rH
r~*





a

«aT






CM
CO











^


a
_j
JS
o
1—



















0
c
^
i
•
0)
TJ
O
S-
o.

(O
m
£
O
. ' S-

*T
o a:
;a
.c >>

c
0 *O
M 0)

00 m

i. 3
»2 ¥
15
tn u
4J
to
a tj
a. s-
0 i
•9C (/)

-------
      The plant will eventually  use  five surface trains for  handling  the MIS
 gas and a total  of eight (seven operational and one  stand-by)  Lurgi  retorts
 for processing  the mined  shale.  The  Lurgi  retorts will  process shale  of
 increasing grade, up to a maximum of 32.7 gpt  at full  scale.   Ultimately, the
 mining plan will allow  high  grading of the ore brought to  the  surface.   The
 full-scale operation may be  reached  in eight  years.  As  stated earlier, the
 MIS processing equipment will be built 25% oversize and one Lurgi  train  will
 be on  stand-by  at all  times.   This would allow servicing of  the  equipment
 without affecting  production.   Therefore, the commercial MIS-Lurgi facility
 will  produce 117,000 barrels  per calendar day  (BPCD) of oil.

 1.5  ASSUMPTIONS

      In performing a  detailed analysis  of the MIS and  Lurgi  processes and
 associated operations, a number  of  specific assumptions  which  influence the
 results of the analysis and  their interpretation were made.   The underlying,
 major  assumptions relating to pollution  control  performance  and  cost,  as  well
 as the bases behind the  assumptions,  are summarized  in this  section.

 1.5.1   Pollution Control and  Performance Estimates

      In the process of preparing this  manual,  applicable pollution  control
 technologies for different waste  streams were reviewed, and controls proposed
 by industry were evaluated  to the point  that performance and cost could be
 estimated.   Equipment  vendors'  estimates  and guarantees  were  used whenever
 available.   Other performance levels were  estimated using laboratory  testing
 data.   These performance estimates should  be viewed tentatively because  very
 little data  based  on  actual  source  testing  exist.   The  major  pollution
 controls  evaluated  in  this  manual are  presented in Table 1,5-1, along  with
 the performance  levels estimated  as a result of the  analysis.

     The  major   air  pollution   control   technologies  evaluated  (Flue  Gas
 Desulfurization,  Stretford)  are  commercially available and are  used in other
 industries at  a  scale  smaller than that indicated in this manual; therefore,
 multiple  units will be  required.  Nevertheless,  operational  difficulties in
 adapting  these technologies  to  oil  shale processing are  not expected to be
 great  and may primarily involve adapting  these  technologies  to  oil shale
 off-gas characteristics.

     In  the area of water  pollution  control,  it has  been proposed  by  the
 developer  that  the  plant will  achieve  zero-discharge of  process  generated
waters.   The processing plant will  be  water  consumptive, and  the required
 amount  of  water  will  be obtained by mine dewatering.  The process waters are
treated  to  the   degree  necessary for  reuse.    The  technologies  considered
 (steam  stripping,  Phosam-W  ammonia  recovery,  kettle evaporators)  have been
 used in analogue industries  and  can be  expected to  be employed successfully
 in  the oil  shale  industry.   Waters   used  in auxiliary plant operations  are
also treated  since  the wastes produced  from these operations  may be used in
processed shale  moistening and thus  may become a source of pollution.   Reuse
of  some waters may  negate  a  need for pollution control; in  such  cases, no
pollution controls in a conventional  sense are  applied.

-------
                   TABLE 1.5-1.  PERFORMANCE LEVELS ESTIMATED FOR MAJOR POLLUTION CONTROLS
Control Description
                                     Pollutant Controlled
                                                                      Control Level Estimated
AIR POLLUTION CONTROL
Baghouses
Water Sprays
Foam Sprays
Venturi Wet Scrubber
Electrostatic Precipitator
FGD Limestone Scrubber
Adsorber/Cooler
Holmes^Stretford Gas Treating
  Process
Raw and Processed Shale Dust
Raw and Processed Shale Dust
Raw and Processed Shale Dust
Processed Shale Dust
Processed Shale Dust
S02
NH3
H2S
COS
CS2
RSH
99.5%
50%
85-98.5%a
99% @ AP = 5" of water
99.9%
50 ppmv
90%
30 ppmvc
15%d
0%d
70%d
WATER POLLUTION CONTROL
Retort Water Stripper   ;
Kettle Evaporator
Phosam-W Ammonia Recovery
  Process •
NH3
H2S
Organic Matter

TDS
Organic Matter
NH3
96%e
~100%e
Gas Condensate:
Retort Water:
~100%d
70%d
92.5%f
                                                                                       83%e
                                                                                     20%e
SOLID WASTE MANAGEMENT
Surface Landfill
Processed Shale, Sludges,
  Slowdowns, Concentrates,
  etc.
                                 N/A
a The dust removal efficiency of the foam sprays varies depending upon the application.
b Reduction of  S02. to 50 ppmv in the  flue  gas was specified by the vendor.   Cathedral Bluffs has estimated
  that S02 is reduced by 95 wt %.
c Based on Peabody Process Systems, Inc., February 1981.
d DRI estimates.
6 Estimates  from  treatability  studies on  similar waters  conducted by Water  Purification Associates,
  unpublished.
f WPA estimates based on information provided by U.S.S. Engineers and Consultants, Inc., April 1978.
Source:  Occidental Oil Shale Inc. and Tenneco Shale Oil Co., April  1981, except as noted.
                                                      8

-------
     Solid  wastes are  managed using a  surface  landfill,  as proposed in the
Cathedral  Bluffs  PSD  permit  application.   The  surface  hydrology control
technologies,  such as a runon  catchment dam, runoff collection  system, etc.,
and  surface  stabilization  technologies,   such  as  grubbing  and stripping,
revegetation,  etc.,  are  traditional  practices  associated  with solid waste
management.  There is insufficient  information regarding the developer's plan
for  control  of  subsurface  drainage; therefore, the  total  cost of pollution
control for solid  wastes cannot be  determined.

1. J5.2  Components  of  Pollution  Control Cost Estimates

     Fixed capital and  direct annual operating costs were estimated for each
piece  of  pollution  control   equipment  and  each  control   activity.   These
figures were  then used, along with  economic  assumptions,  to calculate total
annual control  costs  which include  an annual charge  for capital.  The total
annual capital  charge provides for  a required after-tax return  on investment
of 12 percent.  The approach used to estimate the capital and operating costs
and  the economic analysis  techniques applied to these data are  summarized in
Tables 1.5-2 through 1.5-4.

     Fixed capital  and  direct annual operating cost estimates were developed
on a component  basis,  using current cost data  from  the actual installation
and  operation  of  similar  facilities   and  using  vendor  quotes  for  major
equipment  items.   Capital  cost estimates  are  expected  to have  an average
accuracy  of  ±30 percent.   This level  of  accuracy can  only be verified  by
actual  equipment  installation.   Experience  in  using  the cost  estimating
procedures  for  units  which  actually   have  been  constructed  and  operated
indicate  that  this   level  of  accuracy  should be achievable  if the  unit
installed  is  exactly  as described in  determining  the cost  estimate.   Any
design changes  could  cause  the actual installed capital cost to fall outside
the range.

     Table 1.5^2 lists  the  components  estimated in determining the installed
fixed capital  cost of pollution control equipment.   For simple equipment, all
components may  not be present.   For large and complex  equipment,  estimating
the cost of each component may be a major effort.  A description of the major
equipment included in each  capital  cost estimate is provided in Section 5 of
this document.

     Table 1.5-3  shows   the components  comprising  direct  annual  operating
costs.  -Operating  supplies  include  such items as baghouse bags.  Maintenance
includes   the  cost  of parts  used,  but  the  needed inventory  of replacement
parts is  included  in  fixed capital   cost.  The cost  of  water consumed is not
included   due  to  uncertainties in  estimating the  value  of water.   Direct
annual  operating costs do not include by-product credits; however, by-product
credits are  included  in total  annual  operating costs.  The operating  costs
(direct,   indirect and  total)  for  each  pollution control,  along  with  a
detailed   discussion  of  how the costs  were determined, are presented on  a
component basis in Section  6.

-------
          TABLE 1.5-2.  COMPONENTS OF FIXED CAPITAL COST ESTIMATES

                                 Components
               Major Equipment (vendor quotes)
               Site Preparation, Excavation and Foundations
               Concrete and Rebar
               Support Structures
               Piping, Ductwork, Joints, Valves, Dampers, etc.
               Duct and Pipe Insulation
               Pumps and Blowers
               Electr.ical
               Instrumentation and Controls
               Monitoring Equipment
               Erection and Commissioning
               Painting
               Buildings
               Engineering and Other Indirect Costs
               Contractor's Fee
               Contingency Allowances

Source:  DRI.
                                     10

-------
      TABLE 1.5-3.   COMPONENTS OF DIRECT ANNUAL OPERATING COST ESTIMATES
                                  Components
                Maintenance  and Maintenance  Supplies

                Operating Supplies

                Operating Labor

                Cooling Water

                Steam

                Electricity

                Fuel

                Indirect  Costs  (e.g., supervision, laboratory, etc.)*


* Indirect costs are included  in the labor  rate.

Source: ORI.
     Table 1.5-4  presents the  major economic  assumptions  used in  the cost
evaluations.   Most economic assumptions  have been  standardized so that the
results found  in  all  of the oil  shale  PCTMs may be compared.  A sensitivity
analysis was performed (see Section 6 "Pollution Control Costs") to determine
the effects  of changes in some of  the  standard economic assumptions.  These
changes  include  delayed  start-up,  changing  capital  and operating costs,
financing  considerations  and  others.   All  of the  oil  shale  PCTMs  use  a
discounted cash flow approach (DCF) and constant dollars (mid-1980).

1.6  UNIQUE FEATURES

     Three  oil shale  retorting  processes  were selected  for the  oil  shale
PCTMs  to  allow  consideration  of  different types  of retorting  processes,
mining  and disposal  techniques,  and  pollution control technologies.   Some
features are  found in more  than one  manual, but each process  examined has
important unique features which make the analysis worthwhile.   These features
are listed in Table 1.6-1.

     Table 1.6-2  lists the  pollution control  technologies examined in the
three PCTMs.  The table is designed to assist the reader in locating detailed
information on any specific control  technology.
                                     11

-------
        TABLE 1.5-4.  SUMMARY OF MAJOR STANDARD ECONOMIC ASSUMPTIONS
                      USED IN CONTROL COST EVALUATIONS
                                 Assumptions3
•    Approach:  Discounted Cash Flow Evaluation (DCF)
•    Method:  Revenue. Requirement determined from capital charge plus
       operating cost
•    Required DCF ROR:  12% (100% equity basis)
•    Cost Base:  Mid-1980 constant dollars
•    Income Tax:  In accordance with current regulations (48% combined tax
       rate, 20% investment tax credit); tax credits and allowances can be
       passed through to a parent company that can benefit from them
       immediately, without waiting for the project to become profitable
•    Project Timing:  7 years start-up, 30 years life
*    Normal Plant Output:  117,000 barrels per calendar day (net, after
       in-plant use)
*    Operating Factors0:  Years 1-7    -  up to 80%
                          Years 8-30   -  100%

a A more detailed list of assumptions is presented in Section 6, Table 6.2-1.
  This method permits accurate costs to be determined separately for each
  control using the DCF approach, without the need for an estimate of total
  plant cost.
c See Table 1.4-1 for details on production rates.
Source:  DRI.
                                     12

-------
             TABLE  1.6-1.  MAJOR  FEATURES OF THE OIL  SHALE  PCTMs
                                                      PCTMs
 Feature
TOSCO II    MIS-Lurgi    Lurgl-Open Pit
MINING
Underground
  Room-and-Pillar
Underground MIS
Open Pit
RETORTING
Aboveground
Underground
Direct-heated
Indirect-heated
Solid-to-Solid
  Heat Transfer
Gas-to-Solid
  Heat Transfer
Resource Recovery
  from Processed Shale ...
High Carbon Processed Shale
Low Carbon Processed Shale
Raw Shale Preheating
PROCESSING
High Btu Off^gas
Low Btu Off-gas
Oil  Fractionation
   X
   X
X
X
X
X

X

X

X

X
                X
                x
                X
X

X
               X
                                                         (Continued)
                                     13

-------
                            TABLE 1.6-1  (cont.)
Feature
                                                      PCTMs
TOSCO II    MIS-Lurgi    Lurgi-Open Pit
PROCESSING (cont.)
Oil Upgrading
Gas Upgrading (for sale)
In-Plant Fuel Use
Excess Electricity

POLLUTION CONTROL
Retort Gas Cleanup
Process Water Cleanup
Excess Water Discharge
By-product Recovery

WASTE DISPOSAL
Surface Landfill
Permitted Design
Open Pit Backfill
Groundwater Contamination
  Potential (subsurface
  disposal  or retort abandonment)
Surface Water Contamination
  Potential (valley fill)
   X
   X
   X
   X
   X
   X
   X
X
X


X
X
                X

                X
X
X
X
X
Source:  DRI.
                                     14

-------
TABLE 1.6-2.  POLLUTION CONTROL TECHNOLOGIES EXAMINED
               IN THE OIL SHALE PCTMs
Control Technology
AIR POLLUTION
Diethanolamine (DEA)
Methyldiethanolamine (MDEA)
Claus
Well man- Lord
Stretford
Shell Claus Off-gas
Treating (SCOT)
Limestone Scrubber (FGD)
Absorber/Cooler
Low Flare
High Energy Venturi Wet Scrubber
Venturi Wet Scrubber
Electrostatic Precipitator
Thermal Oxidizer
Fabric Filter (baghouse)
Foam Sprays
Water Sprays
Double Seal Oil Storage
Refrigerated Ammonia Storage
Catalytic Converter
Maintenance

TOSCO II
X
X
X
X
X
X


X
X
X

X
X
X
X
X
X
X
X
PCTMs
MIS-Lurgi Lurgi-Open Pit




X X

X
X


X
X X

X X
X X
X X
X X
X X
X X
X X
                                            (Continued)
                        15

-------
TABLE 1.6-2  (cont.)
Control Technology
WATER MANAGEMENT
Ammonia Recovery
Biological Oxidation
Steam Stripper
Kettle Evaporator
Reverse Osmosis
Carbon Adsorption
Wet Air Oxidation
Vapor Compression
Evaporation
Reinjection
Multimedia Gravity
Filtration
Clarifier
Process Oil /Water
Separator
Runoff Oil /Water
Separator
Boiler Feedwater
Treatment
Cooling Tower
Makeup Treatment
Equalization Pond
Aerated Pond
Solar Pond

TOSCO II
X
X
X

X
X
X
X


X
X
X
X
x
X

X
PCTMs
MIS-Lurgi
X

X
X
X
X
X


X
X
X
X
X
X
X

X

Lurgi-Open Pit
X



X
X


X

X
X
X
X
X
X
; x
X
                            (Continued)
        16

-------
                             TABLE 1.6-2  (cont.)
Control Technology
SOLID WASTE MANAGEMENT
Runoff Col lection System
Upper Embankments
Lower Embankments
Runon Collection System
Stilling Basin
Water Impoundment
Leachate Collection System
Spring Collection/Underdrains
Covers and Bottom Liners
MIS Spent Retort Treatment
Oust Supression
Surface Reclamation
Piezometers

TOSCO II

X
X
X
X
X
X
X
X
X

X
X

PCTMs
MIS-Lurgi Lurgi-Open Pit

X X

X
X


X
X
X X
X
X X
X X
X

Source:  DRI.
1.7  ORGANIZATION AND USE OF THE MANUAL

     Following this  "Introduction"  to  the PCTM are six  major sections which
present material ranging from basic background information to detailed pollu-
tion  control  data  and costs.   In  addition,  a complete   listing  of  all
information  sources  used  to develop  the manual  is  provided in  Section 8
"References."  A brief description of each of the major sections is presented
below.

     Section 2 provides an  overview of the MIS and Lurgi retorting processes
and the case studies examined in the manual.   It gives background information
on the proposed  project development, including the site involved,  retorting
                                     17

-------
 and  mining processes, and the pollution  controls  proposed by the developers
 of Tract C-b.

     Section 3 expands upon the case studies outlined in Section 2.  Detailed
 process  flow diagrams  and  descriptions  are  given for  each  unit  process.
 Individual  streams,  their mass  flow rates,  and  other  characteristics are
 generated  during the  unit  process analyses, and this information is the basis
 for  detailed stream discussions presented in Section 4.

     Section 4  provides  the  detailed compositions  for  the  major  process
 streams identified in Section 3.  These parameters  are then used in designing
 and  costing the pollution control  technologies  discussed  in Section 5.   All
 streams identified in Section 3 are inventoried by  media (gas, liquid, solid)
 and  important features  of  each  stream  are  noted (Tables 4.1-1, 4.1-3 and
 4.1-5, respectively).  Also,  the  detailed stream compositions are summarized
 by media (Table 4.1-2, 4.1-4 and 4.1-6).

     Section 5 presents  concise  inventories  of the available  control tech-
 nologies and  approaches for  air, water  and  solid wastes.   Key features of
 each  technology  are briefly  described  and  many  leading  technologies  are
 analyzed in greater  depth.   The  fixed capital  and direct  annual  operating
 Costs  and  design details  for the  leading  technologies are  also  presented.

     Section 6  presents  the  total  annual and  per-barrel  cost  of pollution
 control based  upon the  cost data developed for the control  technologies in
 Section 5  and the  standard economic assumptions used in all oil shale PCTMs.
 This section also analyzes the sensitivity of the control costs to variations
 in   the  standard   economic   assumptions   and  capital  and  operating  cost
 parameters.

     Section 7  discusses  the  limitations  of  the  data  base  used  in  the
 preparation of  the  manual.    It  also  identifies   important  areas that  may
 require more research.

     Table 1.7-1 provides  a composite  list  of the major process and  waste
 streams generated  by the  facility  described in Section 3.   All  streams are
 identified with a  unique name and number.  An asterisk (*) is placed next to
 the  stream number if the  stream  comes into contact with  the environment at
 any point  in the  process,  and a  descriptive  letter is  given to identify the
 state  of   the  stream,  i.e.,  gaseous  (G),  liquid  (L)  or solid (S).   Also,
 cross-references are  included for  the flow diagrams in which  the stream is
 produced   and/or   processed  (Section 3),   detailed   composition   tables
 (Section 4),  and  applicable  control  technologies   (Section 5)   to  allow
 tracking of the stream from its origin to  its  final disposition.

     For example,  stream 38 in Table 1.7-1 is  the MIS retort vapor—a gaseous
 stream that comes  in contact with  the environment.   It  is produced by in situ
processing  of  the  rubblized  oil   shale  (stream 35),  as  illustrated  in
 Figure 3.3-7,   Section 3.   Table  4.2-15   (Section  4)  provides  the  detailed
composition of the vapor.    Figure  3.3-7  indicates that Figure  3.3-8  is the
destination for the vapor.
                                     18

-------






















1
u*
o
Wl
13
tu
h-
l-a
3C
8
r-fl
i
r-3
a
ft






















in
u
c

at
t»-
£X
U)
O
ej

























^
c?
0
u o
Q) *f
r- 01
O VI
C
o





Q)
.0
™
c i.
O Q)
•r-,0
•J* S
IA 2
a.
s
o
o




1.
JP £
O 2
J.

„_
0 i





ascription of Stream
0
S fc.
re di
11






1 1 1
1 1











1
1

X X




«*• «r
i i
en en
co en
en co co
co co en




+-> 3
tO (A «*-
.= 3 <
.C ffl
2 DJ .=
0= CQ IE


* * -k
rH CM 

rH r-* rH rH CMCMrH rH CO rH
in in in m m m in m mm



i
eg
^
CM
S ?
1 1 I 1 1 1 «fr .1
I.I t 1 II  1
rH r** •
in co rH r*.
i iii
CM CM CM CM

rH i-4
CO CO
co en
• *
en en in
mm m 'm
mm mm
co co co en en en *f «^ *&• «3*  •!- o ex
•p CD c tn i i
CASH'S "^ ,£e
-JcecH-ujoe o c « *m 2 t.
jaw u« >3 raw 5 0)S §*T3 §T
't"?: ^^ * ° IP's u °5"~ « > 4i «*-'3
O £ s > JI 6- e (O 1— S  -J ^J f_o>T--*r-
 01 s- t/> a> 01 o u e o
D; u u_ UL. k: cc u. -j _i _j >


ao en o rH CMCO^S- muar^co
. rH rH rHrHrH fHrHrHrH





CO
1 CM f
1 « '
rH
CM
tn
•4-

CM

^
^
0 0
1 I
CM CM
•* <• t
1
r«» r^ m
co co ^r
~ A.~ ' •




rH rH
rH iH
m co
CO CO
!** "sr" " *f
m co m
en co co



a -. o
 +J
E «J T3 3 **-
« £ «


8> Cb ,H
rH CM CM






1
1
en

in










co en
rH rH
1 I
CM CM




U>
t
CO
en
in in
i i
CO CO
CO CO



CO CS




tn
to
a
+•> UI
o S
01 4J
s I
nj a>
a: ce
3 3
-j —i


CM CO
CM CM






1
1













**"
rH
1
CM






in
i
CO
CO



-4



m
0
s
tA
O
-J
3


CM
19

-------
>l
0?
o .

JU*
. e
u o
0) *r->

-8
o tn
4J
c
a
o
V)

u
C
2 a>
£S
a)  U»
r*» m s.
. , tp. 4)
§^
^ It
«4-
0 i
S.2
>>*>


S
4J
tn
Description of
E t-
IQ 0)
5? I?





1 I
. 1 1













1
1
rH

CM




10
en

en
i i
CO CO
CO CO

-j — j

a>
Dl
2
O
-4J
O
s >» ^

jU 0 O
.** 1
p|j s
*» a. "-
aiz s-'


in «3
CM CM
CO
CM
in
„
CM
1 CM I
1 • 1
in


0) . . C
i- . o *j
o s- u>
W> •— T3
•r- 4-> 01
o o «» ca
wo t. °CI
^ i*- j*: 3 *—
o c cr m >>
> o a*
3: w ro o en i-
•>-•£. yi O)
i- E O *r» Ot t-
O> Ul 4J Cl U 3
£- tO t- O -J
•— I Z -JO.


r^ a) en o
CM CM CM CO




CO
rH I |
1 1


CM
*H
in






CM
~
«* i
i
O CM
CM CM
1 |
CM . CM
rH
rH
1
CO
CO
cT u>
CO CO

CO CO
1 1 t
CO CO CO

U fS '

(D
o
4J O
5 to
5 J ^
S1 S* E
35 ^
OJ O) Ul .C <1>
OJ (U U 4J 0)
i. fc. CL J= RJ
t t2 fl
jr j=*> in
.C J= i- O O
a. a--i t--h>


S S! S?
CO CO
CM CM
in in
-
CO CM CO CM
CO 1 1 t CM 4 rH 1 CM I
• 1 I 1 • 1*1 '|
o tn m in

^CMrH cfrHCOCM CM^rH
rHCOCO rHCMCMCM rH rHCM
in m" m* in'm'inin in m* iii
rH m. en . co
•^ «f ^f en
iii i
CM CM CM CM
^ ^* «• «*-
.
rH CO «f 00 in
1 1 1 1 1
CM CM CM CM CM
1 1 I «* *f <3" *S" I l t *f I
I 1 1 lilt
men, o CM en m 10 co
CO U3 rH rH rH ^- ^ en • rH CO
11 || lltl 1 1
CM CM CM CM CM CM CM CM CM CM
3 rH
1 |
en co
en co
CO rH rH in O rH
cn en en co en en

co co m co en co
i i. i i i i i i 11 i i i i ii
en cocococococo co coco enmenco coco

o v>tncD«j-io -i -10 -IO-JCD -its

4^ O) OJ Q
t- O 4J S.
S«J S. £. H.
•— O >» 0) 4J
O> O. 4-» O)> E- Q. W OJ J= C
^ ^cce m*S ^T o^-r? ££
j=i~iOu?o 3-*J 4^o m»—
Q. E »-«••-» to tn s_ +j to t- o
ra 0) E  t- •*-» E ra s_ .p Q) os 4-» e nj nj > c_
O 01 tn O O r— 0) (U4-) Or— (AlU*r-
s. j«: i— &.O.M&. 4-» cea>
O ui C +J O£-4*> E +* "O  O &.>)w»4J o TJSOIM. war w 4* T-
U)(Dr^O4^4-> (U JC U>D).(AV)(AO)*O
••—£.*«- (. (A O) O)*r* 01 d.4-*k>r—  01 ^ -J S r- c5 -r- E
UJ 4J JU J3 LU *t— *r* O > tn Q, i» i «r" r— 2
vijauietncn o in s- 4^ o o> e tn o co o 3=
C33l-4O»-lt-*tJ >-H 4^0) -r-Qt-l.lJ t-HO
ar 0: E o 2; E a: £ COCK o o E 3= so


«««««««« :* *
<* U)  O rH CM CO *f lA VD f**- 00 Cft
                                              •g
20

-------
 h- +*
   O


 O V)
                              «M


                              c4


                              10.



                              e>4  m co   «n
                                                               o>


                                                               i

                                                               tM
                                        CO
                                        tn


                                            IB  '  
-------
o
II
££
u
O t/1
,jj
c
o
CJ
at
i

c !£
O 0)
•r- ;n
.
was
o
1"
o






1
I™
|i
UL.

CO CO CO
1 1 1 1 I 1 CM CM CM 1
1 1 t I 1 1 ... |
m tn m
rH rH M CM rH
CM CM CM rH CO
in in in in tn

in • en
**• . CM
t 1
CM CM

«r i i t i i i it i i
i i i i i i 11
?in co*
<3- CM
1 III
CM CM CM CM. ,
«*• <+ + +
rH
1
CO

CO

CM rH CO
rHrHrHrHrHrHrHrHrH. CM
rH » rH rH rH 1 rHrHl rH
1 CO 1 1 1 CO t I CO I
CO. • CO CO • * CO • CO CO » «> * O. - . ^ (vj -CM
Is* r"f^Or«. Cn rH ^J- ^- rHrH ** rH
1 III t 1 1 I II I I
CO CO CO CO CO CO CO CO CO CO CO CO
CO CO CO CO CO CO CO CO COCO CO CO

CO
CM
m
rH rH*
CM CM
tn in






1 1




rH rH
1 1
CO CO

CO CO
• .
CO CO
t 1
CO CO
CO CO
co in
1 1
CO CO
CO CO

CO
CM
m
rH
CM
tn





1
1




rH
1
CO

CO
f
eo
rH
1
CO
CO
uj"
1
CO
co

eo
CM
LT>
rH
CM
m






1




rH
1
CO

CO
„
3
t
CO
CO
r-T
CO
CO*

CO
CM
in
f-T CO
CM CM
tn tn





1 1
1 1




S
CO



CO
rH
1
CO
CO
o" co
rH rH
1 1
CO CO
CO CO




CO CO
CM CM
in m





t 1
1 1










S
CO
S «T
™ «
CO CO
                           *
                           CO
22

-------








U)
Ot
u
c
«£
Ot
U)
o
,£j


















o

.§ c
at •»-
H- -P
U
p t/1
g
U




£!
r?
O 0)
"*" ^
•»- 3
01 3
O





1
O) (A
T- at
CaJa
fl
1.
**-
a) at
(X S-

§
s.
-*J
to
s
c
o
*J
a.
T
u
U)
OI
a
is
01 -Q
il


CO
CSJ
Ul
H*
-«
m

S!





CO
Csl
in







i
1


a
A

CO

3
A
fl
1
CO
-J


Boiler Feedwater
1
IS
2:
t—

Si
CO
tri
CO
CO
in
rH
eg
in







i
i



3
i
CO

CO
s
CO
A
CO



01
It.
to at
4-1
•a re
ai 3
Ul
tn oi
U 01
a. -M
ta
f.i
—i

S5
CO
tfj
CO*
CO
in
rH
eg
tn







1
I







CO
iH
CO
CO
X
CO
— J


at
I*.
«*£*
"b * <
ss>,
Si"!
 CO CO CO •
CO
^ . ^ **" ^ *
rH rH rH rH1 CO
CO CO (0 <*->
1 III" 1 1 1 II
tn at to ui at aj x
a> *-> s. 3 m «- 4-> -*j s c
O (D  w>

in to r-. co a» e>
CO
tn
CO CO CO CO CO
t i t i eg ca co e4 esi
in tn u> in tn
» « » •• •>
cvi eg eg eg eg
in m u> . ui tn







i i i i i i i i i
i i t i i t i i i


«• «*•
1 1 rH
M CO 1
• • CO
m co .
CO
v?s"-?aaa a a
CO CO • • CO • • * « ,
en co co eo ro co
coAcoAAmm A m
cocoeoc^cocococo co

?
§ 2 2. « "SS
U) 4J Q, H-( f
0 *» «^- Q E H- >,
£ 0} 5^ *** *r- TJ u
>t,_ *^. 1*~-2t*™S3 wj=s- o)w o»o
to (AUitnottnttuiStrtui >» k cu >, E >,
^^i "2 ^fe " ra* *" r-Ul
' i '5 §5 i« ir^ol'^ "5>*o o ^ i <3 *° i o
wwwS5S3 5 m

f-l CM CO *if » u> |L 00 C>
o o o o o o o o o
                                                •g
23

-------
O
c tn
JZ C
U O

o
jh
e

i
(A
C S-
tr- ,Q
-M g
o x
Q.
|




1
CD u)
A3 J-
f- 0)
a*§

pS ^
U.

15 i
S.2
d. s»



Description of Stream
s t-
11


CO
O4
If)
rH
CM
tn


i
i







s
CO

at

**!
CO


*J




Process Water Makeup to
Stretford Process
(Case Study 6)

§



t
i






i
•







ro


oT

CO
CO .


— i




Steam Condensate from
Stretford Process
(Case Study B) .

a
rH





rH
04
in


i
i










5

CO
CO


C3




Water Evaporation from
Equalization B.asin
(Case Study B)

*
CM
rH
rH





CO CO rH
04 CM CM
m tn m


i i i
i i i







3
m

S S S
1 1 1

ro co co


O — 1 ~1




Cooling Tower Evaporation
(Case Study B)
Cooling Tower Drift
(Case Study B)
Potable/Sanitary Water

*e « *
co rf in
rH rH rH





rH -d-
CM «H
tn in


i t
t t







s
™
CO

3 '

CO
eo


-1 0


CA
3
Service and Fire Water
HC Emissions, Miscellaneo

•K *
rH rH


04 in
CO rH
in in
rH *
CXI rH
in tn


i i
i i



tn
i
CO
CO
s
CO
CO

co tn
rH rH
t 1

CO CO


_J o



m
Storm Runoff
Diesel Emissions - Dlspos
Equipment

Is
rH rH





rH
rH
tn


i











a

CO
CO


<9



s.
Fugitive Dust Emissions -
Processed Shale Conveyo
Transfer Points

CM
rH


**•
CO*
tn
rH
(H
in


i
i










rH
1 *
CO
ro


o



TJ
Dust Emissions - Processe
Shale Pile

£•


CO
CO
tn
rH"
04
in




04
i
04
tn
i
CO "
co
s
CO

CO
rH
1
«n
en


—i




Processed Shale Leachate

Si
























C
1
i
1

5
•5
O

1
4)
U
03
JC
i
(A

-------
     Figure 3.3-8 exemplifies water scrubbing and compression of the vapor to
produce  the compressed  MIS  retort  gas  (stream 45)  for which  the detailed
composition  is  given in  Table 4.2-16.   The compressed  gas can  be followed
sequentially  through Figures 3.3-11  (stream 67)  and  3.3-12  (stream  79)  to
illustrate the  combustion of the gas in steam boilers and desulfurization of
the  flue  gas before  it  is released into the  atmosphere.   Tables 4.2-28 and
4.2-29 give  the composition of the desulfurized flue gas.   Other process and
waste streams can be followed in a similar manner.
                                    25

-------

-------
                                  SECTION 2

                          SUMMARY OF STUDY FEATURES


     The Federal  Prototype Oil  Shale  Leasing Program  was initiated  by  the
U.S. Department of Interior (DOI) in 1974.  The purpose of the program was to
encourage commercial  development of the energy resource  in  the  Green River
Oil Shale Formation.   Six lease tracts, two each  in  the states of Colorado,
Utah and Wyoming, were created and offered to the public on the basis of high
bid.   One  of  the tracts,  Federal  Lease Tract C-b  in Colorado,  was  subse-
quently  awarded to  a consortium  of Ashland  Oil, Inc.,  Atlantic Richfield
Company, The Oil Shale Corporation and Shell Oil  Company.  In early 1975,  The
Oil Shale Corporation and Atlantic Richfield withdrew from the joint venture,
followed by  the withdrawal of  Shell Oil in late 1976.  At that  time, Occi-
dental  Oil   Shale,   Inc.  joined  with  the  remaining  original  participant,
Ashland Oil, to proceed  with the development of Tract C-b.  However, Ashland
Oil withdrew from  the project  in  February 1979,  and Occidental  Oil  Shale
remained as the only participant until  September 1979, when Tenneco Shale Oil
Company entered the project.   The  two  partners formed the Cathedral  Bluffs
Shale Oil Company to pursue the development of Tract C-b, with Occidental  Oil
Shale  as  the  project operator.   According to  a  recent  reorganization  an-
nouncement  (spring  of  1982),  Occidental  Petroleum Corporation  (the  parent
company  of  Occidental  Oil Shale,  Inc.)  has  entered  the partnership  with
Tenneco, with the latter now serving as the operator of the project.

     In accordance  with the  terms  and  conditions  of  the  lease,  a Detailed
Development Plan  (DDP)  for the tract was submitted to the U.S. Department of
Interior's  Area  Oil   Shale  Office  (now  part of the Minerals  Management
Service) in  1976  (Ashland Oil, Inc. and Shell Oil  Co., February 1976),   The
DDP was  based  on using  the  TOSCO  II  retorting  technology with  underground
room-and-pillar  mining.    However,  after Occidental  Oil  Shale  joined  the
project, a modified DDP based on Occidental's patented Modified In Situ (MIS)
retorting technology, but without any aboveground retorting, was submitted to
DOI  (Ashland  Oil,   Inc.  and  Occidental  Oil  Shale,  Inc.,   February  1977).
Following  this,  a  Prevention  of Significant  Deterioration (PSD)  permit
application  covering  the preliminary  phase of the project was submitted to
the EPA,  Region VIII  (Ashland Oil,  Inc.  and Occidental  Oil Shale,  Inc.,
October 1977).   In  December  1977,  the EPA granted a  conditional  permit for
site preparation, shaft  sinking,  and  retorting of six MIS retorts (U.S.  EPA,,
December 15,  1977).    Later,  the tract  developers  applied   for  another  PSD
permit, this time for a full-scale operation based on the combination of MIS
retorting and Lurgi-Ruhrgas aboveground  retorting (Occidental  Oil Shale,  Inc.
and Tenneco  Shale   Oil  Co.,  April 1981).  However,   the  project  has.  been
delayed  indefinitely  by the  current  partners.  Until  development plans  are
                                     27

-------
 revised,  the  information in  the  PSD  permit  application remains  the  most
 current  information  available.

 2.1   PROCESS OVERVIEW

      The  tract development  plans presented in  this  manual  are based on  the
 plans that have been proposed  by the developers (i.e., the plans  upon which
 the  DDP,  modified DDP, PSD  permit applications and permits, etc.,  have  been
 issued).   These various documents  in themselves indicate  how the developers)'
 plans have changed, and  further  changes  may be  made based upon  additional
 research or actual commercial development.

      Two  retorting  technologies—the MIS  and Lurgi-Ruhrgas processes—have
 been  analyzed  in this  manual;  as noted above,  this combination  is  in accord-
 ance  with  the  latest PSD permit  application  (Occidental  Oil Shale, Inc.  arid
 Tenneco Shale Oil Co., April 1981).   Approximately 69,000  BPSD of crude shale
 oil  from  the  MIS process and 48,000  BPSD from  the Uurgi-Ruhrgas process  have
 been  projected  to  be  produced  during  the  full-scale retorting  operation.

      The  plans do not  involve  any mining  for  the  purpose of retorting,  but
 some  oil shale  is removed underground to provide the  needed void space in  the
 MIS  retorts and to create passageways for  access to  the retorts.   This shale
 is brought to the surface and retorted by the  Lurgi-Ruhrgas process.

      Occidental  has  gained  considerable experience with MIS retorting of  oil
 shale.   Several large-sized MIS  retorts  (Rooms 4, 5,  6,  7  and 8)  have been
 processed  by  Occidental  at  a  privately owned  oil shale  site  in Logan Wash,
 Colorado.  The  retort preparation and retorting techniques  to  be adopted at
 Tract C-b  will  be similar to those used for the large  retorts at Logan Wash.

      The  full-scale  retort  dimensions  are  estimated  to be 165 feet  by
 165 feet  by  290 feet high.  The  retorts  will  be prepared in  clusters of 6,
 with  16  such  clusters  per panel, or  a total  of 96 retorts  per panel.   At a
 retorting  efficiency  of 60%   of  Fischer  assay  from the  26.7 gpt  shale,
 96 retorts will  produce 69,000  BPSD of crude shale oil for a period of seven
 months.   Several  panels  of  retorts will be  continuously  prepared  and proc-
 essed throughout the project duration of 30 years.

      The  MIS  retorts will be  strategically placed in  the oil  shale zone so
 that  a richer  oil  shale (32.7 gpt)  is mined  out from the passageways   anrd
 rooms.  This mined  shale will   be crushed  to  approximately 1/4-inch size  and
 then  retorted   with  the Lurgi-Ruhrgas  process.   This  retorting  process   has
 been  applied  to  Colorado oil  shales  on   a  pilot scale  and  is capable of
yielding 100% of Fischer assay  oil.  A full-sized Lurgi retort is designed to
 handle 8,818 TPSD  of oil shale on a 24-hr/day  basis.  "Eight  such  units, of
which  seven  will be in operation  at all   times,  will be used to  process a
 total  of  61,728 TPSD of  oil shale.  An additional 48,000 BPSD  of  crude  oil
will  be  produced by  this   aboveground  retorting  process,  for  a  total  of
 117,000 BPSD of oil from the plant.  Oil upgrading is not planned.

     Two  case   studies  for  the  retort gas treatment  are examined  in this
manual.   The   first  case is   based  on the   recent  PSD  permit application


                                      28

-------
(April 1981) and involves flue gas desulfurization (FGD) after the retort gas
has been  consumed during  steam and power  generation.   The  second  case in-
volves the  use  of the Stretford process to  remove hydrogen sulfide from the
retort gas  before  it is burned.  This case is in accordance with the earlier
PSD permit  application  (October 1977)  in  which  the  Stretford  process was
proposed for the retort gas treatment.

     Anhydrous ammonia will  be recovered from the gas  condensate and retort
water.  The treated waters  will  then  be used in  steam  generation and proc-
essed shale moisturizing.

     After  an analysis  of  disposal  sites  for  the  processing  wastes,  the
developers  proposed Sorghum  Gulch as  the  best choice  for containing the
wastes (Ashland  Oil, Inc.  and Shell  Oil Co., February  1976;  Occidental Oil
Shale, Inc. and  Tenneco  Shale Oil Co., April 1981).   To date, the developers
have  not applied for a disposal permit from the Colorado Mined Land Reclama-
tion Board (CMLRB).

     There  is a  potential  for generating excess electricity  because  the MIS
off-gas quantity is above that required for the process energy needs.   Due to
its low heating  value,  the off-gas has no commercial potential; hence, power
generation  on site may  be a viable route.   A steam power cogeneration system
is  proposed  (Occidental   Oil  Shale,  Inc.  and  Tenneco  Shale  Oil  Co.,
April  1981).

     The quantities  defining the dimensions of the  plant  complex are listed
in  Table 2.1-1.    Process  related quantities  have been  estimated primarily
from  the data published  by the tract developers (Ashland Oil, Inc. and Shell
Oil Co.,  February 1976;  Ashland Oil,  Inc.  and Occidental Oil  Shale, Inc.,
February 1977;  Occidental  Oil  Shale,  Inc.  and Tenneco  Shale Oil Co., April
1981).   These  quantities   form the  basis  for  the  technical  analyses  and
discussions presented in this document.

     Normally,  all  five  of  the MIS  processing trains  will  be operating;
however,  the  MIS  processing  equipment is  built 25% oversize so  that during
interrupt  situations the  stream flows can  be  handled  by  four  out  of  five
trains.  Similarly, eight Lurgi processing trains are provided,  of which only
seven will  be operated  at any  one time.  As a result, equipment downtime is
not expected to affect the production schedule and the on-stream factor would
be practically 100% (or 365 days/year).

     Due to the complexities  involved  in  bringing the MIS as  well  as Lurgi
processing  trains  on line,  a seven-year start-up  period is estimated before
full-scale  production will   be reached.   This  start-up  schedule for  both
processing trains  is presented in Table 2.1-2.

2.1.1  Site Description

     Tract  C-b  is  located in the southeastern portion  of the Piceance Creek
Basin  in  Rio Blanco  County  of  northwestern  Colorado,  as illustrated  in
Figure 2.1-1.   The towns nearest  to  the tract  are  Meeker (40  miles), Rifle
(40 miles)  and  Rangely   (65 miles).   A  map  of  the  tract  in  relation  to
                                     29

-------
               TABLE 2.1-1.  MAJOR PARAMETERS DEFINING THE SIZE
                        OF THE COMMERCIAL PLANT COMPLEX

Parameter, Unit
Net Oil Produced, BPSD
011 Pour Point, °F
Retort Gas Produced, 103lb/hr
Retort Gas Heating Value,
Btu/lb (Btu/SCF)
Raw Shale Processed, TPSD
Raw Shale Grade, gpt
Retorting Yield, % Fischer
Assay
Processed Shale Disposed
(dry basis), TPSD
Retort Water Produced
(average), gpm
Gas Condensate Produced, gpm
Sulfur Produced, MTPSD
Ammonia Produced, TPSD
Potential Electricity Generated
for Export, MW
Number of Retorts
Shale Processed/Retort, TPSD
Project Duration, years
On-stream Factor, % 25%
Mining Method
Total Land Area, acres
P 1 ant Area , acres
Processed Shale Disposal
Area, acres
Source Water Consumed,
acre- feet/year
(bbl/bbl of oil)
MIS
69,000
60
10,998
880 (66)
180,996
26.7
60
--
1,200
3,716
171
332-344
N.D.
96
1,885
*,- •
Excess Cap.
--
—
--
—
Lurgi
48,000
N.D.*
162
9,794 (616)
61,728
32.7
100
46,908
—
148
9
7
N.D.
7+1 spare
8,818
—
7 of 8 retorts

— !•
' —
N.D.
Combined
117,000
N.D.
11,160
1,036 (78)
242,724
28.2
72
46,908
1,200
4,040
180
339-351
up to 190
--"
— •
30
100%
MIS
5,094
N.D.
N.D.
6,940-9,970
— • ~ (1.25-1.80)
..,.,•.'..•.. . . - . -•---. - ... ....
* N.D. = Not determined.

Source:  DRI estimates based on data from Occidental Oil Shale, Inc. and
         Tenneco Shale Oil Co., April 1981.
                                      30

-------











g
•— )
OS
LU
a.
a.
—3
1
t—
as
^f
t-

LU
z
*""
as
o
LL,

LU
_J

LU

«


•se.
o
1-4
H-
O
0
O
as
a.

,^j
1-4
O

LU
<£
•y
V>


*
CM
r-t
Q
-
to
i.
to
a>



in

s-
m
O)
>*



^J»

J.
10
U)




CO

• s-
C0
at
>-



CM

s_
m

>»




r-t

S-
<0
0)
































































































/-N
!n
J2


,
CM
CO



in

.
CO

cn
CO

00*
CM



rH
*!t"
,
«cj*

OV

t
cn
rH





oo
m

r-5

CO
O1

t-5
rH




o
rH

r-5
rH

v
«*






^J«
4(j*
«
O
CM
00

CD




DJ
C
-P
s-
5
a)
as

^*^
•r-
D>
1.

i
**** «j
^g
«) 1—
U O
« r-

J-
3






































































10

R)

P-«
10
4^
O
1—



0
s



o
CO



fs*
r*.






oo
to






r~.









00
CM







o
rH








CM






M
^^
S.
(0

o
s_
a.
10

10
•a

c
o
•o
O)
w
m

u)
C
O
•r"
4J
<0

3
U

(0
U

t— (
«v*
C3


( ,
0)
u
s_
3
O

31

-------
 Piceance  Creek  and  its  tributaries  is presented  in Figure 2.1-2.  As  the
 figure  illustrates,  the  tract's  upper  northeast  corner is  approximately
 one-half mile south  of Piceance Creek at its confluence  with  Stewart Gulch.
 The tract covers approximately 5,094 acres.

      Terrain consists primarily of  undulating  valleys and ridges trending in
 a northeasterly  direction.   Major water  runoff drains into Piceance Creek,
 which flows northwesterly approximately 24  miles to its  confluence with  the
 White River.  The elevation  of the  tract averages about  6,800  feet.   Willow
 Creek borders  the tract  on  the  west  and  is  perennial  from  the  headwater
 drainage area of East Fork Willow  Creek to its mouth  near  the tract.   A major
 ephemeral  tributary to Willow  Creek  is Scandard Gulch, which passes  through
 the western  portion  of  the  tract.   The Stewart Gulch  drainage system  is
 located  along the  eastern  edge of  the tract and also extends south of  the
 tract.   Most of  the channels  generally are dry.   Perennial flows  are found in
 the main stem of Stewart Gulch and West Fork Stewart  Gulch.  Flow in the main
 stem originates  from the seepage  area,  approximately one mile upstream from
 the junction  with  the West  Fork.   Smaller valleys  near the  center  of  the
 tract and close to the plant site are Sorghum and Cottonwood Gulches, ephem-
 eral  tributaries to Piceance Creek.    Flow occurs  only  from snowmelt or  local
 thunderstorms.

      Precipitation, relative  humidity,  vertical  temperature profiles,  surface
 wind  patterns,  and wind speed  on  the  tract  are  dependent  on the  local topog-
 raphy.   From November 1974  through  July  1975,  a maximum hourly temperature
 of  90°F  was  recorded (in July 1975) both  on  the tract  plateau and  in  the
 Piceance Creek valley, which is  600  feet  lower  in  elevation.   The minimum
 temperatures  for the  plateau and  valley were -29°F and -51°F,  respectively,
 occurring  in January  1975.  The climate in the vicinity of the tract is  semi-
 arid,  with snow  cover  occurring variably from  October to  May.   The higher
 plateaus  in the  area generally receive more precipitation than the valleys
 and  low-lying areas.   To  date, the maximum  monthly precipitation recorded on
 the tract was 1.2 inches in May 1975.

     The  surface  wind  patterns  are  greatly  influenced  by   the  irregular
 terrain, which contributes to both mechanically  induced and thermally induced
 turbulence.   Hourly  average  wind speeds  range  from 3  to 10  mph and are
 generally  higher on the  tract plateau.  Wind direction  on the  tract plateau
 is  determined by  synoptic  winds  and  is  predominantly  from the  south and
 southeast.   The  valley  winds  are typically channeled  up the  valleys  in a
 southeasterly  direction  or  down the  valleys  in  a  northwesterly direction.

     Piceance Creek has an  average annual flow  of 14,500  acre-feet, and 80%
 is  believed to be  from  groundwater  discharge.   Chemical  analyses  of water
 samples collected from water quality locations indicate that surface water in
 the lower  reaches  of  Piceance Creek can be classified as a mixed bicarbonate
 type.  Total  dissolved  solids (TDS)  measure  approximately  700 mg/1  just
 upstream of the tract and  increase  to  about  950 mg/1  downstream.  The TDS
 eventually  measure  approximately 2,000 mg/1  at the mouth  of  Piceance  Creek.

     Two rock  formations make up the major strata underlying the area  in and
around Tract  C-b, specifically  the  Uinta and Green  River Formations.   The


                                     32

-------
     I  RIOIW
         MILES
SOURCE: OR! based on Gulf Oil Corp. and
        Standard OH Co.(Indiana), March 1976
                 FIGURE 2.1-1  LOCATION OF TRACT C-b  IN PICEANCE CREEK BASIN


                                              33

-------
                                                                  ro tn
oo
m
CE
                                                                                 UJ
                                                                                       o>	

                                                                                       20
                                                                                      CE

                                                                                      1
                                                                                                   Q.
                                                                                                   <

                                                                                                   5

                                                                                                   UJ


                                                                                                   55
                                                                                                   6
                                                                                                   CVJ
                                                                                                    I
                                                                                                   i"—

                                                                                                   ca

                                                                                                   Ul
                                                                                                   Q:
                                                                                                   O
                                                                                                   o

                                                                                                   u.
                                               34

-------
regional  stratigraphy of  these  formations  is  shown  in Figure  2.1-3.   The
Uinta  Formation  is the  bedrock over  the  entire tract.  This unit consists
mostly  of  interbedded  sandstone,  si Itstone  and  marl stone,  ranging  from
approximately  400  to 900  feet thick  across  the tract.  Stream  alluvium is
present in  narrow  bands  along the main  drainages overlying the Uinta Forma-
tion.  The  thickness  of  this alluvial layer is generally less than 100 feet.
Water  in  the  upper  aquifer,  between the Uinta Formation  and the Mahogany
zone, can be  classified  as a sodium bicarbonate type.   It generally contains
moderate  concentrations  of  sulfate  and  low  concentrations of chloride  and
fluoride.    The Parachute Creek member of the  Green  River Formation contains
the Mahogany  zone,  which separates the upper and lower aquifers.   Because of
its  rich  oil   shale  composition,  this zone  is  the principal  unit of mining
interest.

2.1.2  Description of the Plant Complex

     Figure 2.1-4  shows  a general layout of  the surface processing facili-
ties,  the  initial  mining area  for the in situ  retorts,  and  the  storage  and
disposal sites on the tract.

     The surface facilities  will  consist of five trains  for  the  MIS process
and  eight  trains for  the  Lurgi  process.   Other operations  include product
recovery and  storage, steam  and power generation, and wastewater treatment.

     Mining for  the  in  situ  retorts  will  begin in the  northwest section of
the tract and eventually traverse under the entire tract.  Figure  2.1-5 shows
the anticipated  panel  arrangement for the retorts.   Each panel will consist
of a total of 96 retorts arranged in 16 clusters of six retorts each.

     The shale removed  from  the  in  situ retorts will  be stored  temporarily
before processing in Lurgi retorts.   At present, raw shale storage is planned
for  Cottonwood Gulch, which  is close to the  surface  processing  operations.
This  drainage has  a V-shaped  transverse  cross section  with a  gradient of
200-300 feet per mile and  a  capacity of some 65 million tons up to an eleva-
tion of 6,800 feet.

     Sorghum Gulch, the  planned processed shale disposal area located to  the
east of the plant site, has a net capacity of 212 million tons computed to an
elevation of  7,000 feet.  The  processing  wastes will  be deposited  in  this
area,  and  the completed  landfill  sections will be  continually revegetated.
Topsoil  for  revegetation  will  be  obtained  from  a  stockpile  of  material
previously  stripped during the site  preparation.  A water storage dam (runon
retention  dam)  and  runoff  impoundment,  as  well  as  appropriate  drainage
systems, are planned for the disposal  area.

2.1.3  Description of the Retorting Processes

     MIS Retorting Process—

     Figure 2.1-6  shows  a  cross section of a  single MIS retort.   Occidental
MIS  retorts are formed  by rubblizing a vertical  section  of oil  shale,  in
place, after  mining approximately 23% of the shale to  create the  void space.

                                     35

-------
                                            O
                                            
-------
                                                X
                                                Ul
                                                o
                                                o
                                                «t

                                                o.



                                                 I
                                                 *
                                                
-------
                                                            
-------
 Blasting  expands the  fragmented shale  into  this space.  Retorts have  three
 horizontal  layers:    the upper  level,  where drilling  for rubblizing  holes
 takes  place  and where  required process  air and steam are introduced;  the
 intermediate  level, where drilling  of additional rubblizing holes will  take
 place;  and the production level, where  the products  of  retorting—shale oil,
 gas, and water—will  be  collected.

     After  the levels are created  through room-and-piliar mining, the  shale
 is  fractured through  "symmetric" blasting,  producing a uniform distribution
 of  space and  fractured shale  laterally across the retort (Ricketts, 1980).  A
 relatively  small  particle  size (averaging   6  inches)  and  the  homogeneous
 distribution  of  fractured  shale  in  the  retort  is  desirable  for efficient
 operation.   Regions  of  increased  permeability  promoting  channeling of  the
 gases  could  result in  reductions   in overall  oil  yield  (Ricketts, 1980).

     In the operation of an  MIS  retort,  as  illustrated in  Figure 2.1-7,  air
 and steam  are admitted at the top through several openings  which  connect  the
 retort  air level to  the top of the  rubblized  shale (Ralph M. Parsons Co.,
 March 1979).  Steam promotes  the water/gas reaction  and provides  a means of
 controlling the combustion zone temperature.   Retort  start-up is accomplished
 through  introduction of hot  inert  gas.  When the temperature  of the broken
 rock at the top of the  retort  is high enough,  air is introduced  to  initiate
 combustion.

     An operating retort contains four major  zones.   In  the  first, or preheat
 zone, the  air/steam feed gas is preheated through contact with hot processed
 sha'Je.  The heated gas  then  reaches a combustion zone  where oxygen is con-
 sumed by burning residual  carbon in  the  processed shale.   Below  the combus-
 tion zone is the retorting zone where  hot combustion  gases heat the raw  shale
 rubble (to approximately 900°F) and true retorting occurs.   During retorting,
 the  kerogen  is  pyrolyzed to  produce gas, oil  and oil vapor, as well as  solid
 residue and  residual  carbon.   The oil moves  downward by gravity and precedes
 the  advancing combustion front by  six to ten feet.   In the final zone,  the
 combustion  and  retorting gases are cooled as they flow downward,  condensing
 most of  the  vaporized oil.   During  the early  stages of  the burn,  when  the
 rock is still  cool,- some water is  also  condensed.  The resulting liquid  oil
 and water flow from the bottom of the  operating  retorts  into production  level
 drifts.   The drifts  are sloped  to  gravitate  the  oil/water  stream  to  the
 primary  oil/water  sumps located adjacent   to  the  production level   drift
 bulkheads-  at  each  end of  a  cluster of six  retorts.   After initial  gravity
 separation  of the  water and oil,   the products  are pumped to  the  surface
 through independent systems.   At the surface,  final separation is  carried  out
 in oil-in-water and water-in-oil processes.  The  raw  shale oil is  transferred
 to  product  storage without  further treatment.   The  retort  process  water is
 tre«ited and may  provide part  of  the steam used at the  beginning  of  the
 retorting process.

     The retort  gas mixture  consists of light hydrocarbons from shale pyrol-
ysis, carbon dioxide  and water  vapor  from  the  combustion  of carbonaceous
 residue and  steam  injection,  carbon dioxide  from the decomposition  of  inor-
 ganic carbonate  (primarily  dolomite and calcite), nitrogen  from the combus-
 tion air,  and ammonia and sulfur gases  such  as  H2S  and COS.   The gases  are


                                     39

-------
CD
z
in
en
K
111

I
111
tel
a
      izs^RKS^i^isasgjix^ss?
      —i^&5#?^^?ci€%^4^crM^«fps
      I	ifcC2Aa?(fS3S«'1 oS?5X-N vv^t'vn "X 2  r*cv 

                                         1
                                         w
                                   vf

                                   o

                                   o
                                         O)
                                         in
                                         s

                                         s
                                         o
                     40

-------
                                                 JK^'^V* •--•.•.'-;
oe
                                                                               Ul
                                                                               o:
                                                                               UJ

                                                                               u.
                                      41

-------
drawn to the surface by  large blowers and  fed to gas treating equipment where
cooling occurs,  producing a water condensate and  absorbing ammonia, as well
as  some  carbon  dioxide  and hydrogen sulfide.  Subsequently,  the gas may be
burned directly  or further treated for removal of H2S.  The gas will be used
for  steam  and  power  generation.   The  blowers not  only  transport the gas
stream  but also allow  the retorts  to operate  below  atmospheric pressure
(8.0 psi), preventing  leakage from the retorts.

     In a  commercial  plant,  many retorts will operate at once.  Occidental
also plans  to  continue development of the MIS technology at Tract C-b to the
point that  very  large retorts may be prepared  and processed.   Initially, 96
retorts will operate at one time, measuring 165 feet by 165 feet by 290 feet
high  and  producing  69,000 BPSD  on  26.7 gpt shale.   These retorts  will  be
arranged in 16 clusters  of 6 retorts.  If development  of the technology for
rubblizing  and burning larger retorts is successful, clusters of six retorts
will be replaced by clusters of three much  larger retorts which essentially
include  rock  that was  part of  the pillar structure  between  two smaller
retorts.   Each of these larger retorts will measure  165 feet  by 390 feet by
290 feet high, and 48 will operate at one time,  producing 69,000 BPSD.  The
use of these retorts will also allow the grade of shale mined for processing
on the surface to increase through high grading.   It will take only 24 hours
per cluster or 16 days  overall  to ignite an entire panel  of  retorts,  which
means that there will be almost no staggering of the individual retort burns.
Therefore,  gas   temperature  and  amounts  of  retort water  will   vary  during
different stages  of  the overall  burn.  Once a  panel  has been completed, the
next panel in the area will be operated; water that happens to infiltrate the
spent panel will  be treated  along with water from the  retorts  in progress.

     Lurgl-Ruhrgas Retorting Process'—

     The oil  shale mined  to  create void  space for the MIS retorts will  be
processed in aboveground  Lurgi-Ruhrgas retorts.   A schematic for the  Lurgi
retorting process  is  shown  in  Figure 2,l<-8.   Initial  crushing  reduces  the
size  of  the  run-of-mirie  shale  to minus  8  inches.   Final crushing further
reduces the shale  size to minus 1/4 to 1/3 inches.  The crushed oil shale is
fed through a  feed hopper to a double screw mixer, where four to eight times
its weight of a hot (1,200-1,300°F) circulating heat carrier,  such as sand or
processed shale from the collecting bin,  is thoroughly mixed in,  thus heating
the entire  mixture to  approximately  950-1,000°F within  a few  seconds.   At
this temperature, pyrolysis of the kerogen in the oil  shale occurs, resulting
in  the  production  of retort  gas, shale  oil  vapor  and  water  vapor.   The
circulating heat carrier and the  partially retorted shale are  then dropped
from the screw mixer into the surge vessel, where residual oil  components are
distilled off.    The mixture  of  heat carrier and  retorted shale residue  is
passed to the  lower section of the lift pipe, where combustion  air (preheated
to 450-900°F)  is  introduced, raising  the mixture pneumatically  to  the col-
lecting bin (TRW and DRI,  1975-1978;  York, June 13, 1980).  Essentially all
available organic carbon contained in the retorted shale residue is burned in
the lift pipe.   Supplemental fuel  may be added to the bottom of the lift pipe
to sustain the combustion  of the organic residue  when  processing leaner oil
shales.    Also,   at the  high lift  pipe temperature,  a  moderate amount  of
carbonate  decomposition  occurs  in the  processed shale.   At  the  top of the


                                     42

-------
lift  pipe,  the  hot,  burned shale  is separated  from  the flue  gases in the
collecting  bin.   Fines  are  carried out of the collecting  bin with the flue
gas  stream.   The  coarse-grained  shale  residue  accumulates  in  the lower
section of  the collecting bin and  flows  continuously  to the mixer.   Partial
removal of  the  solids  to prevent accumulation in the  collecting bin may be
required  if the  fines  carry-over is not sufficient.   If the shale disinte-
grates  to the extent  that more  fines  are produced than expected, an addi-
tional  coarse-grained  heat carrier, such as sand  or  low-grade shale, may be
needed.   The  combustion  air  supplied  to  the  lift   pipe  is  preheated  by
counters-current  heat exchange with the flue gas stream  in the preheat  section
of the  waste  heat boiler.  The calcined minerals in the burned shale  combine
with the  sulfur  dioxide produced by combustion of the  organic sulfur  to form
calcium and magnesium sulfites and sulfates.

     The pyrolysis products stream containing shale fines is withdrawn at the
end of  the  screw mixer and passed through two series-connected cyclones to a
product recovery section.   The  fines  are separated  in these  cyclones  and
returned  to the recycle  system.   The  vapor  stream  then passes  through  a
sequence  of  three  scrubbing  coolers  (not  shown;   see  Figure  3.3-5  in
Section 3).    The first  scrubbing cooler  is  designed  to operate  at.a high
temperature (~350°F) and to  remove dust from the  gas  stream by condensation
of heavier oil fractions.  Circulation of the condensed heavy oil through the
scrubber aids  in removal of the dust.  A dusty heavy oil is obtained at this
point.  The operating temperature  of this scrubber is controlled by intro-
ducing  and  evaporating  the gas  liquor  (see  discussion below)  through  the
scrubber.    The amount  of heavy oil and  its properties  can be varied  in this
fashion.  In the next scrubbing cooler, further condensation of the oil takes
place at  a  temperature above the dew point of  water to produce a water-free
middle  oil  (Schmalfeld, July 1975).   Final  cooling of the gas  produces  an
aqueous gas condensate  and a light oil fraction.   The light oil is separated
from the condensate or gas liquor in an oil/water separator.  Partial amounts
of ammonia  and  sulfur  dioxide  in the  gas  stream are absorbed in  the  gas
liquor.  If necessary,  further removal  of these species  from the gas can .foe-
achieved by circulating  more of the gas condensate through the third scrub-
ber.   Finally, the gas is scrubbed with a lean oil in the.naphtha scrubber to
recover naphtha  (C3,  C4,  or C5)  and noncondensable gases,  as deemed desir-
able.   Residual  H2S may be removed from the remaining  gas by one of several
methods.  The  gas  liquor may  also  be  cleaned  before reuse  or discharge.

     The  flue  gas stream  in the  lift  pipe is dedusted in  a cyclone after
leaving the collecting bin; it is then routed through  a  heat exchanger  for
preheating  of  combustion air,  a waste heat boiler to  produce process steam,
another cyclone, and  a humidifier or  flue gas  conditioner.   The  flue  gais
stream is cooled somewhat and conditioned in the  humidifier by adding steam
generated   during  processed   shale  quenching.    After  humidification  arid
cooling, residual dust  is  removed from the flue gas stream using an electro-
static  precipitator  and  discharged  into  a processed  shale quencher/moist-
urizer where  more water  is  added to  cool  the solids.   The processed shale
residue, cooled  to ~200°F,  is  moisturized to  a suitable moisture content arid
discarded.
                                     43

-------
             Ul

             3
             o
             Ul
             IT

• . ••
HUMIDIFIER
1

8
o
                            ELECTROSTATIC

                            PRECIPITATOR
   1
.   S
                                                                           ui
§*
JS a
CD =
O .£>
                                                                                    0,
                                                                                   "^
                                                                                    Q>  OJ
go
•'*
Ul
o
                                                                                              CO
                                                                                              CO
                                                                                              UJ
                                                                                              o
                                                                                              o
                                                                                              £C
                                                                                              fl.

                                                                                              O
                                                                                              IT
                                                                                              co
                                                                                              _j
                                                                                              o

                                                                                              8
                                                                                              o
                                                                                              a:
                                                                                              CD
                                                                                              (T
                                                                                              r>
                                                                                              00
                                                                                               I

                                                                                              cvi
           o
           ul
                                                          Ul
                                            44

-------
      The dusty heavy oil obtained  from the first scrubbing cooler is  thinned
 with an available lighter oil  from the process and subjected  to  centrifuga-
 tion to remove the dust.  The clean oil  is  stabilized  by vaporizing the  light
 oil  components and  then sent  for  storage.  The  recovered light oil is  re-
 cycled to the process and the dust is  fed  to the bottom of the lift pipe  and
 burned.

 2.2   POLLUTION CONTROL CASE  STUDIES

      This  document provides  an opportunity to  analyze integrated  designs  for
 an oil shale complex which  uses  two completely different  retorting technol-
 ogies simultaneously.   In   this  manual, the  Lurgi-Ruhrgas  process is con-
 sidered the secondary retorting method, as it  only provides the  aboveground
 support for the MIS  retorting  technology.   Also,  the  streams  emanating from
 the   MIS  process  have  greater environmental  implications  than  the  Lurgi
 processing  streams,   primarily due  to   their  much  greater volume.   A more
 detailed  discussion  of pollution control for the  Lurgi  processing streams  is
 presented in another  manual  (PCTM for Lurgi  Oil Shale  Retorting with Open Pit
 Mining) wherein it is the primary retorting method.

      Two  different  pollution  control   case studies  have  been  examined   in
 detail,  with  each depicting  a  different technology  for,  air pollution control
 (retort  gas treatment).   Water pollution control is  the same  for both case
 studies.  In the area of solid  waste pollution control and  management, only a
 limited amount of  information  has been published by  the  developer; therefore,
 control  technologies  or  approaches  in this  area  cannot be analyzed in depth
 in this manual.   The specific case  studies analyzed are  in agreement with
 information released  by the  developer; however, they are  intended  to serve  as
 illustrative  examples  only   and  should not  limit  consideration  of other
 alternatives.

      Since  standard  industry practices   are  adopted  for various minor treat-
 ments  (e.g.,  boiler  feedwater  makeup treatment),  these  technologies are not
 discussed  in  detail.   The impact on the  cost of treatment as a result  of
 variations  in  the pollution control strategy  in other  processing  areas   is
 assessed, but  a detailed analysis of the treatment  technology  itself is not
 presented.

 2.2,1  Key Features of Pollution Control

     The Modified  In Situ retorting portion  of the MIS-Lurgi commercial plant
 complex will operate  on  a batch basis.   The panel of 96  (or 48) retorts will
 be started  in  clusters,  and  each  cluster  will  require 24 hours  to  start.
 Overall, there  may be a difference of only  16 days or less between the first
 and  last cluster, while the  entire panel will  burn  for about  222 days.
Therefore, there  should  be essentially  no  difference  in the  output from the
 retorts;  rather,   conditions  similar to those from operation  of  a  single
 retort should be found in the individual retorts in the panel.

     In operating  a single retort,  however, fluctuations in temperatures and
the  quantities  of certain streams  occur,  presenting  unusual conditions for
pollution control.  At the Occidental  Room 6 burn at  Logan Wash,  the retort

                                     45

-------
gas exit temperature varied from an initial value of about 70°F to 325°F over
the 11 months of operation (Loucks, November 1979).  Room 6 was comparable in
size  (164 feet x 164 feet x 334 feet  high)  to  the retorts planned  for the
commercial  operation;  therefore,  a  similar increase  in  the  retort gas tem-
perature can be expected from the panel retorting.

     Above 150°F the retort gas is capable of carrying all the water from the
steam injection  and that produced by  combustion  during  retorting.   From the
start of a panel burn until the gas temperature has reached 150°F, however, a
portion  of  the water will condense  in the retort  and be recovered with the
oil.  The  retort water  quantity will  be maximum  in  the beginning and will
eventually  decrease to zero  as the retort gas  temperature increases.  This
retort water  is  difficult to treat and variations  in  its quantity limit the
approaches that can be used.

     Figure 2.2-1  shows a  plot of  retort gas  temperature  versus days  of
burning  a panel.   A gas  temperature  of 150°F  should  be reached  by about
90 days.  At the  start of  the burn, retort  water  should  be  produced  at
approximately  4,500 gpm,  but  it  should decrease  in quantity  to zero  by
90 days.   At  the   same  time,  the quantity  of  gas  condensate  produced  by
cooling the  retort  gas  stream should  increase from zero  at the start of the
burn (essentially no  cooling is required) to about '3,700 gpm  by 90 days and
then remain steady for the balance of the 220-day burn.  The gas coolers must
also be  designed to  accommodate an increasing gas temperature  up  to  325°F,
with the accompanying  increase  in  gas volume and  cooling capacity  required.
Water treatment systems must be capable of operating effectively over a broad
range of  flows or  compositions if the  gas condensate and retort  water are
combined.

     It also appears possible that the retort gas composition may vary during
the burning  of a panel.  Experience at Logan Wash did not reveal  any unex-
pected  changes  in  gas  compositions  (Loucks, November  1979),  but  a  recent
pilot MIS  retort  burn at  Tract  C-a  indicated  that  the  H2S  concentration
varied  from very  low levels  at  the  start  of the  burn to  as high  as  4%
(Sklarew, et al., February 1981).  The COS concentration was also observed to
increase,  eventually,  reaching  as  high  as  ~1,500 ppmv.  Obviously,  if  a
similar  phenomenon  is  observed at  the  MIS-Lurgi  commercial facility,  the
effectiveness of the  gas  treating  technologies may be impaired,  resulting in
increased SOa  emissions  from the  facility or the  need to  employ additional
S02 control.

2.2.2  Pollution Control  Case Studies

     The block flow diagrams  for the two case studies  (A and B) examined in
this manual  are  presented in  Figures  2.2-2 and 2.2-3,   Case Study A  is  the
base plant  presented in the  latest PSD  permit  application (Occidental  Oil
Shale,  Inc.  and Tenneco  Shale Oil  Co., April  1981), while Case Study B is  in
accordance with the  earlier  PSD permit application which was  approved by the
EPA (Ashland  Oil,  Inc.  and  Occidental Oil Shale,  Inc., October 1977; U.S.
EPA, December 15,   1977).   These  case studies  present   alternate  treatment
schemes for the  retort  gas  only; control technologies in other  areas  remain
common to both.


                                     46

-------
    300
o

LU
ce
ce
UJ
to
o;
o
    200
    100
             START-UP
             GAS CONDENSATE
             + RETORT WATER
                                  GAS CONDENSATE
                                      ONLY
                       151° F, 96 DAYS
                       FROM 1st. START-UP
                   START-UP - 16 DAYS

                   TOTAL BURN TIME -222 DAYS

                   DAYS - 0.868 (T°F)-51.44

                   r2=0.99
       0            50


SOURCE: DRI based on information from
        Loucks, November 1979
 100          150

PANEL BURN TIME
                                                           200
    FIGURE 2.2-1  CHANGE IN RETORT GAS TEMPERATURE OVER TIME FOR MIS PROCESS


                                     47

-------
                                                                                                                    V)



                                                                                                                    3
                                                                                                                    o
                                                                                                                    o
                                                                                                                    tr>
                                                                                                                    a>
                                                                                                                    UJ
                                                                                                                    tv

                                                                                                                    tu
                                                                                                                    ce
oo
coo.
                                                        48

-------
                                                                   •a ill



                                                                         S
oo
ma.
                                                      49

-------
      Case Study A—

      The basic processing and pollution control systems proposed by Cathedral
 Bluffs  Shale  Oil  Company are  presented in this case  study.   A process flow
 diagram  is  presented  in Figure 2.2-2  and  a brief  overview of  the  entire
 process follows.  The  pollution control areas are highlighted in the diagram
 by heavy lines.

      An MIS retort  is  formed by mining out  a certain amount of oil shale at
 several  levels in  a  zone  (this  zone  becomes the  actual  retort) and then
 rubblizing  the remainder of the  rock into the  mined out  cavities.   With
 proper detonation techniques,  fairly  uniform-sized rubble (~6 inches)  can be
 obtained.    Several  retorts  adjacent  to each other,  but  separated by  walls
 50-60 feet thick,  are  prepared  in  a similar fashion.   The retort preparation
 activities (e.g.,  mining, blasting, conveying) generate fugitive particulates
 along  with  an   intermittent   flow  of  blast  fumes.   Additionally,   the
 diesel-powered mining equipment emits exhaust fumes  in the  mine.   While some
 of the  fugitive  particulates  are  controlled by  local  application of  dust
 suppression  agents   (e.g.,  water  and  foam  sprays),  other applicable  dust
 control  technologies are not used  in  the mine.  Rather,  a  very large  volume
 of fresh  air  is  circulated  through the mine and vented to  the  atmosphere.
 The volume of  air dilutes the  pollutant concentrations to  a  very low  level.

      After igniting  the retorts  with external  fuel  or hot  inert gas, control-
 led amounts  of air  and steam are introduced  at the  top of  the retorts.   The
 air aids  in  sustaining combustion  of the shale,  while the  steam  primarily
 controls  the  temperature   in  the  combustion   zone.   The  products   of
 retorting—retort  gas,  oil  and  water—travel downward through the retort.
 The condensed  oil and  water are  collected  in a  sump and passed through  an
 underground  oil/water  separator.    The  separated  products  are  then  pumped
 individually to the  surface.   The  gaseous products  are also brought to  the
 surface  using large  suction blowers.

      The  retort water  contains  dissolved gases  and  volatile organic com-
 pounds;  therefore,  its disposition is  of environmental  concern.   The dis-
 solved  volatiles,   primarily NH3  and H2S,   in  the  retort  water  are   first
 removed  by steam stripping and then controlled  sequentially by the Phosam-W
 ammonia  recovery process and FGD process.  The stripped retort water is used
 as  a source for  low-quality  steam generation.  Steam-heated kettle  evapo-
 rators  are  used  to  produce  this  steam which is  recycled  back  to  the MIS
 retorts.   The  concentrated sludge or blowdown from the  kettle evaporators  is
 used  in moisturizing  the Lurgi processed shale (discussed later).

     The  gaseous  product of  retorting,  or retort  off-gas,  contains NH3 and
 H2S; therefore, its disposition should also be of environmental concern.  The
 retort  gas is  first cooled  by  scrubbing  with water,  which  also  removes a
majority of the NH3,  then is  burned  in process steam boilers to produce steam
and  electricity by   cogeneration.   The  boilers  produce  a  flue gas  which
contains S02  from  the  combustion  of  H2S  and other  sulfur  compounds.   This
flue gas is sent to the FGD system where the S02 reacts with the lime reagent
to  form  a  sludge,  thereby removing  it from  the  flue  gas.   The FGD sludge is
also used  to moisturize the  Lurgi processed shale.   The makeup water for the


                                     50

-------
 FGD system  is obtained from the  cooling  tower in the form  of  cooling tower
 blowdown.   The  scrubbed flue gas,  practically free from S02  (~50 ppmy),  is
 released to the atmosphere.

      The ammoniacal gas condensate,  obtained as a result of the  MIS off-gas
 cooling and scrubbing,  is  passed through an oil/water separator to remove the
 condensed lighter oil  fractions; it is then sent to the Phosam-W unit for the
 removal and recovery of the  dissolved ammonia.   A portion of the ammonia-free
 water from the  Phosam-W process is recycled to the  off-gas  absorber/cooler,
 another portion is  sent to  the  Lurgi waste heat boiler,  and the remainder is
 used in the  kettle evaporators  for raising  low-quality steam.  Again,  the
 blowdown  from  the  kettle  evaporators  is  used  for  Lurgi  processed  shale
 moisturizing.

      Prior to  Lurgi processing of  the mined  shale,  the run-of-mine  shale
 is   reduced  to  approximately  1/4-inch  size.   This  involves  crushing  and
 screening,  both  of which  generate  particulates.   Wherever practical,  bag-
 houses  are used to  control  the  airborne dust.  Additionally, water  and foam
 sprays   are  used  to  control  fugitive dusts  emanating from  the  materials
 conveying  and  transferring operations.

      In the Lurgi  retort, the  oil shale  is  pyrolyzed  by mixing it with  hot
 processed  shale.  The product vapors  are  separated from the processed  shale
 and  sent for product recovery.   The  processed shale, after  the initial  pass
 through the retort, still  contains some residual  organic matter.  The  energy
 from this residual  matter  is  recovered by burning the processed shale in a
 lift pipe.   The flue gas from the lift pipe would normally  contain  S02  as a
 result  of the  combustion  of organic  sulfur compounds;  however,  a  moderate
 amount  of calcination of the processed shale occurs in  the  lift pipe and a
 substantial  amount  of  the  S02  is  claimed  to be  chemically   fixed  on the
 calcined material  (Occidental  Oil  Shale, Inc.  and Tenneco Shale  Oil Co.,
 April 1981).   The  flue  gas is separated from the  processed shale by  settling
 and  centrifugation  in cyclones.   The  last  traces of  the  dust carried over
 with  the  flue gas  are  eventually  removed  by electrostatic precipitation.

     A  required  amount of the processed  shale separated earlier  from the flue
 gas  is  recycled to the  retort,  while  the  remainder is quenched and moistur-
 ized  before disposal.    Primarily  the sludges  from the  FGD  and low-quality
 steam generators are used as the water sources for the quenching and moistur-
 izing  operations.    The  quenching  operation  generates  some steam  which is
 mixed with the  flue gas.   This  humidification of the  flue  gas reduces its
 electrical  resistivity,  which   helps   in  obtaining  a  better   dust removal
 efficiency  in  the electrostatic precipitator.   Processed shale moisturizing
 and  mixing  also generate some  airborne  particulates which are  scrubbed with
water in a venturi scrubber.  The emission,  primarily  steam, is released to
 the  atmosphere,  while the  scrubber sludge is returned to the moisturizer and
 disposed of along with the processed shale.

     The  product  vapors  from  the  Lurgi retort are  scrubbed and  cooled in
 several  steps  to  condense out  various  oil  fractions.    The  moisture in the
vapors  also condenses  as  the  gas liquor.   Most  of the NH3 in  the retort
vapors dissolves  in  the  gas  liquor, while  H2S  remains  in the gaseous phase.


                                     51

-------
 The  gas  liquor  is  combined  with  the  gas  condensate from  the MIS  off-gas
 cooling and  sent  for  recovery  of  ammonia in  the  Phosam-W  unit.

     The retort  gas  is scrubbed with a  lean  oil to  remove higher  boiling
 hydrocarbons (naphtha)  and then burned along  with  the MIS  off-gas  in  the
 process steam  boilers.   The  flue  gas  from the  boilers,  as discussed pre-
 viously, .is  sent  to the  FGD unit  for  the removal of S02.

     Water management activities  consist of  satisfying the process steam  and
 cooling water needs,  as well as efficient management  of  the aqueous waste
 streams.  The process steam is generated in two different types of boilers.
 The  high-pressure, high-quality  steam  is  raised from  the  clarified source
 water.   This steam is primarily used in driving the  steam  turbines and  in
 cogeneration of electricity.  A small portion of  this  steam is also  used in
 other  process units  where  high-quality  steam  is required.   The boiler blow-
 down is equalized with other  waste streams  and  eventually used in processed
 shale  moisturizing.    Process generated  waters   (e.g.,  MIS  gas condensate,
 retort water, Lurgi  gas liquor)  are  used in raising the low-quality steam.
 This  steam  is  primarily  used in  the  MIS  retorts.   The  low-quality steam
 generators,  or  kettle evaporators,  are  driven  by the  high-pressure steam.
 Since  these  generators  do  not use  any fuel, there is  no flue gas emission.
 The blowdown,  or concentrates, from  the  low-quality  steam generators  is also
 used in processed shale moisturizing.  Clarified source water is 'used  for  the
 plant  cooling needs.   The blowdown  from the cooling  tower  is used  as   the
 water  source  for  the  FGD process.

     Other   conventional  water  treatment  practices  include  source  water
 clarification,  boiler feedwater  softening,  cooling  tower  makeup  treatment,
 equalization basins, etc.

     Proper  maintenance  of valves,  pumps, etc., and  suitable product storage
 tanks  provide control over  fugitive hydrocarbon emissions.

     Case Study B*-

     This case  study  examines the alternative of  recovering  sulfur from the
 MIS and Lurgi retort gases  before they are consumed in the boilers.   Specifi-
 cally,   the  Stretford  technology  is examined as an alternative  for FGD.   As
 Figure 2.2-3  illustrates,   the remaining  process  areas and  control  techno-
 logies are identical  to Case Study A.

     Variations  in  the  air pollution control strategy  clearly  affect other
 control  areas  in this  case study.    For example,  the  loss  of approximately
 1,500 gpm of water,  which  occurs  with  the  FGD unit,  is  eliminated.   This
 reduces the  overall consumption  of  water.  The cooling tower blowdown, which
was used as  the  FGD  makeup water, can  now be  used  for  some other purpose.
Additional cooling of the MIS off-gas before feeding it to the Stretford unit
produces an  additional  amount of  condensate which is treated by the Phosam-W
process.  Proportionately   more stripped water  is  produced in  the Phosam-W
process and  sent  to  the kettle evaporators;  thus, more .blowdown',  or concen-
trate,   is produced.   These changes affect overall water management  in  that
the waste streams must be routed differently than in Case Study A.


                                      52

-------
 2.3  SUMMARY OF POLLUTION CONTROL TECHNOLOGIES  AND  COST

      The control  technologies  examined in  the two case  studies  are  summarized
 in Table 2.3-1.   As  a means  of organizing  the presentation,  the plant  complex
 is divided   into  different  areas  of processing  activities  and  pollution
 control.   The  areas  in  which  alternative  controls have  been examined  are
 indicated,  and it can be seen that most  controls  are  the  same in  both  case
 studies.   It should be noted  that the control  technologies  examined here are
 not  the  only  choices  available  nor are  they necessarily  sufficient  for
 pollution control;  rather,  they are  merely examples from  broad  classes of
 technologies.   These examples have been examined on  the basis  that  they  have
 been  proposed at one  time or  another, in  conjunction with  MIS retorting, by
 the Tract C-b developers.  Additionally, good vendor  guarantees and  cost  data
 on these  technologies  were available for the economic analysis.

      Throughout  this  analysis  of  the MIS-Lurgi  project,  the distinction
 between  process  and pollution control  is  not always  clear.  For example,  the
 cooling  and  scrubbing  of the MIS  off-gas  could be  considered a processing
 step  because it affords recovery  of a significant  amount of light  oil frac-
 tions.   However,  the  cooling  and scrubbing  of  the  off-gas  also  removes
 practically  all  of  the  NH3;  thus,  it also  could  be  considered  pollution
 control.   Similarly,  boiler feedwater  treatment,  cooling  water  treatment,
 mine  water  clarification,  etc., are  listed as pollution  control   measures,
 when  they may also be  classified as process  related activities.  In  some  such
 instances—for  example, the cooling water treatment—only  the cost increase
 due to  the  pollution control activities is  included, but this  distinction is
 not always  possible.   Consideration of an activity as a pollution control or
 as  a  process related  activity becomes important when  calculating the total
 cost  of  pollution  control.    Because  all  of  the borderline  activities  are
 classified as pollution control, the user of this manual should be made aware
 that  the  total  pollution control costs are  conservatively  stated  due  to the
 inclusion  of  activities which  could  also  be  considered  process  related.

     All major pollution controls examined in the two case studies  are listed
 in  Table  2.3-2,  along with information describing location, control function
 and size.  The  case  study in which  each control  is shown is also  indicated.
 More  detailed design information is presented in Section 5.  A discussion of
 other possible control choices is also given in that section.

     Table 2.3-3  summarizes  the  costs of  air  pollution  control   and water
 management and  pollution control  for  the  two case studies  analyzed for the
 MIS-Lurgi facility.  The costs for solid waste management are not included in
 the table because of insufficient information regarding the developer's plans
 for solid waste disposal.   Detailed engineering costs  for  the technologies
 analyzed  and the  cost computation methodology  are presented  in  Section 6.

     The  two case studies differ primarily in  the area of sulfur control:
Case  Study A uses   limestone  scrubbers for flue  gas  desulfurization,  and
Case Study B  uses  the Holmes-Stretford process  for the 'removal of  H2S from
the  fuel  gases.   The fixed  capital   and  direct  operating  costs  for  the
Stretford process are  somewhat lower than  those for the limestone  scrubbers.
Furthermore,  recovery of  sulfur as  a by-product  reduces  the  total  annual


                                     53

-------


















4A
U

3

g

t--
-
O
£
8

§

5
—*
o
a.
u.
o
^
1
v-4
i

0*1

1
























































£

§
CJ
<4-
o
in

U) C
c a*
at e
13 -P
0 S

Ift^"
R)
C3





I-

1o g;
26- flj
** -P
i. cQ
O 0}
•P i.

OS

(A
at


SrtJ
0)
DSh-

* .







£: §
P e
o «
+* a)
0 S-
A:t-


 3
re +>
O V)
V) Q ^>
..H ** 3
11 «|
j_j S*»



o1


IE
8§
u. u


U)
ra o
*c m
0 4-> £.

e C a.
<3 (0

€01 OJ
(O > i—
U) O 4->
O U +J
X! fli a>
O. OS ir£
.
0)
§.. y,
*)— (.
i S
t/1 (Q
fe 1

la 2
3; tu
** 01

•2 t>

OS ii£

1
(A


tn o
•— • o
EO
u
•P 4->
ai at
in fr.
O O t-
I- **" N
4-> y> t. «t-
•F- to a* s-
• » CLC3 .. J3 3
-J O. iZ _J WE




u.

o> T3
or c

3 Ul

CD *» S.
(TJ (0 O.
oa 3: vi

<


S
0)
«

Is
3 (0
t (A • C
3 S- O

(A D. S-
5 0>TJ C
o w c 2 § 5
ZCJ IA









IA
IO
i
R)







-------












«
UJ
1-1
1
§


c
s
T£.
|
g

O
g
fe
5;
I
.
01
t

S'-









3
Vt
Ul
flj



(0
I*


u >
£•(•
.p
a. u
'«


II
||
U. UJ




•o
r—
1
C
o
o

Materia




•a
03
Origin of
Material Control 1





r- W
2£
1!
i
<•-»

CO CO CO CD OQ CO CO CO
•< «* <<<  ,*J jj +3 *3 2j
4) 0)  qJ a!


,= .= £ ^c *c 'c *c *c
£ = EXE E E E


II III II
§o o o o o o i
— CD O O O O O I
o o in o o CM o
W CM CsT CM* to r-T CM*
1-4 S •"*


Rf
.c
tt
 .p 4* -P W
3 S s « « SSS
a o a a a a a o
at ai a ai a> 4>iucu
JE 2 « nj ^ W 1 *W £ «i C 3 W*

c o to o"o ro ta o a>
at •*- ui fl) f^- >> o? -P-  «) oJ a)
**" -P C **— A3 (U (O f 4— C Q) O) Ol 4- *—
uium uij=> s- w ui>^>o2 m m Tn -r-
C3i- cuic o 3 e-e-So 2 £ cSL
mio-P to o -P t- aj u> -p o o m J^
t«O 1^2° *" OOl S.3O1 4J 4J I-O
&• >^ S- £1 ^~> i— »•— C t. C 4» ai OJ f_ in
oea> ost- m mo o£ s. t. o
a>£c a>2r2|: ^ ^^ aT £ u § ° ° S?S
c^ S c^'5.5 * i° ?**"u£- *° <" >0-
o o  ^^ V*« ^** »»^
I | III | S £
u. u. U.U.U. uIuTc
o u cjoo oom
^3 «Q ^3  •*->
05 Ul
3 3
o a
o 

£Q
< CQ
<£

C
*, .2 *>
c *> c
Ol IO OJ
e ' c. e
*> ai *>
 0) at
« fe «-

"i §
2 |2
O N
Ul 1—
^ £-
<: 3
<4-
t/) r— ^%
10 30
— H-
I. i- £.
O O)  0)
•P -P +j
^ OJ to
G fa c
§'c c
o o
tn ui ui
UJ Ul Ul
*O 0 O




t- T3
at e;
MIS Absorber/Cool i
Lurgi Pyrolysis ai
Oil Recovery
HIS Retorts


r+\ f~* /•%
t^ f"f rH
S- S- I_
O 0 0
22 2
Cf « flj
0.0. 0.
HI fl> Ol
CO CO CO
t. t- t,
01 a Q]
*>> 4-> +J
Ml
'So 15
55

-------
1
1/1
01
Ul
»O
O '




ra
QJ L.
?4
$.&
O-*>
t. -P
*



01 +>
11
U. Ul


*>
5
CM Tu
t r-
n i
UJ C
m o
ra
1
s




•a
O)

%1
c o
f£
°1
£






_,
.r- U>
*>"=
IS;

O i.
ai
O.H

*"-*
ca co
*,
< <


p -P
c c

ra ra
at 01
t- s-
5 .2
Ul Ul
Ul Ul
0) ai
£ £
CL a.
+*
x
J.
t &
Dl CO
iH CM
to tn
«r



y
0) ui
a>

i i
ra *3
E >
T3 "O
at v
1 • £
at o
O. Ul
Ul Ul
en a




Ji H
o ra
O S.
u ra
"BS 2-

6. *> S-
S« 5
!B §
£ 0
O
ra ^^
S- i*H


i- s.
u. at
a.
>t a.
1- S-
> -P
ra v>
t.
<3 fc.
~. ^^ at
ra 
f I |

E 'Ce

^



^
c
1
01
J_ .


fr.
s
2
O
f

5

*£

ca



•P
c
i
I
>.
5

U)
S
2
CL


(d
i
I







I
•5
•o
O)
8
U)
o




sTIo
as
a.

+J Ul
(/> W
4.

it's
t 2£
S-n o
a,0-"0






S
t.
s
2
O
Q.
ra

£

5£

^C



^
C
at
|
t.

i
Ul
s
2
CL



1-
rH
iO




0)

*
^
1
U)
X
s-
O)
CL
a.

s.
».«
o s-

3.
"* 0
•wee
r~ *
o

^


>
S
ce
•2
L
^ci
i
ui a
o z>
.c
OL

CO



^

a*
I
i.

i
Ul
S
2
a.



i
s-
o
I»T




01

s
•^
i
I
ra
£ '
-P
£-
3
«
•o

S- 0) •«-
10 o.n
n.a.=>
01 «r-

(.M 0
 t. *>
ra 01 o)
2c +J $-
o

^

01

1
cc
42
0
3:^
»*£
JS '
CL
CO CO

<£ <





i- £.
Ul U)

ii ii
g £ g 2
ui f— tn t—
E Z
R) •

5 vi
o
r- tn
O f**
O trt
C3
^j..
O
CO





Ul
1
IS
"5 3?
z" I


1?
01
O
u
s
ra
I |

S ?
u |*>
3 ID *^
•a ui c:
2 20
CL Q.

at *— »
en m
ra *-*

SUl
^:
V) C

o o>
Dl
•S 2
0>N 0
ce m *>
Ol>^ *"
5^ -2
•p c c

u. 5
CO

<





i
Ul

II
t— ra
0) O)
.£*"
IE




i







U)
0
U
^
u






i
Q.

1
0)
Ul
O)
o





Ul
S-
•p
1
1
u
•f—
s
ra

ca

*«





t-
Ul

(U C
01 0)
tuih-
E




1








Ul
c •
o
t
ra
u
2
tj
4?




ii
0)
Ul


Ul
01
s





°H
go,
ra ui
st
|£
« -
3E ui
si >
|S

•CL

< CO






• at at
ra ra
Ul Ul
3 3
at c at c
c: at c a)
»— ra f— to
at at at at
ui t_* tn L-
•5 S



O) Ol
Si S
rH cvi
UJ* ^



U
0)

£. Ul
o) -a
.p ^
2£ V)
O) 0J •
1 1
a. vi
Ul Ul
v> a








1 1
01 0)
c c
s s:





•K
f-l
C
O
J

ra T-

£

< CO  0) 0)
U> H- W H- to H-
Z Z E



111
g s - g.
^






Ul Ul CO
"O T3 , T3
"o "o "o
•O -a T3
O O O
Ul Ul Ul
Ul Ul Ul
O O 0








QI o at
•p -p -p
S 3 5
01 0) 0)
c c c
E E E
•K
ci


c
I
3
0)?s 1?
•S 4J *
;£ i ! •*
•3 ' en
« S ' •£
*p*> ^— O
o a
CO 0

ca






1
to
3
ij
r^- ra
O 0)
vi H-
iE



i .
o
5
CM






to
•a
*o
TI
at
8
Ul
O








0)
Ol
c
s:













                                     I
56

-------
§
f
1

Of
U)




S


Q. O






•2 »r-
(0 C
li
U. Ul





1

£
*•*
C
O
S
t-

P£






1
•si
c
t-s
O f
i.
o>
4->
*d
£









p^ w
ij




111
tf
O>
4J
*>
•0
i

3
VI







(A
•)->
C

J w E
«J f- tO
Of 01 0)
S- O t.







E
S
CO
r-1



^
O
0»
s^
1
•o
tt>
0.
vj







U) <
c
•p
s-
l»

S.

38













aa


*


CO
.5
U)
3'
0) C
C 4)
* $
S2

s





i.
Ol
S





£
0)
{.
1
c
a>
a.
Ul
tn







1
VJ
at
VI S.

re v>

a_









Oil/Water
rator (1)
H- J
O
1
£
u
3
V)







1
I







(A
•o
e
o
•o
01

S
-J







,_
i£
I
3

tA
ttl
3:









4J ^N
gc
J= +J
U C
•*•; g
3|
Si
CUJ
3


CQ



1
3








I
1








(A
0)
CQ
I

1
£







^_
^
(0
_J

5
in
(0
3:









uppression
V)
tA
O

CO


<

§
-P
•fO
N

•i
(T)
VJ
<*-
3








1
1








C
O
(A
£
01

£
VJ







*—
<+-
?
JS

S
(A

3




^j

(O
t

G.
Q.
§a
- C
|I
O

aa


«s

c
o
I

S
t/}
Ol
u
3








1
t








O
£
0)

£
VJ







"i—
1-
I

01

3

0


j2

or
0)
OS
T3
C
m
i
1
U
.ce












_

o
s_
4J
I
C


3
^
Q.
IA
(0
1
(A
(0
Ul
S
£
a.
o
^
it-
o
t
(0
a.

£
0)
J
1A
O
U
a>
J3
t3
3
O
U
•K

(A
•f-
J_

•P

S
5
*S


5
t.
Q
(A
Ol
technologil
1
*




IB
j
VJ

0
(0
1
'i
o
T3

(O
f;
a
£.
or
A
0
u
-
y
«
1
f_
S

5
c
O)
•a
u
(0

u
c

^
o

c
(0
r^
u>
t-

5^
(tt rH

IT

•^
5-5
iv?

tp 6
(A U
Q- Q]
a H-
a>
o
v>
                                   57

-------


























re
**-iC
s
CO

CO
o
u

s
1"^
1
o
i
2


*
CO
t
CO
•
«M
LU
«•!
OQ
•••t
r-



















r^- (A
CU O
S- 
XJ "o C
1 S- 
3 O <-N
C O (A
c •»
^1 r™ CD
O O
i— S- O
re +J -w-
-t-> e s_^
o o
1— o


p
i— U)
re o
3 O s~*
C U)
C O5-
•
P S. v>
o cu
i— a.
o

cu
t— cn
re s-
3 re <"->
£ .£ IA
£ o -

0 0.
H- re
o



•P
«A
o ^^^
U U)
CU i— O
x re o
•r- >P O
. LL« *r~ *t^
Q-xv
re
CJ












s
3
•5
s;
6
P
£
0
O



0
I—I










^^
^^
in

CM
rx







.a
m
00
CM
CM
CM




CM
00
cn








iH
iH

in
00
^t"













. c
o
«f—
3
>- r-
Q r-
3 O
CO
LU «i-
<£
0



CM
T-)










TH
CO
r-.

CO









00
CO
in
in




CO
oo"








^>
m
rx.

|X.
rx









"O
£ i—
re o
s~
•p -p
C £
CU O
€ U
~
3 a
TJ 1—
•i- CO
O LU
CO CO
 £
•p re o
3 £••-
i— re -P
r- S 3
O i—
a. s- r—
cu o
s- P a.
5 5



.
0
3;










B
o


•









a

z




a
z








4
a
<^









•P
£
CU
E
CO
re
£


CU
p
(A
•o
•1—
"o
CO

CO

•r"
+J
I

f>
Q

j^.
re
3
£
•£
re

r™-
re
•P
Q


cu
j=.


£
re
•p
t.
cu
•p
re
cu
J_
CO
p
£
cu
p

•p
p
•a
o
a.
r-
3
£
£


£
re

cu
re
p

•a
£
•i—
•
(A <^N

•^" X**
re
•P (A
cu cu
•a u)
cu
s. .£
O P

cu
to t-
re
£ CL
o
•r- £
P
cu to
co cu .
3 +>
CU l— tA
cu re o
CO > P
re J2










.
£
o

r—

re
0-

-Q
cu

re
s-
CB
CU
£
•r—
C

U)
rj
/*^*s 'r™
• •
a P
Z OJ
x^ e
0)
TJ CO
cu re
£ £
•»— re
s.
cu cu
•P 4^
CU (A
•o re
cu -o
CU v-.
o
•P 
(A 73
•P £

O
P £
O
P
£ (A
CU <~

cu re
rap
re cu
£ -0
re
s s_
o
cu <*-
•p
U) tO
re

73 -i-
•1- p
r-f P
O CU
(A CO
CU CU
-C CU
1— CO
p


































































B
I-H
ce
o

-------
operating  cost  for the  Stretford process.   As  a result,  the air pollution
control  costs  for Case Study B  appear to  be lower than  the  costs for Case
Study A.

     The variation  in sulfur control  strategy  introduces slight changes in
the water treatment technologies.  For example, the Phosam-W ammonia unit and
kettle  evaporators  in Case Study B  are  larger than in Case Study A,  with a
resulting increase in  the fixed capital  costs, total annual operating costs,
and total annual and per-barrel control costs.
                                    59

-------

-------
                                   SECTION 3

                     PROCESS FLOW DIAGRAMS AND FLOW RATES


      Flow diagrams Illustrating all operations in the MIS-Lurgi plant complex
 are presented  in  this  section.   The integrated designs  shown  are consistent
 with proposed development plans.

 3,1  STRUCTURE OF THE DIAGRAMS

      In order to understand the interactions throughout the plant complex, an
 overall flow diagram is  presented first, followed by  flow  diagrams  for each
 unit  process.   Flow  rates  for  all   major process  and waste  streams  are
 indicated on each  of the more detailed diagrams;  flow rates  for streams of an
 auxiliary nature,  such  as cooling  water and steam,  are included only when
 relevant to pollution control activities.   The  following symbols are used to
 indicate the physical  state of each stream:

      *    Gases—Circles

      •    Liquids—Squares

      •    Solids—Hexagons.

      A unique  stream  number is placed within each  symbol.   In  addition,  an
 asterisk (*)  is placed   next  to the  symbol  for a  stream  if  it comes  into
 contact with  the  environment  at  any  point  in the  process.   The  stream
 numbering  system established in this section is used throughout  this manual.

 3.2  OVERALL PLANT COMPLEX

     A  flow diagram  of  the complete  plant complex,  emphasizing  the waste
 streams  produced,  is  presented  in  Figure 3.2-1.   Mining and rubblizing
 activities  will  create   large  panels  of  MIS  retorts  and the supporting
 production shafts  underground.   Each panel will  contain 48  large retorts  (or
 96 small  retorts)  and operate for approximately 220  days.   The retorts will
 be ignited in clusters of six.  First, hot inert gas is injected to raise the
 shale  temperature  at  the top of the retorts to the ignition point; then, air
 and  steam  replace  the inert  gas.   Each cluster of six retorts will  require
 about 24 hours to  ignite.

     The mined  shale  will be brought to the surface,  finely crushed,  and fed
to a surface  Lurgi-Ruhrgas plant  for retorting.   The  raw shale  handling
operations will  generate particulate  emissions  which  will  be  controlled by
baghiouses and by application of wet dust suppressants.   In the Lurgi process,
the  raw shale is  mixed  with hot,  burned,  processed shale, raising  it to a


                                     61

-------
                                 §
                                 a
                                 z
                                 
-------
 sufficient temperature  (950-1,000°F)  to  release  a mixture  of oil  and  high-Btu
 gas  which  moves  to a  recovery section of  the  plant.   After retorting,  the
 processed shale  contains  a carbon residue  which is  burned in a lift  pipe,
 thereby   further   raising  the   temperature   of   the   processed   shale
 (1,200-1,300°F)  before  it  is mixed with the  incoming raw  shale.   Part of  the
 burned processed shale  that  is not recycled exits with  the flue gas and  is
 separated,  quenched with water, and  moistened to 10% water before disposal.
 The  flue gas is  humidified and the residual  dust is removed by electrostatic
 precipitation.

      In the Lurgi oil recovery  section of  the plant, four  oil fractions  and a
 high^Btu gas are recovered.  This  retort  gas may then be mixed with the MIS
 retort gas and  burned  in  a  steam boiler (Case  Study  A)  or further treated
 using the  Stretfqrd process  before  it is  burned  (Case  Study   B).   A gas
 liquor,  or condensate,  is  also produced in  the  oil  recovery section and"is
 combined with the MIS gas  condensate for  recovery of ammonia by the PhosanrW
 process.

      The oil  produced by the MIS retorts  is  collected both  in an  underground
 sump  and through  gas treatment  on the surface.  A large volume of  low-Btu gas
 is  produced  during retorting  and treated  on  the  surface  in  the  MIS oil
 recovery section  of the plant  where water scrubbers are used to cool the gas
 and condense  light  oil fractions.  In addition, the NH3 content of the gas  is
 substantially reduced by dissolution in water.    The process of  cooling and
 scrubbing  the gas  produces a  gas condensate (water) which  is combined with
 the gas liquor from the Lurgi  process for treatment using a Phosam-W process
 for NH3 recovery.  The  combined condensate is used for producing  low-quality
 ("dirty") steam using steam-heated kettle evaporators.

      As  mentioned earlier,  the  cooled MIS retort gas  may be burned directly
 in a  steam boiler or treated before  combustion  using the Stretford process.
 The boiler will  produce steam  which  is  used in  power  drivers  for all  major
 pumps  and blowers  and  in generating electricity.  In  the direct burning  of
 the gas, the  flue gas from  the  steam boiler is desulfurized using  a limestone
 flue  gas desulfurizing process.   In  the case of Stretford  treated  gas, the.
 flue  gas will not require additional cleaning.

     During the first 90 days of operating a panel of retorts, a dirty retort
water  will  be generated by moisture condensation in the cool, lower portions
 of  the  retorts.    As  the  exit  temperature  of  the  gas  and oil  products
 increases,  however,  less  of this water  will  be  produced  until  it disappears
 altogether.   This   retort  water   is  steam  stripped  to  remove  volatile
components and then combined with the gas condensates and used to  raise dirty
 steam  using kettle evaporators.

     This  manual  examines  two  separate  integrated  plant  designs,   Case
Studies A  and B  (see Section  2  for a  detailed description  of each  case
study),  which differ in  terms  of the pollution  controls  applied to  primary
streams.   Case  Studies  A and B use  different S02 control  approaches.   The
water  treatments are basically the same in both cases.
                                     63

-------
 3.3  UNIT PROCESS FLOW DIAGRAMS

      This section describes  the  operation of the MIS-Lurgi  plant  complex in
 more  detail  using  flow  diagrams  for  each  unit  process in  the  plant.
 Figures 3.3-1  and  3.3-2 are  intended to be  used as  road maps showing  the
 relationships between the  unit process  flow diagrams for  Case  Studies A  and
 B, respectively.  Each  box (except the  product storage boxes) in the figures
 represents an  individual flow  diagram,  and the appropriate figure  number  for
 each diagram  is indicated.  All  streams are  numbered  as well.   A complete
 list of  all  the streams,   in  numerical  order,  is  included  in  Section 1.7.
 Table 1.7-1.

      The  individual,  unit process flow diagrams are  presented throughout this
 section (Figures 3.3-3  through 3.3-15);  also, Figures 3.3-16 through  3.3-18
 provide details on the  water, management  system for  the  entire plant complex.
 In each diagram, streams enter on the left and  exit on the right,  and mass
 flows are given at the  bottom.   Composition data on  major process and waste
 streams can  be found  in  Section 4.

 3.3.1  Mining.  Rubblizing,  Crushing,  and  Transport of Raw  Shale

      A  conceptual flow  diagram depicting mining and crushing processes  for
 the  MIS-Lurgi  oil  shale complex is presented  in Figure 3.3-3.   Initially,
 roonv-and-pillar mining will remove approximately  23% of the shale  to  form a
 void  space for rubblizing  the  remaining  shale to form the  MIS retorts.  Mine
 development  will include the construction of  service shafts  to three  mining
 levels,  drilling, blasting,  crushing, and  interim   shale  ore storage.   The
 blasting operation fragments  the  shale and distributes it  uniformly to  occupy
 the  mined  out voids.   A  relatively small particle size (averaging  6 inches)
 and  homogeneous  distribution  throughout the retort is  desirable  for  an
 efficient  retorting  operation.    Regions  of increased permeability  promoting
 channeling  of  the  gases could  result  in  reductions in  overall  oil   yield
 (Ricketts, 1980).  The mined out shale (stream 1) is  conveyed to the surface
 for   subsequent  retorting  in   the  Lurgi-Ruhrgas   plant.   Intermediate
 preparatory  operations  include  coarse  ore storage,  primary and   secondary
 crushing  to  a  size  of minus 8 inches and minus 1/3 inch, respectively,  and
 fine  ore  storage^  Mining  and crushing  operations  will produce appreciable
 quantities of airborne  particulates.  Sufficient ventilation, air  (stream 3)
will  be  used  to maintain dust,  machinery  exhaust,  and  explosives fume
 concentrations  in the  mine  and  mine vent  emission  (stream 4)  within safe
 levels.  Transportation  of  coarse and fine crushed shale between the various
processing  units will  be  accomplished with  enclosed conveyors  to  minimize
dust  emissions.   Water and  other dust suppressants  (stream 82)  will also  be
 used  to control  the  fugitive particulates (stream 6) from unconfined sources
 (e.g., the coarse ore open storage pile, conveyor).   Confined  dust sources
 (e.g.,  crushers, fine  ore enclosed  storage  bin)   will   be equipped with
baghouses for  dust control  at these points.   The raw shale fines (stream 2)
collected  will   be  conveyed  and  fed  to  the  Lurgi   retorts  along  with the
crushed shale feed.
                                     64

-------
65

-------
66

-------
IS
ING
NING
                    £ g
                    s
                    
-------
     Mine water  (stream 12) will be collected  in  sumps,  clarified, and used
as   required   in  mine  dust  control,  processed  shale  moistening,  steam
generation and other plant  services.

3.3.2  Lurgl-Ruhrgas Afaoveground Retorting

     The   Lurgi-Ruhrgas    aboveground   retorting   process   is    shown   in
Figure 3.3-4.  Raw shale from the secondary crushers (stream 1) and collected
dust from the baghouses (stream 2) provide the feed to the screw mixer where
pyrolysis occurs.  Vapors containing retort gases, oil mist, water vapor, and
some processed shale  particulates (stream 16) exit the screw mixer and pass
through  two  cyclones.   Processed  shale  particulates  are  removed  in  the
cyclones and  vapors continue on to the oil recovery system.

     Processed  shale  exits the  screw  mixer  into a  surge vessel  where it
combines with particulates captured  by the  gas  stream cyclones.   Processed
shale is then forced up a lift pipe by injection of preheated air.   Oily dust
from the oil/dust centrifuge (Figure 3.3-5, stream 30) is also injected into
the  bottom  of  the lift pipe.   Combustion of  residual carbon  on processed
shale particles and oil from oily dust occurs within the lift pipe, producing
flue gas and  heat.

     Processed shale particles  then enter a collecting bin which  recycles a
predetermined amount of processed hot shale into  the  retort to provide heat
necessary to  raise  the raw  shale  feed to  pyrolysis temperature.   The  hot
processed shale is mixed with raw shale in the screw mixer in a mass ratio of
approximately 6:1 (Marnell, September 1976; Schmalfeld, July 1975).

     Hot flue gas and entrained processed shale particles exit the collecting
bin  and  enter a  cyclone where  most  particulates are  removed and  fed  to a
processed shale  quencher/moisturizer.   Hot flue gas then enters a waste heat
recovery boiler where the air for incineration in the lift pipe is preheated,
followed by  the  production of  steam through  heat transfer  to the entering
stripped condensate from the Phosam-W process (stream 63).   Both case studies
specify  the   use  of process  water  in  this  waste heat  recovery  boiler to
produce dirty steam for injection into MIS retorts.

     Hot flue gas continues through another cyclone  for  further particulcite
removal and then enters a humidifier and an electrostatic precipitator and is
vented  to  the  atmosphere  as  stream  15.    Processed shale  quenching  and
moistening water  (streams 93, 94 and/or 107) enters the quencher/moisturizer
where the processed shale  is cooled to below 200°F  and is wetted to contain
approximately  10%  water   by  weight.    The   moisturized  processed  shale
(stream 17)    is  then   sent  for  disposal.    The  moisturizing  and  mixing
operations generate additional steam and particulates which are scrubbed in a
venturi wet scrubber,  and a clean venturi  emission (stream 18) is released to
the atmosphere.

3.3.3  Lurgl-Ruhrgas Oil Recovery

     The Lurgi-Ruhrgas  oil  recovery system,  shown in Figure 3.3-5, has three
stages involving two hot oil  scrubbers  and one cool  water scrubber.  The oil


                                     68

-------
                        j
                         00
                         (§5
                         Si
                         II
                                 (VI

                                 01
                                , S;

                                 ci
                                     s
                                       i
                                       i
I
                                                CO
                                                or




                                                T
                                         II

69

-------
 recovery  system primarily  removes oil mists and water vapor from the entering
 retort vapors  (stream  16).

     The  first oil  scrubber removes the  heavy oils and participate material
 from  the  gas  stream but  retains water in the  vapor phase  due  to the high
 temperature  involved.   Gas  liquor,  which is  obtained  in  the latter part of
 the  oil  recovery  system,  is  recycled  to  the  scrubber  to decrease  the
 temperature  of the  vapors through water  evaporation.   Dusty heavy oils exit
 at the  bottom of the  scrubber  at approximately  350°F and enter a centrifuge
 for  dust/oil  separation.    A  small  stream  of  light  oils  is  a necessary
 addition  to  the centrifugation  process to thin the  highly viscous heavy oils,
 thereby  enabling  a more  effective  separation.   Centrifugation  can be  a
 two-stage  process,   coupled  with solids  drying  and  light  oil stabilization
 processes  (Rio Blanco  Oil  Shale Co., February 1981).   Oily  dust  (stream 30)
 recovered  through centrifugation is recycled to the  Lurgi  retort lift pipe.
 The  dust-free heavy oils  (stream  27)  recovered through  centrifugation  are
 pumped to storage.   Retort gas exits the first scrubber and passes through a
 cyclone  for  removal  of oil  droplets  and  particulates before entering  the
 second oil scrubber  for middle  oils removal.

     The  second oil   scrubber operates similar to the first, affording removal
 of middle  oils from the retort gas.  This scrubber operates at a; temperature
 lower than the first,  yet above the  dew point of the  gas  so that moisture
 condensation does not occur; therefore, the middle oils (stream 26) recovered
 from this  unit are  free of water and may be pumped directly to storage.  The
 operating  temperature  for  the scrubber is reduced to about 150°F through air
 cooli ng.

     The  third scrubber  operates   at  a  temperature  low  enough   to  promote
 condensation  of light  oil  vapors  and moisture.   This unit  recirculates  a
 portion of the condensed oil/water  mixture to aid in scrubbing of oil  and to
 promote  removal  of ammonia.   The  exit  temperature  of  this  scrubber  is
 approximately  90°F.   Light  oils  (stream 24)  and gas  liquor  (stream 29)
 condensed from this  scrubber undergo separation,  with light oils being pumped
 to storage  and gas  liquor continuing  on  to ammonia removal  by the Phosam-W
 process (Figure 3.3-10 later in this section).   The oil  storage tanks will  be
 a source of fugitive hydrocarbon emissions (stream 28).

 3.3.4  Lurgi Lean Oil Absorber and Naphtha Stripper

     The  lean  oil absorber and naphtha stripper unit, shown in Figure 3.3-6,
 fractionates the Lurgi-Ruhrgas retort gas  (stream 23)  after oil recovery into
 noncondensable hydrocarbons,  such  as Ci's,  C2's and  C3's  (stream 31),  and
 naphtha (stream 33).   This unit is used  to absorb the naphtha from the  gas
 into   a  naphtha-free  or  lean  oil.    Noncondensable  hydrocarbons  are  not
absorbed  in  the  lean  oil  and  exit  the  absorber overhead  as  naphtha-free
retort gas (stream 31)  for further cleanup and use.   Naphtha is then stripped
from  the naphtha-rich oil and condensed for collection and  storage, while  the
stripped lean  oil is recycled to the absorber.  Makeup  lean  oil  (stream  25)
 is obtained, as required,  from light oils produced in the  oil recovery unit.
                                     70

-------
o*
«*•
to-
1
to
10
o
u.
g
/v
£
p

as
5
gs
JO
^Sn


10
10
(S
ut
e

-------
                       I—O

                       "s
                       SB
                                   §
                                           Ul

                                           §:
                                           «*
                                          S
                                          CD
                                          cr
                                          to

                                          IO

                            0 0
72

-------
3.3,5  MIS Retorting and Oil/Water Separation

     Figure 3.3-7  presents  a  conceptual   illustration  of  a  rubblized MIS
retort.  The  dimensions  of this (smaller) retort, containing 23% void space,
are  approximately  165 feet  by 165 feet  by 290 feet.   This  retort volume
contains approximately 420,000 tons of rubblized shale.
                                                          •
     In the operation of an MIS retort, air and steam (streams 37 and 70) are
admitted at  the top  through several  openings  which connect  the retort air
level  to  the top of the  rubblized  shale (Ralph M.  Parsons Co., March 1979).
The steam is produced from process waters, using kettle evaporators and Lurgi
waste  heat  recovery  boilers.   Steam  promotes the  water/gas  reaction and
provides  a means  of  controlling  the  combustion  zone  temperature.   Retort
start-up is  accomplished through  introduction  of hot  inert gas.   When the
temperature of  the  broken rock at the  top  of the retort is high enough, air
is  introduced  to  initiate  combustion.   An  operating retort  contains  four
major  zones.    In  the first,  or  preheat zone,  the air/steam feed  gas  is
preheated  through  contact  with hot  processed  shale.   The heated  gas  then
reaches a combustion zone where oxygen is consumed by burning residual carbon
in  the processed  shale.   Below the  combustion zone  is the  retorting  zone
where  hot  combustion  gases heat the raw shale rubble to approximately 900°F,
and  the  retorting  process  commences.   During  retorting,  the kerogen  is
pyrolyzed to  produce  gas,  oil and oil vapor, and solid residue with residual
carbon.  The  shale  oil  moves downward by gravity and  precedes the advancing
combustion front by  six  to ten feet.   In the final  zone, the combustion and
retorting  gases are  cooled as  they  flow  downward,  condensing most  of the
vaporized oil.  During the early stages of  the  burn,  when the rock is still
cool, some water is also condensed.

     Oil, water, and retort gas exit the bottom df the MIS retort and undergo
separation in a three-phase separation sump located underground.  Heavy oils
(Stream 39) obtained from  this  sump are pumped to storage.   The retort water
(stream 41)  is  also  pumped  to the  surface and  steam  stripped to  remove
volatile compounds.   The overhead vapors (stream 43) are sent to the Phosam-W
unit, while the stripped water is used in the production of low-quality steam
to be injected back into the MIS retorts.  The retort gas mixture (stream 38)
consists of light hydrocarbons from shale pyrolysis, carbon dioxide and water
vapor  from  the  combustion  of carbonaceous  residue, water vapor from steam
injection,   carbon   dioxide  from  the  decomposition  of  inorganic  carbonate
(primarily dolomite and calcite),  and nitrogen from the  combustion  air.   In
addition, the gas  contains ammonia and  sulfur-bearing  gaseous  products  such
as H2S and COS,  The gases are drawn to the surface by large blowers and fed
to an absorption/cooling oil recovery unit.

3.3.6  MIS Absorber/Cooler

     The MIS absorber/cooler,  presented in Figure 3.3-8,  is  a  five-stage
absorber which condenses Tight oils and ammonia-containing water from the MIS
retort gas.  Humidified air coolers are incorporated on recycle lines of all
stages to control  temperatures.   Oil and water exit the lower portions of the
column and  undergo  separation  in  an  external  separating vessel; the light
oils (stream 46) are pumped  to storage and the foul water,  called  MIS gas

                                     73

-------
              1
x\
\s-  y\
       Ss
       §i
             Q.V)
          bu
       
                       s

                       3 t
                             «2
                             r«$ ro
                             ino
                            O CD
                            r— 
-------
 condensate (stream 48), continues on  to  a Phosam-W ammonia recovery unit.   A
 portion of treated water  from  the Phosam-W unit,  termed  stripped  condensate
 (stream 64),   is   recycled  and   sprayed   into  upper   portions  of   the
 absorber/cooler  to promote scrubbing of ammonia from the MIS retort gas.   The
 MIS  retort  gas   is   compressed   (stream 45)  after  passing  through   the
 absorber/cooler  and is sent either  to the steam boilers (Case Study A) or to
 the Stretford  sulfur  recovery  plant  via a  humidified  air  cooler (Case
 Study  B).   Further cooling  of  the  Stretford-bound gas  produces  a small
 quantity of condensate (stream 50)  which joins the  larger  amount  of MIS  gas
 condensate produced earlier.

 3.3,7   Stretford  Sulfur Process (Case  Study B)

     A flow diagram for the Stretford  process  is shown in  Figure 3.3-9.  This
 process affords   simultaneous  removal  and  recovery of hydrogen sulfide from
 the gaseous feeds containing low  amounts of H2S.   High  concentrations of  H2S
 as  well  as CQ2 are detrimental to  the  efficiency of the  process.

     The Stretford process includes two  separate absorbers,  one each for  the
 Lurgi  retort gas  (stream  31)  and  the  MIS  retort  gas  (stream 45), with  a
 single   solution  regeneration  and  sulfur  recovery  system.   The  Stretford
 solution consists of  a buffered solution of sodium carbonates, anthraquinone
 disulfonic acid  (ADA),  and sodium vanadate  which, in effect, oxidize H2S  to
 elemental  sulfur.  The reactants  are  regenerated by stripping and  oxidizing
 with air,  then are  recycled.

     The gas streams are introduced  into  the absorbers through venturi inlets
 under  the  solution level.   By reacting with vanadate in the  presence of ADA,
 H2S is  converted  to elemental sulfur, which  then floats to the surface and  is
 skimmed  off in the  oxidizer.  After  filtering  and  melting, the sulfur product
 (stream  55) is taken  to storage.   The  treated gases  (streams 51 and 52) are
 used as  plant fuels.

     Stripping air is  purged through the  Stretford solution in the  oxidizer
 tank to regenerate the ADA.  The oxidizer vent  gas,  containing the  stripping
 air with some desorbed materials  (stream 53),  is then burned  in the steam
 boilers  along with the fuel gases.  The  regenerated  solution is recycled  to
 the  absorbers.   Some  nonregenerable compounds like thiosulfates  form during
 the  solution  regeneration.  These  are removed  periodically as :part of  the
 spent liquor (stream 57),  which is sent for  reclaim.

     The  Stretford process selectively  removes H2S, but  it does  not remove
 significant amounts of other sulfur compounds  such as COS, RSH and CS2.  Some
 of  these compounds are partially  absorbed  in the solution  but are  desorbed
 again during stripping.  These compounds eventually end up as S02 in  the flue
 gas from the steam boilers.

 3.3.8  Phosam-W Ammonia Recovery Process

     A  schematic  flow diagram  for the Phosam-W ammonia  recovery  process   is
presented  in  Figure 3.3-10.  This unit  treats  the  combined ammoniacal  gas
condensates,  or   sour  water  (streams 29  and  48),  from the Lurgi  and  MIS

                                     75

-------

n

                   o
                    •§.
                   O
ED
                            o
                            S
                            SI
                         "CO
                         •
                            to 1»J
                            m o
                          0 «>


                          **
                                  03
                                  S
                                  
-------
                     /\  /\  /\
ce
o
Zi
h-
UJ
Q.
CO

S
^
or
e


sS
=3j*-
-JCO
                                           *i]   i   I)
                                            i	,  n^_
                                                            = SS
                                                            g;
«g
                                                                  C0

                                                                  ei
5

£
                                                                       i
                                                           .«s«
                                                            S§1
                                                            QSUji

                                                            &5£?
                                                                  o

                                                                 o ~
                                                                 tf> *T
                                                                 <£) 
-------
 processes,  respectively,  for recovery of anhydrous ammonia.   In addition, it
 receives the MIS  retort water stripper overhead vapors  (stream 43).

     The Phosam-W unit consists of a water stripper, an ammonia absorber, an
 ammonia stripper,  and  an ammonia concentrator or boiler.  The  sour water feed
 is  introduced  to the water  stripper in which the dissolved ammonia and other
 volatile matter are evolved by steam stripping  the water.   Sodium hydroxide
 may  be added  to  the aqueous charge to facilitate  release  of fixed ammonia.
 The  stripped water is  sent to the MIS retort gas absorber/cooler'(stream 64),
 the  kettle evaporators  (streams 65  or  66),  and  Lurgi waste heat recovery
 boilers (stream 63).

     In the ammonia absorber, the ammonia in the released gases from the sour
 water  and  retort water stripper overhead (stream 43)  is  absorbed out of the
 vapor  phase  in a phosphoric acid solution.  A solution stoichiometry between
 monoammonium phosphate and  diammonium phosphate is maintained for efficient
 absorption of  ammonia.   Unabsorbed gases such as H2S and C02  continue on, as
 the  ammonia  recovery unit overhead vapors (stream  61), to  be incinerated in
 the  steam boilers.

     Desorption  of  the  ammonia from the  ammonium phosphate  solution takes
 place  in  the  ammonia  stripper section.   Both  temperature and  pressure  are
 increased and  steam is passed through the solution.   An  aqueous solution of
 10-20% ammonia is condensed overhead, while the stripped or lean solution is
 recycled to .the absorption section.  Ammonia is then obtained  in an anhydrous
 state  (stream  62)  in the distillation section by steam stripping the aqueou5
 ammonia solution and fractionating the vapors.

 3.3.9  Power and Steam Generation

     Figure 3.3-11  illustrates  the  basic  boiler types used for production of
 steam and electric  power.  A general description of stream flows is presented
 below.

     In Case Study A,  Lurgi  naphtha-free gas (stream 31) and MIS retort gas
 (stream 45) are burned in  steam boilers, producing 600 psig steam.  Flue gas
 from  these boilers (stream 67)  undergoes  flue  gas desulfurization  before
 emission to  the atmosphere  (stream 79).   Overhead vapors  from  the Phosam-W
 unit (stream 61)  are also  burned in these boilers and eventually scrubbed by
 FGD before being emitted to the atmosphere.

     Feedwater  to  the steam  boilers  comes from several  sources.   Softened,
 clarified mine water  (stream 12)  is  the major  source of  boiler  feedwater.
Additional   sources  include  steam  condensate returns  from various  process
 units.

     The high  pressure steam  (600  psig)  is  routed  in two paths.   One path
 leads to generation of electric power through use of a steam turbine coupled
with a generator.    Low pressure plant steam (85 psig) is obtained in addition
to the electrical power produced by this  turbine.   The 600 psig steam is also
 used  to  operate   turbine  drivers  to perform work  at  various  processing
 locations of the  plant.   These turbine drivers reduce high pressure steam to


                                     78

-------
                   1
                     3
                      §<
OE
PED

CA
N
AMM
                                       I
                              S£
                                    g
                               ci 0
                                               i
                                               §

                               o
                               0
                                          I

                                          1

                                           sr
79

-------
                          L-
                          z  2
                          S  -
                           I  5
                           s

                         &
                          23s
                        si
                                  10 «a
                                   S?
                                000
                                l*> "(T
                                  Co
                                  1  —
                                  
80

-------
300 psig  steam,  which  is  then used  as the heat  source  to drive the kettle
evaporators.

     The  kettle  evaporators use steam  stripped MIS retort water  (stream 42),
Phosam-W  stripped  condensate  (stream 65),  and  Lurgi  waste   heat  boiler
blowdown  (stream 20)  as  feedwater  to produce  lower pressure  (265 psig),
low-quality,  or dirty  steam  for   injection  into MIS  retorts.   The  kettle
evaporator  concentrate,  or blowdown (stream 76 or 77), with high TDS is used
for processed  shale moistening.   The Lurgi retort waste heat recovery boiler
also produces dirty steam  (stream 19) using low-quality feedwater.

     Power  and  steam  generation for Case  Study B  is  very similar to that of
Case Study A.  Steam and power production occur by the means discussed above.
The only  difference between  the  two case studies is  in  the  composition of
gases which fuel the steam boilers.  Steam boilers in Case Study B are fueled
by low  sulfur  Lurgi and MIS retort gases (streams 51 and 52) coming from the
Stretford sulfur recovery  plant.   Since most of  the  sulfur in the gases has
been removed before combustion,  the resulting flue gases  are  emitted to the
atmosphere (stream 68) without further  control.

3.3.10  Flue Gas Desulfurization (Case  Study A)

     A  schematic for  the flue gas  desulfurization (FGD)  process  is shown in
Figure 3.3-12.   The FGD  approach  chosen is limestone slurry scrubbing of the
sulfur  dioxide  contained in the flue gas from the steam boilers (stream 67).
Limestone (stream 81)  is  first crushed,  then mixed  with water  and  sprayed
into  scrubbing  towers   countercurrent  to  the  flue  gas  flow.   The  sulfur
dioxide in the flue gas reacts with the limestone, resulting in the formation
of a sludge  which  is  collected in  the  clarifier  (stream  80) and sent to the
Lurgi  processed shale  moisturizer for mixing with  and  moistening  of  the
processed shale.  The  limestone sludge contains  approximately 80%  water and
20% solids.   Flue  gas exiting the  top  of the scrubbing tower is heated via
addition of  hot  air to  prevent condensation of moisture  and then emitted to
the atmosphere (stream 79).

3.3.11  Water Management Schemes

     The water management plans for the MIS-Lurgi  plant complex are presented
in  Figures 3.3-13  and  3.3-14.    Groundwater  collected  from  the   mining
operation is  clarified  prior  to  use or  further  treatment.   Clarified  mine
water is the source of  sanitary/potable water (stream 115), fire and  service
water (stream 116),  and process makeup water (stream 110).   Before use in the
cooling tower,  water  is  treated  to retard  biological  growth and minimize
scaling.  Boiler feedwater is  softened in a conventional  zeolite  system to
avoid scaling the boilers.   Treated process waters from the plant, blowdowns,
and concentrates are  recycled  to  appropriate uses.   The  equalization  basin
serves  as  a source  of  water for  processed  shale  moistening! (stream 94
or 107).  Sanitary  wastes  are treated  by  conventional  biological processes;
the effluent (stream 98)  is  then  used  for  processed shale  dust control.
Biological  sludge  (stream  99) is  sent  to the solid waste  disposal area and
used in revegetation.
                                     81

-------
m
*
Isl

CO
*
01
CO



(a!\

-------
/\
                                             s
                                               sr
                                               £$g
                                               
-------
/\
                                                         II
  si
                                                               §•;
                                                                         1
                                                                         ui
                                                                         9
                                                                         UI
                                                                         s
                                                                         UI
                                                                 «o
                                                                 %
                                                                         UI
                                                                         OS
                                                                         ID
                                                                         ta
                                                                 a
                                                                 SS
                                                       Sc
                                                                  S
                                                   S
e>

i
M

                                                                      a
                                                                      5
                  i S
                  '.•S

                  il
                  i S
                  : o

                  11
                  i|

                 o ="
                  o

                 11
                                                                      g.
                                                                      S
                                   84

-------
     Overall   flow  of  water   for  both   case   studies  is  presented  in
Figures 3.3-16  and 3.3-17, while  the details  of gas  condensate  and retort
water  treatment  are  presented in  Figure 3.3-18.   These  figures  follow the
discussion for solid waste management.  Flow rates on these diagrams  indicate
the  amount of  water  in each  stream rather  than  the total  volume of the
stream.

3.3.12  Solid Waste Management

     Solid waste handling and  disposal  procedures  are briefly described in
the  most  recent  PSD  permit  application  (Occidental  Oil  Shale,  Inc.  and
Tenneco Shale Oil Co., April 1981).  A schematic based on that  description is
presented in Figure 3.3-15.

     Of the several  potential  disposal  sites available on Tract C-a, Sorghum
Gulch  was preferred  because  of  its capacity,  proximity to  the processing
facilities, and  small  watershed above the  site.   Site  preparation primarily
consists  of  removing  the  topsail  from  the  area where  the landfill  would be
constructed.   This  topsoil will  be stored  temporarily on the surface,  then
used later to  cover the completed faces of  the landfill so that revegetation
can begin.

     The  waste   transfer to the  disposal  area will be  carried  out in two
phases.  The waste  material  from the processing facility will  be  transported
to the  disposal  site using enclosed conveyors.   It  will  then  be  loaded into
120-ton  trucks   and  hauled to  the  active  area  of  the disposal  pile.   The
disposal  operation will  begin at  the  southern  end of  the gulch  and  move
northward.  The  waste  will  be compacted to  an in-place density of 100 lb/ft3
in  lifts  of 18  inches.   The faces  of  the  landfill  will be  constructed in
multiple  benches with a slope of 4:1 (4 units horizontal:! unit vertical).
The  benches  will be  spaced  at  100-foot  vertical  intervals and  will  be
100 feet wide to provide enough room for  the  traffic.   At regular intervals
during the landfill  development,  the completed surfaces  of  the pile will be
covered  with   12 inches  of  topsoil  and  revegetated  according  to  a  plan
approved  by   the  Colorado   Mined  Land   Reclamation   Board.   The  final
configuration for the faces will consist of  25-foot benches cut every 30 feet
in elevation.   These benches  will  be cross-sloped to  catch  the runoff from
the sides of the pile.

     A  covered   collection  ditch   containing  pervious  material  will  be
constructed around  the  toe of the  pile  to collect  the  runoff.   The runoff
will  then  be  retained  in  a settling pond  at  the bottom of  Sorghum Gulch.

     Another catchment dam will  be constructed above the landfill to collect
the precipitation  from the Sorghum Gulch watershed,  thus  preventing it from
running onto  the waste  pile.   This water will be allowed to  percolate into
the ground.

.  .»  The fugitive dust from  the active areas of  the pile will be suppressed
using water  sprays.   The  inactive  areas will  be sprayed with an asphaltic
emulsion to keep the dust emission low.
                                     85

-------
x\
            co-
                                       ~

                                       <
                                      SI
                                          UJ
                                          ot

                                            —

                                           UJLU
                                          s|
                                          tpec
                                          gs*
                                          ggi
                                          0.0
                                          com
                                          en _i
                                          UJ t-
                                          a: si
                                          1— UJ
                                          « 0
                                                    s
                                                a - s
                                                ^. ^^ Ok


                                               ro ro
                                                S S
                                                                 g
                                                                 CO

                                                                 3
                                                                i
                                                                ^
                                                                to
                                                                UJ
IS
o O

  SO
«. *•»
                     86

-------
                                                      UJ

                                                      •*s
                                                      O

                                                      uf

                                                      UI

                                                      g
                                                      to
                                                      UJ
                                                      ce
                                                      ui
                                                      
-------
                                                      CD
                                                      Ul
                                                      CO
                                                      u
                                                      s
                                                      Ul

                                                      5
                                                      CO


                                                      UJ

                                                      UJ
                                                      OS
                                                      i
                                                      s
                                                      LU
                                                      oc

                                                      o
88

-------
    AVERAGE FLOWS IN GPM
MOISTURE
COMBUSTC
WATER 3<
1098
MOIST 8
COMB.
WATER
a
)N
>4
**
30
*

LURGI
RETORTS
20


CASE STUDY A
140


620
FOUL WATER
480
3500 STEAM ,
MIS
RETORTS

3398 _ ABSC
/COO
979
RETORT WATER 1200
324




2494 1
[
R8ER
LER
4913

i
OIL/WATER SEPARATION
8 MULTIMEDIA GRAVITY
FILTRATION
f

17 LURGI GAS
i 996
TO BOILERS

OIL/WATERSEPARAT10N
8 MULTIMEDIA GRAVITY
FILTRATION
—
)237
PHOi
REC
187

3AM NH3
OVERY
90
STEAM
STRIPPING



5334

1013


TO
PROC.SHALE
DISPOSAL
353J
_^ KETTLE
J EVAP.
'3373


TO
BOILER
3020
                                    CASE STUDY B
MOISTURE
COM8USTI
WATER 3
1098
MOIST a
COMB.
WATER
•a
DM 	 i 	 n
2J LURGI
RETORTS
3020
3500
STEAM
I1
1
1
1
|j
MIS
•*" RETORTS




140



620

LOSSES
\\2_-
LURGI
5AS 17
3398



65U TO BOILER
STRET
SULI
RECO
996,
- —*•
FORD 31
-iin 	 	 ,*
VERY

979f
ABSORBER 491
' /COOLER
*
RETORT WATER 1200

"
51 324

2494
t - .
, OIL/WATER SEPARATION l
3 A UllrTIWFniA RRAUITY —
FILTRATION

OIL/WATER SEPARATION
	 ^. a MULTIMEDIA GRAVITY -<
FILTRATION

-5237
1 PHQS
*" REC
187
. STEA
STRIPf



f
;AM NH,
OVERY
82
M
'ING

5
i
i
~1f

r
673

TO
PROC. SHALE
DISPOSAL
j 692
KET
I*" EV
^3712

1013 ;



TLE
AP. 1
80JLER
3020
SOURCE •• WPA
                  FIGURE 3.3-18  RETORT GAS CONDENSATE AND RETORT WATER
                            TREATMENT, CASE STUDIES ASB

                                       89

-------
     All processing wastes will be combined at the processing facility, i.e.,
there will  be  no separate transport of the individual waste components.  The
wastes  will  primarily consist  of the Lurgi  processed  shale (stream 17) and
its   moisturizing  components,   such  as   the  kettle   evaporator  sludge
(stream 77),  FGD sludge  (stream  80),  moisturizing water  (stream 93 or 94),
etc.  In addition,  the sludge from the sanitary  water  treatment (stream 99)
will  be brought  in  for  the  revegetation  operation,  but  this  is  a minor
stream.
                                     90

-------
                                  SECTION 4

        INVENTORY AND COMPOSITION OF PLANT PROCESS AND WASTE STREAMS


     The  stream  compositions presented in this  section  were  derived,  to the
extent  possible, from  pilot plant test  data.   In the  absence of data from
actual  source testing,  engineering  analyses (by  Denver Research Institute,
Stone and Webster  Engineering Corporation and Water Purification Associates)
were  performed on  the  technology and  raw  stream information  from proposed
industrial  developments.   The sources  of these  data,  whether actual, esti-
mated,  or derived  from published or  unpublished information,  are indicated.

     The  data  presented  are internally  consistent  for  the  overall  plant
complex;   i.e.,  the  principal  chemical  elements  involved  in  emissions,
effluents,  and  wastes  are  balanced  throughout  the  plant.   Trace elements
generally  are not considered because of the lack of consistent data 'available
as a  starting point.  The stream compositions derived by engineering analysis
generally  agree  with the available data  from  published sources.   Therefore,
the data presented in this section, even though partly derived by engineering
analysis,  are believed  to be both representative of the actual operations of
such a  plant  and accurate enough to lead to relevant conclusions in analyses
of various pollution controls.

4.1  INVENTORY OF STREAMS

     All  but  the most  minor streams in the  plant complex are inventoried in
this section, and  quantitative data are presented to define  important char-
acteristics  of  the  streams.   Section 4.2  presents  detailed  'compositions
of the  major  streams  and shows changes in composition,  from one point to the
next, throughout the plant.

     The  streams encountered during the analysis of pollution  control  tech-
nologies for the plant are listed, along with their flow rates and components
of concern,  in  Tables  4.1-1  (gases),  4.1-3  (liquids)  and 4.1-5  (solids).
Whether or not  a  stream must be  controlled will depend upon  its  size,  the
quantities  and  characteristics  of  components,  their  allowable limits  if
released  into the  environment,  and  the  disposition  of  the  stream  in  an
integrated plant design.

     Tables 4.1-2,   4.1-4,  and 4.1-6  list  the  major   constituents  in  the
streams.   The  streams  are  likewise  divided into gases,  liquids,  and  solids
based on   their  physical  characteristics.  These  tables summarize the  data
presented  in  Section 4.2, allowing for a quick  comparison of the  streams.
                                     91

-------








P
z"S
i—
°1 :

> used to provide a suppl;
in the mine and to if lush
issions, particulates, eti
underground activities.
!fi§
1
1









*>,


y^
1
•p"











4:
^»
1
E
^


5S
?
"*" *3
S. 0
•^ w S
(8^0
« C *«
*r*
« x: re
S^o
*.-&§
0 3v
O Ul
*» &. Ul
Ki
-+J C
oj re re ..
en*— 4>> w
S- 3 3**
RJ 0»— T-
C\l r^ IN. tO
'-$8'-'







W» '
(V
•s
I



r*.
0
§
to







e
o
«
S
§
^
c

^


10 0 S- C
_s = . S- •§"•£
"S '5 » • -n ' "S^2> Son
^ .^2 m J3J= x "^i-0
Slit 11 lil' I1!
^ m
iizi lai * * * ' • - ' ^"2^2 in
||o«4 k^t.2 ^ 5 « « * SS'S&S^g
s ?••« 5 « ' ' g 8 o "5 p o "5 o ocSo.*" «.1 =
HI || |o| | 1 | 1 1 1 ?^|'Sl ^gf
•^^oc^o0 ?«>« ai 'ln'^ Im^o
ieigi |«j f f i f f f itjll-llj1!
oo«f-'iD 3^*>co m m m <2 m i=-Si=«iSQ8z5
** »< oofHcai-i m
c5SSa>u:>S "* "^ S " "^ ^ eoo.moooo
- 3S O3 • -
Cd OJ r- CM




01
J2«101 Ul UlMUlvltA WUlji
cotoi at oi COIM
o-w 4J *> * *> 4J <3 43 §w
•g « * n> 
C .P3 '•" t*--r-C-31
Tli *2 >»oi-ioo»«f-o
c C CJ -C T3 O> C Ol 1 |
^ O >O> re C RJ>r-T3 T3

§.^_ 2 t 0} «2 »2 o
WO §»3SlS§)« «
*rr *» .f- JTO os >j=s-"si."sre >
S^j HJt^ W>0. 4-»tUtJ COIOIUOUJO *J
*""c O"tf CS-C*7* C O 18 4J 4J S.
18 1 s'g1 ll's -ll rl g" g| g| - «
*""4^ !E *e *JCu>.Ei:»^-«>oco^OJS
SiS" roS o^iS iS =1 c£ cm gj" '§ I1
"^ 3 S» IO $_ *r* •«— *n* 3 ?
d U.O-OSOU.U.U.J j"
tn tL R. S, 6.' * *- * * <•>"& S
**'• •*** r*» cootorH^f-mii tot
«H t-< rH r-ICSICsl iHCM
s* s
92

-------






Remarks3
5.
If-
U. C
•u
U) C
o
0


C 01
go
o o

fit
11= IE
•— -v, CJ

u» '"w
ui« o
0)
Ul *»
££ Q

3 in *o
u o •
s? ££.£::
(U «n e .n
Q. O» O> .Q
01 O  Ul
Ol >> C Ot
.c:  u
*.E-0 0
O flj O Q.
*"£° , ,-
"SiSb S1
V- § O>fO 3
(D Ul — 1
in to to
•^ 4> »-»  «t- O
mr*- o> c T-
ot to .c T3 -P
4J 4-> +> JS^« M^
«r- i. t3 -i- .p- o
*— O 01 C
rtJ 4J t. r- fi. .r-
3 0) 0) O -i-
CT J. > £- (9 O>
I o +* f—
s «rt o c 01 «
S££8 jS-S
I :







o
31 . 1
Z 1
r-f
O 00
CJ ^f

. oi
C <*- +a ^
a» o t3 o m
J2-r- o> J= >,

T3 Q. O ** g .
rr a • E**- o w
33 OJ 4J 4J i— «
Ul O U> 3 0* O Ol
E(0  *> •>- **- •> £-
« P— •*- Ul O
IE t. 4- e nji-
_. o o ui 01 cna>
•O «^ (0 *f £1
C 5- >» 0) WU>
 c >~i >>
"- a* «»- 3E t
«t3 E. J= Q
Z 01 O *> Ul Ot Ul
Z > 'n -f- ^ ui
o ra j= ^3 ai
O) € £ •*•> Wi U
£2 <'S^=S
O O O O
r-t O3 *? CO
«H OO 00
CJ"






nco rtto
2: z Z3:
m o
r-4 00
S S

•4J
U
3
•o

U)
s. m
o to

« tO J3
to a> nj
CJJ= Ul
T3 C 0
C •!- O)
(0 C
ai
09 ui ai
Ul V) (O
O T) MO)
•»- a> ar
•*•» S- 0)
'f to t*- JS
m or- en
c o "c
o o
^r oo
00







«w>
a: w
to
m
in
r-l

•U
C

Igs
fll **-fa—
3
O Ol OO
f~-*»~ S- CJ
C 3 (0
§E= JC fr-
O -M +J
w(S^ ^
Ul Tl Ol
-»5 1
«1 0» •*-> i—
^- Q. 0* i— i
QC3 0
z z z


Ul
C
o
•?
s
I
i^1 1

O 0
Z 2
2
                                                                                        *S 0)
Treatment prior to or aft
consumption is necessary
potential NOx and S0 emi
                                                                                                              I
                                                                                        r^ m oo CM c
                                                                                        oo CM oo CM c
                                                                                                    t
                                                                                                     u
                                                                                                     g
                                                                                                    I
                                                                                    §   g
                                                                                    ID   cn
                                                                                    *a   o"
f
I  SI
Des
    s
s
£.
5
                         fiZ   S1
                         3    3
cs

I

                                                                                        1
ree
ipe
Em
                                                  s
                                                          J
                                                          •S
ptha-
Lift


Emis
Stora
                                                      5*

                                               93

-------
(
-P
c
3 oi


re tn
tn c •
o o in
J=x» re
Q. s. cn
re



ct^""

"O 01 £

0) -P -P
H*
2».J
•r- re 3

O)

3*

01 Of
5 **

oi*£
C >> .
m t. tn
re c
S. U) O
o tn v-
Ot tA

** c*s
t- - o>
o >n
j*f jjj
c: *> re
III
01 c *>












CO
CM
S
10
01

in
c
TJ
•S
3
U
C
U)

s.
re


c

€
IB 01
•p *>
re re
01 3
s-
-P QJ
. C
•S3 .f-

•e S
li «
0) Ol
x: in
>- 3
*1
(A 3
SS5
4-1
Ol O> 5

.c re re u>
£ a. S £

. S **£
> 0) O

are E
S ra
O (A • 01
CO; tfl -P
(A CH tA .
o f- cn -P
•P 01 C

lux's ** -P
o c re
3 4— 01 *i~ Ol
2S>clt
"1Z1I
to ro ro t-
CM 3 x: in 3
x cr*» •»- *o-
»

s-
3 E t.
4- re o *
r- O>

•P « x: IA 01

-5 .5-
> .u TO re
e o 01 c c

O.*- O **"*f
O E TJ -P
cn m &. c-o

o c -P 3 ro
+J 3 O X)
§C -P »
tn 3 +*
01 re o*f- o c
u &- x: 01
3 o) re w -P s
T3 ,- fTJ •- -P
£-ll"«£
3;|s.|^i
« CL O s- o o
o: ro u P-Q CL
+J
S- O
•i— 01
flj t.
o"0!


tn IA o

o >
S- -P
« Q. C

^ tn c
"O •!*" O

3 8

ff~ t- x:
Ul 01 

CO 3 O) « O. Ill Q. n C X 01 O SZ in o 5*i oi 111 -P re 3 0 "0 o x; ~5 in o it £ s-z ; C) in a) in ID in r*. tn O O O O O e»j in co csj ao CM O CO CM 0>J ooooo O rH «* CM <7» CM m r«* CM 2" o MO v) re ?o oo a 3; ntsi 3± M 22: a z 1 I CO OV Q .O SO - cn ca o Hi • 1 -J *" CT c re II in in Sc 0° e £ O IA •f- i. •

!- ij | *,_ l et -P ** tn to re i- o o o a. o %"$ «"S5 S "*- v> •£'S w | = " oo c en corn rr> I I , to CM CM 94


-------















g
u.
U!
i














1
fc.
M

Is Remarks3
s|

tn c
U) O
o
0



c 
1-
o
o
1
S-
s
s
si
"e *-•
*8

Treatment to reduce the S02 emission
is necessary.
S°°
fl C*5 tH

us CM
CO








0*00
vt 3z o

s

ft"



i
0)
5>5
it
u. */i
201
u)
o t
j= o) C
SUl
u>
O Ol 01
c JT u
"§!
S*2
WT3 ui
S2-
§is
c1-^
-•§•3
rare
s. a> t.
3 S. 0)
:«l
C M 3
m •»- «*-
o CM en
<0> re





















s .
High-quality steam is produced from 1
softened and demineralized mine watei
i











t
i

to
a_
r-~





i
£. '
G
R)
S
t/> Ul
41 0
E. f-
Ul O
S01
t- E
o_ re
0>

5
Ol
to

01
o ;

Various process waters are used to
produce the low-quality steam. *Its i
in the HIS retorts provides control c
hydrocarbons through combustion* and
NH3 through recovery in the retort
water or gas condensate.
Sc3
t i
^- 01
in r-4



Ul
u
i
o
f£?

re
*o
i-4
in
^"
2
s-
3
S
OH
*"H
s
e
re
I
£
m
f.

1
O 1 1
r* eg  C Q.-G 4)
                                         S. £-    ui  Q> 3
                                              WJ O  O «—
                                         >> 0) O) E  3 (*w
                                         "O .C O 4-» "O
                                         re •;-> "o «j  QJ oi

                                         2 E >,*-  u §

                                         «2S°.!2t;
                                           >»- *> C    Ol
                                         «   C O  WE
                                         •*-  JZ  • >t •    S
                                         -s ^ o>    re

                                         x-£«§>.5    £
                                         O ID    •O  OTE^Q   *>

                                         ZS85£&€    w
                                         at e    w    o»
                                         jrcyrec^oo    01
                                         h- t- D5i—  C in Ul   V)
                                                s.s
                                                £ •**
                                               :SJ t.
                                        a
                         St   -2
tretford
Unit (Ca
                                       s
                                       u_ ^^
                                        !.<

                                       Hi
           O    O      O C
           -M   43 E   ^.?
                 l
                 *y>
                         IT    1 y
a>    re o>   at o
£    O) as   y^f

     85 '     C
11


0)0



g-v-
                                          ao en


                                         iSS

                                          "*'«*
95

-------
§







»
O
ui 1:
41
01 C
wi o



t




II
41 U
C C
|3
o*t-
o o





* t-£
2^0
"";£**
« n
,tA« O
toc>tH
Er-l^-'




£

h
t/)
o
c
o


&
•«•
s
s



T>
•
Is «



t—

*,. &
•f-
t. 41 (A
mi— i.
*e
5s!!!
sis
WOO
4> tn s-
tlj ;
C - T3
O IA 0 4)
*»- tn o -P
•P O S- -P
£7 ml
a.« -a *
(O 4J C 4)
> flj 3 J2
03 1.0
««§»
1— *> 0 10









a
z












^
z






tn
fO



i <
tr~

UJ 4-*
0 4)
£ S
e vi
o
 o
Ul i-
4> N
r





s,
o





Q>
If
4)
4)
f
U)

4)
U)
Z
O.
2
to ai e
i 1 's
I II
ui in
S S jc







tn
•
Q 1 tO
z








* tn
e
o
t
to
u
o
=i : I





i^
o
*> s - °
""


t ca
re >i ui
§••§=§
uj •»•» o a>
00 •>- C
ia> £ .2
S- Ul i- I—
*- (0 O «
§" 1"- 1

(Q tn fi> >» ••
t- ra 0113 ui
o ca 73 c
a. o 4J o
ro C h-trt f-
> O Ul
f 5 " s '^
& 3 "^ o ui
1" 1" M





OJ « 1^
rH rH rrl






a>
a. -a
0 4>
S- ui
a. 3
u!

4) 
^- to
2f 2
e C-P
£*r- C
ft) 0
«- i u


































































tn
1
5-
in
c
i
T3
3
|









aa a
3C Z «£












x n
O O O
UZV)






.
0
ss



^.
(0
tn
a
tn
o
i

Ul



UJ £
Q.
ui O*
4)UJ
Q





•K
S
r-l

























o a
SE Z








u) tn
C 41
tO 3
U U
•a E-
£2.


































1
to
at
^ tn 4> to
aj •)-» -P
J= C flj S
u> re t— ro
Ul 3 4)
"O tn u t-
a> a> T- +j
Ul S- .p OJ
IA a. s-
4* a. to c


S.«§fg
jl'Sl
*» ^»*o
^- 3 C
O *^
Ol O J= .
c re tn o
4) U 41 "r*
+J-^- u tn
•^ Q.T3 -r-
O Q. 4) S
s: m s- w









1









Ui
4)
to
3
U
s.
to
o.






B
0
z




I O
11
*5S
IA
*r~ 4) tn

+JV1 O

tn a
Q> W M-
"rap^H1
u.





s





tn
ft? >2
fc. •»- .
wi"^ °- *°
£- P— +J S

£ C °* U)
O "O 4)
**-•>-  c
O +> 01 »r- n-

C 4^ SJ "i" "O
O 4) U Ol 41
•r- O) O 3 13
•P 4J S-  Q. *—
U 4) 4» O
•<- C. 4> JZ C
i— JC 4J »-t
o. n) 4)
RJ 3 "*- U •
u c 13 e
>f~ 41 4) 41 O '
1> 4) tO *" **A
E- TJ t-.f— *r-
4» C 3 •*- E









O
Z








Ul
41
H
u
'S
2






_
a
z




1
tn
4)
u
S
a.
i
tn
e
O 4)
tn i-
tn O.

5|
a





S






"e
4)
t
O
>
•8
l

i
0)
•*•"
1
•§
Ul
O
a,

41
Ul
o
5

£
to
§"

to
0
s-
10
1
s
-a
4)

1
(O

4)
1
O
C
•P 0
C 4)
1 **
I 1
> c
CO*
41 U C
£
 C C 4->
fc i» f ill
In ui /-. W

ui if ! o
(U ra <^^ z
| 2 | "_
•a 4) wi Q
c ^  ja o

timates
o Shale
tn u

c
Of 4)

4»
U
£.
, 3
O

                                      96

-------
w
0


=?
n
o

=1
<3


to
. 3;
W
w

X
ej
^
J3
is
Ul
cr
« Ul
1 i"
t—
1 g
Ul
§

fe s?
cn
|
P_
»r<
£ S
3
CM
A S
«r
3
- *

HI
'*'""*
S ^3 1^
£ i-) .H



Stream
Description
ife5
fl* .n 4»
CO Z (Q

O O O



0 00


O O O




0 O 0

0 O 0

z' z


000

o o o


CO CO
\o 3
yj y>* ^
rH rH
•K
O O O
z z
oo
* ™ °
o o
o o o

*•% **••» »

*c ** *^"
tO ID


g
f-O»
.•S3
Nine Air
Mine Vent Emission
Diesel Emissions - H
Equipment (stream
included)
fO «* tf>


O 0



0 0


o o




o o

O 0

P o
si


o o

O 0



a ta
z z


Q 0
Z

o o
z
o o


° s
Z '**'
s~-
•s
3
1 "^ si
s Hi 11
O  Ol
Fugitive Oust Emissi
Mining Activities
(streams X20 and 1
Production Shaft Con
Transfer Point, Ba
Emission
tJ, ft.


O OOOOO « O O O
o i
t-i ; .

O O O O O O f» O O O
CO
CM TJ
OOOOOO **^OO O 3
a .s
£
5
CO ' ^
OOOOOO CMOO O
cn
cn
oooooo cnoo o
00 :
OOOOOO * O O ! O
• CO '

'
OOOOOO CO O O O
, o'
OOOOOO rH O rH O
CM O
1

ocaooocn CMOO cn
ZZZZZrH in Z rA"

M
o o o o o to • o o o
^D CO

ooooo^r CM o o o ,
° CM in
i
OOOOOO ^D O, O ( O
CO
^ ^ CM' OPOCMtDrH
SCM Cf5 rH «(f f-fOO Cfi O3 O'OO
3 rH ^ Z- 1^3 m ro § cn
»-» i-i ^» •KtcOCn^wCM:^!-
f**' , CM"

S
t. e .~
c cu o - *> s.
•^ t^-n- e 3 3 .
I - U> W> -^ O 4J •*•
T3 O) c o i ( in flj o)
(O C CO •!— "O *O S 'f^ ** t-
5 c *e e £1! oc oc w £ s: S , 3
O Q) O _J O —I O t- t- S
4) ••- W i- t- Ol -^ t- O 0) i O
oiuis.uiomQ)uia}u) Q. c: (— «i- 4^
2.2 S.2 S?g S".S g.2 M 5 £'S 21 , • • •.
SJ -oil g-S fe.1 SJ 3 « S" 3S; •£«
v> c OQ-M -u s- •r-tai— a
a (a«ueacocnoi  t- O f- O U_ CC i— 0> <*- 4J
iS-S S^ °5 °€ °-S ^ <- ^S S1S It
s« 35 go g,g »« o. g. «£ 3« fr;
fO S* »i— *r* *r> 13 3 Ql 4J o
CCUU.U.U.-J -J > tO O
rH CM f*- r*. O
* -K « * * * CO CO rH * « CO <•
co cn o ft <• tnii'ioi co cnii rH
rH rH i-i rH CM CM rH CM rH rH CM CM CM
s* s s*
97

-------
ll
r-
i.
OI.C

W;S
t-
X S
N
O
0
=
VI
5
d

S
>>_

up
5
•0^
X
rag
.j
+v
u


So
sx
o

. z1
0
4[§
A U
i|






c
o
•p

;lb
S- o»
•P 0)
W O
l«
p



p


p
S
in*
S

0


o
o

o


p

0


p


p



p



IO







£.

Ol
3E
•K
f>
CO
rH
**"



rH

S
8
fH
in
s
rH

P


P
P

P


P

0


O


p



0



(JD






Emission
4J
C

o»
c
IE
*
o



0
rH

CM
ea
z*
p
z
p


p
o

P


0

0


p

CO
S
o


o



o
z



I,
= 3
S
1 (8
C -P
o w
U)
W> +J x™*

O. 3
(U 3 U
in CT C
Q
tn
CM
S
>-*



2

Q
Z
P
=
O
z
p


p
p

p


0

p


p


p



p



p
1
,2
(J
(A
J 3
tA IA
(A 01 "0
•§io
ftl
> C 01
•P e-p
u.
iO
CM P O rH
CM CM in Ul



O O O P


O O P P
0 d Q O
z z z z
o o Q ea
Z 'SB Z Z
O O O O


P 0 P p
O P O O

P POO


O 000

0 0 0 O


P OOP


P POO



0 00 0



SO CM kO
^ S S C



km C 4) O
>"§> "m c? 5^
oca — J c *cc: i— ui
O O OJ O
« 0> fr- « f- I. Ql
4^4-* O>V) fc. O) O U)
«£C OJ(A OW >»2
2"S fe*£ ^''S S2
XZ O OS S 5> J^
via. -P uj TJ ui CCT
v> c o to
e t- c a> to cj oca
r *+- 'i- i~3 CD3  tOO CO £. -P
3R3*f- t/1 O» .C O) f-
T3 t- E m'wm ato
o p- uj 2m 3 3
23 « 3 r-
0 o ^_g IV
Ol Oi *r-
cm c ca £-.
U. U. .J
* * * CO CO
S S Se^
0


o

CM

o
p

a
r*!
S
o


o
p
CM

S
CM
.
I
rH
in
rH
S

S

CM
O

O

m
CM

cn
a





tA
i
s
I
cc
*ra
_j
s!
rH
CM


0


O
d
==
p
z
p


p
0

p


p

p


p


p



p

s

CO
fc.
N

3
(A
2 £
=5
o to
U) CO
lU
Ul tA
tA
*r* <1>
||
>
S
0



0

1
o •
o

1

p :


p '
p

p


p

p


0


P ;



P

t-i

p ,




•s :
ID
2
3 I-
11
•*-
ll
t/»
* m
rH CM
<*
                                    f-    CO.
98

-------



















•
I

CM
1
•
«J.
Uj
1











. 3
=
CJ

3


CO
5

If
d
S.
JS
If
S"
Ul
!«
5*-
(4


64



N

"

S

W

r- "** ti-
ll. jOO,
Soo
' ^


Stream
Description
!1|
rH
rH
S
S
1O
s-j
fH


CM
cn

S
CO
S
a

s
CD
S
eg

Sj
u>


in

m

OJ
in
S
m
"»
rH
cn



in
S
1
S
CM 1
CM eg
rH
S
a
to
2
rH


CO
CM
cn

cn
cn
CO
r-t
cn
CO
rH

CO
CO
0
«f
O
0

a
in


•a-
10
CD
r**
eg
in
to
CO
o
a



1
1
s
s^
o
o

o



o


o


p

o

o


o





o

o

o

rH
O


0)
£1
lo
•f— 0
£T3
(U
C -*> "O
O Ul 3
1
rH
.S
3
«
S
rH


CO
CM
cn

cn
cn
CO
cn
CO

CO
CO
0
o
0

&
in




^
"
a
in
in
us
CO
to
CO


3
£
1
at
at
u.
CLCS
as
O rH
CM CM
rH 1 I
co eg CM
00 00
«*•
C3 0 0 "t
== .q
00 0 00
3= cn


00 0 ^
* ' • a

do o co
== en.
'*.*.
Q" Q 0 ^
=£ z R

cn
do o ^
z ft"
do o
25 CM
0 ***
d o a. s
25 •«*"-"


lO
« r**.
O O O rH
• CM
CO
do o "^
• CO.
o o o •
2= S
co
d d co co
• • o cn
z 3 in cn
(O £3
rH

o **"
*J « "O
5-S
5 f-5 i
'Si z -5 o
3 1^ t 1
S S ci2S "* ^
s- a. o csj c «»
u. •»- -^ w o o» t-
i a. w cn E T- *J o

«><>- EOS. 3«J a:
fs ^su |s «
* «. * S
« s « SjcVi
C3
0

o



e


o


a
z

o

o


0





o

0




Q
Z


01 u
1- a/ c«j
D)
o 2 e
(A U) ^J
SCc
SJ°""
I
o
o

o



o.


o


o

°
o
in
o

0





r-
cj
o

o

us
&


i
t_
Retort Water Steam Sti
Overhead
in 03 «
o
S
a
a



s
CM
eg

CM
CO
cn
S
*r
in

m
0
ft
C CM
e •«?•
O S- (O
to t/> *>
Ji*
1
o
d

T3
0 §
c
I
o
o

[
o


0

o

o


o





o

o

d

m
d
s

Ul
I.
C O
a o
Cooling Water Evaporal
from Humidified Air
|
99

-------




























T
I
***
CM
-1
a
i












































|


rt
O
VI
+J
c
0)
c
•o
-
•?o
•j •
+.
•«•

to

*>
£

i
ce
•g,

5
3
CM 1
CM CM
*"
O

3

O


o




*"!


0


o




o


o

o

CO
•..
tD
fH
CM
in

iH

O


.
CO

0
§









a>
3

"Retort
•f-

2
«?
CM. CM
"^
O

O

0


0




o


o


o




o


o

o


o


o

CO
i
d

o


tH
d

1

o
£





a
«4-

a
tn
(1

's
C\J

o

S

0


o



CO
00


o


o




o


o

o


0


o


p


,
CO

10
II

^

CO +•>
£_
o a


. QS


« I1
E 3
w -o
(A3 S-
V->i— U.
«| fc
= +£ «
h- «* D.O
S
^?7!
CO CM CM
•^
00 000

do o o p

o o o o o


0
o o tn o o
pH
tn

* f**
O O CM «*• O
• ff CO
ss.
CM
P O 0 CM O
O

CM
O O O CM O

o

CO
0.0 0 00 0
o*

00 O O O

o o o o o

a m
0 O 0 *^ 0
r*
tn
CM
CO
o o o • o
CM

o d o o d
as z

d o o o o

3
«
as z ' S^ S sc
ID O
= »

0 ^ ^"§
U> +J "D 31 C

CJ Q.r- •-» to C-
(0 O S t-i
•r- 31 C .3E ^
o) sC 5- t. s §
_l S. Ji S. Q. £ fl?
**- c: -r- cd 4- o> CM
41 (A tO '""» • O)
201 c H> co c ro e
a. o CM c -u o i. RJ
.C4^ i- t. OJ Ul O  O f-
Z 3C CJ £ 1C
tn
CM 5- 1^ CO 7* 0
CO CO CO (*> CM ^
V*
0 00

p o o

o o o


o o o


en en

o

**•
00
O CM O
d

CM
O CM O

O*

QO
O OO O
d

0 0 O

o o o


0 00

CM
CO
o * o
CM

in o d
d z

o o o


to o
r^ co d
en 01
'O Z
en
•g
0) -t-> "O
a. u> j= s
O. (O CDr~
.^r « •?• o
i- — i c


O "H
S +J S -^
i « e s
w? v> E*~ eo"
>^» «*- a> 04
t = cffe
*> -a T3 o i* m
«  -F- o o>
2t ai ui u> 4^ t-
0 > 0. iBC^ C
4J O £ O *f~
ce us
co en •**• iH *
co i i i m i r^
<«• CM CM CM •«* CM *r
*-• '^
o

I
o
1
o


o


tn

m
in

Q


p




O


0

0


o

•'
o


p


o


m
s

0)

c *o





rtJ T3
> 0)


Ol tJ
'w'i
f I

*o «*-

1

100

-------
J
CO

. *

to
^


1
s-
5
rH
in

o a:
0

(0


=?


M
' O
u


S


^

Ili

W) *""
tnco m
: SSS



Stream
Description
ss_7
(0 01
f—
rH
rH
s
3
u>
s
d

m
CM

iO
m

«f
9
rH




Stretford Treated Lurgi
Retort Gas (Case Study B
a
Si
s
»
in
rH
3
w

in

si
s
cri
*»•
in

s
o


s
rH
CO
CM
cn
^
jo

cn
cn
CM
cn

rH
S

in

o
£?
10
co"



Stretford Treated MIS
Retort Gas (Case Study B
CM
CM 1
m CM
S
000 0 0 000 00000
000 0 0 000 00000

OOO O O 000 0 0 0 O 0



OOO O O OOO OOOOO

ooo o o ooo 0000,0


OOO O O OOO OOOOO
1
1
go |
O o o com o o o O ooo o o
oo

1
cn <* i :
o O o 10 P* o o o m 10 acaa eJ ei
OO Z O O* 35 3= 21 21 21
co in cn rH
• CM mm
g^o o ?* rn^oo ooooo
CO 00 *-T r-T
CO rH rH
CM i lii in
• co 10 p- p-
SO O ..rH rH O O OOOOO
co O ** **
rH m9 «r **-


iH 00
o o o o P- p*. o o ooo oo
do •-

ooo o o ooo oooo;o


p* p*« m ^- to m ,co
SpC «f *^ig CM rH ID rHO*00 m ID
Cn rH CO CO CO fO CO rH . » 01 rH r*-
p- "«*• p* , t. S.-& i m
O CQ O O U> U) 6 >)WO> 3 3 -r-
4-> <^ f U £- fc O *O 0) .+•> **- -t-» C
c -*j >, -p o a> t 3 > (0 ^ vi o
CD QJ -tf (0 S- CL | ^ 4_ *J 0 S 3 1
> t. 3 t. -F- to  o tn «) e
-M -(-> 0< > 0 0 E *> 0)4JU1<
&»-s O O > V ^-N rtj r-s, S ^-s +J to BJ m 4J S- O *— ' 1
•r-CD +J Ul Olf- fiO (U (U(0< fflCO U1IA O> U £= « O> t- E -P
13 to <*- j= &.&. 01 t. +j ^^ >4-> 02 a. -P -p  I- U £- -r- >, &. 0 <1» >> +J > CJO) VtIA J= 0, 0* T- U>C
SI S^ S2? S -SC:! W1 S= >,« Si- i2T iS • 5 =
•oS ai; SIS5 ° mS« 'S SS SS "- = =S? "> *, °- £?
S- CN 3= 3 tn  a> i 
*t- ui CL-O C€tnH t3<0(nc3wQ-nJ3 ro -P O
•P td a.-*- f- o (C (u 'aim to  E s E  W> 0> 

-• (D (O 03 4-> (O 03 (O 0> >. *— ' t. O 'O ****•> O 3 VI *— ' 3 >»* Olt/1 3£ 0> 9) (UV) 4>3£ 0)Q£ •P-P O f f~ • f^ .f. o ^J ^J +* 4^ ! +J V>V)O Q. U. U. 3S — I MtnvttniA IDXO i£cncocno «f SI •* 1 CO rH 1 1 P*1I 001 Cn Oil r-4 CM M «*> tn CM in CM in U>CMCM o CM CM «>CM vo P- CM CM P*. p^ p* p-, P^, S S S"*" S*1" S S"* 101


-------
£.
If
Sfl
.P~

J.
IS
i—

c?
o
X
, 1
JO
» «
H
U1
+» M
C O
|
' tO •»"*
J3
1—

o
o



o


"°
s
Q

0


O

o
• o
o

o

o


s
fO

i


^^
OQ
-•e?
?5
= «
O
T3 w
 a!
! Is il
C *> >, JJ
-S? n s.
=• S- = i..^
4> 'IS ^
N^% O 0) > 01 x^
SI IS .111
oj o .? x £ 2 3
S- V-- S. O O <4- W
*> +* O
W 01 CJ
u> CM u> CM m
*r ^
X-" S^

o o
o
0 0^
U)
m
_
CO
CM

= 1
CO O t0
0«j "
o o

o o


0 0

0 O
0 O
0 0

0 0

o o
CJ

O 0

in «J* IA

a


£
o
2 o
1 »gS
(U **- r— "O
> a* •*- 3
? Sgo
E eg fo u>
V) 01 4-> O
CL LU
10 en co en
* CO CO CM CM
i-) i i r»» i i
(0 CM CM  CM .CM
s** iw

CD
S - ° °
O
O 0
CM


(s. o O
rt

s . ° °
ra to o
ooo

ooo


ooo

ooo
ooo
0*0 O

o o o

CM
CM CM
0 0 !«.
0 0

0 O O .


si co S
^ ~" ""


u m
a 2
| | S
 °f2
IZ 9c -j
0 **?
$>? 01 0?1
ID CM ua r*. CM c\
S S"

ooo o o
OOO 0 0



ooo o o
'

ooo o p
• • O ' to
a o • en i*.
• • g «-i «»
3, z cn
OOO 0 0

ooo o o
1

ooo o ' o

ooo o o
OOO O 0
ooo o o
- '
ooo o o

ooo o o


ooo o : o
1

° * 8' S > S

, ^ '
CO •
? & 6 §t -2
-a a> *J <*- ** c
iO O t- CJ , 3:
« m *> s- o *w i
o a. tn •*" t- "c o
V> Dl
CO 4J
a> u 
-------











t,
.c
s
Ul
C
O)
1
1



•





If


iS









m
I
w>
e s-
al
CO
X
cj
CO
X
to
u
(O
X
to

to
X
u1
X
o1

s


w»
X

£
z:

=?

s
s

*
§
<
CO
s









5
1
u
tn
0
4
1

0 O



0 0

0 0

O 0
o o

0 O


0 0



o o
tn

U)
a o
r-4
1- 0
O
O 0
CM
d s
m r*
s



o
4-*
re
1
O ra
^^ lS<
w >» t- >»
*> "O Of "O
 i— 13
3 re t.  u' o TJ
O O tO •— •»- T3 OCC O O)
s. e s. e L. r— o a) .,- o •«- o TJ
t--jjj <^-rj 0 0) T3 tnus^ J- 3
era eto to «i *•• •r-cuui 0
H-< ^F-^m uiS* E e c tu'to'c '-S
1ao>» «o>» t->* - -2^S *^ w *o(? c;^^
£- *r- T3 t. V- ^ OJ *O in OJ Ut.O* O 01
&flj -t^ CL (0 +J O -+^ O *r~ C tA C3 O> t- (8 U) *i— 
NV> (O N (/» f— V) •«- E O* V>OQf MO.
> *i- > •!- U1UI£S «} W» H- £ -r- €
LU i— o> ui*— ai cnoi ui a. ra >oiut-«-> eora
(O Ul (ttV) Cut f- i— *F- ff ** •»» t- i. C 4^ _g 4^
4JU1V-- -PUtv^ .OS^- 0>LUIO OO.K-'*- Ul Wl Ul
3C ^ CJ X O U. O
* * * * * -K *
to CM «o r*. en o tH
O) rH f-l 1-4 fH 
-------
£ J=
&^3
*—
s-

o1^
*r-
X.C
2Txt
^~


N
O
O
04


5s
1 "
•fi
' & «
•-

C O
Q) O
L
5fo

is
^
|i

•t-
t?


Sg
o
o
St-^s
i— ^ c£
U. J3 O
WO CO
HSrH







e
o
•1
0) U
S- U)
*> O)
too
!
; »S5
QJ ,5 0>
sli
i »
r-t
m o o o o

o
o
T-^ O O O O
^
§.
O O O Q
cT

o
g 0 0 0 0
s s " ^ a

 >x^
^3 53 O^3 0*J3 ^^3
io Q) .en ci uj i~- 4) uj r— cu w ot
C « ^ ^ o

* CM CM * « * *
Sc^A B § 3 3


o d d d
•z. -z. •£


o d o o
3E

o ca o o
£


o d o o
: .

Z Z S£

O O O -O

00 0 O


0 O 0 0

00 0 0

00 0 0

o o o o


o o o o


r*.
0 O 0 O
d yi
0 O 0 0


6
O '•> •
d o ei • ' '•' a-1
35 SE • as
^


3 *m s- o ts
O W 1 O *O 0) C
(8 V) d > tj <0 "CJ

W ' J2 -2 01 Q. f-
3E c ^ il *ra c ' .5
i 15s lit! lis
(A U4 E H  .cum > QJ « ^-> E o ro
LU «) CT-fJ i— t. t. C +J _C 4J
MS £ ^" ^ w

6 i i a
rH rH rH f-(




g

C
c
1—
T3
C
ra
u
c
*
i
 c
* ;
*; 3 £
g z .
g u —
2 d 5
^ z 1
01 •- f—
S 5 f


* 5 =
*« §
O CO •!—
5U1 +J
01 Q
i c 1
•4J «t- .

_e o "" m
'« E °^
U >r> v* O.
^ w> 7
S "** )»JO
-P U 01 CO
3 | 11
tO Ul
U LU *•
TO It U
C " "
H* O 3
•K O
* -K W>
104

-------


Remarks3
i-
0 -Q
5
U. C
V) 0>
as ui c
• ui C
1 |l
u3 o o
g t°
J3 04-
o o
t"l
y &jr
g ; g|


til O
Ul f-l





(O

ui CX
tn ui
•r- 3
CM
rH
1

CM









t.


5
« in
CO 1
*
.c _>>
4J .
The blowdown is further concentrated
the kettle evaporators and subsequen
used in processed shale moisturizing



?'?

I** m


Ul
«£
T3 C
•r- (O
•521
COO
•o-o
II
"0*0
ui tn
Ul Ul
a a

c?
oo
2r>.
iH *^


t.
01
£1
0
CD
S
0)
-p
•Ul
J

•
s.
«-


g

§
5
r* o «*- in
O 1 1 I 1
CM CM CM CM CM
2.*""*


Treatment may be required if on-site
use as a fuel or oil upgrading is
considered. Also see stream Zl.



Q Q
Z Z








V
oiztn
O 1 1

^%
cn to
CM »-l
N-'





2
s
w
s
Ul
o •
^ .
CD

_J

S1
.3
CM CM
S


4-> 6. 0) fl>
• J= 0 13 ^ ^
E U1O1O WOI4J ..r*
n> V'^-jOr— >o>x: ,S ic:*»g 5^'S fc-
** "("CtftO1*- (U+'C^' OO1
u> *» si m j-iof-m c TS c c
CZ4J IT). r~ *r* >^0>IO <4-^-
w . (0 j-> -a d) o -o « u a) T- -n
•— >> 3Ecuiaii.>ait. <-»«f- ra
ot. o-o •ot
>i(0 S-EOJ atot. j=ofoa>o)
OUl l.t-+J3vi caico- o.s--u 3
CJ ^•£Z£.CO)J=aiUOCUI. v^^- £. o
C *>*-CLOWS Ul
s-4^ •as.uiui e.uaio cmm ais.
aio c j3 ui i »- ocn+>a> 01001^0
*;e . mw-i-c o<=«n>*J 4io)
C »^
>r-ul CM C4JO C CDCXIOO U4AJZ fflO)
_•'- — 0>C <*-^- r-Ou O.>» 05fi-*» g3.
C g O)O4>*r-7 ^*-.i*(A(O4^ S*Q< (4-73
 ^- <4-43o> *>  s- *> C3E-^3 >SOf-cr ej-^-ja •JSiDT-
Ul (0 f™ 3 at Q.*> 1 Ol 3 4O Ul
•>- ffl 01 at o -o tfi— aioiE-P3 oisTs. oiaic
f f- oi fccoi-r- x: w o a) o j=3u i-uio
1— 1— ui i^-^-ios-o t— u> u ^ •— h-_iui i— a u



^_: ^;^: °° -S-ICMI-I i oo
C3 O u O O O ^ 1 vt* to ' 1 ' o O

CMtn rt COVD-


Ul
u


i§
_ _ _ «o
SiS -o-a ^ S
OIL O1S» O) S- Old) '•• Dl fc
C+*r-"£+J^- C*»r- *O*O ; ^**I^
jo -r- 3 ro i- 3 m ^- 3 uiui m«r-3
U *° ? ^ S?33" ^ -^C/1 ,W .°* O»5K W)
oti pit 011 z x'a a ! o i i
[
*~* *~* /^ <-s
O> (** CM «*•
a o CM « •* «r r-C m TJ* o *-*
• O» CO O •*? CM IO O CO i-i f-4
zv ia co cotH co?-< i— i \~* t oo cr»



Q)
rtj cn o '
x: co o»
•»-> t. to a
f 1 1 s |
z o •" t5 ; s
S ** $ S S
uv o O
t ~ ^ fe I! **
* ™* ^ °
r— t^3«j ui aat>j
•i— 
O £_ • S
-»-> o T- *i— ^- •>- o ar
•= « .W • p> C5) 0)5
O1OS S. W fr. &.(/>(/>
•—33 3 3 M
-j --J. -j .. j -j ; s:
3 5; •*'in"co c^ "m
^** rH CO CO t*l CM 4C pH
-to \o i i**- i cn fit co i cn i
CM CMCM CMCM CMCMCMCM fO CM S CM
S S I*"1"* S . S
105

-------
a







(0
2
i-

E
OS



t,
J=
*»- "V,
o .a

I--
tn o
ffl Q.
o





w> C
-t-> fi.
c: at
OI U
c c
o o
fo

t»-
u o
.
§><-x
s.
u.
«
ui o
Ul i-{
s "*""'






£
CO

U)
O

Ascription
w
O
(O 0)
• (JJ _Q fl)
+* §S
012:  in

*£25
m
O CO
CMO
in co
|S
~"S •






^

t- £
Is
3 £
to,
s-g
£| .
•-•

z
O i-4 rH CM CO
* f* T-4 **• ^f «J-
i-t 1 1 III
•Cf CM CM CM CM CM
^^^^••*
JJ jc-o i u> ui
s^«l§J "s £ . J'l £s ^;-^ *j ui? a»Sjii "g "gg *£
"5 *™ ». 5>S °^ «*°§,t; ° *• *- *» ** 3 o Slo'fo sf "'^ s.
2_^B o. u o 41 to a. RJ -*J 53 o xai c
Q,*4J tn£.4^ O(Q34J U1 f— 01 i— 01*00)0) ff O) 1 §" *E 5 **"
oi ai e ^c S^SStr^^*0* c w »i— >>J£«A 0)5 t t;
m §* OC(Ot-3GJflJO O4>>**0> t . 4-> *i— 4t CO O) **~ 4*0) *p-

yj O E t (O CX. 0) *f~ tO O 4-* O rr* 0) r»~ *r« ^— (O Q) (U 3 P^> ^L jJ in
+* o o o> E ^ o ii*^- u >^ TJ »r- /~ f\ "Q p_ j* ^ r- ^ -j ry ji Q ,;,|
•5* s!tn'o(/)S^ oi»»-fi-^^- ^o^^"1 .Q" o»S3
W 0> OJ V> P1" "O +J .it *^ O O) Ul , "O ui 0) 4^ 01 Ul *9 tn C O *~ T3 • C
&" O. O 3£ -CZ +^  +•* Cn 1C <0 41 f~
5Jst§2—lT-. atpaitn-5 aiv>u -r- H- a-t— •»-  :

o o c .*•» i— *o *a
tn u» to t- 3 M to ,
^4J2 £ S*52 w wtn ^* w e> ^
fj^61* 2: CM*-* p**cn cotHv^ 3:
Og COr-T ^.
«J

 ai o 5 !•- 5 *^" 5 *"
tjr oi ui oa)a>oato
a> I-- ^- m O3cjO)O(D
s- ^-* a> w> t/j i*ZZ> cr*Z> s-\2> s_

« . . Q as == «U5>w
2SI12 comco u>co«o
CM I T T ^- U5 CO CO CO CM CO CM *
^- CM CM CM «f «fr- ^ CM CM CM in CM CM m CM m In
S*3"* S'*'* S^* S

E
1
u

u
1
i

«5
^
fi» O)
•r»
*— jro
w u
U)
•r— 0)
•0 J3



































m

0)
tn
m




                                     106

-------


*|j
CO
1
C.
O A
o ^ •
0)
tn c
tn o





ui c
P &.
c o»
o o
t"
0<4-
o o
&
°"u
3*^
u.
n
ui O
ui i-i
nj v-»
E

S
4J
tn
*^>
o
Oescriptior
ft. 2:
o»
SI "§i2
w>z"§


0)
j=
•p
s
Q.
1
to
a
P .
C Ul
tui
u
£2
Q.
-i
ii


i









i
i

tn
o
o
SMI*



TJ
u
<:
Phosphoric
cn
10

o
p
Refrigerated storage tanks are used
reduce the NH3 emissions.


.
O






tn
&.
* ,
2

to
00
CM
r^-
CM


at
O)
2
1
3
a
's
Anhydrous t
>a
eS-o"

a.
m t i
10 
n tn ui
§ a Q


00
to cn
m CM
co cn


o
jj
pped Condensate i
aporators (Case
£. UJ /•>.

'. re so o v** s. <*- Ul u Concentrate Evaporato sf S e re -P Ul 01 0) tn O CO §§ in rH Ul o *o c if •o-o o o U) Ul ui tn So tn CM CO cn m to co CO *f s« si 01 *S EO £~ "-£ Concentrate Evaporato tn * «r r^ CM S ^ The blowdown is used for processed shale moisturizing after equal izatioi with other plant waste effluents. tafia w « 'o'o VI t/> "S"S 8IL tn tn Q 10 S S S Ul 0) *o CQ e to 01 •P c m « ^o The sludge contains approximately 20! solids by weight. It is used as a source of water for processed shale moisturizing. §'• ' IO cn at D) 1 -*1 ^^ - m O r-4 r*- co * |J CD-P •o tn ' »- ot tn tn (O at o •K o 00 l| o> o Ul U

0) O) C T3 «•- 01 € U> tn T3 0) *— e CJ <0 cj 2 a 2: cn 3 tn .1 a. -P 10 E- £ S. •P S * 107


-------

























,-,
4->
0
o
«M^


m
A

*
a
S







































ID
1
m
i
as




•si
c> -

u. c
0}
M C
M O
S g




M C
4J &.
C 0)
(U U
C C
o o
t"
3-S

£-




U-
M O
M rH
(0 s^
**







S
4J
V)
O
•C
o
CL
U
Ul
Of
o
o

(Q (U
fc. 'g p— .
4-> 3 .0
V) -Z flj
fc"
5
t. c

It} Q)
<1J 3
c cr
•r- CD
S S-
II
S*o
s- o
-)-> U

(0 CO
^0) CO

fd -a £!
P- 
r-.*- V>

1 1
1 i















1 1
1 1




a a





^
a>
Ul >
as o
01 u
,c ce
3
•i- ^
ai .r:
1 f
at at a>
4-> > 4->
fl) O (0
oice cn
c: c
oo o
5 3


CO 00















CO
E i
as
4-*
M
0}
V>

I
1















1




O









^J

5
Ol Ol
OS C

M £
t- £
at re
4-» V
re V
3 v»
0) t-
r


09















S
m
as
2

Ul
tu
(O

1
















1




a

2:







s

i
M
S
a.
5
£.
«
01
1


00




£
•r*
s*


gat
. +J
•r- t. rtj

ai c


o
TJ O U)
CUM
•o'j!'2
_0)  Ol
"32
a> a.
H- »p- S-

,
















t
i




tn













4->
(f-
S. x^
cn a>
£$


•K







a.

1 .

Ul
4J

at c
M 3
«g
«
03 CO
a -i *"


at o) -M
oi .c nj
vi H— 5

i •
1 O





M
JO
"O r—
(0 V>


S-S
•— C
O Q)
ui a,
M tn
: s^





^f ro
rH O
CO CM


S.



v> a>
>-» »F*
E <*-
W -p- ^-\
01. -a 
c: f- ui o r—
•r- S nj TJ O
|i5i 15
5 m

«
cn o
03 O>















8

re

M
a>
V)

,
o

sr



u*

"O P—
c o
as vi

TO -a
§•§
r— C
o at
M a.
M M
O t/>




(TO
rH
cn







s-
a>
r-
O)
c
Is
If
f"
O u)
1"

•K
rH
cn





•o
C .
as £

C Ul

Ul Ul
in fls
•PT
s- a»

+-> o
(d **—
0) T3
v a>
N

p2*re
o a>


o
M
O


evi
on
CM


8








£-
as
to
u.
a>
"5
CO
•o
h-


CM
cn





c
•P O


g .2
Ss. re
o a. a>
ui 4>* ai P—
ns M as
o > S u>
fc< M

4^ M *P- U
.2^° 2
S§5a
OP- t- .
(j 0,-a o o

Sfi= (Jt3 N
10 O) at >r*
(0 «^ yi S-
3 4- J3 n z:
"«^- 3 4J
M O Ul C M
J= 3 Ul J= O
(— b f- 4J E


Ct

Z



M
•a
TS ^
C O
tO V)


S3
»— c
o a>
Ul CL
tn M





rH
cn











at

•g!
Ul
M O)
at c
U •!—
2§
a. -P
u>
fi
-j

•K
ro
cn




p!L
O • T3
o c at
U S ui

:l 2 c ?
O) O <0r O) *r-
01 S ^N 5 *r^
%— ' at t.
S.+J - 3
Ul Ol Oi 4- 4J
c ^ U .2
3 ,a c o g
*— 0

<+- c -a U P— '
5 t. a».e
ui "a at ui
ui 2 c £
UP— o>p- at

at s- at u

.s^-g-s0-
I- 0?i4- 3 £-
 -p- ui at H-


a





Ul
•o
*o «—
c o
re 

•a TJ
II

o at
M a.
M Ul
•P- 3




§'
•
O
rH










I 5.
||J
o c in
CL -S 0»
*j

•K
s




.
I

c
4.
•O Ul t3
o> 3 at
u> "O ui
3 3
Ul > M




i- i
§« g
*E W *E

•OT3 TJ
«(— M *("*
4- Ul H-
•r* at *i~
^ s ^
r- £. i—
o a. o

i i
t i





'









i i
i ; t




m to
cn ; CM
* \ co









c
o
U) +J
3 fO
O •!-»
a> s- cn
r— O) Ol
« rP >
f re at
v» 3: C£
-b»- s.
at o o
M t. H-
s^ ».
83 5
ot S


S S?




108

-------
a

















f
O£

i.
<*- v.
0 .0
s1"
O *
C =
o>
(A C
(A O
It
O
O



(A C
•H> S-
C 01
Ol U
c c
o o
tCJ

« „
o **-

8*S.

Lt_
W
(A O
(A rH
m_




1
•s
c •
s.
o
o
B S-Z
m oi
o) ja o)
55 z"§
*-

0)

10

f— tA

U 0)
•f- (A
Ol (A
O 01
*0 0
!S o.


, *"
&.
§,-:
.352
 o> o
T5 10 +J
at a» u»
Ol S- 3




o
z











,
o

z
r*.
CM






S.
01
1
reated Sanitary
i—

.«
8


^fi-
ll- at
R) N




(A t O)
tJ  at .
ai  at .
m > at
r— Q)  "O
+j O)
(A C
rf
r^ S.
TO
fl
o) at
•i— (A
X 3



1 '
t














1 ,
1
O

Z




1
J=
o.
s
1
<*-
team Condensate
Recovery

tA
0>
Of



|
1














1
I
CM

OT



^
nj
tn
O
tC
CL
I
team Condensate
Unit
i/)


rH
S



















i
tA
at
at
V)



i















i
i


**i
m





Is
(*. o
team Condensate
Kettle Evaporat
to


1



















0
o
m
(A
01
at
V)



1
1














1

o
CO
rH




S.
«*£•
S|
§e
to
<<_ HI
team Condensate
Retort Water St
to


i



















o
o
(A
at
at



i
i














t

0

2=





1
|
<*-
team Condensate
V)


o





c
+J O)
C E
at a.
at 3
a a>

5 J:
"S c
•P O
(O
Ol tA

+J ««—
(A O
•r- tA
S-M-
f!




o







Ul
o
W)
73
>
"3
U)
u>




00^
«-•



U)
(-4
It
(O V)
!- tn
O10>
•r- O
o



s







3: s-
o
a>
N-O
•r* 0) •
r- S 0)
«J 3 C
O) C °r-
m t-
tA 3
•i- (A *»
*> (A
C C «r-

!a ^=
•SJ tA
§a. 
Ul
U) ffl
SSi
§£
s- a>
i^. ,—
O
§o
O
T3 S-
2^
S


GD
o
rH


^
at
N I

r- 3
S4J
TA
aTo

t Q}
(O r-
(O
(A J=
a) T3
3 at
r— (A
**— tA
tf_ at
O) U
IA ^
gfe
10 a)
3 Ul •
_O 3 Ol
« = N




a







CA
•o
^?
(0 IO
T3 -a
at at
o at
tA a.
tA tn
•f- 3
a in

CO
CO
rH*





at
Si.
urgi Processed S
Moistening Wate
(Case Study B)
^


o



















i
I
Ol
Ol
to




a
z






1
o
t/)
•o
ai
o
(A
Ul

O




t3
S.

I
/-N
sm
3 3
|§
01 ai
c u
^2
o a.
o
0


I


















:f
§
Z
(A
Of
O)
V)




o
z






(A
c o
(0 V)
V ^
at at
> "O
Sor
a.
tA (A
i- 3
O 
O
CM


I

<+-
Is
If
O t/)
H-
•+J O)
at IA
t. to
*^o
ll
•§_!.
oS
eo


at
S


tA



O>


5
a>
c

'E
1




o.
4» _f»
E.
ai a>
.C (A




i















'i
rH
r-


•o

«£

oS
3 3
41 4-J
^ t/1
(t)
E at
(A
tA ai
tA U
o ai
o.


s



















1
tA
S
V5




1






t







|
1
00
CO




T3
1
4J
2
•*-» /-N
t/> CO
1%
fi. 3

-------














<0
c.
i



t.
o'i

o -
r*» +i
U. C
at
tn c
to o
3g E
CJ






4-» t-
 3
t»- H- Ul
«~*j
•C C flj
|_ Q 2






|
]













1
1





S









c

&. *"^
a m
If
£ 5?
O) 0)
C Ul



s


£-
O



Ul *
3 (A

ui a>

t.
Sfe
*«

J*

•P (0
(0 u>
0)
*1
a. (O
O -P
s- o
Q. P*-






,
f













1






en
CO







5-
» !"•

(0 J=
Ul
**- "O

to CD

o» **- to
4J«*- «
112
« t- Q.
O)
o>S<£

55"S
the processed
is collected \
iventually rei
loisturizing.






i
i




o
Ul *•-•

X S
V) O
t3 T3
II
O O
tn ui
Ul Ul

00





o
3=






"S
in
in
V
u
2
O.



CM
CM 1
CM CM
r-i «





Ul


3

CO
1

5

1
1
•o
u
01
ex.
Ul
0)
Ul
o
f
^

(13
tn
I
2
«
5
5

^
O)
TiL
o.
rd
in
•P




ra
2
**
*> -o
c c
CZ U)
O i—
•si
c c
J S i
^c *~ 8
"5 <= o
0
•M •»- «1

a £ c
4-> Ul O)
CO C
u  C *»
to u *E t>
S ~£ £ "i
S- «r- 0) •*-
** ^3
u» in *—•.
oJ m ° '
•P e 4-> ^*^
« 35 o n ui
o £. o> 01
I if 2 |
* (o ja o















01
""*
^
£.
a.

-------








STREAMS
1
S
P
1— 1
trt
o
i
^
i
i
















^
JS
iponen
3





£
C
p-
U
u
u
1







i
I
4-
(/

£ 1
*•> =
(A 2!
3


U)
U
C
I
«
•3
l/J
O
h-
tn
•£
«
31

S

!
!» U
".a
f l«-
1






C
o
*+»
;u
u>
01
1 O

i
^
1
o o
o u>
CD r~l
SB
f*m
Q
z


ei
z

z
a
z
a


s
us"
*






i.

«
I

CM

o; | « <=>
s

O CO O CJ
z i °. z
s

• CO
or* oo
== K

00. 00
•z.
a ° oo
z
o o o o
z


CM* C?
o o o cn 10 o

E.
0)
•^
o a> R)
co cn JT
(0 -*J
*• • & €
or +j at
0) O O
3 « w
1s £ I
nj E O J<
if $ *&
3: *5> is aJ

^^ (^ O ^ ifj ' ^j«
«in *CO«Ci-«T«fr rH
co i o t i i i «f i m
t-tCM CMCMCMCMCM CM CM CM

000 O 0 00
O <* O O O
O CO O ^ ^
* • A B
CM iH O ^
CM
§O i-t O 4) CM CM
o *o VD -a r^«?
cn f-» evj o c f-. i^-
CM <* <^ in CM o
S • S co s r-t
CO rH 0)

0 0 CM 0 0 00
J 0 CO CM
»H
O O O O O O U3
IO CM
CM
0 0 «* O 0 0 CO
O) PN. yi
i-T CM
0 0 tO O 0 COO
r-i «» in
in^ r*. co
CM CM O
m
O CO
J"J *^* ^N i1™1* CM CD
cn p«. CM ^j* m co
Cn O ^3 *3* CM VO O CO rH r— 1 II
VO CO CO r~f • CO M r"t ^^ CO CO O in
«r-l
t-4 (O
fl)
Ol
01 ' o

Rj cn t/)
t nj Q)
Ok. 0 01
+J 0 4J (Q
t/> ** J_
V) ^J Q ,^v
o o *» e
*» O 3  £. X
•r- ^- O CU  -M fc-
O) O) O) O) rf
^ g & ^£22^

*? ^S ^SJSS SI « S «SS5S!3
CMC!J RiAi S«si mAi « N N i cv

• i
Am
O *f
in co
to r*»
gg
'*
i
CM 00

£o
to cn
d
^3

0

|to
<0'tn
»-* CO
co cn
CO,!-!
r-i m
1



1
nj
*?
O-S
•^>' X
S£

•2-5
t. s.*
4-1
1
• co ^ in
,-*•*«*
i
o o


o in
z *
m

o o

o o
0 0

o o


tri
a cor-'
z SS





§,
£
5
S

-------
                    s
                                                                     58
                                                                                                               CM        tU      to
                                                                                                               CM
                                                                                                               co
                                                                                                                         r*
                                                                                                                         CO
                                                                                                                         m      tn
       58
       §
g~
   cn


gg



COi-T
tn   to


o   CM
Ga
                     S
                    1
Stretford Pre

(Case Study
                              Si
                               30
                                              _ _

in r«» co o» ;
^ s« *


3 °

3 5 =
to at I

at a* ,

<_) +J O •!->
l|* l|°
Zul z"isl
*; « *» 
5


It
"S
« V)
CM CO
cn in
to co
t
o
(0
&.
o
Q.
to
s,
0)
s


I?
"1
a in
          co t
                       S5S
                    O 1  1
                    Ul CM CM
                          j
                          a
        «>cn
        coco
        ij    coiiii    «riiii    mil    *o t  »
        CNJCM   lOCMCMCMCM   (OCMCMCMCM   (OCMCM    IO CM CM
                                                             112

-------

















•g
o
U
2

ui
0
JS



























j=
^
in
*>
i
o
















r



!







•4
C

g
3.
£
vi ;
o
CM
n:


u>
'c
m
O)
«.
o

V)
h-
«o
t/»
B
VJ
X

Z



04
S


IT
.^
1^

o
1 r-l
3
I




£
+J
1?
U U
- u>
J 0
o a
o
-•z.
IS
*l
§§

S"


o




o
Z


0

O




o




to
s
3-
,rH



£
01

O
CO
§
s
1
e
1
m

*
S

o in > • • in o o in ui o
- Z Z Z - - ."i ™. .
tn«? p* in CT to en to
m ID in r-i in *f «•
m i-t m o **• 1-4 1-*
iH rH1

OOO OO OOO • • •
a o a
z z z



§oa oo odo a d a
zz zz zzz z zz

(O
.0 oo oo ooo o o o

o oo oo ooo o o o




O OO OO OOO O 0 0



^
m t CM
OiHcno oo o tn o co cn csj
l-»mc\J. .. . r-l rH CO rH t
to •* ro z zz z r-i o cn iv.
^ CO* OJ* CS1

/-%
^ * fi.
U> > +J T3 » < Ul £.
*" ^ S aJffl « |>i « |j OJ-0-& §o o-a* ^
T3 (/> £- 3: U 3l S V> 3l r- ^ *f- W1 M V) CO
3 O 0) *r~ C fi. tf
t/jtn c c jro) c c n f- u> or— o V) a)
(DO V r-*r- t— i— (0 r— ^ f— 3 O SO SO -» -P oo o o 3: o o o 3: *-•• oo o *—> o>
•r- too oo ooo ,— p- t.
— 1 3tO OO OOO CO CO 1—

* * « -K -K
ocMco ^-in lococn o r-* «M
co TO co co co co co oo QV cn cn



s s ?
m csj

ooo
z z z



dap
z z z


ooo

ooo




O CD O





rH CO CO
cn o cn
t-* 0 •«•
r4*


S
^
3 !
 03
fl fl p
_i _j a.

* * *
cn «*• m
cn cn cn



CO
iH

d
z

t

0
z

i
p
.
p



i
0


(


&
CO




1

c
o
•*->
D)
g
0)
t-
o

1

•K
a



CO
rH


d
Z



d
z


0

o




0





K;







0}

£•
5
'e
«
1
|

*
00
cn

d
z



d
z



d
z


o

o




0





d
z




•1
v>
4->
S
1
to

>«•
t.
0)
^»
s
ra
V)


cn

d
z



o




0



o

o




0





d
z




(0
1
a.
at
Z
I
H-

U)
-1
C
0
J«
V)


o
s

113

-------













«••*
4J
C
O
U

2

3
§
















1
j»
§
E
s













I
•
<
»•
u
(J
b
(i
a



i
*
.<
j
4-
O"


U
••sJ

o
CJ

U
c

«
"~
faO
o


z1


n
yr




^
W


F^
!"



Description


*-N
!<
i xt
=£

o
o
o
to
o



o



o


0





o



cn


i
w
o
JZ
a.
I
Steam Condensate t
Unit


I


g
o
m
o



0



o


o





0



in"



V
1
Steam Condensate 1


Csl
S






























Evaporators





o o o o
goo o o
tn in in
o tn o) cn
0 ° d d d
si z z


o o d d d
Z Z Z


0 O O O 0


O Op O O





O O O - O O



O d 1-4 CM Ol
co . rH cn e*>
ri z co_ r» tn

i W
J; * C
Q. LO 61 4->
VJ •»- Q 3E C -2
»-« fc. eg (-^ T- /*«\ o
s 4-» u. oca -a QQ £
e *" E **>» 'E >» com
os o a. -a ^"§ 15 >.
4-» 3£. t/t (/) re 1-4 4J
4-> 4-> 3H 3* 3£ O "O V>
nj t (D gi wa)
w a> w s- re Em w» «
"a 3= -o jo v ^ u o
c c 3s w IA o *— '
o 4J o s- e s- k
us- o o> « x a) a. S-
O C »~~ O T— • 01
So: a» *o o oo 1*3
4J 0 ^- 3
V> t/5 
4-> S 4-> tt»
v) ar >» w» s. a>
^-s T3 ^s 4^ ^s u> at
-»j &.4J4J o &- t- re
^» o */i >» E >» v-* 01 a» • JT
o -*J QJ tn « 4-» <*- 4-» *t- 3: ^ v
re 4J o re o s- >t 4>
E O (/) **^ 2£ 4> -P 0) C3 S- fc. -- o
&-re s wi £_re u> «i b.-»JU- re
^U 0 fi- «^ C^ OJ *- i^. j=
n> '^ <»- f— "re*""' -S **^ "re re "c *o ^^
3 tn o 3s w c: tn 3: to re c*a,
tn c o wow "^ 3 «
O) 0 ? U (A 0) CJ O D) 0) 4) *y yi
CUO WO O C f— U - W
^o -o^ oto 60 -r -Q •?• s «
§*~ a- o*< o a. ai a. 'o 4^ It o o
*— &. 4-1 OO(D4^&.


CO S, 0 rH 5-1 5, 5> & S,^
s s s 3 22sSS~.
























C
O
>
5
4->
f
contact wi
o
4J
C
U
1
i
|
w
w
a
re
u
•Q
c
i— i
«


















JO
rH
C
5
w
u>
I
I

^
3
•Q
S
re
a
w
UJ
II
o
1
1
»

I
H
2
«




CO
s
p;
1
-
3
O
"re
x:
8
£
C
1—
•a
re
u
5
aT
1

1
T3
8
O

o
o
_!
c
o
w
!
0

-------













t/)
i
n:
i—
a
!lj
s
W-
0
Q±
o
1—
1

z



iri
(H


Ul
S
1—
































Remarks3



^
"*- *^

|y
u. c
-O)
ui C
ui o
£ E
"



ui C


Ol U
c c
o o
0.0

o **-
u o






S€
C£

(An
Is





£
ra
o>
^
4.
o
c
o
4J
Q. '
U
Ul
01
a




llf
4J §S

Ji—


4)
£U
""Si1
§.S^
Oust collection and suppress!
employed to minimize the part
emissions from raw shale hand
operations.






o
S
o






Ul
ra


u

j.
ra
Q.






en
CO
r^

tn



Ul
4J
S
o
'd±

'5
=

S
tu

m
g
o:




5.T
CM
 f—
o to a
*£*"
£.£ 2*5
The processed shale is proper
moisturized to reduce dust em
Proper compaction should redu
permeability, hence leaching






u
00
Z Z




Ul
**
ui ra
Of V)
ra o)

3 .Q
u to
4-1 U
s- ra

Q. _)






m
".


r*. i i t
f-H CM CM CM
«r *r «-r


c

o
TS T3
rtJ S- jQ
13 t- O)
01 4-> C O>
Is I5
u> 01 S
*^ > «-» O) .
•— o c ot
•f E « O r-
o ut *•— r— ra
i. ra jz
> O ui ut
jr -a v -2" 5*
0) Ol Q. U>
>> OJ J= O)
4-1 3 H> 4-> U
U) V* *fr- O
H- U "O 4-> 4->







1
1




^_
O
>>
ra


o>

o
0)









P*.






e =
II
T3
4J >
.c >
t/> (0
01
T3 3=
01
tA O)
0) t-
U 3
g-1
Q.




O
CO



Ul r- O C
•r- Ol O

*- -*J ra c 4J
O W Q. •*- CO
o o> f c
a 4J ra . jc u T-
to ot IA •*-> ra e
*j o_ s- c c at m
The raw shale quantity is tha
necessary to produce 69,000 B
oil. Total raw shale in one
approximately 533,000 tons; i;
of retorts, it is 51 x ifle to;
Groundwater infiltration into
rubblized retorts may cause V
the soluble material and cont
of the subsurface waters.







J














i








00
o

m
f-i

w»
t
o
Ol
cr



c
Ol

en
•o
o>
tot
|
°Z




•K fO
m i
CO 
Ul
3 <4-
2 °
Groundwater infiltration may i
leaching, hence contamination
natural subsurface waters.







Q
z




Ul
4J
cn


^^
ra
JZ

ra
O)







rH
CM

rH
»-t .

^c>
O>
U
ra
Q.
i
c


01
"ra
j=
v/l

Ul
Ol
u
1
2
s




4C tO
UD i
CO CM




Ul

Ul
Ul
ra "c
Ul 01
o en
-ES
4J JT
O
4J Q,
•b
11
U) O
•f- .4J
'f U)
4-> 01
Ul U
U 0.







1
1















1







f-t
Q












3;
o
ra
z

u
Ul
3
ID
0




S




o

c
i
01
£^
Ut
SO)
U)
Ul
T3 O
•s-
•a 01
"5
Ul
•r- S-
O
It
Ul







1
1















1







ID
CM
(A


^
f

01
Ul
to

*~*
o
£

O
01
c
s
Ul
01
E
-4




T-t
00






, UI
**-
y-
3
specified for the Cathedral B
0) .
Ul

, 4->
O)
s-
ra
1

Ul

jr
; s
TS
01

1
ra


, =



0)
S-
4J
4-> C
c ra
o> '
E (A
t£ 2
> , c
C • O

;
1 1
J= ( '
•»• . c
2 o
U -r-
ra vi
4J 0
c . a.
O • tA
0 •»-
• -ft
a '
= 1


(j ci
*. , 5
ra
ra
! '€
2:5

Ul : Ul

Ul 5-
ot ra •
*J £ 4-1
ra at u
o ; s- a>
1 ; J?
HI H- a.
•K ra




tr-4
S
H-)
I"—

(_,
,§•
„

d
o
£
o
£
ra
v»
o
s
c
c
0)
(Z
1
fO


c



J"»
ra
-.C
V)
1^-

o

ra
4*>
-a

t- u
u o
S 0
H- t-
O
c
tA O
C +J
01 ra
§ g
D. O
= 'ifr-
1 e
o «^-
c c
2 O
C "O
Ul
§ra
A
•o
01 CU Ul
4-> c a>
ra *- 4->
•" 1 §
C 4J 4^
•P> O) Ul
•o oi

1 *J M
i o ce
v-* z a
3 " ..
£ • ai
VI O U
ra • f-
^- Z 3
O
J2 (J to
115

-------














tA
1
as
o
8
u.
o
u>
1
r-

i
a
i
0
o












'


o
cl
3:





0







z




o












i ^
* J:
c^
V)







Stream
Description


.
iu .a 
O O O






a>
O CO !>.
s
»

o>
e •?

a -a
1— • +J QJ
(Q IA O
t/} Or—
'"g r?5
-P 01 to >t
vt o» .c >
3-a> 01 re
o u aJ
O "O 3S
tn O. tn i-
3 in O)
0 -r- ® t.
J= O) U 3
n? 3 E™1
CD -J o!



* •* -K r«. co cn
CM t r*» i i i o
CM rH CM CM CM CO

a>
I
•i~
>
c
0
1
+>

3
+>

c
0

o
i
o
u
re
4J
tn
i
0)
s.-
U)
U)
re
u
|

•K


















5
o
U)
.c
u
JT
2
s~
£
3

^
,2

4J
a.
0)
u
«

to
1
0
€
<4-

C
O
•*~

o
(J
I
f
$.
o
t
o
2

1
r—
UJ
(0



































,/*^
JD
rH
C
re
5
tn
U)
a»
••— '

4^
1
C
Ul
C
S

1
_E
I
IA
UJ
II
O







rH
3
[*r-
&.
•§"
-
O
U
L
o
V
o
u
c
c
:,2
'c
10

u
c
1
aT
re

no
r-
o

O
T3
;O
^
I
V
'C
o
4J
re

-------
4.2  MAJOR STREAM COMPOSITIONS

     Since  this manual  includes  two different  retorting  technologies (MIS
and  Lurgi-Ruhrgas),  two  different sets of data  were required for the analy-
sis.   Data  on  the  MIS process have  been published  by Occidental  and others
based  on the  burns  in  Rooms 3E, 5  and 6  at Logan  Wash  (Loucks,  November
1979).   The  retort  sizes  and parameters used for  retorting  in these pilot
runs were significantly different from each other, and different results were
obtained.  The  rubblizing  and retorting technologies used in the Room 6 burn
are  proposed for  the commercial  operation  at  Tract C-b.   Since  the shale
grades at Logan Wash and Tract C-b are different (15.6 and 26.7 gpt, respec-
tively), a direct extrapolation of data from the Room 6 burn to Tract C-b may
be  difficult.   At the present time, the only information  available for the
MIS  technology  is  the Logan Wash data.  Currently,  Occidental  is processing
two additional  retorts at Logan Wash, but the  new data are not yet available.

     Data on the  Lurgi  process  have  recently  been  published  by Cathedral
Bluffs  (Occidental  Oil Shale,  Inc.   and Tenneco Shale Oil  Co.,: April 1981)
and  Rio  Blanco  (Rio  Blanco Oil Shale Co.,  February 1981).   The information
was  derived  from the pilot tests performed on the shales from Tracts C-b and
C-a,  respectively,  and it  appears to be more accurate  than previously pub-
lished information.                                              ;

     Due to the differences between the two retorting processes, the products
of  retorting are also different, both  chemically and physically.   Theoreti-
cally, these differences can have an impact  upon the selection of a control
scheme for a specific stream, but the  streams from  the MIS process are much
larger than parallel streams from the Lurgi  process.   Hence, the selection of
pollution  control   technologies  is   determined  largely by  the quality  and
quantity of the MIS streams.  Whenever possible,  similar streams from the two
processes  are  combined  at a  convenient point for  treatment.  The  Lurgi
streams, when combined with the MIS streams,  have only a negligible effect on
the choice,  cost, or design of the treatment technologies.

     In  the  following sections,  major streams generated from different plant
operations (see Section 3) are listed along with their detailed compositions.
Material balances  for selected streams (both before and after treatment) are
also presented.   When detailed information on stream compositions or perform-
ance of a control technology was not  available, calculations were made on the
basis of engineering analysis.

4.2..1  Material Balances

     The material  balances  for the MIS and Lurgi-Ruhrgas retorting technolo-
gies .are presented in Tables 4.2-1 and 4.2-2, respectively.   These balances
have  been  estimated  primarily from  information provided  by  Occidental  Oil
Shale,  Inc.   The gross product flow -rates,  retort  gas compositions,  etc.,
from  the Cathedral Bluffs  PSD permit application .were  used as supplemental
information  to  obtain  a closure  on the material   quantities  and elemental
compositions  (Occidental   Oil   Shale,   Inc.   and  Tenneco  Shale  Oil  Co.,
April 1981).
                                     117

-------
             TABLE 4.2-1.  GROSS MATERIAL BALANCE FOR MIS RETORT



Material In                                       Flow, 10s Ib/hr

Raw Shale (in-place)                                   15,083    ;

Steam to Retort                                         1,750

Air to Retort                                           6,508

                                 Total In              23,341
Material Out
Processed Shale (in-place)
Retort Gas
Retort Water
Crude Shale Oilb

Maximum3
11,432
10,998
0
911
Total Out 23,341
Average3
11,421
10,398
611
911
23,341

  Maximum  case is  when the  retort has  reached operating temperature and
  there is no moisture  condensation in the retort.  Prior to that  time,
  however, retort water is produced in the retort.  The quantity of retort
  water gradually declines from a maximum value of 4,520 gpm to zero as the
  burn progresses.  The amount of retort water produced is averaged over the
  entire burn period to yield the average case.                  >

  The crude shale oil quantity amounts to 62,040 BPSD.  An additional
  6,960 BPSD of light oils are recovered later during the retort gas
  cooling, for a total oil production of 69,000 BPSD.

Source:  DRI estimates based on information provided by Occidental Oil
         Shale, Inc.

     Table 4.2-1 represents the gross material balance around the MIS retorts
only.  The  raw shale quantity shown  is  that retorted per hour  to  obtain an
oil yield of  69,000 BPSD.   The actual quantity of shale in one retort, after
creating the  void space,  is  approximately 410,000  tons.  In  the commercial
operation, 96  such  retorts will  be processed simultaneously over a period of
about 220 days.   The  average  shale grade is estimated at 26.7 gpt by Fischer
assay, but  the  actual  oil  yield  on retorting  is  16 gpt  (60% of Fischer
assay).

     The  material  balance   for   the  Lurgi-Ruhrgas  process  (Table 4.2-2)
includes the  flue gas discharge  system and product recovery.  The balance is
based  on a   production  rate  of  48,000 BPSD  of crude  shale  oil  (naphtha

                                     118

-------
included)  from  32.7  gpt  raw  shale  retorting at  100% of  the  Fischer assay
yield.   Air is  added to the  Lurgi  lift pipes  to cause incineration of the
residual  organic matter  on  the processed  shale.   The makeup water  includes
the  amounts necessary  to cool  as well  as moisturize  the processed shale.
            TABLE 4.2-2.  GROSS MATERIAL BALANCE FOR LURGI RETORT

Material In
Raw Shale
Air to Lift Pipe
Makeup Water*
Total In
Material Out
Processed Shale (with 10% moisture)
Retort Gas (naphtha- free)
Gas Liquor
Product Oil
Naphtha
Flue Gas
Total Out
Flow, 10s Tb/hr
5,144
2,498 !
1.111 ;
8,753 i
Flow, 103 lb/h*>
4,343
154 :
167 i
584 !
34
3^471 i
8,753

* The makeup water includes 677 x io3 Ib/hr for processed shale quenching
  and 434 x io3 Ib/hr for processed shale moisturizing to a moisture content
  of 10% by weight.                                              ;

Source:  DRI estimates based on information provided by Occidental Oil
         Shale, Inc.
4,2.2  Raw Oil Shale                                             :
                                                                 i .
     Preparation  of MIS  retorts  requires  mining  approximately 23%  of the
shale  to allow  for expansion  on  rubblization and  retorting.   This  mined
shale, along with material  removed from connecting drifts, is then processed
by Lurgi surface  retorts.   To take maximum advantage of the higher oil yield
from the Lurgi  process,  the MIS retorts are  located  in a manner that allows
richer  oil  shale  to  be mined  out for the  Lurgi  process.   Thus,  rubblized
                                     119

-------
shale  in the  MIS  retorts  averages  26.7 gpt,  while  the shale  feed  to the
Lurgi  retorts  assays  about  32.7 gpt.   Since  actual  chemical  analyses of
these shales  are  not available, the  published  analyses of various grades of
shales from the Green River Formation have been used here (Stanfield, et  al.9
1951).   Compositions assumed for  the raw shale  for MIS and Lurgi retorting
are presented in Tables 4.2-3 and 4.2-4, respectively.   The moisture contents;
for the two shales have been calculated from the material balances!
           TABLE 4.2-3.
COMPOSITION OF RAW SHALE IN MIS RETORTS*
        (Stream 35)

Component
Raw Shale (in-place)
Hydrogen (organic)
Moisture
Oxygen (organic)
Nitrogen (organic)
Carbon (organic)
Sulfur (total)
Weight
Percent
100.00
1.52
2.40
0.88
0.35
11. 95
0.63
Mass Flow,
103 Ib/hr
15,083
229
362
132
53
1,802
95
Flow,
103 Ib-moles/hr
—
227
20
,8.3
3.8
150
|3.0
, , - . ... . '. -
* Based on 69,000 BPSO crude shale oil at 60% Fischer assay yield with
  26.7 gpt oil shale.
                                                                   i
Source:  DRI estimates based on information from Stanfield, et al., 1951.
          TABLE 4.2-4.  COMPOSITION OF RAW SHALE FOR LURGI RETORTS*
                               (Streams 1, 2)                      j

Component
Raw Shale
Hydrogen (organic)
Moisture
Oxygen (organic)
Nitrogen (organic)
Carbon (organic)
Sulfur (total)
Weight
Percent
100.00
1.85
2.72
1,03
0.43
14.41
0.80
Mass Flow,
103 Ib/hr
5,144
95
140
53
22
741
41
Flow,
103 Ib-moles/hr
--
94
17.8
i3.3
il.6
62
H.3

* Based on 48,000 BPSD crude shale oil at 100% Fischer assay yieldjwith
  32.7 gpt oil shale.  Baghouse dusts are included.                ;

Source:  DRI estimates based on information from Stanfield, et a!.* 1951.

                                     120                           ;

-------
     Raw Shale Leachates—

     Recently, some  literature  on column leaching of Colorado raw oil shales
has been published (McWhorter, 1980).  Although the quality of field leachate
may  not be  identical  to  the  leachates obtained  from  laboratory  leaching
columns, the results from this reference are presented in Table 4.2-5.

4.2.3  Processed Shale

     Proper  rubblization  of the  MIS retort  is  very important  in  obtaining
maximum  oil  yield  and uniform  retorting  throughout the  retort  (Ricketts,
1980).    Under optimum  conditions,  approximately one-half  of the carbon  in
the  F:ischer  assay residue  remains  in the  MIS processed shale. , Due to the
high temperature  in the  flame  front, the residual  organic matter  is coked;
therefore, only  minor  amounts  of organic hydrogen,  nitrogen,  sulfur, etc.,
are  expected to  remain in  the  processed shale.   The composition of  the MIS
processed  shale,  as  obtained by the material  and  elemental   balances,  is
presented  in fable 4.2-6.   This  is  representative  of  the  expected  composi-
tion.  The mineral  composition  of the processed shale is not known;  based on
the material  and elemental balances,  the carbonate decomposition is  estimated
to be  about  40%  of the available  carbonates.   Information  on  the  physical
properties of the MIS processed shale is not available.           >

     The  composition of  the Lurgi  processed shale,  also  obtained   by  the
material and  elemental  balances,  is  given in Table 4.2-7.  Due to burning of
the processed shale  in  the lift pipes and extensive recycling to the retort,
residual organic matter is  very low.  The moisture content is that  resulting
from the  use of water  for  quenching and moistening  to  10% moisture.   Major
inorganic elements  in the  Lurgi  processed shale have been determined and are
presented  as  oxides in Table 4.2-8  (Woodward-Clyde  Consultants,!October 13,
1980).    The  carbonate  decomposition is  determined  to  be  about 30%  by  the
material and elemental  balances.   Some physical properties of  the  processed
shale also have been determined by Woodward-Clyde Consultants,  and they are
presented in Table 4.2-9.   Due  to partial calcination in the lift pipes, the
processed shale has good cementitious properties.   The unconfined compressive
strength, at  optimum moisture  content and curing period, is high and permea-
bility is very low.                                               :
                                                                 i
     Processed Shale Leachates—                                 !
                                                                 [
     Available information  on  leachate  from MIS processed shale is  presented
in Tables 4.2-10  and  4.2-11  (Stollenwerk,  1980,  and  U.S.  DOE,  May 1980,
respectively).  The  data  are for the sample cores from  the  Room 3E  burn  at
Logan Wash and may  not  be representative of  the  species that can be  leached
out  at  Tract C-b (i.e., the grade of shale and operating  conditions  at the
tract will  be different).   The  groundwater will  be  drawn down during  the
life of the project, and this reduces the potential  for groundwater  infiltra-
tion into the spent retorts.

     The results from column leaching of the Lurgi  processed shale  are given
in   Table 4.2-12   (Woodward-Clyde  Consultants,  October 13,   1980).    Some
soluble elements are reported  as  their oxides.  As  seen in Tab!? 4.2-9, the


                                     121

-------

















a


M
O

i
o


3
8
tr
S
U.^"N

(^ E

S 2

il
i

3*1
O
fe

O
§

I
CM


Ul
CD
<
















O) (0

S oJ o>
C *J 4»*
O O

„_
"fo
C3 V>








P



0

£ TJ
l/> 01


O +»
r- m
O 0)
»B

1 O
°l



01
J
(TJ

m >.2
ff 

1



t
1

tn
o
o





ft

o
i
in
p
d
v



ft
d

i

tn
o
0
v

en
(O
d

s

o
V


CO
tn
m

i
CO
d




R
d
i

in
o
d



*
**
t
a
d


;-
i




5


o.
0


tn
O
o
•
V






tn
o
d
v





in
o
o

o
V


m
o
o
d
v




m

O
d
v





m
o
o

o
V





o
o
d
V,








s



t
1
tn
8
d
i

to
d



s

o
t
d




d

i

CM
rH
d

IN.
cn
rH

m
CM
o
d
v

in
d

i
m
CM

o
v

R
CM
1

m
CM
o

d
v

CO
***
i
a
d


s





to


o
rH

1
d
i

m
o

d


in

0
Ctj
rH
d



m
5
d

i

d

a
P

CM
O
d


CM
d

i
CO
°.

d


00
o
i

S
d



r*.
rH
d
1
rH
(O
o
d







re
CO



i
i

m
CM
o
•
V






in
CM
o
d
v





tn
CM
o

o
V


in
CM
0
d
v




in
CM
0
d
V





in
CM
o

o
V





in
CM
O
d
v


s





0)
CO



1
1

CO
,

to




o
to

9





1

1

tn
CM

O
cn
1
CO
rH



O
rH
m

i
o
s



o
s
rH


O




O
tn

i
s








to
o



1


in
t

rH




O
o
CM
rH
d





S



CO
d

Q
rH
1
CO
d



o
o
CO

1
en
rH





CM


rH
rH




O


0
V


3





CJ



1
1
CO
CO
(

rH




cn

CM
ft
d




S
rH

1

a
d

^
o
i
CO
d



to
CO

1
rH
O
v



to
rH
1

CO
o
d



rH
rH
I
rH
d








8
CM
tn o in in rH
o o co co o o oo; o
OrHirHOlOl 1 lOl 1 lOOlOl lOOtf)
1 1 III tllrH i I I in O
CM in
cn o o in ' o
(ocoo CM co to co in r-. rHcn r*» vom
o CM o *>f to o tn r-i <*$* o o co *fl* .1 i o r*» ro
ddcocMdcoocgdi-iddcMdcodcdtncM ' co co* d
§o
1 f 1 1 1 1 1 1 1 1 O 1 1 1 1 1

CM CM «*• ' >COv >O 'OOrH O >O<-V . CM tn O
O O CO ^" O ^ t-t - > ^t* f^« oo co r*-* o tn tn
coo ino o^r^fcncoooococM .mcM<*to
• * o • co tn f* • — • * «et* . co * • to •.•»».

CM O O
OllfllOIIIIIIIIII • 1 I 1 t 1
* * o
v r<- r*- . o in v CM o rH o o . o •<-) . . CM to m o
O CO rH » rH < • . CO . O « t*- COO CM*
O OOOOVO '• O
O V V V V O
V

O CM i O O
rH O CO CM rH «S* tD in rH I>»r**intO
rocMr-oco omrHr^oomcorH .toior^co
• -. . co in r* * ovoto to '• o
0 V O O V 0
V
CO O tO O 00 i O O
*t *a- o CM cn o *s- to r-- cn tn om
o ^* CM o o , r** o ^ CM CM rH o r> cn • ' rH ^j* in
O O CO CO rHOCodcodcMrHdrHOr«.inrH : tOOtrH
rH C3 O ,
till • 1 O 1 t 1 t 1 t 1 1 1 1 O 1 1 t 1 1
O I
tninmmvcMo^CMcntnocotntnincooco ' cn^*cM
CM CM CM . CO V • O *OrH . O >OOV •! *tOO
OOrHO O • 'J- • • ** • O • . tn 1 r*- rH .
v oooovor*. ; o
O O V V V V 'V
V V •
i
^j- o o tn co co o co
cocno rH tn co rH co co cn CM f o rH cn
OtO» CO OrHCOCOrHrvOCMCO. .|UJ*O
. . r*- tn Oi— i«r«o--».r-..i-t co -o*
O O CO tO ^OlOOrHOtnt^OrHOrHinCM (OCOO
rH O " O '
iiit • i o i i i i i t i i i i o i i t i i
cMtncoaovodcMCMifltnor^r^^tncndcM f incsrH

• -* o*do *dto ; o
OOrH OV OV ' " V
V [
O ' rH CO ' CD O
^ rH o cn tn ^-m o <*oo tnr^-mtcoo
O «* *J- CM CO CO rH O r-. to in rH tOrH *
O ' O
iiiitioiiiitiiiii . i ? i i i
. o
ininoomocar^cMtn^-cncotncninto v CM CM co o CM
CMCM^ . O tn V ' O -fxO »O  . .. rH*
o o.o o or* CMO o
o o v o v v i v
v v !
o tn o
SCO O O r O O
So tnr^coo to oo o co
CO- CO rH O rH O CM CO ** tO Cf» O r^CMp^-CO
o
i i i i t i i i t t i i i i i t i .iiiii
o
ininotnrHrHrHrHCMr<.incntnintn<-co v in tn o o rH
CMCMCO « o . o • o . r*. o eg CM CM o * «o CM eg r«. o
OOCMCn .COOrH -lOO -VO .«IO «O .
OCOO 0.0 «rHO rH;. O
OO * O OVV O
V V O V V
__!-- 	 - 	 , 5; . i . . ,
O Ol | Dl
f * m
\


!
t. 3 o a>oai i-cneoflS'i-ojanro^-co'ac


























































d
CO
a
S-
1
£


s
3
o
122

-------
              TABLE  4.2-6.   COMPOSITION OF MIS  PROCESSED  SHALE
                                  (Stream  36)
Component
Processed Shale
(in-place)
Carbon (organic)
Sulfur (total)
Weight
Percent
100.00
2.40
0.62
Mass Flow,
103 Ib/hr
11,421
274
71
Flow,
10s Ib-moles/hr
--
23
2.2
Source:  DRI estimates based on information provided by Occidental Oil
         Shale, Inc.
       TABLE 4.2-7.  COMPOSITION OF LURGI PROCESSED MOISTURIZED SHALE
                                 (Stream 17)
Component
Retorted Shale
(moisturized)
Moi sture
Oxygen (organic)
Nitrogen (organic)
Carbon (organic)
Sulfur (total)
Weight
Percent
100. 00
10. 00
0.02
0.02
0.27
0.79
Mass Flow,
103 Ib/hr
4,343
434
1,
1
12
35
Flow,
10s Ifr-mole-s/hr
™
24.1
0.1
0.1
1.0
1.1

Source::   DRI estimates based on information provided by Occidental Oil
         Shale, Inc.
                                     123

-------
          TABLE 4.2-8.  INORGANIC ANALYSIS OF LURGI PROCESSED SHALE
                                 (Stream 17)

Component
Silicon Dioxide
Iron Oxides
Aluminum Oxide
Calcium Oxide
Magnesium Oxide
Sulfate
Sodium Oxide
Potassium Oxide
Carbonate
Chloride
Loss on Ignition
Weight Percent
46.00
4.40 ;
12.70
22.40
4.80
3.80
3.20 '
2.70 i
4.40
0.08
4.60 ;

Source:   Woodward-Clyde Consultants, October 13, 1980.
                                     124

-------

















UJ
_J
i
o
Ul
fe
g
cs
1-4
i


to h-
lAJ rH
&8
IS
ce v)

s
s£* .
s




^

Ul
§
fi
































• a
I
CO
s-
R)
2
V}






&

1-1

Sl-
a>
a.


c
o
s
a.
0
















c
•r-

ttf
13
2
(3


















'S isd 'uoissaadiuoQ
.$: " psuuuopun
c
0
u
3 do02T e) pa-inj SA~eQ
isd
'uoisaqoo pa^earnes

ininCMI 1 OOCNJ^-tnOCSlCgCVI OOOrHCMtOrHI I
i-Tr-T ' i-T ' t-T

oer*r-SS.a-S3 001-^S3c5S oc"^l"33as
i
(O en oo
r^* t^t r^ :
|H CM t

CM fO O I
esi m ' in i
CM co «» ;

in o in i
«* CM OO I
9> CSJ O i
i£> ID GO
O O O
1 1 1
I 1 1

m tn 1-4
§0 0
o o ,
o o o


CM CO rH
O O O
O O 0
O O O
« CM CO i
SCO IO*
CO O> '

co in CM
O 00 CO
CO CM CM
CO CO

CMCM
§ 0 §
•p ro *> *u -P fii* 4J (_} tff, ^j
roxui ro x w>  o> CM CM in CMCOCTI
§g §5mco §?S, §S5

rH CO CM tO tn in CM CO CO CM rH CO
r*» in to f*. in m to co co too CM
rH rH rH rH rH rH rH rH rH rH

j
CO CO
"^"x. Ill III 111
CO CO lit lit lit

«-*t  "D 00 -P "D "^- "O 4-
•r- OJ CF1 <*• V  o
u o o or*. uf^>m
o to o o to co co to in CM
02 E*CM ^ §"S csT §*rH 10"
wo-^to O*H om










































a

a

6>
o
"S
o


Ul

c
£
Ul
c

0)
•o
^
u
1
•g
1
o



Of
s
3
0
CO
125

-------
UJ
_J
*E
CO
a
UJ
co
CO
UJ
o
o
oc
Q.
co
i— i
s
S»~
CD
O£
LL.
LU

O
UJ
«J

UJ
^£
1— „
z
(••fl
*"**\
CO rH
UJ «*•
t— <
0 E
UJ (0
(X 4_>
a co
UJ ^^
>
o
CO
co
Q
U.
O

co
•M» .
0
t-4
i
1—
z
o
o
o


s
1
"^1
«^
UJ
_1
OS
j*




















a
*
c
o
•ft-
^J
re
j-
c
at
u
c
0
o

+i
c
(!)
3

•r*1
•P
in
c
o
o















CO
Q






m
o



^i*
o
CO


C4
O
CO






 s-
i— 0)
£»*
o re 3
co z
o
fx.
co
CM"





CO



0
C7)
CD




O






CM
0

O






nH
o
o



•*
CM


m
•
CO



CM

r-4






iH


O
O

«^





O
in
CM


o

en

ex?


o






CM
o

o






o^
o
0



p^
o


rH
«
CM



0

esj






CM


0
in
CM
00





o
S


o

co

in"


o
co
CM





o
r-t

t~%






CO
iH
O



00
oo'


co
«
CM



O

co






CO


o
o
CO
cT
""*




o
CM


o
co
tn

co


o
CM





in
r-i
e
O






co
C3
0



co
in


CO
e
r~>-



o

rH
r- 1






•*

















































O
00
en

,
s_
(U
c
cu

*o
-p
CO

a)

s-
o
co
126

-------
TABLE 4.2-11.  COMPARISON OF CONCENTRATION RANGE OF MACRO IONS FOUND IN
    FIRST FRACTION OF LEACHATES FROM OCCIDENTAL'S MIS CORE SAMPLES
                    AND ABOVEGROUND RETORTED SHALE
                              (Stream 41)

Parameter
Quantity of Shale in Column (g)
Column Volume Collected (v/vo)
PH
Conductivity (pmho/cm)
Organic C (pg/ml)
Inorganic C (as C03) (pg/ml)
Boron (pg/ml)
Calcium (mg/ml)
Magnesium (pg/ml)
Potetssium (pg/ml)
Sodium (pg/ml)
Lithium (pg/ml)
Strontium (pg/ml)
Silicon (pg/ml)
Zinc (pg/ml)
Range of Components
MIS Aboveground
Core/Samples Retorted Shale*
4.0-7.7 3.3-5.5
0.28-1.11 0.41-0.67
7.75-10.6 10.6-12.2
1,300-15,000 7,600-11,500
152-2,455
30-280
1.9-46 3
11-513
0.5-265 <0
70-3,360 4
370-14,400 4,8
0.2-87 8
0.7-10.8 2
5.4-122
<0. 01-0. 48 <0.

* The origin of the aboveground
Source: U.S. DOE, May 1980.

retorted sample is not specified.

127
94-205
36-170
. 9-8. 5
4-281
.5-0.8
40-830
00-8,100
.4-16.2
.4-8.4
15-49
01-0.06
' .




-------
 properly moistened and  compacted Lurgi processed shale has low permeability;
 therefore, actual field leaching may not be represented by laboratory column
 leaching experiments.                                           !
        TABLE 4.2-12.   ANALYSIS OF LEACHATE FROM LURGI PROCESSED SHALE
                                 (Stream 122)
           Component                                Concentration,  mg/1
           Silicon Dioxide                                  18
           Iron Oxides                                      <0.01
           Aluminum Oxide                                   <0.l
           Calcium Oxide                                 1,080
           Magnesium Oxide                                 102
           Sodium  Oxide                                     337   ;
           Potassium Carbonate                               37
           Carbonate                                        90   ]
           Bicarbonate                                      <0.1
           Chloride                                          28
           Sulfate                                        1,810
           Hydroxide                                       222
           Total Dissolved Solids                         3,530
           pH = 11.4

Source:  Woodward-Clyde Consultants, October 13, 1980.

4.2.4  Crude Shale Oil                                           j
     Properties of  the  shale oil  produced from the Room 6 burn ai Logan Wash
are presented in Table 4.2-13.   Since the quality of oil is largely dependent
upon the  retorting process,  and less on  the  origin or  the grade  of  the raw
shale, similar properties may  be  expected for the crude oil from:the commer-
cial MIS operation at Tract C-b.                                 ;
                                     128

-------
              TABLE  4.2-13,   PROPERTIES OF MIS CRUDE SHALE OIL3
                                  (Stream 39)
Parameter
% Carbon
% Hydrogen
% Oxygen
% Nitrogen
% Sulfur
% BS & W
% Asphaltene
API Gravity at 60°F
Pour Point, °F
Viscosity, CST at 100°F
Cleveland Open Cup Flash Point, °F
Cleveland Open Cup Fire Point, °F
Penske-Martin Flash Point, °F
Heating Value, Btu/lb
Volume % distilled at, °F
First drop
5%
10%
20%
30%
40%
50%
60%
70%
80%
90%
Flow,b 10s Ib/hr (BPSD)
Value
84.24
11.771
1.09
1.42
0.65^
0.30!
0. 53
23.3 ;
60
39. 17
220 ;
230 :
185 :
18,800 |
i
376.2
466.8
505.2 :
562.6 '
613.0 ;
660.4
716.0
769.8
822.6
876.2
922.2
911 (62,040)
a The values at 15,000 barrels cumulative point in the Room 6 burn at
  Logan Wash are used here.  The oil production seems optimum at that time.

K                                                              •
  Excludes light oils recovered in the MIS gas absorber/cooler,  j


Source:  Loucks, November 1979.                                  ;
                                     129

-------
      Table 4.2-14  shows the  properties of  crude  oil from Lurgi processing.
 Since the Lurgi retort module  includes three  condensation-absorption towers,
 a  product breakdown into  heavy, middle,  and light  oils  fractions occurs.
 The  API  gravities  and boiling  points  for  each  of the  fractions  have been
 estimated from published  information  (Schmalfeld, July  1975)  and from data
 provided  by  Cathedral Bluffs.   However,  later information provided by Lurgi
 indicates that the combined crude oil  is somewhat  heavier (~19°API) than the
 value given  in the  table.

 4.2.5  Retort  Gas

      The  composition and quantity of retort gas from  MIS processing is given
 in  Table 4.2-15  (Occidental  Oil Shale,  Inc.  and  Tenneco  Shale  Oil-Co.,
 April  1981).    The  retort  gas  is  made  up  of  over  95% (by  weight)  inert
 components which do  not  contribute  to the  heating value of  the gas.   Thus,
 the  net  heating  value  for the  gas  is very  low.   Approximately  5%  of the
 sulfur is. present as  non-H2S species  such as CS2, COS  and CH3SH.; The amounts
 of H2S and NH3 are  significant  enough  to warrant  their  recoveries.  Ammonia
 is removed  from the  gas  in the gas  condensate during cooling  of the retort
 gas  in the  absorber/cooler.   The  gas condensate  is eventually fed  to the
 Phosam-W  ammonia  recovery  unit for  recovery  of  anhydrous ammonia as  a by-
 product.   A  portion of the  stripped  condensate  from the Phosam-W  unit is
 recycled  as the wash water  to the absorber/cooler.  The estimated composition
 of  the  water-scrubbed  gas  thus  obtained  is  presented  in  Table 4.2-16.
 Approximately  6,960 BPSD  of  light   oils  are also condensed  and  recovered
 during the retort gas scrubbing.                                 \

     Tables 4.2-17  through  4.2-19 present  the estimated composition  of the
 retort vapors   from the Lurgi  retorts  at different  points  in  the process.
 The  total retort   vapors   (without   the  entrained  dust) are   presented  in
 Table  4.2-17.   The  vapor cooling and  scrubbing in the  first scrubber tower
 removes the  heavy  oils  along with the  entrained dust.  Similarly, the middle
 oils  are  condensed in  the  second  scrubber tower.   Table 4.2-18 represents
 the vapors after the middle oils have  been  condensed, but the light oils and
 water  still  remain  in vapor form.  The gas  composition after condensation of
 the  light oils  and  gas  liquor in  the  third scrubber tower  is given  in
 Table  4.2-19.   Finally,  the residual cpndensable  hydrocarbons  (naphtha) are
 removed in the lean oil absorber to  produce a so-called naphtha-free retort
 gas,   as presented  in Table 4.2-20.   The reported composition of this  gas is
 presented in Table  4.2-21  (Occidental Oil Shale,  Inc. and Tenne'co  Shale Oil
 Co.,   April 1981).   Significant  differences  in the quantity  and composition
 are noticeable between  the  estimated  and reported naphtha-free retort gas.
The estimated composition of naphtha  is presented in Table 4.2-22.

     In Case Study  A, the MIS and Lurgi retort gases are burned in the steam
boilers without additional  treatment.  The resulting flue gas is then desul-
 furized to reduce  the S02  emissions.    In Case Study B, the removal of H2S by
the Stretford  process is  considered  before the gases are burned.   In  order.
to treat  the  gases, it  is  necessary  to  cool  the  MIS  retort gas to  the
operating temperature of the  Stretford unit.   This is done  in !a precoolesr,
and the composition of  the MIS gas after treatment is given in Table 4,2-23.
The water condensed in  the precooler dissolves a  significant portion  of the

                                     130

-------










i
1-4
r-
O
ee

*~*
Cg
=>
_!
§
Of
u.
^*
o
UJ
wl

«/> CM
M
UJ \O
LU CM
LL. *j°
8 CM
il
a. a>
Si -P
CO
u. w
0
UJ
H4
1—

Ul
a.
O
ee.
O-


*
CM
"* '

Ul
I-J
1
f—















Ul
CU
5 "o
0 E
!•*• 1
U. .Q
W
O
rH

sT s.
O f
!*"• **V,
U. .Q
U)
U) 03
TO o
^— rH



+j
£ CU
O) j
+» t— <
•r- a.
coo
CD


,»«, •
a
a.
CQ
CU v>
•3 4^
i— C
O CU
> 0
CU
a.




u_
cno
c
*f° <*
r-" 4J
•i- C
O -r-
ea o
a.
















c
CU
o
o
o



1 1
1 1






CM CM
r** ot
• •
"* CM
*t 0
rH  <>~s
0 O
o m
in ID
M m
O CO
rH CM
S^X ^^

m t^-
IO CM
CO CO
CM in





0 0
CM CM
Cft CTk
1 1
0 0
• to r^
«0 CM













r**  CM
U> r—
^~ E "f* E
•r- 1C O fO
o cu cu
i- CU £-
> 10 ~a to
(Q ^^ TQ *»^
3= s:



1
1






vo
to
ID
«o





s
CO
CM





s;



^*,
o
m
CM
o"
^^^

§
CO
CM





o
iH
in
1
o
01
CM













rt"
•K 'CM-
in
r- S
•i- ro
O CU
JC VJ
,?''*"'
—1

o o to o 10
o in co o rH
1 P>« O O rH C3
1 (£> rf






O
O O O O O O
• o o o o o
oo i^« oo CM CM in
in 

o r*. r< m in *o o «* co o CM oo O rH rH CM ^- CD O rH CO ^1 m m i i i i i CM 1 1 1 1 1 f^ 0 •t S 0 0 O 1 1 1 1 1 O 1 t 1 1 1 rH O CM cn i i i i i i O 1 1 1 1 1 CM I _, |_| O Ul _J ^c t/^ c —1 0 1— +> C ' C O ' -r- CU 9) 1— U) O> C C35 S= S. O O CU O O 3 D. fc- O) S- J2 <*- E T3 > +> i- r^- O >» X -r- « 3 cj 3: o 2: cj co i i a o in CO U) , o •r- ; 1o N •r- i »r* 0 0} ' -*-> Ul , CU I o cu 1 ^ in : o i jj j- co 1 ^ cu , J_ ' O \ (L_ ^* 1 '> ' RJ S- D) i CX. , B •a cu N ' "g "ffl • . % u> : 0) : S- 10 U) p^ •^» ' O , 1 1 i f^ cn • 1 •- ' cu r- 1 * U c t— < ^ cu *m ^» •^> o p™ • ro CU •o y u o -^ ^ T3 U) f> (O 1 g: •r" +J U> CU fwf cc 0 cu u o V) 131


-------
4!
to
(S
g
OS

to
u.
  ; co
«•-«  
                  co

               3w
               o o
               tn s-
               > m co i
                       CM    r^i
                             i CM en

                              co"^
                                                        ICMin
                                                                         «S|
                                                                              oo
                                                                              in
                                                                              CM

                                                                              co"
                                                                              CM
                                                                              *

                                                                              1
                                                                              CM"
                                                                              CO
                                                                              CO
                                                                              00
                                                                              0>
                                                                                        «3- CM «* (-» CM
                                                                                        Cn CO rH CO rH


                                                                                        t-H CM tO CO P"!
                                                                                        O CM en rH rH
                                                                                        rH «3" Cn rH


                                                                                           CM «a- iH
                       Ot-lOOtOOCsliHOOOOlDOOOOCMOOOrH
                       in CM CMCn^J-i-ir-lOl-HOOOtHOOOOO
                                                                   CM CO


                        mcOCMCMCMrHlOOCMOrHCMtnOOOCO
                       O iH O> tO.O O O'O OOOOOC3OO(-S
                              CM «*                                      CM

                       CnrH«*OOOrHOOOOOOOOO  I
                              CM to                                       I
                       'S-VOOieOCOOf^r-ltOt-IOOCOVO
                       «JDlOi-H«*COeM


                                                            o
                                                 to
                                                                      to
                                                                       COO
                               04     toco  TJ-:E :n :c x: +   osto
                             o  <^a:  N3C  « « « co TC-C- o
                          uozzxuooouo— loooz
                                                                              o
                                                                              o
                                                                             O
                                                                             O
                                                                              o
                                                                              0
                                                                             o
                                                                             o
                                                                              o
                                                                              o
                                                                              oo
                                                                              Cn
                                                                              en
                                                                              en
                                                                                  g

                                                                                  in
                                                                                  CM
co CM co CM to
Cn O «3- rH rH

o CM in o o
   CM «* rH
                                                                                  in
                                                                                  cr>
                                                                                  CM
                                                                                                        en

                                                                                                        3:
                                                                                        oo o to p>« o cj
                                                                                        rH O l~« 00 CM CO;


                                                                                        rH 00* 1^ CM O 3-
                                                                                           CM in I-H    -Pi
                                                                                                        CO
                                                                                        o o
                                                                                          C4  M
                                                                                                        >
                                                                                                        3:
                                                                             «

                                                                             P
                                                                                         0) 0>
                                                                                         c c
                                                                                         3  3
                                                                                        r— r—

                                                                                         U  U
                                                                                         X  X
                                                                                         01  0)
3= O 2 CJ CO  O)



 (O  03  (0  (0  (O *P i
•P -P -P -P -P  tOl
 o  o  o  o  o  01;
r- I— I— I— r- 3C
                                                                                                                0)


                                                                                                                3


                                                                                                                (0


                                                                                                                O)
                                                                                                                a.
                                                                                                                0
                                                                                                               ca
                                                                                                                01
                                                                                                                5-
                                                                                                                3
                                                                                                                •P
                                                                                                                (0


                                                                                                                0)
                                                                                                                   o

                                                                                                                   a,
                        Ol  u>
                        s-  c
                           a>
                        o> *o

                       •P  O
                           u

                        o r-
                                                                                                                •^ i.

                                                                                                                c: w
                                                                                                                2? *^
                                                                                                               ^ 5
                                                                                                                o  55
"It"°
 U1  m
 O  c
 Q..r-

 i  *
 O 4J


    03


-C  U)
                                                                                                                         en
                                                                                                                         i~
                                                                                                                         a.
                                                                                                                         o
                                                                                                                         o
          o

          ai

          re
          JC
          to

          o
          u
                                                                                                                         •a

                                                                                                                         to
                                                                                                                         ai
                                                                                                                         r—
                                                                                                                         m
                                                                                                                         |

                                                                                                                         ai
                                                                                                                         •o
                                                                                                                         u
                                                                                                                         01
                                                                                                                         u

                                                                                                                         3
                                                                                                                         o
                                                                                                                         CO
                                                             132

-------
      TABLE 4.2-16.
COMPOSITION OF MIS RETORT GAS AFTER ABSORBER/COOLER
             (Stream 45)
Component
H2
CO
C02
N2
NH3
H2S
CH4
C2H4
C2H(g
CgHis
C3Hjj
r +
L4
COS
CS2
CH3SH
H20
TOTAL
MWt
Total H
(excluding
Total 0
(axel udi ng
Total N
Total C
Total S
Heating Value
MWt
2
28
44
28
17
34
16
28
30
42
44
72.35
60
76
48
18

H20)
H20)



, LHV
Mass %
0.61
1.59
35.29
55. 11
0.02
0.19
0.84
0.11
0.25
0.11
0.17
0.27
0. 0097
0. 0024
0, 0031
5.42
100.00
28.
0.99
26.58
55.13
11.69
0.19
Mole %
8.68
1.62
22.82
55.99
0.04
0.16
1.49
0.11
0.24
0.07
0.11
0.11
0.0046
0.0009
0. 0019
8.57
100. 00
45





Btu/lb (Btu/SCF) 732
Mass
103 Ib/hr
55.04
143.49
3,184.63
4,972.36
2.22
17.05
75.44
9.82
22.54
9.82
15.44
24.32
0.88
0.22
. 0.28
489.49
9,023.04

89.59
2,398.32
4,974.19
1,054.56
16.89
(55)
Flow,
(10s SCFM)
(174. 05)
(32.41)
(457.76)
(1,123.14)
(0.82)
(3.17)
(29.82)
(2.22)
(4.75)
(1.48)
(2.22)
(2.13)
(0.09)
(0.02)
(0.04)
(171.99)
(2,006.15)







; Flow,
: Ib-moles/hr
27,519.5
; 5,124.5
72,378.0
i 177,584.4
130.4
: 501.6
= 4,715.3
350.8
! 751.3
233.9
! 350.8
336.1
14.6
2.9
! 5.9
: 27,194.0
', 317,194.0
;
i

*
i

i

Source:  DRI estimates based on information from Occidental Oil Shale, Inc.
         and Tenneco Shale Oil Co., April 1981.
                                     133

-------
              TABLE 4.2-17.
COMPOSITION OF LURGI RETORT VAPORS
    (Stream 16) .

Component*
H2
CO
C02
N2
NH3
H2S
S02
CH4
C2H4
C2Hg
CaHg
CsHg
C4Hs
C-tHjo
C4+
Light Oils
Middle Oils
Heavy pi Is
Miscellaneous HC
H20
TOTAL
MWt
MWt
2
28
44 -
28
17
34
64
16
28
30
42
44
56
58
79.4
114
166
274
132.6
18

Mass %
0.39
0.56
7.79
0.56
0.22
0.09
0.03
1.48
0.96
0.98
1.23
0.66
1.08
0.33
1.87
16.13
32.40
15.41
0.03
17.81
100.01
48.49
Mole %
9.43
0.97
8.58
0.97
0.64
0.13
0.02
4.49
1.66
1.59
1.42
0.73
0.93
0.28
1.14
6.86
9.46
2.73
0.01
47.97
100.01

Mass Flow,
103 Ib/hr
3.65
5.24
73, 15
5.24
2.11
0.88
0.27
13.91
8.99
9.23
11.52
6.18
10.11
3.10
17.52
151.50
304. 32
144.72
0.26
167.25
939.15

Flow,
Ib-raoles/hr
1,826.0
187. 3
1,662.6
! 187.3
124. 2
! 25.8
4.2
869.6
321.1
! 307.7
274.2
' 140.5
1 180.6
53.5
220.8
: 1,329.0
1,833.3
i 528.2
2.0
', 9,291.4
j 19,369.3


* Approximately 77 x 103 Ib/hr of the shale dust are entrained in the vapors
  but not included in the table.

Source:   DRI estimates based on information provided by Occidental Oil
         Shale, Inc.                                              :
                                     134

-------
   TABLE 4.2-18.   COMPOSITION OF LURGI RETORT GAS AFTER MIDDLE OILS SCRUBBER
                                  (Stream 22)
Component
H2
CO
C02
N2
NH3
H2S
S02
CH4
C2H4
CgHis
CsHis
CaHjj
C4H«
C4H:lo
r +
t4
Light Oils
Middle Oils
Miscellaneous HC
H20
TOTAL
MWt
MWt
2
28
44
28
17
34
64
16
28
30
42
44
56
58
79.4
114
166
132.6
18

Mass %
0.74
1.07
14.88
1.07
0.43
0.18
0.05
2.83
1.83
1.88
2.34
1.26
2.06
0.63
3.57
30.82
0.29
0.05
34.02
100.00
28.29
Mole %
10.73
1.10
9.77
1,10
0.73
0.15
0.02
5.11
1.89
1.81
1.61
0.83
1.06
0.31
1.30
7.81
0.05
0.01
54.60
99.99

Mass Flow,
103 Ib/hr
3.65
5.24
73.15
5.24
2.11
0.88
0.27
13.91
8,99
9.23
11. 52
6.18
10.11
3.10
17.52
151.50
1.40
0.26
167.25
491.51

Flow,
Ib-moles/hr
! 1,826.0
187.3
: 1,662.6
187.3
124.2
25.8
4.2
; 869.6
321. 1
: 307.7
: 274. 2
i 140.5
; 180.6
53.5
! 220.8
1,329.0
: 8.5
2.0
! 9,291.4
17,016.3
'
Source:  DRI estimates based on information provided by Occidental Oil
         Shale, Inc.
                                     135

-------
   TABLE 4.2-19.   COMPOSITION OF LURGI RETORT GAS AFTER LIGHT OILS SCRUBBER
                                  (Stream 23)                    !
Component
H2
CO
C02
N2
NH3
H2S
S02
CH4
C2H4
CaH«
CsH«
CsHj[
C4Hjjj
64^10
CV
Heavy Ends
H20
TOTAL
MWt
Totail H (excluding
Total 0 (excluding
Total N
Total C
Total S
MWt
2
28
44
28
17
34
64
16
28
30
42
44
56
58
.79.40
81.69
18

H20)
H20)



Mass %
1.94
2.79
37.57
2.79
0.02
0.47
0.01
7.40
4.78
4.91
6.13
3.29
5.38
1.65
9.32
8.80
2.75
100. 00
28. 09
10. 24
28.92
2.81
54.83 ,
0,45
Mole %
27.28
2.80
23.99
2.80
0.03
0.39
0.01
12.99
4.80
4.60
4.10
2.10
2.70
0.80
3.30
3.03
4.30
100.02






Mass Flow,
103 Ib/hr
3.65
5.24
70.64
5.24
0.04
0.88
0.02
13.91
8.99
9.23
11.52
6.18
10.11
3.10
17.52
16.53
5.18
187. 98

19. 25
54.37
5.27
103.07
0.84
Flow,
!lb-moles/hr
1,826.0
187.3
; 1,605.4
! 187.3
2.2
25.8
0.4
869.6
321. 1
307.7
274.2
140.5
180.6
53.5
220.8
; 202.5
287.5
6,692.5
i
i 19,250
, 3,399
377
! 8,590
26
Source:  DRI estimates based on information provided by Occidental Oil
         Shale, Inc.
                                     136

-------
          TABLE  4.2-20.   COMPOSITION OF NAPHTHA-FREE  LURGI  RETORT GAS
                                  (Stream 31)
Component
H2
CO
C02
N2
NH3
H2S
S02
CH4
C2H4
C2He(
CsHei
CsHg
C4Hg
C4Hj0
H20
TOTAL
MWt
Total H (excluding
Total 0 (excluding
Total N
Total C
Total S
Heating Value, LHV
MWt
2
28
44
28
17
34
64
16
28
30
42
44
56
58
18

H20)
H20)



Btu/lb
Mass %
2.38
3.41
45.99
3.41
0.02
0.57
0.02
9.06
5.85
6.01
7.50
4.02
6.58
2.02
3.15
99. 99
24.
9.81
35.41
3.43
47.66
0.55
(Btu/SCF)
Mole %
29.22
3.00
25.69
3.00
0.04
0.41
0.01
13.91
5.14
4.92
4.39
2.25
2.89
0.86
4.30
100.03
58





9,790 (616)
Mass Flow,
10s Ib/hr
3.65
5.24
70.64
5.24
0.04
0.88
0.02
13.91
8.99
9.23
11.52
6.18
10.11
3.10
4.83
153.58

15. 06
54. 38
5.27
73.20
0.84

Flow,
Ib-moles/hr
1,826.0
187.3
; 1,605.4
; 187.3
2.2
: 25.8
0.4
869.6
; 321. i
i 307.7
274.2
140. 5
i 180.6
53.5
268. 6
6,250.2



i
,

, )
[
Source:  DRI estimates based on information provided by Occidental Oil
         Shale, Inc.
                                     137

-------
      TABLE 4.2-21.
REPORTED ANALYSIS OF NAPHTHA-FREE LURGI RETORT GAS
            (Stream 31)                    ;
     Component
                                          Flow,
                                       Ib-moles/hr
        H2
        N2
        NH3
        CO


        C2=
        C2
        C02
        H2S
        C3=
        C3


        HoQ
             TOTAL
     Mass Flow, Ib/hr = 185,616.0
     Flow, MMSCFD     =      67.58
     Temperature, °F  =      95
     Pressure, psia   =      12.7
                                         2,336.9
                                           230.0
                                            18.5
                                           200.3
                                         1,112.9
                                           333.9
                                           400.6
                                         1,868.1
                                             5.2
                                           341.3
                                           215.2
                                           356.1

                                         7,419
Source:  Occidental Oil Shale, Inc. and Tenneco Shale Oil Co., April 1981.
                                     138

-------
                  TABLE 4.2-22.   COMPOSITION OF LURGI NAPHTHA
                                  (Stream 33)
Component
CsH12
CgHg
CsHi4
C7H16
Light Oils
Middle Oils .
H20
TOTAL
MWt
Total H (excluding
Total C
MWt
72
78
86
100
78
166
18

H20)

Mass %
25.19
1.52
18.39
5.84
43.97
4.10
0.99
100.00
77.81
12.17
86.84
Mole %
27.22
1.51
16.64
4.54
43.86
1.92
4.30
99.99



Mass Flow,
10s Ib/hr
8.67
0.52
6.33
2.01
15.13
1.40
0.34
34.40

4.19
29.87
Flow,
Ib-moles/hr
120.4
6.7
73.6
1 20.1
194. 0
! 8.5
i
19.0
442.3

i

Source:  DRI estimates based on information provided by Occidental Oil
         Shale, Inc.
ammonia remaining  in the gas.  The cooled MIS gas and the Lurgi gas are then
treated  for  sulfur  removal.   A  removal  efficiency  down  to ;30 ppmv  H2S
remaining  in  the   treated gases  is  attainable by  the  Stretford  process.
Also, 15%  of COS and 70% of CH3SH are picked up by the Stretford liquor, but
they are eventually released  in the oxidizer vent  gas,  which  is incinerated
in the boilers.  Tables 4.2-24 and 4.2-25 present the composition of the MIS
and  Lurgi  retort  gases after  the  Stretford treatment.   Separate  Stretford
absorbers are  used for the MIS and Lurgi gases so that the treated gases can
be kept separate for appropriate use.

     The Stretford  precooler  condensate  is combined with the MISr gas conden-
sate and  Lurgi  gas  liquor  and  fed  to  the Phosam-W  unit for  recovery  of
ammonia.   Due to this, a slight increase in the amount of ammonia is realized
in Case Study B.  Table 4,2-26 gives the composition of precooler condensate,
stripping air, and oxidizer vent gas for the Stretford process.
                                     139

-------
         TABLE 4.2-23.
COMPOSITION OF MIS RETORT GAS AFTER STRETFORD
    PRECOOLER, CASE STUDY B
Component
H2
CO
C02
N2
NH3
H2S
CH4
C2H,i
c2H(3
CsH,3
CsHjj
r +
U4
COS
CS2
CH3SH
H20
TOTAL
MWt
Total H
(excluding
Total 0
(excluding
Total N
Total C
Total S
Heating Value
MWt
2
28
44
28
17
34
16
28
30
42
44
72.35
60
76
48
18

H20)
H20)



, LHV
Mass %
0.62
1.62
35.94
56.16
0.01
0.19
0.85
0.11
0.25
0.11
0.17
0.27
0.0099
0.0025
0.0032
3.66
99.98
28.
1.01
27.07
56.17
11.90
0.19
Mole %
8.94
1.66
23.49
57.68
0.02
0.16
1.53
0.11
0.24
0.08
0.11
0.11
0.0047
0. 0009
0.0019
5.85
99.99
76





Btu/lb (Btu/SCF) 780
Mass
10s Ib/hr
55.04
143.49
3,182.30
4,972.36
1.20
17.04
75.44
9.82
22.54
9.82
15.44
24.32
0.88
0.22
0.28
324. 20
8,854.39

89.41
2,396.63
4,973.35
1,053,92
16.88
(59)
Flow,
(10s SCFM)
(174. 05)
(32.41)
(457.42)
(1,123.14)
(0.45)
(3.17)
(29.82)
(2.22)
(4.75)
(1.48)
(2.22)
(2.13)
(0.09)
(0.02)
(0.04)
(113.91)
(1,947.32)







Flow,
Ib-moles/hr
: 27,519.5
5,124.5
! 72,325.0
. 177,584.4
70.4
501. 3
; 4,715.3
350.8
! 751.3
233.9
350.8
; 336.1
; 14.6
2.9
: 5.9
; 18,011.0
307,897.7

j
!
!

!
[
!

Source:   DRI estimates based on information from Occidental Oil Shale, Inc.
       ,  and Tenneco Shale Oil Co., April 1981.
                                     140

-------
         TABLE 4.2-24.
COMPOSITION OF MIS RETORT GAS AFTER STRETFORD
     PROCESS, CASE STUDY B
          (Stream 52)
Component
H2
CO
C02
N2
NH3
H2S
CH4
C2H4
c2Hi3
CsHs
CgHg
C4+
cos
CS2
CH3SH
H20
TOTAL
MWt
Total H
Total 0
Total N
Total C
Total S
Heating Value
MWt
2
28
44
28
17
34
16
28
30
42
44
72.35
60
76
48
18






, LHV
Mass %
0.64
1.66
34.62
57.54
0.01
0.0036
0,87
0.11
0.26
0.11
0.18
0.28
0. 0086
0. 0026
0.0010
3.69
99.99
28.
1.02
26.13
57.56
11.59
0. 0091
Mole %
9.09
1.69
22.46
58.66
0.02
0. 0030
1.56
0.12
0.25
0.08
0.12
0.11
0.0041
0.0010
0.0006
5.85
100. 02
54





Btu/lb (Btu/SCF) 785
Mass
10s Ib/hr
55.04
143.49
2,991.36
4,972.36
1.20
0.31
75.44
9.82
22.54
9.82
15.44
24.32
0.74
0.22
0.09
318.78
8,640,97

88.40
2,257.73
4,973.35
1,001.77
0.78
(59)
Flow,
(103 SCFM)
(174.05)
(32.41)
(429. 98)
(1,123.14)
(0.45)
(0.06)
(29.82)
(2.22)
(4.75)
(1.48)
(2.22)
(2.13)
(0.08)
(0.02)
(0.01)
(112. 01)
(1,914.83)







Flow,
; Ib-moles/hr
: 27,519.5
; 5,124.5
i 67,985.5
177,584.4
: 70.4
9.1
4,715.3
350.8
751.3;
233. 9
', 350.8
336.1
12.4
i 2.9
1.8
17,710.1
302,758.8






1
Source:  DRI estimates based on information from Occidental Oil Shale, Inc.
         and Tenneco Shale Oil Co,, April 1981.
                                     141

-------
    TABLE 4.2-25.  COMPOSITION OF  LURGI RETORT GAS AFTER STRETFORD PROCESS,
                                CASE STUDY B                     :
                                  (Stream 51)


Component
H2
CO
C02
N2
NH3
H2S
CH4
C2H4
C2H<3
CsH<3
CsHjj
C4H«
C4H;LQ
H20
TOTAL
MWt
Total H (excluding
Total 0 (excluding
Total N
Total C
Total S
Heating Value, LHV



MWt
2
28
44
28
17
34
16
28
30
42
44
56
58
18


H20)
H2Q)



Btu/lb



Mass %
2.46
3.53
44.75
3.53
0.03
0. 0021
9.38
6.06
6.22
7.76
4.17
6.82
2.09
3.19
99.99
24.
10.12
34.57
3.55
48.56
0.002
(Btu/SCF)



Mole %
29.83
3.06
24. 65
3.06
0.04
0.0015
14.20
5.24
5.03
4.48
2.29
2.95
0.87
4.30
100.00
23





10,070 (643)



Mass Flow,
103 Ib/hr
3.65
5.24
66.40
5.24
0.04
0. 0031
13.91
8.99
9.23
11.52
6.18
10.11
3.10
4.74
148. 35

15.01
51,29
5.27
72.04
0.003




Flow,
Ib-moles/hr
1,826.0
187. 3
1,509.1
187.3
2.2
0.1
869.6
321.1
I 307. 7
274. 2
140.5
." 180.6
53.5
263.1
! 6,122.3


|
'
>


'
Source:  DRI estimates based on information provided by Occidental Oil
         Shale, Inc.
                                     142

-------
       TABLE 4.2-26.  OTHER STREAMS FROM STRETFORD PROCESS, CASE STUDY B
                           (Streams 50, 53, 54, 55)
Component
N2
02
C02
Precooler
Condensate
(Stream 50)
Ib/hr
.
—
2,332
Stripping
Air
(Stream 54)
Ib/hr
384,250
110,450
—
Oxidizer
Vent Gas
(Stream 53)
Ib/hr
• 384,250
1 102,100
: 195,176
 NH3                       1,020                  —

 H2S                          10

 cos                          -                     _.                   132

 CH3SH                        —                                  '       197

 H20                     165,294                  3,000                26,820
     TOTAL              168,656               497,700              708,675

 Sulfur Recovered  (Stream  55) = 16,570  Ib/hr  (180 MTPSD)          :
Source:  SWEC estimates based on information from Peabody Process Systems,
         Inc., February 1981.
     A  recent small  MIS retort burn  at Tract C-a  by Rio Blanco  Oil  Shale
Company  encountered variable and  much higher levels  of sulfur compounds in
the retort  gas  than assumed in this manual (Sklarew, et a!., February 1981).
Should  such changes  occur as  the retort  burns  progress at  Tract C-b,  the
performance of  the  Stretford unit may be  adversely  affected.   A sampling of
the data found at Tract C-a is shown in Table 4.2-27.            !

4.2.6  Flue Gas                                                  j

     In  Case  Study A, the  retort  gases are  combusted  in the steam boilers
without any pretreatment (except  for the cooling and  scrubbing of the gases
to  remove   NH3).    The   overhead  vapors  from  the   Phosam-W  unit  (see
Table 4.2-36) are  also  incinerated in  the boilers.  The  flue ^gas  is  then
desulfurized  by lime/limestone  scrubbing; the  gas  composition,  before  and
after FGD,  is presented  in Table 4.2-28.  All sulfur  compounds in the fuels
are converted to S02  during combustion,  and an FGD efficiency of 50 ppmv S02


                                     143                         :

-------
           TABLE 4.2-27.  SELECTED SULFUR SPECIES IN RETORT GAS FROM
                        RIO BLANCO MIS RETORT ZERO BURN
      Date
H2S Concentration
   (volume %)
Date
COS Concentration
     (ppmv)
10/12
10/13
10/16
10/17
10/20
11/08
11/10
11/11
11/12
11/13
11/14
0.024
0.071
1.10
1. 35
1.53
2.87
3.25
3.73
3.73
3.20
3.00
. —
__
—
—
10/20
11/07
.—
11/11
— • •
11/13
11/14
__
: __
, • --.
i
: 500
1 470
; —
100
--
50
• 50
Source:  Sklarew, et al., February 1981.
in  the  treated flue  gas was  assumed.   The amount  of  NOx  shown  is that
produced  from  the  fuel-based nitrogen  and  does  not include thermal fixation
of the atmospheric nitrogen.                                .     |   '        "

     The  flue  gas composition  reported by  Cathedral  Bluffs  is presented in
Tab lie 4.2-29   (Occidental  Oil   Shale,  Inc.  and  Tenneco  Shale  Oil  Co.,
April 1981).   The  data  in Tables 4.2-28  and 4.2-29  are  comparable,  except
the  latter includes the  contribution  from  burning approximately 2,200 BPSD
of a Lurgi oil.  The amount of S02 in the treated gas  is based on 95% removal
by weight, resulting in lower S02 emissions.  Also, the NOx quantity includes
thermal fixation of the atmospheric nitrogen.

     In Case Study B,  the retort gases are  desulfurized  prior to combustion
in the  steam  boilers.  The  Phosam-W overhead vapors  (see Table 4.2-39) and
Stratford  oxidizer  vent  gas  (see  Table 4.2-26)  are  also  added  to  the
Stratford  treated   retort gases.   The  resulting  flue  gas   composition  is
presented  in Table 4.2-30.  The  S02  emissions in this case are ^higher than
the FGD case,  primarily  due  to the contribution from the sulfur pompounds in
the oxidizer vent gas.                                            \
                                     144

-------
to
e
in
      cr>
«* eat-*

«D    to
   oe
   o
8
03
(M
CM






0?
!*».
E
CO

CM
in
CO
cn
in
*5j"
at
rH
rH


CO
CM
to


fv.
CO
rH
IO
O
8
in

CM

in
CO
cn
in
^j-
•>
rH





CM
CM
IO


•sf
•*
<4>
10


CO
CM




CM
2:

in
o
o
o
IO
^^

^.
in
^-
p>
rH
A
*


in
<3-
rH


^f-
in
CM
CM
in
o
0
o
10



«*
m
^f.
r/x.
rH

•cj*





CO
in
in
i-H


00

CO
CM


5



C4
O
O

CM
CO
CM
CM
CO


rH
CO
rH
^^
CO

CM


cn
cn
rH


<^j-
IO
a
o
rH
in
in



i-H
CO
cn
IO
m
•*
rH





%
rH


CO
CO
CO



a



o
IN
a:

,-j.
i^-
(O
O
rH
^^

^
O
O
*^-
in




cn
in
CM



CM
cn
CM
S
IO
o
rH



f^
C3
O

in







£
CM


,-J.
o
CO



CM
CO




CM
o

rH
CM
CO


O
1-1
CM




O
in
0
o
o

CO
rH
rH
0
O
m
in
CO




CO
o
IO
CO








en
o
o


0
CM
o



IO



a
CM
0
to

«*•
in
o


CO
(O
CM




O
CO
rH
O
O

CM
*^J*
i-H
O
O
in
o




CO
IO
CM







cn
CO
rH
O
0

CO
rH
O
O

CO
O
rH
CO



"x
o
z

to
rH
O


rH

O




cn
CO
o
o
0

CO
CO
o
o
o
S
0




rH

O







CM

O
o
0

o
o
o
o



CO
CM




o
o

CM
cn
CO
rH
rH
e*
S
rH
CM
rH
CM
m

a


o
Q
0
S


o
o
o
S
CO
0
m
CO

CO

"*
to
CM
CO

m
f**.
rH




O
O
O
O
rH

rH
O
O
O
rH



O
I—






















^t"
^J-

CO
CM






























••-i
^1
CM
•
O>
CM





















4J
j^!
21




o co CM in
o m co o
Cn O CO rH
r- to co
m «et- rH
W» A A
CO rH rH










fv>
in
CM co m o
CO CO rH O
• •00
cn I-H to o
rH tO












rH CO CM IO
cn in co cn
e o » c
in o co r«-
cn to co I-H
in «* rH

rH










CM in o o
CM «* «3- rH
• • • *
o *}• to o
CM (O




^*\
O
w
1C

0)
c
• fn
•a
«t
O <— Z 0 to
o
CO CO CO iO CO
•P SM^ ^J 4^ +.)
o o o o
1— r- 1— r-











,
Ul
ai
'o
^3

0)

4J

O

j__
1)

•*-
0)
x:
•f"^

c
"~
1
3
f«B
U
c
•p-

cu
J^
ra

>k
"§
in
O)
co
CJ
in
•i—
JC
•p
S.
o

in
' s-
o
a.
CO
>

•a
CO


o
3

0)
•p
jj;
•r-
-.,
E
Q.

O
in
i
Q)

O
•P

"^3
Q)
E

in
in
CO


0
i-
^J
c
o
u

CM
O

1
J3
CO
O
sT
.0


in
rH

p
CO
•o
O)
CO
5
to
d

t.
(V
+J
+J
CO

ai

cb
"^
u
•r-
4J
J_
CO -
.« c
o o
Ul
i— C
p-
01 c
•i—
CU >~-
3 cu
^*"
CM O
9-0
•• co
•^ s
2 £»
rH
• X
C §
CO

i*:
j=

C^ *"*
cn r<—

/it CO
5r f^j
— *
o *J

"P
_ in
T3 C
g 0
g -Q
3 S-
Ul «
Wl ^l
m o
S—
x -o
Z? -C

o




























































.
Ul
cu

CO
P

^J
in
0)

H-l
o;
Q


, .
0)
U
3
O
to
                                                       145

-------
I
tu
co
co
UJ
O cn

2^
O   -
i-« r*»
I—vo
1—4

O  E
a.  co
o •*->

053
LU
2
UJ
Of
en
CM
«M
UJ


CO


/~>
|*»s

g
CO
O)
i.
co
(A
re
ts
\s
U
CO
co
a
a
u_


/*x


i—
0
E
1
jQ
S-
•N^

f^

M
O
rH






£-
^
W
0)
i—
o
E
1
|i~"

^f


C
0)
c
o
a.
E
O
O
CM in CM rH CM CM
oo ID •si- «D r-» cn
rH CO 00 ID
^" CO "sj* CO
«t «s ««
rH •* CM
rH







^^ VO C7^ (^J 00 GO
r-.  CO rH

CM in VD rH r>.
00 VD «* «D CM
in I-H to cn «3" i
rH CO O ID CO 1
»* co vo co

rH si- t-t
rH







fx. CO f^. CM «efr
i**. ^Q fx, o in i
o «*• sf in co . i
r*. »^- CM tn in

r*> oo cn rH
O  00 rH

00
o
CO «* 00 CM «* r-i
CM «5j- iH CO VD CO






WO 
rH







(D
|x^
00

M
fx.
o
vo





                                                             ou
                                                             •o
                                                             •I—
                                                             0
                                                             u
                                                             o
                                                             a>
                                                             u

                                                             =;
                                                             o
                                                             co
                                146

-------
      TABLE 4.2-30,
COMPOSITION OF FLUE GAS FROM THE COMBINED STRETFORD
 TREATED RETORT GASES, CASE STUDY B
             (Stream 68)                     '
Component
N2
C02
H20
02
S02
N0xb
CO
TOTAL
MWt
Total 0 (excl
Total N
Total C
Total S
MWt
28
44
18
32
64
31.08
28

uding H20)



Mass %
65. 00
23.95
7.98
3.04
0. 0164
Or0101
0.0045
100.00
29.37
20.47
65.00
6.53
0.0082
Mole %
68.18
15.99
13.03
2.79
0.0075
0. 0095
0. 0047
100. 01





Mass Flow,3
103 Ib/hr (103 SCFM)
11,330.08 (2,559.19)
4,174.70 (600.02)
1,391.82 (489.04)
529.29 (104.61)
2.86 (0.28)
1.76 (0.35)
0.78 (0.18)
17,431.29 (3,753.67)

3,568.07
11,330.87
1,138.89
1.43
  Phosam-W overhead vapors and Stretford oxidizer vent gas for this case
  study are Included in the fuel to the boilers.

  NOx assumed to be 90% NO, 10% N02 by weight.  Also, particulate matter
  estimated at 149 Ib/hr, total hydrocarbon at 22 Ib/hr.

Source:  DRI estimates.                                          ;
     The  flue  gas resulting  from burning  the organic  residue  on the Lurgi
processed  shale  is   presented  in  Table 4.2-31.   The  composition  has beisn
estimated  from the  material  and  elemental balances,  and it doles  not com-
pletely agree  with the  values  reported by Cathedral  Bluffs (Occidental  Oil
Shale,  Inc.  and  Tenneco  Shale  Oil  Co.,  April 1981).   The  reported values
for the flue gas are presented in Table 4.2-32.

4.2.7  Process Wastewaters

     Because of the  temperature  profile of the MIS retort gas during a burn,
different  amounts  of moisture are contained in the  retort  gas  at different
times; therefore,  the quantity  of gas condensate, which  may be'obtained by
                                     147

-------
         TABLE 4.2-31.
COMPOSITION OF FLUE GAS FROM LURGI LIFT PIPES*
          (Stream 15)

Component
N2
02
C02
H20
S02
CO
NOx
TOTAL
MWt
28
32
44
18
64
28
31.08
Mass %
55.14
4.45
19.01
21.32
0.0032
0.0712
0.0078
100.00
Mole %
52.83
3.73
11. 59
31.77
0.0013
0.0682
0.0067
100.00

103 Ib/hr
1,913.82
154. 54
659.79
740.00
0.11
2.47
0.27
3,471.00
Flow
103 SCFM
432.30
30.54
94.84
260.02
0.01
0.56
0.05
818.32

Ib-moles/hr
, 68,350.7
,- 4,829.4
! 14,995.2
; 41,111.1
1-8
i 88.3
8.8
129,385.3

* The flue gas composition  is calculated  from  the materials  balance.   S02,
  NOx, and CO are assumed to be 20,  100,  and 1,000  ppmv  (dry basi:s)  in the
  flue gas.  Also, the particulate matter is estimated to  be 284 ;Ib/hr.

Source:  DRI estimates based on materials and  elemental  balances.;
            TABLE 4,2-32.
    REPORTED COMPOSITION OF LURGI FLUE GAS
          (Stream 15)

Component*
N2
02
C02
H20
S02
CO
NOx
TOTAL
MWt
28
32
44
18
64
28
31.08
Mass %
59.80
3.28
20. 34
16.50
0.0035
0.0757
0.0084
100.01
Mole %
59.00
2.83
12.77
25.32
0.0015
0..0747
. 0.0075
100. 00

103 Ib/hr
1,856.04
101. 72
631.31
512. 08
0.11
2.35
0.26
3,103.87
Flow
103 SCFM ilb-moles/hr
419.24 66,287.0
20.10 3,178.6
90.75
179.93
0.01
0.53
0.05
14,348.0
28,449.0
1.7
83.9
8.4
710.61 112,356.6
.''..-' .
* Particulate matter is reported at 0.06 grains/SCF, or 365 Ib/hr.

Source:  Occidental Oil Shale, Inc. and Tenneco Shale Oil Co., Ap!ril 1981.

                                     148

-------
cooling  the  gas,  also  varies with  time.    In  the  beginning of  a  burn, a
majority  of  each  retort  column  is  still  at  ambient  temperature.   The
saturation  volume  of the water vapor  in the retort gas  at that time is low
and  much  of  the  injected steam  condenses  in the  retort to. form the retort
water.  Very  little water  can be  condensed out of the  retort gas and very
little gas condensate may be obtained.  With  the progression of the burn, the
retort  gas  exit temperature  increases and  more moisture  is  carried in the
retort gas; therefore,  more gas condensate  is  obtained upon cooling the gas
and  the retort  water quantity decreases proportionately.   In  any event, the
sum  of retort water  and gas condensate quantities  should not vary signifi-
cantly*  The  text  and tables presented  in  the  following discussion refer to
the  retort at  operating temperature;  that  is, a  maximum quantity  of gas
condensate is obtained, but no retort water is formed.           ;

     MIS Gas Condensate—

     Table 4.2"33  gives  the  estimated  composition  of  MIS  gas condensate
obtained by  modeling the absorber/cooler.   Experimental  values obtained for
gas  condensate  from  Room 6 are  also presented for comparison,   Since the
values for dissolved  organic materials and total dissolved solids could not
be  estimated  by modeling,  Room 6 data  on  these components  have been used.

     Lurgi Gas Liquor—                                          ;

     Table 4.2-34  presents  the composition  of  the  gas liquor obtained from
the  Lurgi process.   The quantity of ammonium sulfite  is  that resulting from
absorption  of S02  in  the  gas liquor.   The miscellaneous  hydrocarbons are
composed  of   phenols  plus   fatty  acids   (Rio   Blanco  Oil   Shale  Co.,
February 1981).                                                   :

     Treated Gas Condensates—                              .     i  •

     As stated previously,  the gas condensates contain a significant portion
of  the ammonia  originally present in  the  retort  gases.  This  ammonia is
recovered in  an anhydrous  state  as a by-product.   The treatment technology
selected for  this  purpose  is  the Phosam-W process.  For both case studies,
the  gas condensate from the MIS process, gas liquor from the Lurgi process,
and  overhead  vapors  from the  retort  water  steam  stripper are  combined as
feed to  the  Phosam-W  ammonia  recovery unit.  In addition,  in Case Study B,
the  precooler  condensate from  the Stretford  unit  is  added  to  the  feed.
Overhead vapors  from the Phosam-W  unit  are  sent to the  steam boilers where
they are burned along with the fuel gas.

     In both  cases, the NH3 level  is  reduced to 0.05  mole %  in the treated
water.   A constant amount of the treated water  is  recycled to the absorber/
cooler to scrub out NH3 from the entering gas.   A portion of the net treated
water  (after  meeting  the  recycle  needs)  is sent  to  the Lurgi  waste  heat
boilers and  the balance  is sent  to  the kettle  evaporators;  both  of these
units produce a low-quality steam to be used in the MIS retorts.  The kettle
evaporators also   receive  the   stripped  retort water  and blowdown  from the
Lurgi waste  heat   boilers.   The concentrated waters  from the  kettle  evapo-^
rators  are  used  for  Lurgi  processed shale moisturizing.  Tables 4.2-35 to

                                     149

-------
               TABLE  4.2-33.   COMPOSITION OF MIS GAS CONDENSATE
                                  (Stream 48)
Component
C02
NH3
H2S
H20
Hardness (as CaC03)
Alkalinity (as CaC03)
DOC
COD
BOD5
TDS
Value,
Room 6 Burn3
14,400
9,600
—
remainder
<2
24,000
800
2,300-3,000
600G
270
mg/1
Estimation
17,200
13,900
125
remainder
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
Mass Flow,
10s Ib/hr (gpm)
33.00
26.65
0.24
1,857.98
<--

1.53

—
0.52



(3,716)







  Analyses performed by WPA on gas condensate from Room 6 burn at Logan
  Wash.

3 Obtained by computer simulation of absorber/cooler on the MIS retort gas.
  N,,D. = Not determined.

  Gas condensate appears to contain bio-refractory material; therefore, BOD
  is; below actual organic carbon.  90% of the organic matter is volatile at
  100°C.

Source:  WPA estimates.
                                     150

-------
                TABLE 4.2-34.   COMPOSITION OF LURGI GAS LIQUOR
                                  (Stream 29)
Component
NH3
(NH4)2S03
C02
Miscellaneous Organics
H20
TOTAL
Mass %
1.16
0.26
1.51
0.16
96.91
100.00
Mass Flow,
Ib/hr (gpm)
1,944
442
2,516
261
162,000 (324)
167,163 (324)
Source:  DRI estimates based on  information  from  Rio Blanco Oil Shale Co.,
         February 1981.
4.2-37  and 4.2-38 to 4.2-40 contain the Phosanr-W feed compositions, material
balance around the Phosam-W unit, and material balance around the Lurgi waste
heat boilers for  Case Studies A and B, respectively.             :

     Retort Water—                                              ;

     As  stated  earlier,  retort  water is obtained  for the MIS process until
the  retort gas is  hot enough to contain all the  water, in vapor form.  The
retort water from Roora 6 was analyzed periodically during that burn (Loucks,
November 1979).   The  average  composition  for the month  of  November 1978,
when the  retort was  judged to operate under optimum conditions, is given in
Tables 4.2-41 and 4.2-42.  The  TDS value of  8,400 ppm  from Table 4.2-41 is
used for  the retort  water.   TOC has  been  analyzed  to  be  3,400 ppm  in the
Room 6  retort water  (Hicks and Liang, January 1981);  therefore,,that value,
instead of the  average value of 2,690 ppm for the month of November 1978, is
assumed.   The  organic matter  is  assumed to be 75% dissolved  organic carbon
by weight  and,  based on the treatability studies,  20% of the organic matter
is  assumed  to  be  steam  strippable.    Finally,   ammonia  is  assumed  to  be
1,300 ppm  of the  water.   (Table  4.2-41 indicates an average of 1,700 ppm was
found.)

     The retort water,  as mentioned previously,  is used in the kettle evapo-
rators to  produce low-quality  steam for the MIS retorts.  It is necessary to
remove a  majority of  the dissolved gases and volatile  organics  before this
use.   The  retort  water is steam stripped to remove the volatile matter.  The
overhead vapors are  sent to  the Phosam-W unit for recovery of ammonia, while

                                     151

-------











>-
o


to
Ul




a-
in

a.

Ul
§
u
•^


fs

3 sT
i «*•
CO CO
s*
o. -
g^
u)
O €
oi m
-tvt
£
u»
1

J!?

(O Ul
** o
O -EC
H- a.



Of

u t-

O) O
OS O <*»*
o *t

°i *" *
*> OJ E
«J .a re
T3 Ul +J

§:<«

S- +•>





(0
fcl~
+J S- CO

O £
tre
S- 




0}
n
m
c ^^
CJ CO
c
01
(A S-
(O 4->
O to


E


!~

u> E
!-S
S"i3

.4












•J
S

^
A


(A
(tf
S





O)

s.
J=

5

M
Ul
(A

^
S
U.
CJ
to
M
o
rH

t.
•5
r^


«
U>
S

^
E
t.



^
u>
U)
n»

^
t-
•"s^
jQ

«
tA
tn
S





c
i
o
§•

o


eg

s



s
)-f






1
1








i


o


o
CO
s
CM



S
CM




o
0
o
CO
CO



CM

rH


S
in
eg*


T-t
in

rH











^ I 1
«tf* 1 i
rH*


s

rH | i
1 1







CO CO CO

Z IE r-


to
O
tn

CM



s
, o






f**
in
rH





§

O


to
Q

0
^.
in
m




tn
o




in
rH



S

o


rH
S



to
rH

O

(A
=1
O
O) Ul
{=. U
HJ -P-
»— e
r— R]
0) D)
u t-
tA O

£


CO
rH
r-





rH
CM
O
O






s






CM
CM
o

O






1
t





1
t



1
1






I
I


s



a-

ep.





«

. C4
2

Vri>*
r-l
CM
 CM
cn cn
r*^ oT
in rH
co en
r-l rH


£ 8

en o

§
**-*
§i ">
1 >o
°J --1
CM] p^
rH| rH

rH O
cn o

ID O
cn o
rH





1—
g
0

£
152

-------













<

§*"

Ul

g

*/»
to
Ul
S
o>


i
Ul
tn
is


^ S
1
V> ID

§«
i I
Ss
i
^

Ul
^c

to
CO
CM
Ul
•J













































c




1—
s-
1




























U

T3 CM
Q (>
£.
0. E
n
(Q Q
•r- &.
C -M
0 V
•X
fi_
o^*
2 Q.1-
1 ««
S» -a n
O «0 0)
s- cr

o
UI

O
O « /—
*> «-m
o~<0
£• O>
SfSTE
> n
a> i
•P i— tr



S253
U. (A



t.
O O "d-
iff
u s- -t->


(_
^

U.
M
t-J
S-
*»^
^



«


&.
^
J3





2



JT
\


c^
t.
^


in
u>
E


£'
S.
i

^
(A
IA

£




+>
ai
.c


o
o
^
CM
•CO
CO '


i if t i t ii
1 g • ' . ! !

CM
in CM O rH eC
m o o o u:
v^
«* •* e i co i o
CM S ° ' g ' °
CO CM Ul
CO «J-



«H
in


1 O 1 CM CM tn i-I
i cn i «3" CM r*. r*.
CO *!• CM CO «*•
CO
in
rs.


^s
I
i to i oo cn r^ o
1 «&• 1 1** CO ID o
t-l 0

CO

I
CM*
i cn i «^* r*» t~) to
1 00 1 r~f tf) P*» OO
in co i-i CM to
I
rH


LO CM CM CM Cn
O O Q O 'CO
i o i o o C3 cn
i i cn

i-4
CM
ID
^ co o *& 10 co r*»
a s g s s s s
co cn CM CM
CO CM tO
CO
CO
s s 1 i 5 s s
i-t o o o o o r--
cn


s
o
co n
i— '£ ^
»— ID «
o> o> «-%
US. 9
e§Ii><^g420I
-------






*^

>•
o
3
1—
VJ

LU
t/>
*^
o

4S
ec
UJ
t-^
o
m
as
LU
>
o
o
UJ
BC

r™
*^
LU
3» ^*^
CO
UJ CD
r-
«/J «
3SCM

1— 1 «
O cn
Gc rH
*^-
«l U>
«-.. —
C.JI (Q
s:  O
C UJ S-
O> -P
O V CO
a r— ^>
0 -P
O -P
0)
*s^*


a.
a>



s-

v^

r—





^o /

U)
(A
re


>^<





U)
•O +J *»^.
§s- cn
0 rH
t- -P
O (U £
u. ee re
0)
e co s-
re 1-1 -P

re
*Om







1
S- £
cu re ***^
•P in co
re o co
3* ^
a. e
-a to
QJ E ai
Q. 0 S_
Q. S- -P
•i- U, CO
£_ »^^
+J TJ
co at
at
u.


^ "^
£
Q.
O)


s-
JZ
-Vs

r—






^^

U)
Ul
re



•p
c
at
c
o
a.
£
0
0




i













i
i



<-^
UO
o

o



CD

rH






CO
o
.,
o










CO

rH








r*.

O
,
o










CO
a:





CO










rH
rH

O












1











1
I









CO
r-.









co
CM
o
•
o










CO
a

       01
       co
r-.    o
CD    o
       o

       o
       r-
                        co


                        o
      r>-
      O
0
rH
                   CM
                   cn
                   cn
           o
           o
                   co  co
                   co  co

                   S  cS
      O  CD
      O  •*
      O  rH


      O ,C?


      CM  CM
                   CO  O
                   cn  o
      cn
      CO
            CO
      CM
      O
CM
O
                   cn
                   cn
                   o
                   CM
                   CD
      o
      o
      o

      o
      rH
      CO
CO
CO

cn
cn
           o
           o
           rH
O
co
co

o
rH
co
o
o
                       O
                       o
    in
    3
    O
    0)  in
    c  u
    re T-

   r—  re
    01  o>
    u  s-
    tn o
 «
O
CO
           P
                  o
                    M
          O

          (U

          re

          co

          o
          u

          c

          a>


          •a

          re
                                 0
                                 01
                                 CO
          c
          0)
         •a

          u
          o
         o
                                 c
                                 o
                                 •p
                                 re
                                 o
                                M-
                                 c
                                 o

                                •a
                                 ai
                                 in
                                 re
                     in
                     01


                     re rH
                     £00
                    •i- cn
                    •P rH
                     U)
                    
                     u
                                 o
                                CO
154

-------













CO
>••
=3

*A
UJ
s

j/>
§

>:
S
1


is

§ CD*
in
J«-
i™
§e»r
«•

Sen"
UJ W
UJ €




!-



O
i .
1-4
i
|


CO

i
CM
UJ
_J
CO
g
















5S
C
4J /
u. r
r- H
SUJ
0



"fc
&r^
OS 0^
t-"S
•*•» a) gj

3c fc Q)
•O « 4^
Of .Q t/)
O.
-P
CO



s
feiicn
id >
SOS
(O
*> (- C)
t- o> t.
SQ.4J
a. vi


u a> o
at *» in
s-  e
e 



tn
*g
s
f~
^
r2

W
Ul
flj
55
1
cn
j.
^
£


in
U)
nj
u?

CO
0
s
^
^
^

«
Ul
U)
E
l^-s

o.
*s.





Ul
Ul

3£






Ul
=
1
cn

|
*

V
ai


*>
s
c
o
1
CM
CD
cn in rH CM en cn co
m cn ro co *f 10 m
CD* CD" CM" in
^r cn CM
in
cn
en m cn
3 S § S S g S
tH CD O* CD* O O P^
cn
§
•^
pH
s
CO

o
CD
o
s
1
CM
i cn i CM in p*. o
i co i o <^ m P"»
in CO rH CM P-
IO

CM
fH
^r m rH
SCM CM CM CO
O CD O CO

1 CD 1 CD O O Cn
i i cn

O CO rH tO in
*r CM o o co
CD CD O CD CM
•^ *~> ^ ^ m
| S S ! S ! |

~ s

CM rs to r*» cn
co p*- o in !*•>

CM CD CD* 1 CD 1 in
i i cn

CO
s
CO
V
CM
cn
cn

en
cn

o
iO
ro
CO
g
to
cn

s

s
rH
£J-

CO
CM 0 0 t 1 1 «*
m CM rH t i i en
CO O CM
CM rH tO
to
rH

to
r* o o CM
ro to o o

rH CD O 1 1 1 CO
i i i cn
to
CO
to
rH


cn
cn

en
cn
<-*
a
p*.
0000 ^ 1 CO
o m ^r CM co t r-.
o to CM in in cn

CO *O rH r*»
co CM in
CO

rH
CM cn p-t CM -co r-..
P*. CO CD O O P*.
rH rH CD O* O t id
i cn
N
cn

rH


fH
§
o
s
*— '

tO *f 1 1 rH .CM Ol m
in cn CM •* CDJ 
o
t/}
155

-------
•£§
§'~
5<

                   CM O
               18 -4-> tO (/}
                      Q.
*     S
HI     U.

£.   £?tn

                    2.
                 S- ID
               &v O tO !
               0) Q.   i
               t. "S CO E
               a CD 10 a.

                 rd ro

              •D   4J ^*.
               u ain jz
              O 0) 0)
              5"8 4;
              " o trt
s
                   £»«
                                                               3
                                     to
                                     0
s
o
                                               •8


                                                           s  s
                                                           POl CO
                                                i   S
                                                          s

                           SCO
                           CM
                      O    O
                                              OJ U)
                                              C U    <0
                                              tti cn   ^
                                              u i-    v
                                        156

-------





oa
>_
C^
«3
to

UJ
CO
s
,,
OS.
UJ
o
en
O£
UJ
1
UJ
t—
2
3=0
. °°
1,1^ to
t—
to •
Is CM

»— 4 o
o cn
gi-l
MO?
-J V>
£:
z  s-
o •<->
O£ CO


U
1
_•*•
S
ca
«c
HH
OS
LU
Q o
•)-> S- CM
(0 O
t- CL E
+> nj re
c > 
S 0 rH
S- 4->
O 0) E
u. a: to
ai
S CO S-
eu s co

CO CJ




/_>
S
U.
o
co
n
o
iH
S-
•V.
i—


^
(A
U)
S




3=
B
Qj {O ^*s
4J W CO
m o co


O O O O CD
Q^

o
o

o
o
iH


(A
3
O
(U  r-l

-------
TABLE 4.2-41.
COMPOSITION OF RETORT WATER FROM MIS PROCESS3
         (Stream 41)
Component
Total Alkalinity (as CaC03)
Bicarbonate (as CaC03)
Carbonate (as CaC03) .
Total Suspended Solids
Total Dissolved Solids
Sulfate
Chloride
Fluoride
Phenol
Nitrate
Oil and Grease
Sil ica
Sodium
Potassium
Arsenic
Iron
Magnesium
Manganese
Boron
Calcium
Vanadi urn
Copper
Molybdenum
Lithium
Zinc
/Aluminum
Barii urn
Strontium
Lead .
Suifite
Nickel
Cadmi urn
Ammonia (as N)
Selenium
Mercury
Range, mg/1
10,200 - 12,600
9,200 - 9,900
1,000 - 2,800
100 - 9,900
2,500 - 13,000
1,200 - 2,500
58 - 180
27 - 34
20 - 44
330 - 640
200 - 300
26 - 28
4,000 - 4,400
81 - 97
0.23 - 0.38
<0.5 - 2
6-29
<0.02 - 0.02
3.7-15
2.7-70
<0.1 - 0.1
<0.02 - 0.04
0.07 - 0.4
2
<0.02 - 0.03
<0.02 - 0.2
2 - 3.3
2-4
<0.02
0-90
<0.02 - 0.04
<0.02
1,300 - 2,000
<0.02
<0.02
Average, mg/1
11,420
19,620
: 1,800
1 410
^8,400
>1, 800
97
31
1 27
460
1 250
27
i4,300
: 89
0.26
0.8
i 15.5
j <0.02
1 10
; 3.4
<0.1
 <0. 02
! 90
; <0.02
i <0.02
H,700
<0.02
i <0.02

a Average for the month of November
One sample analyzed was unusually
' A drastic reduction in the calcium
November 1978.
1978 for Room 6 burn at
high in total suspended
Logan Wash.
solids content.
concentration was noticed from


Sulfite levels were almost zero prior to November 1978.
Source: Loucks, November 1979.


158 -
i
i

-------
       TABLE 4.2-42.   OTHER PROPERTIES OF RETORT WATER FROM MIS PROCESS*
                                  (Stream 41)                    |
 Parameter
                                                         Value
  Range
                                                                  Average
 TOC,  mg/T

 DOC,  mg/1

 S203=,  mg/1

 Nitrogen (Kjeldahl),  mg/1

 Fecal Coliforms,  Colonies/100  ml

 Total Alpha,  pCi/1

 Total Beta, pCi/1

 Radium  226 pCi/1
940 •>. 7,685

838 - 2,561

 56 - 214

  8 - 1,340

   <1

 11 - 29

  0 - 65

0.2 - 1.5
2,690

1,660

  138

  420
   17

   31

    0.8
* Averages for November 1978  for Room  6  burn  at  Logan Wash.

Source:  Loucks, November 1979.
the stripped retort water is sent to the kettle evaporators  for producing  the
low-quality  steam.   Nonrecoverable  compounds from the  Phosam-W  unit  are
removed in the Phosam-W overhead vapors and sent for subsequent dombustion in
the steam boilers.  Table 4.2-43 contains the  balance around the Iretort water
stripper.   Both  maximum and  average flows  and compositions  for  the retort
water are given.
                                                                 i
                                                                 [
4.2,,8  Steam Generation                                        .  >•
                                                                 !
     Two  types  of steam  are  produced  for  the process  needs.  High-quality
steam is  produced in steam boilers using treated  mine water.   T;his steam is
used for  driving  the process  turbines, for  generating  electricity,  and as a
heat source  for  the  kettle evaporators.   Low-quality  steam  is (produced  in
the kettle evaporators  using  process wastewaters as the feed.  This steam is
entirely  consumed in the MIS  retorts.  The  feedwater to  the kjettle evapo-
rators  is  composed   of  the  stripped Phosam-W  condensate, stripped  retort
water, and Lurgi  waste  heat boiler blowdown.  After producing the necessary
amount of steam,  the concentrated  water is  used for  Lurgi processed shale
moisturizing.   Tables 4.2-44 and  4.2-45 'present the material  balances around
the kettle evaporators for the two case studies.                 j
                                     159

-------
S!
Q.


I
I
j-^j.

oe w

si
~
«

UJ



§



/«
rr
f
•s
a
1
o
s.
-01
g
5
VI








• ^
CM
tt
10
1
VJ
J.
0)
1
a
a
to











^
rH

a
1C
£
-P
I
i to
*
I
S












I
01
OJrt
IS

*!
§
s"
II

^£
!a
"~

^

U)
Ul
(O


*•%
0) O.
Ol *.
> ^
J3
*"*



at
3 Oi
|j




Ul
Ul





a>^
0) S-

is




^^
§1
s v
n £
Ex7

U)
(O
a






•a
V
I
S
§00 r? S in
CM o o 03
O O O O CW

•*-•
CO 0 0 »
i en i rH  trt o> w o
CJ 2 X* 0 S z"
§
CO
eo

in
o
sf
tn
m
^

!-

^

o
o
o




i

m"
a





tH
S
cn


o
o
I






1
r-f
to





S
CM
CO
8
CM
S
O
o






—4
O
h-






0.
I
Ul
' 1

Ul
J3
•o
0
w

1
U)
to
CO
Ul
1
1

U
c
o>
o
•e
**—
o
-U
§
0)
o.
•^
3c
**
c? °*
CO en
S rt
S-
>» Ol
c s
3 W
1 1
Ol Ul
c m
*«• 3
-J ^
= E
nj Q
tn 
-------




















—I -P
Q£
1

I
a
s

























c


«
1






























•P
c


.
K-
£
O
<*-
-*r* O
13S"0
I- 3 *>
lei
U O
£= S- OJ
" 1


in

II
01 S-
1^
Ul 1


•gj

as
||
"»-








lO 5
''^ CT

J-

*-""

S
U.
gto
«
IS
t-
4J S.
A




o) a.
Dl O)
IT

< \





E

cn cn
« s.
> XT

r—

^
P &
is

'x f.

s£^
r~

it
O)
1^
*>--«

'e
en c»

li «.
*l




O
E a.
3 cn
£ V
*x t-

jQ

•P
5
§
I
U

ro
in
en
i r*. oo «s- f*»
t co r** o o
^r «j tn m
m rH tO
ft

rH CM f*«-
CM rH in
»— • w en
m
<• i cn i o
tn 1 rH 1 O
m r^ o
a
in
rH
^
S

en

Sr*«. P«» •* f*.
co cn o o
in ^ en en m
in CM u>
00
10

rH
en
rH
O
rH


0 ° 2 ' &
en en rH i o
rH CM m
.
in CM to
s
to
3
en
****
S S S i 3
rH en en co

S °°" S
cn
^^
3
i co cn r- o
i r*. en to o
o
r^
esi


^- cn o p«» cs
CM f«. v en o
If) CM rH CM O
o
rH
rH
rH
^^
r**
rH
m
m

O CM CM in rH
en **• CM r*. P*.
CO ^ CM en «*•
ca
tn
H
| €


CO
-
m
fH
in




S
IO

a"



1
r*-



CO
rH
a
rH
rH






O
en
o
rH

|


161

-------

















CO

1
v>
UJ
s.
l~

1R.
ujg
uj S
13"
as
5i
.< nj
«C v)
u?
i

X
•»
m
S




























1
«S
(0 
Si
1s*
a.
I
^^
at a.
41 fi.
*|


'*O JS
_
&.
4)
m (TH O O £
+> wca CM a.
S BZ 2^
i^^S^
O U)




iO

ID E
Ul (Q
C CU


C V>
O *— '
°3
II
«
•M a.
I 0



*^
0 a.
(TJ X*r


^
r-





s
1 a.
1 ot
Jjz ^^
*§£
^
r—



c
IV
s
0
1
i o co in r-| in
l_ C3 CO 1-i O| CS
tn to co oj m
*f\ tn
cn| ro

*o CM p-
CM rH tn
o o o
^^ *n
«f 1 rH i O
S ' S ' S
s
in
rt
CM
°^
C3
tr>
tn
s
s

r?
CM
p*.

CO*

s § s s s
to m ^ ro o
m CM to
CO
I
«*•
S
rH| rH
rH
O

o o oo i r^l in
("1 CO rH | Ol 00
rH CM SI CO
in" CM «M m
of rH
ml tn

1
•f o *f t m
rH CM in | 4-
rH CO CO 00
S °°~ S
o»
s
in"
en

o
s
*^s
i in to ^^ esi m
, r^ co to oj ^
Sle

en
m
tn
CM
^^
^ m O rH O
co en tn m CD
tn CM rH CM m

p**
CM

rH
o
CO
s.




v-4

to
in
CO
c
fin in co en
<4* CM ro en
I*-*
".
rH
f^
CO
en
a
^

eo
0> O —1
u tn <:
'c £ o
BJ W H-
« co en z o




















































(A
+J
1
**
(A
Of
Q,
3



1
O
CO
162

-------
4.3  POLLUTANT CROSS-REFERENCE TABLES                            ;

     Tables 4.3-1  through  4.3-3 list some pollutants  of  concern;,  by medium,
and provide a  cross-reference to the numbered  streams in this manual.  Many
of these pollutants  are trace constituents, and measurements  toi identify or
quantify them  in  oil  shale processing related  streams have  never been made.
Those pollutants  which  have been identified in the  plant streams are cross-
referenced to the detailed composition tables.   Engineering judgment was used
in  identifying other  probable  pollutants.   The  entry   for  "unknown"  (U)
indicates that no testing  has been done and the presence  of the pollutant is
unlikely.  Judgment  was also  used  in specifying the  pollutants! which defi-
nitely should not be present.                                     !
                                    163

-------
g
             U S-
           r» *r» 0)
           o c *a

           111
           £
               -§
               1
                              z  z  z z
                                                                                                   z  z    z
flu a.  a.  z  3E.
                                                                                        •a
                                                                                        §
                       a.  =s  a- a.
                                                                                                               z  z  z  z
                                                                                                      >-    >• z  z  a.
                                                                                                   z  z    z
                                                                                                      >•    >• z  z
                              zzzzzzzrszzzs
                                                                                 zzzzszz    z



                                                                                 zzzzzzz    z



                                                                                 zzzz=>.zz    z
                                                                       zzzzzzz
                                                                                 2ZZZO.ZZ    Z
                                     3  =3  =  =>=>>•>•
                                                                       >- >-  z >•  >• z
                                                                          Z  Z Z  Z
                                                                                 ~
                                                                                 «r
                                                                          So
                                                                          iH
                                                                        I   I
                                                                       CM CM
                                                                                               CM     CM CM  CM
                                                                                                                      cl,  A  i. A

                                                                 164

-------

   OS-
i— ••*•  a»
O C 4-»
3 « *>
19 U  3



  OS V)
     s
          ZZO.O.
                                          ZZZZZZZZZO.CLO.
                                      z  z  z  z
          ZZO.O.
          zzzz
                                      z  z  z  z
                                  z  z  z  z  z
                                                                 z  z  z  ±>
                                          ZZZZZZZZZZ33
                          zzzzzz
                                                          z  z  z  z  z
                  >->-zz
                  >->-zzzzzz
          zz>->-
                                      z  z  z  z   >-  z
              CM  CM  CM
                                                                                             •£    II  II  II II
                                                                                             1    ..
                                                                                             r   i
                                                               165

-------
2
                                                                >-        Z
                                                                                         >-    >-  Z  >-  >-  Z  Z  >•     >•    !>•>->->•
                   >-  a.  >-     >->•>">•>•    Z   >-  >•
                                                                                     >•  >-    >-  z   z

>- Q- a. zzzs:>-
0. 0. Z ZZZZZ
a.a.z zzzzz
a.o.z zzzzz
a.a.z zzzzz
a.a.z zzzzz
a.a.z a.a.a.a.3
a.a.z a.a.o.o.0
a.a.z zzzzz
O.CUZ ZZZZZ
a.a.z zzzzz
a.a.z zzzzz
a.a.a. a.a,a.a.a.
a.a.z zzzzz
cTin in
«»••* m

Z >• >- >• Z 0. >•
z z a. a. z z z
z z a. a. z z z
z z a. a. z z z
z z a. a. z z z
z z a. a. z z z
a a. a. a. a =3 z
z a. >• >• p =9 z
z z a. a. z z z
z z a. a. z z z
Z z a. a. z z z
z z >• >- z z z
3 a. >- >• a. a. a.
z z >* >- z z z
r-* cj ^r »n
irl ••*'«• m
                                                                                                                        >•    >-    ,>•  >-  a.  a.
                                                                                                                    z  >•    >•
                                                                                                                    z  >-    >-     >.  >-  a.
                                                                                                                                    !Z  Z  >•  >•
                                                                                                                                    iz  z  a.  a.
                                                                                                                                    I.Z  Z  O.  0.
                                                                                                                        a.     a.   j a.  a.  >•  >•
                                                                                                                                         z  >-   >•
                                                                 ~™     ™
                                                         ca    o rH ro
                                                                     -
                        i    i  i    i        i    i    i  i
                                                                 lit    II
                           CM CiJ  CM      CM  CM  CM CM  CM  CM  CM CM CM  CM CM
                                          to  torn  tnooo  o>  «$•  in


                                          «  CJC4  CM CM  CM  CM  CM  CM
                       SS
CM     <-toco     omt£r«>cncMm    <^    'mu^tor^
^     ^^«^     u)mir>mir)<0
-------
to
•»
                                                    z  a.  a.  z
                                                                                                 ZZZZZa-ZZO.
                                                                                a.  a.  a.   z  z
                                                                                                                     >•  a.  a.  >•  a.
                                                                                                         1:20.0.0.0.0.0.20.0.
                                                                                                                 a-za.a.za.z
                           a.  a.   a.  a.  a.
                                                        a.o.o.o.a.a.a.CL
                                                                                    a.   a.  z  z  z
                   a.  z  o.  a.   a.  a.
                   a.  z  a.  a.   a.   a.
                                                                                                             20.0.0.0.0.0.20.0.
                                                                                                                 a.  o.  o.  o.  o.   o.
                   a.  z  a.  o.
                                                                                                         z  z  a.  o.  a.
                                                                                             z  z  z  z  z  a.
                                                                                             z  z  z  z  z  a.
                   a.  z  a.  a.   a.   a.  a.
                                                                                    a.  a.  z  z  z  z
                                                                                                                                      a.   z  a.  a.
                                                            cua.a.a.a.a.a.a.
                                                                                                                     a.  a.  o.  a.   a.
                                                                    a.  a.  a.  a.  a.  a.
                       CO  CO  CO   CO   CO  CO  CO  CO
                                                                                                                     *   -X       *           *   *
                                                                                                 OpOOOOOOoSSSS
                                                                                             O  O  O
                                                                            167

-------










J
£
CM
m
a
S








•









Ul
i>
S













(A
(/)
Ul
1
-C
Q.
O
P
ac '
c
>
re
DC

£
^_
=

S1
U_
S
S.

S
m
S.

s
i
1
jo
0)

>. ^ >.

0. >• CL
Q. >- >•
Q. CU Q.
CL Cw 0.
Cw CL 0.
CL CL CL

0.0.0.
Q. a. a.


a. CL a.
Q, O. Q.
a. CL CL
0.0,0.

CL CL CL
0, 0. 0.
CL CL CL

a. CL O.
CM
r-i
~

1 1 1















c
c
a>
01
.c

o
1
i
o
£
c 3:
^ o> ^e ui
*> *» b> c at
C Cu =3 -*J
ui ai m
£ w >» a* E
£C S- J3 C •«->
Ol CL (0 4) «
•U Ul J5 Wl Of
Ul CL 5E CL CL S
-S II 11 II II °
U >-ZCL=»
ff O
•g .. g
" >l 3
« S 5
168

-------












.
g

a
C-H
_J
8
ee
o
U.
UJ
z-
UJ
QC
a
OS
1
i

s

to
a
§ '































(A
•o
ro
N
w

c
m
r—
O
Q-




























1
c >,
i
4J U

Q- O
*>
+5"
O -^
v >

"> O
p
if?

S"a



SS
i^t A



f- UJ
+> 01
 3

=> = => = 0 Q. = =5





a. a. a. o.o.a.zz

O.O.Z? O.O.O.ZZ


= = = => = = >->.




>->-z >-^o.zz





zzz zzzzz

>->->- >->->-zz






"



ceT
CJ
**


till 11
c\j c\j ca eg CM CM




* < •* -K «
r-i Csl f>« O U) U3 O -ft





























c
1
c
5
.c
;
U
(Q
C
0
s
c
•r*
i
U . 4-> C
«J Ul C
.C XV ^ Ul
+J *> &. C U)
CO.O +J
Ul 0) CO

CO •*•*  O. Q 0) Ul

w S "o 2 2 w
Ul OB 5K Q> CU. C£
•S H U U ii a
(0
0 >-ZO.= »
e s-

169

-------

-------
                                  SECTION 5                     :

                        POLLUTION CONTROL TECHNOLOGY            i


     This section presents an inventory of pollution control technologies and
discusses, in depth, some representative controls for each medium (air, water
and  solid waste).   The inventory expands beyond  describing the;technologies
that have  been  proposed for the MIS-Lurgi processes  at Tract C-^b.   That is,
it  discusses  alternate  and  additional  technologies  that provide  varying
levels of  control.   Although  the inventory is  quite  extensive,'other possi-
bilities may exist and should not be excluded from consideration;   Changes in
the  design  of  the  plant  complex,  changes  in  the  assumptions made  (see
Section 1.5),  and/or  improved  data  from  future testing  could\  lead  to the
selection of different controls.

     Each subject area for control (e.g., particulate control) begins with an
inventory of available technical  approaches,  or technologies.   Promising new
control  technologies  not yet applied  commercially,  even  in  related indus-
tries, are  also included in  the inventory but are not described in detail.
Such new technologies may be applicable to the oil shale industry if they are
sufficiently developed  and  tested in the future.  The  inventory  is  followed
by a discussion  of the most important considerations in selecting a control.
Finally,  a  more detailed analysis  of performance and  cost is presented for
the control  technologies  that have  been considered by CathedraliBluffs Shale
Oil Company in conjunction with the MIS-Lurgi processes (see Sections 2 and 3
for descriptions of the case studies which include the proposed processes and
technologies).                                                   ;

     The  detailed  analysis  seeks to estimate  pollution  control  performance
and  cost.   Performance estimates generally  require  no more than conceptual
designs;  however,  the  reliability  of  the  performance  estimates  varies
depending  upon the  application.   The  estimates should be  highly  reliable
where a  proven  technology is  applied to a stream for which experience exists
(e.g., flue  gas  desulfurization)  but may be much less  accurate: for controls
which  require  testing  and  which  are  applied  to  unconventional  streams
(e.g., biological  oxidation).   All  performance levels  are  given  for instan-
taneous control  and  reflect optimal  operation, which may  be higher  than the
average  level  of performance  actually  achieved.   All  cost estimates are in
mid-1980 dollars and are  taken to the  level of detail  believed to be neces-
sary to  achieve  ±30% accuracy.   This level of  accuracy is based on the cost
of equipment already built and operating in related industries.
                                     171

-------
 5.1  AIR POLLUTION CONTROL

      As in other  industrial  and oil shale operations,  the  MIS-Lurgi  plant—
 from mining  activities  to final product storage  and transfei—will  generate
 particulate and gaseous  component  emissions.   The primary air emissions are:

      •    Particulates,  TPM                                     ;
      •    Sulfur Dioxide, S0?                                   i

      •    Nitrogen Oxides, NOx

      •    Carbon Monoxide, CO                                   \

      •    Hydrocarbons,  HC.                                      l
                                                                 i
      This  section  describes  the current, commercially  available  alternative
 systems for  controlling  the  above primary pollutants.   The following  sub-
 sections provide inventories  of control  technologies for each of;the air pol-
 lutants, a discussion of advantages and disadvantages, and  important  points
 to consider in  selecting a particular technology.   Performance,  design,  stnd
 cost data  for the  leading technologies examined are also presented.

 5.1.1  Particulate Control

      Particulate matter  is generated during the mining,  crushing, conveying,
 and  processing of oil shale.   Particulates are emitted  from fugitive sources
 such as conveyor belts  and  from  point  sources   such  as  flue  gas stacks.
 Fedisral  and State  standards and regulations limit  these  particulate emissions
 because of their  potentially hazardous effects on human health!  and the  en-
 vironment.                                                       ',
                                                                 j
      Inventory of  Control  Technologies—                         I

      As  shown in  Figure  5.1-1,  particulate control  can be  divided into  two
 general  categories:                                              j
                                                                 i
      •    Control  of point sources                               ;
      •    Control  of fugitive  sources.                           '


      The particulate matter  from  a point  source  is  confined 'within some
 equipment  boundaries  and  is controlled  by passing the dust-laden   stream
 through  a  control  device.  Fugitive particulate matter  is unconfined  and is
 generally controlled by wet suppression techniques which are generally  not as
 efficient  as   the  point   source  control  techniques.  Table  5.1-1  presents a
 "listing and review of particulate control technologies.          !

     Control of point sources.   There are  two  primary classes of;  particulate
 control  equipment  for  point sources:  dry and wet.  Both classes;  offer proe~
 esses  that  are  feasible  for  particulate control  in oil shale applications.
 Dry  dust collectors can  only be used  with dry dusts.   SticRy particulates
 tend  to clog  the  dry  collector and reduce its  performance.   In I such  cases,
wet collectors are used.                                          ;
                                                                 i
                                     172

-------
 IPARTICULATE
   CONTROL
 TECHNOLOGIES
                                              .DRY
                                            COLLECTORS
    WET
COLLECTORS
                       CONTROL OF
                       FUGITIVE
                       SOURCES
    WET
 SUPPRESSION
                                                                    FABRIC
                                                                    FILTER
                                                                  ELECTROSTATIC
                                                                  PRECIPITATOR
                         ; CYCLONE
                                                                  IMPINGEMENT
                                                                   SEPARATOR
                                                                   'SETTLING
                                                                   CHAMBER
                                                                    VENTURI
                                                                    SCRUBBER
                                                                 IMPINGEMENT-
                                                                 PLATE SCRUBBER
                                                                     SPRAY
                                                                     TOWER
                                                                   : CYCLONE
                                                                   SCRUBBER
                                                                 aECTROSTATlC
                                                                  PRECIPITATOR
SOURCE* SWEC
                 FIGURE 5.1-1  PARTICULATE CONTROL TECHNOLOGIES

                                      173

-------



















3
go

z
o
_J
o
a&
8
tu

£3

i
UK
O
i2
OS
I
rH
in
3
1







I



tn
1
P
e
flJ
V»
d




Ul
g.
JJP
re
•P
c
re
|





•P

II
•33
> Ul
o>
o



Performance


Operating Principle

&
o
o o
•P ,C
II






































to
a
«j
s
a
„
£ tl
S3 0)
"4J 4J
O> >| re «J
v- 0) "=[
"° *e §£> in
C 3 +J £. O

V) C UI
£ S "° re T
•SS^r^ij
**•• u a> re
«,§^sfe
i£S-SS-g
•b
c
re
>^

c
at
*0 P
•rr W
t»_ O
t«_ y
a* 1
-2
55
12
88.
.e °
#8

c .
a>
I
a.
£
75
u
Z
§


O>13 C O
££3° -&3?
*> T- 01— £
&2J-5.2''* •
C O r— -O S. 01 .t-
0) a. c a* t-
o^S/raVS"-
C .«,-§* 3-2?
»-»« S- O £-•—
93 CT» 3 ••*• a. ra
• ** U. fc. U
^« OT f« 0 .Q O ••-
ra o» s- ca R} iC a.
gl « O <*^ *> >»
i— a.to •£?
B • m a •a
u m w o .c c tn
as oi -*J *» -+P ra^*

*» o> ™
The dust-laden gas passes
through woven fabric or fel
material which filters out
the dust, allowing the gas
to pass on. The filters ar
cleaned by mechanical shaki
or reverse jet compressed
air flow.

1
u_
U
s.
•s
u_

c
O T3
P ra m .
e»r* in o>
c re f i-

>>-P C t-
? » o*

5"°
u s-

<*- (A
*— O.
2s
§5
£ >»
s_
f™
3: ra
S
1
Q.
,£•
re
o
"

|
°

Removal efficiency is
99-99.9%. Operating
temperature is limited
to 850°F, and the
pressure drop is
typically 1 in. H20.
'°
Particles suspended in a ga
are exposed to gas ions in
an electrostatic field. Th
particles then become charg
and migrate under the actio
of the field to collector
plates.

'8 2
4J ra
u u
v to


>>
c .
Q) tn
O i—
*•*>
V £-
- Q.
2-
II
2 <*-
en
C O» 0)
•f- k U
•P Oi-
re s >
o> .re re TJ
Q. OJ
00).-
re i- re
•o o >
C CA *4- O
re re oj £
•— TJ "° 21
not-
"o. re at
O • i" • U
^ -P U.-f
S in o> *»-
O O t- M-
-J O Q. 0)
C
2
I
a.
>•
75

a
§
°

in Q) o
" -o. =
>>a)e.c
 O O) •> Ul U
§01 CLrH 0> •»-
i E of a.
SS55k5-

*^
The dust- laden gas enters a
cylindrical or conical
chamber tangentially at one
or more points and leaves
through a central opening.
The dust particles, because
of their inertia, will tend
to move toward the outside
separator wall and then inti
a receiver.


o
1


=£
C
•2
£
O)
^- •
re
i
1
CO


2 en S at
u re re-a

T3 O >
c tn »*- o
0 "'^ g
re o t.
a. re w
U • r— U
P 0'"
5 v> a> <4—
O O t- M-
-J 0 O.O)
s
>
o
k
>>
75

S
o
o

Removal efficiency is
0-80%. Operating
temperature is limited
to 1,000°F, and the
pressure drop is
typically 4 in. H20.


U) .
a> ui >)
D) W -P 10 T3
C -P- P -r- 4J 0
•i— o» (J ja
Q. ui 3 *»- a»-
E m "a o p- t*O ••P?' 3
P T3  tn
(0 O 4^ <— S-
3 .Q U U 0>  re t. c
h- 0 *O Q.D10

C
Of P
?2
II


&s

S Q.
•r- tn
•r- 01
ts
, c
1 * 1
£. (0 v
3-0 §•
3S£
|
(0

c
*>

s
c1 &
<4J *O
S.3
O> 3
II
±1 Q.
i
>
O
^
o.
>.
75

I
M
£
o
O



































Removal efficiency is
0-50%. Operating
temperature is limited
to 1,000°F, and the
pressure drop is
typically 0.1 -Im-HgO-. -




The simplest type of dust
collection equipment,
consisting of a chamber in
which the gas velocity is
reduced to enable dust to
settle out by the action-of
gravity.


ffe
V) CJ




174

-------




Ul


^
1

(A






Ul
Of
o»

•C
re
1






^
Q)
1.3

'u ™
3°*
a






Performance




ng Principle
1
01
<§•




0
p— «—
o o
b£
e u
O 4)
O H-

.0
I)—

Ul .
CL Ul
o o>
•p "o
>»+»
e TO
flJ CL
*O r-
4- *TO
**- E
UJ S


*;
U
c
a>
"o

(».

*re
I
£
j~
.?
as
c
S
£
Q.
^
^
TO
U
£.
QJ


"


TJ 0
Removal efficiency 1s
95-99%. Operating
temperature is limite
to 40-700°F, and the
pressure drop is
typically 1-50 in. H2


•o
0) O
Ul 4-1
ui re
&.c§
0%™
fc. O +1
re & TO
•o <-> **
•f— TO
§•££ .
= "«58
T>2^<
S s. s. 3
m 3 3 <»-
M+J
c o
38£§


S
o

1 ,.*
S*C X3
3 J3
i >«




ul .
CL ul
£,£
•oTU
>>5
§re
a.
"tjr-
£1
LU Ul


^

U
*y

lt«
4~
III
•5
|
£

^
z
c
111
o
fi.
o.
^
j;
ID
g


g
o •

f
•o d
Removal efficiency is
80-99%. Operating
temperature Is limite
to 40-700°F, and the
pressure drop is
typically 1-20 in. H2
ml S
 (A 01 4J
CL £ "re ^"^ "S
W O) JZ O S
S'SC'-T,3
S-SJd'li^
f- O O *^ f— Ul
U *^ +* •«— •— CL 3
0 t- C 4J 0 -O
i— 0) at nj o j.
«* CL E t- J= T3   J=
re 014- o v
jr c s- wi *>
co j= -i- >^
« t. u o re *—
J= J= C TO 4J fc O
H> 4J re v TO 4^ u


s.
01
1 J2

1 1
01
nla!
1
V

o


Q)

"n
|
£
1

|
re

•o
§•
.
CL.
o
s- .

«8
E- U
ui Ol
Ul C
» Ol >
*° 0 §
•o s- o»
85 *"
T3  C
0) TO O
Ul Ul 0) 'f
4-1 S- 4J
V VI 4-1 U
r- 0> Ul m
o hi wi s
S- N (U —
^i™>.
o" t. i/i ui



£.
1
r
&
s
0)

o


<*-

1
i
2
1
_J

1
re

1
re
Q.
g .
•a *>
28
3
6- -P
CL«
2 oi
0 CL
—I O
c

o
CL
^
£
re
1


@
u


•a
Removal efficiency is
50-75%. Operating
temperature is limite
to 40-700°F, and the
pressure drop Is
typically 2 in. H20.


-C js re
4J
O Ul U
C > C
^££
218
a. re r-
Ul O
€ •?• *
ui re 4-* c
~££.2
TJ 4-> CL4J
•P- Ul U
3 *a TO
a* ui ui CL
3&i^




s.
C A
•it
§5
s.

> C "O



*> O!
01- -a
•*- O C .
Q.HJ Ul
— i. rao
e u =•--
ui ^: to
•b S « S
01 IO 3 0)
Ul &- J- Q.
=3 *> 0 0
•w .
Ul >i
8|
c u

t- a
0)

TJ O

" £
It
re

11
— 1 ID
C
0)
g
CL
-
^
re
1


s
u


13
Removal efficiency is
95-99%. Operating
temperature 1s limitei
to 40-200°F.
j=
*o •»- M
C 3 fc. 01
f- O) «*- t.
e TJ 3
11 I'll
b T) CL.
CO 0) JZ Ul +» 4J
o± c c c
o 4i *o ui re re
H* O) C "- U» 4J
O TO Ul U
111 4^ A) u re
-J Ul O)i— b  U O TO 4->


C
•2
*p> b Ul
4-» O Ul
(U 4-1 O
4* TO t-
Wl +J £L
|n. f
U U
2 t 0
tu a. 3



































o
CO
S

c
o
.>
and Education Associa'
f
S
O)
o:
1
*-
§
'5
|
s
TJ

175

-------
     Dry  participate  removal  from  gases  can  be  accomplished  by several
methods  (shown in  Figure  5.1-1  and  reviewed  in Table 5.1-1).   line baghouse
(fabric  filter) collector  operates by passing  the  dust-laden  gas through a
fabric  network that  acts  as a dust  filter.   Its  removal  efficiency is over
99% and  operating costs are  low compared to  other approaches.   : The electro-
static precipitator, which  also has a high removal efficiency, affords separ-
ation of  dust by passing the  dust-laden gas  through an electrostatic field.
The: dust  particles become charged  and migrate to  collector plates.  Another
technique  is  the  cyclone  separator which operates  on  the principle of cen-
trifugal  force.   The  dust-laden gas  enters  the  chamber  tangeritially.   The
dust particles  have a higher  inertia  than the  gas, so they travel to the wall
of the  cylindrical or  conical chamber and then into  a receptacle.  The re-
moval efficiency  for  cyclones varies from 50  to 90 percent.  Inithe impinge-
ment  process,  the dust-laden gas  impinges   on  a  body  which  collects  the
particles  as  the  gas  deflects around the  body.  The  removal  efficiency is
0 to 80  percent.   The simplest mechanical separator is the settling chamber.
The dust just  settles  to  the bottom of the  tank due to its  heavier mas;s,
resulting in a  removal efficiency from 0 to 50 percent.          !

     Wet  collectors  require  mixing  the  dust-laden  gas with an  aqueous
solution  that captures and removes the dust  particles from  the gas stream.
Examples  of  such  equipment  are   shown  in  Figure  5.1-1  and   described  in
Table 5.1-1.   In  the  venturi scrubber,  the  gas  and  liquid pass  through  a
throat at  a high velocity, promoting collisions between  the  dust and liquid
droplets.   These  units require  a  high pressure drop ("-50  in.  H20) and have
removal   efficiencies  of greater than 90 percent.  Another wet  scrubber,  the
impingement-plate  type,  consists  of a perforated tray with an impingement
baffle  located above each  perforation.   A liquid level  maintained over the
trays collects the  dust  as  the  gas passes  through  it.   These  units  are
similar to the  venturi scrubber and have about the same removal  efficiencies;
however,  the  process -requires  a   larger pressure drop  across 1 the  plates.
Another type  of wet scrubber  is the  spray  tower;  it utilizes countercurrent
spraying of liquid droplets to remove the dust  particles  by impaction at an
efficiency of 50 to 80 percent.  The operation of the wet cyclone scrubber is
similar to  that of the dry cyclone except  liquid  is introducedI into the gas
stream,  removing  the  dust by  inertia! impaction.  The  removal  efficiency of
the wet  cyclone  is  50  to  75 percent.   The  wet  electrostatic • precipitator
operates under the same principle and at about the same efficiency as the dry
precipitator.                                                '     !

     Control of fugitive sources.   Wet  dust suppression can be  used for the
containment of  fugitive dust.   This  process   consists  of spraying  the  dust
source with water or  a foam suppressant which traps the dust and prevents it
from becoming  airborne.   The foam sprays are  relatively inexpensive, consume
less water  than pure  water sprays, and are very effective.   In!a foam spray
system,   foam  is  produced  by pumping a  mixture  of  water and  ia  surfactant
through  an air atomizing nozzle which produces small  bubbles of approximately
100 to  200  microns.   These  wet  bubbles  are broken  by  contact with  dust,
coating  the  particle.   The  foam is only effective when  applied directly to
the source, such  as on a conveyor, or to  a falling stream of material, such
as at  a  conveyor transfer  point.   Once the  wetted dust  agglornerates  with
other particles, it no longer becomes airborne at subsequent transfer points.


                                     176

-------
 The  suppression (or removal) efficiency  is 95 to 99% in terms  of the materi-
 al contacted.                                                    ,

      Paving the  heavily traveled  roads  with a  hard  surface  and  providing
 vegetative covers  for the  disturbed  areas are  additional  technologies  for
 reducing   fugitive   dust emissions.   These  technologies  are  described  in
 Section 5.3.                                                     !
                                                                 i
      Particulate Control Technologies Analyzed—                ,.|

      The  MIS-Lurgi  plant  has  several   processing   areas  where  particulate
 matter  is  generated  and must be  controlled.   The particulates :are  produced
 either  in  the  form of  point  source dust  or  as  fugitive  dust ;from  various
 operations,  such  as raw shale mining, crushing,  conveying and  storage,  Lurgi
 processed  shale pyrolysis  and  moisturizing,   and solid waste .handling  and
 disposal.                                                        :       •

      Dry  dust  is  generated at point sources,  such as the primary and secon-
 dary  crushers, closed conveyor  transfer  points,  and  enclosed  ore  storage
 areas.   For these  point  sources,  baghouses  were  examined  for  particulate
 removal due to their high removal efficiency,  relatively  low operating costs,
 and the dry nature  of  the particulate.                           i

      The   flow rates   and  particulate   removal  efficiencies  'reported  by
 Cathedral  Bluffs  (Occidental  Oil  Shale,  Inc.  and  Tenneco  Shale  Oil Co.,
 April 1981) were used  as,the design basis  for estimating  the size  and  cost of
 the baghouses.  Depending  upon the type  of dust,  particle size distribution,
 and grain  loading,  the baghouses were designed with  an air-to-cloth ratio of
 4.8-7.4 to  1 (ACFM  to sq.  ft. of  cloth),  using  Dacron HCE filter bags.  The
 baghouses  are  equipped  with  adjustable   pulse  durations  and  cycle times for
 compressed  air discharge through rotary  airlock  valves.  When  in multiples,
 the baghouses  are manifolded to a common self-cleaning  inlet,  allowing part
 of any baghouse system to  be shut down for repairs without taking the entire
 baghouse out of service.                                         i

     Additional point  source dust  is  generated  in  the  Lurgi  f:Tue  gas dis-
 charge system  and in the processed shale quencher/moisturizer.   jThe flue gas
 emerges from  the  waste  heat  recovery  boilers  at  a  temperature in excess of
425I3F, which is well  above the design temperature (275°F)  for the polyester
 fabric baghouses.   The  dust  produced  in  the  quencher/moisturizer is sticky
due to  the presence  of water.  The  sticky dust  particles tend; to  clog the
 fabric,  impeding  the  performance  of  the  baghouses.    For  these  reasons,
conventional baghouses cannot  be  employed  in these two dust control  applica-
tions,                                                           i

     An electrostatic precipitator (ESP)  was examined for the control of dust
in the Lurgi flue gas.  The performance  of an ESP,  unlike baghciuses, is not
affected adversely  by the high  temperature and  stickiness of  the dust.  On
the contrary, within  limits,  these characteristics of the  dust jincrease the
efficiency  of  dust  removal  by ESP.  The  use of an ESP  is  in  agreement with
the plans presented by Cathedral  Bluffs,  but design details were jnot given by
the  developer  (Occidental   Oil   Shale,   Inc.   and  Tenneco  Shale Oil  Co.,

                                    177               .          I

-------
 April 1981).  Information  provided by Research Cottrell  Corporation  (an ESP
 vendor) was used  in  conjunction with Stone and Webster Engineering Corpora-
 tion's (SWEC) in-house  experience  to estimate the design  and  cost of an ESP
 for the Lurgi  flue gas dust control application.                 i

      For  the   control  of  sticky  particulates   from  the  processed  shale
 quencher/moisturizer, a venturi wet  scrubber  was  analyzed.  This scrubber is
 particularly suited  for applications  where the venturi sludge  can be  reused,
 e.g., in processed shale  moisturizing.   Again, the  information!published by
 Cathedral  Bluffs  was used as  the basis  for  the design and cost estimates.

      Fugitive  dust is generated from mining and blasting, raw  and processed
 shale conveying, conveyor transfer points,  baghouse  dust discharge points to
 conveyor systems,  truck  loading  and  unloading,  and disposal  operations.
 These fugitive sources of  particulates are controlled by water  and foam spray
 suppression.   This system  is  inexpensive and offers low water consumption and
 high removal efficiency.                                         :
                                                                 i
      In  addition to  the major  particulate sources mentioned  above, there are
 other point sources,  such as the  FGD  (Case Study A) or boiler! stacks  (Case
 Study B), for  which no controls  are applied.

      Table 5.1-2  lists  the  design parameters for   the  particulate  control
 technologies  examined, and Table  5.1-3 gives  the design basis for the  ESP.
 The  capital,  operating, and annual costs  for  the  particulate control  equip-
 ment are presented in Table 5.1-4.  Cost curves based on  the  specific  designs
 used for the baghouses,  ESP,  and venturi wet scrubber examined  in  this  manual
 are  provided in  Figures  5.1-2, 5.1-3  and 5.1-4, respectively.    >

      Other Particulate Control Technologies  Analyzed--

      In  addition to the ESP,  another technology was  analyzed for  the control
 of particulates  from  the Lurgi flue gas~a  spray dryer/baghouseCombination.
 This  technology  has not been proposed  by  Cathedral  Bluffs, buth't is  judqed
 to be  applicable to the flue gas.

   .  As mentioned previously, the flue gas is at a fairly high temperature at
 the point of control.   Conventional baghouses cannot  be used until  the gas is
 cooled to  below the  design temperature.  This can be accomplished with the
 technology combination analyzed.   First the flue gas is  cooled 'in the spray
 dryer  by evaporating some of  the water, then the  baghouses  are used for
 actual dust control.                                             •

     The spray dryer  is a commonly used device for applications w,here gas ad-
sorption on  solids  is desired.   With this technology, a slurry or concentra-
ted solution of the sorbent material is sprayed, or atomized,  in ithe hot gas,
whereby the water evaporates and the sorbent falls out of the solution in the
form of a powder.  The gas is  then adsorbed on the powder.  Additionally, the
evaporation of water  cools the gas.  The application of a spray !dryer to the
Lurgi  flue  gas  is  based on  the  latter phenomenon.    Since one advantage of
this system is that it can use high TDS waters, some  of the processing wastes
(e.g., the  kettle evaporator  sludge,  FGD sludge) can be  used  for flue gas


                                    178                         :

-------



















4/1
LU

LU

i
a.
s
t-«
tn
LU
O
i
I— .

au




«l .


s

fc
3
o
I-*
{2

a.

2

tn
Ul
1





















01
10
3 tn
o c ^-*
•r- 0 S-
fr. tn -^
10 tn .a

.-il^
2
H-
>,

*B 01
o "o &^

ce ifr-
LU


•o^
O !-
Ul f—
3 ^*
a


1
^•g§
O LU <
U.


O
(A
&. 4->

.a c
3
SI









C
O
?
u


r-
£
*->
1


c
.?
Q.


U
tn
Ol
O

b
£.
C
O
o





m Ol
VI Z





CM
O







in
§i



o
S





o
0
o
CM"





CM







3*-*
ui *> a!
•P *- 5
_= 10 0
c2 *" J.

s- o •*-
01 *r- Ul

in u (0
e 3 £.
1O T3 +1


o E ai
> tf» O
CO 0
o
u











ai
in
0
Ol
ra
CQ





r-






S S S
rH O r-i







in tn in
crt p% crv
O) Ol CT*



0 ^*- CO
rH U3 O
CM a> CM
CM CM





§O O
O O
o o in
CM CM CM





CM (-4 CM








C
1
•a
(O
3

g,
m
o

a>
r—
V3











4»  O
tn S- +J
+* U
e « t-
•i- 
U> •!-
er ^c ai
«S cn u
£-30
t— t-
O 4J
o s-S
> *i— O
O "*"











4)
Ul
1
cn
CO





s

179




to cn
r^ o
o o







o in
en cn
cn en



CO 0
R S





S §
CM O
r-7 CM





rH CM








C 3
•i- O
O O

01 01
Ol Ol
£ £
o o


o, g
o o
1 1











4) 4)
tn in
1 1
Dl Ol
 r*«
'"s"




00









S-
(Q
u

O

tn
3
4T
3
LU 4)
•f- Ul






tj o
'I- +J
-i-> m


tn a.
2.JT
CJ
-+J 41
a) n_
LU





in
iH






s
^!
CM






o
8



o
O
CM
P^




O
S
CO*
ro





rH








S-
4)
S
3
O*
4>
"m s-
x: 41
t/) N

T3 fi-
at 3
tn •*->
tn u)
4» *f-
2*
a.









•S *"


b 3
3 S-
4-> CJ
Cl>)
4)





S






CO
CM
in

rt




•K
m

i
S



;





i
i






t
i







«r
If 0
"5 4)
Q.

S- uT
41 41
**- r-
W »r-
C CL


S- V)
o
s?g
> Q.
1°





§„

o
U.


C U)
a) a.





§s
"fH
to









C'
O ^
a
u

a.
§•;.
at
c
0!
§•
Ol;
C
'Ol '
a.
Ol'
•o
CO
cn.
o
CO
&.!
01
5

t
tn
•f~
tn rH
>» CO
<0 cr*
S-< rH

E=< S-

V-
O 0
**- o


5 o
41
•o^ •—
V)'


tn u
4)
Ul. C
Ul t—
aJ ro
01 =
t-! u
0) C
§:
41



V)
>^
0^, »-
a> o
U ' *™
t 1
4) 4)
ro u
> CJ
4)
S- **
: 4)
„ 0
(— 3
0
* , ">


-------
           TABLE 5.1-3.   MAJOR ITEMS IN ELECTROSTATIC PRECIPITATOR*
      Capital  Cost Items
Operating Cbst Items
      Chambers  (8)
      Collecting  Plates
      Transformer Rectifiers
      Fans and  Motors
      Dampers and Ductwork
      Supports
      Handrail ing and Grating
      Piping
      Concrete  and Foundations
      Pai nti ng
      Insulation
      Instrumentation and Controls
      Discharge Electrodes
      Electrical
      Bins
      Discharge and Conveying System
       Rappers
Electricity1
  2,711 kW i
Maintenance
* Design basis:  198,000 ACFM/unit.                              i
Source:  SWEC estimates based on information provided by Research Cottrell
         Corp.
                                     180

-------




















_,
g
£
S
*-«
g
LU


=3
H-t
^
CL

Q

H™
S
*

""3
in

Ul
S
























•K
10 in
3
C r-0
COO
 0 +>
O in
1— O
u
«**>
i— in
CO Ol-
3 CO
C -i- O
c +> o
!-!e
"m o.4J
j_) (^ y>
00
1-  4->
X in
IIS
I
u u-
§,33
P— VM t
LU


in
i. -p
A C
E n
Z 1-
o





=
o
•r"
CO
u
o
_J

"o
s-
c
o
o





£
0
IS
c s-
o u
O in
a





S S-
ta ai
ai -Q
s- E
•*•» -3



CM
•a-








i-i






'§
rH



1
•t
CM






^





S-
*> 1- 3
C CO O
O Ul
0. S-
C 01
S- 0 
f- *» C
in o co
C 3 S-
co -o *>
S- 0
1- S. S.
CL O
o-ES?
£££
> *- o
c >— < o
o
u



i.
01
£'•
u
i.
.0
IB
LU







p^





0^









*






s



o
o
o
CM






rH




^
Ul'5.S
*> ^
c u s-
•i- O O)
o +> t-
o. in ui
c
S- 0) CO
at^- s-
l»- 10 *J
Ul -C
c in f.
CO O
^* CO O
s- c
0 E 0
2?°.°
> <*- o
o
u



Jl

u
to
LU







^^





^^
rH








CM
to






o
in
CXI



o
o
in
CM
r-i






^«





c
•r-
I

o
— J
Ol
t.
o
to

01
r—
5
to

en



i.
"

u
'£
10
LU







CO





00
m








s






co
•3



s
o
CM






r-l







1
10

O)
c
t/1
3
t.
O Dl
c
«'£
2S
to &-
g*
a:



1
£Z
u
'fc
J2
CO
LU







en





rH
in








CM






to
cr>



o
o
0
ID"






rH





i.






Q)
01
s.

u
in '
a
in
CO
o
at
3
LU 0
•»- in
I £
^J



s.
u o
3£
SJ.2-
S- (J
tS£
o> a.
LU







in





in









s






§



o
o
to
s






r— (







a*

m 







00
fH




f^ rH
co en
en o
CM
rH






o in
S 8
CO





CM ««•
0 g;
in co
CO
in

1







1
1




in

c o
O 01
a.
t. in
o o> •- ••
U) «r-

£- U
H-'O
t. SI
o
>> c
Ol O>
> Q-
c o
o
0



o
•o
CO ^)
s- s.
55-
CO
3:

t


o

o
CM rH
iH CM
•rH
ID

i


1
1

1

j
i









'



i
!
+j
in
o
u
i
c:
o
u
lJ-
co
3 0
i S
CO • tO
5 ^
O T3
4* »


^ aj
01 U
0) &-
to a
* 5
181

-------
£OI 2'iSOO 9NUVH3dO IVflNNV
       oo
                                                  oo
                                                  CM
                                                      o
                                                              u
                                                              tu
                                                              •o

                                                              *
                                                              •r-

                                                              O

                                                              O.
                                                              <0



                                                              O
                                                              c
                                                              O
                                                              •a
                                                              a>
                                                              (A
                                   CM
         OI  ?  '1S03 IVlldVO  Q3X!d
                                                                    I



                                                                    (-4
ii

1
O
IJU


I
O
 _
O


v>

8

-------
'ISOO 9NUVH3dO IVflNNV 1338IQ
                                                           o
                                                           O)
                                                           O


                                                           Q.
                                                           +J
                                                           (B
                                                           C
                                                           O


                                                           T3
                                                           0)
                                                           O5
                                                           m
                                                                 I
                                                                 i— <
                                                                 13.
                                                                 l-«
                                                                 O
                                                                 UJ
                                                                 0£
                                                                 13.

                                                                 O
                                                                 '
                                                                 O
                                                                 IJJ
                                                                  o
                                                                  I3£

                                                                  •E

                                                                  S

                                                                  10J


                                                                  I
                                                                  

                                                                  S
                                                                 in
                                                                 la
                                                                 ac
                                                                 1-1
                                                                 11-
9OI % USOO
                      Q3X1J
                                                           o;
                                                           o
                                                           LU
                                                           co
                  183

-------
        ,01 2 'ISOO 9NliVH3dO IVflNNV 133Hia
                             CSI
                                                          O "> i
                                                          IO  O
                                                              «o

                                                          O  C3
S
CM
o
S
                  'ISOO IVJLIdVO Q3XIJ
                                                                      I
                                                                      a.


                                                                      o
                                                                      (0
                                                                      o
                                                                      <4-
                                                                      c
o

•o
a)

-------
cooling.   Increased participate  loading  to the  baghouse,  however, may have
an adverse effect on its performance and/or operating cost.     i

     The temperature of the flue  gas, while within the operating range of the
baghouse,  is kept  above  the dew point so that  water  condensation does not
occur.  With these  conditions, the polyester fabric baghouses can be used for
dust control.                                                   i

     Table 5.1-5 lists the major  items  in the spray dryer/baghouse  system and
includes the capital and operating costs.  Figure 5.1-5 provides: a  cost curve
for the system.                                                 ,
        TABLE 5.1-5.  MAJOR ITEMS IN THE SPRAY DRYER/BAGHOUSE SYSTEM*
Capital Cost Items                              Operating Cost Items

Spray Coolers (8)                               Maintenance
     42' diameter x 42' (constructed                            i
       of 3/8" plate)                           Direct Annual Operating
     Niro Rotary Atomizer                         Cost, $103    1,266
       Model S-350                                              ;

Pumps (2 per cooler)                                            j
     52 gpm @ 20 wt% solids
     Pump motor @ 10 HP                                         i

Coolant Supply Tanks (8)                                        '
     10' diameter x 10'                                         '
     6,000 
-------
% 'JLSOO 9NUVH3dO 1W1NNV 133810
                                               <\J
                                               CM
                                               esj
                                               oo
                                                 ro
                                                          O
                                                               co

                                                               LU
                                                               to
                                                               03

                                                               C£
                                                               0.
                                                               CO
      §

      O
      O
      LLl
                                                  en
   9OI % 'JLSOQ  HUJdVO  Q3XIJ
                                                          O

                                                          a.


                                                          O
S-
o
*-

tr-


O

TO
01
in
<0
XI
      o.

      u_
      O
                                                               8
                                                               If)
                                                                t
                                                               tf)
                                                               0
                                                         O
                                                         CO
                   186

-------
      Total  Particulate Emissions—
                        ,                           '              i
                                                                 i
      The  controlled particulates from the  point as well as  fugitive  sources
 are  summarized  in Table 5.1-6,  along  with the  type  of control  technology
 examined  for each  source.   The  uncontrolled emissions are also'  included  in
 the  table to give  total  particulate emissions  from the commercial  operation.
 Estimates  for  these  emissions  were taken from  the   Cathedral  Bluffs  PSD
 permit  application (Occidental Oil  Shale,  Inc.  and Tenneco  Shale Oil  Co.,
 April 1981).                                                     ;
          TABLE 5.1-6.  TOTAL  PARTICULATE  EMISSIONS  FROM THE  PLANT

Stream
Number
4
7
8
9
Emission Source
Mine Exhaust Shaft
Production Shaft Conveyor
Transfer Points
Raw Shale Storage Load- in
Raw Shale Crushing and
Control
Description

Baghouse
Baghouse
Baghouse
Particulate
Emissions (Ib/hr)
•71.83
2.21
i 2.02
145.03
             Screening

  10       Fine Ore Storage Transfer
             Tower
Baghouse
5.08
11
14
115
18
79
5,119
6,120,
121
TOTAL
Fine Ore Storage Load-in
Fine Ore Storage Load-out
Lurgi Flue Gas Discharge
System
Processed Shale Quencher/
Moisturizer
Flue Gas Desulfurization
Stack
Diesel Equipment
Conveyor Transfer Points,
Open Stockpiles, etc.

Baghouse
Baghouse
Electrostatic
Precipitator
Venturi Wet
Scrubber
.. • ' — •
Catalytic
Converters
Water and Foam
Sprays

. 0.76
j 0.09
365.00
!
1
,24.14
;67.08*
6.00
115.23
I '
704.47
!

* A value of 151 Ib/hr was estimated by SWEC.                    :

Source:  Occidental Oil Shale, Inc. and Tenneco Shale Oil Co., April 1981,
         except as noted.
                                     187

-------
 5.1.2  Sulfur Control

      Processing of sulfur-containing fossil  fuels will  result injemissions  of
 sulfur compounds,  such  as  H2S,  COS,  CS2,  RSH, etc.,  or their  combustion
 product,  S02.  Federal and State  standards  limit sulfur  emissions  because  of
 their potentially  hazardous  effects  on  human  health  and the  environment.
                                                                 i

      Inventory of Control Technologies—

      Two  general  categories of  technologies  are  available  for the  control  of
 sulfur emissions:   (1) removal  of  sulfur  compounds  from  fluei gases  after
 combustion  (sulfur dioxide removal, or flue gas  desulfurization) and  (2) re-
 moval  of sulfur  compounds from gases  prior to combustion  (hydrogen  sulfide
 removal).   Several technologies in  both  categories  offer recovery of  sulfur
 in  a  useful   form,  while others  chemically  fix the sulfur  compounds on a
 reagent which then  requires disposal.                            1

      Sulfur dioxide control (flue  gas desulfurization).   Removal   of   sulfur
 compounds from flue gases—that is, flue  gas  desulfurization  (FGD)--is  based
 on  the physical and chemical properties  of  S02 because fuel-based sulfur  is
 usually  converted  to  S02 upon  combustion.   Flue gas  desulfurization can  be
 divided into  two  categories:                                     i

      •    Wet scrubbing                                         '
                                                                 l
      •    Dry scrubbing.                                         I
     Wet  scrubbing utilizes  a  solution or a slurry to  absorb the S02.  Dry
scrubbing uses either a dry reagent bed or an atomized solution of an aqueous
reagent  at a  high temperature to  remove the  S02.   Both categories  can be
divided  into  regenerable and nonregenerable processes.   The different types
of S02  removal  processes are shown in  Figure 5.1-6,  and Table 5.1-7 gives a
brief description of each process.
                                                                 I
     Wet scrubbing—*The regenerable wet scrubbing processes generally employ
a clean  alkaline solution to absorb S02  in  a  scrubber.   .The resulting spent
solution  is  treated with  an insoluble alkali  makeup  which precipitates the
absorbed  S02.   The insoluble  alkali  sulfite and sulfate crystals  are then
separated from the regenerated solution in a clarifier and possibly a second
dewatering step  such  as  a centrifuge.   The spent alkali sludge is treated by
calcining, evaporation,  stripping,  etc.,  which drive off the  S02.   The $02
can  then  be  converted to a  useful form  of sulfur such as  sulfuric acid or
elemental sulfur.

     In the nonregenerable  processes,  this spent alkali sludge  is  sent to a
disposal area for land filling.
     Dry scrubbing—The dry scrubbing  processes  use a concentrated
alkaline crystals which are atomized and injected into the flue gas
it passes through a spray dryer.  The scrubbing slurry absorbs the
dried by the hot flue gases.   The dried spent alkali is then removed
flue gas by an electrostatic precipitator or a baghouse.


                                     188
 slurry of
 stream as
S02 and is
  from the

-------
   SULFUR
  DIOXIDE
  CONTROL
TECHNOLOGIES
                                     REGENERABLE
                                      PROCESSES
                                     NONREGENERABLE
                                        PROCESSES
                                     REGENERABLE
                                       PROCESSES
                                     NONREGENERABLE
                                        PROCESSES
  SOURCE-- SWEC
£
 WELLMAN-LORD

 MAGNESIUM: OXIDE
          i
 ABSORPTION/STEAM
  STRIPPING RESOX SYSTEM
 — LIMESTONE

   -LIME      \

 —-DOUBLE ALKALI

   -SODIUM CARBONATE
 —DOWA ALUMINUM SULFATE

 I—OIL SHALE (PROCESSED
     SHALE, NAHCOLJTE)
 —CHIYODA THOROUGHBRED 121
   •AQUEOUS CARBONATE
f
LIME      ;

SODIUM CARBONATE

OIL SHALE(PROCESSED
  SHALE, NAHCOLITE)
               FIGURE 5.1-6  SULFUR DIOXIDE CONTROL TECHNOLOGIES

                                   _1S9

-------












trt
Ul
ta
01 TECHNOLO
Q-
f—
z
o
u
F SULFUR DIOXIDE
o
2
=
U*

Lf>
Ul












Ul
a
10
.c
•g
re
•f"
Q




1
P
c
*o



Development
Status




•K
S
1
Of
S
I M
&.
a.
Operating

>j
o
1*2
||
C U
S *
























V)
UJ
V9
UJ
ET SCRUBBING PRO(
3:
UJ
^4
CO
g
UJ
z
UJ

tu
Q£

52
t-°
£2
Q
**• Q.
S'S
<(- 0
u» C
Q) O
•r- 4J
CTf—
c= «
8°
£l!
PI
Of C •—
O (0 3
C U Ul •
RJ •££ xi ro
S. 4-> (O *3
CL, W) E Ul
•a
*o oi •
oJ §•*"
o£ 01
2f*
ro m c
•Mm c
0 S 0

m
3
C§
Of (O
•P -P
3 C
°s
Hi ••
a.
ai o
3 "*§
TJ tn
a! 0) °
0>
„« 5
Sou *a
il« «^
ui *3 x: o*«*- -p
Ul -P O W> <*- RJ
5 •£ ^ "c o! 5 S
•*-<*- E at x: > o»
*3 at *£ S.
N tn s- ui tn "a
O ••- *> *r- s. «
WX,u,cO g*.
jg5?£2*'8
0 Cr^ 3 ° aJ *
XI 3 O > *O Of
*?
o
t
IB
,S

S

*> a
£|
*-T3
•§0
tA Oi tl
Of £ Of
£"*«£
O*wi f—
as: S
 re o o at >p-
•p xi a.t-1 u s-
ui ' re to c
C Ot-D 44 0 0
O > 3 3t Ul »~
E rtJ C O H- -P -P
« X: "i- XI •»- o
"O re c 3
«* 2 "H *- -35.
o) -P of x: ^-" -P
Of c -P o ai «" tn .
x: r- a* a» -r- •»- o ,
h* a.-p>u'tn u u rs

3
»— e
2^
i §
O) C .
581
a.
at 'O ^^
0 10 0
f So
s MTJ
.2 £.2 a, i
tn -P £• 

|P "O 3 -f- O t- CJ C u> V} 3 &**•* Of (tj ^N r- Ul U C CM tn ui t— • o> o? o X* 0» W nj O W> tn «r- *o of O O ^S'SiSkC _3 tn (0 g -g £ s •a Of £ . P E Ul OJ C P O (A "°T» II "° "s P 0 c ° rtj tn 5 § i O.P Of fc in i— O >> 01 in ui XI Of 10 Or- -JtfJ OL a. w in 4^ ui tn a> • S- *Q. SI Of C CO (0 O C OI x: o. c >^> >r- ai Of O -P XI XI Ul Ul -I— CO S at c to -P o S . Ul -P C Of Of >»•£! ui o x: e ui tn 01 c: H -P of o •P O Of P CL O) w» £ 13 t- ui O 3 C| 01 tO O 0) atg . 5.8| •O' * *° "O Of **" U nj o 5 « cole'«-i <*- r*^ * a> '£ *" Jc S £ o cn-P « e to *o -P a. i/> c of o w aix: -p «A a> o in O v*» ai BJ -r- x: +J v> *r- * 4) ^ S £. tn . UJ •P -P a» x: ro 4-> « 3 E t- u 3 C P 4^ Ul Of C O £* Of 3 <"i <— 4) (O •*-> +J Q) vi U -P <4— CVJ O OI' C tn ui o Ul i— " ui»3 OfXt£-OUlUl C3 3 (0 Ul -P 01 2 X r— 1-4 §0) OXi 3 £ rt * Qfl S r-- tD r— *^ . "Ct Ul P CO cr to 3 <^N tn c > to -P ai -^- "o fF- 1-» at o B tj £3S8$dSti£^ g ^. E m c v- *> S 3 *• >> z ^ t/> tu o§ g g Q£ 3£ ai o 5>?§l i1 .1 ,f~ f^. .,_ flj .pi. oi Of r— P- Ul > U1I^-4J> •«— (0 O O •r-OUlO Xt U £- U t. O (J ai ui b. of 01 O a i_ of- a> m s. OfOtJC &-3XC Q.-P o nj co 01 o o» c: C o s. c § «5 "" ."* -P XI C Ul v^ 2 **"" S ^^ * *r" t- o t. OfVs. t. f« O v- 3 X» 01 3 ^*»o»^ a»--x:<*~ 5 42 ai « j £ 2 w §>, o> ^ in t— nj a e c (0 o» nj > c T> E T- O O pOT- P— C Of Ul t»j-.4J a) t. a> Of O.C Of P E o. Q* • x: o «'r- 0 -0 > ^J 4J Q.O r- T3 (O O at O C C i^^jl ^3|| •— G.-P 3 to -a ra P 1- 2 OJ C^QL.U f* W S o .e a. « ui £ tn § re ui ui ui tn re >r- U • Of Of 01 U _ -P a, o >, o a» T- ^uioa u o > <*- OO£-&* 0)b>*r*4~ — J U CL CL >O.d c * x: o > x: o > •P u e -PUS a, Q. ui ci a. in w o. O f- £. 0) U).3(_t^. U) . 3 S- Xt >>r- 01 T3 XI >»>— Of S- Cu> 4J C t. Cvi -M O S- (O (O o £- ra Ul 3 01 £ i— oi 3 O) 5 xi •— x: at xt^-x:S


-------


Ul
01
S1
£
a
1
UJ
0





Ul
a>
Advantag





_p
c

E ui
. &3

0) +>
1""










Ol
RJ
|
at
a.



«
a.
I
'C
.a.

o»
c
cd
1


.0

2|
o at
o ^—
S. P-
UJ XI
S. RJ OITJ P- £-
O TJ 2 TJ C RJ 0)
c<»->0(d3n3ui>
x: v- w> t. P- o
m ai uj ai s o
RJ O. E 01 P- 3 01
re oir^ c»f-x: 3 -5 c
TJ^l OUlh-*r— OO
O RJ O -r" C OWC
u» E +* *> O) u>
mo,. at ui
Ul/-SC+i XFI- Ulf-'i-
a* o o T- a» ITJ e xj
bO*P~O. *f- «r- (TJ fc.
3 04-1- O tO 0> -P U >*-
P*IdTJOt +3 C RI P-
O)
c
Ol i-
5 2
2«ffl§§l
at c: <*- 1- T- a
a. o o *> uj
o +J 3 o at
ui ai t— t. .e
TJ 01 Ul O 01 4^
C E 3 Ul
 XI b> UJ O
f- » Ul UJ ft.
C r— £ at O
•r- 01 S- 0 U .
•P *» rtj 3 Q,
S Ul UJ 0) TJ TJ O
-1 0 « 0 «. «-
01
c x:
O -P
t— *> S- C

t- &. TJ
u ai c c
§at £
0)
> UJ
II
01 TJ
a. o
x s-

c
RJ •
Ul *tO

If
TJ f.
O R)
W V


UJ
Ul
gg

f—
• XI
-P 0)
Or^
U 0)
51
a.
R) 0>
if
_1 Ul

1
p— -p
RI id
•r- £.
£S.
at o

E
>» re
at (-
>a
ui re

u
S5
3
en =i
•a o
Tn *t-
« S
















01

i.
3
»t-

VI
c
o
at
Ul
Ul



















t
at
id
!_
01
I
c
o
c

















£ S 3 g^."° '
a> -p ui .
c *p- TJ e  RJ
r— &.
3 C
O 01
u •
at c >
x: o E=
4->. u a.
01 W
0) O O
o co in
'3 Vfl
^ as
* -P i
Ul S C *r-
•>- TJ ui "u r- O
•POM TJ Q> RJ
O TJ H- RJ &- U>
UJ C ** S- tt» (O O
RJ t. o> x: CL a.
at 01 • c H- ui
c at > ai di o) *'-•
•p- TJ C -P OJ S. TJ
r- .r- o T- ai . RI
flj X U <*- S- C TJi—
^ 0 P- ^0 Ui C f—
"(5 TJ -P UV-P- +*-r- » -P- i- *— TJ TJ
o x: *xi c TJ o o; c
•P E -P S «i- n) a>r—
^3 *F- 3 *> TJ -P
ra ui w ui ujr^**TJ-r-
«
i
«c

at
3
a

i-E
U. 3
§
c|
-p -p
Of re
p- S-
3 C
O Ol

J: o
•P O
S^cS*
VI
€»
0) re
Cc O
TJ
at
§s
1*
UJ
re c
xt-2

o
$1
Absorbs
carbonat

10
' S
aj
II
o to
CO U

i








^
a.
Q.
s
5
e
o
'•pi
O TJ
Ul to
23
S.§
m ai
T3
01
XT >»

11
22.
4-> UJ
Ul -p-























^
TJ
C
re
c


*0
disposed





































1
re
at ui
Si.
2 m
TJ TJ
UJ r—
•p- *rr
i!


UJ f- OJ
uj p- re
ai RI x: at
S^ -iS
^"•2
0) O •
U r- 4- UJ
s|£8
2-§||
oi at R]
ui e RI
ai re 01
x: uj E
O) 01 ui
IA t- U
0) ui o ai
ui at s-x:
3 TJ 0.-P
P?
•2
|


O •
U (/>

1«
•p

§

C
u at
•r*> Q.
TJ UJ
•r-(O 0
RJ ui x:
re ^ TJ
re N
*f- . ^>
x: o 01 "a
2 O *f- O

N-P 3 U)
O 3 UJ -«P*
t/J r—
l"55
0 RI E 3
UJ Of 3 r—
XI r— r- G

J
§_£,
t— 0)
< *>
a fi
O *3
o en







o) a
c c

3 U
S- UJ
u
Ul Ul
0)
t- u
S-i
r— at
u t-
RJ x:
u
ui 7
Ul O
ai -P
U 3
£•5
a. ui






















01
S3
•P
Ul C
E-2
^ 3
O
01 *"


35
.^T3
1 ro
p- Ul















ai
5
C
|

Ul
2
If
RJ *~
OJ
« c
C f-
£2
Ul 3
2fe
a ui






















^
§2
§§S
c a. re
'a a5§
3 TJ
p- a>
re u >

XI (•>
ai-
regenera
sulfate
which Is














































.f
5;
I
ITJ
m
c

•0
1O»
Ul
o
o_
TJ
1







1
Si
Q. (/I
SC *»**" .
O t 0>
XI P- 3 r-

>»RJ C/i 0)
*•> C 0
o o « o
Cc41 £
ui at (d c
m > u o
X at ui e


w *
+•»
W 01 v- c
C 4* r- Ul *r-
•p- C re
•P id x: *> r-
*d TJ ui c 3

S.JJ | "5.5 e
ui at o w
TJ c 41 x: f- aj
C (d O ** CLOD
id o
- s- -P « at
i-* o a. *d *P» o
5.U1 C
»~- » ca p- i-
o . p- p- o a.
<-» Q.-P- U
5 ui a. re x: 01
5 o 3 > » a
II**

Ul C •*-
•I--P 0.
ui re re
ui p— X!
at Q c
U 3 TJ O
|g-§"So
(J Q) 

p 4» O •»- a. x:


-------
a
pe
ont

ech
       c§  .8
       o  e 0) at
          at f— s-
       
       V> W 4->
       o u
       UJ »— O)
       JQ re c
        O i
           •- a. u
•*"" 0) %X3
e S w at t. '"
at -o T- -o 5 ;
+•> ai e c >» u»
i— W O W (3 S- C
O 3 *<- W) fl) O «
.c £ c a. p •»- •*- *£ t
3 at £. 3 o at
Is II 8 III:
•at. i
r-'aJ <3 5
fl) 3 ro
at co S *o
Is'i.s
01 15 oi*S
^ o .c
JO O O) ttl
tA O ^
O *— wi u> u> .
t. 3 c 01 m '
Q. «••-»— O)
1
Q.T3 C C W "^

4J -2* O £ *~ 01 *r-
Ul IA 0) 0) 4«* *O '
01 >» . TD N *r- C C
W ** r?^ -0 "« § 3 .2
Pl|f|||| _
5JcC"ci;S 1 §"
*> *» '
a a
r- &.
§l .
at c >
581
a.
u> «
sss
•a (A i
at to m
•a t.
cz M ai at
to « i- c -i- u e -Mi: uw3
(0 W U o> (— O) nj y>
•a (Q atato j=atc
a> *- atjci— s. *^ i- a> s
4J O C J= +J .— +J . 4^ 3
U -f-»— OU'-^OUlr-f-
(DC U>UOICL4->*f-O'O
•MOO) ^r-I-S Mo
c T- 4-> .s-eaiLUj-J-Pw
o+> m t- o at v^c»T-flj
o'sctu'wj:*.® -o
r~OXl^^>OI-Ul(UCCI
in o jo .a nt o t. -t- to
*p-tA&-3 "O O) -4-> UJ O)
Rf^a>C(Afat~.cr-* at
yi*auo4J«i3+j 2tD4j
SOtlARJ o£-*J'*0«
ME C -J3 O. U r— U C
•«- 3 t. o -a oj-r- 3 at o
at s*r- o)ja at (a UTS u»^:ja
30T3>vS--f-.QaiO (A4JS.
*— 4-> O fc. fO E- S. £. O> •*- (O



J| ;

o o
s-s
5-3 1
12
[
j

'
. ,




•
t

1
j


[
,
;
!

i

•

i

i

i
f


1


i


t


iolution to form sodium
iulfide. The sodium sulfide
s then reacted in another
'essel with C02 in the off-gai
rom the reducer vessel to
•egenerate sodium carbonate
ind evolve hydrogen sulfide
las. The hydrogen sulfide ga:
s sent to a Claus unit to
iroduce elemental sulfur.







i
13

IS

-------






























~
4J
8
""
A
ui
I

























S- *- 41




tn
i
P
3
•o
re
IA
o







tn
f
re

^j









s
E ui
O P
f- re
41*1
> V)
41
a







I
• **••

o!




ing Principle
*>
<8
£.
*





S-
O

o o
11
OH-
3 O 1 41 r-
*- m s- xi
>» «— 41 N to .r-
f— 3 in «i— xt tn
i«» tn 3 r— O) « tn
re re -r- -r- 41 o
tn >> o 41 3 u

r— *""" ' +> iV 41 r^-*
tAre41TSCai'r-r—
•r-Uf-4141>O(B
•r- 4) C 01 i- 3
E E x: s. m 4* tA
41 O 2 3 41 • »4- 3
PC XJ S- 41 41
Ul O 4) p p
>»u f— ^tn 3s rei— o
U) >> UJ f— COO
•i-f~flj4»4»oE 5 re

re Q. ul T3
41 f- 3 01
O 3 4) tn TJ
C *> J£ tA 41
•i- to m 4) oj
V) Ul E r— C

tA 41
PC fc.
3 c tn
O 41 *> fi-
si o^r- 3-2
o Q. re >>P
O*r- =5 P 0) P
§4» 41 "5 S- C
s- x: *o 3 o
i— re -P re u o
3
>H O

r- S- .
•P 4J >
3 C E
o 4i a.
u a.
ISo
«"?
41 O O
O V) O


4> re o
as DIP


re c
x: aj ^" -^
•i- o .tn
v> *a . * a> o
V> (J £- X» VI *O O *•».
ui re -3 xi u 41 a.
O -P r— 3 41 i— V>
o cm s. x: c 41 ui
a. u 41 in x; s- ^
2E .r- ?I 41 (. -CF 41 *>
m ui -o £* S = 3 .2
ca re. 41 "o ja o >r»
>- uT re in *^ *a re a.

o
UJ


I


ui re

3,2
re xi
s. re
. i.
C 4»
O -r- O

'" re a>
121
•r- C
O 3 tA
41 *»*^
3 4> 3
re a><+-
o rer-
ttl 41 3
A S- V}


















































>» O 41 IA
17 U» > T-
T3r-.r-
«C u) S.
§C 3
Q.r^
r- Ul X 3
tn 41 vi
J4)
U C 41
P O fd . r-
&^4251
^-g^SiS
tA*r- 01 P 0
41 3 (II E.

v» tn in s. c



t
4>
•*— •
i— IA
ui
41 41
x: u
-P O
i.
J- a.
o
e
S "*"*


II
V) U)

c
41 I r—
xi c re
§
re ai
x: *o 41
tn re -r-
tn ui

I.'S^
41 tn s-
x: a» P
41
C 0

41 tO

i§§
o S.
a> c Q.
58o
Ul dl-4
4) O 1
o vj in
3 r-.

a S5


41 4>
5 **"*"** § §
•p- 41 ui -P
.5 tj» 4j . x> c 4i re
o re fc s- 41 « -P
T3 C 41 0 XT 3 —
5 oxjxix14Jx:-2'
U tn 3 S. C *O U
•r- 41 O 41 C •»-
42 v o 2?*2 T "~ re
N ui *o re *o "O **
^^ 0 £ 3**~ « *>X
41 re 41 CL*r- "r— O O*
3 3 tn t3 «r- 41 V)
r— CO* O O O r— Ul





re


3 O
•5 fc
o re
v> u

>. ^41
•o xi
re
1 .1
r— ul O
tA U

** £ o
£0.0
t»-> O) U)
C -r-
Ul *i—
at "3 5

re u 3
v> tn v>
re"S
Ul
» IA 41
&SS5
'5E*.
4j o.re

p- in o r-
Ul X)
OJ 01 >» «
*> O Q.*^
fc o. (d
t. 0.3 >
o ui re
CPU)
Ul »r- C -r-
re xi re

re.u xi x:
v» in re tn

S
>> <1>
"C-S"0*!
°5^2
in c-r-
-•S-n11
S-5 *
Sin e
3 13 0
o +» c
SL&"?
«Slt!
£ O"- U
t-- U 4J 4J
Ic
•H O

41 re •
r— S- >
•P P E
3 C 0.
O 4) O.
0
41 C O
x: o tn
P O rH
tff etO
sss

fin
re o
OS O3-P


c
re c 41
5 >»*"
is contacted wi
absorbent slurr
ryer scrubber.
minerals in the
•o
Ul "O 41
as&^
§111
r- 4-> r—





^ T3 '"^
« 0> 0)
r- Ul J->
18 Ul t-
JC 0) *r«
in o o o
^£-S5
5i« =














tn o>
*(— O
s i
•^.u
o o.
II
• •(—
41
•r- *3
IA «)-


re 41 ui
'o.'ttea

tT M >. ^
41 4> 1 r-/ S
> •- 41 (Q.O 41 -P
o w o £ aro r- tn
X: U 4>H- 0
r— O ^O Ul
.-•r- S- C O) 41 -P *r-

*re -r- O) 41 ** 3 "^*
^15^511
r-x:o'r-njajs-o>
O.-P S- *— O) E Q. S-












ll
Wxi oo
3 o 4) 4> re
•r- ui x: ui P
U XI -P 3'i—
f— re o a.
re 13 x:-^-
u *-* c 01 o
ui re re o*
>>4I XJ t-
ill:«
J«£*"S
c.re TJ 4J
a. u 41 a> tn
E TO U S. .
Q) 3 O) P »— *
re "C air— 41 vi
x; o o o *— uj









'
i




s
!



i

i

r
!

;
,




i

c
0
re j

i I
41 '
0)
re i
£ :
10 |
in i
a> • '
c
ra '
i-

41 '
»*- !
Ul
C
'•P !
re ;
S- !
c ;
41 ,

o i
U ;
CJ
O
Pom
4) s- r-^
•5 ^ S
e J -a*
O P f—
re 41
ui E <»-
•a £ c
§O 41
«*- tA
a. c 41
' = 3
s ° 1
x: TJ re
2 41
E re S
o xi o
tn ^£
4) ui re '
O 3B
| " '
o tn
•!- ei >
I § i
a. s ;
4C v>






































r*.


s .
o
>i CO
1 ?
re *r»
H» fc«


e- «
0 J-i
0 3
§ s
bster Engineer!
sr Research Ins
a> S
i»
§ 13
O 41

VI UJ
JD U





193

-------
      In  the regenerable processes, the  spent alkali  is reduced ;to  a sulfide
 and  then^reacted with C02  to  regenerate the alkali and evolve H2S  ,gas.   The
 regenerated alkali  is  recycled,  while  the  H2S gas  may  be converted to elemen-
 tal  sulfur  in  a  sulfur recovery  unit.         •                   i

      In  the nonregenerable  processes, the spent  material  is se;nt to a  dis-
 posal  area, for  landfill ing.   The spent  material  also  may  be; recycled  to
 increase alkali  utilization.

      Hydrogen  sulfide  control.   H2S  removal  can  be divided  into two cate-
 gories:                                                          ;

      •    Direct conversion                                      i

      •    Indirect  conversion.

      Direct conversion actually oxidizes  H2S to elemental  S.  Indirect  con-
 version  involves removing  acid  gases (H2S and  C02) from  the gas stream  and
 requires  downstream direct conversion  or further  processing  to treat  the
 sulfur compounds.   Figure  5.1-7  lists the H2S removal  systems  available,  and
 Table 5.1-8 presents a brief description of the  process technologies.

     Direct conversion—As  shown  in  Table 5.1-8, several  direct conversion
 technologies   are   currently  available,   including  Glaus,   IFP^  Stretford,
 Beavon,  Giammarco-Vetrocoke,  Takahax,  Ferrox  and  Haines.   Thja conversion
 of H2S to  elemental sulfur takes  place  in the  liquid-phase  in all  the proc-
 esses, except  the Claus and Haines which are  dry gas-phase  removal processes.

      Liquid-phase  direct  conversion   processes  are ideal  for  treatment  of
 gases containing low concentrations of H2S.   In  these processes, ithe  acid  gas
 components  are absorbed  by alkali solutions  and then oxidized with  dissolved
 oxygen to  elemental sulfur.   High circulation  rates  of  the alklali  solution
 are  required for high  performance and to  reduce thiosulfate precipitate for-
 mation^   High  selectivity  for  H2S  removal   can also  be achieved by taking
 advantage of the higher H2S versus C02 absorption  rates.

     The gas-phase  direct conversion  (Claus  and  Haines  processes)  consists
 of thermal  oxidation of  one-third of  the H2S to S02, followed by a  series  of
 catalytic reactors  that react  S02 with the  remaining  H2S  to fo;rm elemental
 sulfur.  The heat  for  combustion in the furnace is  obtained from the oxida-
 tion  of  H2S;  thus, the  H2S  concentration  must  be  high  enougn  to sustain
 spontaneous combustion-  Therefore, the gas-phase  conversion requires an acid
 gas  stream  with  a  higher H2S concentration than the liquid-phase; conversion.

     Indirect conversion—There  are essentially  five classes of ;commercially
 available,  indirect H2S  removal technologies that  are used  in; conjunction
with direct conversion technologies; these are,  removal of H2S by:

       I. Alkanolamine

      II. Alkaline salts

     III. Aqueous ammonia                                        i
                                                                 i


                                     194                         ;

-------
SOURCE: SWEC
                                                              -CLAUS      I
                                                              -IFP
                                                              • STRETFORD
                                                              •8EAVON     i
                                                              • GIAMMARCO-VETROCOKE
                                                              •TAKAHAX    ;
                                                              •FERROX
                                                              • HA1NES     ;

                                                              •MEA
                                                              •DEA
                                                              •MDEA
                                                               ADIP/OIPA   i
                                                               DGA(ECONAMINE)
                                                               SNPA/DEA  i
                                                               SCOT
                                                               BENF1ELD    ;
                                                             -CATACAR8    i
                                                             —GIAMMARCO-VETROCOKE
                                                             -ALKACID(ALKAZIO)

                                                              -OIAMOX     i   .
                                                          —j—CARL STILL, j
                                                            L-COLLIN      !
                                                             —SELEXOL
                                                             —FLUOR SOLVENT
                                                             ^PURISOL     |
                                                               SULFIMOL    |
                                                             — AMISOL
                                                             — RECTISOL    !
                                                               MOLECULAR ?;iEVE
                                                               CARBON BED:
IRON OXIOE(SPONGE)
KATASULF   >
ZINC OXIDE  :
               FIGURE 5.1-7  HYDROGEN  SULF1DE CONTROL TECHNOLOGIES
                                      195

-------


Disadvantages









Ul
Ol

1
to
>
T3
<




1
E ui
0*5
Of 4->
• > V)







Of
o
c .
i
(.
1



0)

CL
i

£_
Q.
£
0)
CL
O



o



c u
O 0)
0 t—
« fr.
SU1 3 E Ul "O
C M- O 10 0)
j= ji 3 £ ^re
4^ S- Ul ^ Ot
•r- re •o-r-t.
2 U Cf 01 (0 4«*
U> S- 3 4-» 0)
C T3 tO •<- jO
0 >»4J € .
•r- ^ U) Of Ul O
+J Wl -P
U 4^ C Ul Of
re JCT--O o-o
Of -O) C O 01
6. *F- *> 3 S- O)
r— r- O Q. C
Of 3 Q.
-0^0 Wl E 0> >»
•t- c at o .c re
to (9 £- U >P E
5-
i^

•o -p
° m
0>£


'flf &I

't. r-
X ui w>
O) O
f— CJ
ui m

a. "a) s.
•o
at
t__
^i
>ȣ-
o >
3 Ul
C C
C Ul
O Of
U "O



to
?C
O
^.
re
>
o
§-
t-
•B
o c
4-* O
M -P C
zc* re "*"


p :c
c c
o at +•
re a>
"O in t
X 3 Of *
o ui o at
to ui
to o 3: re
a. to CM o)
s
UJ
>
z
o

1— <0
U Ul
UJ 3
as ra
i-» *»
o o
i
Of
o ^
n_
If.
0)
m
>
2
s
— '
e
5tj
>

IO -C i— "lO Ul
wi ""^T * to 3
d^"** O O U *~-
:n ui y +i «j
re >>  T- x; .
o re e $. ui a.*-\
•r- 4J OI Of 3 C
+> J^ > T3 O
a. in*— c s. f- «r-
J. 3 (0 O 3 3 4J
o m >> o "*- o* u
u> i— »— i— «f- re
ssassce






-^_
u_

1 I—
I Q> J3
. i- 5 a)
at ie ar-a c *—
j= oi  C «P O
OI 3 (0 O) Z -i- Q.
O OS- Ul T? O
ui in c at ot c: f-
reot*^i-iA3O3
NOcScgEr-
oo.ofoaa.ua.

t

£.
10
>
t- re
0
4- 4-
Oi °
•— C •
.O O ui
4J 4-» nj
•»- nj a>
3 N t-
Ul f- *J
S- Ul
Ul 3
Ul 4- Ul
Of ^" to
U 3 Ol
£u>
ai **-
Q- -0 0
>>
nj
u
i.
i
8 .
O Of
r-
S3
a. as
in
ei
A
4J
7j 5
o c
0.5

4J (0

S S a.
as o cr>
-P
•o *ra

cr"^ Of e
i- + C 3

•o^Ti'S'S
S^^ 5
0-2 C (0
f* *J (O
4-» « <*-
a.*o c o
o S "^ c
Ul O O O
m ui^s
C4J= *O
S CX.f/1 Ul

D_
^



S

V)
^
§""..
Of O ^'
Of 0)
£ Ul
tn ui
Of
i S
,
To
?
0)
0
Ul J3
ui to
Us
& m
«
C4
*
4->
*— O
i =

55

OT 4J E
at c CL
u of a.
€Mo
of o in
o: u v

e -o -o
tO O) fc.
S- 5 i— O
C 3 0 (QM-
O ^4— »-" -P -P
." ;_ ^- c oJ
4J 3 O Of S- .
C Of Crt Of
Olr— t/> *0f Ol O
o re «4 .c .0
'•S.o'o*
f *» >> e of
IA S. *r- Ul
o *i- « ai ui v^
T Ul T3 > 3
^.^iS^S
f— O O Of 3 0)
 4->
S. *C
to at
£ <5
,,12
T3 CU-P
|"§

T C ui

** 5 •
C Ul «0
t- Ul S-


E c1^


o as
-P C
at c: at
fu a) ui
o
(At/lO

<*~ i
0 C
0 "*«
t. •»- "O
0 4J C UJ .
**- *a re at ui
N Ul Rf
f— C a> 0
J3 3 > r-
to •*- o ui re
v-*3 0> *W 3
re ui J* oj 4->
> at o £ re



s-
g
i
*
4 «
•i- O <*-
=>.;?' o


•O^ltp

E= O
C O Ul
55«*J
4^(0 r-
Q.-O c re
S. f- .^- (A
O X
ui O O U
J3 N*r-
re at z e
Ul 0)
w> 
ui re
c re
*r- c *re
•p «?• >
 c ,
V

T3 at

2 tj
4J Of 4J
-P Of
en at i—
c-ac

o o

2 c S
CL'^-

o re
4J C I
at c at 4
p- O > *
J3 O O <
re
CL Ul t/> ;
to re P* <
U 013= (

*? 5
§&
| =

It
&. at
is-

to
M

0
*re
>


t-
IS
Ol
§1

£ t, :

O1 01 •


-o^i *5J

absorption .
se oxidation
H20 in an a
«JS *






re

V-
)
j
i
s
j
0
D











1
;
j
j
i
j
j




















j
i

3
3-
3
3

I
3 .
Ul
r *o
3 C
J Q.
3 0
A U









196

-------
























^
^J

g
*•*

CO
1.
t-4
in
Ui
n


























to
O»
1
flj
>
T3
(0
(A
a




w
SL
I
s
>
•a
«e




£
at
IS
O 4-»
•35
> tf>
at
o








*
o
Control
Technol
41
X i—
2.H
a +>
s. +> c
•£=•0 i
U) C U
£ +» *° ra J=
^ 1 g^.-?


o» v> *nj (a
•3 2 o J: o
t/j o.**- u u

5
a -o
&•§!
in

u ra ra
g *; jj


J°--3
•a SI! °
0) A O S~
^•0 2>2

+»
Q
'S. C

2^§
a *>'5

s-
3s at QJ
U. (0 o

*»-
o
re

i
2
.p
1
S


•i °V
t- 4- C
•— O .
"iS1?^
w e*oo
el .si
lgo««
ra d» ac o
*^t.C "*" (B*
a: p- 3E




•°x
2
1
w
•o e
S .2
O tS* fc
•»- O (U
el's S
o **- o»


III
O >» Q,
oi iff m

0
*7i<
4- .
«?•
"-P 0 C
O. (0
•S S 8


•^ ui
^ <0 0)
O J= >
s^l
.
(O
RJ
c
^ m
tA C

,2 §
&£

0 £.
r— 
L. .



0£ 0 V
'^r .
VJ-o£? 3
z'tt,*^
Ili-s
£<;A £ c
Ui *" T3 H
0) V) C 4)
J- t^ "° O
||p
r~ T3 o N
K n» «** w»




A
in
1
*5
zc

S 8
+3 .c
£- O -P

ailS^ >»


Oi^
o a! S si ?
zv «•- «

"^g
= -I
•SS"
*- V)
*S»2 z1

e u p
w So


0) «J
c • t-
flj C4-P
+J O C
f— CJ 0*
•Ills

3S0 ».
^- W) 4J "O *i-
| g-gSJ
+> ** ""ra 'c

§£1*5 w
«o >>
•i 1 °~
;'.;^.SS
:

«s|
f'=l
S-^P
o o a*
W (0£
ra fc § « ,
O*r-*O S-
•o £5 1o
fO C O Cl
tt) O Q.
w o c p
O 32 i- E +>

i
u
.
Q "*

«2 a-»2 a tl
1 £ E 15 *^
•r- C) M S-
*> C •»- U) (0
O *i- *O C
a» s (O as
*a) 5 3 -p :c
0*5 ra 8 ^
za > cc as
I 1 .
•c o a>
$. w z1^
 Q)r-^ C -P i—
y •*" nj ai (/> c P
i- x: s- o o ra o
"5 *o "« 8*- "^.p

T3 -P J= lO C
ll 1 =j*.E § E °

**•• W tA ,C p » g S

Q. P Q.*i «P 
i— i—O
(0 (o e
E E
;* ^f
I 1^


"5-S ^§ =
.O O nj
ll-S tol

dj *JS * *° *" "°
o1*— is. * c">,
*o s- c ra **- a>  01 a* E f^ +3
z s- a -P co ja ^




. .0
A  -^- a «r
o -P > u e
3illS2
(A
ra ^3
^I
S-o •

ra tj
£ ?

0 u) O
S- C T3
iS'S
31
V

3
O C
o
(U f—
.c *» .
^21
S 'c §:
leg
11?


^•c
U *r~
P O
CL 0> C
I. .—  ^*5

•a.
 re

« 3
s *" E

0 . c a
** a *>


i— 4> 10 "r-
« £. O 3
1121

c°
s
o c

in ^
ra «-

s. &
5



-------



















^^
I
00
A
in
LU


























Ul
O)
O)
m
£
5
B
IA

D





01
0)
cn
3
C
(0



£ i o> "a. •*- - u c s- a. . cn c ** Ol s- o o o iss c u o a. c o ,-51 3 Ul t- ||Sg .C U <4- &- ai to w 3 a -P VI -*— S- O O O as Ul Ul C 01 O D) (Q £ 3 3 v> o s- O O S- J= U P 0.+J 1 . J= »— O 4-* a> a» S s- CB ui a) P -C 3 'r- C C O O 4J 4J tb O (0 <+- C O *i- i- (J >> o e 3 c u P— U +* U) Ul § £. o* ss e o 42 o, t. C P Ul i— ai •f- a. 0) 01 v 5 Q. 01 "** 1 C_> P 3 01 0) •— OO 3 E. Ul 4Ji^ U Ol „ •— O U re .C CJ OJ f=~O O» CO .C •*- S- 8'S S £ "Go .eg "3 °g -is^I^ ?"o - a ••• °- S-S-^cig "S-g 5'g-cg'g «&S £ £ "i^gi s£ •S^£°«, o)oio> 3 3 a> ^ -P- f- . «j o. •^-oiai. >&-U ui ui £- • -P >i (U

>,i23c3-* O O 3 oso*> a z £ is to u<— ai o.f— sawuio 0) c! *; J! a • . W QJ 1 i— (A &. e t— : "i^ =3& «R «2*£ -2"° "°; i «l*s 1 " «i "I £ §! goo. v;; tJ x>— ""e" "aJocouI WUM ; Ot-3 e V t-f "OCO'T- > v- OJ P P -r-UI . UC fc. 4-> {sCM&-OI Ul' TJ nj a» re > re re -p ttt P 3 o T3 <0 -f- 3 t- MI t. at ai a. $- ai u re r— i. c c H- ex >c r—o>'-n(<^ "Or— ti.' <*-•!— u a»e-»-ai 4.*ok a> to 3 e QJ 3 s 0*0 f— 3 &.aiv} -i- -^ v re o oj o s. 5 3 Ul 01 3 (J « OS £. P ^ 0) -P 4J 3 Jj Q. S uim *> c oj 3O.S ai . s. •»- e -as- » o re o a> *a ex E — J t. at > o oo o; *"" ^* ^ O) O (0 Ul IA •*• ^rf 4J £X,"O °O 3 1C (0«j«^ ex >> £. njc. uiuiut- oio» uiw u re s p- Q. N • 0)0*0 co"Oaio MOIOI* « »— «J -f- P O> J= VI TJ UP- O £- (U f— (0 4- 4_ 01 0) £X «<*- 4^oiuai£-_a> -r- s- t-.a) P 01 ws- > *^* Ul f* • > 01 E f* 4J O O Ul U Ul 4«* O) d Ul Q O 3 fX:C*OX:n}**-. 3Ur— 0) "O3CU 3 EOIC0 0) 0 V) E OJ 0) C *-Cf-V>i*. 'r- OJ (0 0 3|fO oi Q.I— t-*fr-*r-ov «»- 4j 0)£I(BC O. N 01 'C UP o f ex oj re 4J .C 3: 4J •£ o •!- S o t- re N p o £- s-' re P o o) ^- 1— o i- OJt. -I-f-r-(0 01 &.CC4J OJ(d U-P E w r— .X Ql O> £X , d *i— O.' >j o o.u *^ aio *. • OOCM 4^ . ca» °^e^o<5 a. ^3 'a. . C ffl T3C -^- t3 fui*p* >* E C i- 'O 3 ^-•^i-H uixt.ot •?• o)-t»u» ^Ira o ° 3 *,«, tA^OtO (AS 3T3UI*-C POO. S-teOl t-oioi o'O^ai *>-a o re - a> o com oi •*- -= <1) P O U r— 4J &. C r— if O O S *f * Of O M ' P >*^C O £- £- <8^ 4JS-tnEPV)OT3 E'S Ji§» J:i£5 si «-§38-2= SS-5 3;i5 « - . v» v> v> w, O CO 01 Oi C4 C4 CJ i *P ' 4^ " 4J 4J 4J 0) *• «*- 0) Of 01 01 •— O OO -— O f— O r- O r- O 3 r- r- "3** -P -P "3** Is 1*^ o c re re oc oc oc o'c «| || ^5 55 o4J |l 4J«. 0)0) **2 -P«> +J«0- 4J|iO> W «P S U14^> 0» 4-» > 01 4^ € U» V* Q. a* c a. &«&? QJ c E ex oo) ot o o ^ o 4) o in o) o in 01 o o v o ui CC O CO OlrH QSUV OS U V DS U f-l Ol'Ot V> ; U Ul N ^ •»— V) U) U Ul • Ul ' • Q) O t- >» 0)4-> V) C*r^ WJ f— OI OJ !C ^uib-ivi OA x: >> ui oc S i « •-• S S t- (O ITJ C Ul +J ^- • CJ -*^> (0 Ok 4J U (J •»— O OH 01 O A "O ftf CO ^ t ** Ol O 0) O >» O P Ul Ul O)P (!•-* (OOI .G4JOQS O3t» t. +3 Jj o S_ Q.*— J3 i— 13 4) OPt- 3T^Z WO ^-S-4J t-U>0 5*'§.1S .4^ Sog . -o^ S Sc§ 553^ ^ig** JA E .O ^ T3 **/ 4->OIC r-(OOVl OO O O 3 O ; .C Ct. (D U M *™* X -P C O> •*" •*•* 0) Ul t- P >P 0} C *r~ *^ S to *v-> SG^^00™ SJ^tS *£rS S 3S--3 fc5§^ fc»-s« 3C(AC £-3 O) CX 4^ O O OJ CO P E ***s CO '(0 >»x i--- t*jai.^r— 4^ 4J a> u co a> .t.o a>^ai x^ioa: xc^ns* S*>3 e v> c «i « s. p Q.4-* t— oj re c oz ozt? U>*OO.e40) 3SX 4> O 3 •*- OIU1<*- 01 IS 0» UIOV>*»4JZ> .Ul-^TStJ S.10* « ui ^"5 ^ "§ ° 4§ ^t »3S *" IA W MS- CL^ dl Ul Ul C 3 re **— •*" HH ui (Q ^£ 4J U) 3 4J ' 2 ^ S«*- Z 0) t- o p o y re oi ^- *r- uoio'o S c i- f*. at c o 3 2LO C C V> n3 4- 04J«40> EOIT3 UJ o «? 4- (Z^.^1; rS.S.O' NOOJ*J(-0) ^ O O &• *f OJ T3 Ul kfi.tfr-O OIUIUIO OI iOl Cs) «»- a.xzuioo)j3 a., cxo a. v>3m v> a. ex o re co 3 -.- C-- to 3 C-i- *'! • • 5.1 * Ul *"^* I J5 t-f . •o 4J 4J A o ^ re" ^ C^ i ^a i— o re &. s- o -a *»- .0 4J - a> o. c re idu*f-N x v> ' U Ol 31 (Q (t) *^* Ol r— ^£ HH flj ; 198


-------




Ul
&
1
re
1
IA
a







S
Advantag




Development
Status








a>

1
I




01
'a.
'i

i.
a.

Ol
1 £
2
I




O O


c u
3,2
.0
C
re
Ol
s.
o .
Ul
at *o
> c
§3
„ j
•P U
if

TJ
O
O
C3

Ul
Ul
u ^
i. at
0.0)
£+>
3 C
ui re
Ul r—
at a.
a. ui
' 3
5 ,2

Ul
Ul
at
u
r- 01
(0 ui
j- c aJ
at "I- o.
g o
o c ui
v>


0)
I5
1 =
o •
Ji£ I
s- CL
Ul 4*3
•tJ C »
at o c\j
ce u i
to x:
Ul P

i!«
0.0 c
r— 4J fc!
co 0. at at
§0*00
Ul >fP

t. re o >»
v> s- s-
>£:
r— Z3 ' '
to UJ


fe-s
a. re
S1
• o
a» c
> re
O V»
ui o •
CJ Ul
x at 3
o > o
sit
£28
1 Ul
2S i
at s. m
C 3T3 TJ
'(- 4J C C C
re re re ui o
to c re f-
4-1 +> W O1+*
C S- C-r- .,-. r-
3; o at c J- £-
at H- s- >» ai 3
u. P 4J w -a o.
VI
a?

at
4J 2
o c
o
4^ re
t. •
s-si
11-
at O rH
ce o v



u x: "o 4->
e o -P- *u xi o
re x: re x:
01 s. 3 -o 4-»
s- at ui a» *r-
ui at o *- f at
3 i— >, O S- S-
O >»i— Ul 4J 3
s- x: 01 ui ui ui
•o +j •*- to

fj^ g >v*f- |j_-£
c *> x: *re re c
re c P u •••• oi
at ai •«— ui u c
Ul > >» Ul Ot 3 »r-
at r— »— >» ui -a -a
ui o o x: re at "a
=5 ui a. a. 01 1- re
XJ^

re





to


re ""

•a §
a> o
c
4J^
at re o
> so
o s- <«-
CO O. O







Ul
8
S
1
1

§ 1
«f--a re
to re «
*» o
a» ui u
owe
CO O •
£ Ol'i- Ul
i- 4-1 at
cire w
ui O c re
4J CJ f- Ol
S s-*§ to
»— o o «
v>
X


f— O
3
o a
o
£5
4J re
s. •
(J Q) O.
3 u a.
"O C
at o in
O£ U V

at
•P
re ui
u c at
T- O >
01 re ui
s_ o w
Ul C
3 a> >»



x: o •»— •
C S- Wl Ul
re a. >) at
x: ui
C -P a. re
re c 01
at x:
Ul^^U^I
41

o


S-
o
3
d
• l-o^
at **~
t- 4-1 O
||«
t. !5 3
|i|
at t.-r-
4j re s
o> c c
4^ A 4-* S-
re &•  at 3
at ui u cr
a. 3 at
Q E re 01 1-
u
"c


a, o

."g
>i re
i- t/i
> o •
•i- O ui
P -a
O Ul C
a> at 3
*oj o o.
CO S. U
t— 3
X4J Ul
cn

|H
,-.£<*-
(O O
y c ui
s- o re
III
O i— 4->
re re
t. 4J t.
3 ui at
O^C 0.
VI
X

01
•— o o
O C CJ C
o o
4-» re re re

Ol +J > *J I—
at c E c o
^ O^f 0*T
at
c

•0 ui
U *(— O)
CO*—
5>S;S
£. £ Ul
O 1 "-
Ul 1

£ X?J^

tat u
f *uJ ui
re ss >»ai
x: ui
c 4^ ex re
ui > CJ "O
gr- -r- 1~
o x: u
2 ui 2 re
XI

re

o
Ul


if
2" >»
> x;-
3 re ui
ui at re
oi jC i—
CO) *4-
O k Ul •
•r- o.xi ra e
+-> i- C 0
re x: o •«- -r-
t. O) W S. P
o o" re
ui c: at a.
E at o s- at
S s- i- to
fill!
>,
U Ol
re *r-
0.x:
re
o P v>
re M
. £
vT-?^
Of x:
•o~2
C 0 3
re c ui
•r- tn
CO H- Ot
Sr- S.
3 a.
to
Ul r-
o> at re
§S-
<*- re
ce o a.
c
c re
application
treatment of
ral, refinery
hesis gases.
at 3 4->
•o at 4J c
VI
£
4-> O
at +>
= 5 «
o c S
o

S- >
ui -P > E
SitS
•§g°-o
at o r-i in
o± u v v


•P
II
0) Ul 5-
U r— 4>>

Ul T3
ai >» c


x-a'oT
*E re re
ui a. •—
Ul O Ul
"^
re"

o
c



3


cn
x

at
ai
1
i






re
I .
> Ul
11
o o
i— S-
re <^
CJ Ul

*« e
f~ o
serai -commerc
ts in operati <
ii

* s
4J
at M

o c -o

at 'i- m
521 .

ui 4-1 a. >
at c a. E
at o o m
oc u v v


re

at re
fj£
Ul
m >> •
f *™*
o o

fc TI x:
3 c: +*
4J re a*
*i^N-'
UJ -P
reo c
•** at
ra >-* ui





o
Ul

I
s.
at

ui o> ui
. at -r- ui
c: ui x: at
o ui u
•r- 0 J- S 0
4-» i— O O 1-
re <*- _j a.
t. -P
at c T3 at
a. at at • t.
O > -P Wl 3
^- -^ 01 4^
x o 3 s- re
at ui ui 3 t-
r— Ul Ol
d-x: 4-> ui a.
E O) to Ol E
Of- at &. at
CJ X CO O.-P

% «


at s-» ra
c c
at •*- «— 01 *r*
cn (O r— 4-» Ul
3 4-> re c
re c at re
O »*- Ul C
at re at o c
3: ui s o *~»
5^S^|
3 3 • XI *
Q.4J O) re x
c re e s. to
at x: to
4^ Q. Ul O) " O.
(TJ E re "C NO)
at ai P- c to 4-1
X 4J 4- 3 O Ul

at
Ul >
4-> C i—
c o at $-
re .f- 3 a>
,— 40 i— -a .
Q. rd c c
f. 30
i *^ re 3
fc "^ r— 4J Ul
•r- 0) S- -f- C
x: t- o c o
»- re 5 3 u
V)
X
4J
1)

o c
o
OJ'r"
x: +> •
+j re >
t. s
Ul 4-» CL
at c a.
Mat
U M
*o c •
at o o
Ol U V



3
C P
.0 «
4-1 at
s-t
S'S

re ^

re
£•8
l"o
a. c
re
Ul X!
ai 4->
si
js
(O

o
Ul

4-1
u

:.=


< C
i ui to
iT3 E re
[ at re oi
1 ui at
;3 t. c
>, oi-2
'l££75
£. 3 Ol 01
r ai ui c o
.»*- ui at CL
£01 6) ui
S. O) v-
r



P at
i e >
at >> at
tr_  Ul
i^l«
i
is=

at
!53
: 3
i ° =

x:**s
|P re

Ul 4J >
III
Jit
|


:3 _
1 ui ui
II
Ii- O
; ui a.

(O U
3 fc
i O 3
, '* ,'1"
i(O *3
! S ui
'°1
! at w
I
j S-


. 3 re


•— at

                                      ^
                                      3
199

-------
































,-N


i
"**

CO
A
tu
I






















|




U)

+>
1
•o
m
Ul









Ul
en
3
C
Q
•o







^
c
s
E Ul

i— rt)
0)
C3







01
O
s
1
1
2

0)
'a.
u
e
a.
CD
C
1

*





o
o *o
i. ft
*J J=
o a>
Of—
•o
* >
C f. Q g
O OJ O CX
•r* 4^ ^. Q
•o to a» "a. o .
OJ U > E C 0 ID
•P i- P 0 O tO 
> •»- ai +> t-i <»-
f- U S. u
*> 3 . « C
00. 0 « £ . -^
HJ +J v *J ui



o 2 £ « S a.x*
T3
at
c

3

O -

U) <9
£- €
£ ft
*3 O


C
o
1— 4->
*U  i- 3 O) O)
•^ "O "*- 01 >
u'x'a 3*0
^ o 'to •** o»



i,
O>-
m
c
.0
to
o

**s, M
1 Zs
•— 18 X
O . Ul
> ui o -a n
at a. c o

i— O)T> S- U_
o E- o at
*- 3 M 4->
ui at . to
a> ui u. *o c

ta a. at f- n?
+J t— 3 4^
•~ 2 3 CTC
3 o o at o
V) i— U. S. O

to
ScX
U 0
O X
i.
^"o
o*^—
t. to
•a >
0>§
^2
Ul
Q.^
JO
o
at
CD
ra
•p— f^-
Ul (0
to ro o
Sgoj£


^i.*
•o ui o c
c 3**- s

>»<— p— to at
s» ••— to at ui
« *a o t- to
>• > O to t. CD
i— t/1 -^- «
Q) 't *'_ O
i— fc. CM 4J O
o. at -*->
€ <*- t at
0 I- 03
U .C (/) 3 V>
-o^^Sa?
at s to a.u.
§c + ui u>
o ct •

U NO € <*-
CO (0 Ot d*r- f—
waiul^'x 3
32 S- CXI to O .ui



•> ci
(0 en
*o o
*•- o.
XV)
°c
C 0
o s-
S-. I-H


01
e§
O Ul *
••- Ul
Ul f Ul
f^'S: 0

o *> o.
Ul
*at *x Jc
at at ->J
+>
ui in <*-



O CL*£
I

|



a»
S
(0
«
to
Ul *
S3
•^•2
£"5
a. in


e
0
re 4^

i- O)
01 a.
i°o;
0 CT3



511.
«N

OJ'i-
Q> Ul
it
Ul (A


INI tO
<*-
O
(9
I
i



**
"a.
0
u
fl3
!

>x

re
J- 01
o CL
8-S-S


Is?
C f— O


at ia o
o'o *i
2
tJ
4-* V
o c

at t- s
5+-» a.
reo.
$£"!
o at o
301
*O C CM
ai o •
a: o o
en
«o c t
£(A
V 4*
a. +>
o o
Ul C Q *
•i— «^- at o
J2 j. «. *
at "a  i—
re nj jr
.0 i- a
O ^
1 re *


Ul
at
1-
3
to
200

-------
       IV.  Physical solvents

        V.  Dry bed processes.                                     ;
                                                                 i
      The alkanolamine processes (I) remove acidic impurities,  i.e.,  H2S,  CQ2,
 COS,  and  C$2,  from gases  by  an  acid-base chemical reaction with the  amine.
 The process involves an absorption-regeneration cycle of a circulating  amine.
 Commonly used amines are monoethanolamine (MEA), methyldiethanolamine (MDEA),
 diethanolamine  (DEA),   diisopropanolaraine (DIPA)  and  diglycoTamine  (DGA).
 Major equipment systems  used  in  the amine process are  a gas-amine  contactor
 (absorber) for absorption  of  the  acid gases  and a regenerator (stripper) for
 releasing the acid gas  from solution.   A downstream  sulfur recovery facility
 is  required to oxidize,  or recover, the H2S.                     >

      Alkaline salt  processes   (II)  use  an aqueous  solution   of  a  buffered
 potassium salt.   The weak  alkaline  solution  absorbs  the acid  gas components
 of  the  feed  gas.   The process operates  at medium to high pressures because
 the absorption capability is influenced by the  acid gas  (H2S and C02) partial
 pressures.   The alkaline solution  is  regenerated by  reducing the rich solu-
 tion  pressure  to near  ambient pressure,  followed  by  steam  stripping   and
 sulfur  recovery.                                                 |

      The ammonia process  (III)  uses the same mechanism for  H2S  removal as the
 alkaline salt  process  (II)  except the  ammonia  is   used  as  the absorption
 agent.   Regeneration  and  additional sulfur recovery are  necessary.
                                                                 !
      Physical  solvents  (IV) have  low  heats of solution and cari absorb  acid
 gases in proportion to their partial pressures.   These processes require  high
 acid  gas partial  pressures which  are  achieved  at low gas  pressures and  high
 acid  gas concentrations,  or at  high gas pressures and  low acid  gas concentra-
 tions.   Physical  solvent processes are most economical  when  the feed gas is
 at  high pressure  and bulk  removal of the  acid  components is desired.  A  high
 degree  of selectivity of H2S   absorption  is  possible, but additional equip-
 ment  is required, increasing  costs.    A  downstream sulfur facility  is  also
 necessary  to  recover the  H2S.

     Dry bed  processes (V)  generally employ two techniques  to remove H2S  from
 a gas stream:  (1) adsorption  onto  a  dry bed,  such as  a molecular  sieve or
 activated  carbon,  followed by  desorption of the H2S from the bed using a hot
 gas stream;  and (2)  reacting   the  H2S  with a dry  bed material  such as  iron
 oxide to form a  solid  sulfide compound,  which  is then oxidized by  air to
 regenerate the dry bed and to form elemental sulfur.             !

     Sulfur Control Technologies Analyzed—

     The  prime sources  of S02 emissions from  the MIS-Lurgi  plant  are  the
 Lurgi flue  gas  discharge system and the process gas combustion boilers.   The
fuel-based  sulfur in  the  processed  shale is  converted  to S02 during  the
combustion of residual  organic matter   in the lift pipes, while the source of
S02  in the boiler flue gas is primarily from the combustion of H2S in the  MIS
and Lurgi retort gases.
                                     201

-------
      The  S02  emission  in the  Lurgi  flue  gas  is  reported at; 20  ppmv (dry
 basis), or 107.5 Ib/hr (Occidental Oil Shale, Inc.  and Tenneco Shale Oil Co.,
 April 1981).   This  value is  equivalent  to  0.003%  fuel-based sulfur  in  the
 processed shale, which  is  very low for an  indirectly retorted Ishale such as
 the Lurgi processed  shale.   It is entirely  possible  that  a larger amount of
 SOj, is produced during processed shale incineration, but this S02 may then be
 irreversibly  adsorbed  on  the  calcined  material   in  the  processed  shale,
 resulting in  low  S02 emissions.   This   possibility  has  been mentioned  by
 Cathedral Bluffs and  by  Rio  Blanco Oil Shale Company, which had also planned
 to use the Lurgi  retorting  technology for Tract C-a  development (Rio  Blanco
 Oil Shale Co., February 1981).   Colony Development  Operation has! also experi-
 enced a  similar control of  S02 by  its  adsorption on  raw shale during  the
 preheating of the  shale (Colony  Development Operation,  1977);.   Since  the
 $02 concentration  in the  flue gas  is reported to  be at  suchi a  low  level
 (20 ppmv), S02  control  technologies  were  not examined for  the Lurgi  flue
 gas.   However, the effectiveness  of  S02  adsorption on the  processed shale in
 the lift pipes needs  to be documented.

      Two  S02  control  technologies  were  examined  for  the  boiller  flue  gas.
 One of  the technologies—limestone  scrubbing (Case Study A)—deals  with  re-
 moving the S02 from  the  flue gas after the  combustion  of  the process  fuels,
 and this is in agreement with the latest  plan presented for Cathedral  Bluffs
 (Occidental  Oil  Shale,  Inc.  and Tenneco Shale Oil  Co.,  April 1981).   The
 other   techno!ogy—Holmes-Stretford   (Case  Study B)--removes   H2S   from  the
 process  fuels  prior  to  their  combustion.   Ashland  Oil and Occidental  had
 earlier  proposed to use  the  Stretford  technology to treat  the MT.S retort  gas
 (Ashland Oil,  Inc. and Occidental  Oil  Shale, Inc., October 1977).   Further-
 more,  the Cathedral   Bluffs  developers conducted  a  Best  Available Control
 Technology (BACT) assessment  of seven commonly  available  H2S removal  tech-
 nologies  and  nine  $02 removal  (FGD)  technologies;  they found the  Stretford
 and limestone  scrubbing  processes to  be  the best  available  choices in  the
 two categories.                                                  ;
                                                                 !
     The  FGD technologies have an  advantage over  the H2S removal  technologies
 when  treating  some gaseous  streams because  a control over total fuel-based
 sulfur  is achieved.   Since  all  sulfur compounds, such  as  H2S, COS, CS2  and
 mercaptans, in the fuels  are combusted  to  S02, all are controlled to  the same
 degree.   On the other hand, the  H2S  removal  technologies selectively remove
 H2S from the gas, but  the removal efficiencies for the other sulfur  compounds
 vary  considerably.    For  example, the  Stretford  process removes only minor
 quantities of  COS,  CS2, and CH3SH, and these are not recovered las  elemental
 sulfur but are released in the oxidizer vent  gas during the reagent  regenera-
 tion.  As  a result, the net removal efficiency for the other sulfur  compounds
 is  zero;  at  an H2S removal efficiency  that  is comparable to the S02 removal
 efficiency of  the FGD process,  the combustion of  the Stretford1 treated gas
will result in higher  S02 emissions.

     Tables 5.1-9 and  5.1-10  give the major  equipment lists  for the FGD and
Holmes-Stretford  processes,   respectively, while  Table 5.1-11  provides the
cost of  sulfur control.   Figures 5.1-8 and 5.1-9 present the cost curves for
the two processes.                                               ;
                                     202

-------
            TABLE  5.1-9.  MAJOR ITEMS  IN  THE  LIMESTONE  FGD  PROCESS*
 Capita]  Cost  Items
Operating Cost Items!
Scrubbers  (20)
     24' diameter x 24'
     100'  TT vessels

Reheaters  (5)
     42,000 ft2 bare tube area

Sludge Thickeners (2)
     160'  diameter

Pumps
     40 @  12,000 gpm, AP = 100 psi
     30 -  Steam turbines @ 900 HP
     10 -  Pump motors @ 900 HP

Limestone  Feed Preparation

Agitators  and Mixers

Support Steel

Excavations and Foundations

Ductwork,  Expansion Joints and
  Dampers

Duct and Pipe Insulation

Electrical

Instrumentation and Controls

Pai nti ng
Limestone           :
     212,000 tons/yr
                    I
Makeup Water        •
     9.5 x io8 gal/yr

Steam               j
     2.18 x io9 Ib/yr

Electricity         :
     1.73 x io8 kW/yr

Manpower            '•
     83 Men/yr      I
* Design basis:  177 LTPSD sulfur removed.

Source:  SWEC.
                                     203

-------
          TABLE 5.1-10.   MAJOR ITEMS IN THE HOLMES-STRETFORD PROCESS*
 Capital  Cost Items
 Operating Cost  Items!
 Knock-Out Drums (30)
      16'  diameter x 35'
 Hoimes-Stretford Mix1
     405  Ib/day      |
 Absorbers (30)
      36'  diameter x 140'
 Oxidizers  (10)
      37' diameter x  62'
Soda Ash
     15,275  Ib/day

Process Water
     71 gpm
 Pump Tanks  (5)
     37'  diameter x  50'


 Circulation  Pumps (3)
     13,500  gpm

 Flash Drums  (10)
     20'  diameter x  52'
Steam
     5,200 Ib/hr

Cooling Water
     350 gpm

Electricity
     38,300 kW
Slurry Tanks (5)
     26' diameter x 50'
Slurry Pumps (5)
     350 gpm


Filter Systems (5)
     7,000 Ib/hr


Sulfur Melters (5)
     3.5 x 106 Btu/hr
Sulfur Decanters (5)
     6' diameter x 17'
Sulfur Storage Pits (5)
     200-ton capacity

Evaporators (5)
     500 gpm liquor feed
Manpower
     7 Men/day
                                                         (Continued)
                                     204

-------
                             TABLE 5.1-10  (cont.)
 Capital  Cost Items                          Operating Cost Items

 Heaters  (3)
      1.5 x 106  Btu/hr                                           ;


 Coolers  (3)                                                      i
      1.0 x 1Q6  Btu/hr                                       '    :


 Feed  Gas Boosters  (30)
      90,000  ACFM <§ 0  psig                                        i   •


 Flash Gas  Boosters (7)
      5,000 ACFM                                                 '•

 Plot  Area                                                        i
  •    305,000 ft2                                                 :

                                                                 I
 Site  Preparation and  Foundations                                 \

 Ductwork and Piping                                              !
                                                                 i

 Electrical                                                       '


 Instrumentation and Controls                                     '

 Painting


* Design basis:   177 LTPSD sulfur recovered.

Source:   SWEC estimates based on information from Peabody Process Systems,
         Inc., February 1981.                                    ;
                                    205

-------























_J
§
jy
0
z
a

t—
3

o
a.
ee.

u.

^2
to

u.
o


to
8



r-l
1-4
1
v-l
,
If)

UJ
1
t-





























•— *
o ^^
i. in
1=o
r- O O
ID CJ O
,9 •— ^-"

c o
•xcj
D)
C
•^ **"N
4-> U>
1- O
^- Ol O
ID CLO
•*•» O «»•
O v. '
1— i—
ID *>
3 in
c o
C CJ
«e
ID in
•i- O
O.O
to o
w
•o

X in
•r- 0
U. CJ




in
S. -P
O) f-
ja c
E =3
•n
z 
s. a.
cT
o u
O U)
O)
a



0) 13
in 3
ID •U
u to



E S-
(0 01
£!

 z



CM
CO
o
p^"
CO




J^
CO
SM

f*^







CO
s
^r
CM
CM









O









in
ID


01
3

U.

S.
01

o
OQ




o
cs
u_
5-
O) 0)
C J3
S^
in s-

•r-
_J



^J







to





o
in
in
in
to




^.
^^
o
•s
to
CM






to
a
CO
o
CM









C3 '
CO







*^?
c
ns


t- «fj
01 C
> 01
O E
U +J
0) ID
CC 01
01 t—
ID








^J
s-

J-J
£

to



CD






in
^.

CO






























-u
o
u

o
s-

c
o
u

f^
at
•s
c
c
18
r_
nt

o


01

i *

o
c
o


(D
-U

§
u

c
o
in

(D

01
j_
O
to

c
o
]£>
u
01

-------
gOI $ !iS03 9NIJ.VeJ3dO
                                         103cJi(J
                to
                                              CM

O
CO
CM
                                                               o
                                                               CM
                                                               (M
                                                                                   co
                                                                                   Q£
                                                                                   Ul
                                                                                   oo
                                                                                   03

                                                                                   QC
                                                                                   O
                                                                                   co
                                                                           I
                                                                           Ul
                                                                   CO
                                                                   or
                                                                   £
                                                               o
                                                               CM
                                                     co
                                                                            TJ

                                                                            •8
                                                                            C
                                                                            O
                                                                     (0
                                                                     g.
                                                                     o
                                                                     c
                                                                            o
                                                                     V
                                                                     (O
                                                                     
-------
        gOJ  g '1S03 9NUVH3dO 1VDNNV
CO


                                           •a



                                            I
                                            o.
                                                                        (8
                                                                        o
                                                                        
                                                                              o
                                                                              o
                                                                              I'JJ
                                                                              ae.
                                                                              2
                                                                              ,_»
                                                                              :=»
                                                                              u.
                                                                              o
                    o
                    o
                                                                              :=>
           gOi $  '1S03 1VJlldV3 Q3XIJ
                                208

-------
      Total Sulfur Emissions—•

      The major  sources  of sulfur emissions (as S02) from the MliS-Lurgi plant
 are the FGD  stack (Case Study A) or  the  boiler stack (Case Stujty B) and the
 Lurgi flue gas  discharge system.   In addition, very  minor quantities of S02
 are emitted  from the mine  ventilation shafts  and from  the diesel-operated
 vehicles.                                 .        •          •     !       .

      The steam boilers consume approximately 2,200 BPSD of an oil  produced by
 the Lurgi process,  in addition to the MIS and Lurgi retort gases  (Occidental
 Oil Shale, Inc.  and Tenneco  Shale Oil  Co., April 1981).  In Case,Study A, the
 retort gases are  not  treated before burning; rather,  desulfurization of the
 flue gas  is  carried out to remove 95% of the S02 generated  frjom  the above
 fuel sources.   In Case Study B, the retort gases are treated by the Stretford
 process  before  they are burned.  This technology reduces H2S to a  level  of
 30 ppmv  in the  treated  gases  but does  not remove  appreciable  quantities  of
 other sulfur compounds.   Upon  burning the fuels,  the  residual  H2S  and other
 sulfur compounds are converted  to S02 which is emitted to atmosphere without
 further  control.

      Table 5.1-12 gives  the estimated  S02  emissions from  the! plant.   The
 Cathedral  Bluffs data in the table  are  derived from  the  PSD permit applica-
 tion and indicate 95% removal  of  S02  by FGD  (Occidental  Oil Shale,  Inc.  and
 Tenneco  Shale Oil  Co., April  1981).  The emissions estimated  by DRI  are based
 on information  provided by vendors  (50 ppmv S02 in the flue gas for the FGD
 case and 30 ppmv  H2S  in the treated  fuel  gases).  Since the composition  of
 the Lurgi  oil burned in  the boilers  is not known,  its  S02  contribution is not
 included in the  DRI  estimates.                                   :
                                                                 !
 5.1,3  Nitrogen  Oxides Control                                   i
/                            '                                    i
     In  oil  shale processes,  nitrogen  enters  the system  f rom: two  primary
 sources:   (1)  the fuels  derived from  the  raw  shale, and (2)  the air  required
 for combustion  in  the   various  furnaces,  heaters,  auxiliary -boilers and
 incinerators.  A portion of  this  nitrogen  is  converted into  other forms  such
 as  nitrogen oxides (NOx) and ammonia  (NH3).   The  NOx produced during fossil
 fuel  combustion  are emitted  as NO  and  N02  in  flue gases.   These compounds
 are  formed from the oxidation of nitrogen compounds  (e.g., ammonia, cyanides)
 in  the shale-derived fuels and/or from the fixation of atmospheric  nitrogen
 (N2).  A large  portion of ammonia resulting from  the pyrolysis of the shale
 is  usually removed  in  the gas  condensate, or  foul  water,  when  the  retort
 gas  is cooled  or scrubbed with  water.  This removal and subsequent  recovery
 of  ammonia provide an  indirect control over  NOx emissions.   Since the re-
 covery of  ammonia from an aqueous solution  also constitutes  water pollution
control,  this aspect of  the  NOx control is discussed under water management
 (Section 5.2).  The  portions  of ammonia and fuel-based nitrogen that are not
removed  in the   gas  condensate  may  require  removal  or  control  prior to
emission to the  environment.   Federal  and Colorado State standards and regu-
 lations  limit NOx emissions  because of their potential role in the formation
of photochemical  smog and acid precipitation.                    I
                                     209

-------


























^"

<£ .
aJ
O.

Ul
1—

^:
§
u_

o^
z
o
CO
CO
1— 1
s
Ul

w
o
co

_l
'^C
H-
p
t—


*
9

!T"4
*
ift

ixj
^j
CO
<:
i—
















'






















£•*
.C
x^
_Q
r—


U)
-C
o
•l~»
U)
in
•i—
£
UJ

«
O
co















c
0
•r—
-P
m
E
•^"
-P
in
Ul

t— t
O*
C^












"m
5-
-o
0)
•p
(0
u






















































E
fQ
cu
s.
•p
co
CQ
^
73
3
•P
CO

CU
in
m
o




•^


TJ
3
•P
co

O)
in
nJ
O




(0
m
f*i

to
t
3
r—
CQ




e
o

'•p
a.

'si
u
to
c^
0

^~
o
S-
•p
c
o
0











0)
0
S-
3
0
co

c
o
•n"
in
in
•r-
£
Ul





5-

10 r- i o o
t-i o i co »-t
tH CO^
r-T






cn
£H
•r*
J3

"O 3
S- S-
O U
<»- CO
1 1 -p 1
1 1 Ol 01 1
s- c
•P 0
CO 4->
VI
CD

Jj





-p
*t™
(0 ^
J= U
CO <0
C CO +J
0 C
11 in a)
•P <0 E
(0 C3 -^ CL
I— O •!-
•r- S CT
C i— CO O Ul
CD U_ (0
> S- -P i—
•«- O> CO O)

en





















































_j

,— i
CD CO
J= en
1— iH

pH
»-4 "si
a: o.
a 
-------
      Inventory  of  Control  Technologies—                        •

      There  are  three  categories  of  NOx  control  technologies:

      •    Reduction of  nitrogen  in  the  fuel                     •
      «    Combustion  modifications
                                                                i
      •    Stack gas removal.                                    j

      These  processes  are shown  in  Figure 5.1-10 and are discussed briefly  in
Table 5.1-13.                                                   i

      Reduction  of  nitrogen in the fuel.  Burning fuels  low in nitrogen is the
simplest  method of controlling  NOx emissions  arising  from fuelj-based nitro-
gen.   Hydrotreatment of fuel  oils and  water scrubbing  of fuel  gases are
fairly effective in removing the fuel-based nitrogen.           i

      Combustion modifications.   The generation of NOx  by thermal! fixation  of
atmospheric  nitrogen  is dependent  upon the  flame temperature,  concentration
of  nitrogen, time history  of   individual  combustion   gas  pockets,  and the
amount of excess  air present.   To  some extent, these  variables! are control-
lable, and the  production of NOx can be minimized for a particular combustion
process.                                                        ;
                                                                i
      Combustion control  of NOx  may be  accomplished  by  several  methods.   One
approach  is design and operation  of burners  with  fuel-rich mixture ratios.
This  technique,  called  off-stoichiometric  combustion,  produces  low  flame
temperatures and,  hence, potentially low NOx formation.   A significant excess
of oxygen is avoided in the combustion zone by diverting some portion of the
inlet air through  remote locations  in the burner or through entirely separate
secondary combustion  air ports.                                  I
                                                                i
      Another NOx reduction technique, based on combustion modification, takes
advantage of the strong temperature dependency of nitric oxide (NO) formation
on peak combustion temperatures.  Reduced flame temperatures may be obtained
by  direct reduction  of  gas  temperature  or  by  indirectly increasing  heat
transfer.    Direct  techniques include  recirculating product flue  gases  back
into  the combustion zone where they serve as diluents absorbing heat, thereby
reducing  maximum  flame  temperatures  achieved.   Other  direct techniques are
reduced combustion air preheat and water/steam injection.   The latter is more
applicable  to   gas  turbines.   Indirect NOx reduction  relating! to  the  com-
bustion  process  usually  involves  furnace  designs  with  increased  burner
spacing and  heat  removal  capability.   Flame temperature  reduction  does not
reduce  NOx   formation  from  fuel  nitrogen but does,  reduce atmospheric  N2
fixation.

     Stack gas  removal.    Flue gas  treatment  for NOx removal is  a relatively
new,  developing technology.   Two  broad  categories may  be  defined:   v/et
processes in  which NOx  is absorbed into an aqueous solution, aind  dry  proc-
esses in which NOx is reduced by ammonia.
                                     211

-------
NITROGEN OXIDES
    CONTROL
 TECHNOLOGIES
                             FUEL NITROGEN
                                REMOVAL
                              COMBUSTION
                              MODIFICATIONS
                               STACK GAS
                                REMOVAL
SOURCE:  SWEC
     NH3
  SCRUBBING
                                                             TWO-STAGE
                                                             COMBUSTION
                                                             LOW-EXCESS
                                                               AIR
                                                            FLUE GAS
                                                           RECIRCULATION
                                                          LDWERTEMPERATURE
                                                          THROUGH FASTER
                                                          HEAT RELEASE
                                                             ACTIVATED
                                                              CARBON
                                                             ABSORPTION
  CATALYTIC
DECOMPOSITION
                                                            SELECTED
                                                            CATALYTIC
                                                            REDUCTION
                                                              THERMAL
                                                              DENOx
                                                           ELECTRON BEAM
                                                            SCRUBBING
                                                             ABSORPTION
                                                             REDUCTION
                                                             ABSORPTION
                                                             OXIDATION
                                                             OXIDATION
                                                            ABSORPTION
                                                             REDUCTION
         FIGURE 5.1-10  NITROGEN OXIDES CONTROL TECHNOLOGIES

                                    212


-------





















,*
|
3
A
u>
0
S





























cn
01
en
•Q
to
Ul
Q




tA


ID
flj
•o
^





I
Hi tn
&i
•S3
> to
O
o






41
g

I
S-
0.

V
"a.
u
c

Q.
Ol
C


2

=3



> u
§3»
Q
S- — J
.p
3 -B
"§ £

£1


.
"S31
•P ^~
+j 'o
Ul S.
C 0)
O E
§1
a u
.
to
o
f
tm
X
§

IS
s
s
a.
£3

§1
2^d


_e N +
•o Sz1


u <^
?i+
Hr-Tz

x
a
Thermal

_. s
dS *o tn
<*3 U 01
.a t.
U) f- .
Power consumption i
of plant output for
accelerator. High
capital cost. Requ
high efficiency ESP
8

0
'ra
>
a

2
(A
3
O
e
a x
4-> O

Ii
V> Q
&

0)
I
0 >,
£§
«
M
1

x"


&S
O >
4J O
e
3 fc -

xl^

c M*J -a*

ej^iScS-
to +> at

*t-'5*o £
o
C 01 to
r— O U +1 .
(O -f- C O rt
> *> 01 3 O
ISS?^
£2kl:i

i
03 o)
£ C
li
II
Ul V)


V
01
01 I- "O
> 10 C
Requires an expensi
column. Consumes 1
quantities of NH3 a
H2S04.
T3
2
3





S1
cn
c
N
•5
x
o
z
•a

to .
Ul ^
QJ t
•o 5
z u


s
^?
a*

x
•O
^"w
trt >
il
r- t.
S||
t/) i- O
CO »— CM
3: *^-
sz o RJ re
3t355
0) *>-
•a 4- 3 -P
O) <*- Ul
aJ oiSilo

C-r-^ «

(A O *«— -fr— C
•i- s- as
O -JT (O 
R)
1
73

Z
= 2 .,
•O T3 VI
o c-o
Ul O C
.fl *p- R)
CO 4-f



W if O
004*
to c
S TJ
"O 2 CO
C*x. M
§ a o


c
o c
•i- O
o-o
Ul -f
€5

«
(A
r— 3
Q) Q (0 U>
•P Ol U i—
Chloride in the was
stream causes dispo
problems. Nitrate
formation can also >
disposal problems.
Oxidation material
very expensive.
o
CO
tf_
o


Q

1
Ul
3
O
(U
J s- t-
s
(U
(A
3
2


o21
«. 3



°«
£- N
5^5
•^ X
tit O


ill
•P CL-P
fO t. O
T3 O 3
•i- U> "O
<*€£






















03
S
S-
.0
• o
-p
Ul

o
-p
Q
S-
o
2


-------
      The wet NOx removal  processes also serve as a mechanism to reduce sulfur
 dioxide emissions and, as  such, can provide  effective  environmental  control
 where both pollutants are present.   However, due to the low solubility of NOx
 in aqueous solutions  and the low removal  efficiencies obtainable, absorption
 techniques usually prove  to be very expensive.

      Dry  NOx removal  systems,  in general,  display  higher m'itrogen  oxide
 reduction capabilities  and  are  economically more  viable  than !wet  systems.
 These processes are  usually  ammonia based and may  be  selective1or nonselec-
 tive and  catalytic  or  noncatalytic.   Depending on  the  individual  process
 applied,  ammonia is  injected into  the  flue gas at  some  point after complete
 combustion and prior to a minimum gas temperature of 350°F.   In the resulting
 reaction,  NOx  combine with  ammonia to form molecular  nitrogen  and  water.

      Nitrogen Oxides Control  Technologies  Analyzed—            '

      The  boiler  flue gas  is the primary  source of NOx  emissions from  the
 MIS"Lurgi  plant.   A significant  amount  of the fuel-based nitrogen (NH3)  from
 the  process  fuel  gases  has  been removed  prior to burning  in the  boilers;
 therefore,  the  potential  for  NOx formation  is already  reduced.   Another
 significant  source  of NOx  is the  Lurgi flue  gas discharge system.  The  NOx
 emissions  in  the  Lurgi flue gas  originate  from the  fuel-based nitrogen  in  the
 organic  residue  on the processed shale  and from the thermal  fixation  of  the
 atmospheric nitrogen during processed shale incineration.        ;

      The  NH3  appears in both  the MIS and  Lurgi  gases and is  removed by water
 scrubbing  before  the gases are burned  in  the boilers.   Ammonia :in the Lurgi
 retort  gas is removed during  product liquor condensation.   Since  this is an
 integral  processing  step   in  the Lurgi technology,  it is  not considered a
 pollution  control measure.                                       \

      On the  other hand,  the  MIS  retort  gas  coo'ling  and recycled ;scrubbing is
 specifically  carried out  to  reduce  the  NH3 level  in the gas.  Although some
 light  oils are  also  recovered  during   the  cooling process,  MIS  retort gas
 absorption/cooling is considered  an  NOx  control technology.      •

     Once  removed  in the  Lurgi gas  liquor  and MIS gas condensate,  the  actual
 recovery of NH3 is achieved with  the Phosam-W technology.  Since 'the Phosam-W
process  is a water  treatment technology,  it is discussed  in Section 5.2.

     The  low-Btu  MIS  retort  gas,  if it can  be burned alone,  Will  produce
 fairly low flame  temperatures, reducing the potential for NOx formation.  It
 is likely, however, that the  Lurgi retort gas may need to be fired  separately
and the hot gases from the combustion then used in the MIS gas firing.  Since
the  high-Btu   Lurgi  gas  will  produce  fairly high  flame  temperatures,  the
formation  of   a  substantial  amount  of  NOx  is likely.   Cathedral  Bluffs  is
proposing to use low-NOx burners and low excesses of air in order to minimize
the  NOx emissions  from  the  boilers.   Since  low-NOx  burners have not been
proven commercially, costs have not been estimated.              ;

     Some  combustion modifications  can be applied  to the  Lurgi processed
shale burners  to  reduce the NOx emissions  from  the  Lurgi  flue gas discharge

                                     215

-------
 system.    Since  this  would involve  redesigning  the  lift  pipe|s  (a  process
 modification), such modifications are not included in the analysis.

      Table 5.1-14  lists  the major equipment  and components  included  in the
 cost estimate of the absorber/cooler,   fable 5.1-15 summarizes the  cost of
 NOx control.  Refrigerated storage  tanks  for NH3  are  also  included  as the
 indirect  NOx  control technology.   A  cost curve specific  to the  absorber/
 cooler examined  in this  manual  is presented in Figure 5.1-11.

      Total Nitrogen Oxides Emissions—                          I
                                                                I
      The  NOx   emissions   from   the  MIS-Lurgi  plant   are  presented   in
 Table 5.1-16.  These emission estimates have been obtained from the  Cathedral
 Bluffs PSD permit  application  (Occidental  Oil  Shale, Inc. and Tenneco Shale
 Oil  Co.,  April  1981).   The NOx  contribution (as  N02)  from the fuel-based
 nitrogen  in the MIS  and Lurgi retort  gases  and Phosam  overhead  vapors  is
 estimated at.3,B93 Ib/hr for Case  Study A  and 2,605 Ib/hr for Case  Study B;
 therefore, as  the  table indicates, a  majority  of NOx are formed by  thermal
 fixation of  the  atmospheric nitrogen.
                                                                . !
 5.1.4 Hydrocarbon  Control                                      i

      Hydrocarbon compounds  are emitted  to the  atmosphere  as a  result  of
 incomplete fuel   combustion or  as a fugitive emission from  small  leaks  in
 processing or  storage equipment.                                !

      The hydrocarbon  emissions from  noncombustion  sources  are  usually  re-
 ferred to as volatile organic  compounds  (VOC) or reactive hydrocarbons (RHC)
 in  government  regulations  restricting their emission.   Federal and  State
 regulations  limit  these  hydrocarbon  emissions because of their  role  in  the
 formation  of photochemical  smog and ozone production.           i

      Inventory of Control Technologies—                        i

     As  illustrated  in  Figure  5.1-12 and discussed  in  Table 5.;1°-17,  hydro-
 carbon emissions can  be controlled by  the following categories  of control
 technologies:                                                   ;

     •    Additional  sealing of process equipment               '  •
     •    Vapor  recovery                                        I

     •    Complete  fuel combustion                              i

     •    Catalytic converters
     •    Thermal oxidizers.                                    ;

     Additional  sealing of process equipment.   Hydrocarbon emission  control
by additional  sealing of process and storage  equipment is best 'accomplished
by engineering these  features  into the plant.   This  includes double seals on
taniks, pumps,  and  other rotating machinery,  closed-loop sampling,  caps on
open-ended valves,  and periodic monitoring of equipment  to  find  hydrocarbon
leaks quickly.    This  will result in a  minimum additional  plant 'Capital cost

                                     216                        I

-------
         TABLE 5.1-14.  MAJOR ITEMS IN MIS RETORT GAS ABSORBER/COOLER*
Capital Cost Items                          Operating Cost Items

Scrubber Towers (10)                        Electricity
  40' diameter x 77'6" (lower section)           5,300 kW
  40' diameter x 8' (transition section)
  32' diameter x 43'  (upper section)        Maintenance

Ailr Coolers, Lower Section (each tower)     M
   2 - Tube bundles <3 64,400 ft*            Manpower
   2 - Fans with 16'  diameter blades             A* men/aay
   2 - Fan motors @ 30 HP

Combinaire Coolers, Lower Section
  (each tower)
  10 - Tube bundles @ 64,400 ft2
  10 - Fans with 16'  diameter blades
  10 - Fan motors @ 30 HP
   3 - Pumps @ 13,200 gpm
   3 - Pump motors @ 1,000 HP

Combinaire Coolers, Transition Section
  (each tower)
   2 - Tube bundles 0 64,400 ft2
   2 - Fans with 16'  diameter blades
   2 - Fan motors @ 30 HP
   3 - Pumps @ 2,200 gpm
   3 - Pump motors @ 200 HP

Combinaire Coolers, Upper Section
  (each tower)
   2 - Tube bundles @ 64,400 ft2
   2 - Fans with 16'  diameter blades
   2 - Fan motors @ 30 HP
   3 - Pumps @ 1,000 gpm
   3 - Pump motors @ 200 HP

Cooling Tower Circulation (each tower)
   3 - Pumps @ 2,500 gpm
   3 - Pump motors @ 200 HP

Site Preparation and Foundations

Ductwork and Dampers

Electrical

Piping

Instrumentation and Controls

Insulation
* Design basis:   894,000 ACFM/unit; total of 5 units with 2 scrubbers each.

Source:   SWEC.                                                     ;  *•
                                     217

-------
























—1
§
z
o
o

z
o
HH

1
s
(A
t» i
a
i— i
X
o
z
UJ
1

1
i— <
z

u.
o
!••»
V)
O
o

^
ITS

^
!— 8
a


UJ

CO
<


























re

O m
g ^ ^
4-> O
C O
i— O O
re o to-
i * ^^ •
O i—
(— re •)->
3 01
c o
c o




O>
c
4-> U)

2 0
i— ~\
re u>
*>-
•i- O
Q.O
re o
o -w-

~)J5



.
V) Z




^^ ^*^
m oo r*-
1-4 ID m
o in <•
•> •»
|H 0
CM CM
*^s **^








0
X" N ****
in <* T-)
co r*> VD
CM ?-«_
OO CO
S S








l-l O ?-«•
or> co 
A « «>
CO CM If)
O O
CM CM






•a >>
a s-
ra oi
>
>> o
S- 4-> U
a> c   re
a» re t-
os 

"S eo
0 3C
o z

S- T3
0) 
o

c
o
^J
re
^^
3
a.
E
0
U

c
0

(A
I—
•1—
re
43
a)


s.
o
1~
^D

C
o

40
u
a>
to

0)
O)
to

re
(A
ai
O)
£•
re
x:
u

O)
c
•^
4J
re
s-
O)
a,
o
•a
c
re
r—
re

*f»
a,
re •
u re
i— '£
re o
3 E
C E
c re
re
i—
r— O
re
+J C
° S
0) 0
XI f")
4^ rH
4^9*
D)
C +>
•r- re
u o
re o
*> *"^
XI O
3 CO
(A 00
*•
£• !**•
0^ 4A"
<«- M-
re o

4-' •p
*r" »r™
M- "O
O  u
re 3
O TO
•r^ O
•a s-
c ex
•i— i
^)
s**\ **i

^•^ f™
re
U) 3
0) C
in c
o re

+^ CD
C D)
at re
s- s-
m 
re
c
•r- Ol

 M—

x>







































.
o
UJ
3:
to

_^>

•o
ai
•a
•i—
>
o
ex

c
o
'43
re
E
S-
o
M-
C
•«—

C
o

•o
O)
v>
re
o

(A
0)

re
E
•i—
U)
O)

t— 1
Q±
a


, .
a)
u
i.
3
O
to
218

-------
        £01  % 'ISOO 9NU#H3dO 1W1NNV J.038IO
                                                           8
                                                           o
                                                                             LU


                                                                             O
                                                                             O
                                                                             o
                                                                             UJ
                                                                             CO
                                                             3=


                                                             t-1
                                                                             i
                                                               2
                                                               trt
                                                                       UJ
                                                        I
                                                        o.

                                                        c
                                                        o
                                                       •1""

                                                        CO


                                                        O
                                                                             u.
                                                                             o
                                                                             o
                                                                             o
                                                                             UJ
00
OI $ 'ISOO
                                                                             u_
                                                         CSKO

                                                         (O
                                                        o

                                                       •a
                                                        at
                                                        in
                                                        to
                                                       JQ
                                   Q3XU
                                                                       UJ
                                                                       O
                                                                       O
                                                                       €/»
                               219

-------
               TABLE 5.1-16.   TOTAL NOx EMISSIONS FROM THE PLANT
Stream
Number
4
15
68
79
5,119
TOTAL
Emission Source
Mine Vent
Lurgi Flue Gas
Discharge System
Boiler Stack
FGD Stack
Diesel Equipment

Cathedral
Bluffs Data
266.7
385.0
6,924.2
162.0
7,737.9
NOx Emissions
DRI
Case Study
266.7
406. 1*
6,924.2
162.0
7,759.0
, Ib/hr
Estimation
A Case Study B
266.7
; 406.1*
! 5,636.2*
I 162.0
1 6,471.0
 Source:  Occidental Oil  Shale,  Inc.  and  Tenneco  Shale  Oil  Co.,  April  1981,
         except  the quantities  marked with  an  asterisk (*) were estimated by
         DRI.                                                    :

 and  will  more than pay  for  itself due to the  value of the hydrocarbons which
 are  prevented  from being emitted.                                !

     Vapor recovery.   When hydrocarbon  vapor  emissions cannot be controlled
 by additional  sealing of equipment, a vapor recovery  system can |be installed
 to collect  and  condense the vapors by  refrigeration  and  return! them to the
 process.                                                 •        i

     Complete  fuel combustion.  The  most cost-effective way to  control hydro-
 carbon  emissions from fuel  combustion  processes  is  to operate! the process
 with  enough  excess air  to ensure complete oxidation  of all  hydrocarbons to
 C02 and H20, i.e., complete fuel combustion.                     |

     Catalytic converters.  When complete fuel combustion  does  not occur, the
 hot  exhaust  gas  from  the process can  be sent through a catalytic converter.
 In the catalytic  converter,  the  gas  is  passed  over a  catalyst  where the
 unburned hydrocarbons  are reacted with  the excess air in  the exhaust gas and
 are converted to C02 and H20,                                    •

     Thermal oxidizers.   Hydrocarbon vapor  streams or any other  waste gas
 stream containing unburned  hydrocarbons  can be  burned  in  a  thermal  oxidizer
with excess  air  and  additional fuel, if needed; this completely bxidizes all
 hydrocarbons to C02 and H20.                                     ;

     Hydrocarbon Control  Technologies Analyzed—                 >

     The hydrocarbon emissions  in  the MlS-Lurgi plant emanate fr^m the leak-
age  in  the  valves, pumps,  etc.,  as  the fugitive  emissions from; oil  product
storage, and due to the incomplete combustion of the fuels.      ;


                                     220                         '

-------
     HYDROCARBON
      CONTROL
     TECHNOLOGIES
                                  ADDITIONAL SEALING
                                     ON PROCESS
                                      EQUIPMENT
                                        VAPOR
                                      RECOVERY
COMPLETE FUEL
 COMBUSTION
                                     CATALYTIC
                                    CONVERTERS
                                       THERMAL
                                     OXIOiZERS
SOURCE^ SWEC
       FIGURE 5.1-12  HYDROCARBON  CONTROL TECHNOLOGIES

                             221

-------
g



iu

g

o
u


I



&



S
»

S
31S
0) 4-1
                    y> -Pi—
                      £c  o
                      oi  t.
               C   CP


               ai c   s^
               r- (0   f-
              •P C C
              Wl O flj
              O) U i—
               "8.S-S 5
               TJ 01 £. U -P
               «— C 4^   Q» C
               3 »r- Wl Oil fc tO
               OS.CC.
               .e 3 o o o **-
               V) "O O E 4-» O
                           •o

                         «5
       $*°-J!:£!
       u -a C *» -»*i

                Ul j
                  c ra
               i— n> us o

               •     *"J
        9 •+*      -  —
        i  ui a) oi .a  o
        9  O S- 3  S-  S-
          U O -O  fOH-
        3    e    U
          O)   -P  O T3
        »  C >» 01  t-  Of
               3 4- (A £ -P
               O   T- 4-> C
                 €4-6'i- O

                  O W » 0
                    Gl
                   » > W
                   /»- 0)


                    SS
                to e c o  •
                OJ   « J3 -P
                U) d 1 S- C
                  c c m o>
                Q)*r- O) U €

               SS8-25-

                SSc^g-
               o t. o S or
                go

               5?!
                                             r- (0
                                             0>4J
                                             3 £
                                             mm

                                             O* E
                                             52
                                                 S
                                  fO -P
                               .e T- ui

                               £§§
                                  o *w
                               S  ex u»
                               •p  oH
                               Ul 4J O)

                                  at o

                               si.1
                               m  o. ui

                               s:*
                               S.  W 1-
                       2
                       a.
                                    •»- oj *—«
                                             2
                                             a.

                                             X
                                  c°"S
                                  O O) C
                                  JS ^ S.
                       O "O 3 t3 in
                          €>j W) C >»
                         f 3 n u
TJ at >,
aj *- S
+2 to
+>   -O    U)
i- +i at c  u>
£ c w> ai  a>

"SS5S


ifli-
o. o" o to  at
to 01     ^:
.>   TJ C -P
   (A C O
C t/t fl? T-  O
O OI   4-> 4->
J3 O T3 (0

 W
                                                  o     •- XT —
                                                                           au= ui
                                           ll«
                                           ill
                                                                           °i=
                                                                             (0 -F*
                                                                          4J "O Ul
                                                                           ft) C -P
                                                U>   4J
                                                at tn 3
                                                O (D O
                                                           C Ul TJ
                                                         o o m c
                                                        4-» ja o> ffl .
                                                           ' at ui

                                                           i o o
                                       = -S     t%5
                                                         0)
                                                             S- f
                                                          £- ui <
                                                                           m

                                                                          ?
                                                                           O S- O
                                                                           4J <0 *>

                                                                           a> o e
                                                                           0> ffl (0


                                                                           o o at
                          o o) •— E +J u» s-
                          u x: at m o at at

                          c^S^s-SS   =-c5-<
                          0} 4- •*- -P O (- O   (O O  C
                         u o TJ tn 4- a. u   OIHI-<
                                                              Ji8
                                                         ui 4-> o in
                                                                           Wl fc. Ul -r« N U
                                                                           S *0 4)   '^"
                                                                           «J (J O *— TJ O

                                                                                    '^
                                                                     f -W r— >, 0
                                                                   (ff   *^. (0 p— .Q
                                                                   ID t3 3 C 01 k

                                                                   ""e-o-Sa S

                                                                   3&SS-5.S
                                                                         *
                                             "-§
                                                                           r-s
                                            222

-------
      Hydrocarbon  emissions  from diesel-burning  equipment are  controlled  by
 Installation  of  catalytic  conversion  systems.   The  least costly  fugitive
 hydrocarbon emissions control  for  storage tanks is proper sealing.   Alterna-
 tively, vapor  recovery  can be used,  but  the expense is extremely  high for
 these systems.   As a standard industry practice, double-sealed,  'floating roof
 storage tanks  are  provided for  volatile product  storage.  Internal  plant
 leaks are  controlled by use  of adequate  seals and strict  maintenance pro-
 cedures.   The  furnace and  boiler stacks emit partially  burned  jhydrocarbons.
 Except for using proper  combustion  practices,  no other  technologies  are
 provided   for   controlling  hydrocarbons  from  the  fuel  combustion  sources.

      Table 5.1-18  lists the   hydrocarbon control  practices  and  equipment
 considered,  and Table 5.1-19 presents  the costs for hydrocarbon  control  for
 the entire plant.                                                [


         TABLE  5.1-18.   HYDROCARBON CONTROL PRACTICES AND EQUIPMENT
 Capital  Cost  Items                                 Operating  Cost; Items

 Floating Roof Storage Tanks  (3)                    Maintenance
  200' diameter x 48', 268,000 bbl  (each)
  Welded API  650 code                                            :
  Double seals
  Carbon steel

 Complete Combustion of Fuels

 Dual Mechanical Seals on Pumps and  Valves

 Catalytic Converters on all Diesel  Equipment
                                          -                       r
 Monitoring Equipment
Source:  SWEC.
     Total Hydrocarbon Emissions—                               ;
                                                                 !
     Table 5.1-20  summarizes the  hydrocarbon  emission  sourcesi and control
equipment used for the emissions.

5.1.5  Carbon Monoxide Control                                   i

     Carbon  monoxide  (CO)   is  usually  formed by  incomplete combustion  of
fossil  fuels.   Normally,  an excess  of oxygen is  supplied to  a combustion
process to ensure  that all  of the carbon  in the  fuel is converted to carbon
dioxide (C02).  When  a shortage of oxygen occurs  in the combustion process,
somo  of the  carbon  is  only partially oxidized to CO.   Federal  and  State


                                     223

-------


























o
§
o


o
I—I
3
2

z
m


CJ
§

>*

LL.
O

r-

O
«J
^


UJ
1

































n)
o in
•P o
c o
r— O O
10 o vt-
O r—
1— re +J
3 in
c o
c o
-

01
c
-p in
re-
S. 0
n- ai o
10 CLO
•P O V*
O *»*'
15 +>
3 in
c o
c u
"*


re in
•P -
•f— O
0.0
reo
O««-
Ol -P
x in
'£. o




in
i- -P
ai •«-
fc '
=9

O







O
•P
re
u
o
_j


£
e
o
u





c:
o
•I—
+J
O.
'£
u
in
0)
o.


2

c
o
.ej






re a>


V) Z



^^
u>
vo
""^












en

S^^










O
rH








1








.
U
ai
•»
in



o.

U)
Ol

i











0)
u
c
re
c
Ol
c
•^
re
^r







r*.
^






00













in
m











00
CO








,










c



•r-
3
CT
LU
,_
0)
in
01
O




in
s-
Ol
4J
s-
0)
c
o
o

u


3?

4J
re
o






^rt
rH
^i
tn




«*"s ^**\
o en
r-t 00
rH <— '










r^v

CM) IO

CM1 CSJ
"••^ *^









O 00
!? S








co










a)
O)

S-
o
+J


u
3
•a
o
a.









in
<<- c
o re
§L *~

0)
o> o
c re
"-P O
re -p
o t/>

u.


^g
LH
0
r-

CO «*
00 O
CM *»•

































in
O
u
,_
o
£_
+J
1=
O
u

re

c
c
re

^_
re
S

O)
.G


1-
O
C
o

-p
Z3
t
o
u

c
o

in

•r-
5
01
tJ

S-
o



c
o
•r-
+J
U
0)


0)
at
V)
re
224


re

c
c
re
01

.j

o
s-
It-
in i—
O) •>-
ra o
m i-
/r Q
U

rn f^
C ^

+» CM
re co
S--W-

O.4J
o re
•0 J=
re o
re ••
•P in

a. c
re re
U -P
r— Ol
re oi
3 re
C i-
10 4^
w
"io a)


^j
0) o
.E S-
•P <<-
O1O
C 0
H- O

U CO

£c3

3 -a
in c
re
s.

•P O
<(- C
re re
c
+> ai
•r- .p
<<- C
O -r-
s. ta
a. e
a> s
•P 0
re s.
u <*-
•r-
*o o
c o
•>- o


1^
in
Ol *
> ^
•°
















A
^


























.
U
UJ
.3
to

^
xt
•a
ai
•o
•r™

O
S.
a.

c
o

re

o
c


c
o

•a
Ol
tn
re
tn
ai

re

•r*
•P
in
01

i_i
en



. .

u
s-
3
o



-------
           TABLE 5.1-20.  TOTAL HYDROCARBON EMISSIONS FROM THE PLANT
Stream
Number
79
117
5,119
28,34,
40,47
TOTAL
Emission Source
FGD Stack
Valves, Pumps, etc.
Diesel Equipment
Product Storage

Control Description
—
Mai ntenance
Catalytic Converters
Floating Roof
Storage Tanks

Hydrocarbon
Emissions (Ib/hr)
: 23.0
• 65.5
1 7.7
i 98.3
1 194. 5
 Source:   SWEC.                                                   |


 standards and  regulations limit  CO  emissions because  of their  deleterious
 effect on the  human  respiratory  system.                          ;

     The  easiest and  most cost-effective way to  control  CO emissions is  to
 use  excess oxygen in the  combustion processes to  ensure complete  combustion.
 When  incomplete  combustion does  occur,  catalytic converters  of  thermal  or
 chemical  oxidizers may be  used to  oxidize the remaining CO to C02.

     Inventory of Control  Technologies—

     Figure 5.1-13  shows  a list  of  the applicable  carbon  monoxide control
 technologies,  and Table 5.1-21  describes  in  detail  the features  of these
 control methods.                                                 j

     Complete  fuel combustion controls CO emissions  by  not  allowing them  to
 be  formed.  This  is  done by  operating with  enough excess  air  to ensure
 complete  oxidation of  all  carbon  to C02 instead of only partial 'oxidation  to
 CO.   When CO  is formed in a combustion process, a catalytic  Converter  or
 thermal or chemical oxidizer can be used.

     Carbon Monoxide Control Technologies Analyzed—             ;

     By far, the largest amount of CO is emitted from the Lurgi flue gas dis-
charge system.   The  sources  of  this  CO may be the  incomplete  combustion of
the  residual  organic  matter on  the processed  shale,  decomposition  of  the
carbonate  minerals,   and  a  steam/coke  reaction  in  the  processed  shale
quencher/moisturizer.  To  maximize the  combustion of the organic1 residue, an
excess of air is  used.   Decomposition of carbonates is  unavoidable because
the  processed  shale recycle  stream  has  to attain  a  high temperature  to
provide the heat of retorting.  The steam/coke reactions  may also be unavoid-
able.


                                    225                         i

-------
     CARBON MONOXIDE
         CONTROL
       TECHNOLOGIES
                                    COMPLETE FUEL
                                     COMBUSTION
                                     CATALYTIC
                                    CONVERTERS
                                     THERMAL
                                     OXIDIZERS
                                     CHEMICAL
                                     OXIDIZERS
SOURCE- SWEC
      FIGURE 5.1-13  CARBON MONOXIDE CONTROL TECHNOLOGIES

                          226                         !

-------

















«
UJ

i
•j

1
g
|
Ui
a
*- j
g
i .
i
s

s

u
§
i
UJ
art

d
A
in
Ul
r






















Ul
0)
OJ
5
c
10
T3
<0
Ul
O




(A
01
I
- C
«0
•o





4J
S
€ Ul
O -P
•S3
a








01
.u
i
o
s-
0)
a.


o.
u
c
"£
a.
i
1
o



t

g|

c u
3,2
•o
S
i— "(0
0) -P
«££
C i

J3

•P -P
|I
11

S
0
s. o e
o *» o
•P ui
TS C S.
01 0) 01
if S

•P 01 O>
w S -P
at tO

c -p "at «
.,_ y) t__ Q
5 § E
2- O O O
c
O>
a
s-
OL
>,
(O
1
§




OS
•p
a> o
S"2 N
*t) 3S
•P f O

O* (0
C «*- *0)
O O 3
fcl§ 01
CJ rH -P
T3
(U
•P O
flj o
(U O) •— <*- O
0. t-r- 0 **
0 3 tO
ui -a c
ui c 4-  o* c a.
3 »— a
fv- O (O .C
> 0 U 0


i
u. c

^ 3
f% Jj

oo

Ul
"^ 1^

££5
's *j -5
Ul 0
«• 3-r-
ui at
>> £ a.
S^^
8 ||
f « £
^
•a *m
f~ ^ »S
§«E
^S^
c m at
(Q -P U
s. c
t. & c
3 Di-P
0* C C
£«r> «t—
> «
O £
•P E
O Q>
C O C
O) Ul 3
O (O O
O -C i.
c
0)
£
Q.
>t
15
1
0
0


^o a*

0) « O1O> Ul
O U» O C Ul
•P 0) CJ *^" O O
*i— a +» Q.
3*^ 3 3 Q.U>
•P H— Ul

§-P 4- ui ui
f— Ol Ul S.
*- 3 t. o a>
(0 (0 0) U >
C J= J= 0 C
(O *t- X *» fc O
o o at o a. u
||S«
o y
•a^ 2 c
O) (0
S8JU


ra o
O O
1


•o
C tn 
0 fi- E
c ^
s ll
•S at c t!
*X 01 Ul
O (— fc.
a. ai u>
S15S
01 U O
O (O (0


01 O O
C-0 V)
3 - C -P
Ul O O C

3 o o u
c
at
o
a
>>
5
1
g



•jg
O 
O u>
e '5 -o o
•p- 0)
C Ul OJ r—
•r- (A C r-
(0 0) (Q
•P O H-
wSllS
m'5**~ o
£-0*(0 >*
(A c o a>
slS2
o> -a a. •
O) 'O S  s- « o o
Islss



Ul
fc.
r— Ol

^'•5
at •*—



^
<4- U)

S^i
3 S

.C U
•p
Ul >
Is
3 01
•P
1
4- flj
S5
8t
O *» •
** (0 E
at re
O -P
O) -P U)
•P r- in
O) ro
m 3 ra
5»s
•r- -i— -p
X u> C
030)
c
0)
£
Q.
,>,
"5
1
o
u



^ s
s«
= c^

s.
at o o
I"E
O *— RJ

O O ui
£
(0 ui
0 i-S
O C X •'-
o o •a
O)-»- -f-
C 4^ — X
•^ 3 W O
C *•• U
+* OJ *T-
^_> (Q .p O
Ul «i- CO
E 2 O) 0)
(0 e os o
0) T3 f~ (0 -P
+3^5 o»o
ui J3 nj c cj
ui &> C N 4>
(Q U O c»- J=



_ w

-------
     The  CO  content of  the  flue gas is reported  at 1,000 ppmv (dry basis).
This may  be  reduced further by the post-combustion of the flue gas; however,
due to the  large volume and low  heating value of the flue  gas,|  it would be
impractical.   Cathedral  Bluffs  has estimated  that  some  12,700 BPSD  of oil
(~76 x 109 Btu/day) would  be  required to burn  the CO to C02 (Occidental Oil
Shale, Inc.  and Tenneco  Shale Oil  Co.,  April  1981).  Additional  pollutants
may also  be  generated  from the combustion  of the oil.  These factors negate
the need to reduce the CO level i,n the flue gas.                i

     Diesel-powered  equipment is  another source  of the  CO  emissions.   The
diesel engines  are  equipped  with catalytic  converters to  control  the CO.
Since the converters also control hydrocarbons, they  have been included under
hydrocarbon emission control.                                   ;

     Mine exhaust  vents also  emit CO generated  from the underground diesel
equipment.   The machinery  is equipped  with  catalytic converters,  so  ad-
ditional  control is  not applied to the  vent  emission.   Cathedral  Bluffs has
estimated the vent flow rate to be about 6.8 x io6 SCFM  and the CO concentra-
tion to  be 16 ppmv  (Occidental  Oil  Shale,  Inc.  and Tenneco Shale Oil  Co.,
April 1981).  Due  to the large volume of the vent gas  and low concentration
of CO, additional CO control may not be practical.

     Total Carbon Monoxide Emissions--

     Table 5.1-22 summarizes the carbon monoxide emission sources and control
equipment used for the emissions.                               !
                                                                i

              TABLE 5.1-22.  TOTAL CO EMISSIONS FROM THE PLANT  ;
Stream         .                                                CO Emissions;
Number    Emission Source               Control Description       (Ib/hr)
4
15
Mine Vent .
Lurgi Flue Gas Discharge
; 476.7
1 2,351.7
            System                                              '

5,119     Diesel Equipment              Catalytic Converters         28.0

     TOTAL                                                      '  2,856.4


Source:  Occidental Oil Shale, Inc. and Tenneco Shale Oil Co., April 1981.

                                                                •
5.1.6  Control of Other Criteria Air Pollutants

     In  addition  to the  primary air pollutants discussed  so far,  there may
be  other criteria  pollutants emitted  from  the Cathedral  Bluffs  facility.
Cathedral  Bluffs   has   estimated  the  maximum  emission  rates  for  these


                                     228

-------
 pollutants  and most are below the de minimis rates.   Table 5.1-2i3 lists these
 rates  along with  the  de minimis  values.   Some criteria  pollutants,  such  as
 asbestos,  beryllium and vinyl  chloride,  have neither been found  in  the core
 samples  taken  from Tract C-b nor are they formed during oil  shalk processing.
 Nonvolatile pollutants are  emitted  as  the constituents of the  raw  and proc-
 essed  shale  particulates,   and  the  control   of  these   particulates  also
 provides the control of such  pollutants.   The mobilization of  Volatile pol-
 lutants  such  as  mercury is  temperature  dependent.   Since the  Waste  streams
 released from  the plant will  be below the boiling  point  of mercury,  release
 of  mercury  vapors  is  not  anticipated by  Cathedral  Bluffs.   iAny  released
 mercury  will be as a nonvolatile constituent of the  particulates;
                                                                 j

       TABLE 5.1-23.   ESTIMATED EMISSIONS  OF OTHER CRITERIA POLLUTANTS
                                                  Emissions. TPY  ;
Pollutant
Ozone*
Lead
Asbestos
Beryl 1 i urn
Mercury
Vinyl Chloride
Fluorides
SuTfuric Acid Mist
Hydrogen Sulfide
Total Reduced Sulfur
Reduced Sulfur Compounds
De Minimis
40
0.6
0.007
0.004
0.1
1.0
3
7
10
10
10
Cathedral Bluffs
<40
; 0.15
0
0
0.003
0
7.8
! °
1 o
o
; 0
•- - • 1 • . - - • • • •-;•.-
* Ozone is measured as volatile organic compounds (VOC),         ;

Source:  Occidental Oil Shale, Inc. and Tenneco Shale Oil Co., April 1981.
                                                                 i

5.1,.7  Control of Noncriteria Air Pollutants                     j

     Meaningful test data are not available to determine whether :emissions of
noncriteria air  pollutants are  a concern.  Consequently,  no information on

                                     229                         ;

-------
 control   technologies  for  such  pollutants was  generated  for ithis  manual.
 Mention  of species such  as  POMs (U.S.  EPA, 1980)  and  trace elements such as
 arsenic  (Fox,  Mason  and Duvall,  1979;  Girvin,  Hadeishi and Fox, June  1980)
 are noted.                                                       !
                                                                 i

 5.2!  WATER MANAGEMENT  AND POLLUTION CONTROL

      As  in other industries and oil  shale operations,  the  MIS-Lurgi  plant--
 from mining activities to  final product and waste disposition-rwin  produce
 water effluents  which will  require proper disposal.    These effluents  may
 contain  the following  pollutants:                                |

      •     Suspended Matter,  Oil  and Grease                      ;

      »     Dissolved Gases and Volatiles

      •     Dissolved Inorganics                                '   ,
      •     Dissolved Organics.


      This  section  describes the  current,  commercially  available  alternate
 systems  for  controlling the  above  pollutants.   The  following  subsections
 provide   inventories   of  control   technologies  for  each  of  the  pollutant
 classes,  a discussion of advantages  and disadvantages, and important points
 to  consider in selecting a  particular  technology.   The performance,  design,
 and cost data  for the  leading technologies  are also presented.  . •

 5.2.1 Suspended Matter,  011 and Grease                          '

      Undissolved  matter  found in  wastewater effluents  includes Isolid parti-
 cles  as  well  as oils  and  greases.   The  solids are usually  the raw  and proc-
 essed shale particles that  are  washed into the retort water and those that
 are entrained  in  the retort vapors and  subsequently  removed! in  the  gas
 condensates.   The retort water  and  gas  condensate also contain! trapped  oil
 and oil-in-water  emulsions.   Service  and  storm  runoffs  contain  suspended
 matter,  as  well   as   oils  and  greases.   Also,  the  source wa^er  contains
 suspended soil particles and debris.                             \

      In general,  the control of suspended matter at oil shale plants will be
 accomplished  using conventional   technology.   For example,  clarification in
 gravity  settlers   (with  addition  of flocculants)  and  multimedia filtration
will, in most cases, provide adequate control.  Associated energy consumption
and costs are generally low.                                     ;

     The  control  of undissolved oils and  greases  in  oil  shale; wastewaters
has  not  been  studied in detail.   API-type gravity  settlers have the po-
tential to  provide  adequate control for most of the waste streams generated.
It  is possible,  however,  that  some wastewaters  will  contain 'oil-in-water
emulsions;  if so,  additional  control  steps may  be  required,  jHeating the
water or adding chemicals may be sufficient to break the emulsion; otherwise,
filter coalescence (or possibly ultrafiltration) may be required.^
                                     230

-------
      The  degree  to which  emulsified  oil  needs  removal   is  I dependent  on
 downstream  processing  and  reuse.   In  cooling  towers,  the  Oil  may  foul
 heat exchange  surfaces  and  thus require prior  removal.   Similarly, fouling,
 and  possibly  foaming,  may  occur when  stripping  the  retort  Swater or  gas
 condensate.  The extent  to which  such problems will  arise  is  not known.

      The energy  consumption and cost of oil separation  by  gravity means are
 generally low.    Thermal or  chemical  treatment,  if required, would cause some
 increase in  costs.   Filter coalescence  and, in  particular, ulftrafiltration
 generally are  more  costly  and  would be considered only if other procedures
 prove inadequate.                                               :

      Inventory  of Control  Technologies—

      Figure 5.2-1 shows  different types  of  technologies that appily to control
 of suspended matter  and  oils and greases.   Key  features of these1 technologies
 are provided in Table 5.2-1.                                     I  .

      API-type separators.   For  gravity separation  of oil  in  large  holding
 tanks,  separators should  be  designed within the  following  limits:  (a)  hori-
 zontal  velocity of  less than  3  fpm,  (b) depth between 3-8 ft, ahd (c) depth-
 to-width  ratio  of approximately 0.4.   Oil  is  skimmed from  the  surface  and
 collected for  reuse or  disposal.  Gravity separation is  not  effective  for
 emulsified  oils   that  might  be present   in  some  retort  waters  (American
 Petroleum Institute, 1969).                 .                     '•

      Sedimentation.   This is  a  gravity process  in  which   the: solid  phase
 settles  and  is  withdrawn  as a  slurry.  Clarification may be carried out  in
 large holding ponds,  plate  (lamella) settlers  or hydrocyclones.   Chemicals
 (flocculants  and coagulants) may be added to precipitate  salts (softening)  or
 to  aid settling  of suspended solids (Humenick, 1977).

      Flotation.   This is a gravity process in which the  solid phase rises  to
 the  surface and  is  skimmed  off  as a slurry.  Air bubbles may  be introduced
 into  the  flotation vessels to assist  separation  (Humenick, 1977)1

      Centrifuqation.   This  is  a modified  gravity method  to  afford  sepa-
 ration  or  settling   of  fine,   suspended matter  and  oils.    The  wastewater
 is  subjected to  a  radial  force greater than the gravity  field  by  rapidly
 rotating  it.   Suspended matter  denser than  water moves  radially away  from
 the  center  of  rotation, while the lighter matter moves toward the center.
 Concentrated  matter  can be  removed periodically  or in a continuous manner.
 For  continuous   operations,  the   sludge  should  be fluid to  facilitate its
 removal.  The technology  may not  be applicable  to  highly viscous fluids.

     Coagulation - flpeculation.    Fine particles  suspended  in  :a  fluid are
 subjected  to size  enlargement   by  addition  of  chemicals   (coagulants and
 flocculants), then  allowed  to  settle  by  gravity or under  applied force.
Gentle agitation alone sometimes may afford the  flocculation of  the parti-
cles.  The technology may also be applicable to liquid dispersions and liquid
particulates.                                                    !
                                     231

-------
   SUSPENDED
 MATTER, OIL a
 GREASE CONTROL
  TECHNOLOGIES
                                  GRAVITY
                                 SEPARATION
                                CENTRIFUGATION
                                  PHYSICAL/
                                  CHEMICAL
                                  FILTRATION
__ API-TYPE
   SEPARATORS

  •SEDIMENTATION


  •FLOTATION
  COAGULATION-
  FLOCCULATION

  •CHEMICAL SEPARATION

  . THICKENING:




  • SOLIDS FILTRATION

  •FILTER COALESCENCE

  • ULTRAFILTRATION
SOURCE- WPA
  FIGURE 5.2-1   SUSPENDED MATTER, OIL AND GREASE CONTROL TECHNOLOGIES

                                 232

-------











UJ
vt
2
§
i
O
S
i
S


LU
|

ee
o
u-

LU
H-t


1
s

u.
o
is
u.
rH
~
in
UJ
t—




















Ul
c
s

s



Ul
-P U)
•s u»
1*
1 "O
>» C
03 tO
in ui
•P C
g,2
IS
T- S.
•O 3 +a
01 O*U>
01 HI 01







M
•55
> U


C£ UJ

Ul
Component
Removed
,>•;•• .
. 01
"a.
1
s-
}

re
s.
1









o
£§
'e'o
OH!
(A
C •
0 u
•f V
UJ I—
it

0 *
XI

>2 ""
s&
= 0,
i%
U)
01
P)
•s
3
Ul •
U)
Ul *•-
is
is
01 Ol
s S
•S 3 S


2E Ul 4-i

4- fi.
**•• C*
^ O
 re -P
o u nj c
tl'S.'c s_'£
P E I"" fO


m i— u» m C

u> 0)
T3 - o i- Ul
C (ft O -O
fl» *O - 0> T-
«•£ £*i §•
3 o re E i-
t/> U) +> •»- •—
Of ^^
u . -o s-
C U> 01 Ot
o o -P -a i— 01
T3 4J C 3 -P J3
fi. u» .re a. -i~ E •«- o
Ul S- E re -P*r-
oi 01 01 .t- o o> *~ M re 4-*
l^itfe^lilS
•o c-o •— re E-^r»
re O) 01 S u> -P s-
•*- P "e ° e u u £ .2 '5

&»^- J= 1- CL Ul "O
creui •pfi.uiotrea)
0 30) 3 C >
•»— CUI-PC. w* a» t- o r—
v 5fi-*^rere»i— w
o^Er-a-re**"* 01*"
O.-P (O U» ^ Ul -P O 3 **-*-
c
o
.,-.
m
£. C
re o
a. *T-
a) in P ^s
v> 01 s- re c

I?T S 1^
re a. o."O o
(. •< 01 Ol »—
UI^>V) V) U.

01
s- c
>» 0 -F-
re c oi*r- m
50 c: > a» <*-
f- -^ re u o

01 «0 S. O) > C
> s. -a at o
•*- re ai E TJ <^-
u> ex t- o v
c o> a. t- c re *
ai ui ^ o fi- ui
a, s- f- re o*
•^ Ol fc. Ul »r»
ai > TI T3 re -P
s- 
1
(O
U)
s
2. . «
tS*"?^
>\ re o
4-> i- -U
re ^ re
f a.
•P a. o •
fO P C
fi. 0
Ol U) C f-
4-> -f- O -P
fi. f- re re
cno) +> ex
•f- o at

ill



e
o
» >i*>
"tfg
at > re
E re ex
re &. ai
to D» ui
P. Of
a) re r—
O)»»- ui X)
t. ai re £-
TJ o o ra
2 O 01
*)•» r— fi.
< o •*- re

t»» j=
•p- *^ C
r- 3 ,OJ
re w •£
> T3 0> UJ
§.p. r- 4)
F- ja -a
o> o re
S. S > s.
0) 01
(^ ati- a.
4- C JS O
O i- O S-
cn o- « o.


O T) Ul
Ul Ol 0)
at r— U) P—
"o >r^*aJ ^
E o'aJ D.P
£1^42^
D_ t-**- -o a.
-a c -
•PC 5
at u c
O 3 • **-5 -P
E w ui c re
Sf— O t-
at •*- o re
a. t= o a.
s^lf >
V) O Of P
•P Ul Ul t-
C 0) fi. 3 >


 ai f— oi .
<*- w ui re re w
o at *o $- at
r- «i- O* J2 U
ui o o at »P- s-
=» u uiC7 2 &


re


HI c,s



•nj ,- — fa -p c
M re u E re u
>> O O 01 OL-r-
^ o r- x: QJ x:
O. *»^U. O CO *—
at
Ul •
fi. 3 Ul
o c
v-o


U_ ^^ •*• CX E






Ul
§?s
CTIT-

65
o

O C 01 Ul
re fi-r—
m • 3 Of
•a s at -P •*-
c: 3 u> u fi.
a. "5 re c fi. 4^
a i S <£ ui i
fi. in
0) *r-
-P fi.
re at P-
gS.2^1
*J v 8-
u>  S '-5 « o
c: ,c ai t- re
*-* -P n "o xi


1 C
re §
• fi. >r*
P fi. --P
cC^ 2 S £
O U. f— C -P
•r* ^-  U> U. O f-
re ^3- u> **-
+*£- C r- fi.
*— O O (O 4->
1- V» "- .O *—

































.;

are used
industria




















233

-------
      Chemical  separation.   Addition  of  chemicals  to break  emulsion may  be
 used in  conjunction with  filtration  and is  normally  followed  by  gravity
 separation.   The  type and  dosage  of chemicals  required is  djetermined  by
 trial  (American Petroleum Institute,  1969).   Chemicals  may also! be  added  to
 precipitate  salts  or to increase  crystal  size.                   :- •

      Thickening.   Slurries  previously obtained from  gravity, cehtrifugation,
 and  filtration  methods can be  further concentrated, or thickened] by  addition
 of chemical  agents or binders.  The  thickened  slurry  may then beisubjected  to
 the   same  methods  for   final  disposition  (Adams   and  Epkenfelder,   1974;
 Humenick,  1977).                                            '     !     .

      Solids  filtration.   The water  stream is  passed  through  a filter medium
 which  holds  back the solid phase.   Filters  may be of the fabric type,  as  in
 plate  and  frame, rotating drum (vacuum)  and cartridge units, or-granular,  as
 in sand filters.   Filtration  is  generally more expensive  than sedimentation
 but  can remove  smaller particles  (Humenick, 1977).               !

      Filter  coalescence.  Gravity separation  of  oil  from water  is  standard
 industrial   and refinery  practice;   however,   the API-type  separators are
 inadequate  for  very small   oil   particles.  One  very   important method for
 removal of small oil droplets is coalescence  (Water  Purification Associates,
 December 1975).

     When  a  dispersion  of  micron-sized droplets  of  one liquid  (oil)   in
 another  (water) flows  through an appropriate porous solid,  coalescence  of
 the  dispersed  phase  is  induced and  separation of  the  liquids  results.   The
 dispersed  phase can be  allowed  to  accumulate without leaving the porous
 medium, with periodic regeneration to  remove accumulated oil.     i

     Filter  media  are usually  either the packed  fibrous  type  (e.g.,  fiber
 glass, steel wool) or unconsolidated  granular materials (e.g., sand, gravel,
 crushed  coal).   Because  of their   large  specific surface and 'high voids,
 fibrous media  are  usually more  efficient in  removing  droplets; for a  given
 bed  depth  than  are granular media.    However,  fibrous media are more suscep-
 tible to blockage  by suspended solids and are more difficult to' regenerate,
 in addition to being more costly than most granular media.       l

     Advantages  of filter-coalescers  include  high  separation  efficiency for
 dilute suspensions of very  small  droplets, potentially  small  space require-
ments, the possibility of continuous operation, and the potential; for the re-
covery  of  the   dispersed  phase.    Disadvantages  of  this  process  are  that
 suspended  solids can accumulate  to  require frequent medium  regeneration or
 replacement, and pumping  costs  can  be substantial.   As  far as  is known, the
system has  not  been  evaluated on retort waters,  and extensive;pilot plant
testing would  be  required  to  determine  its  feasibility  on  these  waters.
                                                                 I
     UHrafiltration.   Passage through  a submicron-siied membrane  filter
separates  emulsified  oil  as  well  as  suspended  matter  and  l4rge  organic
molecules  (MWt  g 1,000).  The  oil droplets are collected  in the'concentrate
and removed by gravity separation.  This process is significantly; more costly
than normal filtration (Water Purification Associates, December 1975).


                                     234                         ;

-------
      Control  Technologies Analyzed—

      The  streams that require removal  of suspended matter, oils and  greases
 are:
   1            '    '        •  ,         '                           !
      •     Mine Water (stream 12)

      «     Retort Water (stream 41)                              :

      •     Lurgi  and  MIS  Gas  Condensates (streams  29, 48)

      •     Runoffs  and Leachates (streams  13,  118,  122)           ;'

      •     Slowdowns  and  Concentrates  (streams 42,  78, 80, 90,  91 i, 109).

      Mine  water  is  obtained from  dewatering  of  the deep  aquifers  under
 Tract C-b.   While  the  water does not  contain any oils and greases,  it does
 contain  suspended  matter.   Sedimentation by  gravity settling arid clarifica-
 tion  with addition  of alum  are  the  approaches  proposed  to reduce the sus-
 pended  matter in  the -mine  water.  Table 5.2-2  presents the design features
 and cost  data for clarification,  and Figure  5.2-2 shows a  cost  curve  for the
 clarifier.  This activity could be considered as part  of the process rather
 than  pollution control.                                          l

      In the  Lurgi  retorting process,  the gas liquor is condensed along with
 the  light oils  in the  third condensation tower.   In  the  MIS  'process, gas
 condensate is obtained by cooling and  scrubbing  the MIS retort  gas, and some
 light oils are  also condensed.   Furthermore, during  the early burn stage of
 the MIS retort, some  of the retort water is condensed in  the lower, cooler
 parts of the  retorts and  collected along  with the  shale oil  in an underground
 sump.   These  process water  streams are treated in API-type  oil/water  separa-
 tors  (with channel  covers)  for the removal of  oils and greases; followed by
 multimedia gravity  filtration  to  remove any  suspended solids!   As stated
 earlier, the  oil/water separators  are not fully established  as useful devices
 for shale oils,  but  difficulty   in  separating  out  the  light  ;oils  is not
 anticipated.   Table  5.2-3 presents the design  and  cost information for the
 API separators,  and Table 5.2-4  gives  the design  basis and cos;t for multi-
 media  filtration.    A  cost curve   for  each  technology   is  presented  in
 Figures 5.2-3 and 5.2-4,  respectively.

     Service  and fire water runoff,  storm runoff, and leachate  from shale
 piles may contain  oily materials.   Again,  an API-type oil/water separator
was examined  as the  control.   This will also allow  separation  jof suspended
matter  along  with  the  water.   The cost  and design data  for this separator
 are  given  in  Table 5.2-5,  while  a  cost  curve  is   already  ;included  in
 Figure 5.2-3.

     The blowdowns,  sludges, and  concentrates from various processing units
will  also contain  suspended matter.   These  streams  are  collected in  an
equalization  pond  for possible use in processed shale moisturizing.   Since
gravity settlement affords  separation of the suspended matter, the equaliza-
tion pond  also might be viewed as  a  pollution  control.  Its design and cost
are presented in  Table 5.2-6,  and a cost curve is given  in Figure 5.2-5.
                                     235

-------
          TABLE 5.2-2.  DESIGN AND COST OF MINE WATER CLARIFICATION3

Item
Mine Water Flow Rate
Flow Rate/Clarifier
Number of Clarifiers
Retention Time
Diameter
Alum Rate (~30 ppm)
Fixed Capital Cost
Direct Annual Operating Cost
Maintenance @ 4%
Alum 
-------
                         soi$ 'isoo  9Niiva3do
o
                          o
                          in
                                       O
                                       ro
                                       o
                                       CM
                                                                                O
                                                                                O
                                                                                o
                                                                                s
                                                                                tn
                                                                                en
                                                                                o
                                                                                o
                                                                                O
                                                                                o
                                                                                tn
                                                                                o
                                                                                CSJ
                                                                       UJ

                                                                       jZ

                                                                       CE



                                                                       O



                                                                       O.
                                                                       o>


                                                                       uT


                                                                       IT



                                                                       O

                                                                       u.
                                                                                o
                                                                                o
                                                                                o
                                                                                o
                                                                                ut
                                                                 S

                                                                 u_
                                                                 o
                                                                                           co
                                                                                           o
                                                                                           CM
                                                                              in

                                                                              tu
                                                                              Of

                                                                              o
o
o
o
tn
«*>
O
o
CO
o
in
CM
                           £0l$ 'iSOO ItflldVO
g
CM
                                                                                o   o_
O
in
                                           237

-------
          TABLE 5.2-3.  DESIGN AND  COST OF  API  OIL/WATER SEPARATOR
                              FOR  PROCESS WATERS                 :
. . . ----, , 	 : 	 „-. 	 . 	 : 	 : 	 . 	 	
Item
Process Water Flow Rate
Flow Rate/Channel
No. of Channels (1 standby each)
Channel Cross Sectional Area
Channel Depth
Channel Length
(channel is covered)
Fixed Capital Cost
Direct Annual Operating Cost
Maintenance @ 3%c
Total Annual Control Cost
Unit
gpm
10s Ib/hr
gpm
—
ft2
ft
ft
$10S
$103

$103
Quantity3
Retort Water Gafe Condensate
!
4,520 ' 6,721
2,303 j 3,434
2,810
3 3
101 I 115
7 ! 7
164 164
2,484 1
:
61 ;
739 ;
. • • • - ' ... . ' '
  The retort water  rate is maximum.  The  gas  condensate rate includes the
  maximum rate MIS  gas condensate, recycle from the Phosam-W unit and Lurgi
  gas liquor.

  The flow rate  is  based on four channels  in use at any one time.   The fixed
  Capital cost and direct annual operating cost are based on six channels.

c Maintenance is based on the fixed capital cost less contingency.

  Siee Section 6 for details on computation of the total annual control cost.

Source:   WPA estimates based on information from American Petroleum
         Institute,  1969.                                        i      .
                                     238

-------
     TABLE 5.2-4.  DESIGN AND  COST OF MULTIMEDIA GRAVITY FILTRATION UNIT
Item
Water Flow Rate
Flow Rate/Unit3
Total Number of Filters
Number of Standby Filters
Filter Diameter
Unit
gpm
gpm
—
—
ft
Quantity!
Retort Water Gas
4,520 !
610 1
10
.'2 |
23 ;

Condensat
6,721

14
3
23
Fixed Capital Cost
Direct Annual Operating Cdstc
                                                         6,465
                                   $103
Maintenance @ 4%
Labor, 12 hr/day @
TOTAL
Total Annual Control
$30/hr
Cost0 $103/yr
210 ;
118
328
2,102 :

  The flow rate is based on 19 units in use at any one time.  The fixed
  capital cost and direct annual operating cost are based on 24 ijnits.
  Maintenance is based on the fixed capital cost less contingency.
c See Section 6 for details on computation of the total annual control cost.
Source:   WPA estimates based on information from American Petroleum
         Institute, 1969.                                        !
                                     239

-------
         £oi$ Isoo
o
 •

Cs*
o
 •

O
o

VC5
o           o
 *          <  a
v           CM
                                                                   O
                                                                   in
                                                                   O
                                                                   O
                                                                   in
                                                                   CM
                                                                      a:
                                                                   o

                                                                   §
                                                                   CM
                                                                      Q.

                                                                      Ul

                                                                      CO
                                                                                o  °*
                                                                                o  -
                                                                                m uj
                                                                      a:

                                                                      5
                                                                                § •
                                                                                o
                                                                                            o
                                                                                            »-»



                                                                                            1
                                                                                            tu
                                                                                           tin
                                                                                           llJ


                                                                                           I
                                                                                           I-»
                                                                                           o
                                                                                           u.
                                                                                           o
                                                                               o
                                                                              IU
                                                                              nr
                                                                              :D
                                                                              o
                                                                              »-4
                                                                              ti-
§
to
                                       o
                                       o
                                       CO
             s
                ,01$ '1SOO 1V1WVD  G3XIJ
                                              i
                                                                        IU
                               240

-------
.01 $ 'JLSOO 9NllVy3dO IVflNNV 103810
       o
       o
o
o
o
o
rvi
o
o
                                                        o
                                                        o
                                                        o

                                                        s
                                                        C«J
                                     o
                                     o ,
                                     O [
                                                           IE
                                                           Q.
                                                        o
                                                        o  te
                                                           u.
                                                        o
                                                        I
                                                        o
                                                        C3
                                                        o
                                                        CM
                                                        O
                                                                        O
                                                                        U.


                                                                        t—1

                                                                        i
                                                                        ts
                                                     £
                                                     I—I


                                                     §•

                                                     u.
                                                     O


                                                     O





                                                     in

                                                     01
                                                     oc
                                                     =3
                  o
                  C3
                  O
            o

            §
            CM
     gOl$ '1SOO IVlIdVO Q3XIJ
                        241

-------
          TABLE 5.2-5.  DESIGN AND COST OF API OIL/WATER SEPARATOR
                          FOR RUNOFFS AND LEACHATE
Item                                    Unit               Quantity

Runoff Flow Rate                         gpm                 191

No. of Channels (1 standby)              —                    2,

Channel Cross Sectional Area             ft2                   9;
                                                                 I
Channel Depth                            ft                    3
                                                                 i
Channel Width                            ft                    3\

Channel Length                           ft                   50
                                                                 i
Fixed Capital  Cost3                     $103                  47'
  Mai ntenance @ 3%                                             1;
Direct Annual Operating Cost3           $103

  Maintenance @ 3%

Total Annual Control Costc              $103                  14;


  The fixed  capital  cost and direct annual  operating cost for the standby
  channel are included.                                          !

  Maintenance is based on the fixed capital cost less contingency.

  See Section 6 for details on computation of the total annual control cost.

Source:   WPA estimates based on information from American Petroleum
         Institute, 1969.                                        !
                                     242

-------
              TABLE 5.2-6.   DESIGN AND COST OF EQUALIZATION POND
Item
Flow Rate into Pond
Pond Area
Pond Depth
Unit
gpm
acre-ft/yr
acre
ft
Case
A
919
1,482
1.22
10
Studies
B
; 1,345
2,169
1.78
'. . 10
 Liner Material
Fixed Capital Cost
Direct Annual Operating Cost
Maintenance @ 2%a
Total Annual Control Cost
$103
$103

$103
68 !
1
1.1 ;
18 :
99

1.6
27

  Maintenance is based on the fixed capital cost less contingency.

  See Section 6 for details on computation of the total annual control cost.

Source:  WPA estimates.
5.2.2  Dissolved Gases and Volatiles

     Dissolved  gases  include ammonia, carbon  dioxide,  and hydrogen sulficle,
while  volatile materials  are  low molecular  weight organics.   Methods for
removing  these substances  from water are  summarized in Figure 5.2-6.   Steam
stripping  is  the most  likely process  to  be used  and  has been
successfully
demonstrated on  a  laboratory scale for some oil shale wastewaters (Hicks and
Liang, January 1981).

     Inventory of Control Technologies—                         :
                                                                 i
     Table 5.2-7 presents  an  inventory  of applicable  control  technologies,
along with their key features, for the dissolved volatiles.  Basically, most
technologies involve stripping of the dissolved gases by either elevating the
temperature,  applying  vacuum, or  displacement  with  carrier  gases.   More
specific removal can  be accomplished by using an adsorbent selective for the
gas in question.                                                  :

     Steam stripping.   Steam  stripping  of sour  waters  (e.g.,  ;waters  con-
taining  dissolved  ammonia  and  hydrogen  sulfide)  and  coke-ojven  liquors

                                     243

-------
Isoo 9Niiva3dO'ivnNNv
                                                        o
                                                        CL
                                                        to

                                                        8
                                                        m
                                                        in
                                                        uu
                                                        se.
       'ISOO  IVildVO Q3XIJ
                                                  ui
                                                  u
                                                  a:


                                                  I
                244

-------
       DISSOLVED GASES
         8 VOLATILES
          CONTROL
       TECHNOLOGIES
                                        STEAM
                                       STRIPPING
                                        VACUUM
                                      DISTILLATION
                                        INERT GAS
                                        STRIPPING
                                       ADSORPTION
SOURCE:  WPA
  FIGURE 5.2-6   DISSOLVED GASES AND VOLATILES CONTROL TECHNOLOGIES

                               .245                          :

-------



















UJ

§

<

iU
CO



S
>
,J
S
o
g
u.
40
UJ

s
g
1
§
g
8
u.
o
CO
s
u.
•gj.
..

1
^i
in

UJ
1
















in

O)
I








Ul
*M ui
MS

I?
rare


Ul U)
•P C
c o


o> u


o> cr ui
01 V V
U_ Q£ Q£





u
c
•5.2
> u
o •*-
it
C£ UJ


Ul
, C
0) T3
C OJ
o >
11
O Q£

,£

• •£
• c

fc
a.
g1
1
g.
o




S


11
e u
at

c >
II


•o •*- re 4J ui
*o o>
re o >»«t- u
*» o o o
U C fc
3U» O -I- O»
3-r- > C
O « s..Q 01 U 0,
^ 01 v-
•F- a 4)»- fc
u re .c 01 4->
< o -P ui «i

01
0)
Ul
a-o
O)
•o c
01 at
a. -a .
a. c e
fc o a>
 3 Ul
i .

' w'<5
•i— 3 c

UJ T3 v-

S 3C 0*


ill
"O
\'i- si"

2*fO *F- £
^ O C S- *r- T3 .

X £- r- O. C
o °r- u *re > fc c
e w o > 4J o
01 re o»o: fc *Ss o S

Ul
•P C
*JZ O
^ V)^O)J3
*o x1*^ re
re u
Ul * * O
«So*S*-o
m ra o o >,
z cnv-'i: jc
13 01
re o ui at
r— re r— ui
£! **"* ^ jj «°
30) at re *c
+> > js »— re s
re »r- *J o en re
S. +J > t. 0)
•i- c g ui ai
ui •*- f3 u >
re *o a> * •*•* o
o *«-•*•* fc c:
fc > to QI re ^
u o *> oi-4-»
c: fcif- re fc*r-
»-H a. o 5 o s
CD
c
1
i.

V)
i

u>
Ul
•4J
at J 1

•i— ui at
3 +* re »—
cr u> cnxt
QJ o c c re

Q.*r-
gslf 1
0) -P +J
C •!-«>,
0) - ** i—^

^: -P Q. fc -a
en c e a> re
a: m o s fc

Ul
a>
Ul
re
en
•c
0)
a.
a.
«






0)
1

re






at
§
•s
Ul

.-2
M°-
S§
2-S.
a. a.
i'S
«l Ul


c
o
+*
re

15
U Ul
> o
s t
0) O)
to






re ai
Ul
•a re
or en

VJ ••-






at
o
.£3
re
U)





Ol
o
.a
re



at

o
re
s at a>'
cn0*^

•^- 0 C
& •*r"

fc at re
t!?01
sit
1=1
4-> ""*"
ui fc at •
SreS re
re a>
ca»^- +*
I-'5"1
t5 u> > w-
vi 3 re o



Ul CR
(O C
O T-

Ot fc



re

Ul
re
•o ci.
at ai
Ul -P
^f
re ^=
fc Ul

0 Q.
u>
•oS
C Ul
re re


re c
fc 0)
S€
ai o
en in
a> *o
a: re



^- O Ul
^3 O C


4g.cp*>
w JT fc

•P fc "C
o o 01
sc <*- u



re at

9 U •
SCO)

j; i— u>
en1*- ui
1-H- 0
5C a» a.


o ui


«J C
» re re
a: *o fc
a: > o
* Ol
*4J
re u

C S OJ
9 5

*|t
<*-4J 0
O^g
C 9 9
9>—
•r- *^- (A
-P +J U •
O. Q.H- Ul
fc O C C
o c re «f-
ui >^ CR ui
5r— fc a>
U 9 fc



9


e- •
9
Ul
T3

-------
 (e.g.,  waters containing  dissolved ammonia  and  carbon dioxide)  is  standard
 practice  in  the  petroleum  and  steel  industries.   Stripping  has  also been  used
 as  part of the "Phenosolvan" process on  coal  gasification process  condensates
 (American Petroleum  Institute,  March 1978;  Beychok,  1967).

     The  dissolved  gases  are  stripped  from  the solution  by bubbling steam
 through it,  generally in packed  or  tray columns.  The steam may  be  directly
 sparged (live)  or used indirectly  in  a  reboiler, as  in distillation  columns.
 The stripped gases,  along with  other volatile materials,  are ^removed  in a
 relatively concentrated  gas  stream  which may  be  treated  for  adsorption/
 recovery  of  a specific substance or incinerated.   Carbon dioxide is  readily
 stripped  at  efficiencies  of +99%; ammonia  strips less easily,  and pH eleva-
 tion  may be  required in  some cases for 99%  removal.   Hydrogen ,sulfide  does
 not strip as easily as carbon dioxide  but can generally  be removed  down to
 the 10-20 ppm range.  Costs are  for equipment and steam and are:proportional
 to  the  volume of water to be treated.

     Steam requirements  range  from  approximately  10 to  15 Ibs  steam  per
 100 Ibs water treated.  For  a given  separation, a  greater column height is
 required  for a  lower steam rate.   The  selection  of steam  rate  and column
 height  is  based  on energy and equipment  costs.                   ;

     The  stripped gases  may  be incinerated  or  treated furthet*  to  recover
 ammonia  and   sulfur.   Ammonia  may   be  recovered  as  anhydrous  ammonia,   aqua
 (20-30%)  ammonia or  ammonium sulfate.    In  cases where the sulfate is  derived
 from flue gas desulfurization, the  sulfate route may be viable depending, in
 part, on  the marketability of ammonium  sulfate and  on the costs of alterna-
 tive flue gas desulfurization  processes.   Because oil shale plants generally
will have ammonia available as a by-product, S02 scrubbing  with  NH3 may be
 attractive when  the technology is  sufficiently  developed and  tested.   Re-
 covery  of anhydrous  ammonia involves considerable capital and energy  (steam)
 requirements, but  these  are partially offset  with  by-product ammonia sales.
The  stability of  the ammonia market  must be  considered when! selecting  a
 recovery process.                                                '

     Vacuum distillation.    Distillation  at reduced  pressure  has: many indus-
trial applications, but these primarily  involve distillation or fractionation
of  compounds  with  high boiling points or low thermal  stability.'  The method
may  be  applicable  to stripping of gases and  volatile compounds,  but  the
energy  requirements  are high  relative  to those for steam or inert gas strip-
ping.

     Inert gas stripping.    This  method  is  applicable  to  dilute,   or  low
strength,  wastewaters  for  which  steam  stripping may  not be practical.   The
operating  principle  is  similar  to  that  for steam  stripping, except  air,
nitrogen,   carbon dioxide,  or  other  inert gases may be used.  Its application
to  high -strength  liquids,  is  generally  not  practical because  large column
heights and gas compression costs are required.                  :

     Adsorption.   Dissolved gases and  volatile components may be adsorbed on
specific surface-active materials by passing wastewaters through a bed of the
adsorbent.  The  gases may  then be  desorbed  thermally,  and  the regenerated

                                     247                         :

-------
 adsorbent is  recycled.   This  method  is  generally  used  in  trace  removal
 applications.                                                    •

      Control Technologies  Analyzed—                             ,-

      The  streams that  may require removal  of dissolved gases and  volatiles
 are:
                                                                 !
      •     Retort Water  (stream 41)

      •     Gas Condensates  (streams 29, 48).                      ;

       ''                                      '                    1 •
      Suspended matter,  oils,  and greases were  removed from these streams  in
 the oil/water separators and by  multimedia gravity filtration, but some polar
 organics  (e.g.,  phenols, fatty acids)  and gaseous components  (e.g.,  NH3, H2S,
 C02)  remain  dissolved.   Steam stripping of  the retort water was examined  to
 remove  the  dissolved gases  and volatile  organic  matter,  and  the Phosam-W
 process was  analyzed for the  recovery of  NH3  from the gas  condensates.  The
 Phosam-W  process includes  a steam stripping section  to remove the  dissolved
 gases and volatiles from the  waters;  these  gases  are then  combined with the
 gases  from  the retort water  steam  stripper  and the NH3  is  [subsequently
 recovered in an anhydrous form.  Table  5.2-8  presents the design parameters
 and  cost  information for  the retort  water  steam  stripper, and Tables 5.2-9
 and  5.2-10 give the design and cost details  for the Phosam-W process, re-
 spectively.   Figures 5.2-7 and  5.2-8  provide  cost curves  for the two proc^
 esses  based on  their  specific  applications  to the  MIS-Lurgi  wastewaters.
 The description  and material  balance for the  steam  stripper are included  in
 Sections  3.3.5 and  4.2.7,  while those for the  Phosam process are included  in
 Sections  3.3.8 and 4.2.7.
                                                                 i

 5.2,3  Dissolved Inorganics
                                                                 i
                                                                 i
     Dissolved inorganics  are  usually not a problem unless the compounds are
 judged  to be  hazardous (e.g.,  trace metals)  or  when fouling  of equipment
 (e.g., boilers)  occurs  because of the high  salt content of the ;waters being
 used.  Natural waters and  waters that come  into contact with the solids may
 need  to  be  treated  if they  are  intended for  critical  uses in  the  plant.
 Processed  shale  moisturizing,  on the other hand, may  not require control of
 dissolved inorganics.  In fact, waters with high salt content can be used for
 this  purpose,   thereby   avoiding the  need  for other  controls.:  Since  gas
 condensates  do   not  contain  significant amounts of  dissolved  inorganics,  a
 treatment may not be necessary.

     Inventory of Control Techno!ogies--                         i

     Methods for removal  of dissolved inorganics are  shown in Figure 5.2-9,
while  some  of  the  key  features  of  the technologies  are  presented  in
Table 5.2-11.  The  operating  principles  for some of the methods :shown in the
 •figure are detailed below.                                        ;

     Precipitation.   Chemicals may be added to precipitate salts, e.g., lime
addition  for carbonate  (hardness)  removal.   Processed shale is also believed


                                     248                         '<

-------
         TABLE 5.2-8.  DESIGN AND COST OF  RETORT WATER  STEAM STRIPPER
Design Parameter
Retort Water Feed Rate
Maximum
Average
Steam Rate (average)
Cooling Water Circulated (average)
Stripping Column
Number
Diameter
Height
Refooiler
Number
Surface area
Stripped Water Cooler
Number
Surface area
Feed Heat Exchanger
Number
Surface area (each)
Unit
gpm


103 Ib/hr
gpm

„„
ft
ft

__
ft2

__
ft2

—
ft2
Quantity
i

4.5201
1,200
90.0
2,700

3
10
73;
i
6
5,000
i
4
5,000!
i
21
5.0001
Fixed Capital Costa                     $103
   Stripping column
   Heat exchangers

Direct Annual Operating Cost3    .       $103

   Maintenance @ 4%
   Labor, 24 hr/day @ $30/hr
   Steam @. $3/MMBtu
   Cooling water @ 3
-------
TABLE 5.2-9.  DESIGN OF PHOSAM-W AMMONIA RECOVERY SYSTEM
Design Parameter
Gas Cpndensate Feed Rate to Stripper*
Ammonia Rate
Steam Rate
Cooling Water Circulated
Electricity
Chemicals
H;3P04
NaOH
Absorption Column
Number
Diameter
Height
Material
Reboilers on Absorber
Number
Surface Area (each)
Material
Heat Exchangers on Absorber
Number
Surface Area (each)
Material
H3P04 Feed Tank
Number
Capacity (each)
Stripper Tower
Number
Diameter
Height
Material
Unit
gpm
10s Ib/hr
103 Ib/hr
gpm
kW

Ib/hr
Ib/hr

ft
ft

ft2

ft2

gal

ft
ft
Case:
A i
6,721
27.7
463 1
17,000 !
535 i

51 :
101

5
8.9!
50
SS ;
!
5
5,000
SS ,
i
35 !
10,000 I
SS !

2
8,500 ;

5 :
2.2
60 !
SS
Studies
B
7,054
28.6
476
11,286
535

51
101

5
9.0
50
SS

5
5,000
SS

36
10,000
SS

2
8,500

5
2.2
60
SS
                                              (Continued)
                          250

-------
                            TABLE 5.2-9   (cont.)
Design Parameter
Heat Exchangers on Stripper
Number
Surface Area (each)
Material
Distillation Column
Number
Diameter
Height
Material
Unit

—
ft2
—

—
ft
ft
.
i
Case
A
i
5 :
5,000
SS ;

2
3.0
64 !
SS
Studies
B

5
5,000
SS

2
3.0
64
SS
Heat Exchangers on Distillation

  Number
  Surface Area (each)
  Material

NaOH Feed Tanks

  Number
  Capacity (each)
ft2
gal
    2           2
5,000   s    5,000
   SS   i       SS
    1   !        1
2,000       2,000
* Maximum, including recycle to MIS gas absorber/cooler.         '•

Source:   WPA estimates based on information provided by U.S.S. Engineers and
         Consultants, Inc., April 1978.
                                    251

-------
          TABLE  5.2-10.   COST OF AMMONIA  RECOVERY  BY  PHOSAM-W PROCESS

Item
Fixed Capital Cost
Towers
Heat exchangers
Drums, etc.
TOTAL
Direct Annual Operating Cost
Maintenance @ 4%a
Labor, 36 hr/day @ $30/hr
Steam @ $3/MMBtu
Cooling water @ 3
-------
    £0l$ '1SOO 9NliVy3dO IVflNNV
             o
             o
             o
o

§
CO
o
o
o
CM
o
o
o
         \
            \
              \
                 \
                      \
                        \
                          \
                            \
                              \
                                                     o
                                                     o
                                                     o
                                                     o
                                                     in
                           o
                           §
                           «*•
                  o.



                  uT



                  a:

                  S
                  o
                                                     o  u.
                                                     CO
                                                     CM
                                                                         a.
                                                                         a.
                                                                         >-t
                                                                         0£
                                                                         IX)
                                                                         i
                                                                         a-
                                                                         IJL.
                                               is.


                                               CM


                                               ID


                                               tu
                                               53
CM
             §
             o

             c»
o
o
o
o
o
vo
         £0l$ '1SOO IVlldVD 0.3XIJ
                                                                   ui


                                                                   I
                                                                   o
                                                                   to
                          253

-------
£0l$ '1SOO 9NIJLVH3dO IVfTNNV
  o
  o
  o
           o
           o
               o
               CM
             O
             O
             o
o
o
o
           \
               \
                 \
                   \
                       \
                         \
                                                 o   :

                                                 Soi
                                                 to O '
                                                   o ••
                                                       CM '
                                                       o :

                                                       Si

                                                       O '
                           \
                             \
                                 \
                                   \
                                     \
                                        \
                                          \
                                            \
                                              \
                                                   g
                                                   o :
                                                   o

                                                   s
                                                   09 :


                                                      • E
                                                      , o.
                                                      : O>


                                                      1 uT

                                                   <=  fe
                                                   o  ^
                                                   o i o:
                                                   r*»
                                                   .   ; 3:
                                                      ! O
                                                       O
                                                       O '
                                                       o •
  o
  0
  CM
O

8

o
CM
                        o
                        o
                                                   o '
                                                   o
                                                   o
               O


               §!
            O CO '
            o
            o
            to
                                                                      V)
                                                                  IJJ
                                                                  o
                                                                  <-


                                                       IXI


                                                       ip

                                                       IXI
                                                       i as
                                                                  o





                                                                  IX.
                                                                  O

                                                                  J-


                                                                  O
                                                                  
-------
      DISSOLVED INORGANICS
      CONTROL TECHNOLOGIES
SOURCE' WPA
                                      CHEMICAL
                                    PRECIPITATION
                                    ION EXCHANGE
                                     MEMBRANE
                                    PROCESSES
                                    EVAPORATION
                                    FREEZING
                                     SPECIFIC
                                    ADSORPTION.
                                                        REVERSE
                                                       ' OSMOSIS (RO)
                                                         LECTRODIALYSIS(ED)
r—THERMAL


  .VAPOR   :
  COMPRESSION
        FIGURE 5.2-9   DISSOLVED  INORGANICS CONTROL  TECHNOLOGIES

                                  255

-------




















tfj
CJ
z
i

o


—i
g

»— i
a
a:
S
to
Ul
1
§
g
Ul
H-

.J

g


u.
o


g

^
>•

r4
C*J
U)


1—





















in
S



CJ






Ol
4-> tA


*O ui
o to

s-l

x^
Ul *A

C O

§ t5

i- fc.
tJ 3 *>
at o* tA
ot v «




c
f— at
rat-


ai <*-
ce LU





Ul
4-*
£
SI
O >
11
O OS



ai
"cL
I
&.
a.
f

to
£
at
a.
o







^


ll
II

J
ai &.

£il
O fO Q


^*.2"S.2

(0 Rf (0 Q.
S+J •»- O
i— *» W)
SCS^S.

*
Rf IA


O T- +3
U 3 ai
E


•O -P >
3 as to
r— c at
-a
tT fc.

a ui 3
>» to o-
^ ot
O (0 fc.

* W> .Q
jjl$
-J to E


c: u>
0> C 3
*- •*- .p

(0 £4*
i- at  "O tA 0)4-
(O &» ••— O £ Ul >
. at -p e s- T- G «—
ui 01 •— i- Q. ro O O
fO *A .O fc. P*« .p «P- Ul
at to at o> £ +* IA

+> a. a. 13 •» to (A £ t.

(£ ^^t^I^+J^ £ tA
«*- i- >> at to o u •
«;.£•— fi.££3U*r-tn
a o^— oatw>*o*r-t-o
s: CLU ^ € 3 3 •£ o w



tA .
*> (A
C £

ft. tA
Ol 0)
•P C &»
l-fl





c at

at u tA
£ tO £


1

*ife&
Ul £ £
o at at
E 01 3
Ol O" S-

*f. 4- ^ Ol
• £
a^ u> c to to
T £ 0 fc.
C3 O *r- Ul tO
Ol «r- +J 'f- Q.
tA


tA U
_ a)
to ex.
4J Ul
0} <•

>»CJ •*-
« - to
Ol 1 U
1C UL. IA



!•*• O
.fl Ol •*"
T3 £ £ -M 3
£ O tO •*• r~>
•P U Ul
•*• u x-o
3: at uj 01 +•»
*f- J3 (0 (O
O 0 . f. Ul
U) 01
£ i. at £ S.
O O t- Ol O
•f- •*- U &
4j 01 oi at
3 (A Q. S. 01
*f- O Ul ^
4J '- u n
.a i E « T-
3 Z O 01 U
CO O •** S- Rf





at
01
c
fO
£1
UJ
£
0
"01
S'r^ O
3 (0
w at i^
c « -PO
0> «- I

> U Ol •



Q.JH e -P

•ofc.ce
SO (0 

£ O X. Ul 10 t- 4J 3,- +j fO o at fc- o Ul &? 0) . i i— CD O IA tA to Ul 13 01 N **« C O I—} at at 0) 10 V> > 0 (A ^% •SS28 Ul 01 Q.'^' ui a. 4- tA Ot -P O T3 O tO £ Of O >> Ot • i~ & at -P 13 c *" c Q.-P "E o (O ^IlSfe tA at IA Ul at ^ at |i I§ ^ s- c tn •i- 0 «. S-" 54-5 SO to r" tO •P fc- 3 3 £ £. O 4- •P "O O) O to > at o -P > -P O (A £ O at 0.1- ui at at -P at at T3 r— cO r— E Ol Ol O C O O tO 01 CO 3 Q.O JC -P c O 0) a Ot -P at *— ui T3 -P .O fO 01 (tJ-r- 3 fc. 01 tA at £ £ o • §at ai IA at •OT3 01 £ C C (A -i- 01 O O fO S- DC U U CTJ3 01 f- i at fO 3 U 01 -P » u> 01 -O v^ at 3 a> £ IO £ £ -r- at ro tA at «£.£.£ at > a. Ul •o 0|0>£ Ol »— "O -*• tA O) O T3 01 at i— £ (O f— J3 O 3 £ > «v- £ IA o at c -8S SS-2 «"^!S HI +» 10 Ol CO > U at a> £ JC O 0 U *l- -P 0 fc. O U fc. •*- +J at *> a* ** • ss-|i ^— is *> a> O. OJ W £. <"1n § tn s- i5*.! +J *— IA O fc. fc. §"£ §" > 1— O 1 lo £. 4J S . §>. 1— • at r- •o to 4J*y 01 fc. ^* s Is at +9 (0 fc. 11 O) Ul Ul o a. 0 en tA •P to tA *o 01 . O) £ ui >-— u O 3 £ Ul r— fO ui o a» -r- C t- O ••- O t- o - C t5 O Ol • i- *» Ol 4-> fO C «» t-1- E to fc- t. O.JQ O 01 <*- 01 OJ E -P*r- £ 3 "5 E |i£ "o O) c •f- N at 2 U. O) i c ui a. , to S i Ul t— Ul Ul fc. 5 O. ! i Ul at o : J3 ' to < >» ui r— g fc. 01 at -;-* a. o> S5- a. •o c at .p. C •4- tA O Ol ot •a | T u! O r- 3 Of *i- ai -E £ Ol O U 03 -P "E at M ,a II u to **- fc. ^- ai &fc •5° £ £ ^P Ol o b tA 4>> Si . C O o *^* M— CL L> O Of U> 5-S - ^ gj Source: 256


-------
relatively  clean or  mildly  brackish supply.   The organics present  are not
removed and may  foul  the exchange resins (Calmon and Gold, 1979),

     Reverse osmosis  (RO).   Sometimes  called  "hyperfiltration,"  RO  is  a
process for recovering relatively pure water from  solutions.  Water is passed
through  a  hyperfilter,  or  semipermeable  membrane, which  rejects dissolved
materials.  As  in normal  filtration, the driving  force is  hydrostatic pres-
sure,  but  in  this  case,  the pressure  has to be greater than  the  osmotic
pressure  of  the  solution.   Osmotic  pressures  are  related   to the  total
molar  concentration of the  solution and  its  temperature (Hicks  and Liang,
January 1981).

     The  water  is  passed under  pressure  (greater  than  200 psi)  through  a
membrane  which  is  impermeable to  most inorganic salts and  many organics.
These  "rejected" substances  remain  in  a  concentrate stream  Which  may  be
10-20% of the feedwater volume.  The treated water or permeate will generally
contain  less  than  10%, and  often less than 1%, of the rejected substances.
Costs  scale primarily with  the  volume of  water to be treated !but are also
dependent  on  concentration.   At  very high   solute  concentrations  (e.g.,
seawater),  costs increase  rapidly due to the high applied pressures that are
required. The flux of water through the membrane,  i.e., the permeate recovery
rate,  increases  linearly  with the  pressure by  which the  applied pressure
exceeds  the osmotic  pressure.  Fluxes  of 10 gal/ft2/day have been measured
for  retort  water at  an applied  pressure of 600 psi.   Typical  applied pres-
sures for brackish waters range from 200 to 600 psi and greater.\

     Membranes consist essentially  of a thin skin (0.1 to 0.25 pm) of active
chemical  (cellulose acetate,  polyamide)  on a porous substructure,  which may
then be  housed  in  a spiral-wound module for commercial  application.   Other
geometries  are  also available.   Rejection  of strong electrolytes is normally
in excess  of 90% and can exceed  99 percent.   Nearly  complete rejection  is
obtained from  most species with  molecular weights  greater than  about  150.
However, low molecular weight nonelectrolytes  (e.g., small  organic molecules
like urea,  and  weak  acids such as boric acid) are  poorly  rejected.   Rejec-
tions of these substances can sometimes be improved by adjusting the solution
pH to  a  value  where the compound dissociates (e.g.,  boron  is  rejected above
pH = 10).                                                       :

   .  Some advantages of RO treatment are the low labor and space requirements
and the high  rejection  rates  obtained for a wide  range of dissolved  contam-
inants.  Of particular  relevance to  oil   shale  retort  water is  that  both
organic and inorganic compounds can be simultaneously removed under favorable
pH conditions  and  that  such  a  system can  accommodate changing water  flow
rates.    A  serious  disadvantage  of  the process  is that the  membranes  are
susceptible to   blockage  by  deposition  of  solids.   This so-called  fouling
results from  solids present  in  the feed  solution or  from  precipitation  of
solids as the concentration in the brine exceeds the solubility limit; it may
even result from biological activity on the membrane surface.

     Fouling rates  may be  reduced by proper pretreatment and by reducing the
concentration increase in the brine.   Reverse  osmosis does not  destroy the
pollutants,   it  merely  concentrates  them  into   a smaller  liquid  stream.

                                     257

-------
 Reducing the  concentration  increase  implies  reducing the product recovery cind
 increasing  the amount  of brine  for disposal.   Fouling can  be further con-
 trolled by  periodic washing, although there is generally a certain amount of
 irreversible  fouling  that  determines  membrane   life  and  operating costs.

     Costs  scale  proportionately with the volume  of product water recovered,
 but  they  are  also  dependent on the degree  of  recovery and membrane fouling
 characteristics.  As the  concentration of pollutants in wastewater increases,
 so does the osmotic pressure; hence, higher  applied pressures are required to
 maintain  the  desired  permeate  flux.    Energy  costs,   however,  are  normally
 small relative to membrane  costs.                                '

     ETectrodialysis (ED).   Electrodialysis  is the  use of  an electromotive
 force to  transport ionized materials in a  solution through  a diaphragm, or
 membrane.   The  process  can be made  selective by using ion-specific membranes
 which allow  passage of only certain  ions.   A common application of  electro-
 dialysis is in the desalting of brackish waters containing 1,000-5,000 ppm of
 salts,  A removal efficiency of 90-99% is usually  achievable.

     Thermal evaporation.   This  approach includes  processes in which heat is
 applied to  vaporize  water,  leaving a  concentrated  solution or  slurry for
 disposal.    The high  energy  required for  evaporation  is recovered  in  most
 processes by  condensing the water vapor and, as a result, producing  a stream
 of  relatively pure water.   Volatile  contaminants,  if present,  may require
 removal in an upstream stripping process in  cases where a clean product water
 is necessary.  Multiple effect boiling (MEB) and  multistage  flash  (MSF) are
 two  procedures  commonly used for evaporation (Water Purification Associates,
 December 1975).

     Disadvantages of thermal  processes  are that volatile substances are not
 controlled,  and  (energy) costs  are  generally higher than  for processes not
 involving a phase  change.    Problems  related  to  scaling  of heat  transfer
 surfaces and  corrosion  are  also encountered.  These problems may be accentu-
 ated with waters  containing high organic loadings, such  as  oil  ,shale waste^
 water.  Thermal processes may find application if there  is  a need for dirty
 steam, as occurs in many  in situ processes.                       ;

     Vapor compression evaporation.  This  is a method  for  evaporating water
 by the use  of mechanical energy,  Thermal energy required for evaporation is
 obtained by mechanical  compression of the vapor instead of  by heating.   The
 wastewater is  boiled  in an evaporator to produce a vapor which is compressed
 in order to raise its temperature, and then  it is passed through ,the tubes in
 the  evaporator where   the  necessary  heat  exchange  between  the vapor  and
wastewater takes place.   The vapor cools and condenses upon heat Exchange and
 a relatively pure water is produced.

     The advantage of vapor compression  is  that the heat  required  for vapor
 formation is  recirculated so that the amount that must be dissipated is  much
 less than the latent heat  of vaporization.  This approach  results  in rela-
 tively  low   energy  requirements  and  essentially  negligible cooling  water
 requirements.   The penalties  are the high capital costs associated  with the
 compressor,  which must  handle  the  large  volumes of  vapor,  and  increased
                                                                 !
                                     258                          ;

-------
 maintenance  costs.   Other disadvantages of  vapor  compression  evaporation  are
 similar  to those  of the  thermal  processes.

      The energy  required  for. the  single  effect  vapor  compression units  is
 about 70-90  kW-hr per thousand  gallons  of product water.   Some  $ingle  effect
 vapor compression units  (RCC evaporator) can  recover  up  to 98%  of  the  waste-
 water containing  up to 11,000 mg/1  total dissolved solids.

      Freezing.  The water is reduced  in temperature to produce  a solid (ice)
 phase and a  concentrated brine.   The ice   is washed  free of salts and then
 melted to produce a virtually pure water.   Both inorganics andlorganics  are
 removed  in  the brine stream.  Since the costs scale with the  vojlume of water
 to  be treated, freezing would normally  be applied to  relatively-concentrated
 low volume wastes.   While this  process  is  theoretically more efficient than
 evaporation,  it has yet to  be applied commercially.   It  is included in this
 inventory as  it may be  useful for  controlling retort  waters,  provided  opera-
 ting  problems can be resolved in the  future (Barduhn, September 1967; Water
 Purification  Associates, December 1975).

      Specific adsorption.  The processes in this  category are similar  to  the
 ion exchange  processes,  except that the affinity  between the  sorbent materi-
 als and  the  solutes being removed  is  of a physical nature.  The^sorbents  may
 be  natural  or synthetic  and  usually have  pores, or lattice vacancies,   of
 uniform  size  and dimensions which are  specific for  the  solutes.   The proc-
 esses  are not applicable to high strength wastewaters and are generally used
 for trace removal applications.

      Control  Technologies Analyzed—

     The  following  streams  may require  control  of dissolved inorganics:

     •    Lurgi Waste Heat Boiler Slowdown (stream 20)
     •    Stripped MIS Retort Water  (stream 42)

     •    Phosam  Stripped Condensate (stream 65 or 66)
     •    Boiler  Feedwater (stream 92)

     •    Cooling Tower Makeup Water (streams 89, 105, 108).     l

     The  MIS   retort water  has  already  been  steam  stripped to  remove  the
 dissolved  gases  and volatile  organics.  These  components  are  also  removed
 from  the  MIS  gas  condensate and Lurgi gas liquor during  the Phosam-W ammonia
 recovery  process.   However,  the  stripped retort water and condensates still
may contain nonvolatile  compounds.   A portion of  the  stripped condensate  is
 sent  to  the  Lurgi waste  heat boilers  to produce low-quality  steam, and this
 results  in a  blowdown with a higher concentration of nonvolatile  compounds.

     Cathedral  Bluffs  has proposed  using steam-heated kettle  evaporators  to
 raise  low-quality steam  from the process waters (Occidental Oil Shale, Inc.
 and  Tehneco  Shale Oil Co.,  April 1981).  With  this  technology, the  process
waters are  heated  indirectly  with  a  high  pressure steam to produce  a  low
pressure, low-quality steam for use in the MIS retorts*  During this process,

                                     259                         !

-------
a  blowdown,  or brine  effluent,  containing nonvolatile  compounds  is  also
produced,  and  it  is eventually used  for  moisturizing the  Lurgi  processed
shale.   Since  the  evaporators  afford  concentration  of  the  nonvolatile
compounds  into  a smaller stream, they  have  been  analyzed  as a control tech-
nology.   Both  the  inorganic as well  as  organic nonvolatile  compounds  are
controlled  by this technology.    Design and cost  information  for the kettle
evaporators  is presented in Table 5.2-12,  and  a  cost curve  is  given  in
Figure 5.2-10.  Sections 3.3.9 and  4.2.7  provide  the process description and
material balance,  respectively.                                  ;
            TABLE 5.2-12,   DESIGN AND COST OF KETTLE EVAPORATORS.


Item
Feed Rate
Steam Rate
Number of Columns
Diameter
Height
Material
Reboilers
Number
Surface Area (each)
Material
Heat exchangers
Number
Surface Area (each)
Material
Fixed Capital Cost
Direct Annual Operating Cost
Maintenance @ 4%a
Labor, 72 hr/day @ $30/hr
Steam @ $3/MMBtu
TOTAL
Total Annual Control Cost

Unit
gpm
103 Ib/hr
—
ft2
ft
—

—
ft*
--

—
ft2
--
$103
$103




$103
Case Studies
A ; B
3,373 3,712
1,450 ; 1,595
20 20
10 10
12 12
ss

20
10,000
SS

16
5,000
SS
35,235

1,146
710
37,586
39,442
49,503

a Maintenance is based on the
See Section 6 for details on
Source: WPA.

fixed capital cost
computation of the

260
less contingency
total annual cc


SS

20
10,000
SS

18
.' 5,000
SS
36,000

1,171
710
38 ,,309
40,190
50,464

r.
mtrol cost.



-------
£oi$ 'isoo 9Niivy3do "MINIM i03yia
  o
  oo
S"
 _
9
   o

   S

   S"
    £0l$  'ISOO IVildVO Q3XU
                                               oo
                                                         S
                                                         O£

                                                         2
                                               8 -
                                               o
                                                         co
                                                         o
                                                         o
                                                         in


                                                         ui
                                                         on


                                                         CD
                                       |
                                                    o
                                                    CO
                   261

-------
      Softening was  examined  as  the  most economical  treatment
of the  mine
 water makeup to prevent scaling in the boilers.   In this  process,  calcium and
 magnesium ions  are  replaced  by  sodium ions  using a  zeolite ion  exchange
 resiin.   Total  dissolved solids  and silica are not removed by softening,  and a
 relatively large boiler blowdown  is  required to maintain acceptable  concen-
 tration levels  in  the boilers.   The boiler  blowdown  is used for  processed
 shelle moistening.   The blowdown does  represent an energy  loss frpm the boiler
 system, and some heat  recovery  from  this stream might prove cost effective.
 The  zeolite  softener is regenerated with a  saline solution prepared  from salt
 and  clarified mine  water..   The waste regenerant, containing mainly  calcium
 chloride,  is  disposed of on  the processed shale after equalization with  other
 blowdowns.   Table 5.2-13  gives the  basis   for design  and   costs  of boiler
 feedwater treatment, and  Figure 5.2-11 shows  a cost curve  for  the  zeolite
 softener system.  This  technology could be considered part of  the  process
 rather than  pollution control.

      Clarified mine water is used  as cooling tower makeup.   As;a treatment,
 some  sulfuric acid is  added to  convert calcium carbonate  to  the:more  soluble
 calcium sulfate.   The cooling  tower  is  operated  at  1.5  to 2.4 cycles  of
 concentration  for Case  Studies A  and  B, respectively,  which means that  the
 concentration  of dissolved species in  the  blowdown is  from  l.Sito  2.4  times
 that  in the makeup.  Since  this concentration is not excessive^   the  cooling
 tower blowdown  may  be  used for  process  uses such as  makeup to  the   FGD.
 Table 5.2^14  contains  design  and cost information for the  cooling  tower
 makeup  treatment,  and Figure 5.2-12 presents  a  cost curve for the treatment.
 The cooling tower makeup treatment  could be  considered as part of  the  process
 rather  than pollution control.
                                                                i

      Other Control Technologies Analyzed—

      One additional dissolved inorganics control technology—a solar evapora-
 tion  pond—was evaluated as  a post-treatment  for the process  waters.  A  solar
 pond  is simply a lined pond with  enough surface area to provide an evapora-
 tion  rate that  is  higher  than  the rate of  inflow.   The  precipitated sludge
 can  be  removed  periodically   and  disposed  of  in a  proper manner.   This
 technology  has  not  been  proposed by  Cathedral  Bluffs;  however,   it was
 analyzed  as  a viable option in  the event that the process waters are reused
 in the plant  and  the  resulting wastes are  disposed of  separately  from the
 processed shale.

      For  example,  the  retort  water  after  steam  stripping  can   be treated
 further  by reverse osmosis  (RO),  which would concentrate much ;of the water
 soluble  organic  and  inorganic material due to rejection by the RO membranes.
 This  concentrated material can then be placed in a solar evaporation pond for
 additional concentration.  The RO treated water, or permeate, can  be polished
 for  final  organics  removal  and then  used  as  makeup to  the steam  boilers.
 Similarly,  the  stripped  gas condensate from  the. Phosam-W  process  can be
polished and  then  used as  boiler feedwater makeup.  The concentrate from the
boiler  feedwater treatment and  the blowdown  from  the steam  boilers, in  this
case,  can  also be  placed  in the  solar pond along with  the RO ; concentrate.
Thus,  all  of the  process  generated aqueous wastes are eventually placed in
the  solar pond.   A  flow scheme  depicting  the above  treatment  and reuse


                                    262                        I

-------
       TABLE  5.2-13.   DESIGN  AND  COST OF BOILER FEEDWATER TREATMENT3

Item
Boiler Slowdown (50% of softened
mine water makeup)
Steam Losses
Softener Regeneration Waste
TOTAL MAKEUP (clarified mine water)
Fixed Capital Cost
(includes one spare train)
Installed equipment
Contingency and contractor fee
TOTAL
Direct Annual Operating Cost
Maintenance @ 4%
Labor, 2 hr/ regeneration @ $30/hr
Chemicals
Resin replacement @ 3% per year
Salt @ $45/ton
TOTAL
Total Annual Control Cost0
Case
Unit A
gpm 146
gpm 73 :
gpm 73
gpm 292 '
$ios :
!
126 ;
29
155 ;
$103
5
66 ;
i ;
56
128 :
$103 178
Studies
B
144
72
..71
287

124
29
153

22
100
1
55
127
176

  Tfiis technology  could be  considered part  of the process  .rather than
  pollution control.

  Maintenance  is  based  on  the  fixed  capital  cost of one  train  less
  contingency.

c See Section 6 for details on computation of the total annual control cost!

Source:  WPA  estimates  based on  information from  Peters  and Timmerhaus*
         1980.
                                     263

-------
             £0l$ 'ISOO 9NllVH3dO IVflNNV 103810
o
o
u>
o
o
o
o
                 \
                  \
                                                  °0
                                                    o
                                                    vo
                                                                 O
                                                                 o
                                                                 s
                                                                 
-------
          TABLE 5.2-14.  DESIGN AND COST OF COOLING WATER TREATMENT0

Item
Evaporation and Drift Losses
Slowdown
TOTAL MAKEUP (clarified mine water)
Unit
gpm
gpm
gpm
Case Studies
A B
1,551 1,580
2,951! 1.090
4,502 2,670
Cycles of Concentration


Sulfuric Acid Addition



Direct Annual Operating Cost

  Sulfuric acid @ $65/ton


Total Annual Control Cost
mg/1 (ppm)
  ton/yr
   $103
   $103
                  86
   91
                            2.4
  135      255
1,323    1,492
            97
103
  This technology  could be considered as  part of the process  rather  than
  pol1uti on control.

  See Section 6 for details on computation of the total annual control  cost.

Source:  WPA estimates based on information from Peters and Timmerhaus, 1980.
                                     265

-------
                                                                         UJ
                                                                         UJ
                                                                         OH
                                                                         UJ

                                                                         i
                                                                         o
                                                                         o
                                                                         o
                                                                         to
                                                                         o
                                                                         o
                                                                         CM
                                                                         in


                                                                         UJ
                                                                         Q£


                                                                         t3
C3

O
o
o
n
O

O
    £0l$ '1SOO
                                                                  UJ
                                                                  o
                                                                  O
                          266

-------
 option,   when   applied  specifically  -to  the  MIS-Lurgi  process  waters,   is
 presented in  Figure 5.2-13,  and  the design  and  cost  data  are  given  in
 Table  5.2-15.   A  cost  curve  for the solar pond  is  presented  in Figure  5.2-14.


          TABLE 5,2-15.   DESIGN AND COST OF  SOLAR  EVAPORATION  POND
 Item                                      Unit                  Quantity

 Flow  Rate to  Pond                         gpm                     623
                                       acre-ft/yr                1,005

 Evaporation Rate                          in/yr                     15

 Pond  Area        .                       acres                     800

 Liner (chlorosulfonated polyethylene)   103 ft2                35,000

 Fixed Capital Cost.                       $103                  44,300

 Direct Annual Operating Cost              $103                   ;

  Maintenance @ 2%*                                             .  720


 * Maintenance is based on the fixed capital cost less contingency.

 Source:  WPA estimates.                   .                      ;



 5.2.4 Dissolved Organics                                       ',           , .

      Removal  of  volatile organics  by stripping may  be  sufficient  for reuse
 of  process waters  in  processed  shale  moisturizing;   however,  nonvolatile
 organic  components  are  not removable by stripping.   Therefore;, for higher
 quality  uses, further  treatment may be necessary.   Some of  t|he  available
 approaches are discussed below.

      Inventory of Control Technologies—
                                                                i
     The technologies  available for dissolved organics  control are  shown in
 Figure 5.2-15 and are described in Table 5.2-16.

     Biological treatment.   Biological   processes  may   be  aerobic,  where
organics  are   oxidized to  carbon  dioxide and  water,  or anaerobic,  where
the organics  are reduced to  methane.  Both  approaches  produce  sludge  as a
waste.   Aerobic  processes  are  faster  and   less  susceptible 'to  toxicity
problems than anaerobic  processes,  but  oxygenation  equipment is  required.
Bench-scale tests  on retort waters have  shown that  minor  changes  in retort
water composition  can result in  a significant reduction  in  the  performance

                                     267                        I

-------
                                           UI
                                           «a
                                           cc
                                           S
                                           S
                                           s
                                           UJ
                                           UJ
                                           o
                                           ev
                                           UJ
                                           S
                                           O
                         cr
                         g
                         CO
268

-------
            'JLSOO 9N!iV«3dO 1VDNNV 103810
o
in
O
o
to
o
m
O

8
                                                          8
                                                          o
                                                          o
                                                          o
                                                          o
                                                          o
                                                          oo
                                               
-------
 DISSOLVED  ORGANICS
 CONTROL TECHNOLOGIES
SOURCE^ WPA
                                  BIOLOGICAL
                                   WET AIR
                                   OXIDATION
                                  CHEMICAL
                                  OXIDATION
                                   THERMAL
                                  OXIDATION
                                   MEMBRANE
                                   PROCESSES
                                  ADSORPTION
                                   FREEZING
                                   SOLVENT
                                  EXTRACTION
                                  EVAPORATION
                                  DISPOSAL AND
                                  CONTAINMENT
-REVERSE OSMOSIS(RO)


-ULTRAFILTRATION(UF)


  •CARBON     :

  •RESIN
             i
  •PROCESSED SHALE
 •STRIPPING   ,

 •COOLING TOWER
L-SOLAR
    FIGURE  5.2-15  DISSOLVED ORGANICS CONTROL TECHNOLOGIES

                                  270

-------











bO
1


C3
lAl
0
1
S
!
s


§
_j
§
c3
u
u_
V)

s§

*c
si
s
0

in
UJ
-j



















1
CJ



Ul
4-» Ul
ss
•o ui

£l



Ul Ul
Feed
Requirement
Restriction



>>
Removal
Efficienc


Ul
4^
S-a

o >
ti
O Ol



01
"o.
1
'fc
o.
D)
(0
£.
0)
O








0
go
-I- C
o o>
CJ I—

in at i- 01
01 a»< v ai

•»•» r— • D) O* U)
Ul C O> r-
Ol 0> i— -i- S- 01
o s- ai E- ui
C •*- Ul 3 >» U)
01 3 ui ~o 
•r- O* > Ul .
ui s. c c 01 -a
01 t- o o .c at
&. *-> o *F- «F- 4^ in
Ul 4-> Ul 4-> O
O) >» U Ul (. 0) t- £. 4J (0 +> *>< Ul  C IS £ Oil! .N ~U1 . E 4J Ul § "c 3
4J 5 a> cL«5 £ 'E ^ E n -o s £ •£ °"
at o 01 co aiv-ui >»xtf >> 3 3 01
DC U 4-> m r- t- E = U? 0 (D U?V> C JD
I- CJ
4- o . »4-
O t- X C "O C
£- 4-> $- O -C *>
*>o5£.S--5
oa <» *• e'o
in 1— £. uj a to

I


a
o
O3

CJ
4-
« O
CJ 01
U
o c
O 4-> OJ
•0-2 Q.
C 4J
3 .C T-
o'lu"'1* fe
o t.*]" «
4J O **•» £t
O O 5 «
f- •«- O "O
4-> ^Q £. C
nj o at a>
•o t. m a.
•r- 0) C U)
X (O nj 3
O >-^*«— • ui







U
^1
o
o
CO
I TJ Ol
« Ul Ul Ol >
U 3 r— T3 u) ,,- .p. i_
=:£5 S ^§^: I tJ.28
4JQ.O&- aim c -r- o .oi4-> a» •)-» *r-
oo.o)0) uioi aj ui s- ^- c ui . v- to e
C CD -r- ^J 3£ S.U1U14JOCO ' 4» C. « .
&. (O 10 ,)J 3 a) **~ C k &. -*J ' 0) O) Ul
•*->«£ T3  ^1 Ot O1&.W
3f->* « at .c /— Q, ai u 4-> c E >> "O) c o at
ja ^: •— e "o ui>>4-> s 30 ai t. •*- u
4-» t. o at ^n}*i— . WOIMOIJ3U E4-2 • O JS J^ o
* *r~ *p» &. jQ E S t i- O t- O EUl F— ^
OlCIO4-l k(OV)"-OIOI EC i T-3O.
c-^u.03 aimui+j o 3>> Z >*»— ja
•F- 3O* C -J-> E (O Ul T> O**r- 'r- O) O) ' r— O i—
me £.-01 — c 5 5 cc OJ c o> -P u> -M c , ja ex ro nj
•p-0)*4J^ S. flj (— QJ 3Z *F- (TJ t 
E > c tn o "o Ji *-» zu 0101 oip— ' ja ID c o
OOOCO) F— "F- O Ul 0>X >*t- O. C 3 ' ' O (O Is
£. &. -i- O £» jC X S- »tJ 4- O.O ro «*- X O O : £- Ul J= 5
0. Q.-P U ffl 0 O O. 5 FriuiZEUJO) -iC Q. (TJ +J t.

1 jj
c -o c
O * C 4J S
u ui 10 c -S
*St. . . a; S ^
U1O-PO3 U1&. Ul 4J O. . O
Oi cj ^r J3 **- otoi . 0) fouiui in
U> Ol t. f— . U14JCU1U1 &. O> ^"O
 c « t- « 0 4-J 4^ u t3 at o at ja ' c
c ••- «TJ n at c ui 4^cjj=ztn > S t- Q. (Z cjlns 5"
j

.* ai Q) f- . • ;
c i- ja 01 4J
ai - nj • 13 3 $_ • c '
CD y *> •oa»4-oc -at !
>^f~U)C i— 4-J «*- O C S *»- .
XECOI 3 H3 01 ••- O 4-» O • 4->
O £->COUl » O t- XJ *O 4-> f- Ul Ul C
<*- OJ O 1- O) 4J ^=4^30) (O 4-» 3 r- 4J Ol
S_.r.j=M-4Jt. c U1C*O£. fc. (0"-lflJC ^
o 4->4->*F-o. re aiaift-o s- TJ > re s-
B4JOUT3 T3 T3L)t-3O)Q.-*-»fl30r-l O
S- (fl -P "J C 4J t- Ol C O"4-> to t— E 3 Ul
•F-oi3aioo x a> o o at nj > 'r- a: at o ~a
*£ X: 03 6. O C O U. O 4^ &. ^ 0) U.O.(-4-i  !Q4->F-
r— O 4-> f (OftO Ul ' O-
a} l~ a> i~ *J s- >3 >> >» . i— i-i. ui
> ""~ 53 Ol Ul • F<*> Ul ul ' (O to *O J-
o *^ aio *i- 01 c c *— 4*4i4J i > o at at
£ a T- £ U -C . ^=COO m >>t3 O r- C : 0 -F- £ 4-*
a> o ui at c s. (jv-.r.tp. .^.CF—OI .aai • Eo.*om as
&.cjui4-»a>oo) nj -a 4-> *J 4J -^ i- c: . %emc : S^co) 5
OWOC4J C>r>(Q C 01 CT CO S- 0 ' t. 4> O3 t. OI 5
dfi * O- >>f" O "Ot» O> e>^ CL*r- Ol AI O. ' 4^ r— 4J
•4- a w ui at + Q. c at mooui ICXE >* o s at « w
o o in OI4-&. ooioa. uiot-oi oaio o o ro t- jz 03
O> CQ *r- f8 £. O O) O> "O U O UJ tr* Q. "O LflUlCJ j Lfl t~ £- O. Ul 2
i
» & Ul -
§O O r— F— Ol O ui
tfl O JD 3 1 0) r-Ce U
CJ • CJ • (0 Ufi-N^ ^— ' *F-
ui at ui aim N oioi*F-(0!C
• fl) F- u - f— O -f- . F-4J(nNui m
§-•§•£ §•§'£ 2S i^o-E^ £"
CO r— M to COMtO X *i— 4^O3O
ai-r-oi T-.O) oc a> •* nj »r- (j
a«*5§ '8*5! £§ fe^iil t
t-:
*» uicoi loilcc-ac
•F- . "J «JC *F-t-»F- -r- O S OJ J=
3*> e .0 (o T3 E at <*- ^3 o at 4->
^ • i" I "O 4J C <]) "O Ul S- Q* *** f—
NOI+*UI oi air- r5uico): ores.
O Ul CO O) Ul C 4-> 3 3 S- >F-UU1U1
OS- (J *«r- ME £• >» 3 C •COCO
0*Ooi5 'coo J[*u) S^cui S^ 4= ^ .2 w
uip «IF- E (nfi.iQOii s- 4J wi c 4J at
C to U) S- ' Ol^ .C OU1 2OI&-£~ O t ja c O
•F" C > Q. O *F" 4^ 4J g ' '[u .^. j^ 5 S_
4-> i- E 3 t- at E o  4- o 4J o nj *»-> a.
O"OO) 4-0 UrtJ. , EEO Uf-UC
(o*.«4J ot. RJOI-O efcfe°: cwH^OF-
OIOIM at ui . t. at o T3 at a) o a> ~a u m
I_ 4J *.- "O C 4-> O) Ul U14^4^ 'F- Ol *— O ••- >i E Ol O
to t- a> o m "o 4J uuira 4J>^c 4-» .n >»•*-> e: •«—
u at ui m 13 a» x  "*" o
£4-*ui> (j4Jo<- *o r-
uioiai BJ w s- T- en 4-> m a. m ^ 4- w 4-> 4J at O
•r»(dS.r- 0) 03 0" X t-(0> QJ -r- OJ C i T3 Oj S. O W -r-
O3O-
•F- 4-> »F- * Q)
4-> (O +J ' C i—

"O «F- ~O ' Ul ,C
•F- X 'F- OI W)
x o x a. 'cos
o o : o TI
^ « r— O : 4J C* Ul
•F" u to oc CL o in
^ 'E 8 ,Q. o"£S
4*> aj o) E U- in (O o
Ol -C f Qi "^ ' T3 t3 S-
3 Oh- E-^ 
-------




























1=
8
?
CM
UT>
g
"

































Ul
t
tt)
 Ul

?3 "in
(tj
3:
a.
1 "O

3S
e o

£ -P
Of U

•0*5 -P
01 Ot O>
U. C£ Q£




C
15.2
> u
§•*•»
4-
01 *K
OCUJ

to
c
S^J
41
g-g
O '0)
o c&



41
.£•
8
S.
a.
O)
c
1
2.
O







§5
o

2|
C U
O OI
CJ (—

st>

UJ3
C OJ .
0) C Ul TJ
C O 0) 0)
O P— •— -P
a.  o c  o >^
£lii 2
•P S- C "O Oi
*— 01 01 +•> E
O S- £ O 0
> (0 -p >> y


58
(0 v
£.

01 (0
U 0)
0 *J
o«










a»
5
Ul
Ul
o
a.
o
en


CO
t—
CJ
o
t—

•a .
ai o
-P C
at s- s-
U itl J3

i- -P
3 0) (O
a. s. s-
S * "(=

0^0 0
ill








en

N
Of
S.
U.
Ul
Ul
0>

C ui
3 -^-
If
a> o
J3 Ul
•P 01
•r— 3 O
.3: ui 4-



•o -.
2U1
u
0) •<—
> C

u o>
0=0
at -P
Ol Ul
at >>

+^4J C
CCO
01 Q) *r"*
r— f— (8
0 O i-
(/) Ul 0)
fc.
O
4-
a> o) u>
JQ > W
S4J r— .p
U (O (0
•§£««
3 O» i— Ul
O C «r- (O
U_ *r~ O f
C
0)
01 C O
•P-r- U)
a> 01 u
s*^ §>*s
O O S- Ul
U ui O 3
0)


U > Ul U
>, U» r- S- -t-
»- -r- 0 3 C
0) E u> O 10
•P E Ul O Ol
'p- flj 4J +i (Q
S c: -r-
ui at -P £- o>
•i- (tj > S- 4) 01
r— (O 

ui X O) Ol-P i— (O i- S_ S. 0) O 3: E o o J3 ui £ o 4J s- X c 01 ^ o irt c o s. O) '^« in i— 3 (O . -p- -t— 3 C a> 4) 01 01^ o o W O C p- U) '.p E OJ o m co as *> Ol C *p- O C t. u s- a .a a.»~ o £ xi'-o at'o re" •^ to o c s. o > Q E O ro to U> 0) S- +J ex &» (O -P > c at •o o &> at fll ^3 fc > C -P O to ui *- Ul . O -P ^3 at c 4-> O Ot O (O Q.*<- g ,— E at o o s- os > « ex §1^ • ra'-P ui S*i5'o at i ^ o T ex at ** i" H3 O) £ M- O > "O -P O U c/> ° o "" • Ul 4-» E c " 5 s- at at E 4- >»»— c nj a» 1—^1- o at 01 e u> +j Q.-P C S- 3 CO S Ul <8 3 O r— O f 4^ O» O u to u a> c > ••- x t. m c at > ot +-> o

01 S o) at c: i- c - -M . 4«» *>» c »^ e t. -a «8 P- 0) O (0 4-> C s- ex o i— c 3 o ex t. o a. at o ex re fo u ex as *— at at c s > >* O JC JT O O uj ja o» +J -P o p O) c o o Cj *-s t C - (O O O")*~ •^ c o *» *r- f/> RJ & ' ' LU V^ 1— • C 3 1 O *r" >, ra J w at E $- o> •>» ex-p • 0) « 3 "c O *CO 4J 13 U) W JS 3 C T3 C >, QJ at ••- o» TO r- x "O -P « *» c f— *i- at Ol -P U *r> (O **- Ul ra c a> e o ui U *C* 4-> *E •— * U at -i- c ai f— o J= 0) 0) 0 J= (0 t. (~ J3 S- CJ O U Q. 4- Ul . O -P 'O at c ai r— P— O) J- *0 -r- C S. > -p o at O (O Q-*<— at *o o 2 cc > u a. •a en §U1 T- 31 -0)1 i aic.cs- . r— -p- 4J S- Ol ^•a at 3 t- «O C E Ul O T S. o> -a tj *o at ^ c t. O V) 272


-------
 of a  well-acclimated system.   In  the presence  of biorefractory  (nonbiode-
 gradable)  organics,  powdered-activated  carbon  may  be  added  to  the bio-
 reactors  to  achieve  acceptable  reduction  in  organic  content.    Necessary
 pretreatment   includes   stripping,   pH  adjustment,  and  nutrient   addition;
 control  of  specific  toxic materials  may be  required  as  well  (Adams  and
 Eckenfelder, 1974;  Hicks, et al.,  June 1979; Hicks and Wei, December  1980).

     Wet air oxidation  (WAO).   This  is a  procedure  for the  destruction of
 organic  matter dissolved  or suspended in  water or wastewater  by  oxidizing
 with  air at high  temperatures.   The temperatures  used are  above the  normal
 boiling  point  of water,  and the  reaction is  carried out  under pressure to
 prevent  boiling.  The pressure is  usually  600  psig or above.   The  degree of
 oxidation  achieved  depends  on  the temperature  and  the material   oxidized.

     The advantage  of WAO is that  the  organics do not have to be biodegrad-
 able  to  be oxidized.   In fact, WAO often produces biodegradable substances
 from  refractory  material.   For economic reasons,  it  is recommended that WAO
 systems  be  designed to remove no more  than 80% of the organics. :  The optimum
 effluent is one  that has a  COD/BOD  ratio of  unity, i.e., the chemically oxi-
 dizable  material  is also  biologically  oxidizable.   Biological  oxidation can
 be  used  as a  post   treatment  (Water Purification Associates,  December 1975;
 Wilhelmi and Knopp,  August 1979).                               :

     The WAO   procedure  is  normally used  for  high strength  wastes because
 costs  scale  with the volume of  water to be  treated.   The  energy needs for
 WAO  often  can  be  supplied by  heat released in  the  process  itself  if the
 wastewater has a high concentration  of  reactive material.  It is;an expensive
 process and would be considered only for high strength wastes not amenable to
 other treatments, such as solvent extraction.                    :
                                                                i
     Chemical  oxidation.   In  this   process,  .oxidation of  the j organics  is
 caused by  adding  oxidizing  agents to the  wastewaters.   The oxidants  are
 usually  comprised  of  ozone,  peroxides,  chlorine,  chlorates, : etc.   These
 chemicals are  nonselective; that  is,   they oxidize  total organic  carbon  as
 well  as  some  inorganics.   The  oxidation  may  be carried  out at ambient
 temperature, which  is  an advantage.  Formation of obnoxious wastes is likely
 with  chlorinated oxidants.   Explosion .is  also  a possibility ;under uncon-
 trolled conditions.                                              /

     Thermal oxidation.   The  wastewater  is   evaporated  and  the  dissolved
 organics are  simultaneously combusted  by  directly  firing  burners  that are
 submerged under  the wastewater.   Organic nitrogen and sulfur  compounds will
 convert to NOx and  S02, which is a  disadvantage.  Additional waste gases may
 form if the fuel  combustion is  incomplete.   Heat  transfer  within  the waste-
water  is efficient; however, due to the  presence of  a Targe  amount of non-
 condensable combustion  gases, waste heat  recovery from  the overhead vapors
may not  be practical.   Energy  requirements  can  be reduced by using a pre-
 concentrated wastewater.                                        i

     Reverse osmosis.   In  addition  to removing  inorganics,  this, process
 removes  organics to a  certain  extent,   particularly if  the organics  are
 ionized.   Tests on in situ retort waters have shown that, at a high pH, about

                                     273

-------
 95% of  the  organics are  removed.   Modern polyamide thin film membranes  are
 available for  high  pH  operation,  but additional  data  on membrane  fouling
 characteristics with retort  waters are  required.   The  concentrate  stream
 produced requires  treatment, possibly  by  WAO (Water Purification Associates,
 December 1975;  Hicks and Liang,  January 1981).

      Ultrafiltration.   In  addition to  separation of  oils  and  suspended
 particles,   Ultrafiltration  will  also   separate   large  organic  molecules
 (MWt § 1,000).   It is unlikely that Ultrafiltration  will be  incorporated into
 a  treatment train  for  the removal of  large  organic molecules, as  these  are
 not a  significant  fraction  of  total  organics in  retort waters.  However,
 Ultrafiltration may be  used for  emulsified oil  separation and, in that case,
 would serve as  a  useful  pretreatment  to  RO  (Water Purification  Associates,
 December 1975).                                                  ;

      Carbon adsorption.   This  technology is  used to remove  organic  materials
 from sewage and industrial  water,  as  well   as  taste  and  odor from drinking
 water.   It  is  usually  used in  conjunction  with  biological  treatment  as a
 pretreatment  or  polishing  treatment  (Cheremisinoff  and  Ellerbusch, 1978;
 Water   Purification   Associates,  December 1975).    Laboratory  results  from
 combined carbon adsorption and biological treatment of modified  in situ  oil
 shale  retort water indicate that up to  85% removal  of  dissolved  organics  can
 be  achieved compared to approximately  50% removal  with biological  treatment
 alone  (Jones, Sakaji  and Daughton,  August 1982).                 :

     Activated  carbon is produced by charring wood  or  coal  at high tempera-
 tures.   Charring temperature  is  the main  factor  determining the adsorption
 characteristics of granular or powdered-activated carbon.         !

     Carbon  must be  regenerated  when  it  is  exhausted. The regeneration is
 accomplished by passing the  carbon through  a furnace at high temperature,
 usually  around  800-1,000°C,  with restricted  oxidation  to  remove the adsorbed
 layer  on the carbon.   The quality of  carbon after  regeneration  is slightly
 lower"  than  the  virgin carbon,  and  small quantities  of virgin carbon must be
 added  to retain the  required activity.

     Activated carbon has  ion exchange groups and can be used to remove metal
 ions  from water.   It has  been found  that,  under proper conditions of pH and
 oxidation, some metal ions are adsorbed  very  strongly.           ;

     Regeneration  costs  are a  significant part of  overall  treatment costs,
 making  the process  uneconomical  for high strength wastes,  for which frequent
 regeneration is required.   Regeneration  also  is  not  attractive  for small
 units.   Energy  costs for running  an  activated carbon wastewater treatment
 plant  are  small, not considering regeneration, and are proportional  to  the
pressure  drop   across the activated carbon  contactor.   Fouling in  carbon
adsorption units is  reduced .if the influent stream  is adequately pretreated.
     Resin adsorption.  Resin adsorption is a physical process for removal of
organic materials.   Normally,  it  is  considered as  a polishing
bulk organic removal  in  upstream wastewater treatment steps, but may be used
                                     274
step,  after

-------
 on waters having higher  loadings  than would be used for carbon.   Also,  it is
 useful  for removal  of specific toxic materials and phenol.      ;

      The polymer  (resin)  surface  can  be made  hydrophobic or|  hydrophilic.
 Activated groups  can be introduced to increase selectivity.   Regeneration can
 be accomplished by washing with methanol, weak acid or weak base.   Steam can
 be used to vaporize adsorbed  materials.

      Adsorption on  processed  shale.    This  method  has  been  proposed  for
 organics control   in  retort  waters  at  oil  shale  plants.   In  studies  at
 Lawrence  Berkeley   Laboratory,  processed  shale   from  the   Lurgi,   Paraho,
 TOSCO II,  and  three simulated  in  situ processes were  contacted with  four
 separate simulated  in  situ retort  waters in batch  and continuous  (column)
 systems (Fox,  Jackson  and Sakaji,  1980).   These  studies indicated  that  the
 processed shale reduces the inorganic carbon  by  50-98%,  the organic  carbon by
 7-73%,  and elevates  the  pH  from  initial levels  of 8-9  to  a final  level  of
 10™. 11.-  An advantage of the  process is  that  the increase in  pH would facili-
 tate  downstream ammonia stripping and would  reduce the  loading Jon downstream
 organic removal steps.                                          \

      Freezing.   As  previously  discussed,  freezing also  removes  dissolved
 organiqs.   One  advantage  of freezing  over  evaporation processes  is   that
 volatile organics  are  removed as  well.   This process  has yet to be  applied
 commercially   (Barduhn,   September 1967;   Water   Purification '.  Associates,
 December 1975).                                                 \

      Solvent  extraction.   When  wastewater  is  contacted with ,  a   sparingly
 soluble  immiscible organic   solvent,   the  dissolved  organic 'contaminants
 partition  themselves between the  aqueous and  organic  phases ;according  to
 their relative solubility  in each.  The  organic  phase  is  separated and  the
 dissolved  contaminants  removed in  a distillation  step.   Alternatively,  the
 solvent and  dissolved  organics may  be  incinerated.  Solvent  extraction  is
 most  economical for high strength wastes because costs scale with the volume
 of  water to  be  treated  and  are   relatively  independent of the  amount  of
 substances  removed.   Unfortunately,  effective solvents for the wide  range  of
 organics present in retort water have not been found, and it appears  unlikely
 that  solvent  extraction  will  be  useful  in  retort water  treatment  (Hicks,
 et al.,  June  1979).                                             ,

      Stripping.   Volatile organics  are removed along  with ammonia  and  the
 acid  gases  in a stripping column or  other thermal evaporative process.   The
 amount  of organics  removed depends  essentially  on their volatility  relative
 to water. Organics  in retort water are relatively nonvolatile and indications
 are  that less  than 20% will  be removed  in a  column  stripping 99% of. the
 ammonia.  Organics  in  gas  condensates, such as  the TOSCO II  foiil water, are
 significantly more  volatile,  and  bench-scale tests have shown that up to 85%
 of  the  organics are  removed  along with the  ammonia.   The  volatile organics
may  then be  incinerated,  along  with  the other  stripped  gases, or may be
adsorbed  from -the  gas stream  prior to  ammonia  recovery (Hicks  and Liang,
January 1981).                                                  ;
                                     275

-------
      Cooling tower.   The cooling tower may  be  Regarded as a water  treatment
 system.   As  such,  its main function  is  to  concentrate the dissolved  salts,
 which may  then  be  removed  at lower  cost in a sidestream or blowdpwn  treatment
 stage.   When  using process wastewaters  as cooling  tower makeup,  upstream
 removal  of  ammonia  and organics need not be as efficient (and therefore as
 expensive)  as when  the wastewater  is discharged.   It has been1 demonstrated
 that  refinery phenolic  wastewaters can  be  used  in  a cooling tower and that
 bio-oxidation  of  phenol  will  occur  with  very  high  efficiencies  (Hart,
 June  11,  1973).   The  conditions necessary  for successful bio-oxidation are
 low  sulfide  (below  2  ppm) and small variations  in  pH (between 7.8 to 8.3).
 Chlorination is used  to prevent biological  growth.   Corrosion;of  steel has
 been  low.    Ammonia  will  not  concentrate  in  a  cooling tower,: but it will
 vaporize with the water.

      Solar  evaporation.  Solar radiation  incident upon  the  surface of an open
 evaporation pond  is  used as the energy source.  Large, lined,  shallow ponds
 are   feasible  for  this application.   The  rate of evaporation  depends  on
 humidity,  wind  velocity and solar  energy absorbed.  Dyes may be; added to the
 wastewater  to increase the energy  absorption,  with  a consequent increase in
 the rate of evaporation.   Land is a major cost, and problems related to final
 disposition of the  concentrated wastes  may  arise.   Biological  'and slow air
 oxidation  of the  organics may  occur.   Volatile and  odoriferous  components
 must  be removed from the wastewater prior to  its evaporation.

      Disposal and containment.   Wastewater can  be "controlled" with  a minimum
 of treatment by some disposal  or containment options.  These options include
 processed  shale wetting as  part of the  disposal procedure.   The water and
 contaminants  are  either  "cemented" or  adsorbed .into the processed shale.
 Provision  of an impermeable lining under the  shale pile  can prevent water
 from  percolating through to the ground if the  shale does not cement.   Water
 used  for  processed  shale  wetting   should not contain  any  volatiles.   Since
water  used  for revegetation  and  leaching  of processed  shale  piles  will
contribute  to  runoff,  it may have  to be  of  considerably, higher;quality than
that  used for moistening.
                                                                 i
     Wastewater may  be  injected underground  (deep  well   injection),  as  in
disposal  of  some  oil  well  brine  wastes   (Mercer,  Campbell  and  Wakayima,
May 1979).    However,  costs  for underground   injection  may be; significant
because deep wells  are required  to prevent  contamination  of upper  level
aquifers.    Legal   and  environmental problems  associated  with  underground
injection have  not  been clarified.   Reinjection of mine  drainage  waters  may
be a  possibility for disposal  of this stream when  excesses exist.  Geologic
and hydro!ogic effects may require evaluation.                   ;

     Control Technologies Analyzed—

     The major streams  which may require  control of  dissolved  organics are:

     •    Lurgi Waste Heat  Boiler Slowdown (stream 20)

     •    Stripped MIS Retort Water (stream 42)

     •    Phosam-W Stripped Condensate  (stream 65 or 66).         i


                                     276                          !

-------
     As  mentioned  earlier,  these waters  are  used  to produce  low-quality  steam
 using  kettle evaporators.  This technology  has already been discussed  under
 control  of  dissolved inorganics.                                 :

     Other  Control Technologies Analyzed—

     If  the use of wastewaters with  high organics loading is npt acceptable
 for  processed shale moisturizing or  reuse  in the plant, additional organics
 removal  efficiency can be achieved by several  technologies,  such as reverse
 osmosiSj  carbon adsorption and wet air  oxidation.  Again, these, technologies
 have not been proposed by  Cathedral  Bluffs,  but they were analyzed based on
 their potential  for  application in oil shale  wastewater  treatment.

     Reverse  osmosis  (RO)  is a useful technology  in that it affords simultan-
 eous removal  of the  dissolved organics and inorganics.   With this technology,
 the  wastev/ater  is forced through a  semipermeable membrane  which allows the
 water to pass through but  rejects the dissolved matter,  especially that which
 is highly  ionized.   At optimum pH, up to 95% of  the organics and inorganics
 can  be  rejected.   The  permeate  is  usually a fairly  clean  water  that is
 suitable  for high quality water needs.    Reverse osmosis of  in situ retort
 water has  been successfully demonstrated on  a  bench  scale (Hicks and Liang,
 January 1981).   A  specific application of the  RO technology to:the stripped
 MIS  retort  water is illustrated in Figure 5.2-16; the estimated!compositions
 of the  feed,  permeate, and concentrate are given  in Table 5.2-17; design and
 cost data for the RO unit are presented in Table  5.2-18; and a cost curve for
 the treatment is provided in Figure 5.2-17.

     The permeate from RO may still contain some  low molecular weight organic
 compounds.  This stream  can fee combined  with the Phosam stripped condensate
 and  Lurgi waste heat boiler blowdown and subjected  to  organics  polishing by
 adsorption  on  activated  carbon.   With   this  technology,  the wastewater is
 allowed  to pass through  a bed  of activated carbon  on which the  dissolved
 organics  are adsorbed  and a  cleaner water emerges.   The  spent  carbon is
 regenerated  periodically by  steam or  hot  gas stripping, and  the  desorbed
 material is  incinerated  before  it is vented  to the  atmosphere.  ! If the bulk
 organics and inorganics have been removed previously (e.g., by RO treatment),
 the carbon  adsorption  treated  water can be used for high quality water needs
 (e.g.,   as  a  makeup  to  the   high-quality  steam boilers).   Figure 5.2-18
 presents the flow scheme for the carbon adsorption technology when applied to
 the MIS-Lurgi process waters,  while Table 5.2-19 indicates the composition of
 the treated water  and Table 5.2-20 gives the design  specifications  and cost
 information.   A cost curve  for  the carbon adsorption  treatment in  this
 specific application is shown in Figure 5.2-19.

     The  material  rejected by RO would contain  the bulk of the  dissolved
 nonvolatile compounds  from  the  retort water.  Either the whole stream can be
 concentrated further  in  a solar pond (discussed earlier in Section 5.2.3) or
 the organic portion  can  be destroyed by  chemical  oxidation  before  the waste
 is sent for disposal.  One available technology for oxidation of  ;the organics
 is wet  air oxidation  (WAO).  With  WAO,  the wastewater  is subjected  to high
 temperatures and pressures, and  air or oxygen is introduced  into the reactor
to cause the oxidation of the organics.   Since the method is  nonselective, it

                                     277                          i

-------
   SIPPED
 FROM STEAM
 STRIPPER

[COOLING
[ WATER
CARTRIDGE
 FILTERS
                                                                                 CONCENTRATED
                                    LOW PRESSURE SYSTEM
                                                                                 TO CARBON
                                                                                 POLISHING
STREAM
IDENTITY
FIDWRATE'
I03lb/hr(ov.)
gpm(ov. )
TEMPERATURE °F
PRESSURE, psig
STRIPPED
RETORT WATER
513.9
1013
too
AMB
RO PERMEATE
380.3
760
110
AMB
RO CONCENTRATE
133.6
253
110
AMB
COOLING WATER
500
80
AMB
     SOURCE^ WPA
                       FIGURE 5.2-16  REVERSE  OSMOSIS PROCESS FLOW SCHEME

                                            278

-------
              rH| rl
          m   m | m
                 §
                 §
      i
      £
      U
      *e
      Dl
      S-
      o   t—   az
279

-------
        TABLE 5.2-18.   DESIGN AND COST OF REVERSE OSMOSIS TREATMENT OF
                             STRIPPED RETORT WATER               i
Item
Stripped Water Flow Rate
(maximum)
Number of Elements
Number of Pressure Vessels
Surface Area
Degasifier
Membrane Flux
Fixed Capital Cost
Direct Annual Operating Cost
Maintenance @ 4%*
Labor, 12 hr/day @ $30/hr
Electricity @ 3
-------
o
o
o
O
o
o
in
                        goi$ 'isoo
o
o
ivnNNv losaia

   8
                                                 o
                                                 CM
            O
            O

            O
                                                                          O
                                                                          O
                                                                                    LU

                                                                                    CO
                                                                                    ULJ
                                                                          o
                                                                          o
                                                                              £
                                                                              o.

                                                                                    o
                                                                                    t—<

                                                                                    
-------
X\   X\
       O
       ^
/\

s>o
UJCO
^or
«*«
Su



°t
t9
_l
UJ
a .
tk




CB
•3
OUIUJ
III
t^j CO
12
cou.
o
UI
I—a:
His
^~3
0
IS
ceui
111 10
flog
§1
tno
ce
-3
Q.Z
iyo?

= 0
_J
f— Jj^
£u-
_j

j?«>
5* t
£ S
S °
V3 «•

O
z • '

a
z
,
:


o.
CM ;
»o :

CO
O
O

Ci
z
ci
'
CO
0
o

o
CM
to



m f
0 0
S UJ
3^«
^

CO

-------
  •a o
   to co s.
  •*•»    £
   re o *x.

   2** 5
§

SC
O

g

g
So
a> as
01 S.


"m
  "ma: .e
  S.   >s.

  *> 
-------
         TABLE 5.2-20.
DESIGN AND COST OF ACTIVATED CARBON ADSORPTION
      FOR PROCESS WATERS
Item
Process Water Flow Rate
Orcjanic Loading
TOC
COD
Organics Removed
Carbon Capacity
Total No. of Adsorption Beds
Mo. of beds on line
Bed Diameter
Bed Depth
Carbon Volume/Bed
Carbon Regeneration
Regeneration Period
Carbon Loss in Regeneration (5%)
Furnace Area
Fuel Rate @ 3,000 Btu/lb C
Fixed Capital Cost ~
Direct Annual Operating Cost
Maintenance @ 4%*
Labor, 16 hr/day @ $30/hr
Regeneration and carbon
replacement
TOTAL
Unit
gpm
mg/1
Ib COD/hr
Ib COD/1 b C
=-
ft
ft
ft3
Ib/day
days
Ib/day
ft2
10® Btu/day
$103
$103


Quantity
3,120
!
; 213
; 1,100
! 860
0.6
7
• 6
i 14.4
16.4
2,670
36,000
6
! 1,800
720
108
9,975

324
175
400
899
* Maintenance is based on the fixed capital cost less contingency.

Source:  WPA  estimates  based  on  information  from  Cheremisinoff  and
         ETlerbusch, 1978.
will destroy any organic matter.  Only high strength feeds are economical for
WAO treatment;  therefore,  a preconcentration of the waste, such as by RO, is
desirable.   A process  flow scheme  for the WAO  technology is  presented in
Figure 5.2-20.  The  composition of  the WAO sludge  and the  design and cost
information  for the process  are given in Tables  5.2-21  and  5.2-22, respec-
tively, and a cost curve is presented in Figure 5.2-21.          ;
                                     284

-------
        9oi$ 'isoo DNiivaadO ivriNNv
p
CJ
                            in
                                         -f-
                     \
                      \
                                           8
                                           o
                                           If)
                                                                          O
                                                                          to
                                                            o
                                                            CO
                                                            as
                                                            
                                                            o
                                              
-------
                                                                             EXHAUST
                                                                              GASES .
                                                                             TREATED    \
                                                                             CONCENTRATE /
                                                                            TO PROCESSED
                                                                            SHALE
                                                                            MOISTURIZING
FROM RO
HIGH PRESSURE PUMP
STREAM
IDENTITY
FLOW RATE:
K)3lb/hr{oy)
gpm (ov
TEMPERATURE, °F
PRESSURE, psig
CONCENTRATE
133.6
253
no
AMB
TREATED
CONCENTRATE
95.5
182
160
AMB
AIR
48.5

AMB
AMB
EXHAUST
GAS;
86.6
;
160
AMB ;
        SOURCE* WPA
                      FIGURE  5.2-20 WET AIR OXIDATION PROCESS FLOW SCHEME

                                           286

-------










i
1
I

eg
Ul
t


a
§
UJ
o
u.
tit
03
1
s
o
8
§
111
i
t—
as

UJ
ee.

S
a.
a.
S
tn


u_
o

o
t— t
r-
»— 1
o
£
8

rH
CM


.
in

UJ
1




























4->
C
0)
E
m
s.
0)
















2

a.
VI
2
f
(/>
 ja

•s1"




2 &.


X A
m r-
•£





1

S

*a
OJ
Of
u.

s
ID
S-
•P
C
a)
u
c
o
o
o


a> a.

ra-_.
0) 1-

<£•>.





st
"3 Ol



*o ^c
J3



+>
C
0)
c
o
a.
o
u


§i i CM cn o
1 1 91 O) O
1^ rH CM CO
PO rH 00 CO

CM 1 f fs.  CO
CM rH
.
CO O
CO rH




1 t 1 1 rH in
i i i i in «!•
CM CO
.
«* CO
S m




^^
CO
in
CM

I o r-» CM I !
rH CO ID

CM «3-  co 01
r-T co" to"
rt r-
«•



u

c
m
N CO V> 0
O t- O OJ ?4 N
CJ O r- ^ Z O


Itn
to"

ICO
to
°.
to
CM
CO






to
rH
in

in"





en
to
r--
cn"
CO



Iffl
5
.







Icn
in
-
CM
S
f~9






03
O


CO
CO
rH






(O
CO
CM
CO
o
in

<:

o
h-

































C*
S
w->
tn
|>
<

a.
Q.
|

I
(O

'e

0)


•»
^

o
M-
o
i
s.
£
c


c
o

^
U)
(0

w


m

•2
w
V

-------
            TABLE 5.2-22.   DESIGN AND COST OF WET AIR OXIDATION OF
                     STRIPPED RETORT WATER RO CONCENTRATE        !
 Item                                   Unit                    Quantity
 Concentrate Feed Rate (maximum)         gpm                      ;    954
 Organic Concentration:   TOC           mg/1                       ', 10,750
 Reactor Residence Time                 hr                             1
 Reaictor Pressure                      psia                      :    600
 Air Compressor Rating                 Ib/hr                      182,000
 Fixed  Capital  Cost                    $103                       '23,370
 Direct Annual  Operating  Cost           $103
  Maintenance  @ 4%*                                              '•    750
  Labor, 10 hr/day @  $30/hr                                     •    110
  Electricity  @ 3
-------
         90l$ 'ISOO 9NLLVH3dO "WnNNV JL03HICI
                                          oq
                                          O
                                         
-------
      The Lurgi  waste  heat  boilers use  a portion  of  the Phosam-W  stripped
 condensate  as the feedwater.   Low-quality steam produced from this  water  is
 also sent  to the  MIS  retorts,  while  the  blowdown  is  sent  to the  kettle
 evaporators.                                                    .

      Table  5.2-23 presents  a  rough balance  for the overall steam system  in
 the MIS-Lurgi plant.   The  uses  indicated in the  table condense the  steam.
 Noricondensing uses,  such as  in driving the process  turbines  and ;in generating
 electricity,  have not been estimated,  but the net steam  (produced steam minus
 the uses)  is  available for these  purposes.   Cathedral  Bluffs has estimated
 that approximately 190 MW of electricity  may  be  generated, most of which will
 be  used on site  but  some may  be available for  export (Occidental Oil  Shale,
 Inc.  and Tenneco  Shale Oil Co., April  1981).

      Approximately  1%  of  the  total steam circulated is  assumed to be bled
 down and another 0.5%  is  assumed lost.   These losses are  made  up with  clari-
 fied and softened mine water.   Table 5.2-24 indicates estimated water quality
 parameters  for the boiler feedwater.   During the feedwater softening,  about
 25% of  the  makeup is  removed as the feedwater treatment  concentrate,  which  is
 used along  with the blowdown for  processed shale moisturizing.
                                                                i
      Cooling Water—

      Typical  cooling water  requirements  for  the two MIS-Lurgi ^case studies
 are  summarized in Table 5.2-25.  Treated  mine water is  used as the makeup  to
 the  cooling tower.    The water quality parameters  for the cooling water are
 indicated  in  Table 5.2-26.  The  cycles  of concentration are  kjept  low; the
 relatively  large  amount  of  blowdown  is  used, after equalization with  other
 streams,  for  processed shale  quenching   and moistening.    Sulfuric  acid  is
 added to the makeup water to control carbonate scaling.

      Processed Shale Moistening--                               '

      The  hot  processed shale leaving  the  Lurgi  retorting area must be cooled
 and  moistened with water in the processed shale  moisturizing jnixer before
 being sent  to the disposal  area.  The hot  shale  is  first quenched, resulting
 in evaporation of approximately 1,354 gpm  of water.   The steam generated from
 the  quenching  operation  is scrubbed  in  a  venturi wet  scrubber and then
 emitted  to  the  atmosphere.   The quenched shale is moisturized to  a   final
 moisture content  of approximately 10% to facilitate  compaction arid stabiliza-
 tion.   The  optimum  moisture  content  and  the  extent  to which;  wastewaters
 should  be  treated  have  not yet been determined.    The blowdowns  from the
 cooling  tower, boilers,  and  clarifiers   could  be used  for  quenching and
 moistening.    These water streams should  not  contain volatile  material  which
would be released upon contact with  the  hot shale.  Table 5.2-27 indicates
 the water flow rates (gpm) for quenching and moisturizing.      ;

      Processed Shale Disposal—                                 !

     At  the disposal  area,  water  is  needed for  dust  suppression  and for
 revegetation.   Table  5.2-27  also includes  the water requirements  for  these
 needs.   The water required  for dust control  is  2.9 mass percent of  the dry


                                     290                        •

-------
       TABLE 5.2-23.   STEAM PRODUCTION,  USES AND BOILER FEEDWATER NEEDS
Parameter
Steam Production
Steam Boilers (high-quality)
Lurgi Waste Heat Boilers
(low- quality)
Kettle Evaporators (low-quality)
TOTAL
Steam Uses
MIS Retorts (low-quality)
Retort Water Stripping
(high-quality)
Phosam-W Ammonia Recovery
(high-quality)
Stretford Gas Treatment
(high-quality)
Kettle Evaporators (high-quality)
TOTAL
Net Steam Circulated (high-quality)
Feedwater Makeup Requirements
Losses (0.5% of circulated)
Boiler Slowdown (1% of circulated)
Softener Regeneration Waste
TOTAL FEEDWATER MAKEUP
Case
Unit A :
103 Ib/hr . !
7,286i
240 :
1.510
9,036^
10s Ib/hr ,
1,750
90
476;
• — ;
2,757''
5,073 :
gpm 14,572 i
gpm \
73 1
146 !
73 i
292 ,
Studies
B
7,180
240
1,510
8,930
1,750
90
476
19
2,81.0
5,145
14,360
72
144
71
287
Source:  WPA estimates.
                                     291

-------
        TABLE  5.2-24.  WATER QUALITY  PARAMETERS  FOR  BOILER  FEEDWATER
Parameter
TDS, rag/1
Total Alkalinity, mg/1 CaC03
Total Hardness, mg/1 CaC03
Iron, mg/1 Fe
Copper, mg/1 Cu
Silica, mg/1 Si02
Specific Conductance, umhos/cm
Low Pressure
0-300 psi
2,300*
470*
0.3
0.1
0.05
100*
4,700*
i
High Pressure
500-750 psi
1,300*
: 270*
0.2
! 0.025
0.02
20*
2,700*

* For a boiler concentration factor of 1.5.

Source:  WPA estimates based on data from Krisher, August 28, 1978.



               TABLE 5.2-25.  PLANT COOLING WATER REQUIREMENTS
Water Use
                                                          Case Studies
Unit
A
Evaporation
  Retort Gas Absorber/Cooler
  Lurgi Retort Gas Cooling
  Stretford Gas Treating
  Phosam NH3 Recovery
  Steam Boiler Power Generation
  Retort Water Stripping

     TOTAL EVAPORATION
Cooling Tower Drift
gpm
             1,061       i    1,061
                53       !       53
                         1       28
               364             364
                 Air cooling only
                58       .       58
             1,536
             1,564
gpm
(1% of evaporation)
Bl owdown gpm
TOTAL COOLING TOWER MAKEUP
Cycles of Concentration*
15
2,951
4,502
1.5
: 16
I 1,090
2,670
; 2-4

* Case Study A uses all of the cooling tower blowdown as makeup to FGD.
  Case Study B does not require such makeup; therefore, less blowdown is
  produced by keeping the cycles of concentration high.

Source:  WPA estimates.                                          :
                                     292

-------
    TABLE 5.2-26.  WATER QUALITY PARAMETERS FOR COOLING TOWER RECIRCULATIONC


Parameter
Langelier Saturation Index
Ryznar Stability Index .
ptt
Calcium, mg/1 as CaC03
Total Iron, mg/1
Manganese, mg/1
Copper, mg/1
Aluminum, mg/1
Sulfide, mg/1
Silica, mg/1
(Ca)-(S04), product
TDS, mg/1
Conductivity, mi.cromhos/cm3
Suspended Solids, mg/1
TOC mg/1
NH3 mg/1
CN" mg/1


Limits
Minimum Maximum Remarks
+0.5 +1.5 Nonchromate treatment
+6,5 +7.5 Nonchromate treatment .
6.0 8.0
20-50 300 Nonchromate treatment
400 Chromate treatment
0.5 •
0.5
0.08
1
5
150 For pH < 7.5
.100 For pH > 7.5
500,000 Both calcium and
sulfate expressed
as mg/l CaC03
2,500
4,000
100-150
600
100
5
i ' '
  Concentration in  makeup obtained  by  dividing values  above by cycles of
  Concentration.
                                                                   i

  The limits  for  the  Langelier Saturation Index  (an indication of  CaC03
  saturation) presume  the  presence  of precipitation inhibitors in nonchromate
  treatment programs.  In  the  absence of such additives, the limits would be
  reduced to 0 and 0.5.

Source:   WPA estimates based on data from Hart, June 11,  1973.     •

                                     .293

-------
 processed shale  rate,  and  the  requirement for  revegetation is  4.1 mass
 percent.   Any water used in  revegetation  at  the  disposal  area  should  be of  a
 quality acceptable  for agricultural  use.                        j

        TABLE  5.2-27.   WATER REQUIREMENTS FOR  PROCESSED  SHALE  DISPOSAL
                              AND DUST  CONTROL
Water  Use
Water Required
Mass % of Shale
Shale Rate
10s Ib/hr
                                                                  Water  Rate
 Processed  Shale Disposal

  Quenching

  Moistening

  Processed Shale Dust Control

  Revegetation

 Raw Shale  Dust Control
     17.3

     11.1

      2.9

      4.1
  3,909*

  3,909

  3,909

  3,909
1,354

  868

  252

  326
At Mine
Crushing
At Plant
3.2
1.6
1.0
5,144 :
5,144 i
5,144 ;
329
165
103

* Dry processed shale rate.                                     ;

Source:  WPA estimates.

     Dust Control—

     The water requirements for mining, crushing,  and fugitive dust control
are  also  summarized in  Table 5.2-27.   These requirements  are  given as flow
rates  (gpm),   as  well  as  mass  percents of  the  raw shale rate.   The mass
percents are  3.2%, 1.6%,  and 1.0%  for mining, crushing,  and  fugitive dust
control, respectively.

     Water  used  in confined  mining operations should be  low  in  volatile or
toxic  materials  because  mining personnel  will be directly exposed  to it.
Also, the water  should contain low amounts of suspended and dissolved solids
to reduce clogging and scaling in spray nozzles.   The water used in mining,
crushing, and fugitive dust control operations cannot be recovered.

     Miscellaneous Requirements—                               >

     These  include potable and  sanitary needs, as well as  service  and fire
water  requirements.    Table 5.2-28  summarizes  these  water requirements  in
terms  of  makeup,  discharge  and  overall water consumption.   Any treatment
necessary for  these waters is standard practice and  not a pollution control
activity and, therefore,  is not discussed in depth.             j
                                     294

-------











1
1— 1
3
LU
OS
tr
LU
§1
LU
o
1—)
Q*
LU

Q
i

LU
ml
3
£
a.
*
co
CM
i
in

LU
ad
•**
















 in





i-
0) -P
S 5
•^* J»
re -P +j
•P C O) 0) C <0
o re c s. re c
""*•». Q- s u. a. s
>5 -V.
S- -P -P O) -P -P
re  .
C i.
re ai
 oo








































U)

^^
a.
3!
ai
u
s_
3
O
OO
295

-------
 5.3   SOLID WASTE MANAGEMENT

      The  MIS-Lurgi  processing facility will  be  a source of large  quantities
 of  plant  wastes  which will  require  disposal.   Table 5.3-1  indicates  the
 makeup  of the  waste material that  will  be  discarded  from the plant over  a
 period  of 30 years (project life).   Sections 3  and  4 give information  about
 the origin and  composition of these  streams.                     \

      The  waste material  disposal  approach  and  the practices ;used  in  the
 disposal  can have  a long-lasting impact on  the  atmosphere and hydrology of
 the area  as  well  as on  the  local  aesthetics and habitat.  The primary  areas
 of environmental concern in this regard are:                     :

      •    Surface Hydrology                             .         \          '

      •    Subsurface Hydrology

      •    Surface Stabilization                                  ;
      •    Hazardous Wastes.


      This  section  briefly  describes the  disposal   approaches that  may be
 applicable to the wastes produced from a combined underground and aboveground
 retorting facility  (e.g.,  MIS-Lurgi) involving underground mining  of the O'il
 shale.   In  addition,   a discussion of  control  technologies  available to
 mitigate  the potential  impacts  in  the areas mentioned above  iis  presented.
 The  applicability  of  these  technologies  should  be determined; on  a  site-
 specific,  case-by-case  basis.   Specific  information  for  the   facilities
 involving  open pit mining  and  aboveground  retorting  can  be found  in the
 Lurgi-Open  Pit PCTM,  while  specific information for  abovegrouhd retorting
 operations involving underground mining  can be  found  in  the  TOSCO II  PGTM.

 5.3.1 Disposal Approaches

      The following discussion applies to the  basic methods for  handling  solid
wastes  produced by the  MIS-Lurgi  processes.  Generally,  the  mining method,
 geography and  hydrology  of  the area, and the waste characteristics influence
 the applicability  of a disposal  approach.  The key features of each approach
 are summarized in  Table 5.3-2.   A  discussion  of  the  control technologies
 applicable to these disposal alternatives is presented later in this section.

      Landfills—                                                 !
                                                                 !
     A  landfill basically entails  placing the waste  material  as' a compacted
 fill   in a suitable  location.   The  wastes  from the  processing facility are
transported  to  the disposal site  by conveyors  or trucks  and  then  hauled to
the active  portion of  the  landfill.  Usually,  the   solids are laid  down in
 lifts of  9-18  inches  and compacted to  a  suitable  in-place   density.   The
compacted  fill  may  be  built  with  a proper slope to  a vertical  height of
40-50 feet and  then flattened,  or  benched,  to provide a  passageway  for the
disposal equipment and to facilitate runoff collection.   The overall landfill
can be constructed gradually in this fashion, using a multiple-bench arrange-
ment.                                                             .         •   •

                                     296

-------
         TABLE 5.3-1.   MAJOR WASTES PRODUCED OVER A PERIOD OF 30 YEARS
Stream
Number Stream Description
3.3
17
76
78
80
95
97
98
99
116
118
Raw Shale Leachate
Lurgi Processed Shale .
Concentrate from Kettle
Evaporators
Slowdown from Steam Boilers
Lime Sludge from FGD
Processed Shale Dust Control Water
Water for Revegetation
Treated Sanitary Water
Sanitary Water Treatment Sludge
Service and Fire Water
Storm Runoff
122 . Processed Shale Leachate
90, 91 Slowdown from Cooling Tower and
MIS Humidified Air Coolers
— -


Boiler Feedwater Treatment
Concentrate
Source Water Clarifier Sludge
Trash, Construction Debris, .etc.
TOTAL
Material Quantity
Quantity, as a Percent of
106 tons Total Waiste Quantity
N.D.a
513.60 -
24.18
9.59
12.68
32.39
21.42
1.77
N.D.
2.04
10. 51
N.D.
48. 36b
4.80
3.94
N.D.
685. 28
;N.D.
74. 95
: 3.53
!1.40 .
:1.85
;4.73
3.13
;0.26
!N.D.
0.30
1.53
iN.D.
7.06
!0.70
10.57
N.D.
100.01
— — , • '. — •
  N.D. = Not determined.

  A portion of the blowdowns is used directly for processed shale mois-
  turizing, and another is used indirectly in the form of lime sludge from
  FGD.                                                          •

Source:  DRI estimates based on information from Occidental Oil Shale, Inc.
         and Tenneco Shale Oil Co., April 1981.
                                     297

-------





















UJ
3c
U

O
Of
a..
Q.


o
r-)
'
O
tn

u.
o

ty)
UJ
oe
1
u.

>-
Ui



e
CM

t^
0
in

uu
_t
fin
^5
1—



























































































































in
at
cn
cO
4J>
C
(0
•o
10
in
•p-
a












in
Ol
O)
(0
4»>
c
(0
>
•a
"*















01

"a.

o
c
•P»
s-
a-








P» ^
at o
in 
o ai
o>
c ai
0 >
.P- oi

r— U)
a, R)

at
p- t-
O. 0
E
•p- e
«n ^o

^>4™*
t*- 10
ai P-
> 0
•r- U>
•p «f—
(0
t— -a
01 C
Q£ (0

C
»p»

p- Ol
p- O
•p- 10
t^v t^M
s-
in 3
to in

in 4->
Ol C
•P Ol
in •!-
as c

>
Ol C
0 0
a> o

a. to







in
|-~
!«••
•p-
•o
c
'O
— 1



ai
>
•r—
in
c

4J>
C
•p-
1
s-
o
.a
ID

^^
P—
at
.>
4j
(0

"a>
s-


j_
*J
3
Ol
s-
01
IP-
s-
at
•p
c
•p-

•p
o
c

in
at
o
o




at
•p
as
^••3
O
in
•p"

•o
C
m

*••
o
•r™
•P
(0
o
o
i—


















•a
c
IO
m i—

tn <*-
Ol O

S.-P
3 C
0 S
o o
O E

. -P
in c
C 10
0 0 .
*>  S-
CL'P- 3
o tn in











•
c
o

'•P
o
3
•o
0
s-
a.




o>
c ,

•5
c
3
O
S-
s- .
3 4->
in c
at
Ol E
f C
•P O
s-

0 '>
s- c
 s- at p- x:
10 3 O 3 +>
p- in  a> a. p- at
o .-at.
•p ie -P at
o c >><»-
•P s- at p- s-
p- "*- E ai at
3 C > -P
O in o T- c
•1- Ol S. +-> -r- .
 i— TI o
•PT » at
s. o E as o
at 3 «P- as sc s-
O W) -P i— 3
c =p- o o
at >)*o oi • in
•o t. -o *. -a a>
 .
at p- 10 >,
tn i»- p- c in at s-
«0 o • «r- at -r- o ai
at it- .p c >
s- at -o c ^ « o
O N C i- i- £1 O
at . i- 10 10 o c at
O in T— E 3: at S-

c
•r-
IfM
r- O

•p- in
*f** |-i^
s-
in (0
re a.

in at
at >
-P -r-
in -P .
to o at
3 « c
C -r-
O) -p- E
o
10 at at
p- JC JC
a- -P -P
at
c

sr

"•o
c
3 " '
O P-
i. P-
OJ-r-
Ol ^
73,0
C (0
O CD


.
5*>
GO
o

o

f
o
at
•P

•o
ai
a.
o

"oi

at
•a
(0

•P
o





CO
o
c
Ol

in

3
in

in
at
in
as
at
i.
o
at
Q
^
c
at
a.
in

01

•P

c
• pB

tn
•o
•p-
O
>

in
r-»
pi—
•p-
U.






^jt
s-
o
•p
at

tn
p- 1
SI




























,
in at
01 4->
N as
•i-l
•r— C
C 3

O)
•a
c c
10 O

p- 01
IO O
•r- C
-t-> at
C 3
at f^

o c
Q.-P-

p—
f3
•p-
5. .
at >>
+J.

£ f^
Of«
(0 O
(0
J± 01
4-> E
•p- S-
3 ai
a.
tn
•P 5
s- o
O t—
4J
at ^t—
s- o








o>
c
•r»
4->
3
O
S-
C3


,
X
•o at
C p—
 JQ
O

S-* (0
to S
c c
o o
O •!-

o at in •O J3 10 ai IO °P- jc m in *•> c ^ 'm •O E ai c JC 10 1— O tn i * in -a as c in -o 3 C O O "a a. s. fQ ^O N at m c p» Ol O 10 as T— C a. -P- at •P in IO 3 in 3 O •a c 03 0 M Ol IO IO a: -J P« at > at ^. r** at > °p- +j P_ 21 s. . at c > o O •!- +J O in S- 0 *> Q. C in O •!- OT3 . € OJ *^_> O ^J (0 "o U) •r™ 1 j : | . i • i i ; 1 • i | ' 1 ! 1 i h ;• . O LLI • 3 tn . ' «« at o : 3 O to 298


-------
     Depending  upon the geography of the  disposal  site,  the landfill may be
built  on  a level or nearly  level surface,  in the head of a valley, or across
a  valley.   The applicable control technologies  will  vary somewhat with site
topography  but still  will be designed  to  protect the surface and subsurface
waters.   Applicable control technologies  include  runon  and runoff catchment
ponds,  embankments  and  diversion systems, liners  and covers,  and revegeta-
tion.   Provision for  structural  stability of the  fill is  also  :a major con-
sideration.

     A  surface landfill  of  some type  will need to  be included in most oil
shale  developments.  This results from the shale  undergoing  a volume expan-
sion upon  mining,  crushing,  and  processing, which  precludes all of the shale
being returned to the  mine.

     The head-of-valley  disposal  approach for the MIS-Lurgi processing wastes
has been proposed by Cathedral Bluffs (Occidental Oil Shale, Inc: and Tenneco
Shale Oil Co., April 1981).  A description  of the proposed landfill design is
presented in Section 3 of this manual.                           i

     Underground Mine  Backfill—                                 |

     In this disposal  approach,  the waste  material is placed in the inactive
portion of the underground mine, while production continues in other parts of
the mine.  This approach is attractive from several viewpoints.   ;By returning
the wastes to the mine,  the size of a surface landfill would be Deduced.   The
potential for mine subsidence would be diminished,  and revegetation would riot
be necessary.  Backfilling the mine may enhance  resource recovery by increas-
ing  the amount  of shale  that  can be  mined safely.  Disadvantages  include
possible  release  of  volatiles  underground  in the  workplace  and  possible
groundwater contamination.                                       '<

     The major considerations in backfilling involve developing logistics for'
carrying out simultaneous mining and disposal operations while providing pro-
tection for workers and the groundwater.  For fine processed shales, like the
Lurgi, hydraulic or slurry backfilling may  be practical.   However, additional
water, above the moistening  needs,  would be required and a drainage collec-
tion system would  be  needed.  The wastes  may be transported to  the  mine by
conveyors  or trucks,  then  compacted  in  place, but  the space; limitations
reduce the  practicability of this  approach.    Alternatively, the wastes may
be backfilled  pneumatically,  but this approach may be difficultito implement
at the scale required.
                                                                 !
     Underground mine  backfilling will  be  of limited utility in ;the disposal
of the MIS-Lurgi  processing wastes.   Practically all of the  spent retort
volume will be  occupied with the MIS processed  shale; therefore, waste dis-
posal must be accomplished in the drifts and passages, which represent only a
fraction of the  volume necessary for backfilling.  Future access  to  the ore
body or  the  spent retorts  may  also become difficult if the  passages  are
sealed with the waste material.
                                     299

-------
     MIS  Retort Grouting—

     An MIS retort is formed  by  removing  a  fraction  of  the  material  from  the
 intended  retort volume and then rubblizing the  remaining material  to  create  a
 chamber filled  with fractured  rock.  This  fractured material  is  then  retorted
 and  left in  place;  as  a  result, it may  create a potential for  groundwater
 contamination.    Filling,   or  grouting,   the   interspace  between the  rock
 fragments with  an impervious  material may reduce the permeability of  the
 retort and, hence, the  impact on the  groundwater.   Potential for subsidence
 may  also  be reduced.

     The  design  details  required  to   accomplish  this  MIS  grouting  include
 modifications to the  retort chamber to prepare for grouting  and the  grouting
 process itself.   The  product level openings at the bottom of the  retort must
 be sealed except for a  number of pipes to be  used in grouting.   A slurry of
 the  grouting  material  would be injected at  the bottom of the retort chamber
 and  pumped until  the  interspace is completely filled.  The openings at  the
 top  of  the retort,  except for  a few  pipes used  for pressure  relief during
 grouting, may also require sealing.  This  process would be similar to  that of
 producing prepacked aggregate concrete.  That is, aggregate is placed  without
 cement  and cement is then added  by   tremie  grouting  to  fill  ithe  form or
 trench.                                                          ',
                                                                 i
     Other  considerations  involved in  the design of  an  MIS  grouting  program
 are  selecting  the most  advantageous  grouting material  and determining a
 method for  grouting.   These selections will be  based on ease and  consistency
 of penetration,  overall  permeability effected  by grouting,  stability of  the
 grouted retort and expense.                                      :

     Hazardous Waste Lagoon—

     A hazardous waste  lagoon would be a permitted facility either on  the
 project site  or off  site.   It would likely  consist of a lined pond designed
 to be suitable  for the containment of hazardous wastes.   The major consider-
 ations in the design  of  such a pond would include a runon diversion  system,
 an  embankment,   one  or  two impervious bottom  liners  with  a  drained  sand
 layer below or  between  them,  a slurry wall beneath the embankment, a  surface
 seal   layer,  and  provisions  for  reclamation   and  revegetation  (U.S.  EPA,
 September 1980).

     Once  the lagoon is  filled   to  its capacity,  wick  drains  could  be   in-
 stalled  to facilitate  evaporation, allowing   quicker  consolidation   of  the
 sludge.    Gravel  could also be added to  aid consolidation.    An:  impermeable
 surface seal  may then be  added  on  top and joined with the  bottom liner to
 isolate the wastes from the surrounding environment.   The final aspects would
 include placing  subsoil  and topsoil  over the seal, followed by  revegetation
 of the surface.                                                   '••

5.S..2  Surface Hydrology Control  Technologies

     Solid  waste  management  practices  in  the area of  surface hydrology
entail  the  handling  of  surface waters  on and  around the disposal facility.


                                     300

-------
 Specifically,  surface  streams  and precipitation  are prevented  from  running
 onto the waste pile and  contaminated waters  (runoff, leachate)  are kept from
 mixing with the  natural waters.

      The technologies  discussed  below  are  those that are  applicable to  a
 surface landfill,  and they are  summarized in Figure 5.3-1.   The key features
 of  the technologies  are  highlighted  in Table 5.3-3  and  a  more detailed
 description with cost  data  is presented  in the text.             •

      Runon  Diversion System—                                    '

      A runon  diversion  system  will   generally be  needed with, any  surface
 landfill  to prevent surface  water from  flowing  onto the waste'material and
 becoming contaminated  or causing erosion.   The  system may  include ditches,
 lined channels,  conduits,  and  embankments  arranged to direct; the flow of
 surface water  around or  away from the waste  material,  and  energy dissipators
 to moderate the  impact of the flow.

      The  complexity and  extent  of the system  will  vary widely based on the
 amount of water  to be  diverted  and  the  arrangement  of  the site.   For a fill
 on a  relatively  level site, runon  diversion  may  require only  a  system of
 channels  and small embankments  to deflect surface  flow away from the  land-
 fill.   In the case of a head-of-valley fill  or a cross-valley fill,  runon
 diversion  might  include  an  embankment   dam  to  retain peak flows from the
 design storm until  they can be passed  through  a conduit  beneath  or  around the
 fill.   Alternatively,  the  system may consist  of  a  conduit or channel  large
 enough to pass  the design  flow  without an  embankment (without retention).

      The  costs for three  runon diversion systems were estimated'and they are
 plotted  in  Figure 5.3-2.    Examples  1 and 2  consisted  of runon retention in
 combination  with continuous controlled  release.   Example  3 was ^designed for
 no retention,  which necessitated a  large  channel  and  extensive use  of re-
 inforced  concrete  energy  dissipators;  the higher cost associated with such a
 system is illustrated  in  the figure.

      Examples 1 and 2  also consisted of an earth embankment for the retention
 of runon  and an  embedded  conduit  for  controlled  release.   Channeling of the
controlled  release  flow around  the waste pile  in Example 1 was accomplished
with  a lined canal, while  Example 2  utilized an extension  of ;the embedded
conduit for the controlled release.                              ,

     The cost of a runon  diversion system will be influenced by:; the size of
the  drainage area  and topography which  affect the  runon  rates, retentions,
and  embankment  material  quantities;  the  size,  length,  and complexity  of
controlled  release  structures and channeling  systems;  and the  need for and
extent  of energy dissipators  and/or  drop structures.  For example, the runon
from  a site with a large  drainage area  in a gently sloping topography could
be  diverted quite efficiently  by  an  unlined  canal   or  channel;  another
site  with  small   runoff  rates,  but  highly erodible  steep  topography,  may
necessitate  cost-intensive  lined  channels,  flumes  or  conduits, as well  as
drop  structures or  energy dissipators.  In summary,  the cost of this system
is highly site-specific.                                         \

                                     301

-------
    SURFACE
    HYDROLOGY
    CONTROL
    TECHNOLOGIES
                           RUNON
                         DIVERSION
                           SYSTEM
                     •  WITH RETENTION


                    >—  NO RETENTION
  RUNOFF
COLLECTION
  SYSTEM
                         RUNOFF/LEACHATE
                         COLLECTION PONDS
SOURCE'• SWEC
FIGURE 5.3-1  SURFACE HYDROLOGY CONTROL TECHNOLOGIES;

                        302                          ;

-------




















(/)
LU

3
g

o
z
IE
0
LU
—1
§
Z
o
o

^1.
o
o

1

^K
^^

LU
0

u.
OS
n
to
u.
o
LU
Of
P
25
u.

^M
Ul



•
<*>

*"!
in

LU

co
 *O
S- C
P X:
C O
O OJ
CJ H-
01
c
•i—
s- u
(U 3
•P -a
re a)
3 s-

b« >»
0 X?
O)
P S-
C 0)
3 X: -
§4-9 Ul
4J
A Ul
•a o
Ol Ol O
JC P
P 03 P
c c.
10 «r- 0»
01 E E
o re -P
3 P re
•a c a>
Ol O S-
C£ U P


S-
Ol
>> re
•P 3
•r"
i— <«-
•r- O
•o x>
c re -P
re P c
m 3
c o
O 0) E
•i- +j re
Ul ••—
O Ul 0)
S. J=
01 in P
0)
Ul Ul Ul
a) re  O
•"- Q) O
01 S-
c a. E
CO
re o s-

u
m s.

X C P
:=> E 3


c
o

U)
s-
Ol

•r-
Q

C <3)
0 P
C Ul
3 >>
at i S-
3 S o
0) <*-

x: a> i—
P x: re
•p "r—
ai P
c • c
»i— r** O
•P re P
.
4J
r* • «^»
4> ^— "t3
c .r- a>
c x» -p
re -i- u
x: x o>
u >» «« •—


s- o t-
ui re s-> o
P 0.
C P 0)
Ol «l- Ul
E 3 . 3
0) T3 tJ
s. n o>  c
P in 01 o
C 3 •!-
Ol O -P
Ji— Ol (0
<4- Ul f—
c re o
re J^ a> o
xi re r— s.
E fl) Oi fl)
LU Q. J- CL

C
O

-p
c

p
Ol
nf

e~
P
•r-
3:


























•
£^
0)
•p
re
3








































.
•a
c
3
£
OJ


















c a)
o s-
c o
3 E:
s-
•a
s. c .
o re o)
t- o
to c
•o >•!-
C Ol P
o > c
u c oi
O P
5- U Ol
°0^
•— P O
0) C
c -o
c 01 x:
re N P
XZ "r- «r—
O Ul 3



C
0

'•p
c
at
4->
01


0
•z.




•o
c 01
re x:

c
C 0 1-
re •!- o
P
01 c w
C 01 D5
«r- 4-> S-
ui at re
3 s. x:
u
C i. in

f i^a an
p
•P T3 •
a» c a) 3

JfBM ^w
O <»-
C C S-
^i re 4-9 ^
o.X) c re
X E O Ol
O) Ol U Q.









































.
s-
Ol
p
re
3


















i
c
•l~
re
E

Ul
Q)
•o s-
C -r-
re 3
o°
C Ol
o ex
•r"
Ul
O •
i. C
0) O

Ul °P
01 re •
m s- 01
re 4J o
Q) r— C
s- •!- re
u *«- c
Ol C Ol
C3-1- +>


•o s-
c o
re
0)
I— . Ul
1—1—3
•r- r- 0)
 <>-
C C
0 'I- S.
•^ 0)
Ul C P
o o re
S. ••- 3 .
Q) 

Ul i— re o i— 4-> a. O •!- Ul U CX'i- •r- -0 Ul U oi oi oi x: s- x: U O-P c Ol 0) C o •O E Ol Ol 0) C c s- ••- . •r- i— ttl re TJ i— 4-> s. e re T- a re t- E O 4-> C Ul 3 >> ai*s> I 'tfk Ol • in a) 3 Ol oi s- s- re x: s- u O ui 1 "5 s- 449 c re re 3 in c 4-9 C) (J g Ol P i— re i— 0) 0 S- 0 4-9 ' i •r" E 2 c o u <^* o 01 Ul re re o C 4-9 C •i- QJ ^3 4-9 C re o x: a. u re c O) 0 •J »r~ S^ 4-9 <»- U "o 4i C i— 3 O CC U „ O' LU 3s « 41 •3^ U 3 0 CO 303


-------
        I.OQ
       0.75
    to
    o
    o
       0.50
    a.
    O
    LU
    X
    UL  0.25
                                02
                                               J_
  I
                      250         50O         750
                            RUNOFF  RATE, cfs
IOOO
NOTES:           "           .    ;••                                ;
  Examples  1  & 2  include retention  with  embankments  and  continuous
  controlled release through an embedded conduit.
  Example 3 was designed to handle the maximum flow without retention.
  Example 1 is specific to the MIS-Lurgi case studies.           ;
  See  Section 6.2.3 for  details  on the  solid  waste management  cost
  methodology.                                                   ;
SOURCE:  SWEC
                     FIGURE 5.3-2  RUNON DIVERSION COSTS
                                     304

-------
      Runoff Col lection System—

      A runoff collection  system usually  consists of  a  system !of  channels,
 ditches,  and conduits arranged to  prevent the  surface  water that  has  con-
 tacted the  waste  material from  leaving the  site.   Another purpose of  this
 system is to drain the surface water from  the  wastes  to limit the  erosion and
 infiltration potential.   Collected  water may  also  be used  to meet process
 needs.

      The  basic  elements of this  system are backsloped  benches  on  the face of
 the  landfill and  a  means of collecting  the water from  the fill  surface.
 Generally,  half-round  pipes,  impervious membranes,  or highly  compacted  soil
 or wastes  are used to line ditches which  collect the  runoff  from the bench
 and the  segment  of the landfill  slope above  it, as shown  in Figures 5.3-3
 and 5.3-4.   The ditches empty  into central  conduits leading to  a containment/
 evaporation pond  at  the toe  of  the landfill.   On  larger  piles  or  in areas
 with extensive  rainfalls,  small embankments on the  crest of the  landfill  or
 on the benches might be  used to retain the  runoff  and  thus  limit the  peak
 flows into  the rest Of the drainage  system.

      A  problem  with  limiting  the peak  flows  using  embankments on the waste
 pile is that the water ponded  on the landfill will have a greater  tendency to
 infiltrate  the  waste material.   This   increased infiltration could have a
 detrimental  effect on the stability of  the slope and will  somewhat  increase
 the amount  of water which must be  handled by the leachate collection system
 (discussed  under subsurface hydrology).                          •

     The  costs   for  a  variety of  runoff  collection  system designs  were
 estimated and  these  are  plotted  in  Figure  5.3-5.   Example 1 iused shaped
 benches   with  unlined ditches  for lateral  conveyance and  concrete  weir
 collectors  and  corrugated metal  pipe  with energy dissipators for vertical
 conveyance.   It also  incorporated some  temporary  retention of runoff on  the
 waste  pile  surface,  which reduced  the necessary capacity and cost of   the
 vertical  conveyance portion of the  system.  Example  2  used split corrugated
 metal pipe  to'line the collection ditches  to  facilitate  lateral! conveyance,
 and concrete weir  collectors  and corrugated metal pipe with  energy dissipa-
 tors  for  vertical  conveyance.   Example 3 used  the lined  ditches  for lateral
 conveyance.,  with a concrete flume and a stilling basin for vertical convey-
 ance.                                                            !

     The  cost data,  as can be seen  in  the plot, are highly dependent on the
 particular design, and no single cost curve relationship can be drawn through
 the  data  points.   Example  1, which assumes a more modest design,  defines the
 lower boundary  of the cost envelope,  and Example 3 defines  the high end of
 the cost envelope.

     Runoff /Leachate Collection Ponds—

     At the  outlet of the  collection system for surface  runoff,; a structure
 is  needed to contain  the collected water for reuse,  treatment an;d discharge,
or  for  evaporation.    The  structure  would  consist of an embankment  across a
 former stream channel  to form a pond,  and  the pond  may be lined  or unlined

                                     305

-------
s
to

fe
Ul
«z

Q


I
£
a.
a
3
X
I
o
00
g;


•g


1


.1

 S
 0>
o>

§.
                                                                 o
                                                                 o
                                                                 O
                                                                 UJ


                                                                 cn

                                                                 ui




                                                                 §
              CO
                                                                              en

                                                                              I


                                                                              I
                                                                              8
                                                                              u_
                                                                              I

                                                                              or
                                                                              Q.
                                                                              KJ

                                                                              ih

                                                                              iri
                                     306

-------
                                                    o

                                                    5
                                                    UJ
                                                                         ui
                                                                         z

                                                                         
                                                  UI
                                                  a:
\
         *"

                 '
    FLOW LINE

5
H



3NI1 MOld
                                 2
                                 O

                                 I—
                                 O
                                 111
                                 V)
  oo
                                                         -
                                                          a» «
                                                         5 Q.

                                                         CO O
                                  UI
                                  o
                                  oc

                                  o
                                  en
                                  307

-------
          i
          u
          o
          ec
          UJ
          CL
          O

          f- 2
          O
          UJ
          er
                          O
               U2
                                      0
                           I
I
                          100          200          300


                        RUNOFF QUANTITY,  ACRE-FT
                       400
NOTES:
  Example 1  utilizes  shaped benches as unlined ditches  for  lateral  runoff
  conveyance.
                                                                t

  Examples 2 & 3 utilize split corrugated  metal  pipe to line ditches for
  lateral runoff conveyance.


  Examples 1  & 2 utilize buried corrugated  metal  pipe and energy dissipators
  for vertical runoff conveyance.


  Example 3  utilizes  a  concrete  flume with  stilling basin for vertical
  runoff conveyance.


  Example 1 is specific to the MIS-Lurgi case studies.          ;


  The costs indicated are cumulative for the project life.       :


  See  Section 6.2.3  for  details  on  the solid  waste  management  cost
  methodology.         "                                         ;
SOURCE:   SWEC
                    FIGURE 5.3-5  RUNOFF COLLECTION COSTS
                                     308

-------
depending  upon  the nature of the  impounded  material.   If a liner is needed,
it  would  be protected from wave action,  as  necessary, using rip-rap, a sand
layer,  soil  cement or similar materials.  Since the pond would be located at
the  base  of the landfill, it might also be  used to collect the leachate from
the  fill.

     Cost  data  for  four  examples of  runoff/leachate collectipn  ponds are
presented  in Figures 5.3-6 and 5.3-7.   Figure 5.3-6 presents  the total  cost
of  the  embankment  and  liner  as  a  function of  the  construction  material
quantities  used in  each  case,  while  Figure 5.3-7 isolates the!  cost of the
liner as a function  of the liner material quantity only.  Examples 1^ 2 and 3
utilized compacted processed  shale as the liner, while Example 4 used Mancos
Shale as  the liner.   The relatively high cost of using an off-tract material
(Example 4)  is  evident  in the figures.  The cost increase is incurred due to
the  source  development,  processing and hauling of Mancos Shale. j  Slight cost
differences may be observed between similar  systems, and these can be attrib-
uted to  site-specific features,  such as the arrangement and configuration of
the embankments and  ponds.

5.3.3  Subsurface Hydrology Control Technologies

     The  technologies  and practices  in  the area  of subsurface  hydrology
involve  the handling  of  groundwater  seepage  under  a  landfill  to  prevent
infiltration of the pile and the  control  of water from  the pile to prevent
contamination  of  the  groundwater.   The  technologies,   as  summarized  in
Figure 5.3-8, are  applicable to  a surface  landfill,  and their 'key features
are  presented   in  Table 5.3-4.   Detailed  descriptions of  the  technologies,
along with cost information, are presented below.

     Liners and Covers—

     A  liner is essentially  a  material  with low water permeability  that is
installed at the bottom of a landfill or pond.  Its purpose is to prevent the
contaminated waters  from the wastes  from mixing  with the groundwater.   It
also  prevents   groundwater fro.m.  .infiltrating  the bottom  of   the. landfill.

     A cover is also made up of a low-permeability material and it is used as
a surface  sealer  for the landfill.  It prevents the runoff from infiltrating
the  pile,   thereby  reducing  the  quantity  of  the  leachate  and  minimizing
stability problems.

     There are  several materials  which can be considered  for  the liners and
covers.   Probably  the least expensive material would  be  compacted  processed
shale.    It has  the   advantage  of  being readily available at  the site.   A
similar lining  could be  made  of processed shale or clay from off site if the
quality of  the  processed  shale  from the site is  unsuitable;  however,  these
options would be  relatively  expensive  due to the  extra handling  and hauling
costs.   There  is  also  a  variety  of  synthetic liners which  could  be  con-
sidered.  High-density polyethylene,  for example,  would  range  upward from a
price similar to  that for the off-site materials, depending upon the thick-
ness used.   This would make it very  expensive  for use in a processed shale
landfill and it may  have questionable long-term durability.  Another option

                                     309                         I

-------
     <0
     o
     V)

     Q
     O
     o
     UJ
     X
                                 JL
                    O.I          0.2         0.3         0.4


                 CONSTRUCTION MATERIAL VOLUME,  I06 yd3
0.5
NOTEIS:



  All! Examples include cost of embankments and pond liners.      •



  Examples 1, 2 & 3 include pond liners constructed of processed ishale.



  Example  4 includes  a  liner  constructed  of Mancos  Shale (off-tract

  material); cost is increased due to processing and transport. "\



  Example 1 is specific to the MIS-Lurgi case studies.
                                                                 i'


  See  Section 6.2.3 for  details  on the  solid waste  management  cost

  methodology.                                                    ;
SOURCE;  SWEC
                  FIGURE 5.3-6  RUNOFF/LEACHATE POND COSTS
                                     310

-------
     1000
      8OO
   w
   o
    - 600
   V)
   o
   o
   o.

   < 400


   O
   UJ
   X

   u_
      200
                                 100
                                                         zoo
                       LINER MATERIAL  QUANTITY,  10'yd3




NOTES:                                                         ,


  Examples 1, 2 & 3 include liners constructed of processed shale.


  Example  4 includes  a  liner  constructed of Hancos Shale>  (off-tract

  material); cost is increased due to processing and transport.



  Example 1 is specific to the MIS-Lurgi case studies.          :


  See  Section 6.2.3  for details  on the  solid waste  management  cost

  methodology.
 SOURCE:  SWEC
                FIGURE 5.3-7  RUNOFF/LEACHATE POND LINER COSTS



                                     311

-------


LINERS
AND
COVERS



     SUBSURFACE
     HYDROLOGY
     CONTROL
     TECHNOLOGIES
 SOURCE' SWEC
                                                r- SYNTHETIC

                                                   OFF-SITE
                                                   NATURAL MATERIAL

                                                   COMPACTED
                                                   PROCESSED
                                                   SHALE
                            LEACHATE
                           COLLECTION
                             SYSTEM
                           GROUNDWATER
                           COLLECTION
                           SYSTEM



SPENT
RETORT
MIS
TREATMENT



r- GROUTING

   ACCELERATED
   LEACHING
   HYDROLOGIC
   BARRIERS
   HYDROLOGIC
   BYPASS  !
FIGURE 5,3-8   SUBSURFACE HYDROLOGY CONTROL TECHNOLOGIES

                             312

-------
UJ
§
_J
o
c5
UJ
*—
o
os
t—
3E
CD
U

s-
o
CD
_J
O
cc
s-
3C

UJ
o
>.
ta

,
**•

m

in

LU
-j

£












U)
•p
c
G'
0
o





















o
CL
s-
3
0.














CD

"a.
•r"
U
C
*r**
i.
o.




>,
o
11
•p x:
c u
O 01
O 1—







.
tu
•P 0) Q)
ro +J x: r-
x: 10 -p  C S- -r-
i*. -r- , s. •<- -a
(0 xi a. in -P  O1T3
•>- E 0) . C -r- C
4J IO 4J r- -r- E 10
R> -P ,
S- 0 13 4- 0) U 4->
O U C -P -i- -P- .
H- 3 ID rc -C i — O)
4-> O -C 3 3 -i- -P
a> c s- -P -o xi  c - m x:
3 > E 3 r— -P 0
T3n>a>ooi— inns
QJ S— ^^ S« S» "^ C Q)
Q£Q.4->> u
*?••-
•I- i.
•r- U>
XI 4)
> •
s- Z? at
0) 0> OJ
Q. S- (C
a> a.
3 > a)
o at  r—
                                                               in 3  +J
                                                               O 13  ro   ,a  05      r—
                                                               *J    ro t-
                                                               •—  Q.T3
                                                               •—  0)  e
                                                               o  a)  *
                                                               o  in *—
 U

•p
x:
•P
c
                 CO
                 t.
                 3
U> S-
i  a>
    (O

   CO

•o -o
 at  
 (J  in
 (0  0)
    tu
    P
 O  S-
<_> a.
    U>

   3?

    c
    o
 a» -i-
•»•> -p
 to  u
JC  0)
 U r—
 « r-
 01  O
—I U
 O)  C
•P  O
 
-------



































""7
-p
c
o
u


*4*
«
•
U)

Ui

1
*"°
































































































































us
•p
c



o
o
















41
US
O


3
O.














41
!"•»
O.
•t—
u
c
'si
a.






81
o
11
-P x:
c u
O 41
0 t-





























us
41
N .
e ••- t—
°.s .I0

4) °C T>
O -i- C
c s oi
41 -P
3 O
r- . O.
1- S-
C 41 41
»i- -P O
to c
ui 3 ai
4> -a -o
U C -r-
3 3 US
•o o .a
41 &. 3
o: 01 us



















•p
i-
o

01
Q£
V) -P
l-l C
•p -p
c (0
4) 41
Q. i-
 1—







10
c
o
•o oi
41 i—
•P 10
to u
s- u>
+J
US I—
C 10

E U
01 S.
"O 41


O O
z u

1
«"•
 US
*£• 41
U- S-






OS
•r_
-P
O
1.






















































*
to
•r-
41




^*
4^
9^
|—
•^
to
41
a.




















to
c
o
•o
41
•P
10

•p
UJ
C
o
E
Ol
•a

•P
o
Z

OS
c
'p
u

ai


g
41
•P
1
01
c
o

4)
U
3
•o
ai
oc


ai
•P

j=
u
to
01


>^
(KM
1—
to
c
o
+J
1
1— 1



•a
41
+J
2
01
"ol
u
u













41

"io
U
U)

!••
10
•r*
U
S.
ai

•

u
+j
u
OS
41 O
•P S-
to a.
j_
Ol 0)

"o> *>
u
u os
to c

>»"£

•o
15 OB
•i- C
•p ••-
C .C .
41 U 01
•P 10 4-
O 41 •!-


41
S.
a

03
s- .
01 S-
> 01
41 -P
us to
3

4J ^_
•i- O
3
us
us Ol
01 e
•P 3
US t—
IO O
3 >






OS
•f~
u
to
41
—I


g!
O 41 Ol
t— .e x:
O -P -P

JC  Ol
T3 «r- +J
0) +-> ro
•P U 3
IO 41 

•o u c c 3 Ol 2^ os « 41 O O •!- 3 -P •o to 41 S- o: -P os c •r- -P 10 f— O i. *tO U 3 0 >, O) c s C J. 10 •r* Ol Ol •P S •P to s- O 3 41 •^» "a Q. •P 3 •!- US O 41 S- C OS OS IO u OS UI o s- p- 41 o ••- s. s- •o s- •T* gQ • 3 0 t^. s- 01 °r* 3 to 4^ S- o +J 41 ,4.^ C 41 a. us 41 4^ •a 3 to 00, to > -a i to to 4-> c: C 3 3 O 41 S- -i- O IO C -P o oi -P c 41 US O O Ol > IO i— -O r— J= •r- H- 10 O -P

,.p x: s- 4i ai to us u o 1- A 10 S. E to •P 3 o oi s- . •PC +J JC -P Ol O tO "O 41 -P US US C C 01 S- CO 014J E 0 Q- >» IO U 41 O E S. IO *» Ol J= fc. Ol 3 S US •!-> -P >*- T3 Q. 1 i— C OS c c .iC s- u 41 fO •P 41 «0 r— "O 41 C U 3 C O 41 i. .C OS us c 41 O O v- 3 -P •a to 01 S- O£ -P T3 S- C Ol IO II- -P -P O JC UI 10 41 S- Ol E O. •• Ol t- to C UI . "4- <0 41 3 OS'i- S- O 41 • 3 Ol -P S- J= 41 CTJ= UI OS+i ^ <0 4-> C 41 -a n oi t- o jz c 41 J= o -a •P 3 S- -P O to E -P to CO S- S- 10 O 41 •P 10 -P 41 01 Ol S- S- S- -P S- •<-> IO 41 3 O IO -P C > O -P 3 us -i- 41 •r- r— Ol 41 Q. 41 -C ei i- s. -o 3 s- .p ^ •1— OS o t— US Eus re T3 D. •T" gQ ^ o UJ to a • 01 s_ 3 o (AS 314


-------
 that could  be  considered,  particularly  for a  hazardous waste  lagoon,  is
 simply  a  combination of  a  synthetic liner  with one  of the  other  liners
 mentioned  above.                                    .             ;

      Linings  made of  natural materials will dry  and  crack if they are  left
 exposed to the weathering  elements  for long  periods.   Therefore, if a pond  is
 not  expected  to  remain  at a relatively  consistent level, a synthetic liner
 might be considered.  Hazardous waste lagoons  sometimes have double liners;
 however,  the  catchment  and evaporation  ponds  presumably will  need only one
 liner or  no  liner  since  they will  not  contain  hazardous materials.   If a
 combination  of two  liners is used,  the  synthetic liner may  be iplaced above
 the  natural  material  liner  to  prevent  its  drying and  cracking.   In cases
 where a synthetic liner is used,  it should  be covered  by a layer of sand  or
 gravel  to protect  it from traffic and  wave  action.   Also,  because  of the
 weight  of the  fill  and  because  the  fill may be  placed above an underground
 mine, the  liner must accommodate a certain  amount of  subsidence and stretch-
 ing  and still  function properly.

      The  cost  of liners  and covers  depends  on  the  quantity  and  type  of
 material used.   Figure 5.3-9  presents the costs for three separate liner and
 cover systems.  Examples 1 and  2 assumed the  use of  highly  compacted proc-
 essed shale  for construction  of the  liners,  while Example 3  assumed the use
 of Mancos  Shale.   The compacted processed shale represents the lowest mater-
 ial  cost  option,  while Mancos  Shale is  a  more  expensive natural  material
 since  it  has  associated source  development,  processing and  hauling costs.
 The  cost  curve  in the figure may  be  used to obtain  an "order-of-magnitude"
 estimate  of  liner  cost utilizing   highly compacted  processed shale  as  the
 construction  material.   The  estimated cost  for  other liner  materials would
 fall  above  this curve to a degree  which  is  dependent on the source develop-
 ment, processing, and hauling costs associated with delivering these materi*-
 als  to the disposal site.

      Leachate Collection System—                                ,

     The purpose of a  leachate  collection system  is  to collect! water which
 infiltrates  a  landfill  and  drain  it  efficiently in  order  to prevent  the
 saturation of the landfill  and contamination of groundwater beneath the waste
 pile, as well as to facilitate handling of the leachate.         ;

     Leachate  collection systems  typically consist of blankets,  or zones, of
 highly  pervious  sand and  gravel.    In  some cases this  is  augmented  with
 embedded perforated  pipe to  increase the capacity, and  it may  also  include
 collector ditches where the system emerges onto a broad level  area.   The sand
 or gravel  layer would be located just above the bottom liner and it  may be
wrapped in  filter fabric  or  surrounded by carefully  graded sand  filters to
prevent infiltration by  the processed shale  particles.   In either case,  the
collection system should be designed so that movement  and  settlement do  not
 result  in  discontinuity  of the gravel layer or impede  drainage; to the col-
 lection or evaporation ponds.

     The costs  for  four  distinct leachate collection  systems were  estimated
and  these  are presented in Figure  5.3-10.   In  Examples 1 and 2, due  to  the


                                     315

-------
            25
            20
         to
         O
         #>•
         o
         o
            15
         Ul
         o I0
         oe
         o
NOTES:
                          1
                          4           8          12

                        MATERIAL QUANTITY, I06 yd3
16
  Examples 1  & 2 utilize  3  feet of highly compacted processed 'shale  for
  liner material.                                                !

  Example 3 utilizes  3  feet  of compacted Mancos Shale (off-tract material)
  for  liner material; cost of processing  and hauling this material makes
  this option  more expensive  than the others.

  The costs indicated are cumulative for the project life.       i

  See  Section 6.2.3  for  details on  the  solid  waste management  cost
  methodology.
SOURCE:   SWEC
                          FIGURE 5.3-9  LINER COSTS
                                    316

-------
 valley shape of the disposal  site,  only the  drain  material  was  necessary for
 the collection  system.   The leachate in these  two cases was drained in  the
 runoff/Ieachate  collection  pond located  downstream from  the landfill.   In
 Example 3,  a  toe ditch  was  necessary  to collect the  leachate  due to  the
 presence of the broad valley  area at the toe of the landfill.   The  ditch was
 then  drained into  the  common runoff/Ieachate  collection pond.  Example 4 also
 required a  toe ditch which was drained into a leachate collection  pond,  while
 the runoff was  impounded separately  in evaporation ponds  on the waste  pile
 surface.  Examples 3 and  4 required  the  same  drainage material quantity.   The
 cost   difference  between  the  two   examples  is  due to  the inclusion  of a
 separate collection pond  in  Example  4.   Data  point  5 on the  figure represents
 the cost of drainage material  only for Examples  3 and 4.  The cost of the  toe
 ditch may be  obtained  by  subtracting data point  5 from 4.        ;
                                                                 r
      The costs for similar  systems should be  proportional  to the volume  of
 drainage  material  used,  but slight  deviations  may  be encountered due to  the
 site-specific conditions.

      Groundwater Collection  System—                            ; •

      The  purpose of a groundwater  collection  system is  to relieve  pressure
 from  the  seeps and springs beneath a landfill.   This  situation is  most likely
 in  the cases of cross-valley or  head-of-valley landfills.  The system will  be
 essentially identical  to the  leachate  collection  system except it would  be
 below the bottom liner rather  than above it.                     '

      Groundwater collection  systems  typically consist of blankets  or  zones  of
 pervious  sand  and gravel  drained beyond the perimeter of the landfill.   This
 may be augmented with  embedded  perforated pipe  to  increase capacity  and with
 collector ditches.  The sand or  gravel layer would  be lined as necessary with
 filter fabric or surrounded  by properly graded sand  filters to prevent infil-
 tration  of  smaller particles from adjacent materials.  The  system must also
 be  designed to maintain its  continuity despite possible subsidence or settle-
 ment  of the landfill.                                             |

     The costs of two groundwater collection systems were estimated and these
 are plotted in Figure 5.3-11.   Both systems used  gravel blankets under the
pile  to collect the groundwater seepage.  In  Example 2  the gravel  blankets
were  used only  above  the seeps  and  springs,  while  in Example 1 ;an extensive
 network  of  the  blankets was  considered,  resulting  in  a higher  cost.   The
cost  of  the collection system should be proportional to  the quantity of the
drainage material used.

     Spent MIS Retort Treatment—

     The  object  of this  technology  is  to  treat the spent  MIS  retorts  such
that  the  interaction  between  the  retorted  material   and  groundwater  is
minimized and the  potential  for subsidence is reduced.   Several  technologies
for achieving this have been proposed.                           ;

     Grouting.   This  technology  entails the filling of fractures  and  void
space  in  the  spent retorts  by pumping in a  grout slurry.  The material  used


                                     317

-------
       100
    fr-
    
-------
         fe
         o
         o
         5  3
         a:
         UJ
         O.
         O



         a

         £  2
         o


                                    I
                  O.I    0.2   0.3    0.4   0.5    0.6   0.7    O.8   O.9



                         VOLUME OF DRAIN MATERIAL, 10s yd3
NOTES:
  Examples 1  & 2 consist of  gravel  blankets for  collection of groundwater

  from springs  and seeps; extent  of  blankets dictated by the  existence and

  extent of such conditions.



  The costs indicated are cumulative  for  the project life.



  See  Section 6.2.3  for details  on  the solid  waste  management  cost

  methodology.
SOURCE:  SWEC
                 FIGURE 5.3-11  GROUNDWATER  COLLECTION COSTS




                                     319

-------
 in  grouting should  penetrate the interspace with  ease and should result  in
 low  permeability  throughout the  retort  volume.   Some  preliminary studies
 indicate that this technology may be an effective means of  treating the spent
 retorts (MaiIon, January 1980).  Fine processed shale alone or in combination
 with  lime  seems to  yield an acceptable  grout material  (Persoff and Mehta,
 January 1980),                  '                            ,    ',             .
                                                                \
     Advantages  of slurry grouting  include isolation  of the waste material
 from  the  groundwater and  strengthening  of  the material  with  a  resulting
 decrease  in the subsidence  potential.   The main  disadvantage ;of  the tech-
 nology  is   that  it  is not  yet developed  for  application to  MIS retorts.
 According  to  some  preliminary estimates,  the cost of grouting may range from
 $2.70/bbl  of  oil  for Tract C-a to $3.80/bb1 for  Tract C-b (Persoff and Fox,
 April 1979).

     Accelerated leaching.   Intentional,  accelerated  leaching of  the waste
 material and  treatment of the leachate may be carried out  during the project
 life to avoid long-term leaching problems.  This would entail  pumping water
 through the spent  retorts,  collecting and treating  it,  and then reusing the
 treated water.  A  mass saturated with water will  remain in the retorts, the
 consequences  of which  are  not known.   Additionally,  the  materials  removed
 during treatment would require proper disposal.  The cost  of collecting six
 pore  volumes   of  leachate  and treating  it by reverse  osmosis and  carbon
 adsorption  has been  estimated to be about $1.20/bbl of oil (Persoff and Fox,
 April 1979).

     Hydrologic barriers.    This  technology would   consist of  constructing
 pillars,  or  grout curtains,  around the  spent  retort area  to reduce  the
 infiltration of the  groundwater into the retort field.   The  approach is not
 anticipated to be completely effective as the retorts are likely to intersect
 the existing  aquifers.  In  concept,  the costs of constructing grout curtains
 for Tracts C-a and C-b are estimated to be $1.70 and $2.80 per barrel of oil,
 respectively (Persoff and Fox, April  1979).

     Hydrologic bypass.   Diverting  the  existent  aquifer  flow  around  the
 retort area by  first dewatering the aquifers and then  reinjecting  the water
away from the retort area has been conceptualized.   This type of^system would
 need to remain  in  operation  indefinitely.   Furthermore, the effectiveness of
the approach  for stagnant water  bodies may be uncertain.   Preliminary cost
estimates  for  bypass systems  for  Tracts  C-a and C-b range from  25 cents to
50 cents per  barrel   of  oil,  respectively  (Persoff  and  Fox,  April  1979).

5.3.4  Surface Stabilization Technologies                                     ,

     The activities  and technologies  in  the area  of  surface  stabilization
involve the treatment  of  the disturbed land surface and the problems associ-
ated with  the disposal and  reclamation of the waste material.   These tech-
nologies are outlined  in  Figure 5.3-12  and their key features are  presented
in Table 5.3-5.
                                     320

-------
                            OUST
                           CONTROL
WATER AND
BINDERS  ;
PAVE HAUL
ROADS   :

REVEGETATION
aunrwx:
STABILIZATION
CONTROL
TECHNOLOGIES




EROSION '
CONTROL



                                             i— MULCH
                                                REVEGETATION
                         STABLE SLOPE
                            DESIGN
SOURCE' SWEC
       FIGURE 5.3-12  SURFACE STABILIZATION TECHNOLOGIES

                            321

-------

















«rt
bU
1

53
si
O
tu


5S
CHJ
}n<
§

_J
^•4
CO


rt
•r-
0
'£
O.






§1
o

o o
t. c
•P -C
c u
o at
CJ r-


























-cn
c &.
•f- O

•P o in .
in i— ai u
3 XI 0 v
•Q -tO t-
13 4- l»-
in c s. to
•P -r- 3 S-
i- 3 m -P
E
•r- E 13 S-
r— O O) CO
s. «n F—
S. 4- O 3
O Q. U
C X •!-
in o a> x:
C -P in >
ai 3 in
> •- 0 E
Q, O. (O M-


























^H
o
•p •
c
o
o

•p

' 3
O




0) C
0 "i-

O 13
c ai
x: in
, C
i— O
TS C«r-
OTO -P
OL E ce
0 E S-
i-Ofl)
0) in
•a -r- a>
r-i- -P -i-
r— co e
oi x: •!-
3 *> E



























ai
c
Ol-r-
x: 4-. '
•P S-
Cl _C° nfft
° ** tu
T3 m O)
ai "a o
>» c .p
CO »P*
I. xi in
Q. ai
U> Ol f-
u u
^3 cp *^
. '5 s- t!
r— 3 «
u. in o.






•c
c
• (0 «
. s.
5- 0)
Ol 13

fO "r*"
3 ea







,
o -a
•f to
<*- o
!+- S-
10
s- ai
•P x:

at
> c
£°
ts
•r- O

•a '-p
"5 -5
O C
x: o
I/) U




























Ol >»

4^
in +J .
c +J  <•-
u  >
in
•o
CO
O


"3
2^
•
ai

IO
CL


13
ai

§ 01 3
x: ai in
•p x: i-
••- 3 -a

S- O) .
in o c: in
(0 -i- Ol
0) O Ol -i-
S. f- XI -P
CO 11- -r-
H- in >

T- S. '*" 4J
•P Ol O
i— o ce
3 -P CO
"4- C t- t.
01 01 s. ai
in E 3 x:
3 a. in -P
i- O
•P 3 Ol
o crx: >,
z ai -p xi

























•P
in
3
•o

in
c
ai
0) -0
S- c
Q.T-

c
0 >>
•r- Xt

ia -a
•P 01
a) u
Ol 3
ai  u



c
0
•1—
•p
01
O5
01 ' •
>
a>
Of



























i >>
E X!

•P in
ai c s-
»x; o OJ
c -P u -p
o ce
•f^- 1»- in 3
•P O -P
(O C Ol
E fll Ol U
CO OS > CO
i— 2 S- S-
Ol O O. 3
S- 0 in

in xi C •»-
ai ce o
•i- in
4- -P - C
'i- c in o
.- a> e-r-
Q. >"- -P
£ G) f8 (0
°r- S- S- C
 QL"O »r-























f—
Q
s-
+J
o
o

c ,
o
•r* .
in
o
i.
Ul



































.
f—
CO

"fc
ai

^
ai
TJ
o
s-
Ol






































x:
u>
•^_
E ^)
O 5-
U CO
U J-
CO O
Q.
O E

>P

in to

!§ .
m ai
in i.
^ °r- 3
u in
•r- 4-> ID
3 3 01
O-XI E



























O


CO 01
in O
^M ^^
co in
'si ai c
01 x: o
•P -P -r-
(O in
ECO
o s-
in ai
3 •«
0 01 -P
•r- O T-
S- ro E
CO f™ *f~









x:
u
r— •
3 '•
•ST*



o
•p
5
,2
in

^^
3
XI

^«
O
s.

c
o
u

ai 01
c >
ro Ol
E ••-
s- x:
01 U
Q- CO


























•o "
ai


ce E
*>-r-
O> pr-

u> o
x: ai
•P Q.
3 o
O r—
s- in .
en c
ai o
c -P in

al o ai



c
0

s
a>
en
O)

01
o:




.

;














i




E


'Ol
en
CO 0)
'C -P •
-'r- in ai
r— « 10 +J
0 ,S- 3 1-
's. HO c
•P . in i-
C TJ 4-> 4-
0 C 0 01 •
o co «i— tj 10
t. 01
c o-p ro s-
o :c in co
•r- :o 01 o
in -r- ce -P 13
£13 ^8
a> 4J . co >i-
Ol S- M- t-
in en a) s- 01
ai 01 «- 01 -a
^ > in +J 01
CO 'Ol CO <0 t-
s ; s- ai E a.


Ol
N
•r- "O
.E;C

'E
'1:1 • .
01
5 S
«.£ .
0. Q. 01
O 0

in -P ro
•r- C
Sir— O>
•?:xi "c
in '« T-
Ol -P CO
a in E
1


i

ai
§-.
Jo

01 ' C
•—•en

re in
•p ai

-------
     Dust  Control--

     The  purpose  of dust  suppression  is  to limit  pollution  from airborne
dust,  particularly  during  the  placement of the  waste material  in  a fill.
Dust  suppression  can be accomplished by spraying  the haul roads  and fill
surface  with water  or  a combination  of water  and  a chemical  binder.  Haul
roads could, alternatively, be paved.

     Use  of  water  alone for  dust suppression would  necessitate  repeated
applications,  often more than  one per  day,  to be  effective.   Water with a
chemical binder should necessitate only  a few applications to a given surface
to  stabilize  it  for a  year  or  more  unless  it  receives hestvy  traffic.
Finally,  vegetation would provide  perhaps the  most  permanent  means  of dust
control, but this  would not be  practical  except on surfaces which would not
be disturbed for a number of years.

     The dust  suppression technology assumed in developing the cost data for
two examples  consisted  of routine spraying of the processed shale pile with
water and  additives  to minimize the  dust generated due to  the  wind  and the
waste  hauling and  placement activities.  Depending  on the  processed shctle
characteristics, this operation could either be continuous or intermittent.
The  cost curve  in  Figure 5.3-13 is  based on the assumption that both the
manpower and equipment operation requirements are continuous.  Theoretically,
these requirements could differ depending on the rate of waste production and
the surface  area  of the particular waste pile; however, both cases estimated
were assumed to be equivalent in this respect.                   '.

     Erosion Control—-

     The purpose of erosion control is to keep the waste material in place so
that the surface drains remain free flowing, the slopes remain stable, eroded
material does  not  pollute surface streams, and  reclamation and revegetation
efforts are  not  hampered.   Some means of limiting erosion include contouring
the  surface  with  short and  gentle  slopes,  providing  for drainage  of  the
slopes  at  frequent  intervals,   using  mulch  or  filter  fabric to  dampen  the
impact  of water  flow,  and  revegetating  the  completed   faces.   Of  these
measures,  grading  and drainage  are  essential,  take  effect immediately,  and
last as  long as  they are maintained.  Mulch  or  filter fabric also provide a
quick control, but  they  are of a temporary nature.   Revegetation provides a
permanent control,  but it is generally slower to take effect,

     A  major  consideration  in  planning  erosion  control   measures   is  the
severity of  rainfall in  the  area.   A  large  proportion of the Water  from a
high-intensity  rainfall   would   run  off  the  surface,   thus  increasing  the
erosion.

     Reclamation and revegetation consist of  placing a subsoil! and  topsoil
strata of  sufficient thickness  to  support vegetation, and  then  seeding the
disposal area with native or introduced species.   The greatest contributor to
the magnitude  of cost for  this control  technology is the  thickness  of the
soil   strata  and  the costs  associated  with  the  delivered soil  material,
i.e.,, the source development,  processing and hauling costs.   Soil  and  subsoil


                                     323                          I

-------
         50
         40
     «D
     ©
      OT

      8  30

      ©



      i
      K
      UJ
      OL
      O  20
      8
      cc
         10



                            J_
                             10                2O


                             PROJECT LIFE, YEARS
30
NOTIES:


  Example 1  assumes a  30-year project life,  while Example  2  assumes a
  20-year life.


  The MIS-Lurgi case studies have a project life of 30 years.


  The costs indicated are cumulative for the project life.


  See  Section 6.2.3 for  details  on  the  solid waste  management  cost
  methodology.                                                   '.
SOURCE:  SWEC
                      FIGURE 5.3-13  DUST CONTROL COSTS
                                     324

-------
 stripped from the disposal site  may not be available  in  sufficient quantity
 to  meet the  reclamation needs.   The cost curves presented  in  Figure 5.3-14
 illustrate  five   examples.    Examples  1 arid 5  included  2 feet  of  subsoil
 (sand-gravel  material) and 30 inches of topsoil,  both of which ;were  brought
 in  from off-site sources and  thus had  additional  costs involved.   Examples  2
 and 3  also used  the same thicknesses,  but the  soils were available  on  the
 site.   Example 4  used  no  subsoil  and only  6  inches  of  topsoil  which  v/as
 available  on  the site;  therefore,  additional  material costs  were not  in-
 volved.   All  examples included the  cost of revegetation.   It is evident from
 the figure  that the cost of erosion control can vary  significantly depending
 on  the factors  considered;  however, in any category, the costs are  propor-
 tional  to the  area reclaimed and  revegetated.

     Stable Slope Design-*-

     The  purpose  of  designing  the slopes  to be  stable  under  prevailing
 conditions  is  to minimize  the  maintenance of  the  landfill  and  to  avoid
 hampering  of  the reclamation  and revegetation  efforts.  The techniques used
 in  designing  stable  slopes  are a well  developed  part of soils engineering.
 To  arrive  at  the most advantageous  slope design,  other factors besides basic
 stability, such  as erosion,  ease  of placement, reclamation and revegetation,
 must  be  considered.   However,   the physical  characteristics  p'f  the  waste
 material  will dictate a  limiting  slope  angle.   The costs  of  achieving  a
 stable  slope  design  are incidental  to  the  placement and revegetation  of  the
 fill material; hence, additional  costs are  not involved.

 5.3.5  Hazardous Waste Control Technologies                      ;

     The control  of  hazardous  waste  involves its  permanent impoundment in  a
 permitted disposal facility.   This  facility may be built on the project site
 or  the wastes may be sent to an existent, off-site permitted facility.   These
 options are outlined in  Figure 5.3-15 and their key features are presented in
 Table 5.3-6.

     On-site Disposal—

     Hazardous waste lagoons  are  a well developed  and accepted, approach to
 solid waste management.   They  are actually an integration of several control
technologies  discussed  in  Sections 5.3.2,  5.3.3  and  5.3.4.   ;Some  of  the
 included technologies  would  be an embankment surrounding the lagoon, a  runon
diversion system,  one  or two bottom liners, a surface cover, reclamation  and
 revegetation,  and monitoring.

     There are certain advantages to building a hazardous  waste; facility on
site.   This  option  automatically assumes  segregation of the  hazardous  and
nonhazardous  wastes  and,  hence,  their  separate  disposal.   An  advantage  of
this approach  is  that much of the material necessary for the lagoon would be
available on  site  or  it  already would have  been brought  in for  the non-
hazardous waste  landfill.   Furthermore,  transport of  the  wastes  beyond  the
property boundaries  will not  be  required.  A  significant advantage  may  be
that the producer of the hazardous wastes (the oil  shale developer) will have
complete control  over the disposal of the wastes.


                                     325

-------
            60
        
-------
     HAZARDOUS
     WASTE
     CONTROL
     TECHNOLOGIES
                              ON-SITE
                              DISPOSAL
                             OFF-SITE
                             DISPOSAL
  SOURCE- SWEC
FIGURE  5.3-15  HAZARDOUS WASTE CONTROL TECHNOLOGIES

                        327

-------




















W)
UJ
(-4
o
f*l
3


31
<->
{iJ
_i
o
OS • ,

^2
o
o

UJ
1—

^c
3B

Z3
O



O.JZ J=
o -P
r— t-
,
> ja

•O "o T3
S- 01
Q) •*-> U
f— C 3
(O O T3
.coo
U) S- .
01 Q. >>
t- 4J 43^
•1- O> U> •!-

O) E U) O
f O ro fO
I— U S <»-


UJ
HI

UJ O
<0
3 0)
C
Ul °r™
3 UJ
O UJ
T3 O)
S- U
ro O
N S-
ro Q.
>» •
^^~ O uj
O O)
•o i—
Ol 0) ro
UJ U JZ
O 3 UJ
CXT3
UJ O r-
•r- S- -i-
a o. o




UJ •
3  ra
UJ UJ +»
•f- ro uJ
O 3 01

ro
UJ
o
a.
in
a

0)

•r«
UJ
1
C
0
Ul
C Ol 1 JZ
O 4-J £= +J
•r- U) Ol °»—
•U <0 V 3
U 3 0
ai a- *•>
f— Ol C
01 .£= at
UJ +•> • E
•o 01
S- J= 01 >
Ol OJ4-> i—
T3 3 S- 0
ro O o >
o x: a. c
S_ +J in "r—
ja p~ c
ro ro UJ •
ro S- in in
•• •*-* 
01 01 ai uj
T3 +> ja >, ro
> UJ +J i—
O UJ ro Ol
S. <*- 3 -f- J=
Q. O S -4J -P


UJ
Ol
•!-> 1-
UJ O
ro
3 01

Ul «r-
3 Ul
O Ul
•O 0)
S- U
ro o
N 5-
ro O.
>> •
•f- .^ Ul
O O)

41 

> 01 ro C OJ -P >> •r- S. UJ +> ,_ o .^ .,_ ja x "- ro 41 41 T- •P 4J (J Ul


-------
     There  are also  certain disadvantages to  on-site disposal  of the  haz-
ardous wastes.   To be efficient  in evaporating the  liquids  and  consolidating
the  sludge, the  lagoon  should be located preferably  on  a level site, which
may  not be  readily available.  Rugged, uneven terrain  would  increase the  cost
°T .S1".te  Preparation,  runon  control  and  reclamation.   There  is also a  pos-
sibility that  the lagoon may  interfere with other ongoing activities and the
resource recovery.                                               ;

     Off-site Disposal-"-                                         I

     Off-site existent facility.  This would  be an already existing facility
where the  wastes can be disposed of  on  an "as needed" basis.   :A payment is
required for every  shipment, but the cost may be lower than that of building
and  maintaining  a  new  facility.   Also,  a significant  amount of  time  and
effort involved  in  the licensing, design, and construction of a! new facility
can  be saved.   The capacity and  distance  of  the  existent facility must  also
be considered in selecting the disposal approach.                 ;
                                    329

-------

-------
                                   SECTION 6

                            POLLUTION CONTROL COSTS


      This  section provides an  analysis  of estimated pollution control  costs
 for  the MlS-Lurgi case studies  analyzed in this  manual  (see  Sections  2  and  3
 for  descriptions of these case  studies).   Section  6.1 presents fixed  capital
 and  direct  annual  operating costs  for each control  and explains how  they were
 developed.  These  costs are referred to  as the  "engineering costs."

      Section 6.2 explains the cost  analysis methodology used to develop the
 total  annual   and per-barrel  pollution  control costs.   These  costs  combine
 capital and annual operating costs,  allow for taxes, and incorporate a return
 on investment.   This is an approach  similar to  that which a private  developer
 might use to determine costs or  assess the economic feasibility o;f a project.
 Section 6.2 also details  the economic assumptions  that  are incorporated into
 the  calculation  of total  annual  control  costs.

      Section 6.3 presents estimated  total  annual control costs and per-barrel
 costs for  each control  using a  set  of standard economic assumptions.   These
 costs are  assembled  into  total  per-barrel  costs  for  air and water  pollution
 control  for the case studies  examined  in  this  manual.  This  section also
 examines  the   sensitivity of  the  per-barrel  control  costs  to 'a  series  of
 changes in  the engineering costs and  economic assumptions.       :

     Section 6.4 provides more detailed  information supporting Sections 6.1,
 6.2  and  6.3.    Section 6.4.1  provides   the  algorithms  that were  used  to
 determine  total   annual   control  costs   and  per-barrel   control: costs, and
 Sections 6.4.2  and 6.4.3 provide  examples, respectively,  of fixed  charge
 rate calculations and cost 1 eve!izing calculations.               |

     Section 6 uses  a large  number of cost and  economic  terms.   The inter-
 relationships  among  the  more  important of  these  terms  is illustrated  in
 Figure 6.0-1.   Each term  is  explained when  it is first used in the text, but
 the  reader  may  find  it  helpful to  use  this  figure  to provide  an overview
while  reading the various sections.    In  addition,  Table 6.2-4,  presented
 later in  this  section,   indicates the  estimated  relative magnitude  of the
 components  of  per-barrel  control cost for a typical major pollution control.

6.1  ENGINEERING COST DATA

6.1.1  Bases of Engineering Cost Data                            i

     Throughout  this manual a  distinction is made  between capital  costs and
annual operating costs.   There  are two types of  capital  cost,  fixed capital


                                     331

-------








S
o
§
UJ

v>
35
j

Z
ENGINEER
jfe -i-r
UJ O o 10 _1
Q: o p 5) o -id
* , *•« H «*3
m o " x < ^ |
Q- 03 Q | fc
O
CL
CD
8^L
gig <3
IIs *'


„
2


to

to
8
i i- -&
Z S r-i oT _ ta
£ | g » £ =5 o"
< .££!_,~ £ «
y~'g^t'«^S?0«r-
OU>TOO.O!-I «<
°0x" ?Q"«,2P
3« ~ * P ! g" 1 *• | §"
Z) >>C.o>u.oi SC
Z ». n ^^ Q. *^ »- »— *
z s.gi*-r




a
tf


O
o



















c
u





1
1
v /
\ /
\l
tO "m
S 1
8 :
Cf>
1 ?
o s
i °
1 £























^
.




/
r





i
(
i



<
L
f






























?
O
i
m*


J 
u*
X X
u. 5
cc cc
cc


UJ
_ CHARGE

^
0.
2
tD
Z
^
cc
^5





*•
C"
a
a
3* ^jj -d
— 5* C

cc a. L.
50 ;
c
3




l-lto6.l-3)
1 (Tables 6.




i



i— i
to
c
c- Assumptio

§
1
»*-
M

QC

|


1

•« .
1 :
•

^

j

> :
» '

,




                                                   o

                                                  J
                                                  £
                                                  o
                                                  f
                                                  1
                                                  f    ce
    0)

    S

    K

    UJ

    H-


    O
    O
    y.

    I

    a

    f


    §
    o

    S
    q
    5:
                                                           o
                                                           £
                                                           5:
                                                           m
                                                           y.:
                                                           o
                                                           Ul
                                                           Ul
                                                            I
                                                           q
                                                           ui
                                                           a:

                                                           it
                                                           u.'
                                                  10

                                                  18
                                                  *
ill
§

I
332

-------
and  working  capital,  and  two types  of  annual  operating  cost,  direct and
indirect.

     Fixed  capital  is  investment  in  construction  and  equipment,  whereas
working  capital  is  money that is required to  operate  the plant,  e.g., that
which is tied up in  inventories.

     Direct  annual  operating  costs  include maintenance, operating supplies,
operating  labor  and utilities costs.   Indirect  annual  operating costs com-
prise additional annual costs, i.e., property tax and insurance, ;an allowance
for  extra  start-up  costs, a credit  for severance tax not paid and by-product
credits.                                                        ''      .-     '

     Section  6.1  only   considers   fixed  capital  costs  and direct  annual
operating  costs.   Working  capital  and  indirect  annual operating  costs are
considered in Section 6.2.
                                                       -          '
     Assumptions Used to  Develop Costs—
                                                                 !
     All  costs  are  expressed in  mid-1980 constant dollars.  The  following
data apply to  air  and water pollution control costs.  Solid waste management
costs were developed on  the basis that these  activities are contracted out,
since they are all  construction-type activities (see discussion l.ater in this
subsection).

     Fixed capital  costs.   Fixed  capital  costs  are  of  the  ."preliminary
estimate"  category.   Physical  plant costs  for  air emission controls  were
developed by Stone  and Webster Engineering Corporation  (SWEC) and  for water
pollution  controls  by Water  Purification Associates  (WPA).  Actual  vendor
quotes were used for major items of equipment; costs for other equipment were
obtained from  data files maintained by SWEC and WPA.   Total  physical  plant
costs were  developed from  the equipment  costs by  adding  appropriate allow-
ances for the following:                                          !

     •    Site preparation,  excavation and foundations           ;

     •    Concrete  and rebar                                     ;
     •    Support structures

     •    Piping,  ductwork,  joints, valves, dampers, etc.
     •    Duct and  pipe insulation
     •    Pumps and blowers
     •    Electrical

     •    Instrumentation and controls                           ,

     •    Monitoring equipment

     •    Erection  and commissioning                             '
     •    Painting

     •    Buildings.


                                     333

-------
      To arrive  at  the total  fixed  capital  cost, the following  factors  were
 added to the physical  plant cost:
                                                                  f,
      Engineering and
      construction overhead:        25% of physical  plant cost.    ;

      Contractor's fee:             3% of bare  module  cost (physical  plant
                                   cost plus engineering and construction
                                   overhead).                     ;

      Contingency:                  20% of bare module cost.
                  . '        ,                    .                   i

      For an  explanation  of  this method of  developing estimates  of fixed
 capital  costs,  see Uhl  (June 1979).   A 20%  contingency  factor was  chosen
 because  there  are  only  pilot plant data for the  MIS  and Lurgi  retorting
 processes.                                                        •

      It  is considered  that the accuracy of  these cost estimates  is  within
 ±30 percent.   Although  the  accuracy  of a preliminary fixed  capital  cost
 estimate is  normally  regarded  as  ±20 percent,  uncertainties  about  stream
 magnitudes  and  composition  decrease  the accuracy  of  these  estimates to
 ±30 percent.

      Direct annual operating costs.   There are two components which make up
 the  total annual operating  cost.    The  direct annual operating  icost can be
 regarded as  the  basic  (or engineering)  cost, while  calculation of the in-
 direct annual operating cost makes some  adjustments to this  cost.: By-product
 credits  are  included  in the  indirect  annual  operating cost.   Data on the
 bases  of direct  annual operating  costs are given  below,  while the bases of
 indirect annual  operating costs are  outlined in Section 6.2,      :

      Direct  annual  operating costs are made up of  the followingicomponents:

      •    Maintenance
                                                                  i          . , •
     «    Operating supplies

     •    Operating labor

     •    Utilities

          —Cooling water

          —Steam

          •^-Electricity.
                                         1                         i
     Maintenance  costs  include  maintenance  labor  and replacement parts,
consumables used for maintenance, etc.                            :

     Operating supplies are  consumable items  (such as chemicals);used in the
regular  operation of the control (as opposed to use for maintenance).
                                     334

-------
     Operating  (and  maintenance)  labor  is  costed  at  $30/hr.   This  is a
 "loaded"  rate, meaning that  it  incorporates some overhead-type costs to avoid
 developing them separately.  The  rate  is made up as follows:

       A.  Wages for direct  labor                   $11.00/hr

       B.  Fringe benefits (45% of A)                  4.95

       C.  Field supervision (15% of A + B)            2.40       ;

       D.  Overhead (50% of A + B + C)                 9.20       •  •

       E.  General & administrative charge
           (9% of A + B + C + D)                  •     2.45

               Total                                 $30.00/hr


     In  mid-1980,  examination  of union agreements showed that oil refinery
 direct  operating  labor  was  receiving  approximately  $10/hr  in  Colorado.
 However,  it  is  anticipated that  when  oil shale development occurs, this will
 bid  up  local  labor rates, so $ll/hr, which was used for the oil shale PCTMs,
 is  a  reasonable   value.   The  multiplier  factors,  used to  arrive  at  the
 "loaded"  labor  rate  of  $30/hr, were suggested  by  SWEC  basedj on  project
 experience in the western U.S.A.

     Cooling  water  is costed  at 11.3 cents per  10s  gal circulated (3
-------
of a construction  nature,  subject to uncertainties similar to those inherent
in fixed capital costs.
                                                                 i
6.1.2  Details of Engineering Costs

     Tables 6.1-1, 6.1-2,  and 6.1-3 present details of the fixed capital and
direct annual operating  costs for each air and water pollution control.  The
operating costs relate to  a year of normal operation, i.e., full production.
For the  start-up  period,  direct annual operating  costs are  modified to an
appropriate level  by the cost analysis methodology.

     Table 6.1-4 details the solid waste management  costs  on  a year-by-year
basis.   These costs are allocated to fixed capital or direct annual operating
categories  in  Section 6.2   (Table 6.2-3).    Insufficient  information  was
available to  develop  a complete plan for  solid  waste management; operations.
Consequently,  the  solid  waste  management  costs   presented   here  are  for
certain items only and do  hot represent the total pollution control cost for
solid waste.                                                     ;

6.2  COST ANALYSIS METHODOLOGY                             . •     '.
                                                                 i
     In the cost  analysis,  engineering cost data  are transformed  into two
primary measures—the total  annual  pollution control  cost and .the control
cost per  barrel  of  shale oil.   These costs  incorporate both ;capital  and
annual  operating costs and consider project timing, taxes, and the necessary
return on investment.

6.2.1  Overview of Cost Analysis Methodology

     In private industry,  one of the most widely accepted methods of evalu-
ating the economics of a project is the discounted cash flow (DCF) approach.
Using  this  approach,  a project must  be  able  to   demonstrate that  it can
produce some  established  minimum  rate  of return on investment-,-known  as  a
"hurdle" rate—to be acceptable.                                 !
   •                                   .                           !
     One method for applying the DCF approach to a complete-oil shale project
is to determine the selling price which would provide the revenue required to
produce a minimum  acceptable rate of return  (DCF ROR).   With  this method,  a
sellling price for oil  can be established by distributing the required revenue
uniformly over every barrel of oil produced.                      \

     The  same technique can  be utilized  to  determine the  total  annual and
per--barrel costs of pollution control.  In practice, pollution control is not
a  separable  aspect  of  an  oil  shale project.    Consequently*  a  private
developer will  require  the  same  DCF ROR  on pollution  controls as  for the
entire project.                                                   :

     If  the  revenue   necessary to  provide  the required  DCF RbR  for each
control (expressed  in constant  dollars)  is  distributed  uniformly over each
barrel  of shale oil produced, then this also implies a constant total revenue
requirement  in each   year  of  normal  (full) production.   However,. in the
start-up years, less oil is produced, with the result that the annual revenue


                                     336

-------
1














_j
s
•z
u
•pr
g
3
2
i

I

J2
§
i

S
s

s
o

to
a
§





















-I?
HI
Q O
*tg p« 5J
21-8
d £

> u

o **
I 5
t! 6
cS S
o ' w>
1 a '
S~ -r- J-
tl» +> O
a R) .a
°I;J3
"iSo"
C
•§ raw
4J 4- 42
eel
•r— 01 3
a a.w
o
45 g
c e
„ g
1 .3
€ C

*
Ul
ifl
•i- .*•» O
U. r*-«-
U


e
o
ijj

+*
"c
2°
14



W
Of
 o
CM CM co CM in »H en to en
r-i i*» m r-^ en
tn r-i

III! 1 1 III t 1 1 f* CO t
- i i i i i i iti i i i in «3- i
«"

1111 i t 111 i i i to «-» in
1111 i t iii i i i •**• P-  1 1 +» (|_ i- O •*->, * Oi 0) C
c c -a T3 c -a M t i c u t. f — « i -J *>ui3 a> a)
t-t-cjajs-g^ s- MI- or u»t.

CCOOC&»3 £. t-t.CCl.fO (OS. -^ C O >
|— H- H- (fl KV) t/> (/> r— 0 OJ *2 3>»3 W C
o a) c a> ^* 4J3 TJ s. _j s. i— cea>
f>>.C JZ >>(— JC > C 4-» W* Ul C O £>> COfO
of tn v> ot tst ^ ? 41 a* •»— ui 01 > "a. t. m ^^
i? •*- 01 M *-
>->*-N/^^-**-S J^K /-% -^X^-S S. 0 X» «^ 0)

&.(.(-£-£. fc. S- S. £. (d O VI O* *3^-'X»

£*i£*f** *i *; ££"* loS'S "^ a 2^
tubuu^i^iZ tZ tZ tZiZ cr IAUI s- uijao u>
 - <-^
WUUUUU U U UU t. O t- -4J •*- C3 3 ^ O
Ofc»fc-k&-£. t. S- £.£.Of U(O4J 0)01 OJ O 4->
£-^^AAJ3 A -O jaj34* 0) *» C E E- 3 to t/) C
•pcocotOQfo to R) cotont f— a) •*-> 4-> *— >-* o
c i^ u_ u. u. u. u. u. u. u. 2£ ui >• cat/)u.£' o
o  *
1.-S-SS S
ui c, w -a >
O 3 O) O •—
S 5i 5


2?


J£ Ul
§ a» «
s.IJZ*™'
at o> o w

E- O O CO

>•*- £- Ol
o 'to a *» c
§ «J r- *CO
< o u. £



03_ 03^03^ 03_
«s «e*s «







'





t
13
: t.,
:| :
cu
, 1
1 en

' vpj
£

•o
. c
to

; 1
!|
5>
Jj

• a:
I
; ^
;l
£
• M
' trt

: | j

.£3 VI
J.J
O Ol
: s 5
s I
en o.
• OJ C
•*- ,°
' *. 5
. Q 2

c o
1 5 1

. e c
T- O
! i -g
, U u»
• CO
i as &
1 Ul Ul
1 •S S

-------








«e

Q
'1
UJ
to
g


U)
1
1
§
HH
g
O
Q.
o:
UJ
ee
o
u.
to
1—


u

z
H-e
ee
UJ
UJ
z

LLJ
S

1-4

t
a

,

to

UJ
eo

i—
















c s.
a> 03 in
•f- 0) O
O Q.O
r- ° °

5_B %„,»
Id
0 =*>
1— c in
CO



^
t
*v.

to
S
a
c

fl
s.
a>
a
o
f^
1
c
4J
U
t

a

4-
O

IA
+J
C

C
o
Q
3





or-
U

f-
jj
UJ





1
55
O>
C t-
-5
§5

O)
II
o» -J
a.
o

O)
c tn

1d£


a. 5"
O V)



a>
a
c

c

5




0) +> -«













^

s.
c
o
u


iH COCO 00 CM «3- to CO I i-l rH
to corn CM «*• p-i co ca i i-i
CO |H CO «1- iH i-l CM

*cf co en co
iH CO If)


•• '
1 CM 1 1 1 II 1 1 1 CM
1 CM 1 1 1 1 1 1 1 1 CM







1 CD C3 1 to t 1 1 1 1 to
i oo i ao i i i i i aa
co co tn QO
CO CM f** CM
1-1 co m


i to to i i i i i i i CM
i o^ iiiiiiiin
tO iH f.


i in r- co o i i to i t to
i J£> co r-j i-i i i to i i co
co CM i-i f^ *r
i-l






i o m i i co to r^ i i to
i OCM ticocomiiin
i-i 1-1 <•







r-»oo ototo i m iiHen
tomiH I-I«J-CMI i o
^- CO CM iH Ifl

<-> CM






co cno tocoo!mto4-£
•a-enmTTCMoo IH r»
CM CM en" to" in" r»T
CM co r-.



«
4J i.
>> CO
S- * 0) <->
s.  E  c 5 s-
o i- * o ns td
fd U .01 £- £= O> CL
s- o> a. o) +J s- ai
, in-i-idt— w>
Q. •r-.U+JS-V-O) T>
O) (d S» *^* 'r— O •rH &• £• C S-
t/) *f— 4^ ^ C 4^ ^ ^— d O 01
C  TO =3 Id Id *•> O. -U
S-O &. $. r- S. (d .Id
0*1= &-OCOOO2C3
+»B ai'OO. -u-So"^
id.a>!so>4-> *f— i-+» o>r—i— id o
W 0 =5 4J I— U. 4-> C 0-r- 3 C
< O. OS ££ ^ S O CO UJ Q£



















1
1

o
1

*o
a.
re
5

5-
1

Id
i.

U)
0)
0
o <
^ c
a. !
ai :
•s ^
4- <
O T
«!
•*-> :
s- <
id
0. 1
IA 1
10
tJ ^
0) 1
1-
5 ^
U> 1
c
o
u
<
a>
•
•a
r— <
3
o
U <
<
tft

*5i *
o •*
r— (
o
c
JZ »•
u c
a> c
+i
V
tn
a*
f
•K t-
.338

-------













03


§
t-


UJ
t/1

0
w



°£
g
^J




fr™
3

o
CL.
f*
UJ
i
0£
£
U
8
S3
H-l
Of
UJ

»— 1
to
2

o

!-•
H-
O

CO


UJ
CO

1-
















c. 'sT
4J-,- >,
O +J \
0) 10 in
S. S--
•i- 01 O
0 0.0
O o

(O 1— >M^
•u m
0 3 *»
1— c in
CO
 tooin i mensem
o» m «d" o to rH oo
CM CM en 10 to co
CM . CO |v.



^

.£? * § 2
i. 01 *J E ro
S> C *J t.
os- * o> « , ui-r-ioi— 
o, .^ *> +> s. v- o) -o

"* "e: !/? §5 1o « *"" 2 cu *>
s- o s- s- r- i- ra ra
^ M o5o oL^'w o ^

<3t S5gu|.S*i2wog
o «Jiti^^i2I3:.5 oi^t1"
M O3+>i— iZ+Jc'ov- 3 C

!


1
1








;








1

'
, .



*
£ i
+> .
c '
o
u

c
o
4j ;

r~
O
PL
C
10
5
i
S.
4J
10
s-
tn i
in
01 I
u :•
£ S.
O. 3
0) >>
J= J3
*" .Q
4* at
o -p

a £
Q. O.
U) C
10 O
^ 1o
1 1
in c
C "r-
o
0 C
o
01 '
.£3 T3
O)
•a in
r— 10
3 .a
o
u in
0) IO
'5, 5
o +>
i— in
o ai
c
O Q£
a> a
a> ••
tn ai
£ 3
o
« to
339

-------
















V)
UJ
ft
5
S
**
s
£
1
Ul
IS
s
8,-^
—J M
jjjl
°• *J  fxj -f— *r- £ C
So* -*-» s u >— i u» s- no
e = J= •»-> W -J yj *J >r-
o >c o o c i"™ w ai v) c +*
os o+3a>r- ca t-oiow
a ••-> — oj e o < a. - c -r- +j
>- to  c a wi =3 c s. g o>
Hi (»• re <^ 4^ t/>*^m E 
eg

t8
C.
A

U
OJ
s. o
CX. CM




Activity
;
i



.



!




V
• k
••* •
'S
•«tf
CO
'CO
§
co"
ass
rH en |^
CM :00*
CM co 'in
rH rH L0)
rH co ;cn
CM" ;^

CM m [co
a s !?
CM [rH
a 3 i
CM rH
CM cn ico
rH rH O>
CM 'rH

* S S S

- *i ti « -2 SIS: -o
CSCt—  4J E U »-t(A£- fO,O
— J e 3 j= •»-> w _ju>+» v-
o .c o o c f— t-i aj vj cr 4^
S 5 - -Si o § k .g 5«
5 3 g °l °i te §• gr «i§,
r* to E 
U O 1 O S O >i O +* ^3 •"• r*> 4)
g.c= S ciS cv?S « Bo ua
a:cc3c£ ce fe a o a
ui to i




































i
%
•o
5
1
•i §
Rt -P
{- ra
01 E
§* o
Ifr.
s. e
> T3
ti S
S- A
c s
01 4J
5 |
f |
t. OS
1 =
a 1
0 0
S vi
340

-------
requirement  is  prorated.   Additional  costs incurred  in  the start-up period
were  spread over  all production  in order  to  produce a  uniform per-barrel
control cost.

     The  total  annual  required revenue  is  utilized to  satisfy two  major
components:  the total  annual  operating cost, and  a  component that provides
the necessary return  on investment, called  the total  annual capital charge.
Note  that  with the  DCF  approach,  profit  is  based  solely  on  investment;
operating  costs are passed  straight through as  one component  of the total
revenue requirement,  without addition of any profit element.  This is normal
practice for industrial project assessments.                  •   i

     To  relate  an  annual  capital  charge  to the  correspond!ng, investment,
a  "capital charge  rate"  was  used.   In  practice,  there  are two  types  of
capital  investment:  fixed  capital   (i.e.,  physical  equipment) -and working
capital  (which  is  nondepreciable  investment).    The "fixed charge  rate"
is  defined as  the  proportion of  investment in  fixed  capital that  must  be
recovered  in  a year  of normal production  in order  to provide the required
DCF ROR.   The  "working capital  charge  rate"  performs  a  similar  function
for the working capital.  The total  annual - capital  charge  for, a pollution
control is  the  sum  of the annual  fixed capital  charge and the annual working
capital charge.                                                   :

     Fixed  charge rates have several economic assumptions  embedded  in them.
Some  of these  assumptions are common  to  all pollution  controls,  i.e.,  the
project life  and operating  (stream) factors, the  income tax rate,  and  the
required DCF ROR.   (Although the MIS and Lurgi  production schedules build up
at  different  rates  in  Years 1  through 7,  a  single aggregate  production
schedule  was  used  for all  cost analysis calculations.   This appropriately
treats  the  project as  an  integrated  whole,  rather than  as two  separate
parts.)                                                          ;

     Other  assumptions  vary  according  to  the pollution controller  group  of
controls.    These  are:  the  timing of  the  investment in  fixed Capital,  the
depreciation  period and  the  investment  tax credit  details.   Consequently,
different  fixed charge  rates are  used  for different groups of  pollution
controls.*   (These  rates,  as  well  as   the underlying  standard  economic
assumptions, are listed later in Table 6.2-2.)                   :

     The working  capital   charge rate depends only on the  project  life  and
operating  factors,  the timing of  the investment in working capital  and  the
required DCF ROR.   Since none of these assumptions varies  among controls,  the
sam« working capital charge rate is used for each control.
  The  use  of  several  different  fixed  charge rates  in  the same  oil  shale
  PCTM  may  appear complex.   However,  since  the  manuals  examine  several
  alternatives  for pollution  control,  an  accurate  evaluation of  capital
  charges  is  needed.   A  less  accurate  approach,  such as assuming a single
  capital  expenditure  profile  for  all  controls,  could conceivably  affect
  the per-barrel cost ranking of pollution control alternatives, j

                                     341

-------
     As  already indicated, the total annual cost  for a  control  is the  sum of
 the  total annual  capital  charge and  the total annual  operating cost.  The
 total  annual  operating cost  comprises  two components.   The "direct  annual
 operating cost" consists of maintenance,  operating  supplies,  operating labor
 and  utilities.   The "indirect  annual   operating  cost"  comprises  an  annual
 allowance for  property  taxes  and  insurance,  any  annual by-product credits,
 and  an allowance for extra start-up costs,  i.e.,  those  that  are in excess of
 the  direct annual operating cost prorated in  accordance with production.  J[t
 also includes a credit  reflecting  a reduction in  the Colorado  severance tax
 that, must be  paid,  because the  cost  of  each pollution control [reduces the
 severance tax liability.*  Extra start-up  costs and the severance tax  credit
 are  "levelized" to  distribute them uniformly  over  each barrel  of shale oil
 produced since they  do not vary  in proportion to  production.   '(Levelizing
 takes  a  cost  that does not  vary  in proportion  to production  and finds an
 economically equivalent  cost  that has  the same  time-profile as production
 [see Sections  6.2.3  and 6.4.3].)  To summarize:

     Total Annual  Control  Cost = Annual  Fixed  Capital Charge  + Annual
     Working Capital  Charge +  Direct Annual  Operating Cost +  Indirect
     Annual  Operating Cost.

     For air and water  pollution controls,  direct annual operating costs are
 specified for a normal  year of production and are implicitly prorated  during
 the  start-up years.   In practice,  operating costs during the start-up  period
 will   be higher,  but  this  is  allowed for  via  the   extra  start-up  costs
 discussed in Section 6.2.2.    The solid  waste  management costs  are developed
 in  the form of a  year-by^year cash flow (see  Table  6.1-4) which must be con-
 verted into  equivalent  fixed  capital and direct annual  operating: costs for  a
 full production year (see  Section 6.2.3  and Table  6.2-3).

     The per-barrel   control  cost  is obtained by  dividing  the  total  annual
.control  cost  by  the production  in a  normal  (full  production) year.   (Per-
 barrel  operating  costs and  capital  charges  can  be calculated in the same
 v/ay.)    The  detailed algorithms  for  these  calculations and for determining
 fixed  and working capital  charge  factors are given in Section 6.4,1.

 6.2.2   Economic Assumptions Used  in Total  Cost Calculations

     To transform engineering cost data provided  in Section  6.1.2  into total
 annual capital charges,  total annual  operating  costs, and  total  annual or
   The distinction between  the two components  of operating cost is made  for
   convenience in  performing the  calculations  and  is  not fundamental.   The
   direct annual  operating cost is  comprised of basic cost elements,  whereas
   the indirect annual operating cost  comprises a series of adjustments that
   are influenced  by  other factors,  such as tax assumptions.  Direct annual
   operating costs for  each control  are given in Tables 6.1-1,  6.1-2,  6.T-3
   and 6.2-3.   Indirect  annual  operating costs for all  controls are  calculated
   using a standard algorithm  (see  Section 6.2.2), except for  any  by-product
   credits which  are  given in Tables 6.3-4 and 6.3-5.

                                      342                         :

-------
per-barrel control  costs,  a number of economic assumptions  were made.   Most
of  these  assumptions are  listed in Table  6.2-1,  and Table 6.2-2 summarizes
those  assumptions  that vary  from control  to  control.   The  values  given In
these  two  tables are  the  standard values,  known as  the  "standard economic
assumptions,"  which have  been  used  for the cost analyses  presented in the
oil shale  PCTMs.   Some of  these are varied in the sensitivity analyses which
are used to show how control costs change in response to alternative economic
assumptions and to changes in the engineering costs.

     Where  appropriate,  the  standard  economic   assumptions  arie  discussed
below.  Others are  discussed in connection with  the  sensitivity analyses in
Section 6.3.2.                                                   ,

     Timing of Control Capital Expenditures—

     Table 6.2-2  includes  the  fixed   capital  expenditure  profiles  for each
category of  control.   A construction  schedule was developed  by  DRI  based on
data  supplied by  Cathedral  Bluffs Shale  Oil  Company  (November ;14,  1980).*
Engineering judgment was then used to determine when  the  pollution  controls
would  be  procured  and  installed,  incorporating the  impact  of payments made
during off-site  fabrication.   In  general,  capital expenditures  on  controls
tend to be incurred later than those for most retort construction activities,
since the controls are usually among the last items to be installed.

     An unusual  factor  in  this PCTM is that completion of the five trains of
MIS retorts  takes  place over four years, while completion of the: eight Lurgi
retorts occurs  over  a period  of five  years  (see Section  1, Table 1.4-1).
Since  a  separate  air  pollution  control  unit  is  associated with  each MIS
retort train  or  Lurgi  retort,  this means that the individual units  will be
placed in  service  over a period of four or five years.  Therefore, deprecia-
tion  is  similarly  apportioned  for calculation of fixed charge  factors.  In
contrast,  all water management equipment, except the kettle evaporators, will
be placed in service prior to the operation of the first retort,  i Consequent-
ly, the same  timing is used for all water management controls,  leading to a
single capital recovery factor for all water controls  other than the kettle
evaporators.**
* These data do  not necessarily represent the current plans of the Cathedral
  Bluffs Shale Oil Company.                                      '•

**In other  oil shale  PCTMs4  site water  management equipment  (e.g.,  clari-
  fiers) has been assumed to be installed early in the construction schedule,
  whereas other water  management  equipment (e.g., the ammonia recovery unit)
  has been  assumed to be  installed at  the same time as the  retort air pol-
  lution controls.                                               :
                                                                 i
                                     343

-------
                       TABLE 6.2-1.  SUMMARY OF STANDARD COST AND ECONOMIC ASSUMPTIONS
                                                 Assumptions
COST ASSUMPTIONS.                                                                          ;
•    Base Year:  Mid-1980 dollars                                                         \
•    Basic Labor Rate:  $11.00/hr*    '                                                    ;
•    "Loaded" Labor Rate*:  $30.00/hr                                                     :
•    Fixed Capital Costs:  25% engineering and construction overhead and 3% contractor's fee included*
•    Contingency Allowances:  20%, all fixed capital costs*                               i
                               0%, roost operating costs*
                              20%, solid waste direct operating costs
ECONOMIC ASSUMPTIONS
•    Project Life:  30 years, including 7-year start-up period                            |
•    Normal Output:  117,100 Barrels per Calendar Day (BPCD)                              ',
•    Proportion of Normal Output During Start-up Period:
          Year 1      -   2%            Year 5-68%
          Year 2      -  10%            Year 6-77%                                ;
          Year 3      -  28%            Year 7-80%
          Year 4      -  47%            Years 8-30  - 100%                                ;
•    Approach:  Discounted Cash Flow Evaluation (DCF)*                                    ',
«    Discount Factors:  Discrete,* year-end basis                                         ;
«    Method:  Determination of Revenue Requirement .to provide specified DCF ROR*
•    Technique:  Annual Capital Charge plus Annual Operating Cost                         1
•    Required OCF ROR:  12% (100% Equity Basis)*                                          j
«    Cost Escalation:  None (constant dollar evaluation)*
*    Combined State and Federal Income Tax Rate:  48%*                                    i
*    Depreciation:  Method  -  Sum-of-Year's Digits*
                    Period  -  16 years, most items*
                               10 years, solid waste area
                                5 years, mobile equipment
0    Investment Tax Credit:  20%, most items*                         .
                             13 1/3%, mobile equipment
«>    Additional Start-up Costs-.(spread over Years 1-7):  3% of fixed capital, plus 50% of a normal year's
     direct operating cost    ••-••••
»    Working Capital:  30 days' total operating cost (excluding by-product credit), plus 60 days' by-product
     credit                .               '.       .  .
«    Annual Allowance for Property Taxes and Insurance:  3% of fixed capital
»    Colorado Severance Tax:  Credit allowed                                              ;
«    Timing of Investment:  Initial fixed capital expenditures can occur in Years -3 through +5;
     expenditures and tax considerations for each control are phased  in accordance with the construction
     and initial operation of each control (see Table 6.2-2 for schedules)
»    Corporate Financing:  Tax credits and allowances can be passed through to a parent company that can
     benefit from them immediately, without waiting for the project to become profitable*
o    Federal Depletion Allowance:  Does not affect pollution control-costs                i
•* These methods and factors are in accordance with the recommendations, dated April 22, 1980, of EPA's
  ad hoc synfuels cost committee.                                                         '
Source:  DRI.                                                                        •     ;
                                                    344

-------














g
p
f
o
o
g
cc
u.
i
!•-
jj=

1?
1
u
1
UJ
CM
B
CM
UD
UJ
i
















Q
re
b;
re

w
i
x
**•
u.


c
o
re
u
£
Q



^
1
X
re
r-
|
«
 «* CO •*£
fH rH CM CM


«e»* CM CM CM rH rH CM CM CM

???¥ ?5??¥¥ ? ?

rererere re « m re re re re


to to to to
rH fH iH rH


•Q *** ,O XJ
(A i— O»r— U>r- (A r—
rere rere rere, rere
£ ** ** **
SI" Is #t 5s




CM CM CM CM



rH rH CM rH CM rH ' f— t rH CM CM rH rOQ'CM rHCMin.CM


CM rH O rH CM CO «*• rH O rH CM CO ^ tn CO CM rH O ->•>•>->->->- >->.>.>.>.>.>. >->•>•>• >->.>->.

(A
* >4
I , £
o a.
*»- IA
o *T e
•as. c re
Q) 4^ Ql fll O
+j tn i— w * - e >4_
re*» ait- g. •- (A
••--*> #— O f-« O 13 »—
u>u*a> a +j as- s. c o
co^£ -a ra 0*0 ** m s-
•r-W». ,O*J O) -«3 C 4->
re w •*• * £ »r» re o t» c

>>cnf— "a "o .Q ai o. ai re
v)i— co- .£-01.0 . em +J 5 c
i-H «r- f- O * 3 .*• 3 • O) > re O
Z ft. 4J U -J0.fi. -DIO) P- » ja
re i--x o *J re 3 « t.
i E o t- row • - c c aj o t. re
•^4^C» »r- O) (T3 •— *r-fll O
'O! S_ 4) jQ Ul O +* 4^ S £ •*-* +J 4^ O
CO. Si:*: Creg ffl^+J J.'r- °
•f- oo •*-4J*3t a (- o re-«- -a
f ._ KH .a re .^.Q^. c^ £
4-> 4-» JT * o. 4^ u *» a> o *s^ -2
fi-,C4Jore £.oic s- ^- o c ja c
o o **"" o > o *~* o> oi r— x i~ re o
a « S E 1


co o :
r-» CM
C3 OD
CM in


BifeSB8
.
rH CM CO CO "*• O ID
1 4- 1 + rH CM CM

>I ^>! >i>i>!>i


rH • m tn in in in in

linn

WIT- CM «..» «S- 0 <0
"5 • *. + ?¥¥
rere rererererere
(/i U at at at at at at
>- >- >• >- >• >•

T» [
5^

O CO
CM rH
i

'
roj§ IcfMMcfo

1

1 I -r + rH rH CM
rere rererererere
>• >• ^ ^ >- >• V >-

'

,
o

- ®
!i :
a.
a .
re tA /-N
2 a *» :
O > U C i
4J r— (A Ol <
M re -S- €
re* 5 .? I
f-i<»- t. 3
co at o* :
E O O •— ' '
~re c o o>
re u>
T? C U (U
C 01 *f +*- '
«« « -o
il | s :

345

-------
                  i
         +

         i
                              u> t—
                              «£
«M
 t
e\i
u>

a
?!
        £
        5
                   I     i

                   i      I
                   C i—
                     J-4-*
                     a
                     0
i—   as
-4-*   C
a   ro
0  E
                   El  I
                                                 -   i.
                                        •8   2

                                        t   £
                                         S   Q.
                                             X   E
                                             fO   N—
                                         85^
                                                      g   S
                                                              346

-------
     Assumptions  for Taxation*--

     Depreciatlon.   All  oil  shale  PCTMs used  a 16-year depreciation period
 for  most  assets.   This  corresponds  to  the  mid-point of the  IRS1  Asset
 Depreciation  Range (ADR)  guidelines  for oil  refineries.   In practice, many
 companies  would  use  the  lower end  of the  ADR  range,  which  is 13 years;
 however, it has been found that this would make  very little  difference in the
 results of the analysis.                                         |

     Some  equipment clearly qualifies for a  shorter  life.   Controls associ-
 ated with  processed shale  disposal,  such as  embankments  and water impound-
 ments,  were  regarded as mining equipment, for  which  a 10-year idepreciation
 period  was  used.  A  5-year  depreciation  period  was used for  the  mobile
 equipment, and  it  was  assumed that  this  equipment was  replaced five times
 during the project  life.                                         ;

     The  depreciation  method  used for  all  taxation  calculations was  the
 Sum-of-the-Year's Digits method.

     Investment Tax Credit (ITC).   A  basic  20% ITC was used for jail items in
 accordance with the Energy Tax Act  of 1978 (PL 95-618).  The mobile equipment
 has  a  depreciation period  of only  5  years,  so  the  credit  is  reduced by
 one-third, to 13 1/3 percent.                                    !

     Where payments for a  control  extend over  more than one year,  the  tax
 credit can be taken as the  capital is  expended, in accordance with the IRS1
 progress payments rule.   Otherwise, it is taken when the asset is: placed into
 service.                                                         i

     Income tax rate.  A combined State and Federal tax rate of 48% was used.
 In practice,  Colorado has  a 5% tax  rate,  so the  effective percentage rate
 should be:   5 + ([1 - 0.05] x 46) = 48.7%.   The error introduced by using 48%
 is negligible.                                                    ;   •

     Depletion allowance.   The  Federal  depletion allowance  has  not  been
 incorporated into the calculation of taxes.   The justification for this is as
 follows.  The percentage depletion allowance  is 15%  on  the- "gross  income"
 from an oil  shale property.   In this case,  since the sales or transfer price
 of shale oil (and,  hence,  gross income) is independent of pollution control
 costs,  the depletion allowance will not affect  those  costs.  However,  there
 is a limitation that  the percentage depletion allowance cannot exceed 50% of
* All analyses were conducted prior to enactment of the Economic Recovery Tax
  Act of 1981  (PL 97-34).   As far as an  oil  shale project is concerned, the
  main  impact  of  this  act is  to  permit very  rapid depreciation  under the
  Accelerated Cost Recovery System (ACRS).   Using ACRS, most property would
  be depreciated  over 5 years and mobile equipment would be depreciated over
  3 years.   A rough  estimate  of the effect of the provisions of the Economic
  Recovery  Tax  Act of 1981  on the  pollution  control  costs  is  given  In
  Section 6.3.1*                                                  !


                                     347

-------
the  taxpayer's  taxable Income from the  property,  computed without allowance
for  depletion.   Since  pollution  control  costs  reduce the  taxable income,
they could  affect  the depletion allowance if  it  was limited under the above
rule, and this would then be a cost attributable to pollution control.  While
this might  well  be the case  in  a start-up year,  it  appears  that this limit
is  unlikely to  apply  during a  normal  year's  operation.  This  is because
the  complete project's  total annual  operating  costs  are a  low proportion
of its  total  annual  costs,  including capital-related costs (DRI calculations
based on  data provided  by  Cathedral Bluffs Shale Oil  Company [November 14,
1980]).                                                           :

     Hence,  the .impact  of  the  Federal percentage  depletion allowance  on
pollution  control   costs  has been  disregarded.   This  may  introduce  minor
errors during start-up years, but complete project cost data are not publicly
available to permit the effect to be calculated.  Cost depletion,  which might
at times be taken  instead of percentage depletion,  is  clearly irrelevant to
pollution control costs.

     Other Assumptions—                                         ;
      -                                                          i
     DCF ROR.  Twelve  percent (per year)  was used  as  a standard assumption
(see Section 6.3.2).                                             i .

     Project life and start-up profile.*   The  MIS-Lurgi  project1 is  unusual
in that there  is a very long build-up period of seven years before full out-
put  is  reached.   (This slow build-up largely  results  from the nature of MIS
retort  construction.   Retort development occurs continuously,  arid  it is not
feasible to bring  all trains  of  MIS   retorts into  production at  the same
time.)  For this reason,  a  project life of  30 years, i.e., 23 years of full
production, was  used.**   Furthermore,  the  production build-up profile is not
concurrent  between  the MIS  retorting  and the surface  (Lurgi)  retorting,  as
the  latter  generally  achieves a smaller proportion  of  its ultimate capacity
in any one year.                                                  ;.

     The  production   schedule   for  the  MIS-Lurgi  project   is   given  in
Table 6.2-1.  This schedule involves a change of mining plan in Year 8, which
results  in  a  significantly  higher  grade of  shale  being fed to  the  Lurgi
retorts.t   However,  only seven  out of eight  Lurgi  retorts will;be operated
at any time.  In Year 8, the MIS operations change from operating four out of
five trains at any one time to operating all  five simultaneously.'.  All equip-
ment associated with the MIS operations is  designed 25% oversize,; which in an
emergency would permit four trains of process and control equipment to handle
the  normal  output of  five  trains.  Because of this redundancy,; evaluations
* This section  is based on  data provided by the Cathedral  Bluffs  Shale Oil
  Company (November 14, 1980);  however,  these data do not necessarily repre-
  sent the company's current plans.
                                                                 !
**C.f. 20 years in total for the PCTMs on other oil  shale processes.

t This is termed  the  "Phase II mining plan" in the Cathedral Blujffs project.


                                     348

-------
have  been made,  as  proposed by  Cathedral  Bluffs,  without incorporating any
additional  operating  (stream)   factor  for normal  production  years  (i.e.,
Year 8 and beyond).*

     Components of Annual Indirect Operating Costs—
                                                                 i
     The annual indirect operating cost  is  composed as follows:  ;

          Annual property tax and insurance

          + Extra start-up costs (levelized)

          - Severance tax credit (levelized)                     :

          - Annual by-product credit (if any).
                                                                 i
     Property tax and insurance allowance.   The  annual  indirect  operating
cost includes  3%  of the fixed capital cost as an allowance for property tax
and insurance.  This value was selected by DRI after review of a wide variety
of sources.
                                                                 !

     Extra start-up cost.  The total extra  start-up cost (which i£ treated as
an operating cost, as opposed to being capitalized) is derived frbm the fixed
capital and direct  annual  operating costs.  The capital-related component is
3%  of the  fixed  capital  cost  as an allowance  for "fix  it" 'costs.   The
operating  cost-related component,  which  is  50% of  a normal  year's  direct
operating cost,  allows for  hiring and  training  employees  before production
commences and for higher unit costs during the start-up period.

     A standard value  for  the  extra start-up  cost  for surface  retorting
plants with  a 2-year* start-up period  was selected by DRI after  a  review of
several sources,  including estimates  for TOSCO II (Nutter and Waitman, 1978)
and Paraho (Pforzheimer  and  Kunchal,  March 24, 1977) plants.   This value was
3% of  fixed  capital cost and 20% of a  normal year's  direct  operating cost.
Because of the  long start-up period for the MIS-Lurgi project, the operating
cost-related portion was increased from 20 to 50 percent.   This is in reason-
able  accord  with  the developer's  estimate (based on  DRI  analysis of  data
supplied by the Cathedral Bluffs Shale Oil Company [November 14, 1980]).   The
extra start-up  cost  was  assumed to be incurred over the 7 start-up years but
is levelized  to spread  it uniformly  over every barrel of oil  produced  (see
Sections  6.4.1 and 6.4.3).                                        :

     Severance tax credit.    Under  Colorado   HB 1076,   enacted'   in   1977,
severance tax  is  levied  on the production of a commercial oil shale facility
at the rate of 4% of the "gross  proceeds"  for surface retorted oil, reduced
to 3%  for oil produced by in  situ methods.  "Gross proceeds"  is  defined as
the value  of  the  oil  shale  at  the  point of severance and is  calculated by
subtracting Costs (e.g., retorting and mining) from the  gross  sales income.
* Other oil shale PCTMs use a 90% operating factor (i.e., the ratio of actual
  annual production  to maximum  production based on  continuous  operation at
  full output) in normal production years.


                                     349

-------
Since  pollution controls  add  to costs, they reduce  the  gross proceeds by a
corresponding  amount.   Hence,  a credit for  severance tax not paid should be
deducted from  the pollution control costs.                       ;

     While  operating  costs  are  clearly  allowable  in  calculating  gross
proceeds,  return on  capital  does not  appear to  be  (the statute  refers to
allowing   "...costs,   including   direct   and   indirect   expenditures  for:
(a) equipment  and  machinery	").  Hence,  when this credit is! calculated,
the capital  charge  must be replaced by some form of amortization.  For this
analysis,  the  severance  tax  credit  calculations  are based on|  direct  and
indirect annual operating costs, plus 5% of the fixed capital cost to provide
a crude capital amortization.

     In applying this  credit,  allowance was also  made  for exemptions to the
tax for  the first 10,000  barrels  per  day of production  and for plants that
have not achieved  50% of their design  capacity,  together with reduced rates
of  tax in the early  years.  The  credit  is levelized in  order  to achieve a
uniform per-barrel  cost.   The methodology  utilized  (LFAC2 in Sefction 6.4.1)
is not precise, but since the severence tax correction is typically less than
2%  of  the  total  annual  or  per-barrel  control  cost (see Secition 6.2.4),
further refinement is not justified.*                            :

     By-product credits.  The by-product  credit  (if any) for each control is
shown  in  Tables 6.3-4  and 6.3-5.   (There  are  no salable  by-products  from
solid  waste management.)   By-product  values  of  $110 per ton  for  ammonia,
$30 per long ton for sulfur, and $32 per barrel  for oils were used.
                                                                 i
     At present,  there  is no  significant  market for  sulfur in  the Rocky
Mountain Region;  in the past,  shipping costs  to move recovered sulfur  to a
chemical complex could  have been greater than its delivered value.  However,
the price of  high  quality sulfur has gone  up  substantially  in recent years,
reaching values as  high  as $129 per long ton  (U.S.  DOI,  August 1981).  High
demand for  sulfur  is projected through the year 2000 (Rangnow  and Fasullb,
September 28, 1981).   Hence, a nominal  $30 per long ton has been included for
recovered  sulfur.   However,  if  in  the  future  a  sulfuric  aci<$  plant  and
fertilizer complex are developed in the area, the values  of by-product sulfur
and ammonia would be raised.                             ' •   ~    j
                                                                 - i
     Working Capital—                                           i

     The working capital associated with  a control was taken as:one month's
total   operating  cost  plus  three  months'  byproduct  credit.    This  is  equiv-
alent  to  be  one month's  total operating  cost  disregarding  the  by-product
* Since this analysis was conducted, the Colorado Legislature hasiamended the
  severance tax  legislation pertaining  to  oil shale.  While the  basic rate
  for aboveground  retorting is  unchanged,  the various  exemptions discussed
  above are  reduced, and  the  reduced rate  for in situ  retorting is  elimi-
  nated.    This  will  result in  plants paying  slightly more severance tax,
  which marginally increases  the  severance  tax credit, thereby  marginally
  (less than 1%) reducing the pollution control cost.             ;

                                     350

-------
credit,  plus two  months'  by-product credit.   Two months' by-product credit
represents  one month's inventory and one month's receivables.  These values
were selected by DRI after review of a variety  of data sources.

     Working capital  is advanced in accordance with  the direct annual oper-
ating cost plus the extra start-up cost,  as follows:
Year 1
Year 2
Year 3
Year 4
Year 5
Year 6
Year 7
Year 8
Percentage
of Normal
  Output
     2%
    10%
    28%
    47%
                     Extra Start-up Cost
                      as Proportion of a
                   Annual Operating
                   Cost Relative to
                     Normal Year's Direct   a Normal Year's
    77%
    80%
   100%
Operating Cost

      5%
     10%
     10%
     10%
      5%
      5%
      5%
                             50%
Operating Cost

       7%
      20%
      38%
      57%
      73%
      82%
      85%
     100%
 Working
 Capital
Increment
                                                         100%
     Seven percent of the total working capital is advanced in Year 1 because
the  annual  operating cost  comprises 2%  of the normal  year's direct annual
operating cost  and  there is a 5% extra start-up cost.  In Year 2, the direct
annual operating cost is 10% of a normal year, but the extra start-up cost is
also'  10% of  the  direct annual  operating cost, for  a total  of;20 percent.
This  is  13%  more than  in  Year 1,  so  13% of the  total working  capital  is
advanced in this year.  And so on until Year 8, by which time all the working
capital has been advanced.   Working capital is recovered in Year 30.

     The working  capital charge rate (RW)  is  calculated  in a similar way to
a  fixed  charge  rate .(see  Sections 6.4.1 and 6.4.2).   For 12% iDCF ROR and
normal project-timing assumptions, RW = 21.80%.                  ;
                                                         '        '
6.2.3  Solid Waste Management Costs                          '    '.

     Throughout this manual  a distinction is made between fixed capital costs
and annual operating costs.   The importance of this distinction is related to
the treatment for determining  income tax liability.  Operating  costs  can be
claimed as an expense in the year in which they are incurred, whereas a fixed
capital  cost  must  be  depreciated  over  the  period  for  which the  asset  is
expected to be  used.   The  effect of classifying a  cost as an operating cost
rather than a capital  cost  is to reduce the tax liability in any given year.

     For  air  and water pollution  controls,   the  distinction between fixed
capital and annual  operating  costs is unequivocal.   For  solid waste manage-
ment  costs  which are  developed  in  the  form  of year-by-year  cash  flows
(Table.6.1-4),  the  distinction  is  less  clear.   Costs  that  occur in  only
Year 1 (the  runon catchment dam and  low-level  outlet)  or  Years  1,  2 and 3
(the runoff catchment  embankment)  were treated as  fixed capital  Costs, while
those that continue  for 25  or more years were considered as operating costs.
                                     351

-------
 Costs  that occur  at the end  of the  project (e.g., revegetation) were also
 treated  as operating  costs,  since there  is no  remaining project life over
 which  to depreciate  them.                                        ;

     Since the solid waste management  operating costs are  not proportional to
 production,  they were  "levelized"  to transform  them into equivalent direct
 annual operating costs that are proportional to production, so that they can
 be  treated in the same way as other  direct annual  operating costs.  Level-
 izirig  involves determining the annual  cost that is proportional to production
 and which-has the same present value  (for a given  DCF ROR) as the irregular
 operating  cost stream.   Further  explanation and an example are provided in
 Section 6.4.3.  Costs designated as fixed capital were not levelized.

     Table 6.2-3  presents  the  solid  waste  management  fixed  capital  costs
 and direct annual operating  costs (levelized  at 12% DCF ROR)  derived from
 Table  6.1-4.                                                     !
        TABLE 6.2-3.  FIXED CAPITAL AND DIRECT ANNUAL OPERATING COSTS
                         FOR SOLID WASTE MANAGEMENT              i
Activity
   Fixed
Capital Cost
  ($000's)
 Direct Annual.
Operating Cost
  ($000's/yr)
                                                                           a
SURFACE HYDROLOGY

   Runon Catchment Dam and
     Low-level Outlet

   Runoff Catchment Embankment

  'Runoff Collection System

SURFACE STABILIZATION

   Dust Suppression

   Grubbing, Stripping and Clearing
   Reclamation and Revegetation
    4521

    460£
                           51
                        1,948

                       !   483

                          250
a
  The direct annual operating costs are levelized with respect to'production
  at 12% DCF ROR.                                                i
  Spent in first year of production, Year 1.

c Spent uniformly in Years 1-3.

Source:  DRI.
                                     352

-------
 6.2.4  Control Cost  Example

     Table 6.2-4  provides  an  example  of the  composition  of  the various
 elements  of  per-barrel  cost for a single  major pollution control, the Stret-
 ford system.   Per-barrel  costs follow identical proportions to annual costs.
                                                                 i
                                                                 i
        TABLE 6.2-4.  PER-BARREL COST BREAKDOWN FOR STRETFORD SYSTEM
                (Standard Economic Assumptions, Case Study B)
Cost Category
Cents/Barrel
Percentage of Total
Fixed Capital Charge
     Equity Return (12% ROR)
     Income Taxes Paid
     Investment Tax Credit
 84.3
 23.7
(16.9)
                                             91.1
    55.0
    15.4
   (11.0)
                                 59.4
Working Capital Charge
          1.3
             0.9
Direct Operating Costs
     Maintenance
     Operating Supplies
     Operating Labor
     Cpoling Water
     Steam
     Electricity
 10.0
  8.8
 21.9

  1.3
  6.0
     6.5
     5.7
    14.3;

     0.8
     4.0;
                                             48.0
                                 31.3
Indirect Operating Costs
     Taxes and Insurance
     Extra Start-up Costs
     Severance Tax Credit
     By-product Credit

          TOTAL COST
                          9.3
                          3.2:
                         (1.5)
Source:   DRI.
                                     353

-------
      It  can be  seen that  the  fixed capital  charge  amounts to 59.4% of  the
 total  cost, whereas the working  capital  charge  is  only 0.9%  of; the total
 cost.   It  is  interesting  to  note that the  fixed capital  charge! is almost
 entirely  return  on  equity,  as the  investment tax credit  (20% of  fixed capital
 cost) almost offsets the  income tax  liability  over the project life when both
 are  discounted at 12%, which is the specified DCF ROR.  This illustrates  the
 effect of the  time-value of money,  as the tax credit is given before produc-
 tion  commences,  whereas  the  regular  tax  liability is weighted  toward  the
 later years of the  project.

     The  direct  operating costs for  the Stretford  system make up 31.3% of  the
 total  cost.   Operating  labor  (14.3%)  is the  largest component, followed by
 maintenance, operating supplies and  utilities  (electricity and steam).

     The  indirect operating costs amount to 8.4%  of the total  cost for this
 control,  of which 9.3% results from the cost  of property tax and insurance.
 There  is  a by-product  credit of 2.6% of  the  total   cost,  and  the  extra
 start-up  costs and the severance  tax credit are 3.2% and 1.5%, respectively,
 of the total.                                                       ;

     These cost  proportions for the Stretford  system are typical ofi those  for
 air  pollution  controls.   However, for some  controls,  the indirect operating
 cost or even the per-barrel control cost can become negative where there is a
 significant by-product credit.

     Water  pollution control  costs tend to  be less  capital-intensive,  i.e.,
 the  ratio of   the total  annual  capital  charge to  the  total  annual i operating
 cost is lower.    This is because some controls  have high utility costs.

     Solid  waste management costs  are  different  in that  they  are: basically
 either a  fixed capital  cost or a  direct annual  operating cost, but not both
 for  a given   control.   This  reduces working capital  and  indirect  annual
 operating costs,  respectively,  to essentially zero.

 6.3  COST ANALYSIS RESULTS

     The  methodology used  to  develop  the  data presented  in this  section is
 identical to a complete  discounted cash flow  evaluation;  that  is,; it solves
 for the annual  or per-barrel revenue required to provide the specified return
 on the investment (DCF ROR) associated with a control.   This revenue require-
ment  is   known  as  the  total   annual  or per-barrel  control  cost.   The  cost
methodology is outlined  in  Section 6.2,  and further  details are provided in
Section 6.4.1.                                                      !

     Three control  items—proper  maintenance  of  valves and pumps,  floating
 roof oil  storage tanks,  and  the   MIS absorber/cooler—have  relatively  large
by-product  credits  which lead  to negative  total  annual  costs  (ij.e.,  total
annual cost credits).   Although  these  items might consequently not  be  con-
sidered pollution controls, the costs  of all three have been included in the
total cost of  air pollution control.  The  net credits associated wHh proper
maintenance and  floating roof oil  storage tanks  combined  represent a  very
small proportion (less than 0.4%) of  the  total air pollution  control  cost.

                                     354                           !

-------
The net credit for the MIS absorber/coolers, however, is quite large (29% for
Case  Study  A  and 37%  for Case  Study  B  of the total air  control  cost under
standard  economic  assumptions).    In  some  of the  more  severe  sensitivity
analyses  considered   in  Section   6.3.2,   the  total  cost   for  the  MIS
absorber/cooler  actually  becomes   positive  (as increased  annual  capital
charges  become  large   enough  to  offset  the  annual  by-product ,  credit  for
recovered shale  oil).   This  is one  reason  for including the cost of the MIS
absorber/cooler in the total  pollution control  cost.              •
                                                                 i
6.3.1  Results for the Standard Economic Assumptions*

     The term  "standard economic assumptions"  is used to describe the normal
economic assumptions  presented in  Tables  6.2-1  and 6.2-2.  The  majority of
these  assumptions  are  in  reasonable  accord  with   normal  engineering  and
economic evaluation practices.   The most critical economic assumption is that
of 12% required DCF ROR.  This figure was adopted for the oil shale PCTMs and
would be  appropriate   for a  mature  industry,  but it is probably  low  for a
pioneer plant  at  this  time  (see Sections 6.2.1 and 6.3.2 for a discussion of
factors influencing the selection of a DCF ROR).

     Table  6.3-1 provides  a  summary  of  pollution  control costs developed
using the standard  economic  assumptions  for the  two  case  studies  considered
in this manual.   Table 6.3-2  provides  additional detail based on the control
groupings listed in  Table  6.3-3.    Note  that total  costs  for solid  waste
management are not  provided.   A complete solid waste management plan for the
MIS-Lurgi project  has  not been  proposed.   As  a result,  cost  estimates  are
available for particular items only, and no estimate of the total 'solid waste
management cost can be made at this time.                         ;
* As already mentioned, this analysis was developed prior to enactment of the
  Economic Recovery Tax Act of 1981.  The rapid depreciation (ACRS) permitted
  by  this  act  would  significantly reduce  the  values  of the  fixed charge
  factors,  especially for  normal  ("pass through")  financing as  opposed  to
  stand-alone financing.                                           ;

  For standard economic assumptions, very rough estimates of the decreases in
  total annual control costs are as follows:

          Air controls:       20-25% decrease on aggregate.
          Water controls:      5% decrease on aggregate.
          Solid waste mgt.:    0-15% decrease, depending on item.   ;

  The large effect on the aggregate cost for air controls arises from the MIS
  absorber/cooler credit.

  As an alternative assumption, if the energy portion (10%) of the investment
  tax credit were  allowed  to expire at the  end  of 1982, the combined effect
  of this and  ACRS would be to cause small  increases in total annual control
  costs.

                                     355

-------











za»
O
i-t
}•»
**
3jj
to
VJ
*
o
••M
1
Ul

§

gt '
y*
«3J
H-
tri
OS
O
u.

8

1TBj
I
g

o
1— I
H-
3
_i
2

It.
O

^*
O£


«


r-1
1
if)
«
to

UJ
— 1
OQ
*CC
1—













UJ
CO U
C 0}
r— +> O 3
« UJ »r- r—
S. O -P CO
S- O S- > *~.
.3.- ° vS

i.225^
0) 4-> 0.
0. C 1-
O CO O
o

•P
r— UJ ,—»
O> O r—
S- O J3
CO t— "V
£1 O w)
Lt- 

=J 0 t- C 0 >, C S^ 4; P- ui o - r- S- O CO -P O •P C O o o *»• 1— O «-* r«. 10 **^ 3 O> S- < -P UJ UJ CO O - <— &. o o co 01 o •P O. O 00 <& ^mm V- _-f CO /*N 3 ij i- c i— a> >, C CO OJ-v. CO «*• p^ in i^* r^ **N ^"s SOO 1^ 1^* CM 00 O CM in co co CM CO in ID CM co in in CM CO «* CM 10 CM «* cn 00 ID CO *<4* ^f O CO 00 cn cn rH «H iH Cn •* !>• i-« in in cn IH in r»- co *« * •» A in co ^» oo 00 tD (*v (*i -*• <* ro i— S. 0 4J «- '• C •P 0 C 0 o U C o C •!- O < CO -P a> U C 3 •yw !«•> D5 ^ (C C S- > •i- O ^ ^ if) &» «i— §£-> O f— 4- -r* 0> O "O O 3 O> CU f— £- r— U TO fO C JZ ^ •r- O 0) -P U) O o a> c C 13 •>— 13 E U> r— 3 (U O U) o ic w Q I-H


-------



-

trt
^y
O
p-»
§=

1-4 ^^ 322 S • | ~sr tf. r- co UJ 3: O u. A o. g-*\ CD _J O en 2* 0 u CO •1 t/) r- 1 i § O 0 32j • O I— i HP •M! _lj s • CM ft^. * to UJ 9 r- •' 03 ^ ^3 3 t/J 0) U) re u •p 1— UJ l~> o) o p— £- 0 .Q *» «o X) O UJ 1 t- -p S- -P C Q) C O) O. O U O s.* r- +» 10 U) /-* 3 O t- o •P C O o o -w- I— cj •— - ja UJ o ^^ ^3 (•) UJ 0) X r— O •r- m o u. -p o ••- <«• O.^ to u .p J •a •p VI a» o p— 4- o ja i- A .n o uj Li^ 0) C OJ o. o u O •>-•' p-"

<••* 3 O S. c o >> C V. 0 CL>— • re u re 0. 3 O C3 f-m O s- •p c o o 00 «4- rH CM 0 rH rH in en en co to •l «t CM •* *1" l^» GO ^h CO f*^ oo i^* en CO tO CM m o «*• CO rH rH CM «* rH •rH r^ cn §rH to O «* CM" o rH to <3- O GO SCO !•>. CM Cn co" GO" CM m CM ^^ +> r— r— • C O O 0) 5554: c c i— O fO 33 P- P- O -P i— P— V- i. «> O -P O O O. S. -P to IO 0) -P- t- o. ce. s •r— ^^ |<»« rH CM rH O l-H en «* o to CO f1^ oo »o to o to" rH r>. ^j c i- o oj •P to IO 3 i 10 : UJ 0) **T Ol x: o o> o s- ec a 3 o t0 jQ -CO 357


-------
                        TABLE 6.3-3.   CONTROL GROUPINGS
Group Designation                      Specific Controls

Air Pollution  Control                                             \

   Particulate Control:                Fabric filters, water and foam sprays,
    •                                   electrostatic precipitators, venturi
                                       v/et scrubber.
                                                                  i
   Retort Gas  Treatment:               Stretford, flue gas desulfurization,
                                       MIS absorber/cooler.       :

   Miscellaneous Air:                  Ammonia storage tanks, catalytic
                                       converters, floating roof oil storage
                                       tanks, maintenance of valves, pumps,
                                       etc.
Water Pollution Control                                         .  j

   Condensate  Treatment:               API oil/water separator, Phbsam-W
                                       ammonia recovery unit, retort water
                                       stripper, multimedia gravity filtra-
                                       tion unit, kettle evaporators.

   Miscellaneous Water:                Mine water clarifier,* boiler feed-
                                       water treatment,* cooling water treat-
                                       ment,* equalization pond, runoff oil/
                                       water separator.           ;
«•*••-'	'" I*.	' ' ll"1' •''" " •"" "'"-'• '." •"•"'" "" ""• '•"• '•''!' "••••" '• • -—•—•••"••••I iii ii.ii.i	•!..•! in.1.1.in.ii.ii in --	ii mi.i.	'.nil	IIMII	'i 11' i ..n nto ,.'11 Jiii.iii. . i .1 .H...I .1 •..»*...—^.—
* These technologies could be  considered  as part of the process rather than
  pollution control.

Source:  DRI.


     Table 6.3-1 shows  that the total fixed Capital cost  for air pollution
control  equipment  ranges  from  $464 million  (Case Study B)  to  $485 million
(Case  Study A),  while  the  total  air control  cost  ranges  from $1.33  per
barrel (Case  Study B)  to $1.70  per barrel  (Case Study A).  The fixed capital
cost for water pollution control  is nearly identical for both case studies,
totaling approximately $78 million.  Total  water pollution control costs are
also virtually identical—$1.72  per barrel  for Case Study A and  $1.75  per
barrel for Case Study  B.

     Table 6.3-1 also  compares the  per-barrel  cost of pollution control to an
assumed $32 per-barrel value for  shale oil.*  For air pollution control, the
* Other  prices  for  the  value  of  shale oil  are  used in the  other oil shale
  PCTMs, reflecting  quality differences.

                                      358

-------
proportion  is  5.3% for Case Study A  and 4.2% for Case Study B.  Total water
pollution control  costs represent about  5.5% of the $32 per-barrel value of
shale oil.
                                                                 i
     The  works^gate value  of  $32 per  barrel (mid-1980 dollars)^for the MIS
and  Lurgi shale oils was based on two sources:   a developer's estimate of $29
per  barrel  (Cathedral  Bluffs Shale Oil  Co.,  November 14,  1980),  and a study
by   Peat,  Marwick,  Mitchell &  Co.   (September  1980) which  derived current
values  for  shale  oil.  This  study concluded that  the per-barrel  value of
shale oil (at the  project site) was $31.50 to $32.50  for surface retorted oil
and  $34.50  to $35.50  for MIS  retorted oil.  In  no  case  was  upgrading in-
volved.

     It  is  generally anticipated that  the real  price  of oil will increase in
the  future.  Hence,  the value of $32  may be considered to be a conservative
estimate  because   it does  not include  any element of escalation;relative to
the  general  level  of prices.  For example,  if oil prices were to. escalate at
only 2%  per annum relative  to general  cost  levels  (which can be! expected to
include  pollution  control   costs),  the  real  value  of  shale  oil|would reach
almost $58  per barrel  (in  mid-1980  dollars) by the  year  2010,  i.e.,  at the
end  of the 30-year project  life.

     If  Case Study A  and  Case Study B  are  compared  (see  Table!6.3-2),  the
major difference  between them  is in  the gas treatment.   Case Study A uses
Flue Gas Desulfurization (FGD), whereas Case  Study B uses a Stretford unit to
desulfurize  the retort gases prior to  their combustion.   Both  fixed capital
and  total  annual   operating  costs for the Stretford  unit  (Case Study B)  are
lower than for the FGD unit  (Case Study A).

     Water  treatment  controls  and  cost  are virtually  identical   for  Case
Studies A and B.    Case Study B has marginally greater  fixed capital  and total
annual operating costs due to somewhat larger kettle evaporators.i

     Cost Details—

     Full  cost details for each  air  and   water  pollution control  (using
standard economic  assumptions)  are  presented in Tables 6.3-4 and  6.3-5.   As
already  noted,  three items—the MIS  absorber/coolers, proper maintenance of
valves and  pumps,  and  floating  roof oil  storage tanks—were  found to have
negative total annual  costs.  In these  cases, the annual  by-product credits
were large  enough to  more  than  offset the  total annual capital  charges  and
total annual  operating costs.   These  items  were,  nevertheless, incorporated
into the total  air pollution control  'costs.                      !

     Table  6.3-6   presents  the  costs  of  six solid  waste  management  item;;.
Of the  six,  dust suppression  ($2.1 million  total  annual  control  cost  or
4.8 cents  per  barrel)  and  grubbing,   stripping and  clearing  (|0.5 million
total annual cost  or 1.2 cents per barrel)  are  the  most costly items.   Both
of  these  items  are  primarily  operating expenditures  (zero  fixed  capital
cost).   The  only   solid waste  management items  with  fixed  capital  costs  are
the  rundn  catchment  dam  and  low-level  outlet and  the  runoff  catchment
embankment  (totaling $0*9 million  in  fixed capital, but  representing  only


                                     359

-------







1
»•«
£
«*
o
S"4
UJ

o
cc
£
(ft
s
S
3
„!
II
|
O£

«C
&
..J
»-«
in
ia


•a-
™
ID
UJ
3*
j_











•ss
(U r— 4J
ja o c
fcIS
a. o
nU1n
o o ^^
sji;
+j e o
£< Q.O
jQ ^
O r- WJ X.
at as o u»
£!"g

s^g-l

4-* fi-
U >»
73 13 «r- tft
3 O 13-
c s- to o
c a. t. o
ca* 25

^-%
O f tff o
S- O.O
3l U ^— '


!•— U)
•a ra +>-
W •*•» U» CO
x •*- o o

O v-«

-0 Ino-s
X « tjw

U.  v-^— ' CO ^'j^> iOl t 1
1 1 rHOIrH rH| f
ef CM [CM ml 1
asli sll

cMCMiotD «r»n *"* S lA^crt tn co ID r-t|tD co rHJrH r^-j in rHJco en I
S" CM l rH~ rHicT CM] m" i-tU^ rM
rH t CO CM[lD l**| ID CM( co «<-> CM CM CM CM en CM


* mirH COI 1
5* colcn CM
O CMJiH inj

CM !co I r» coltn CM] t u> m)r- col 1
1 I co «f>IcM csj| | CM io|ro ro| |


CMCMtnmrHrH^rHCMin m ID|CM ^ ft o CMj^- o mien rHj j rH en'jco' o"|
*°* n* Q ^ysi ""i^il0. **H
T-l JrH ^ CO CMJ«i- CM[ j



U U TJ
"°.| i
titiiitiii lit it CM colm i cnlcn ml en cnkn ^*| j
I rHjrH rHj rH rHfCM COf j






lOtDlOtOCOCMCOrHtnm CO CM ICO 1 rH rH 1 CM I** ^TfrH U3I 1 CO ^IP-* CMI t
CM CM rH CM O in i-tlCO 1 CO rH 1 «*• O l^lfiO O rH t^- CO rHl 1
rH CO O IO rH rH rH CMO CO) j tn Cmf f"*l 1
rH iCM O1 COiCO .OJ | C3 COJCD rH| 1
f CM Jco ^-i I CM ICM col 1


rHrHCOCO OCM rHCO CM CM CM CO tn CO OI^ ^* CM ID to] 1
CM rH r«* ICM ff rHjio r»- e*ycn col
fC |cb" co"cMJin" ^H I
1 1 ^ «a-|co  Q)
i o - §
c i- O ro
O 4-> «* rH O GQ
U C "— ' t» to
r7-p >w ro =3 o o yi « =3
»•— ' Rt - t E- I— •*- rH n) r- r-
M f— UJ U» O *r* Vl-r*Si^>CIZ V)
>> £.3^uia)4J< (0 O
(0 0> O C S. > V> UJN£-4->CJ UJ
£. ^^£t •*- (0 O ^- . t/> T- O t. V)
OCQCMCMCMCMrHrHr>trHCMV> s-x 3 £- S- > >r* « O3O-P O U
•3 e s- o a. cn > 4- -s 2; i— WQ>a>QfOJo£*> r- (. 0 00 r- M£.r- —I
(/)r.r_^.t_r_t_r.l~^_ (Q 4J 41 >1 +» Ua>Q±CO-*J UJQJ34y O UJ
Uj^«.^-^.v-.f«^.^-.r-^.-rj4J^-3JO t/> O C xv O V> *- O O- C/1
jQ Jl J3 ^3 J3 J3 A /^ i^ 4J nj. O. C ' E 4-> *t~ Ct» O K" OS 3 t/t ^—1 Of
r-uirororortJrtJflSflnsnsrer- a» gram r- ^-r-*-, < H-
S*£ O O O
p  O
*-^CJ OS r-
ro s. r- — J
t-M O
O 0.
J- 0 -P
ojg-g g
*> «X CO «5
£« _,
S5S S
g
i


























g
rH
CM CJ
II 3:
VI

. T3
SO}
•a
s- *>
«. 0
U Q.
r- . B3

ro t- c
o o o
'O) 4-» C TJ
trt 3 r^ 5 S
.^ "CJ jQ • ttt
t- a ' .a cn ^
§S- *v. C
Q. CM O W
1 £ ^ | |
Q) 3 i— -p U)
;X C *r* CO 0)
F ™ « ^ s
U> UJ r- 
-------









s
§
2
u
iu
!
£
o
CONTROL
§
**H

2
s
£
i

o
1
Q

tn
i
en
to*
a
§
*~



















f~ tn
23-
!- tft
-a*o =
I S- 0*
4) C >»^
O. O
=J O >,
*re 4J O
o o **-*
H-CJ
i— «1 "X»
»— (O O W
(0 3 O -
43 C 0
0 C .0
r- < 0.0
04*

^
& i.
u f— tn "x,
2 3 CJ ^°
••-co
•ac . o
c O
x •*- o o
f- Q-O 0
""cS iS


01 t.
45 «^
u. o u_








c
o
m
u
«4-
I
-
** 0 S~
a o v
Q. 5"^+J t.
0 10 t-.f-.r- 0

t. O *" t. £.


cnenencncn
C CM CM CM CM CM


to
£~o
+* t-
r— CO

•2* "c -0 2
«T5 « re re
tn t. E CJ O.
C 0) 4-> t- 0)
CJ *r- (O r— t/)
•o <*- cj "a
c T- £ s- c i.

^ ^2 c. "« °~ to
o> s £.uco>— o o 3 c 3:
< m  w •!- ea -w t. m a -i- r-
>- * a =e "^ '** *


t/> 10 e o -*J f- -p
1-4 O 3 •*•» »— U_ +J
1 *£ si "
.a m o) N
3 3: C S- -r- <*-
tfl *i- CJ r* >*-
inn

<0 *4-| I
ssl
rt Ml






Wl



C- H-



0 1
in h-

E -J
re o.
Sec
Ul

v» 3
I
_

r*- CM r* cn r-t
rH in en «*• co
en VH .r-t


en cn o CM •*
co en r*. o to
r- O CO rH?
rH in


CM m CM tn TO
rH en tn m i-»
com CM


Sea «*• r* en
CO rH rH O
en ^ CM to
tO CM
u
1 O 1 11
1 CO 1 11


rH CO 00 CO O
to en rH CM en
en rH CO rH
in* en" o"
rH *T



f*^ •* CO r» rH
cn cn en tn r**
. m o en m to
U? CM rH f*.





to to CM *T rH rHICO cnf I
en o o o o o r-i «H
r*. v r*.
rH ' 1 rH| |


rH lO O r-* CM rHJCO Cn •
CM CM rH rH jm r«-j I
S ' SI 1


r- to r»* r- en co(o r^-t l
m o o TO in ol I
Cn rH rH rH m CO]
a 1 sll


i si's"'0? |j
co" col

O I 1 1 t 1 I Ol I
CO 1 1 1 1 1 1 CO) I
00^ COJ


O CM (v- r^ 1 rH P*- P*.|
S «°>a' S Sj
S ' 81



a s «~^a ?J
s s]



CM tn ^f tn tOICM en CO rH rH rH en rHI 1
rH rH en 4* toJen rH v v CM tol 1
r^> CM "M*4* vj t
CM cnlto toll

§*f o mo
Ol CD tO CD
en m «r o
CM CM en to ua
CM co


cn cn cn cn IH
CM CM-CM CM rH







o >


re a: ^ >»
CJ (O t. T- *r- O
W» i- *J > £Z 4J
t- o *" 2 = £

en m i en-en r*-!** M 1
«s- m i in cn «*|in cn I
V tO rH Icn COJ 1
s 1 sll


SmSSS
4J e

£ *j t. o
r— £ Q Ol
•a cj *S s. i—
v •*-* E re v z
+* C 4J S- 4J O


f(«_  S C ^ r- O
•M € o* o ex (O +J T3 o ^ re o-
s 5? ^is£


m ui c o -*-> «i- -p
t-t O 3 4-» r- U. *>
UJ O_ .C 
VJ <0- Q£E i^
0
-M +J u_ re o -M uj

(/j T- 0> r— <4- t/> S
CJ r- r-* re O
e o ••- 3 c -J
•*- o o cr 3  ' *t" ui re
i- ?O C T3
o. « o
SS- U C
0 0
i (U
CB 4J J3 T3
C U CJ
^3 .-aw



• I O V
•0 • >, rH W 4^
C XS rH CJ m
W : r- ** *» 4=
*a re +j o **
x c *o w
•^ c re e
tt_ tq »• ^ fc-i
C U OS
u» • ui o a> o.
' to ! a> s +J
T3 T3 S

»— i i— tn v
l-( ' HH U, r- 3
re , ^i u "O vi
361

-------
0.4 cents  per-barrel  control  cost).   The per-barrel  figures  are  somewhat
more  than doubled  if expressed  with respect  to  Lurgi retorted  shale,  but
are  still  small   in  comparison  to  the  costs  of air  and  water pollution
controls.   However,  it   should   be  remembered  that  these  costs represent
only  a  portion  of a total  cost  associated  with a  complete  solid  waste
management operation.

6.3.2  Sensitivity Analyses

     This section  explores  the sensitivity of the  results  to changes in the
engineering costs and economic assumptions.  In general, only a single change
from  the standard  economic  assumptions was made in each  case,  enabling the
impjict of this change to be  isolated.   Table 6.3-7 summarizes 'the  changes
made  for each  case, while Table 6.3-8 displays the fixed and working capital
charge rates  used to calculate per-barrel  control  costs.   Per-barrel  pollu-
tion  control costs,  expressed as a percentage  of  a $32 per-barrel shale oil
value for both case studies, are given in Table 6.3-9.   Table 6.3"10 provides
additional detail for the absolute per-barrel control costs and includes per-
centage  changes from the standard economic assumptions.  Comparative results
for   Case  Study  A   for   the  various  sensitivity  analyses  arie  presented
graphically  in Figures 6.3-1  and 6.3-2.    No  sensitivity analysis has  been
performed on the solid waste management costs, as only partial cost estimates
v/ere available.  Each sensitivity analysis is discussed below.   '••

     Twenty Percent Increase in Fixed Capital Costs—            ',

     Cost escalation  is  always a problem with  pioneer  plants because of the
numerous  uncertainties (Merrow,  September 1978;  Merrow, Chapel ahd Worthing,
July 1979).   A  20%  increase is not at all unreasonable despite the inclusion
of a 20% contingency in the fixed capital  cost estimates.        ;

     Table 6.3-10 shows  that the effect  of a 20%  increase  in fixed  capital
costs varies  significantly  among the control groups.   Retort gas treatment,
which is capital-intensive,  shows a greater percentage increase (32% for Case
Study A  and  41%  for Case  Study B)  than water  pollution control, which  is
operating cost-intensive  (only 5% increase for both case studies).  The cost
of particulate  and  miscellaneous  air controls increases by 17% fbr both case
studies.                                                          ;

     Overall,  the  difference in  the  total cost  increase for  air pollution
control   between the two  case  studies  is  not large, since  both  case  studies
are  equally  capital-intensive.    Relative  to  results  under  the  standard
economic  assumptions,  the increase  in  total air  pollution control  cost  is
28 to 36%, or 47 to 50 cents per barrel.  These results indicate that the air
pollution controls  are fairly capital-intensive.   In  contrast,  the increase
in  the   total   water pollution  control  cost  is  relatively  small  in  both
percentage (5%) and absolute terms  (9 to 10 cents  per barrel),  ks the water
pollution controls are not capital-intensive.
                                     362


-------













Ul
•g
at
5

4^
U Ul
3 -P
TJ *i—
fc at


OQ

ai
c
•p
re
S- Ul
ai 4-1

4->
U
£
a




*re


Q. en
rtj 4J
CJ Ul
a
13 tj
X


a±
s
o






Ul
Ul
' 1
. ^>
4->
1
at





















2
to








UJ
CO








o
CM

"8
Ul
re
2
g



S




Ul
•P
Ul
o
3
s-
CJ
T3
X
U.
1
+




















2





M
CM

s
Ul
re
£
U









2
CO





rH


Ul
+•>
O
CJ
CD
C
4J
£
o
i
•*•




















2
CO




c;*
o r*
4J tO

i«

jj 5
r-' fc.
rr> U
*J C
3f-







2
CO





«





tn
•P
tn
tillties Co
S
1


















8
CM

TJ
O>
Ul

U
&


&
o








2






rH






•P
a.
>P
3
O
1
to
£!
4-
o

CO



re
c
o
01
Ul
re
£
1
Ul

re •
»— at
O T-
re
is
"?
c a.
m
£-
O R)
p-g.
a» i




2
to








2












2
to





s






at
s
1
t.
re
at
>*
CM
U
c ai
CJ f-'i-t
ai o a-
•P +J
o 3 tn
•P TJ
5 2 *~
13 en*"
£4=5.
O r- O) .
o^'s re
O >» 3 01
to t. o
tn c ro
flj O TJ
5 •»- c **

s- o n 1
ta co at
Hi*





2
to








2
t/1











2






S .;







§•
i
1
I
•1
Q


4»
X t
i!
s °
Ul C
c -o
c
* i.
ui re
c ai
o

£.1
r- -P
U •**
»8
U £-
11
re re
CJ -P
"5
S£
u. u

r? '- •


S S








2 2
CO CO











2 2
to to





S S






I
1
li-
ce o

S 1
rH CO



e m
^~ re
re v
Ul
(O S.
ge

•P Ul
if
a>
•Q J=
" w
111
3 Dl
8 .. S
at i. c
« S =
3>- T3
m c e:
s- >r~ "5
>• Ul t-

<— — »


2








2
' CO











2






a






O)
c
"i
gg
T-S
o

m re
+j
CO
u
c at
(j (r. ._
Q£ O
C S-
at o o-
51«

5 Is
"g n,*-
05 •!- •!-
11-12
o e to

".£o
ui c rn
re o ~o
£ RJ re
*— *3 01
flj CO Of
>>S Ul *"
i i. at





UJ
CO








2
to








O


•o
«';*• .
•£ -.-• .-

k-l -


S




wT
«T3
CJ 5
15 §"
H- +J
a. s.
01 T3 U.
^X 01 CJ
CM



o at
Q& E-
£ §
^0,1
O JZ •!-
-P -P -P
5,5
C U
B"°i
.I'gf
o o
O..Q T»
t. re c
o -
+J
>i re x o
re r— re -P
r- 3 -P
Mil
CM -a > o '
<:S5S




s








2









^


tn

2

*"*


rH




uT c
to Mr2
O rH re
•5&1
•»- *i CO
331
. t/> re en
at TI o£>f-
.5 S.S S
LL. nj re
o o a u.
















Ul
o
-p
Ul
Ul
re

u
1
c
o
s
1
1

c
o
•a
Ul
S

tn
Ul
"re
s
i.
o
*"
•o
ai
3
01
Ul
5
Ul
re
tn
01
t.
03
Ul
Ul
O
u
a
5
•P
Ul
1
•a
a
S
•K
364

-------





















V)
€/>
_I
g
S
r-
i/»
sc
o
iZ
«rt
IU
g
til
g
s
u

00
A
to
a
?






































tn
0)
to
*«
5
•£>

Ul
c
&






























ui i m
T3 C T3 Ol
U O C C
C V- (0 0) T-
•r- •+•» -*J C O
ja cut/* o c
S E i— (U
o 3 J= (0 c
CJ V) -P •«-
in *^ U.
Ul
•o c
o o
So.
•§ §•
(A
O)
t C OS
Tf 01 T- M O
+J i— nj LL.
W ro C +•» O
s: ida
, w
111
4J i— (O
W> (0 C
Ctf
l-l U.
*J


•»§•
• H
•33
o to

t- -P
(U Q>  01
r*« to •*• •)•*
* O r— Ul
to £•!£ o
t£> U *> U
C
0>
tft
« *> CB
£ «^ «
CJ U rfJ *>
S52S
« = £"
8"1"0
S-D
C U. «r- V)
!-• O.O

g""0

C
•a o o
111
g||
V) UJ Ul
**









S^h en to in co en rH
en m rH o CM en rH
inrHrHCMCMrHOo*
^•entotoin^^rro




r*-tnmooentnco
ocnotncncncMrH
tn CM to to QO to o fn
cocM^-srcocnrocM



in rHOOrH CVICO CO rH
rh>cor»CMococM^>

mc.*»« cncn tricM en pC
CM rH CM CM CM r*»rH rH
cnrHo^cnmtoo
m tn co rH m rH co tn
to en «?• m en r*. CM o
CM rH co en CM r*- CM CM


lOCMCn^^rHrHin
cMOCMtncMcnocn
^- rs. oca to en r4 en'
CMrHcOCOCMtOCMrH


r^cnmeotncncncM
tn to Cf! rH CO CM tO CM
CMrHCMCMCMtnrHrH


rHCOCnrHr^CMtOCM
cn«s-cn^-CDootoin
rHrHCMCMCMinrHrH



tncMencoenoocn
rHOOCftrHp^CMlOCM
rH rH CMCM CM SrH S


incMencoroooen
rHCOCnrHP*»CMtOCM
aaaas'gaa'


tncMmcocnoocn
rHCOCnrHp^CMtOCM
cn-een^eacototn
rHrHCMCMCMtnrHrH



tn CM enm en o o en
rHOOCntHrfcCMlOCM
a a .53 a a s a a
»—
e =
c ji
ej» i i 01 e: «j ra ^-»
Q CD O)f- E OJ O «• i—
ecciAcseu +J t. « CM «
S £2 JHZ § iS ^*o -^"t! S*71 w *°

6 -tw> t 2* fc - gt C^ r^C "bS T3 S 0
•o 3S 53 | c£ |S 25 r^ ^b 5
xoe cc 5S 5 ej 5 v>""sf
-E ' ^


in
CM
S




8
CM



en
to
_j
s

§
rH
CM
S
to
s


s
si


en
to
*H
CM


O
CO




o
CO
rH '
CM


rH
CM


O
CO




§
i-i
eg



. -
£
5

RJ
£
U
















!
1
;

.



, j
§•
*> :

10 '
*»
vt
"S i
>•
to
i ;
1 !
I


S 1 ;
S 1
u ,
V) J=
-M u :
Ul (8
C
*m **" '
11
•o c '
X
c 1
C L.
**~ C
fl) O
U) U
ia
b 1
c 7
i- 3
S 0 ;
CM O.
2 0
IO *^
» f
O CM
H" "o
.3 r—
(A A
« z s
•0 o §

I I s
3 S S
o
«0 A t/1
365

-------
               TABLE 6.3-9.  SENSITIVITY ANALYSES EXPRESSED AS
                       A PERCENTAGE OF SHALE OIL VALUE
                                           Per-barrel Control Cost as a
                                       Percent of $32/Barrel Shale Oil Value
Air
Sensitivity Analysis
Standard Economic Assumptions
20% Increase in Fixed Capital Costs
20% Increase in Direct Operating Costs
66.7% Increase in Utilities Costs
80% of Planned Output
20-year Project Life
Delayed Start-up
15% DCF ROR
Stand-alone Financing
Stand-alone Financing at 15% DCF ROR
Combined Assumptions*
Combined Assumptions with
Stand-alone Financing*
A
5.3
6.9
5.9
6.2
7.6
6.2
7.0
8.0
6.4
9.7
13.5

17.7
B
4.2
5.7
4.7
4.5
6.4
5.0
5.8
6.7
5.2
8.3
12.0

16.0
Water
A ;
5.4 :
5.7 !
6.3 ;
8.1 |
6.3 i
5.6 I
5.7
6.0
5.7 i
6.4|
7.1 ;

8.0 :
B
5.5
5.8
6.4
8.3
6.4
5.7
5.3
6.1
5.7
6.5
7.2

8.1

* Combined assumptions are 20% increase in fixed capital costs, 15% DCF ROR
  arid delayed start-up.

Source:  DRI.
                                                                 !

     Twenty Percent Increase In Operating Costs—                '•.

     Operating costs  are often  better defined than capital  costs,  which is
v/hy  an operating  cost contingency  is not normally  included in  the direct
annual operating costs.   However,  there are many reasons why operating costs
could be higher than anticipated.  For example, regional shortages of skilled
labor  could  result in  higher  wages and  reduced productivity.   Also,  labor
costs  may escalate  faster than other costs.   Maintenance  costs  could  be
higher than  expected, and  both  utility requirements and  utility unit costs
could deviate from expectations.                                 ' !      .

     For air pollution  controls, the overall  effect of an increase in direct
annual operating cost is  much  less than that of the same percentage increase
in  fixed  capital  cost.   For  a  20%  increase, the  retort  gas treatment cost
increases  by 19 cents  per barrel  (13%)  for  Case  Study A and  }5 cents  per


                                     366                         !

-------




















%
CD

cs
s

21
8

m

tu
CO

•_j
«c
§
£
«-*

1— 1
CO
z
LU
CO


S

CO
CO
UJ
-J
CO
j*





















•o
c
c
IO «P
eZ a
•p
<*- 3
o o
£3
CD
oo
OJ
c
10
JZ
0
&«



To
J3
* •«
T*7-
in
43
a> in
in o
10 O
4)
i. in
a a,
C «r-
co =3
CO
a


01
O)
c:
re
o

**
JQ
•v.



in
•P
O) U>
in 4J o
re u o
gj o>
O •!- C
H- » .p
c re
SS •.- i.
CD Q)
CM O
01
en
(0
JZ
o
^?

r~*
j2
^Q
\
O]-^-
i— a>
10
0) -P
in •!-
10 Q.
0) (O
s. cj in
U -P
•c T3 in
1-1 ai o
x o
CD ' '
CM
C
•f-
O)
(O
0

EH?



§

*>•


in
c
13 O O
S- •!— 'i-
ie E -P
•a o a
C C E
IO O 3
•P u in
co UJ in
• >- OS
o •>- og a> es a r-
o; s: E •=>•=> -z.
1— •« -P r- h- O
Z ~O 10 CO CO O
O c in u> a> «S CO
o (0 1— a> s- ujui z
O -i- t— >, >, CO CO O
Z. Ctl »•  -p 3
1— i— O CO C3 CO CO « - — 1
=330 ee as ~J
—10 O>-PO>CU MM o

o -P •»- to o ie  . 
-------






























•*•>
ff
o
U


o
1
CO

to

JLUI
»4
SO
«t
I—
































CjJ
c o
o c
i c:
t3 «0
(0 -f-
+J U.
to

> 0
1 CU
O "~3
CM O
CU
0)

c
 U 0)
CO LU O)

t_
J3
>^
•W-


Q.
3
O
s-
o
P«
0
0
o

•a
C '


nj
•5
cu
S»

in oo in CM r***

oo co o rH m
H- CM CO CM CM




CM ^ (O IO 00
co r«- co o 10
rH rH CM rH



rH i-H !•». IO rH

«* .
c\3 us p«I CM cn
rH CO *d" CO CO




co CM co in r»*
co cn in CM co
rH rH CM rH





CM rH o ur> cn

cn oo co to cn
H- rH CM rH i-H






CM IO CO CO O
CO 10 CM CD U3
rH rH rH rH



cn o  1^ CO
rH rH rH rH



< 00 — 1
o ca *> o
— J 01 C >- >• OS
O •!- c3 CU Q Q r-
Q£ S E => =3 Z
1-^  HJ r*- (U t- m 1 1 1 *y
O'l-l— >»>> COCO O
Z 01 L. -0 -ff-tf -P3U>33 O <_) r-
1— I IO C -P  +•> O
r- r- O CO CO CO CO •« « -J
=> 3 o ce a: —i
— i u a> -t-> a> as I_H ,_i o
_i -i- i_ ui s- ui to 44 a.
O -U -r- CO O <0 (0
o-i-cjo — i — i ce
CO CU  ^^
H* H*




rH CO
co co
rH rH



10 in

r-i rH
t-H rH



CM in
cn cn
rH rH


CO CM
to to





CO to
oo co
rH T-H





V0 ID

CO CO
'






cn rH
r~- oo
rH rH



CM in
i-H rH








< CO
3 3
4-> 4J

tn u)
CD (O
O O








!



ff^l
73
' 
-------



















^^
.
o
u


o
rH
1
<*»
to
CO
^c






































to
c
0 0)
•i- C
•P O
a..— *
E <8 a
0) T3 -r-
01 C U

•P 0)
•a co c
a> •!-
C .C Li_
!£i-

o
at
o>
o
&9




r~
-g
Vs
•t*
o




(0
•a c
cu o
C •!-
J3 a.
£ £
O 3
O U>
in



C
R)
O
!*8


S
SX,
^^*




-p
at 
^^
*>s
**



Ul
C
•a o o
S- «r- •!-
•a o a
C C £
(8 O 3
•p u in
CO Ul U>
sc



r™
A

•W-





Q.
3
O
13

g

C
o
o
TO
c

m
•r-
TO
Q)
S


<* in in IH to
rH in CM CO CO
rH CM CO CM CM
4- + + 4- 4>





«*• CM r»- to I-H
to O «* to rH
m 4* in m






P-. CM CM rH !•-
r~ -CM C3 *d- to
to r- CM in co
+ rH CM rH iH,
+ + + +


en CM <* r-t co
^ CO cO co CO
CO CO ^f CO





F** CO f*^ CT> rH
to rH to rH Cn
co en rH co en
T T rH H^ 4*
4-




o en to en to
«* to CM o to
CM CM CO CM








en o ^c o <•
CM «3- o r«. co
rH i— 1 rH rH





*
 o
—I Ul C >• >- Q£
O *f c3 01 O O r—
OS E E =5 = Z
1— < 43 |_ t_ o
Z 73 18 CO tO O
o c in tn a) > >» CO tO O
za> i— i i— i o

g-p -r- re o nf re
S- -j o o 
S-. 0
-P
U3 0)

TO TO
: 0)
«" 15
r— S-
(U 5-
*O (8
C S-
18 
+J
C
U. O)
0 U
E
g I
TO
u>  at
tn *
CM 
. i. Ul
18 a>
D>
Ul C
C (8
•<— U

a. a>
E O>
, 3 as
Ul 


-------
                         a nil;
                                               CK
                                               s

                                               8
i«/sr 'ISOD IOSUNOD Nounnod
                   370

-------
                                                    g
                                                    a:
                                                    o
                                                    (9
i
-------
barrel (14%) for Case Study B.  Total air pollution control costs increase by
15  to 20 cents  per  barrel,  or  12 percent.   The  costs of  water  pollution
control, which  are  more operating cost-intensive, increase by 28 to 29 cents
per  barrel,  or 17 percent.   Once again,  the difference  in  increase in cost
between case studies is small.'                                   ;
                                                                 i
     66.7% Increase In Utilities Costs—                         ;

     Operation of various  controls requires inputs of electricity and steam.
Under  standard economic  assumptions,  electricity  is  valued at;3  cents  per
kW-hr,  and  it  is assumed that steam  is  generated at  a cost  of  $3/MMBtu.
The  electricity  charge of 3  cents per kW-hr  may very  likely  underestimate
the  true cost  of  power purchased from the grid (should this prove necessary)
as  it  is a  compromise value between  plants that  can sell  power  and those
that  must  purchase  power  (see  Section 6.1.1).   The  MIS-Lurgi ifacility is
expected to  be self-sufficient  in power,  but it  is conceivable that excess
electricity  may be  available for  export.   However,  to  allow  for  the pos-
sibility that  a power plant is not  built,  a 5 cents per kW-hr rate (a 66.7%
increase) was  considered.  At  the  same time,  the price of steam  was also
increased by 66.7%,  as the standard rate for this input of $3/MMBtu may also
prove  to  be conservative.  Three dollars  per million Btu is a  typical 1980
value  used  for  heat  inputs  in  engineering studies,  but no detailed cost
evaluation was conducted  for this  manual.   Hence, the  steam  cost  must be
considered uncertain.                                            •

     The results  indicate  that  utility costs  constitute a  major  component
of  pollution  control costs.  Water pollution control costs  show a dramatic
increase, rising  51$  (88  to  89 cents per barrel).   This increase  can be
attributed to  the large  quantities of steam required to operate the kettle
evaporators,  ammonia  recovery  unit and  retort  water  stripper.   The  in-
creases  in  air pollution control  cost are less  dramatic.   The retort  gas
treattment cost increases   by  19%  (28 cents  per barrel)  for  Case  Study A
and  by only 7%  (8  cents  per barrel)  for  Case  Study  B.   Case  Study A dis-
plays  the greater increase because the FGD  unit  uses  much larger quantities
of  steam and  electricity than does the Stretford  system in Case Study B.
Particulate   and miscellaneous air control   costs  increase only ,6% (2 cents
per  barrel).    Total  air  control   cost  increases  by  17%  for  Case  Study A
and 7% for Case Study B.                                         i

     The absolute cost  of  pollution controls ranges from $1.43  to  $1.99 per
barrel for air  controls and from $2.60 to $2.64 per barrel for  water manage*
ment.  The  severe increases  in  the total  cost for water pollution control
suggest  that  further analysis  of  the  cost  of  steam  would be  desirable.
Uncertainty about the  cost of electricity does not have a major influence on
control costs,  so whether  the project buys from or sells to the electrical
grid is not  an important issue.

     Eighty Percent of Planned Output—                          i

     A  frequent problem  with pioneer  process  plants  is  that  they  fail  to
achieve their planned  output.   Occasionally they produce more.   When a plant
fails  to reach  its  planned output, the annual  fixed capital  charges must be


                                     372

-------
spread over reduced output, and the direct annual operating costs decrease by
a  lesser  proportion than  the output because some  components  (such as main-
tenance) are virtually unchanged.                                .

     For the  case of a  plant which achieves only 80%  of  planned output, it
was  assumed that  direct  annual  operating  costs fall  to 90%  of  the full
production  costs.   Production in  the start-up  years  and  by-product credits
were prorated to 80% of the standard values.

     Overall,  the  results are  fairly  severe,  with  the capital-intensive
controls showing the greatest increases.   Retort gas treatment costs increase
by 48 to 60%  (63 to 68 cents  per barrel).  Particulate and miscellaneous air
control costs  increase  by 24%  (7 cents per  barrel).   Total air pollution
control cost increases 44% (75 cents) for Case Study A and 52% (69 cents) for
Case  Study B.    The less  capital-intensive  water  pollution control  costs
increase 17% (30 cents per barrel).                              '.

     Twenty-Year Project Li fe—

     A shorter project life might occur because of technological  obsolescence
or some  other currently  unanticipated  reason.*  There is little doubt that
the  oil  shale  reserves on Tract  C-b are adequate  for the  planned 30-year
life.   For most  projects, extension of the life  beyond  20 years  has very
little  effect  on  the total  costs  because  the  later  years  are  so heavily
discounted.

     This case examines  the  impact of reducing  the  life to 20 years.   Over-
all,  the effects  of this change on  control  costs are relatively, mild.  Once
again,  the more  capital-intensive  air  control  Costs  show the  largest in"
creases.  The  total air  pollution control  cost  increases 17% (28 cents per
barrel) for Case Study A and 20% (26 cents per barrel) for Case Study B.  The
total water pollution control cost increases  by only 4% (6 to  7 cents per
barrel) for both case studies.                                   !            .

     Delayed Start-up—                                          I
                                                                 i
     Because of  the time-value  of money implicit in the  discounting  proce-
dure,  anything  that delays  or curtails  production  raises  annual  capital
charges and,  hence, the  per-barrel  control  cost;  conversely, anything that
accelerates or extends production reduces the costs.              '

     For this  analysis,  production  is  halted for two  years  (Years 3  and 4)
and  then  follows the  normal  build-up profile displaced by two years.   (The
project life remains at 30 years, as this is likely to be determined by tech-
nological  obsolescence.)   This profile  corresponds to  the scenario that the
plant initially  starts production  according to schedule;  then,  a;t the  end of
  A 20-year life  was  recommended for the oil  shale PCTMs.   However, because
  of the exceptional  7-year start-up period, it was considered inappropriate
  to use a 20-year life for this cost evaluation rather than the 30-year life
  proposed by the developers of the Cathedral Bluffs project.

                                     373

-------
 Year  2  (which  would correspond  to  only  20 months'  actual  operation),  the
 plant is  closed down because  serious operational  problems  have  developed  and
 must  be  solved,  which takes  two years.   Fortunately,  not all  the  fixed
 capital  has been  expended  by the end of Year  2;  only two MIS  retort  trains
 and one  Lurgi  plant are operational, but construction has  started  on  several
 others.

      The  effects  of  this  case are  moderately severe.   Total  air pollution
 control costs  increase by 33  to  40% (53 to 55 cents  per barrel).  The water
 pollution  control  cost for both  case studies  shows only a small 6% increase
 (11 cents  per  barrel),  as water  management  costs  are dominated by the large
 operating cost  of  the kettle evaporators.                        !

      Fifteen Percent DCF ROR--

      The  minimum  acceptable  DCF  ROR  used in a project feasibility study is
 normally  not divulged  by  developers and,  in  any event, is  influenced by
 alternative  investment opportunities  and  other factors.   However, there is
 broad confirmation that a  rate  between  12% and  15% per annum (in constant
 dollars)  is appropriate for  evaluating oil  shale projects (Denver Research
 Institute,  etal., July 1979;  also  see Merrow, September  1978).!   This ROR,
 which is  called a "hurdle rate,"  is higher than  the return that a company
 actually  earns   on its  capital for  a number of  reasons.   First, it  is  an
 unfortunate fact of life that many projects earn less  than the projected rate
 becciuse things  do not  work out as expected.  This  is only partly offset by
 the few that  do better than anticipated.  Second, project evaluations  do not
 usually include such  costs as  R  and  D,  exploration and  reserve acquisition;
 also,  they may not  include  recovery  of some  general  corporate  expenses.
                                                                 i
      The single most important  factor that influences  the required DCF  ROR is
 the perceived riskiness of the project.  A  high  risk project is,expected to
 pass  a higher ROR  hurdle than a low risk project.  Some of the types of risks
 that;  might  be  subjectively taken into account in selecting a minimum accept-
 able  DCF ROR for a mining project in  the U.S. include:

      •    Unproven technology (and, hence, uncertain equipment costs);
      •    Geologic uncertainty;                                  :

      •    Very  large investments in relationship to total corporate assets;

      •    Rapid inflation in some cost components;
      •    Long construction and start-up periods;                :

      •    Market uncertainty;                                     •

     *    Regulatory uncertainty (leading to delays or added costs); and

     •    Difficult working conditions or adverse socioeconomic impacts
          leading, to manpower problems.


     For any first generation commercial synfuel plant, all  the above factors
are present, with  the  possible exception of geologic uncertainty.   At this
time,  most  of  these factors  are strongly  present  in  oil  shale  projects.

                                     374                         ';

-------
The MIS-Lurgi plant is particularly susceptible to these risks because of its
complex technology and extended start-up schedule.               :

     The standard  economic  assumption is 12% DCF ROR,  which  is  probably the
lowest  acceptable  ROR for  a private enterprise shale  oil  plant with proven
technology.  For a pioneer  plant of this type, industry is likely to require
at 'least 15% ROR,  unless it wishes to "buy into" a new industry.  Of course,
if another party  (e.g.,  the Federal government) were  prepared  to share the
risk in some way, the required ROR would be reduced.  Even though some of the
risks  listed above  do  not  apply to pollution  controls,  industry  does not
perceive environmental costs to  be separable from the total project.  Hence,
all  components  of  a project,  including pollution  controls, must  earn the
specified DCF ROR.                                                '

     Increasing the  required DCF ROR from 12 to 15% has a substantial effect
on  the  costs.    Once  again,  capital-intensive  controls  are ! those  most
affected—for example,  retort gas  treatment  costs  rise by 56 to 72% (75 to
79 cents per barrel).    Particulate  and  miscellaneous  air  controls increase
by 24%  (7 cents per  barrel).   The  increase  in total  air  pollution control
costs,  relative  to standard economic assumptions,  ranges from  51% for Case
Study A  to  61%  for Case Study  B (or 86  and 81 cents, respectively).   The
total water  pollution control cost shows a moderate  12%  increase (20 cents
per barrel).                                                      ;

     Stand-alone Financing—                                     !

     The term "stand-alone  financing" is used to describe a project in which
investment  tax   credits   and allowances  for  depreciation  cannot be  passed
through  to  a  parent  company (or  companies) which  can  benefit from  them
immediately.   (These benefits are  treated  as negative  income  |tax  in  con-
ducting the  alternative  "pass-through"  form  of project evaluation  which is
used under the  standard  economic assumptions.)  Instead,  it is necessary for
the project to become profitable  before the tax benefits can be obtained.  It
is difficult to determine  when  this might  occur because it requires  a de-
tailed knowledge of  the  overall  project economics; in  any  event, the timing
of the  benefits 'will  be  affected by the  selling price  of  the  shale  oil.
However, it  is  known that  some   of  the  developers are assuming stand-alone
financing  for  their  evaluations since  it more  closely  reflects  their tax
positions than does pass-through  financing.                       |

     To  determine   the   approximate  effect  of   substituting   stand-alone
financing for pass-through  financing, it was assumed that  no investment tax
credit or  depreciation  could be claimed until the fifth year of production
(in which  output averages  68% of a  full production year).   This assumption
was  based  on  examination   of   the  cash  flow  analysis  for an  MIS  plant
presented  in a  recent oil  shale tax study (Peat,  Marwick,  Mitchell  & Co.,
September 1980).    It  must be emphasized that this assumption i's  very  sim-
plistic (and probably conservative), since  the relevant details  in the tax
study were  significantly different  from those assumed in  this  manual.   As
expected,  the effect  was  the  greatest for  the capital-intensive  control
groups.   The overall effect was to increase total  air pollution control costs
by 21  to 26% (34  to  36  cents  per barrel) and total water  pollution control

                                     375                         ;

-------
 costs  by  5% (8 to  9 cents per  barrel).   A more  refined calculation  might
 yield  substantially  greater increases,  especially if a low value was used for
 the  price  of shale oil,  thereby reducing profitability.          ;

     The effect of stand-alone  financing  was  also evaluated at|l5% DCF ROR,
 using  the same assumptions  as  above.   This  probably comes closer to a devel-
 oper's evaluation.  In this case,  the  increases in costs  are  quite substan-
 tial,  ranging from $1.32 to $1,39 per barrel (82 to 99%)  for  all;air controls
 and  33 cents per barrel  (19%)  for water pollution control.

     Combined Cases—
                                                                 /r
     Two combined cases were  evaluated  using  the  components already  dis-
 cussed.   However,  ft is  not sufficient to construct these analyses  by simply
 combining  the  results  from  the  earlier findings,  so  new  analyses  were
 developed.   The two cases are  as  follows:                        :

     Combined assumptions

     •    20% increase in fixed  capital  costs
     •    Delayed  start-up
     •    15% DCF  ROR                                            ;

     •    Everything else as standard economic assumptions.

     Combined  assumptions with stand-alone financing

     »   20%  increase in fixed capital  costs
     •   Delayed  start-up
     •   15% DCF  ROR
     •    Stand-alone financing

     •    Everything else as standard economic assumptions.
                                                                 i

     These  combined  cases  are  intended  to  be  quite  plausible  adverse
scenarios  (i.e.,  20% increase  in fixed capital  costs and delayed  start-up)
looked  at  from industry's viewpoint  (i.e-,',  15%  DCF ROR,  with;  or without
stand-alone financing, depending on the company).

     The results clearly  indicate that,  if everything  else remained the same,
these  cases would constitute disasters for the MIS-Lurgi project,; since total
project costs would respond in a.similar way to pollution control' costs.  The
most capital-intensive control  group (retort gas treatment) increases in cost
by between 172  and  220% ($2.30  to  $2.42  per  barrel)  for  regular (pass-;
through) financing and by  between  258  and 330%  ($3.43 to $3.62 per barrel)
for  stand-alone  financing.   Overall,   the  increase  in  total  air pollution
control cost  ranges  from 154 to 187% for the regular  (pass-through) case and
from 233 to 283% for  the stand-alone case.

     Total  water  pollution control  costs  rise approximately  32%  for  the
regular  case  and  48%  for  the  stand-alone case.    The  absolute  level  of


                                     376

-------
pollution  control  costs ranges  from $3.83  to  $4.31 per  barrel  for all air
controls and  from  $2.27 to $2.30 for water pollution control for the regular
(pass-through)   case.    For   the   combined  assumptions   with  stand-alone
financing, absolute  control  costs  are $5.11 to  $5.66  per barrel for air and
$2.!>6  to  $2.59  for  water.   These  results represent a more than1 tripling of
the absolute cost of air pollution controls.
                                          •      •                 i
     Summary—

     Returning  to  Table 6.3-9,  it  can  be  seen that  total  air  pollution
control costs  are roughly  4 to 5%  of the assumed  $32  per-barrel  value for
shale  oil  under the standard economic  assumptions.  Total  water  pollution
control costs are about 5.5% of the value of the oil.            !

     With  respect  to air pollution controls, only the last three sensitivity
analyses (stand-alone financing  at 15% DCF .ROR  and  the  two sets: Of combined
assumptions) produce dramatic increases  in  cost.   For stand-alone  financing
at 15% DCF ROR,  total  per-barrel costs increase  to  between 8 and 10% of the
shale  oil  value.  For  combined  assumptions, air control  costs  increase to
between 12 and  14%  of the  oil  value, while  for combined assumptions  with
stand-alone financing,  the air  control  costs rise  to between  16 and 18% of
the  oil  value.   The more  capital-intensive air control  costs| tend to be
greatly affected by the  sensitivity analyses which adversely  impact annual
capital  charges.   The   cost  of  the  MIS absorber/cooler  causeis the  total
operating  cost for  all  air controls  to  be negative,  with  the  result  that
changes  in capital  charges  are  magnified  when  translated  to  per-barrel
control costs.   In all  instances,  Case Study B remains the lower cost option
for  air  pollution control  due to  the lower fixed capital  and  direct annual
operating  costs  associated  with  the Stretford system, as  oppose
-------
 instance (the 66.7%  increase in  utility costs)  do  water pollution  control
 costs  become substantially larger  than  air pollution  control  costs.

     Figures 6.3-1  and  6.3-2  split  the control  costs  into  a  per-barrel
 capital   charge   and   a   per-barrel   total  operating  cost.   These   figures
 effectively  illustrate the  response  of capital-intensive controls (air)  vs.
 operating cost-intensive  controls   (water)   to  the  different   sensitivity
 analyses.   Note  that the  total  operating cost is  always  negative  for  air
 pollution controls.

 6.4  DETAILS OF  COST ANALYSIS METHODOLOGY                      "\

 6.4.1  Cost  Algorithms                                           !

     This section provides the algorithms  used  to calculate  total  annual  and
 per-barrel control costs  and  capital  charge factors.

     Calculation  of Total  Annual and  Per-barrel  Control Costs—

     The total annual  cost  (TC) of each  item considered for pollution control
 is  the  sum  of the total  annual  operating  cost  (TOC) and the annual capital
 charge (CC).  That is:                                            !

               TC  = TOC  + CC

     and    .  TOC = DOC  +  IOC

     where:           DOC  = Direct annual  operating cost
                     IOC  = Indirect annual  operating  cost

     and      CC  = (FCC x RF) + (WC x  RW)

     where:           FCC = Fixed capital  cost
                     WC  - Working capital
                     RF  = Fixed charge  factor                    ;
                     RW  = Working capital charge  factor

     The cost per barrel  (CPB) is the total annual  cost divided by the normal
annual  production, i.e.:                                          !

               CPB = TC -r (BPCD x 365)                            '

     where:           BPCD = Barrels per calendar day

This corresponds  to a 100% operating  factor  in  normal  years,  as explained
earlier.                                                           ;

     The derivation of each cost component is explained below.    j

     Direct annual operating cost.    DOC  is a data  input  derived from  the
engineering  cost  analysis.   It is the  annual  cost for a  normal  year  and is
taken from one of the basic data Tables 6.1-2 through 6.1-4 or 6.2~3.


                                     378

-------
      Indirect annual operating cost.    The  indirect  annual  operating  cost
 (IOC) is calculated as follows:

                IOC = TIA + ESC - STC - BP

      where:           TIA = Annual  tax and insurance allowance    ;
                      ESC = Annual  extra start-up costs (levelized—see below)
                      STC = Annual  severance tax credit (levelized--see below)
                      BP  = Annual  value of by-products

 BP is an input generated from stream  data and shown in one of the tables  in
 Section  6.3,  and:                                                 ;

                TIA = 0.03 x FCC

                ESC = (0.03 x FCC + 0.50 x DOC)  x LFAC1           '

                STC = 0.04 x [(DOC  + ESC + TIA - BP) +  0.05 x FCCJ x LFAC2

      LFAC1 and LFAC2 are levelizing factors  that spread ESC and STC uniformly
 over  all  units of  production.  LFAC2  also makes adjustments for the severance
 tax exemptions allowed for low production and allows for the reduced rate  for
 underground production.   These factors  are as follows:            ',


         OJ£  + n ?n r   1   +  l   4
         1+r     "^ L(l+r)2   (1+r)3
 LFAC1 =	—	
         0^02    0^10   0.28   0^47   0.68   0.77  0.80  rCl+rr7'
       •  1+r    (1+r)2  (1+r)3  (1+r)4  (1+r)5  (1+r)6  (1+r)7  L


      where:     N =  last year of  production (= 30  in most analyses)
                r =  Discount  rate = OCR  ROR                        :


      This  levelizing factor  distributes  the seven  annual components of the
extra start-up cost  uniformly over each  unit  of  production  throughout  the
project's entire life.


      LFAC2 = BPC° - *M°°   x   ri-«:Si42£°w
                                                                  i

         1 .   0-47   1 .   0.68 .  3 .   0.77 .   0.80 .  r(l+r)~7 - (l+r)"N-
         8   (1+r)4  2   (l+r)s  4   (1+7)6  (1+T)7  L^       iT^     •*
     X   —•	1	r—    . i'  '	     i  ' 	'.	__>*	  . ;•
                         [Same denominator as in LFAC1]           |


     where:  BPCD = Barrels per calendar day                      i
* 69,040 -f 117,000 is the proportion of below-ground production.


                                     379

-------
 A numerical  example  of a  levelizing  calculation is given in Section  6.4.3.

      Capital  costs.   Fixed capital cost  (FCC)  is an input taken  from  one  of
 the  data tables.   Working  capital  (WC) is calculated as  follows:
                                                                  I
                WC = 1/12 x TOC  + 1/4 x BP                        ''..'•

      Capital  Charge Factors—

      The fixed charge factor equation  is:                         :


                      N
                      I  [(1 + r) n x (K  - T x  D   -  C )]
                    n=J                 n        n    n            ;
                RF =
                               N
                       (1 - T)  I   [(1 +  r)"n OJ
                              n=l             n
     where:          Kn = Capital expenditure in year n (2 K  = 11000)

                     C  = Investment credit  in year n

                     Dn = Depreciation in year n                  :

                     0,, = Operating income in year n (0  = 1.000  in a normal
                      n   year)                        n

                     r  = DCF ROR (= discount rate)               ;

                     T  = Tax rate
                                                                  i
                     N  = Last year of project

                     J  = First year of project (i.e., -3)
                                                                  *
Note that the first year of production is Year 1.
                          ,  '   ,                                   i
     The same equation is used to determine the working capital charge factor
(RW), except that the Dn and Cn terms are omitted.

6.4.2  Example Calculation of a Fixed Charge Factor

     Table 6.4-1  provides  an example  of the calculation  of a  fixed  charge
factor.  The  data used  are for MIS surface facilities,  using standard eco-
nomic assumptions (see Table 6.2-2).

     The  following  is  an  explanation  of  the  calculations  in the  table.
Expenditures are  shown  negative, while  income (and taxes avoided)  is  shown
positive.  Column [2] is a schedule of capital  expenditures to be made over a
seven-year period, totaling  an  arbitrary $1,000.  (Unit value is used in the
equation above.)  Columns [3],  [4],  and [5] deal with  allowances associated
with this  capital expenditure.    Column  [3] is  a schedule  of depreciation,
commencing in Year 1 when the first part of the asset is placed into service.
The  irregular  series  in this column  occurs because  there  are  five  retort


                                     380                          ;

-------
is
SI
UU 4->
X O.

Ci
   Ul

S<

Ul U
     -2S?


     t"



    I -p
   *J ^
   0) "O  i

   B23
               O 0)
               •r-  Q)
      LEn
      ocn

   " c*"1
O *»   CO
U» U +> t_l


O U.
                    2U>
                    4—1
               « e

               u o co
               Q> Ei-4
                          in oo o co en	 .
                          CM vo o co mo <
                          rH ft CM t-t TH r-t ••
§§§
                                  OICTXTHOOOOOOOOOOOOOOOOOOOOOO
                                                                                                       OOO
                                                                                                       o CD o
                                                                                         O O O O O O O O O
                                                                                                                   S
                                                                                                                   S
                          o
                          o
                                                                                          xxxxxxxxx


                                                                                        '<(j-

                                                       OOOOOOOOO.OOOOOOOOOOOOC3
                            rH 1*1 O O O O O O O -O O
                                                                                   >ooooooooooo
                      xxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
              X X XOCMIO*«*CD«i>mOt-4CSICSlCslCMCMCMCSJcM<\JCvlCMCNJCNJC*JO4CNJCVJCMCMCSJCMCMOiJ



                                                                                                     > O O O O|
                                           --
                                           -^-«*«*CO
                                                                    fH*-t
                                  lOCMt-trOf^CMrxCMr^CMtOOOOCOmCOCOCMi-IP^
                                  C3H'*^00^'t-tP^^'Or**fOOtOCMO^mCMC0^1«*'
                                                                                            OOOOOOO
                                                                                                      S
                            800000000000 o o ooooo
                            U) O tA O Lfl U)
                          l-l tH CM iH CM r4 s^
                                                                                                    ooooo
                                                                                   to
                                                                                                                           ra

                                                                                                                           01




                                                                                                                           i
                                                                                                 2
                                                                                                 O.

                                                                                                 •S

                                                                                                 2
                                                                                                 o
                                                                                                                                g
                                                                                       CMCMCMCMCMCMCMCMCMm
                                                                  381

-------
 trains,  placed  Into  service in  four  different  years.   Column [4] gives  the
 value  of the depreciation allowed  to  the company.   This value  is  the  income
 tax not  incurred  as  a consequence of  the  depreciation deduction,  and it  is
 48% of Column [3].  Column [5] is  the  20%  investment tax credit Available  in
 each year a  capital  expenditure is made.   (This  is a direct credit against
 tax and  does  not have  to  be  multiplied  by the  tax rate.)
                                                                 I
     Column  [6]  represents   the  income  stream  resulting  from the   $1,000
 investment  (Column [2]).   Income in a  normal, full  production year is  desig-
 nated  by "l.OOx."   Since  income is  proportional  to production, and  production
 in  the start-up years is  less than full  production, the first seven years  of
 •income are appropriately  reduced,  e.g, , 0.02x  in  Year 1,  O.lOx  in Year  2,
 Q.28x  in Year 3,  etc.   Column [7]  shows the  residual  income to the company
 after  income  tax is paid  on  the income  in Column [6].            :

     The 12% discount factors in Column  [8] are used to generate: the present
 values in Columns  [9], [10],  [11]  and  [123.   After summing the columns  of
 present  values   of  after- tax income,  depreciation  allowance, investment tax
 credit,  and  capital expenditure,  an equation  is constructed  to determine the
 gross  income which must  be  generated  by the $1,000 of capital  to  achieve a
 12% DCF  ROR;  thus:


               2.7168X =  925.36 - 220.04  - 185.08
                                                                 i

                       =   [12]  -   [io]  -
     therefore:     x  =        = 191.49
     (x  represents  the  gross  income  in  a  full  production  year that "is
     necessary  to provide  the specified  DCF ROR, 12%,  on $1,000  of fixed
     capital.)
     hence:    RF = -       = 19.15%
6.4.3  Cost Levelizing Calculations
                                                                 i
     While most  direct operating  costs  vary in proportion  to  plant output,
the operating costs for solid waste management do not.   For example, the cost
of the runoff  collection  system is a uniform annual cost, starting in Year 1
and finishing in Year 25.   To spread these costs in a pattern consistent with
production over  the 30-year  project life, these operating  costs  are trans-
formed into an annual  figure for a  normal year,  and this figure'can then be
used  with  the  standard methodology  above.   This  is  done by  calculating  a
"levelized cost" for a normal year's production.  This technique is also used
to spread  the  extra  start-up cost  and  severance tax  credit  uniformly over
shale oil production.                                             i
                                     382

-------
      A "levelizing factor"  is used  to  make this  transformation.   The  fol-
 lowing equation  shows  how  a  levelizing  factor  is  used  to arrive  at a
 levelized cost (i.e.,  a  stream of  payments  having the  same  profile  as produc-
 tion),  given  the  present value of  a  nonuniform  stream  of payments:



                Levelized Cost = I(Presenf Va]fe! ofca  j;ost  stream^
                                         Levelizing  Factor


 By  dividing the levelized cost by a normal year's  output,  a cost per unit of
 production is  derived.

      The  equation for  calculating  the levelizing factor (LF) is:


                                   S                         .    :
                I P = PVFA       -   3
                Lh   PV™(r,N)      J
     where:          LF = Levelizing factor                      :

                     PVFA,  N-. = Present value factor of a uniform series of
                            '     payments for N years            ;

                     PVF,   .  = Present value factor of a single payment in
                        tr'nj    year n                          \

                     r  = Discount Rate = DCF ROR

                     N  = Number of production years

                     S  = Number of years in the start-up period i

                     n  = Any specific year in the start-up period

                     L  = The proportion of normal output during any given
                          start-up year; the series of L  values Constitutes
                          the "start-up profile"        n        :

     The  second term  on the  right-hand  side  of the  above equation  is  an
adjustment to  the  uniform  series represented by the first term.  The comple-
ment of  the   L   figure  (i.e.,  that  portion of each start-up  year  which  is
less than  full production)  is discounted, summed, and  then subtracted from
the uniform  series.  Since  the start-up years have high present values, the
effect of  subtracting  this  term has  a substantial impact on  the levelizing
factor.  Because  the levelizing  factor is the  denominator  in  the  equation
which determines the levelized cost (and, hence, the unit cost), this adjust-
ment term raises the per^-barrel cost.                             |

     Cost Levelizing Example—

     To illustrate the  concept of cost levelization,  a calculation of the 12%
DCF ROR levelizing factor used for this manual  is presented below:
                                     383

-------
                   Proportion  of
      Year      Normal  Output  (l_n)        PVF @ 12%          (1-L  > x  PVF

       1               0.02                0.8929               0.8750
       2               0.10                0.7972               0.7175
       3               0.28                0.7118               0.5125
       4               0.47                0.6355               0.3368
       5               0.68                0.5674               0.1816
       6               0.77                0.5066               0.1165
       7               0.80                0.4524               0.0905
       8    )
       I     >          1.00                3.4914               O.boOO
      30 '   '
                                          8.0552               2.8304

     Hence:     LF,_.,^ N=3Q yrg) = 8.0552 - 2.8304 = 5.2248
 (Note that all present values are expressed with respect to Year p.)

     This factor is the same as the denominator in the levelizing expressions
 L.FAC1 and LFAC2.                                                 ;

     As  an  illustration  of a  levelizing  calculation,  consider  the runoff
 collection costs.   The "engineering cost" (Table 6.1^5) is  $34,000 per year
 for Years 1 through 25.

     The present value  of these costs, expressed with  respect to Year 0, is
 calculated as follows:
'ear
1
2
3
Expenditure
$34,000
34,000
34,000
PVF @ 12%
0.8929
0.7972
0. 7118
Present Vali
$ 30,359
27,105
24,201
          25           34,000         0.0588              1.999
                                                       $266,665

     Thus, $266,665  is  the present value of all the runoff collection costs.
To  turn this  into  a  cost  that is  distributed uniformly  with  respect  to
output, it must be divided by LF(r = 12%j N = 30 years),
     Therefore, Level i zed Cost =         = $51,038
     Thus, $51,038 (rounded  to  $51,000 in Table 6.2-3) is the annual cost in
a normal  production  year  that  is equivalent  to the  irregular  cost profile

                                     384

-------
given  above.   This direct  annual  operating cost can be  used in conjunction
with  the  algorithms given  in Section 6.4.1 for calculation  of  total  annual
control cost  and per-barrel  control  cost, whereas  the irregular  stream  of
expenditures from which  it  was derived cannot be used with the standard cost
methodology.                                                     j
                                                                 i
     In summary,  cost levelization redistributes  a cost series  that  is not
proportional to production over the project life in such a way as to yield an
equivalent  series  that   is  proportional  to  production  and has  the  same
economic value.                                                  !
                                    385

-------

-------
                                  SECTION 7

                     DATA LIMITATIONS AND RESEARCH NEEDS


     A  number  of  limitations  associated with  stream  characterization and
pollution  control  technology performance were  identified in  the  data base
during  the  preparation  of  the Pollution  Control  Technical Manual  for the
combined MIS and Lurgi oil  shale retorting  processes.   It is  important that
users  of this  manual  be aware  of  these limitations.   It is also important
that  these  limitations  be  addressed  prior to  development of an  oil shale
facility of  the magnitude analyzed in  this  manual  and proposed1by Cathedral
Bluffs  Shale Oil Company (e.g., 62,000 TPSD oil shale mined and 117,000 BPSD
shale oil produced).                 "

7.1  DATA LIMITATIONS

     The   descriptions  of  the  MIS   and   Lurgi   retorting  processes  and
information  regarding  applicable control technologies, performance, and costs
used  to prepare  this  manual were obtained from reports  on the :operation of
pilot   MIS   and  Lurgi   retorts,   vendor  descriptions,   and:  engineering
calculations  used in  conjunction with experience transferred  from analogue
industries  such  as  the petroleum,  utility,  and  mineral  mining industries
which  utilize similar control technologies.  Until  "hands on"  experience is
obtained from commercial-scale oil shale operations, these sources constitute
the best  available data  base.   However, the  limitations of this  data base
should  be   clearly  understood.   Pilot  retorts  were  built  and  operated
primarily to improve  process design and not for demonstrating operation of a
commercial-sized  retort  with  attendant pollution  control  systems.   Many
pollution  control  systems  have never  been  pilot tested  with  an  oil shale
retort.  Even for  those  control  systems that  were pilot  tested,  often the
data collected have been very limited.

     To date, the only MIS retorting experience is comprised of the operation
of one  small  (Room 3E) and three large^sized (Rooms 4,  5  and 6)  MIS experi-
mental  retorts  processed by Occidental  Oil Shale,  Inc.,  and  the  data from
some laboratory-scale  testing.   Two  more large-sized retorts (Rooms 7 and 8)
have  been  processed   recently,  but  the  new data  are  not yet  available.
Although the  large  experimental  retorts have been comparable in size to that
planned for  the  commercial  retorts,  they have been burned  on  an individual
basis  (with  the  exception  of  Rooms 7 and 8  which  have  been  processed
jointly).   By contrast,  96  retorts  in  an operating panel  will :be  processed
simultaneously  for the  commercial-scale  production.   A  scale-up of  this
magnitude is  likely to involve  some design modifications which could produce
changes in  the  stream compositions,  flows,  and performance of  the  control
technologies.                                                   :

                                     387                        ',

-------
     The  primary experience  with  Lurgi retorting  involves two 'pilot plants
 (5 tons/day and  25 tons/day)  and several laboratory-scale retorts operated in
 West  Germany  during  the  past few years.   Shales from Tract C-b, Tract C~a,
 and  the  Colony  mine  in  Colorado  have  been  processed  recently,  and the
 available  data  from  these tests have been  used  in this manual.  ^A full-sized
 Lurgi  retort  is  expected  to process  8,800 TPSD of  raw  shale,  and seven of
 these  retorts will be  needed to  produce  48,000 BPSD of  shale oil.  Again,
 this   represents  an  enormous  scale-up  of  the  pilot  retorts;  therefore,
 improvements  in  the retort design and operating  parameters may be inevitable,
 resulting  in  some uncertainty about the performance  of control technologies.

     Variations  in the grade  of the shale also introduce modifications to the
 operating  parameters  and,  hence,  the data.  The MIS  field retorts have been
 operated  at  Logan Wash,  while  the  commercial  operation  is  iplanned  for
 Tract  C-b, which is  located several  miles  north of the Logan Wash site.  The
 grade  of shale at the two sites is significantly different—15.6 gpt at Logan
 Wash compared to 26.7 gpt at Tract C-b.  Furthermore, the  mineralogy of the
 two  sites is different,   i.e.,  Tract  C-b is higher in pyrites.   During a
 recent MIS burn  at Tract C-a, which is located  in the vicinity of Tract C-b,
 up  to 4%  by volume  H2S  and 1,500 ppmv  COS were  measured in  the off-gas
 (Sklarew,  et  a!.,  February  1981).   It is likely that the  shale at Tract C-b
 may  also  produce an  off-gas containing higher  amounts  of  sulfur compounds
 than measured at Logan Wash.  Again, this  may translate  into an uncertainty
 in control performance.

     Given  the  potential  problems  associated  with process  scale-up  and
 variations in the quality  of the  shale,  a linear extrapolation! of the data
 from   pilot   operations  may  not  be  entirely  applicable   to  a  commercial
 operation  or  to  other development sites; therefore, a direct transfer of the
 information must be made  with caution.  Also,  the MIS  retorting operations
will likely be more sensitive to site-specific hydrologic conditions.

     It should  also be noted  that,  to date,  the MIS  and  Lurgi  pilot plants
 have primarily consisted  of the retorts only.   The Room 6 MIS experiment did
 include an absorber/cooler to recover light.oils from the off-gas, but it was
 sized  to  handle  only  15%  of  the  flow  from  a  single MISS retort.   A
 thermosludge  boiler,  or kettle evaporator,  was  also  employed  to  raise steam
 from  the   retort  water.   Other  pollution  control  ^technologies:(e.g.,  FGD,
 Stretford, Phosam-W, steam stripper)  that form the basis  for a complete plant
 as  proposed   by  Cathedral  Bluffs  (see Sections 2 and 3)  have not  yet  been
 tested with   the  MIS  and  Lurgi processes  (the  recent Room 7 and 8  burn  at
 Logan  Wash included testing of the Stretford process and steam stripper, but
 data on these technologies are not yet available).  Therefore, actual control
technology performance and  compatibility   with  the two retorting  processes
 have not been documented.                                         :         .

     The  fact that  the processing  streams have been measured in  terms  of
major  constituents  only is  an additional   limitation.  Information  on minor
constituents,  which  may  be  of  concern from  an operational  as  well as  an
environmental   viewpoint,   is  not  well   documented.   Examples   of  such
constituents  include  regulated  and  nonregulated  pollutants  (e.g.,  trace
                                     388

-------
 elements,  specific organics,  Inorganics),  all of  which can  have  an impact
 upon the choice and operation  of downstream control.

      Assessing  the limitations  of  existing   data  sources was :an important
 by-product  resulting  from  the preparation of this manual.   Since  the  best
 available  information on each subject was selected,  this manual represents
 the best currently available data base on the MIS and Lurgi processes; also,
 within the limitations of available data, it accurately estimates the control
 efficiencies achievable.                                        ;

 7.2  RESEARCH NEEDS                                             '.

      The limited potential  for the transfer of control technology from pilot
. and semi-works retorting tests and from analogue industries to cpmmercial oil
 shale operations emphasizes  a  genuine need for research  in certain areas of
 oil shale processing and pollution control.   This need is strengthened by the
 fact that, even with  several years of experience,  the oil  shale industry is
 still  in an early state of development.

      While it  is  recognized that  further research will be essential  in all
 phases of  oil  shale  commercialization,  the major areas of data  uncertainty
 regarding characterization of  streams  and control  technology  performance,  as
 revealed  during  preparation  of  the  MIS-Lurgi   PCTM,   are   identified  in
 Table  7.1-1.   The  status  of the  information   is presented  according to  the
 development stage  of the  source and  technology.   The  specific  information
 sources  are also identified.   A reliability or confidence ranking  is assigned
 to the data for each  stream and technology based  on  a subjective evaluation
 of the  direct  applicability of  the  data  to  a  commercial-scale  MIS-Lurgi
 facility.   Some  salient features  and  caveats in  the information base  are
 noted,  and specific  research  needs  are  identified to overcome;  some of  the
 data  limitations.                                                ;
                                     389

-------















Bj
1
ac
t—t
i
i
£
Ul

"~ '•



























Ul
"S
0)
3S
x:
s
S
0)








!
£

O
•3*
•r-
XI
m
tf-
I
*i- 
4J 01 U.
*O Ul (A
S 51 S 1 5
J .. I; 1 s | . • g ;
•*- *£ at x: at *? x: o» ' .& 2
*« w .ll £ •** ^ 5 x» . 5- £
 ui ^ S *o» « c
S Io5fcc i fe= i a« i
-- ^*"S S-S . i • 8-S i .t
§^  4^ *J O (O *^- • CS* (O*^> C*^ *ffl
O XI C Wi S- O1TJ Xi <0 £. CTT3 XT fl) 3
&-O CfD O)£.0> O > GJ t. OJ U > *5
*t- 04^f-0.3C 0» C3.3C S O
(U . 3  O —> t— +J O) CO
O 4** O Q. *13 J— 35 O h— 4>* h™ S£ O J^ 5 H»
^?* r— m
«o O) *— ro S
1- 4J C (d 3 Ol C<*-

E « -3j»-4J ^ 1£ *i c*03 c *^-o>4 •oo"0*'^ S-o^wm "5.
•i* O C *t- 3 C f- O.XJ 
•P . o >»••- o £--OO> ^uv oi5cc(-*4^u) E c: w» Q. o>
*4?'ffl'Ot.3 *"uT3 C'S'o.eUl 3^2*0. 4J<4J*U1 ^5 i2 "o "2 W **

'SlSS't " 112 i§l*l Ss5i *s8si '5J^feE 1
c >^ (j (Q ^4J'a <£*£.£> CT-&-c o *^- *3 K w 15 4J
aj>3oiwio. 4-» x: 3 at o 3 at ui u at x: &. « at at *o>  o at ^ t- i ^c S o»

csj CM i-H eg iH to
t

n 3.
(**• r^ IH
»-t rH


j SC *~<

S-
t. «
 r- >
.u>1r J^
t'«- 4J O)
O ft. 3 .
i ro a. jo **— • i
i o.^ O.C- !
Ul
0 E
•^ S
u> u_

*i w *a M
ui a> c ro
' u> «•"•» ia •' ta
0» • 3 CO w
-!-> 01 £. >, +J
^2 £ en at 5r s_

t 01
j3 . ^
* U
tOH--— ' 0. JE
390
ro
X: r

*o
i| :
c

xi v) at
a; «j E c
t5 §
j= t= x: o

Ji Sxi*-g
liili
c to es a»ja
^1 « co t- +>
a> s- s- o o
x x a. at s-
at at o s- 1—
i






;






!

1



00 '


*T* :

r*»
t!)
•
^ !


-------
s






Ul
"8
01

x:
2
CO
8










Remarks




u
xt
to
c
•2"°w

^ §
si 3
O O
»*- 
C
o
(0 3
E4J
rO
O 4*
«*- V)
C
*••*
f £
152
«— 4J
£O
U


o
s-
c
o
u
i!7
CO 0)2=
O
§•52
CO C 2
2x: at .
0 v-
a
T3 4->
t- E
3 O
Ul W
(O «*-
CD
e ui
co

XI
ofi
4-* O
13 0)
o> s-
01
C V) •
01 flj
»-l-.e
tl Itf V)

wo1?
fc«0
3 C 4J
1- (O O
p— CO
3 C t-
W>-»- 1—


ro x: ui
J= 4-> C
C 4* 01
e 01 c t-
m ui o 01
:pls
uT-o !o S *~
il-SSi"
g^'S)

s. 8.1 ra*i5
•2 e .* «
S S ra &•£
01 .a C31 E E























0)
U A
c o
IS
<*- 01
o c

01 *
c u
ui 01
XI
Zs
O "U


$ ° TJ
o> « o>
Ol i~ (-
ess


I
(O
T3
C
3
O
t
nitrogen co
•o
-«®
1 O
c a.
2= J-
























•
ffl
C
,f~
2
€


3

tJ

4->

-o
a.
3
1
(0
U


2 «
o 4->,>>s-
£i/) *C *»
• S £ ° £
t» 3 *O
0 01 Xt 0) 01
^5«55
« c m a m
M "" 0 f 2
** ."^ 0) "c 3
01 o x: 3 o
5 *> *" *~
>>'§iliS «
DJ*i~ >• (D
o r- s- cn
lES-SS
x: ro cn to 4^
u 3e
01 P34J 
rt



u


1
-J
* Ul
15

£.
jS*
1


1?
O CO
5CJ

£
(J Ul
Ul 01 01
SoS
x: **- «
4J 01 O)

c *— aj



01
a. 03 3
"S o >-d


(Q «4-> 4>>
t— 0) (0 U>
at c 01
i"£'C a
0) O T3
x: o c o
1— U CO 4J
«—
» o cn > or
fc* x: c o ai r-
ro v **- e x: xt
*ra O)*al s- o tu '-P
cw.-e'a es-xrw
uioiaiuios- *— no
*I""*-4JO 'P-3E01 01X) O
«x:**--f->,EfOX> uiu
(0 U i~~ O •"" (0 C C 3 01
4J w c T o uti^o
«t- 3 xt
C O l-l O flL-r- 4-> •— O r~ >)
xi'a. 4J - cu x: *p- o4>>coE
Xt E • C T3 4J U
301UIU1O >> 4-OU1

"c-^^SIIa^ *«fioe4J
01 E 3 O »~ ' *r* *r— «i— 01 O _Q O
30-^s-«a>— 
II
Ul Ul
ui at *
« s * u
x: o 4-> 4-> *o
4-1 S- -i- 0> C 01
CL E x: o> 4-> •
TJ £1 +J O  U Ol 01 01 O>
Is* l^«t
tx si c**" co
 a o. ui ra'O
50 x^ ^o c
>va> 01 ^a1!^
O} S- *r> Ol <0 C rv
o <*- c cnx:
O *-» T3 4-> 4-> Ol O
C £ O . CO $• 4^ O
.C S (- O OS
4^ rnx:"? I^Silxi
£ 4-> 3 4-*
H- Q.-^- ••- 1— £ .O -H-

-

VO
uT
<£
CO

»-4
"




i1




^

5?
£*!
4-> CO
(/) 'W

|3

c
?t
s^

(Q Ul
!- •
01 01


5 «•!=
S"SS
O f* O


J= S"0
u > o
Sai*1
0,^-g
x; o a)


5?* Is
r- U Ol
(TJ 3 "O
i«££
U -P V)
U> -4J 01
(A T- n
•*- s- x: *<-
4J 4J 0
O T3 »— C
r- C (O 


-------





Ul
•3







1
Q-



U
.0
re
* u
re u
*c *^
c
£

•P tn
re 3
1 re
O -P
•«£ w>
2 1
Is
r— c
0 O
0.0
o
fi.
1
tn <••%
•o to •
§•51
i-52
« B 3
V .C CD
SJlSS



s*
fej
**" S
U) C
.*
c o
0) P
•r— 41
U
**- U)
**- C
o> re
P
The contro
CS2 s merca
determined

o
C 01
1 tn »r-
|J

E C
O f-
3 *£
<4~ <*-
ui "a ol
nil
1 O -C
c u u
5K 2-4J































VI Ul .
N O "O
*ic
oo,-
>» o c
S t2 cr
•f- .a
u «o a
•r- Ul J2
<*- o> o
01 TJ P
 0)
tn re .c:
P &. -P
c o
iz's
ia>,
0) +?
ai -a »i-
5o-S
Ul 4J 3
«i a-
a> ^
o c at
UI4J+J

































(O
•^ s
£ U
re •
•a -a
U S. O)
fi. fi. C
o -P re
V> 3
 -p
il.1
*> ^O)
« O «-?
E m .a
s. re
f 5S
5 5-1
i- c ra
Is"

> *^ IA •
*• re t-
OJ 0) OIO
*» r- T3 fi.
re 01 o
q > +J ui
-P o re ja
O) 0) S-
C fi- -P O
T3 t/) 0) O)
fi. «-C C
Jut
(O 4^ (0

































•D
0)
c
(0
•P
0
o>

s
0)
2
re
•M
re
Q.
3
1
U
V)

I
tn c
re o>
x: P
*> s- ui
'555
01
Of t. *
U 01
o> O) re
*ST 3*5
O) —J
Q. *-
X -P -F-
0) O O
Oȣ- il
e Q. i
** «* T3
o) ""v, re c
&C S- O)
•p"~ §
^iji
h^CM ,P"O








^






Cj"




1
1


I
t
1
01 Jo
•F- I
O CO
Is

"O O>
0) U .O
t-«£ *C 0
O > O T3
<*«• Q) 4— 0)
o ^a o c

o> o a) *
C CO
0) tn 0) -P
w ~a m Q)
fi. S- S
0 tn O ID
S*r> U C
u u re
ss. §& .
ui tn tn *o
Q) (U * 4}
£ s. S w-S
a. 3 o. « ^*-
o^: 0Zt
f 3 .C £ Or
1— in I— to >

J** l
5 5 *> i!
re o re
f 3 -S
ui J3 C
41 - I
c ui a.
a> 01 o
a>
> -p a>
5 e §*
•»-*»- s-
O *^ "^
V) C C *
*O Ul P3 O)
§2= It
CLt- I O
(/) r— C O.
« « 3 o at
Z .Q in Z fi.






























tn
•a
   -C ui ui t* a)
•r- •** 3 -P J3 -P •
S. Ul T3 S- m ^-N
t'*r- >j c o o O) 
i.!-J>,'::Sls-
O **~ +J ^— 0) ^^ i~
Q) ^_ ,_ (n 53)
)_ «J J) O Ul OJ^ *J








^
s





3^
C3


(/)
d
X


^
<2aT
•P i
•P CO

c
re •
0) Ul
tn re
at CD
ill

t
o
•P
VI
E
£.'
3
Ul
S-
re
1
01
I _
a) ui
a> re































392

-------







c
t— t
f ™

+» in
1 3
s- re
O +J
c
T3
re ^
IS
1— C
o o
a. u
*o
+3
c
0
o w^
•o oi .
(3 *D>Z
0
Io2
IB C 3
2 ^u ^*
«££
o
•p
in
e"S
O Ot
? ^.
in p
o c
tgj
£
U 0

to x
010

3 111 .
C +* o>
*— >)£
1? i


U O.
K S 5
" >> 0>

O •»•• +*
The information on the flue gas
composition has been obtained fron
the Cathedral Bluffs PSD applicati
and it is calculated from the qual
and quantity of the fuels used in
steam boilers.


OJ


rt





,_,






I
1


Ul
(O
o
Ol
3
tZ *~*


r- CO
O CO







&














•P e

A lime/limestone scrubbing system
95 wt% S02 removal efficiency has
been included in the PSD applicati


«


rt





t~4





04

S




*->v
pH
1
O •
O CO



4A

1
c
£
£
•8
Si
(J_

C
to


>T3
O*-^
*0^
x: at
u >


01
JZ O
t— -p
s.

P >» £
The operating experience with the
retort gases is not documented, bu
the technology is used commerciall
in many flue gas desulfurization
applications at a scale necessary
the HIS-Lurgi application.


CM


fH





3=
(S



















V)
•S a

cC . «
i— ™ .e
O 10 w re
V> 3 fO *»
"oS" °
*• s- at
co .a
U CJ C
C t- t- *J
 m •
T- Ul TJ
III & CSl

t. 
*-s

X! -P D)
«*- t- E
e* a. t-
at a> -P
x: 4= a>
^ «p T>

B) 4J ffl ON
n c j= o
4J tO-r- .r- 01 =» +J NV>
•C 41 • IA C *r*> O O
»*r- «J3 fO 0) (U r- (A
13 ^•** O O .Q -P £ -P O) (A ^O U JC QJ
o* insure +Jt.in ." « c 5 ai c S
•^>-o u -»-o»o u^uim IAQC
•a a> a> in r— •>- S*»JE 3 t— m i— «*- 3 01
C *— fsj *r- (0 r- 0> r- ^imORIUlL.
"•-»•£>,§§: 81-*- ^ .a:-0^0"'^
goSSI10 £•&« 51515.°S'S2
.r.4jr_ s- r- TJH-cnu)f cnja
oo «t- itz a»oo -P o> f~'avt 3
^eaiaia)^ w^w c«S«mwc
c f>*
«r- fc. +J »— +5 C CCLI ** O TD 0) fl) W
». « e S <="• £ >,°-d §5** §S 8- §
-s^-^i^'S s-stj^s "•o's^^ss^
C C > OJ -M +J <»\fl3C: MO>Oll0£.OO(d
w tO E S- (O C3. K S- QJ O -P "O **•• 0) S- 'P* EZ
>uo. s- o o OH- E W3&.=if->a.tftre
Q. m O) •£• 4-» =3 O'i-94)r* Q.
.c o o j= o c JztnfS j=0)u>rtji-^Gx
H-V)tni»^->r- h-esi-P*O h- t- -i- E •—• -P Oi  in '
t— CT \



Q)  E «»
1 2 sl*l i
tJ C W) r—
x o> o ai
O -P U O
SE t~~t3 C O
o c) nj 4-*
(U Q. in,i— «
.e 
h* &* -O J3 -Q











'







;












393

-------
s?





Ul
T3
O)


J=
2
<0

U>
O
OS




/c Remarks
10
I
" C
0 .Q
•^ to
*> a
i SJ

O O
is "
c
o
•r- CO
4-> (A
§3
•*•»
o 3
**- t/1
C

13
"e t2i
II
il
£
•*-»
c
o
o
Ul <"•%
C •!— O
(0 ens:
o
H*0 2
10 C =

S- O "i-
4J Ot U.
h-^





















An electrostatic precipitator to
remove the particulates from the
flue gas has been suggested in the
PSD application.
m




i-.





t-4
CJ

Ul
O)
4-*
(0
3
U
1
o
** o
*> (0
U) 4J
O •«- *~*
SIS
uj a. ^*





T)
1
CO
1
0)


o

•o
0)
c

(0

•8
s-
1
or
nj
u
(A
The operating experience with the
Lurgi pilot plant has been obtained.





























Ul
"S
c
5-
*^
.n
CO
s-
<£

u>
§
t.



O *^*'
1!
0 >
0)
-M 0)
0)
h- 4J
(O CO 3
O U) •*-
0* C0 *r-
§'« a
T3 4J
v> c at
o .,- o
111?
U CO
O> U Ul
^ S 01 (0
t— T- c en
CM




S
r«.
rH



ar
«

















4-
o
at
5l'a,

** O
Ul 0) «)J
C i-
O Ul Ul
•»- 01 T3
+J t. 0)
CD at
'flj *> ui
> 0)

**- O (0
O i—
Ql 3 .
-u-a o -a
u »o •»• ai
a> s. 4^ i-
 at

c *» c

 U
41 C 1-
^: o <*-
H- O O





















Moisture in the flue gas generally
decreases the resistivity, thus
increases the control efficiency.
The fugitive hydrocarbons are
estimated from the properties of the
oil products.
The double-sealed, floating roof
storage tanks for volatile product
storage have been specified in the
PSD application.
CM




*•-

rH




•-*





1
1




U
I
si
7 c
•- i
11
if 5
tM




rH






»-•

C
o
f
s
o
s_
I
s-
o
oe
en
i .=
> +J o»
;CO J^
) ° a
' Ll. H"
i

i






















The floating roof storage tanks are
used commercially for oil storage.
rH




00
rH





.j.
O





































Routine maintenance of the valves,
pumps, etc., is a commonly used
operational practice to control the
hydrocarbon leakage.
rH




S






0

Ul .
o
•£
CO
u
*

0>

10
c
Ol
••s
I







,















j

All diesel-powered machinery is
equipped with catalytic converters
to control hydrocarbon, and CO
emissions. The catalytic converters
are a commonly used technology.
rH




S :





-T-
<3 '•

U)
O
f :
CO
u
2
•a


o £.

S •«
11 :




                                         394

-------



















-

s
c
8
*•.*'
1
•


a
1








































01
•o
Ot


2
s
U)
at







1
i




u
>v
•P

I
i
* OS
c
o .a
•^ (A
rO O
I! 3
O O
c
o
.F- IQ
4-> 01
i |

O -P
*5




4-) at
C •—
to *—
3 S


r- C
O O

*o
s-
£
o
o
c •»- o
to cnz
o
w> F— .at
i c 3
£"6.?
-P Ot U.
. 4-> Ol Ol T3 Ul
at £ a> at * a* j= •*- 01
T3 C *r> "O *t— Ot 0) 4— U " T3 ^* 4J *4— aj
ot at o <*- at .a .co c o o 01 at -P •*- c ]
•r- 4J >i.C £ •»- £. >» >, Q. Ot •<- OVr- +J C >»
<3 OJ+* C flj Ot <£ (A 4-> (J +J IB C U) (Q +J ,
•P COiO-ptf- 4-» "O ••- COIR] 4J .<- « at 3 ..-
jg IP- i— I*. 3 J3 |/) ip. y ,_ gj ^. ^p Ja > r> 3 Q- i™
O O O O" O C 3t 01 *r- *r— (Q O O 7 *i—

A U >»-P J3 J3 4J W Ul S- f- O J3 £- O C S.
C£*r- »— t- O <^-r-4^< 3 . -r- O Ot
at 4J nj 'oat S-.RI c "T3 c .P.POUI c
TJ ^ *r- 3 y> T3 r— i- O. S HJ C S- >»-*- T3 >s C *O «** "O" CO
at *^ ui tyo o) o 4— c- (do »~- E 01 u o 3 w t
 Ol C *"~ C 4-> 4-* W »— £> O) C U r*— 4— 0> 4-J
** O t, 4J 4rf r— Ot at O *"~ ^~ O 0) *O -P *r- C CO C O *f~ •
ra o> >* at i-r-o,  o c  C t— O H- 4->
•ni >>!. • ' . .
f— c *>~ "oatQicu*o • <• ai *
ra&* at *?- -P 3 OO *— E -f .c 4-> ' in >> •— 4^ i- 4J c u> C
.^*J OJO^C t.*Ht.ir* O»-r-gO «*-S "D **"
4^*a.c 01 at u •  o ai 3 x: s s- o t- at otc >» 01 01
I- 01 W t- Ot >> 3: **- -P > ••- t^XT-P
O C (Q iF-(tIO.O) 4J O) OCrQOI*r*>C
4J t- S 0 01 O S- 01 U UO2 5 O 13 3 i- RJ C lO (O OO) O 01
at re 4J a> a> «— oatai*p- >r- at ^a at "a 4J ••- s in c gene
L.-PC e 4-> s. o 4^ 01 j= 4J at-Patj= otutc rou> CL c «i T- ECO
^a m at -r- &. to 03 >— o ja i- x: *» u 4^ 3 •»- s- TJ O.-POI ••- E o •»- a.
at o en E 01 x: T3 s- at re TI 4J c o • 4-> i- t-^ai -o «j u r— E
.cov-4J>»njt-s- 4-»-aj»;atc:w>i-«— o &.O.Q o •— o
-p c _j s.' (— i- .c Q. ai . a. op-r— -P-P <+-  C C0> t- O) X; 4- r— Ol Q} Ol O S-
c at 4-> Q.'«- *a w "o at "o v- E- at ••- >>-P o s-  01 +» at
o .a «o xu4^c C-POI >» • 4-> ia o. oi o <«- u x: £ IAUI .,- c »—
ait.c 3 o ••-
CMC at at at £3 E o at o at at r— c- a> -P.CC c to ra o 4->
O « £. .C E S- >> -P 01 4-> ,C 4J -PO'r- >>.C (O -P £- 3 U C 09
f- £ 3 oiEa)Oj(Of*-4->>» 01 nj o)nc 04^ ^ n o •>-£«<—

&. *i— c ja T3 s- •p-atotso) 01 a> v> wi ra s- 4-> »o u 01 ro 01 at • s. ai id at
O -P E rat O) O > S- E •<- i— 01 •— in S. O >r- •«- "O C U O) E > Ol t. 4->3QI-P
C Ol O O r- 1- »-< S 10 U 4-» E 0> U oi at O 01 .C-PGC uica. scoot
Q. U C < S. S  S C ' H Oli— U HJ Oi fO ••- re JS oi 4J
at E at at *o nj at o *d *-* a> at co 4-> s at *»— 3 c •— at o 01 s- at o 01 01
J=QJ= jz s- o J= coo MC •»- >,^i at j= t-« 3 o x: 4- E a>o^= X&.-P 4-»  «
•a at at o z
C (A "C r— f- 2
ca at c s- *p- c
01 o> a -P m - i
ui re n,4-> re oivi
«— • at u> *> *— s. «
1 'f- J- 3 (O OO3I
t 00 VIE >Ci -
0) '

<0 C '£•* '
t. -S- *P- O S- :
at o -o ••»- 4J
s_ 4-> *» *^ at >»4^ tn *-*
« ? IS 'B^-p iS»

•P r"« o to *w» as CD ui w> **-•
£.1
15

395

-------



















i
•s
o
u
iH

1 *4
I*-
i

































Ul
1
j;

re
«
0£






Remarks

o
$
1
"at
OS
e
O -Q
P S
e tJ
O 0
**— VI
c
I
£ Ul
re 3
I ?
c


*.!
C F^
11
0.0
"o
fc.
-p

o
w -*-»
1*5 £
a» js oi
•P 0) U.



•o
a>
c
s
•8
at
s
•a

c
ra
-P
to
•o
§•
1
Q»
S
tn
c
C 3
 u c
*O *C O)
u> « t.
Ul O} O
00~



t-
•3 *~»
0» S- t-i
Si.A
•P re <
o* > m


Ul
T3
ai

&
^
R!
0)
(A
IO

** .
O T-
1— <*-
O i-
C fc.
^ ai
u >
is
_>,

m
d commerci
The technology is use
in other industries.



M



00
*"1
r5



3:
C5*
















Ul

0)

01

0)
s-S
P- C
.a o .
OT- -a
E_ 4J — Ul -P
C 0) S-
c -
S5? >,Ji-g
cf l|i*o
U "O E W ui
^ O S- O» 3 O>
WO U GJ O) <0 *~~
S.t» +JT3 0 J2
0) ^0 ui re 3 at >r—
•P «r- S i— .Q p
(00) 4} V> ' fi,
"a -P a» u> t- re- u
<*— «r— o re ui
o £ u Q.P tn ui E
j= S •*-•?** "~ In
010 at c 4-> tr o
So. i^ini.Snii.



CO



00
*~1
r»*




>— »
















Ul
•o
• 0]
•a a*
£
5 £
•§ £
at |
0 1 -
-P Ul
•a re
ai S-
g ** .
a oia
•3 ||
& II
S; So-
lo at10
iJ SS
S.


Q£ V) dl -P O. O O
+> a> E re «»- co
§t- O EC "D O *>
O U O 1— * U> t. O> *r-
•P3 CJ •r-OI>-P'O
Ul Ot Ul -P r— U O)
TD 3 3 Ul C O U1013
3-PO =70r-4J*^S-*^3
4J .,- t- O t- T3
Ul Ul T3 Ul-PCO S^ W
at *r> re -C -P a) LO *r—
>> c -i- u u at f 01
S^ t. S*— -P >* ai
i— re o CL "O 4- r— -p
i. ore^za. -P to at
o -P e c -P a. c RJ E r-
J2COI JCI- ' •? 0 B ^
P— E o a> f **~ -p -P x *»~ >
4J 4->P(SUl o •
ot oc in

(
>>


o 'Sla
&'&'«_«
at 3 a) M
u i at re
*- Z: o
™ at1" §!-d '>
C -P Ot i— •*- :

>» o c ^ Z
•P <*- Ul U 01
•r- i. 01 > '
S««^5
U) -P 4-> O '
re > :
c o)-ff
^•0 -rj 4-» CO


Ol •(- (TJ *-M VJ O 'Jc
c &- r~ u ui +J &>RIUU
o n, ci * c 
^J ••-  3 ca c en
j= C 3 x nj ra i— c a) o 3



m
.


(-1 '
*
*"t
o
1-4

« !
W





*O C !
« RJ
.2 ?
QO
s



o
•P CO
I IX
S_ in ,
re -o in

i
396

-------







01
1
at
z
x:
u
i-
s
£











S
S.
CC

u
£
x>
re
a>
Q£
c
0 XI
T~ Ift
% s
s s-
t- 3
| 5
»H
•r—  Ui
I 5
£ re
O -P
4- W)
*."§
a^
IS
r— C
O O
0-0

3
J
c
D


~'S °
5 *O £
ux: ai
3 ai tZ
/i h- ^^
(A


4* s- a>
o*».oc
>» O "O >»
0*4J C *?
c ot re f
a» s. f-

O W> 0) XI
 C
c oi re
re t- s-
O 0) +J
£ *£ p a»J5


w re at x: ot
301 C U >
b 0)

QJ O *P 0)
i£al 35°

>>o> w fc w
,» .f— (pa Q _g £J
re -P i x: «t- -P GO at •
•«||^c^|
at a. re i— « «i a> -P i—
§O 3E 3 01 4-> O
o re T3 c
Sat 0) • Ui *r- £ O) XI
.C r- -0 -r- C -^ OJ 0
t— re oi re x TJ a>
ot wi c 3 t. s. •«-»
3 in ^- E ^- O. 0) *f-
o» ••- 5 o **- < £. x:
w •*- O o c o re 4^
•e- t- OX!
o "o 3 o 4->recai
§*" *r- oi x: 3 -P O)S
o u> +* s- c &. re
x: t- c -i- 4-> a> o -P
o at a) » w o u
o a> at 3 u 4J -P
0) O.-P CO) Ul
xrexrerexjo**-*


m





*
rH

S
00


nT

o


01
c

o

I
s

e
O ^-s
E- f- O
— 4-* CSJ
Sl~
3: o S





•a
w
13 £
•— .p re
re re f. -P
U» 4J . Xt
o •»- -a o
a, a, a*
•p- u re xt
•O 0) 3
t-r- 0
•o a. re +J
x: at
C +* 0) • Qi
"U o o re
re 4- -P -P
N re
H— y) *o *O
£• 0) at
5-gS §•
o re i
re o (n 0)
S- t- -P t—
re a.r- re
x: a. re u
u re ui t/i
c * -a
t- o at •— at T? at
re *f- i xj re -p r- *i
$. r- +j ai 3 u >t o re
oore-P>>c&.a)-Px:Di 01
<*-(/> t. oi re re at fi-j«r- c c
o re E E x: a) u o *i~ ./r ot
•a a-3 -P s. ^-p c u> £-i-a>->-a>c w
r— re a) at c o at 01 > > o re
§% O.-P 13 I-H <4~ +J re O O >P> Ol
oioreat ro s- t. +j
E -P s- +J "o s o O.-P re • at
E in c o re . ,01 -p 3 s- 01 x:
u 3: re i- i— 3 x: s- x: a. o
c > o.^- -p -p re -P ra -i— 4-
ui ai o a) T- re yi c «r- > s- o
•P-POO)**- O*r-Ot 1 O. C
>j C-PS.T3>;Ut.S-3 0
^.f§"g «Z^|£ ™'re'2J S
g-Puv>x:aio.p3u3:at-P 01
rec3H-o.cre(/ireo)x:re o
x: s- -i- x:&. 4- +j -P -P a.
Ss_-aato uo£ >r-u
otc-psatc -o at i- ,cx:35- x:


CM m





°1
rn ID
7-1 *




aT ""t
*> u
o

T) O

11
» §
at-i i
?
O
a. ot
c . re
o ui
*r- C
tO CO "D
£.fH C
t. O t O
5&~ "
W U S (0
<3
i
Ul U)
at T3
Ul 4-> 0)
i «*- f— re at
s- 0*1-01 c:
£ x°S >>
5 . rsi s
•o at o *-
41) 0> *l~ ^~ U ' *r~
x: *^ u re xi
f C O S S-
t- $. 4- E ai at
O O) 01 Q> • 4-

*» at c s- -P .P re
*i- xi re o re t.

!S 3 5'^£*re >>-d
re t~ oi1*- > oi o)

tnot «i— c w xi c s-
c c ui x: re x: at
re re u at o u >


x: « x; x: c at x: o
H-e h--H<0= t— *>

o> c

i at ui at re re •o «i ro x» en •*" i^^fe -c-d S at o c "O 01 +J at a) at o xt -^ -P s re s- o x: o 3 f- QJ at o -p c u "o xz o_fi£ at o ot u at o *C 3 ui 3 f- r- x: at -P at n ore*»m CLO ^jn-j- IO C O S *r- O» -P O S- O f— Ul >, Ul £ «r- Of S- at O>«- Ol 3 CK13 WJO'OE -PO) O'^ at o u ai re -p c. ate o. c t. s. re x: t. x: -r- E a> •!- a . at ui ua> •PS o x: s +j t- a. c at x: m ot at 0.1— -a o o -P a» t- 4-> e o at c at s. at x: o at o o x: o x: c e\j a i*« i-t a: 0 ? u> "S m re 00 s- s- 5S^ re re co ? ^ ' 00 O Vt *+s ". en i : o : 0) -P T3 .5 S U) Jl £1 Ul £ g Q.-0 C 0 = Ul Ul • • ^11 >— O XI .1 II O U) ! c ° ** 1 1 •»— 0) at +J o> c* i +^ ^ r-n'm = = £ S-s:^-0 E0«0 : S 2 *. >, o re o t- i "- o. re i « at ui w • **- W r— « 1 a. 3 S < "5I = •^ >1^ «) : 1 ; , 1 397


-------

s.
o
V)
i.
41
1
Ul
•a
4)
J=
re
4)
4>
4) -P

4)
re
3
•P
1



s

1
Ul
i
2
41
4)
en




4)
55
C
•p- TJ
O
T3S
C 4)



S£
€ .
Ul
c
p- re
o u
o "a.
ai a.
+J re
tw M_





Ul
Ul
s
O
t.
o.



1
S-
*c
I
£. .
4) ui
> f-
 c

0)
5*3
.= §
•P
4> Ul
U S-
C 4)
4> -P
41
O. ui
X ui
01 g
0)0
c: s-
re 41 4i
4i *rd £r
CL.C: o>
OWE
J=£ a
ogy transferability needs
ated.
•— 3
O P-
C (O
JC >
Is
^
,_
re
1

y


4)
Ul •
3 ui
OJ
Ul »r*
>l W
O T3
8-
J= S.
U 4>
O
!.£
Ul
§,
41
.C
•P
U
*c
s-
°
Dissolve



U)
re
j=
-P

c
Ul
1
S1
O
T3
4>
>
O
Ul
•P a>
o
*i ai
a. o
E C
t- 4)
S
x: 4»
^ "^"S
re o re

condensa
efficlen
to be es
re
i— C
^ 0
|l*3




« 4> r*-
t- re
4) U 3

to »C
J= t- 4)
&«5
E j= -a
*j =
re o >) .
Ul S- -P
C -P 4f U
f« o-a
a. u o
O £ 4> S-
lity and efficiency of
ogy for the gas
need to be evaluated.
51s
ui .c re
re u ui
0) 4> C
H- -P 41
III

*"O
5|t1
-C 41 4J
3S O 4)


C -P Ul
41 o re

O.*f- C31-P
x o re
O) Ul r— 5
0) O
cn-p c P
c re .c: t-
•r- W O O
*» C 41 -P
re 41 -P 4>
S- TD £.
4> C 4»
Q. O J= 41
O U P J=
4> U) 

JS u s- re 4) Ul 4) 4) -P S-

«p- •P -P 3; *ui t? -P §c § E O 4> *P- U J3 L. 41 ui a. £ re x 1 S- 41 1 Ul C .c if « re *J See rese. Condensa •P re c 4> O Ul re CJ3 tn i— • t. 4) C 3 Ul S- re 4) 4> ! 4) S- 4> ,-a cr 3 Ul "8 4) C ^: 2 re 3 Ul 4) » S- t- t. S 3 • *3 I 41 V) I-H s- 4) TJ 3 U) t. re 2 s Ul : *" : S- • 4> •o •S ; s ; C See rese. Condensa' : o ' re : c ; T3 s H-l i SE If • 3 Ul i. re 4) 1 41 1 3 i. re o -P 2*5 3 £- » »— a» S S a r*T nj ui TJ U O»- Wl -r- ^.SS o c en ui re t- Ul OJ O •f— &• C OOi-* S • 0> > CO 3d UJ *— ' in i CO CO s. s- 4) 0 •P -P s~* €re tn &. i re ro 'r- CS. - •p- 41 CO O >,+* E -P re •r- -r- i. •P > -P f- re P- 3 t. «f- Zb O LL. » >»^ . 1 (0 I- O E-r- OJ !-i re c > i . .e e « co O-. «C OS ^^ 398


-------














I
A
3
r









































•s
1
1
10
d)
Ul



Remarks
3f
1
•p.
i
c
o ja •
S 8
ltJ U
0 0
<*- w
c
t— 1
i
•r— (tj •
4>> (A
re 3'
S- R)
5 «
c

i "O


(O r-
||

£u


•e
c
6
V
"0 01 .
S'S.-S
re 015=
o
Ul r— ®
EOS.
re c 3
o» JE en
i- u i-
*> at u.
« H- •— »


w

V)
K
£.
at
•o
3
ui
"S
at
c
S-P
to
U) U)
£S
ol
at o
V) U
See remarks under MIS Gas Condensate.

CO



 O C
Sil1
ssl




i.
o
re t-H
-
U)
"si
ll
I
J
I
to
S.
O)
T3
3
Ul
i
£
Of

CM



a






3C

c en s--jj
re t. «fc- 01
S-0.."0
* ai c
a) w> -P at
H- ac 3 .a

«




01






"








t
1
S-
O)
1
-p
tn
S-

^

«lp
t, £ i
o s. PO

at > co
o= o ^


U)


isS
a) a
u} tn
a) c
£. O
•a
OJ c:
01 O
CO U
See remarks under MIS Gas Condensate.

N



S
~~






x_
«T







X
^


0)
g
o
Otf
? «0

re c i
OS*







c at
.^- a> •»-
"ot- ai
.S ° ffl
S§0
-a 5 **
ai re u»
or f. -o
c at ai
**- Q)
re re c
"O S. O
§" at re
4,51
r— O
re -o <*-
u c c
v> re •*•
The MIS processed shale composition
for Tract C-b has been derived from
the Room 6 burn data at Logan Wash
and material and elemental balances.

CO



J3
CO
fH






U








t
t





U)

Ul
're I-— «
T3 1


o en

TJ
01
c
re
o
J3
O
-P
T3
U

re
•P
•s
Q.
3
1
Of

The Lurgi processed shale composition
has been derived from the pilot plant
information on the Tract C-b shale
and the material and elemental
balances.

CO



S
a






o
























T3
O>
c
re
+j
*
4!
O
•p
0)
c

re
•P
re
•a
§•
t
at
re
u
en
Some physical properties of the Lurgi
processed shale from Tract C-b have
been measured.

«




s






0
























T3 •
O> "O
C O>
•r- Ot 'r-
S^T
a> ° *
S|o
•oS **
O) £- T3
c ot at
4- S
re ui c
•P C
•a s- o
+j tf.

a> 

sf J •a J3 Sre w t--a C O) 0> <»_ at re re c T3 t. O §*at "fo a) 5 ^ re T3 <*- u c c: t/> re <^- The quality of the leachate from the Lurgi processed shale has been determined in a laboratory experiment. CO 3 03 • 0) •^ "•* o *0^ i C T3 O 0) ' £ S ui at ' O Ol . O.T3 ; u u> r- t..T3 re o at 3 4J C -p re •••• sis 0.0) a) U I— u -a The quality and quantity of the kettle evaporator sludge have been ..estimated based on .calculated - . compositions of the process water feeds and an assumed efficiency for the evaporators. ; * ! , tH i M 1 399


-------























in
•o
'as

2
(O
o>
 .c
-P 0)
•P
I
er
a
(A
1

0
tn
+>
3
V)

13
^
!
O




T .
o
01
t-
u.




u.
rt g|
t-'s
0 £
111
J!
f O>
tn xt
f°
U Vt

H-lii

o c
The quality and quantity of the FG
sludge have been estimated based o
an assumed efficiency for the FGD
process.


«*•


iH



»*M
















r»
03
01 U U)
J*'" r— ^
(0 U)
f 03
O <8 W ^O
£01 U 01 "O "O -P
s- d c cr o> c
0.'

« u •P .C +J O O U» t3 O P O> ••- W 3 0) jr -P *o ui Q. o c U J= >» T- ^~ £ 0) 'r- A D. JT flJ fc. o ra-p .c: M- 01 01 -P U) C -P O C TJ fc. .^ W ,^ •PS C 0» 4J O X 0) 01 fc. O -P 0) tt> i- 01 O) 0) -P ** O r- C Q. T3 H- 5 J3 U) U O.T3 1= P 0) C r- Cooling tower blowdown, boiler blowdown, boiler feedwater treatme regeneration waste, source water clarifier sludge, storm runoff, service and fire water, etc., are combined to form the processed sha moisturizing water. * fl 1-4 ,2 ra o> ^ *o 5 w *o C *f U) 01 f O» •p- i— O fl» O Ol •n"-5 C E. .$1-^ r— Q tn J3 o .p s. or N tn •T~ r— Ql O £§U-? »f i— £ "ra The technology is proposed in the PSD application as the method to control the particulates generated during the processed shale quenchil moisturizing. « ff M or 01 to u to °" £ f 0> ^-* S- -Q ^fr 5 3m o» u M (0 O 3 «£5^ *J 0> 01 t. JS5S. The operating experience with the Lurgi processed shale is not documented. 0) x: u i O" 'i eval uat in •c a c *^ 1 £ t~ •P 1! ' s* •P O) .Q Is ^. The technology is used commercial 1; in other industries. The claimed efficiency of 98% appears to be achievable. CM S -^ O> U) O) C S. 'f -O C .Q t/t OJ O 0) (J OJQJ 0 C ^Q S- o *» o> 3f •o to r— tn 3 (0 05 -P 4J 4-i t- 0 TT7 The operating experience with fieli plots for the leaching and revege- tation studies is not documented. S 1 3 : tn ^^ 0> r- :»! to o *o -P t. C U» W (9 t*** 13 ^ « 01 "O 3' U e^ u>


-------







Ul
•0
at
1
re
%
£





1
Q=
O
£•
0
ce
c:
0X5
•i- Ul
•P CJ

9 o
c
1— 1
c
o
f- (0
•P U}
tO 3
<£ **
.C
1— t
T3
•P O
=1 fi-

U
2
•g
O
u
Ui *••*
*o a> •
c •*- o
(0 OJZ
o
ui *— at
re i 3
t- U T-
•p at u.



o
w
o at In
•f JS to
•P J3
iS 0
's «C
ffl T3 t-
•P 0) U
c at at
fell
s— *J *f~
r- i ".
•*J re c
C S. 0
a> 3
•P -P "O
o re o
o.cs
at at 3
££$


L
Groundwater or surface water inte
actions with the landfill are
site-specific.












































•o oi .
2 ^ ^|
A runon catchment dam 1s proposed
in the PSD application as the met
to contain the precipitation fall
in the watershed above the landfi


N




S
1-4






««
re 3
x= o
U Q.
*S
C
"6

to
CJ
c

£g
















u)

•jr
The operating experience with the
processed shale landfills is not
documented, but the technology is
used coinmerciaTTy in other Indust




























^ ^
0> 1-
*> 1-
ra -a

tjf2
5 a
S^"S
i- J-> i.

a» c c
*- 0  «» at
O TJ »—



According to the PSD application,
the precipitation is allowed to
percolate in the ground.










t

































•P
„ s
A French drain containing perviou:
material is provided in the PSD
application as the method to colli
the precipitation falling on the
landfill.


CM




J5
tH






0> Ul
"§ §

o a.
(C £
.3 (II
So
>-*>
U)
4)
t_
The operating experience with the
processed shale landfills is not
documented, but the technology is
used commercially in other industi




























0) o  S *O T3
•o M &. c
§c o -a m
Q.°US"'
•o 3 at
re at a> j=
01 at o -P
t- to x: m
"^ ? c 1 .!*
"S5""^i
Sra u» 3 3
3 t. « O
»— 0) £.
01 re -P at t-
x: > 
c_
The operating experience with the
processed shale landfills is not
documented, but the technology is
used commercially in other industi




























401

-------







(A
ffl
ffl

x:
u
&.
fO
ffl
w
*
OS












(A
i




s,
4?
!C
I

i

O X)
•r* (/»
-P ffl
1 &
O O
4» M
e
»— i


•r- m
*» Ul
2 =
£ to
£ £
C

T3
+» ffl
11
O O
Q. U

1

O
(A ^"%
T3 Ol .
C'r- O
CO O)Z
si*
II §
+* ffl I£
V) »—•>-*
tA
"S
ffl
ffl
C

•P-


X)
(0
•
(n
. c
to
f-£
.2
r— "4—
O *r-
C S-
If
XI
x; p
C (A
2 fA^ "£
3 ffl C *»•> ffl (A
§0 ffl e -o £. 3
3 01 0 C CO TJ
^ Ol fr- *r~ nj C
•" £ £ n "So *~ ffl """
*J Q. C (U ffl -r- t-
*nJ 4* T- f- £ +5 o*x:
x: s- -P o. •— +J
O. O -P (O O. O O O
ui •»- y> .p nj N C
ro *f* ffl i— -*~ c
O t» •*•* > Q_ jQ 4J ,>j
C 3 k ffl 4^ 0)^
o TJ "O x: us w»  ^'S § at o
O.OS'r-tAfflUU
(0 U 4- Xt O E (0
H- CO 4* Ol Q.-P tA 3



eg




t-l
iH









fc

IO
3
U

C
o

to
N
IH
t-s
5S5


^>> w

M "O r— ffl
•O O C 10 ffl
4-> S- »r— O O
n) ffl ffl  4J
(A C «r- ffl -t- C ffl
(O 3 U) 4J 4-> *i— £.
O X) ffl C
(A t. 3 3 ffl >.v)
E Ol tA<— > XV M
ffl «J ffl Z
lfl«5lg
O.
4->O*r-C+JUCffl
is i .i.tS a>
•X! -p . ffl O .O
x: -f- o -P x: ro ffl o
i— 3 U d) -P 3 — -M
• re s.
ffl Ul ffl 3 ffl .
> -p E-a +J o>

f-Ul fflO<»-E-4JC43 10
&-C S- +J O 3 >* 3
3 O £• ' Hi (A O t- *—
•o f- »-o x: -P s- o »— *—
c: *> *. o.J^ 'si ffl .p »t- c5^ 3
•i- O CLU)*r-ffl 1A 01 O *r- C -P
5 ^x: J2ffltnofflocofflC
nj o -p E s- c x: -i- at a>
« t.« »— nj co'~"iz5
•o • o x: v) o c s. ai nj
« «*- +j +j (o *r- .p x: «*-
ffl*- S-ffl r— -P O> O
•P O *P S- tO 4^ t— I "~ OT «2
S- U >r* C +i ffl fO -p Jj
oai4Jat+JOi— E i— -o flj

U ffl ffl ffl ffl E >t O)*r- >* O C
xx:$x»x- S ffux ro*2o
UJ 4J XI 
||
11
"


to
HH
com
ffl -P .
a. at m







































+j
I
f t
S- 4^
ffl tA
*E ^ * **3


*A tA *»
3 tA t-
t- T3 3 (TJ •
O C *O t— (A


"ro r" *°
7 CO r— >r» 'Q ffl •
3X1 ffl O ffl fc C
«X^ 1 +3 1 0
r— (A P— WJ 4^ W
*-*• O "*~ *r~ fc> «i— g O
' ffl i o ~a i -a t. •*-
; • O 1 1 3 1 3 O -P
t-l ffltAUlffltAC*—
W XT -^- ffl »r- »P- 3
jg r— C3^^-3r- *Or-
CO (O U) (A M> •(-
•P *+J 1 ffl | > O)
t/) «— >»C(rt»— i— i— OC
O -P -P CL O U « (J ffl
•«- a.ffl s s- i t- £- at
ffl OOO-r-SOE'O'p-
o u «J a. v) u ^ u >• LU
HI «moQtuu. 0=0-4
«






























I
1
ffl
CO*
e
0
u •
ffl rH -
V) oo r* .
ot r-*r*
C r-t CJl P*.
-0 C 5^^
1 !• ||
*" Xi £
ffl • ffl U
xt o - u. o
_ <-»*£
c r** * -
nj «— CT> . .
U •*- fH O O
o c c
O ffl W*"* *"*
•r- t— «J » *

i ^-i5!i
o o u- to co
**" °
8 I^?H

3 T3 -p- +J «P
0 CO C C
ffl O ffl U O O
r- C J= U U r-t
ffl »-* VI O O _
^^ «-j « ffl <0 ^
x: ... ffl
ffl c c c m
U r— >-4 I-H t-H ffl
S- '^- (J

t/) f— *r— «f— *r*
•*• ffl c c c: LU
•P "O ffl ffl (O
E tj xl x: x: i/I
,0 o«c<:<=>
c
xt
;

























,
1

















in

m
: tH
[CO ffl
f.


1 s- - .
o o s-
Crt ° « 3
0V r- 03
JII3
J3 <— (TJ C

z;S't-a
•>. to a. co
j^im i- «
3l 0 * "S
U> f- CO 0

402

-------
                            -o

                             £
                             01
                          •o u
                           01 C
                         01 o m •!-
                         8- C € *>
                         u >i.n t3
                         C (O O O
                         «E^E



                         slff
                         >»^- I  0)


                        Q. O W»
                       i §•« S'g

                       S i  s- y> -a

                       *- *^>
                       O. Wf- ••- «
                        « e *3 j= o
                       a* oi c: 4J j=
                       P- -p- m o 4J
                       ja w o .a *^-
                       CO Ql 1-   2
                       u T3 t- -u


                       i.sl*s
                       a. o ••-  - ai
3 (fl W

•sag
                       
-------

-------
                                   SECTION 8

                                   REFERENCES                     j


 Adams,  C.E.  and W.W.  Eckenfelder,  eds.   1974.   Process Design Techniques for
      Industrial  Waste Treatment.   Associated Water  and Air  Resources  Engi-
      neers,  Environmental  Press,  Nashville,  Tennessee.

 American  Petroleum Institute.  1969.  Manual  on Disposal  of Refiinery Wastes,
      Volume  on  Liquid Wastes.   API,  New  York.                     :

 American  Petroleum Institute.   March 1978.   A New Correlation of NH3,  C02 and
      H2S  Volatility   Data  From  Aqueous  Sour  Water  Systems.    Publication
      No.  955.  API, New  York.

 Ashland Oil, Inc.  and Occidental Oil  Shale, Inc.  February  1977:   Oil  Shale
      Tract C-b:  Modifications  to Detailed Development  Plan.

 Ashland Oil, Inc.  and Occidental Oil  Shale, Inc.  October 1977.   Prevention
      of Significant Deterioration;  Application  to  U.S.  Environmental  Protec-
      tion Agency,  Region VIII.

 Ashland   Oil,   Inc.   and  Shell  Oil  Company.    February 1976.    Oil   Shale
      Tract C-b:   Detailed Development  Plan  and  Related Materials.   2  vols.

 Barduhn,  A.J.   September 1967.  The  Freezing Processes for Desalting Saline
      Waters. Progress  in Refrigeration Science and  Technology, Proceedings  of
      the  International  Congress of  Refrigeration,  12th,  Madrid.   Vol.  1,
      37-55.                                                       ;

 Battelle,  Columbus Laboratories.   October 1978.   Control  of NOx'Emission  by
      Stack  Gas  Treatment.   EPRI  FP-925.   Final  report  prepared  for the
      Electric Power Research Institute, Palo Alto,  California.

 Beychok, M.R.  1967.  Aqueous Wastes from Petroleum and  Petrochemical  Plants.
     John Wiley and Sons, Surrey, England.                        ;

 Calmon, C. and  H.  Gold.   1979.  Ion Exchange for Pollution Control.  2 vols.
     CRC Press, Boca Raton, Florida.                              ;

Cathedral   Bluffs . Shale  Oil  Company.   November 14,   1980.   Proposal  for
     Financial  Assistance  in  the  Form  of  a  Loan   Guarantee;  Volume V.
     Submitted  to  U.S.  Department   of  Energy  in  response  to  Solicitation
     DE-PS60-81RA50480.                                           ;
                                     405

-------
 Cheremisinoff,  P.M.  and F. Ellerbusch.   1978.   Carbon  Adsorption Handbook.
      Ann Arbor  Science,  Ann Arbor, Michigan.

 Colony  Development  Operation.   1977.   Prevention  of  Significant  Deteriora-
      tion;  Application to  U.S.  Environmental  Protection Agency, Region VIII.

 Colony  Development  Operation.   March  1980.   Application  to Colorado  Mined
      Land Reclamation Board for Solid Waste Disposal  Permit.     ;

 Denver  Research  Institute/Water  Purification  Associates/Stone and  Webster
      Engineering  Corporation.   July 1979.  Predicted Costs of  Environmental
      Controls for a Commercial  Oil Shale Industry.  U.S.  Department of Energy
      Report No. COO-5107-2.
                                                                 i
 Dravo Corporation.   February 1976.   Handbook  of Gasifiers and  Gas Treatment
      Systems.   FE-1772-11.   Final  Report,  Task  Assignment  No. 4,  Engineering
      Support Services.   Submitted  to  the U.S.  Energy  Research  and  Development
      Administration.

 Electric Power  Research Institute.  April  1980.  Economic  and Design  Factors
      for Flue Gas Desulfurization  Technology.  EPRI CS-1428.

 Fox,  J.P.,  D.E.  Jackson  and  R.H. Sakaji.   1980.    Potential Uses of  Spent
      Shale  in  the  Treatment  of  Oil  Shale Retort  Waters.   13th Oil  Shale
      Symposium  Proceedings,  Colorado  School  of  Mines,  Golden,   Colorado.

 Fox,  J.P.,  K.K.  Mason and  J.J.  Duvall.   1979.   Partitioning of Major,  Minor
      and Trace  Elements  During Simulated In Situ Oil Shale Retorting.  12th
      Oil  Shale  Symposium  Proceedings,   Colorado  School  of  Mines,  Golden,
      Colorado.
                                                                 i

 Girvin,  D.C.,  T.  Hadeishi  and J.P.  Fox.   June 1980.   Use of Zeeman Atomic
      Absorption  Spectroscopy for  the Measurement  of  Mercury  in  Oil  Shale
      Gases.  Oil  Shale Symposium:   Sampling,  Analysis  and Quality  Assurance,
      March 26-28, 1979,  Denver, Colorado.   EPA-600/9-80-022.   U.S. Environ-
      mental Protection Agency.                                   [

Gulf  Oil Corporation  and  Standard Oil  Company.  (Indiana).   March 1976.  Rio
      Blanco  Oil  Shale   Project:    Detailed  Development  Plan,'   Tract C-a.
      4 vols.   Submitted  to  U.S.   Department  of  the   Interior,   Geological
      Survey, Area Oil Shale Supervisor.                           :

Hart, J.A.   June  11,  1973.   Waste  Water Recycled for Use in Refinery  Cooling
     Towers.  Oil  and Gas Journal.   71(24):92-96.

Hicks,  R.E.,  et al.   June 1979.  Wastewater  Treatment  in  Coal' Conversion.
     EPA-600/7-79-133.  U.S. Environmental Protection Agency.    •

Hicks,  R.E.  and  L.  Liang.   January  1981.   A Study  of  Reverse Osmosis for
     Treating Oil Shale In Situ Wastewaters,  Final  Report.   DOE/LC/10089-5.
     U.S. Department of Energy.                                   ;
                                     406

-------
 Hicks,  R.E. and  I.E.  Wei.   December 1980.   A Study  of Aerobic Oxidation and
      Allied Treatments  for  Upgrading In Situ  Retort Waters,  Final  Report.
      DOE/LC 10097-1.   U.S.  Department of Energy.                !

 Humenick,   M.J.   1977.   Water and  Wastewater  Treatment:   Calculations  for
      Chemical  and Physical  Processes.   Marcel  Dekker, New York.
                                                                 1 !
 Jones,  B.M.,  R.H.  Sakaji and  C.G.  Daughton.   August 1982.   Physicochemical
      Treatment Methods   for  Oil  Shale Wastewater:   Evaluation1  as Aids  to
      Biooxidation.   15th Oil Shale  Symposium  Proceedings,  Colorado School  of
      Mines, Golden,  Colorado.                                    i

 Kohl, A.L.  and  F.C.  Riesenfeld.   1979.   Gas  Purification.   3rd  ed.   Gulf
      Publishing Company,  Houston, Texas.

 Krisher,  A.S.   August  28,  1978.  Raw Water Treatment in the  CPI.   Chemical
      Engineering.  85(19):78-98.

 LouckSj  R.A.   November 1979.   Occidental  Vertical Modified  In Situ  Process
      for the Recovery of Oil  from Oil  Shale:  Phase  I, Final  Report,  Parts 1
      and 2  for U.S. Department  of Energy.                        \

 Mai Ion,  R.G.   January 1980.   Preparation  and Injection of Grout  from  Spent
      Shale  for Stabilization of  Abandoned In  Situ Oil Shale Retbrts.   Third
      Annual Oil Shale  Conversion  Symposium,  Denver, Colorado.

 Marnell,  P.   September 1976.   Lurgi/Ruhrgas Shale Oil Process,>  Hydrocarbon
      Processing.  55(9):269-271.

 McWhorter,  D.B.  1980.   Reconnaissance Study  of Leachate Quality from Raw
      Mined  Oil Shale—Laboratory  Columns.   EPA-600/7-80-181.    U;S. Environ-
      mental Protection Agency.

 Mercer, B.W.,  A.C.  Campbell  and  W.  Wakayima.   May 1979.  Evaluation of Land
      Disposal  and  Underground  Injection  of  Shale  Oil  Wastewaters.    U.S.
      Department of Energy Report  No. PNL-2596.

 Merrow, E.W.   September  1978.   Constraints  on  the  Commercialization of Oil
      Shale,  R-2293-DQE.  U.S. Department of Energy.

 Merrow, E.W.,  S.W.  Chapel  and C.  Worthing.  July 1979.   A  Review of  Cost
     Estimation in New Technologies:   Implications for  Energy Process Plants.
      R-2481-DOE.  U.S. Department of Energy.

 Mutter, J.  and C. Waitman.   1978.  Oil Shale Economics Update.  Tosco Corpo-
     ration, Los Angeles, California.

Occidental   Oil Shale,  Inc.  and Tenneco Shale Oil  Company.  lApril   1981.
     Prevention of  Significant  Deterioration;  Application  to  U.S. Environ-
     mental Protection Agency, Region VIII.
                                     407

-------
 Peabody Process Systems,  Inc.   February 1981.  Paid  study  on suitability of
      the  Holmes-Stretford  Process  for  Oil  Shale  Projects.   Prepared  for
      Denver Research Institute, Denver, Colorado.                     :

 Peat, Mcirwick, Mitchell & Co.   September 1980.   Final Report:  Oil Shale Tax
      Study.   Prepared for  the  Committee on Oil  Shale, Rocky Mountain Oil  and
      Gas Association.   Washington, D.C.

 Persoff, P.  and J.P.  Fox.   April 1979.  Control Strategies  for Abandoned In
      Situ Oil Shale Retorts.   12th  Oil Shale Symposium Proceedings, Colorado
      School  of Mines,  Golden,  Colorado.

 Persoff, P.  and P.K.  Mehta.   January 1980.  Cement Preparation  from  Lurgi
      Spent  Shale.   Third  Annual  Oil  Shale Conversion Symposium, .Denver,
      Colorado.

 Peters,  M.S.  and K.D.  Timmerhaus.    1980.   Plant  Design  and  Economics  for
      Chemical  Engineers.   3rd  ed.  McGraw-Hill.

 Pforzheimer,  H.  and S.K.  Kunchal.   March 24,  1977.   Commercial  Evaluation of
      an  Oil  Shale Industry Based on the Paraho Process.  Paper presented to
      the American Chemical Society  National  Meeting,  New Orleans,  Louisiana.

 Ralph M.  Parsons  Co.  March 1979.   Modified  In  Situ Oil  Shale  Process.
      Occidental   Oil   Shale  Inc.,  50,000 BPD  Commercial   Plant:   'Summary
      Operating  Cost  Estimate and  Capital  Cost Estimate.  For U.S.  Department
      of   Energy,   Cooperative   Agreement  No. ET-77-A-03-1848,  Subcontract
      No. 5788.                                                        ;
                                                                      i
 Rangnow, D.G. and P.A. Fasullo.   September 28, 1981.   Rapid  Growth  is !0utlook
      for Recovered Sulfur.  Oil and  Gas Journal.  79(39):242-246.

 Research and Education Association.  1980.  Modern Pollution Control technol-
      ogy.,  Vol. I:  Air Pollution  Control.  New York.

 Ricketts, T.E.   1980.   Occidental's  Retort 6  Rubbilizing and Rock  Fragmenta-
      tion Program.   13th  Oil Shale  Symposium  Proceedings, Colorado  School of
      Mines, Golden, Colorado.

 Rio  Blanco  Oil  Shale Company.    February  1981.   Modification to the Detailed
      Development Plan, Tract C-a:  Lurgi  Demonstration Project.  Submitted to
      U.S.  Department  of  the  Interior, Geological   Survey,  Deputy  Conserva-
      tion Manager - Oil Shale.

Schmalfeld,  I.P.   July 1975.  The Use of the Lurgi-Ruhrgas Process for the
     Distillation of Oil Shale.   Quarterly of the Colorado  School  of Mines.
     70-3:129-145.                                                    :

Sklarew,  D.S.,  et al.   Feburary  1981.   Preliminary Report,  Measurements  of
     Sulfur Species  in Offgas  from  Rio Blanco1s Retort 0 Tract C-a Colorado.
     U.S. Department of Energy.                                       :
                                     408

-------
 Stanfield,  K.E.,  et  al.   1951.   Properties of  Colorado  Oil  Shale.   U.S.
      Department of the Interior, Bureau of Mines Report No.  4825.

 StoTlenwerk,  K.G.   1980.   Geochemistry of  Leachate  from  Retorted  and  Un-
      retorted  Colorado  Oil  Shale.   Ph.D.  Thesis,  University  of  Colorado.

 Stone and  Webster  Engineering Corporation.   January  30,  1979^   Reference
      Fossil  Power Plant, Book 2B-1.

 TRW  and  DRI.   1975-1978.   An  Engineering Report  on  the Lurgi  Retorting
      Process  for  Oil  Shale.   U.S.  Environmental  Protection Agency Contract
  •    No.  EPA-68-02-1881.                                         ;

 Uhl,  V.W.   June  1979.    A Standard Procedure  for Cost Analysis of Pollution
      Control  Operations:   Vol.  II, Appendices.   EPA-600/8-79-018b.   U.S.  En-
      vironmental  Protection Agency.

 U.S.  Department  of  Energy,   Office of  Health and  Environmental  Research,
      Division of Environmental Control  Technology.   May 1980.   Environmental
      Research on  a  Modified  In  Situ Oil Shale  Process:  A Progress  Report
      from the Oil  Shale Task  Force.   DOE/EV-0078.
                                                                 i
 U.S.  Department of the Interior,  Bureau of Mines.   August 1981.  Minerals  and
      Materials:   A Monthly Survey.   Washington,  D.C.
                                                                 i
 U.S.  Environmental  Protection  Agency.   December 15,   1977.   Prevention  of
      Significant  Deterioration of Air  Quality Conditional Permit  granted  for
      Tract C-b  Shale Oil Venture  Project.

 U.S.  Environmental  Protection  Agency.   September  1980.   Lining  of Waste
      Impoundment  and Disposal  Facilities.  Report  No. SW-870.    '

 U.S.  Environmental Protection  Agency.   1980.   Environmental  Perspective  on
      the  Emerging Oil  Shale Industry.   EPA-600/2-80-205a.
                                                                 i
 U.S.S. Engineers  and Consultants, Inc.   April 1978.   Communication with Water
      Purification Associates, Cambridge, Massachusetts,  regarding;  information
      on the Phosam-W process.

Water Purification Associates.   December  1975.   Innovative Technologies  for
     Water  Pollution  Abatement.   NCWQ  75/13.   National  Committee  on Water
     Quality, Washington,  D.C.                                   i

Wilhelmi, A.R. and P.V. Knopp.  August  1979.  Wet Air Oxidation:  An Alterna-
     tive  to  Incineration.   Chemical   Engineering  Progress.   75(8):46-52.

Woodward-Clyde   Consultants.    October 13,   1980.    Preliminary  Laboratory
     Testing, Lurgi-Ruhrgas Retorted Shale.   For Occidental Oil Shale, Inc.,
     Grand Junction, Colorado.                                   ;
                                     409

-------
York,  E.D.   June 13,  1980.   Rio Blanco  Oil  Shale  Company.   Correspondence
     with Denver Research  Institute,  Denver,  Colorado, regarding information
     on the Lurgi retorting process.                             j
                                     410

-------
-------












o
F-l
1
ss
o
o
.U4

1
12*
V)
8
fc

3£
Ul
s
Ul
1
0
3
S
o
2
S
a

us
A
to
.1
1













S. V •»-» O '«'

.a *> or a» c

b O *f- (0 O
o. s. tn ^
«s
&. 
a> s.
"O O) O
3IS8
u. u u.







c
o

trol Identifica
c
0



O O O r-J CM r-l




Csj M rH CO CM tO
O O O ft rH O

§m ^> to o tj-
co in m r-t to
o m CM
CM


* in co o» r-* ch
i-* iH in rH o in
o in CM
CM



5- tn CM IH co en
r-l rM p^ rH



t 1 rH CO («1 O
t i m «s- co in
OTi Tf CM
rH

S*H rH r** cr> tn
r* *»>



rH rH * CO CM Csj




CM O 1 1 it
** ^j-


Scn
CM
to in i i ii
rH rH. i | ii


C
"e °

g s m

+> c *> "S
eC f J? z CT f
m 3 tu o co>
o o e »-i -r- ce
-P o i— e n.
>. 4J !_ £; .,_ ^ Q Q_ -g
0 COI §) *> fsli-^0) C
O  H o H-ttnuciQ
-ISOIJZO) _J tn 4J-£
o x; i— or- I-H ort/>&. c
o: u i -M i— eat* coo
a -PS n) o ^ f% « at .f—
^ m 0 O O r— 0. O)rr- *»
uj c *o **_<*_ ui A ts ia
u on o o o •»-> .a c i—
£ I10 | | £ | 1* |

W3 VI































g
rH •
CM O
II 2C

S ^
* "O
to -<
s- ce
S 5 *=
1 - ..
73 .. S
c at t.

o o
x z to
363
-------














V)
UJ
s
5

tu
*~
§
s


to
UJ

»c
^
F NITROGEN
0 •
CO
CK
£5
U.
->-
*
3

TS
in
3
S












Ul
01
Disadvantag







Ul
%
Advanta







+>

tin
5
i— m
0) -P
> t/J
d>






O)
i
£
f
-.£




a.
Operating Print


Control
Technology











































§
DC
Z
UJ
O
§
t-t
Z
_J
UJ
o
U.
c
X >>4- C
§J3 P 01
PI
OI Ol P X •
3 it ^P ° 4^
•S£3I"
x. .P to e
Ul <*- p
•Si,- is
C >r- fO Ol U>
Wl E P 3
U» U> ft. ft. JO
8-iJSl
Q 01 -P C U

2
P Ul
"S**"
A ^

X Z

U
•s^
*2
U CL
ui . ai
4) *O U
> Of 3

111
os •*- a.
c
at
->
p
ft.
Q.
>,
«—
U
ft.



CO (0
3= 01 ft.
S t- c
0 «| ™ .
l^o'S^
«) 'i- u> ft*
P > O> P OI
aim

L C.

11

^"5
Absorption of NH3
current scrubbing
ICATIOHS
u.
1-4
oi o
= S
i i
£ i
CO
a E
3= 0
2 U
0)
Ul
3
U •

U £
g-S
Si!
f!
 5
r:
Ul P
w 2

C ft.
3 C
oa -^
>>
ft. ^*
ot re

p &
A QJ
= 1 .
Qua
£ui A
C CO
c-01
fc w n
CO *O (d


X
i ^
p- (U

ft. 4)
0) -J ft.
5 £
"III

O U O P
IO 3 3 ft.
i T3 -a 4^
?£-«•£
i «^ e

p c i^- -P
P -^- p rtj ui
5 -P O C 3

=•§ =5 s
P U *O
ai T3 re -P
ft. C O) 01 P
•P P -0 C U
•s~ss5
(A * Ul ••>
•r- Ul ft. U> "O
01 3 C OI
ft. £= O P -0
•^- P .*J.*t--"O
«C N P -P (0
^
g
C^P £-T3 C
TO-*- C ft. «^
(Q +J $- O U> Q> -P
•P Ul Ol *r** ft. HI 'Ul
tn 3 x: ui at c 3
i J3 -P ui c *^- .a
§g .1- .p. ft. o> e
S ai E 3 c 5
h- O '*-' 01 £t Ol O
U 0)

£
a.
>^
Z-
(0
a>


t
c
p
u
"O
2
I

1
S
c
0) u> P
i£tl
" 2 IS
"E c ?
IO .|"« S>
>.*
in ci
Reduce excess air
to reduce reaction
of N-radlcal and 0

w-
Low-Excess A
^
0)
f.
Ul
1 . tl
re*. *£•
-8 oa
«o *.o,
i-OI *»-.-
O. c •— *a
flj «r* 3 Wl
U *» U f
jsfi CSS
.?g. 2: =
3= 0 Q-S

0)
3
P

ra 5
C 0
•r- . rj
2t *r* X
= ^0
elo 5"z
o s. *w> <»-
= 1 ~i
•P «*r-

*M CO 33
Of <1) Ul "P
ui -jj ai Q)

. •
o  >
2 2
Q. 0.

r— ^
£ £
41 O
I I






I 1
Si Si
CM *P- OJ .1-
P U ' P U
£2 ^1
at *
U 

3 P *- ui C
0«c 3*.
o£- ^?2
2S2 s.3
3 « (0
W C*> f— ft.
tO P CO -r- 01
DJ-r- fc. P O.
•P «> ^ M^
§ui a. a>
3 E t. *» .
r— _n ai a> a» x
«*- a -P o)« u o
p s- u «o z
a) o J* « 3 c
E nr •— > -o s- u.
P P 0) 0) 3 O
V> *J Q.  ^
•p a. p nj
10 E S- Q» V)
U) r— O> ^ Z — o) u. p4-> -r2 p-
0 C U P Q
•?1 felii-
S U O. CJ (Q U

e? « i,
 « z


^ CB 0

§C
•°
2 «§•
3 11 '.
1. £8
m x ai s
** O CL P

*3 ® T
^E "o ^-6
t/J  O) *^" »2 pL
^-t i— RJ ui (0 *p-
+JOI *» Of U O )C3 U1U1 U1U)C^>
3 P TD C Ul |; fl»
U1C-P U)fO O « C U>
P -i- O « (-3 P«r-POI
g "O t- o « -P t. o i- *n
S^lo0 °-g- "-fe-SS .
•P-C&-JC *U &-E&.UOI
e re O) en EC: 3 g o> p r-
3 r— O.-r- . p p p Q. t. .Q
V)O.PJ= Q: U U_ 0 0 CL fD



15 ;
i S '
IN! ^ *
-^ s
Z o . S ''•
§ 1 <" i
s1- s .
1 CI
rs « rp i


« - i
8
ft- Ul .
~O OJ O> *-^
C > Ul (A Ul
 3 4->
**> c at p u>
xJ » ^8T^
OS- P» 2: U CO CO
Z8 5 »fi!->1o
"5-0 £ ^dg10
o to TJ re ••- >,
C -P > O)*-" Ul ft?
p « m u : 3 m
•r* > 3 -P 4J
•Pi- «8 T3 Ul ft. 4U
S-tJ ^ 2^5-E
P OJ ^CJ (0 i— Q.
u> x *J E P
•a c p o « *^ s.

Tf p  -r- p
+J 4J *> O •»- 4J t-
u re *o re at at re 0) t/>
< o <: o o vt o as *w*




ontinued)
0








































'
213