EPA-600/2-75-050
September 1975
Environmental Protection Technology Series
EPA ALKALI
SCRUBBING TEST FACILITY:
ADVANCED PROGRAM
FIRST PROGRESS REPORT
U. S. Environmental Protection Agency
Office of Research and Development
Washington, D. C. 20460
-------
EPA- 600/2-75-050
. September 1975
EPA ALKALI SCRUBBING TEST FACILITY:
ADVANCED PROGRAM
First Progress Report
ERRATA
Page 4- 5, delete sentence:
Two Universal Interloc Electric Analyzers are used to monitor
electrical conductivity.
...-.
Page 7-11, delete section 7.9. 1 and insert:
7. 9. 1
pH Meters
The main problem (see Reference 1) associated with the Uniloc
Model 321 submersible pH meters ,(Universal Interloc Inc., Santa
Ana, Calif.) has been occasional scale formation on the probes
which causes measurement error.
The scale is removed by rinsing
with HCl.
All probes are routinely rinsed with water about twice
a week and calibrated when necessary on. a less frequent schedule.
In April 1975, a continuous ultrasonic cleaner (a Uniloc add-on)
was installed on the venturi/ spray tower inlet pH meter to aid
in the prevention of scale buildup.
Although the device has operated
-------
Errata .
EPA-600/2-75-050
-2-
for les s than a month, due to the unit No.1 0 boiler outage, it
appears to have significantly reduced scale buildup.
During this
period of scaling operation, scale was removed daily from pH
probes.
On the probe with the ultrasonic cleaner, once every
five days was sufficient.
Page 7-12, delete last paragraph and insert:
Both rubber and Flakeline coatings have shown very little erosion
or deterioration.
Successful'repairs have been made using
Epoxylite-203 (Epoxylite Corp., Anaheim, Calif.), an epoxy resin
formulated with selected fillers making a paste material.
\
The
resin is cured with No. 301 amine hardener.
A patch on the venturi!
spray tower effluent hold tank agitator blade has shown little
wear after over 9000 hours.
.. "--"'''''-~'' - --_. - .. .-. "--. ._. - _.'.. . - .
-------
EPA-600/2-75-050
EPA ALKALI SCRUBBING TEST FACILITY:
ADVANCED PROGRAM
First Progress Report
Dr. Michael Epstein, Project Manager
Bechtel Corporation
50 Beale Street
San Francisco, CA 94119
Contract No. 68-02-1814
ROAP No. 2lAAZ-001
Program Element No. lAB013
EPA Project Officer: John E. Williams
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
September 1975
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EPA REVIEW NOTICE
This report has been reviewed by the U. S. Environmental Protec-
tion Agency and approved for publication. Approval does not sig-
nify that the contents necessarily reflect the views and policies of
the Agency, nor does mention of trade names or commercial pro-
ducts constitute endorsement or recommendation for use.
RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U. S.
Environmental Protection Agency, have been grouped into series.
These broad categories were established to facilitate further devel-
opment and application of environmental technology. Elimination
of traditional grouping was consciously planned to foster technology
transfer and maximum interface in related fields. These series are:
1. ENVmONMENTAL HEALTH EFFECTS RESEARCH
2. ENVIRONMENTAL PROTECTION TECHNOLOGY
3. ECOLOGICAL RESEARCH
4. ENVIRONMENTAL MONITORING
5. SOCIOECONOMIC ENVmONMENTAL STUDIES
6. SCIENTIFIC AND TECHNICAL ASSESSMENT REPORTS
9. MISCELLANEOUS
This report has been assigned to the ENVmONMENTAL PROTEC-
TION TECHNOLOGY series. This series describes research per-
formed to develop and demonstrate instrumentation, equipment, and
methodology to repair or prevent environmental degradation from
point ,and nonpoint sources of pollution. This work provides the new or
improved technology required for the control and treatment of pollu-
tion sources to meet environmental quality standards.
This document is available to the public for sale through the National
Technical Information Service, Springfield, Virginia 22161
Publication No. EPA-600/2-75-050
ii
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ABSTRACT
This report presents the results of advanced program testing per-
formed from October 1974 through April 1975 on a prototype lime/
limestone wet-scrubbing test facility for removing S02 and particulates
from coal-fired boiler flue gases.
The test facility is located at TVA's
Shawnee Power Station, Paducah, Kentucky.
Te sts were conducted on
two parallel scrubber systems, a venturi/ spray tower in lime service
and a Turbulent Contact Absorber (TCA) in limestone service, each
with a 30,000 adm (10 Mw equivalent) flue gas capacity.
The primary
objective was to achieve relia}:)le operation of the mist eliminators.
The venturi/ spray tower system was maintained essentially clean in
an 823-hour run in lime service at 8.0 ft/ see superficial gas velocity
"
and 8 percent slurry solids concentration. In this run th~ 3-pass,
open-vane chevron mist eliminator was intermittently washed on both
topside and underside with makeup water.
The TCA system was operated successfully in an 1835-hour run in
limestone service at 8.6 ft/sec superficial gas velo'city and 15 perc.ent
slurry $olids concentration.
The. TCA mist elimination unit consisted
of a Koch Flexitray in series with a 6-pass, closed-vane chevron
mist eliminator, both with underside wash.
Both scrubber systems operated with better than 99 percent particulate
removal efficiency and with outlet. grain loadiIlgs of 0.01 to 0.03
grains / sd.
Pressure drop tests were made on the TCA and a cor-
relating equation is presented.
Hi
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ACKNOWLEDGEMENT
The following Bechtel personnel were the principal contributors to the
preparation of this report:
Dr. M. Epstein, Project Manager
A. H. Abdul-Sattar
D. A. Burbank
'J. S. DeGuzman
Dr. H. N. Head
Dr. J. A. Hoiberg
C. C. Leivo
R. G. Rhudy
C~ H. Rowland
L. Sybert
Dr. S. C. Wang
The authors wish to acknowledge the various personnel from the
Environmental Protection Agency and the Tennes see Valley Authority
who also contributed to the preparation of this report.
The author s also wish to acknowledge the contributions of the Bechtel
and TVA on- site personnel at the Shawnee Test Facility.
iv
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Section
4
CONTENTS
Page
1.1
SUMMAR Y
1-1
1
1.2
1.3
1.4
1.5
2
Venturi/Spray Tower Lime Reliability
Test Results
TCA Limestone Reliability Test Results
1-3
1-4
1-6
Operating Experience
Particulate Removal Test Results
1-10
1.- 1 0
TCA Pressure Drop Data
INTRO DUCTION
2-1
3
TEST FACIL;I,TY
Scrubber Selection'
3-1
3-1
3. 1
3. 2
3. 3
System Description
EPA Pilot Plant Support
3-6
3-9
TEST PROGRAM
4-1
4-1
Test Program Objectives and Schedule
Closed Liquor Loop Operation
4-3
4-5
4-7
4. 1
4.2
4.3
4.4
Analytical Program
Data Acquisition and Processing
5 VENTURI/SPRA Y TOWER LIME RELIABILITY
TEST RESULTS 5-1
5. 1 Performance Data and Test E'{aluation 5-1
5.2 Material Balances 5-19
5.3 Conclusions 5-21
6 TCA LIMESTONE RELIABILITY TEST RESULTS 6-1
.6. 1 Performance Data and Test Evaluation 6-1
6.2 Material Balances' 6-23
6. 3 Conclusions 6-25
v
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Section Page
7 OPERA TING EXPERIENCE DURING
LIME/LIMESTONE TESTING 7-1
7. 1 Mist Elimination Syst'ems 7-1
7.2 Scrubber Internals 7-3
7.3 Hot-Gas/Liquid Interface 7-5
7.4 Reheaters 7-6
7.5 Fans 7-7
7. 6 Pu,mp s 7-7
7. 7 Waste Solids Handling 7-8
7.8 Alkali Addition Systems 7- 9
7.9 Instrument Operating Experience 7-11
7. 10 Lining Materials 7-12
8 PARTICULATE REMOVAL TEST RESULTS 8-1
9 ANALYSIS OF TCA PRESSURE DROP DATA 9-1
10 REFERENCES 10-1
vi
-------
Appendices
A
B
C
D
E
F
G
H
Converting Units of Measure
Scrubber Operating Periods
Properties of Raw Materials
Graphical Operating Data from Venturi/Spray
Tower Lime Reliability Tests
Average Liquor Compositions for Venturi/Spray
Tower Lime Reliability Tests
Graphical Operating Data from TCA
Limestone Reliability Tests
Average Liquor Compositions for TCA
Limestone Reliability Tests
Definition of Statistical Terms
vii
Page
A-I
B-1
C-l
D-l
E-l
F-l
G-l
H-l
-------
Figure
3-1
3-2
3-3
3-4
3- 5
4-1
9-1
9-2
9-3
9-4
9-5
ILLUSTRATIONS
Schematic of Venturi Scrubber and Spray Tower
Schematic of Three-Bed TCA Scrubber
Test Facility Mist Eliminator Configurations
Typical Process Flow Diagram for Venturi/Spray
Tower System
Typical Process Flow Diagram for TCA System
Shawnee Advanced Test Schedule
Pressure Drop Across the Four-Grid TCA
Without Spheres
Pressure Drop Across the Four-Grid, Three-Bed
TCA with Five Inches of HDPE Spheres per Bed
Pressure Drop Across the Four-Grid, Three-Bed
TCA with Five Inches of TPR Spheres per Bed
Pressure Drop Across the Four-Grid, Three-Bed
TCA with Seven and One-Half Inches of TPR
Sphere s per Bed
Comparison of Experimental Data and Predicted
Values of Pressure Drop for the Four-Grid,
Three-Bed TCA
viii
P~
3-3
3-4
3-5
3-7
3-8
4-4
9-3
9-4
9-5
9-6
9-7
-------
TABLES
Table Page
4-1 Field Methods for Batch Chemical Analysis
of Slurry ,and Alkali Samples 4-5
5-1 Summary of Lime Reliability Tests on
Venturi/Spray Tower System 5-2
5-2 Summary of Material Balances for Sulfur and
Calcium from Lime Reliability Tests 5-20
6-1 Summary of Limestone Reliability Tests on
. TCA System 6-2
6-2 Summary of Material Balances for Sulfur and
Calcium from Limestone Reliability Tests 6-24
8-1, Overall Particulate Removal in Venturi/Spray
Tower During Lime Reliability Tests 8-2
8-2 Overall Particulate Removal in TCA Scrubber
During Limestone Reliability Tests 8-3
ix
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Section 1
SUMMARY
This is the initiaf report on an advanced test program conducted by
the Environmental Protection Agency (EPA) to test prototype lime and
limestone wet- scrubbing systems for removing sulfur dioxide and
particulate matter from coal-fired boiler flue gases.
It cove r s the
period from October 1974 through April 1975. Results of an earlier
test program have been reported in EPA-650/Z-75-047. The program
is being conducted in a, test facility integrated into the flue gas ductwork
of boiler No. 10 at the Tennessee Va.lley Authority (TVA) Shawnee
Power Station, Paducah, Kentucky.
Bechtel Corporation of San
Francisco is the major contractor and test director, and TVA is the
constructor and facility operator.
There are two parallel scrubbing systems being operated during the
advanced test program:
.
A venturi followed by a spray tower
A Turbulent Contact Absorber (TCA)
.
Each system is capable of treating approximately 10 Mw equivalent
):< . ,
(30,000 acfm @ 3000F) of flue gas containing 1500 to 4500 ppm sulfur
*
Although it is the policy of the EPA to use the Metric System for quan-
titative descriptions, the British System is used in this report. Readers
who are more accustomed to metric units are referred to the conversion
table in Appendix A.
1-1
-------
dioxide and 2 to 4 grains/ sd of particulates. During this reporting
period, the venturi/spray tower has operated on lime and the TCA
on limestone.
Objectives during the advanced test program are:
.
To continue long-term testing with emphasis on operation of
mist elimination systems.
.
To investigate advanced process and equipment design varia-
tions for improving system reliability and economic s.
.
To evaluate ways of increasing limestone utilization, improv-
ing waste solids separation, and reducing waste sludge production.
.
To evaluate variable load scrubber operation.
.
To evaluate existing technology for producing a waste sludge
with improved properties.
.
To evaluate system performance and reliability without fly
ash in the flue gas.
.
To determine practical upper limits of S02 removal efficiency.
.
To evaluate the TCA with lime and the venturi/ spray tower
with limestone.
.
To characterize stack gas emission.
.
To evaluate, under the direction of TVA, corrosion and wear
of equipment components and materials.
.
To develop a computer program, in conjunction with TVA,
for the design and cost comparison of full- scale lime and
lime stone sys.tems.
1-2
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1.1
VENTURI/SPRA Y TOWER LIME RELIABILITY TEST RESULTS
Lime reliability tests were conducted on the adjustable throat venturi
scrubber followed by a 4-header spray tower.
The spray tower had a
3-pass, open-vane chevron mist eliminator with provision for both
underside and topside intermittent wa shing.
Scale-free operation with a clean mist elimination system was achieved
in an 823 hour run under the ,following conditions (Run 624-1A):
Spray tower gas velocity
Venturi liquid-to-gas/ratio
Spray tower liquid-to-gas ratio
Percent solids recirculated
Effluent re s idenc e time
Scrubber inlet slurry pH (controlled)
8. 0 ft/ see
25 gal/md
50 gal/md
8
1 7 minute s
8.0
S02 removal was 70 to 87 percent at an inlet S02 concentration range
of 2250 to 3750 ppm, lime utilization was 90 percent, and total pressure
drop was 13 inche!3 H20 including the, mist elimination system and 9
inches H20 across the venturi. Scale-free operation was expected
because the sulfate (gypsum) saturation of the scrubber effluent liquor
was 120 percent.
Earlier tests have shown that sulfate scale is a
significant problem only if sulfate saturation exceeds about 135 percent.
During Run 624-lA, the mist eliminator was kept clean by a combina-
tion of intermittent underside wash and sequential topside wash, both
, ,
with makeup water. The undersid'e wash rate was 3 gpm/ft2 at 45 psig
for 8 minute s every 4 hours.
The topside wash was accomplished by
operating 6 nozzles in sequence. Every 80 minutes, one nozzle was
activated for 4 minutes at a rate of O. 5 gpm/ft2 at 13 psig~
1-3
-------
A 4-pass, closed-vane, cone- shaped chevron mist eliminator was
tested during 4 runs (611-1A, 618-1A, 619-1A, and 621-1A), but it
continually plugged and further tests will not be made.
Te sta have shown that sulfate saturation, and thus potential for sulfate
scale, can be reduced by:
.
Increasing scrubber slurry solids concentration (Run 603-lA
versus 60l-lA).
.
Increa sing effluent re siderice time (Run 62~-lA versus 6l9-lA).
.
Adding makeup lime to the scrubber downcomer rather than
to the effluent hold tank (Run 609-1A versus 610-lA).
Run 61l-lA has demonstrated that the scrubber can operate unsaturated
with respect to sulfate by adding magnesium ion (MgO) to the circulating
slurry.
Gypsum scale from previous operation dissolved dUJ;'ing this
run.
1.2
TCA LIMESTONE RELIBILITY TEST RESULTS
The TCA scrubber was operated with 3 beds of 1 1/2-inch, 5-gram
spheres, each 5 inches deep. The mist elimination system consisted
of a 6-pass, closed-vane chevron mist eliminator preceded by a Koch
Flexitray tJ.1sed as a wash tray.
Reliable operation of the TCA and its mist elimination system in lime-
stone slurry service was demonstrated during Runs 535-2A. and 535-2B,
which continued for 2325 hours without cleaning the mist eliminator.
1-4
-------
Test conditions were:
TCA gas velocity
Liquid-to-gas ratio
Percent solids recirculated
Effluent residence time
Percent S02 removal (controlled)
8. 6 ft/ sec
73 gal/mcf
15
15 minutes
84
Inlet S02 concentration ranged from 2000 to 4000 ppm, scrubber inlet
liquor pH ranged from 5. 7 to 6. I" limestone utilization was 65 percent,
and total pressure drop was 6 to 7 inches including the mist elimination
system. Sulfate saturation of the scrubber exit liquor averaged 11 0
percent. This is below the level of 135 percent predicted from earlier
tests as being the point above which sulfate scale is a significant problem.
In Run 535-2A, the mist eliminator was washed continuously on the
underside at 0.3 gpm/ft2 (15 gpm) with a mixture of process liquor
and makeup water containing 40 percent process liquor. The Koch
tray was fed with the mist eliminator wash plus 9 gpm clarified liquor.
The underside of the Koch tray wassparged with 125 psig steam for
1 minute each hour.
Solids buildup on the walls between the Koch tray and the slurry spray
nozzles, which had been a problem in Run 535-2A and,previous runs
was eliminated during Run 535-2B by replacing' the steam sparger with
a single-nozzle underspray using Koch tray effluent.
The underspray
had sufficiently wide coverage to flush both the Koch tray and the
adjacent walls.
1-5
~
-------
In subsequent runs at higher scrubber gas velocities, soft solids tended
to build up on the chevron mist eliminator.
In Run 538- 2A at 10 ft/ see,
the mist eliminator was 8 percent restricted after 562 operating hours.
In Run 539-2A at 12 ft/sec, the mist eliminator was 11 percent restricted
after 215 hours.
During Run 539-2A, the scrubber recirculation liquor was unexpectedly
low in sulfate concentration (only 25 percent of saturation), and sulfite
scaling occurred on most scrubber surfaces below the Koch tray. A
seri.es of exp10ritory runs indicated that these conditions were probably
caused by a relatively high scrubber liquor pH (IV 6.0 at the scrubber
inlet) and a relatively low liquid-to-gas ratio (43 ga1/mcf). Liquid-
to-gas ratio in this run was limited by flooding at the 12 ft/ see gas
velocity.
The causes for unsaturated operation during Run 539-2A
are being further investigated at the EPA pilot facility in Research
Triangle Park, North Carolina.
1.3
OPERATING EXPERIENCE
Mist elimination systems have already been discus sed.. This section
covers other aspects of scrubber system operations.
1. 3. 1
Scrubber Interna1s
The 5-gram thermoplastic rubber (TPR) spheres used in the TCA
had a weight loss of only 11. 5 percent in 3784 hours of service (2757
hours at 8. 6 ft! sec and 1027 hours at 10ft/ secga s velocity). Five-
gram high-density polyethylene (HDPE) sphere s failed after about
1100 hours of service (800 hours at 12 ft/sec and 300 hours at 8.6
ft/sec gas velocity).
1-6
-------
The 316 stainless steel bar-grids in the TCA have shown no evidence
of erosion after 9000 hours of operation.
The 316 stainless steel slurry
spray nozzles, operating with 15 percent slurry solids at 5 psi pressure
drop, have shown no evidence of erosion after 4500 hours of operation.
..
In the spray tower, stellite tips on the spray nozzles have shown
negligible wear after 7200 hours of slurry service at 10 psi pressure
drop and 8 percent slurry solids.
A 15 pe rc ent weight 10 s s ha s been
observed, however, in the 316 stainless steel nozzle bases.
Some erosion and stress cracking has been observed in the venturi
scrubber.
Successful repairs have been made by welding the cracks
and covering eroded areas with neoprene rubber.
1. 3.2
Hot-Gas/Liquid Interface
The TCA flue gas cooling system consists of3 slurry spray nozzles
in the flue gas inlet duct and a soot blower.
Soot blowing frequency
was successfully reduced during this reporting period from once every
4 hours to once a day.
1. 3. 3
Reheaters
The reheater on the venturi! spray tower includes a fuel- oil-fired
external combustion chamber.
This unit has operated with few problems
for over 7000 hours.
The inlined-fired reheater on the TCA was
modified during the May 1975 boiler outage to incorporate an external
combustion chamber.
1-7
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1. 3.4
Fans
No significant problems occurred with fans during the current reporting
period.
1. 3.5
Pumps
Frequent packing failure has been a problem on 50 to 100 gpm rubber-
lined centfiguga1 pumps in slurry service.
Adequate purge air cannot
be maintained on the air flushed seals without vapor locking the pumps.
Failures have been less frequent on larger pumps because the purge
air volume is small compared with the pump capacity.
seal is scheduled for testing on the smaller pumps.
.A mechanical
Moyno pumps for feeding 60 wt % limestone slurry are purposely over-
sized and allowed to wear until flow can no longer be maintained.
Typical operating life has been 2000 hours for a rotor and 1000 hours
for a stator.
1. 3. 6
Waste Solids Handling
The Maxibelt rotary drum vacuum filter was converted to a single
roll type with air blowback and scraper discharge in February 1975.
With the new arrangement
operating experience has been too limited
to predict accurate cloth life.
The centrifuge was operated intermittently for 1745 hours during the
current reporting period.
Significant wear was noted during the May
1975 boiler outage but no repair s were made.
1-8
-------
The TCA clarifier was overloaded at times during scrubber operation
at 12 ftl see gas velocity.
The feed well wa s extended during the May
1975 boiler outage to improve overflow clarity.
1. 3. 7
Alkali Addition Systems
The lime addition system ha s operated reliably for over 9000 hours.
After modifications early in the program, the limestone addition
system has given satisfactory service for almost 70"00 ope rating hours.
1. 3.8
Instruments
A continuous ultrasonic cleaner has been used successfully to reduce
'scale buildup to routine weekly cleaning on a submersible pH probe in
slurry service.
Several failures have been experienced with Scothane and Adiprene-L
linings in 1 1 12-inch magnetic flowmeters.
No difficulties have been
experienced with larger meters lined with neoprene or smaller meters
lined with Teflon.
The 1 l2/-inch flowmeters will be relined with Teflon.
1. 3. 9
Lining Materials
Both neoprene rubber and Flakeline 103 linings have shown excellent
resistence to erosion and deterioration.
Epoxylite-203 has been used
successfully for lining repairs.
1-9
.....
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1.4
PARTICULATE REMOVAL TEST RESULTS
Overall particulate removal efficiencies were measured periodically
during the lime/limestone reliability testing.
For the venturi/ spray
tower system, particulate removals of 99. 0 to 99.3 percent were
obtained with outlet g1"ain loadings ranging from O. 015 to O. 024 gra.ins / sd.
For the TCA system, particulate removals ranged from 99.0 to 99.7
with outlet grain loadings of 0.010 to 0.029 grains/ sd.
1.S
TCA PRESSURE DROP DATA
During Februa:ty and March 1975, a series of tests were made to obtain
pressure drop data for a 3-bed, 4-grid TCA configuration.
Pressure
drop was determined as a function of gas velocity, liquid rate, sphere
bed height, and type of sphere s.
It was found that flooding occurred
at an overall pressure drop of 8 to 10 inches H20. Pressure drop
was independent of type of sphere (5-gram HDPE versus TPR).
The data for non-flooding conditions were fitted to a corre1ai!).g equation.
This equation replaces a correlation developed earlier for the for
the TCA system with wire mesh grids.
in place of the wire mesh grids..
Bar-grids are presently used
1-10
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Se ction 2
I1'iTRODUCTION
In June 1968, a program was initiated under the direction of the
)'C
Environmental Protection Agency (EPA) , to test a prototype lime and
limestone wet- scrubbing system for removing sulfur dioxide and par-
tic;:ulates from flue gases. The system was integrated into' the flue
gas ductwork of a coal-fired boiler at the Tennessee Valley Authority
(TVA) Shawnee Power Station, Paducah, Kentucky. Bechtel Corporation
of San Francisco was the major contractor and test director, and .TVA
was the constructor and facility operator.
The test facility consisted of thrE;!e parallel scrubber systems: (1) a
venturi followed by a spray tower, (2) a Turbulent Contact Abaorber (TCA),
and (3) a Marble-Bed Absorber. Each system was capable of treating
approximately 10 Mw equivalent (30,000 adm @ 3000F) of flue gas
containing 1500 to 4500 ppm sulfur dioxide and 2 to 4 grains I sd of
pa rticula te s.
The results of testing at the facility during the original program, which
lasted from March 1972 to 0 ctober 1974, are presented in Reference 1.
The most significant reliability problem encountered during the testing
):c
The National Air Pollution Control Administration prior to 1970.
2-1
-------
program wa s as sociated with scaling and/ or plugging of mist elimination
surface s.
The TCA mist elimination system consisted of a wash tray
in series with a chevron mist eliminator, both with underside washing.
Long-term operability of this system was demonstrated at a scrubber
*
gas velocity of 8. 6 ft/ sec. The venturi/ spray tower mist elimination
system consisted of a chevron mist eliminator with underside washing
Long-term operability of the venturi/spray tower system was not
demonstrated. Operation of the Marble-Bed Absorber was discontinued
in July 1973 (see Reference 1).
In June 1974, the EPA, through its Office of Research and Development
and Control Systems Laboratory, initiated a three-year Advanced Test
Program at the Shawnee Faciltiy.
Bechtel Corporation continued as
the major contractor and test director, and. TVA as the constructor and
facility operator.
The major goals established for the advanced program
were: (1) to continue long-term testing with emphasis on demonstrating
reliable operation of the mist elimination systems, (2) to investigate
advanced process and equipment design variations for improving system
reliability and process economics, and. (3) to perform long-term (2 to
5 month) reliability testing on promising process and equipment design
variations.
This report presents the results of advanced testing at the Shawnee
facility f~om October 1974 through April 1975. During this period,
~:c: .
In this report, all gas velocities and liquid-to-gas ratios are at scrub-
ber operating conditions, 1. e., saturated gas at scrubber temperature.
With flue gas operations, the scrubber temperature is approximately
125 of. The ga s ve10citie s a re all supe rficia1 ve10citie s.
2-2.
-------
the ventur'i/spray tower has been operated on lime whil~ the TCA has
, been on limestone. Testing has been conducted, primarily, to evaluate
the operability of modified venturi/ spray tower and TCA mist elimination
systems at increased gas veloclties.
2-3
-------
Section 3
TEST FACILITY
Two parallel scrubbing systems' are being operated during the advanced
test,ing program. Scrubbers incorporated in these systems are:,
(l)' A venturi followed by a spray tower
(2) A Turbulent Contact Absorber (TCA)
Each system has its own slurry handling facilities and is capable of
treating approximately 30,000 adm of flue gas from the TVA Shawnee
coal-fired boiler No. 10. This gas rate is equivalent to approximately
10 Mw of power plant genera.ting capacity.
Boiler No.1 0 normally burns a high- sulfur bituminous coal which
produces S02 concentrations of 1500 to 4500 ppm an d inlet particulate
loadings of 2 t'o 4 grains/ sd in the flue gas.
3. I
SCRUBBER SELECTION
The major criterion for scrubber selection was the potential for removing
both sulfur dioxide and particulates at high efficiencies (sulfur dioxide
removal greater than 80 percent and particulate removal greater than
99 percent). Other criteria considered in the selection of the scrubbers
were:
3-1
-------
~
Ability to handle slurries without plugging or excessive scaling
Reasonable cost and maintenance
.
.
Ease of control
.
Reasonable pressure drop
The venturi/ spray tower and the TCA were chosen to meet these criteria.
The venturi scrubber (manufactured by Chemical Construction Corp. )
contains an adjustable thro~t that permits control of pres sure drop under
a wide range of flow conditions.
The venturi is an effective particulate
removal device, but it has limited capability for gas absorption in lime/
limestone systems because of low slurry residence time.
For this reason,
the spray tower was included for additional absorption capability. The
TCA scrubber (manufactured by Universal Oil Products and described
in Reference 2) utilizes a fluidi~ed bed of 1 1/2- inch -diameter,' 5- gram
hollow spheres which are free to move between retaining grids.
Figures 3-1 and 3-2 (drawn with major dimensions to scale) show the
two scrubber systems along with the mist elimination systems selected
for de-entraining slurry in the exit gas streams.
The chevron mist
eliminators used during the testing on the two scrubber systems are
depicted, to scale, in Figure 3- 3. The cros s- sectional area of the
TCA scrubber is 32 ft2in the scrubbing section and 49 ft2 in the mist
elimination section. The cross-sectional area of the spray tower is
50 ft2 in both the scrubbing section and the mist elimination section.
Future planned modifications to the scrubber and mist elimination
systems are discussed in Section 4.
3-2
-------
SPRA Y TOWER
INLET SLURRY
THROAT
ADJUSTABLE PLUG
VENTURI SCRUBBER
Figure 3-1.
GAS OUT
CHEVR()N MIST
ELiMINA TOR
GAS IN
EFFLUENT SLURRY
WASH LIQUOR
WASH LIQUOR
INLET SLURRY
5'
I I
APPROX. SCALE
Schematic of Venturi Scrubber and Spray Tower
3-3
-------
MIST ELIMINATOR
WASH LIQUOR
INLET KOCH TRAY
WASH LIQUOR
RETAINING BAR-GRIDS
GAS IN
GAS OUT
EFFLUENT SLURRY
CHEVRON MIST
ELiMINA TOR
KOCH TRAY
KOCH TRAY
EFFLUENT LIQUOR
INLET SLURRY
MOBILE PACKING SPHERES
5'
I I
APPROX. SCALE
Figure 3-2. Schematic of Three-Bed TCA Scrubber
3-4
-------
SPRAY TOWER
SPRAY TOWER
TCA
3-PASS. OPEN-VANE. 316 S. S.
CHEVRON MI ST ELIMINATOR
4-PASS. CLOSED-VANE. 316 S. S.
CHEVRON MI ST EliMINATOR
6-PASS. CLOSED~VANE. 316 S. S.
CHEVRON MIST ELIMINATOR
-------
3.2
SYSTEM DESCRIPTION
The Shawnee test facility contains five major areas:
( 1)
(2) The operations building area (including laboratory area,
tricalgear, centrifuge, and filter)
The scrubber area (including tanks and pumps)
elec -
(3)
(4 )
The thickener area (including pumps and tanks)
The utility area (including air compressors, air dryer, lime-
stone storage silos, mix tanks, gravimetric feeder, and pumps)
(5)
The pond a rea
The test facility has been so designed that' a varied number of different
scrubber internals and piping configurations can be used with each
scrubber system.
For example, the TCA scrubber can be operated
with one, two, or three beds of sphere s or with only the support grids.
Solid separation can be achieved with a clarifier alone or with a clarifier
in combination with a filter or a centrifuge.
Typical system configurations for lime te sting with the venturi/ spray
tower and limestone testing with TCA scrubber are shown schematically
in Figures 3-4 and 3-5, respectively.
Such process details as flue gas
saturation (humidification) sprays are not shown.
For both systems, gas is withdrawn from the boiler ahead of the power
plant particulate removal equipment so that all the entrained particulate
matter (fly ash) can be introduced into the scrubber.
The ga s flow rate
to each scrubber is measur.ed by venturi flow meters and controlled by
3-6
-------
2 :.?~--O----f?"------------i
I I. D. FAN I
~~ J
WATER I
1...-
>: FLUE GAS >- (> ~
I
I
I
W
I
-J
.
.
> LIME
>-
.
Blesi
SCRUBBER
EFFlUENT
HOlD
TANK
o Gas Composition
~ Particulate composition & loading
@ Slurry or Solids Composition
- - Gas Stream
- Uquor Stream
t
.
.
STACK
Discharge
1- I
SETTU NG POND
Figure 3-4.
Typical Process Flow Diagram. For Venturi/Spray Tower System.
-------
>~>4
~ -.... - . RBiEATER - - - -<>- - -@- -il - - -
I. D. FAN
--------
W
I
00
Discharge
MAKE-UP
WA1Bt
LIMESTONE
.
Ble&!
SCRUBBER
EFFlUENT
HOlD
TANK
o Gas Composition
~ Particulate Composition & Loading
@ Slurry or Solids Composition
- - Gas Stream
- Liquor Stream
Figure 3-5.
Typical Process Flow Diagram For TCA System
--...
I
I
I
I
L_-
t
.
STACK
-, -~I
SETTlING POND
-------
dampers on the induced-draft fans. The concentration of sulfur dioxide
,in the inlet and outlet gas streams is determined continuously by Du Pont
photometric analyzers.
The scrubbing systems are controlled from a central graphic panelboard.
An electronic data acquisition system is used to record the operating
data. The system is hard wired for data output in engineering,units
directly on magnetic tape. On- site display of selected information is
available. Important pr'ocess control variables are continuously recorded.
Trend recorders are provided for periodic monitoring of selected data
sources.
3. 3
EPA PILOT PLANT SUPPORT
Two smaller scrubbing systems (300 acfm each), which are capable
.
of operating over a wide range of co'nditions, have been installed at the
EPA facility in Research Triangle Park, North Carolina. The small
pilot scale scrubb~r systems are capable of simulating the Shawnee
scrubber systems with exc'ellent agreement in the lime/limestone
wet- scrubbing chemistry. Preliminary data is generated on the pilot
~cale system to verify and guide the selection of those promising concepts
which should logically be investigated on the larger scale Shawnee units.
Some of the results from the support program have been presentec;l in
References 3 and 4.
3-9
-------
Section 4
TEST PROGRAM
This section contains a description of the Shawnee Advanced Test Program,
which is tentatively scheduled to run from June 1974 through June 1977.
4. 1
TEST PROGRAM OBJECTIVES AND SCHEDULE
The goals of the test program are:
( 1 )
To continue long-term testing with emphasis on demonstrating
reliable operation of the mist elimination systems.
(2). To investigate advanced process and equipment design varia-
tions for improving system reliability. For example, testing
will be conducted with magnesium ion (MgO) addition in order
to operate the scrubber systems with liquors unsaturated with
respect to calcium sulfate (see Reference 3).
(3)
To investigate advanced process and equipment design variation
for improving system economics. For example, testing will
be conducted to i~vestigate the practical upper limit of the
gas velocity (i. e., minimum scrubber size) at which the scrub-
ber mist elimination systems can be reliably operated. Also,
tests will be conducted to evaluate system performance under
conditions of minimum energy consumption for the desired
levels of S02 and particulate removal.
(4)
To evaluate process variations for substantially increasing
lime stone utilization and reducing sludge production. Tests
will be conducted with scrubber effluent passing through three
4-1
-------
stirred tanks in series to approach a
and at reduced scrubber liquor pH to
utilization (see Reference 4).
"plug-flowll condition
increase limestone
(5)
To perform long-term (2 to 5 month) reliability testing on
advanced process and equipment design variations.
(6 )
To evaluate scrubber operability during variable load (e. g. ,
cycling gas rate) operation.
(7)
To investigate methods of improving waste solids separation.
This may include testing of a multiple-plate thickener, use of
coagulants, attempts to relate sludge characte'ristics to operating
conditions, and operational improvements of the centrifuge
and filter.
(8)
To determine the effectiveness of existing technology for pro-
ducing an improved throwaway sludge product. Tests will be
conducted to evaluate scheme s for oxidizing sludge to calcium
sulfate (gypsum)/fly ash mixtures, in order to improve solids
settling characteristic s and to reduce the chemical oxygen
demand (COD) of the sludge.
(9 )
To evaluate the effectiveness of three commercially qffered
sludge fixation processes and of untreated sludge disposal.
Fixed sludges (Chemfix, Dravo; and IUCS) and untreated lime
and limestone sludges are being continuously monitored in
ponds at the Shawnee site. Aerospace Corporation is:the
major contractor and test director for this effort:
(10) To evaluate system performance and reliability without fly
. a sh in the flue gas. Te sts will be conducted with flue gas
taken downstream of the Shawnee Boiler No. lO electrostatic
precipitator, i. e., with less than O. 1 grain/ scf of particulate
in the inlet flue ga s. '
(11) T'o determine the practical upper limits (;)f S02 removal
efficiency. Te sts will be conducted to determine the practical
upp~r limit of S02 removal by increasing the scrubber slurry
pH, increasing the slurry rate, increasing the scrubber gas
pressur,e drop, and adding magnesium ion (MgO) to the slurry.
4-2
-------
(12) To evaluate the TCA performance with lime and the venturi/
spray tower performance with limestone.
(13) To characterize stack gas emissions including outlet particulate
mass loading and size distribution, slurry entrainment" and
total sulfate emissions.
(14) To evaluate, under the direction of TVA, corrosion and wear
of alternative plant equipment components and mate"rials.
(15) To develop a computer program, in conjunction with TV A, for
the design and cost comparison of full- scale lime and lime stone
, systems.
The test program schedule, based on the defined objectives, is presented
in Figure 4-1.
As can be seen in the figure, as of the May 1975 boiler
outage, test's were in progress to demonstrate reiiability of mist
elimination systems at increased gas velocity, i. e., at 8.0 ft/ sec
in the spray tower and 12 ft/ sec in the TCA.
4.2
CLOSED LIQUOR LOOP OPERATION
A closed liquor loop is achieved when the raw water input to the system
, is equal to the water normally exiting the system in the settled sluge
and in the humidified flue gas. For lime/limestone wet-scrubbing
systems, the solids concentration in the settled sludge is normally
equal to or greater than 38 percent by weight.
I.f wast~ solids are
purged at a concentration below 38 percent or if a separate liquor
purge is taken, then the system is considered to be in open liquor
loop operation.
4-3
-------
oj:>..
I
oj:>..
IUT.............".. - .... .... ....
.1-1.101.1. . . .1-1-1.1.1-1.101. . . . - - -1.1.1.1.1.1. . . Fl. I A I. .
FIXAt. \'EM - ~ I FISCAL YEAR - I FISCAl.. YEAR an
I. ~ AIW.uK:ED'TUI'WG WITH TCA SYSTEM
IIISTn~TORTElT8GfI:J
VAR1MlL( LOAD TUrIIMI -
IIAX8IZI AUtAU urlUZAT808 TOr" lit
""""'OXJD(~TErI'8M1 io--
IMX88Z£ IULFm 0XIDAT808 TUfllGO#- BLEED nRUII 8DIUA .,
FN:I'ORIA&.1"ESf.-a'" . - OUT"",,"
FLY AlH-FltEE 1'UT8G
REUA8IU1'Y~T"R1.8 8DIUA
OUT"""
~ PlP8GYunUZATIDJI TESI'8I -
a...- ADVAM:ED TEJhG"'" VUITl8IUSi'RAY T08ER IYPUI
IItIJ n8M8ATOR TUI1IG III
VARIMUE L.Oo\D TUf8IG -
IMX-.zt: IUU'fT£OJI1DoI.T808 'IU11MII OF REED~
FACIOIUA&. ~Ict - -
FLY AlII. fItU: T£JT-.
....--.OXJDE AOOfT1(8nsr8Q -
R£UA8lUTt'~T808-
-.zE OIERGY U11UZAT808 'T'Bnm -
1 ~ REUUtUTY All) FACIORIA11'Un8G81IIvarn....... T08ERImDI
... L-'.UA8lun All) fACTORIAL TUntG 81TH 'lCASYSrDI
I. TUI1Im~ ro.:JTHTAA8I
EVALUATE ~IIEPAAATI08I. EXISI1MI~
IUJDGE CIUIUCrDIIZA'JImI
"'AClC.GoU~OWUICTDUZAn:.
IMTDtaAUNCI aJU8IIEWf nsr8Q
.. TESn8IG AT IEMftUJT FAaUTY IIIItESEARCIITJtIA8K.f PIIUUI.
J. QUIEMI. ~11081tU011T DRAI'T.-TTAL o.m . . .
~~ UlQIIB'8tESEIITIEOUE-.:B8acM"'YIlE~DUII_TNIrotIDD8m8CA:rm.
lit DICU8JU JUJ8G AT 1UW-GMVElDCITY.
.. -=umu TUT'1IOG 8ITM IEJtID tOLD 'A8I N8) AT UDUCED-=--:-IIdIIIY....
IcIIIIICLI.aQ "'IMX8IZ8Q 8D:I ..:wAL EHtCIE8C:"r TBnIICI.
liD 8CUIDEI tt:IT1MJ AT ---- ATTAaUU....-Y TOWER GAl WI.OCITY C - .........
Figure 4-1.
Shawnee Advanced Test Schedule
-------
With few exceptions, the advanced program te sts are being conducted
in closed liquor loop operation. The exceptions are typically short
exp1oritory runs with limited. objectives. They will be noted as open
liquor loop te sts when they occur.
4.3
ANALYTICAL PROGRAM
. Samples of slurry, flue gas, limestone, lime, and coal are taken
periodically for chemical analyses, particulate mass loading, and
limestone reactivity tests during the testing. Locations of s.1.urry and
gas sample points are shown on Figures 3-4 and 3-5. A summary of
the analytical methods for determining important species in the slurry
solids and slurry liquor is pre sented in Table 4-1. A laboratory
procedure s manual is being developed for distribution on reque st by
the end of the year. A li~ting of the compositions of the raw materials
used in the testing program is presented in Appendix C.
Four Du Pont photometric analyzers are used for continuous S02 gas
analyzing at the inlets and outlets of both scrubbers. Values of pH
are monitored with Universal Inter10x pH analyzers. Scrubber inlet
and outlet liquor pH and Koch T ray outlet liquor pH are monitored
. continuously.
Process water hold tank pH is monitored periodically.
Two' Universal Inter10x electrolytic analyzers are used to monitor
electrical conductivity. A modified EPA particulate train (manufactured
by Aerotherm/Acurex Corporation) is used to measure mass loading
at the scrubber inlets and outlets.
4-5
-------
Table 4-1
FIELD METHODS FOR BATCH CHEMIGAL. ANALYSIS
OF SLURRY AND ALKALI SAMPLES
oJ>..
I
0'
SPECIES.DESIRED FIELD METHOD
SO.LIDS LIQUIDS
Sodium - Atomic Absorption
Pota s sium - Atomic Absorption
Calcium X-ray Fluorescence Atomic Absorption
Magnesium X~ray Fluorescence Atomic Absorption
Sulfite Amperometric Titration Amperometric Titration
Total Sulfur X-ray Fluorescence Ba(C10 4)2 Titration
Carbonate Evolution Infrared Analyzer
Chlorides - Potentiometric Titration
-
-------
4.4
DATA ACQUISITION AND PROCESSING
Operating and analytical data are recorded automatically onto magnetic
tapes at the test facility. Additional data are recorded manually in
operating logs and graphs by on-site personnel. All data are sent to
the Bechtel Corporation offices in San Francisco for processing. In
San Francisco, data received from the test facility are entered into
a data base.
The data is sorted, further calculations made (.e. g. ,
percent sulfite oxidation, stoichiometric ratio), and reports are pre-
pared which present the data covering a specified period for a given
scrubber. After startup problems, the data gathering system has
functioned well in providing an up-to-date log of the scrubber operations.
4.4.1
Operating Data (Scan Data Acquisition)
Over 150 pieces of scan data (flow rate, temperature, pH, etc.)
are recorded automatically at fixed time intervals onto magnetic tape
at the test facility.
The scan data acquisition system was designed
and installed by Electronic Modules Corporation, and the tape recorder
was supplied by Cipher Data Products Corporation. A backup printed
record on paper tape is available if the recorder malfunctions.
4.4.2
Analytical Data
The analytical data acquisition system, which records the results of
laboratory analyses on magnetic tape, was designed and (in part) in-
stalled by Radian Corporation. A mini-computer receives inputs,
either directly from laboratory instrumentation or indirectly by reading
4-7
-------
cards.
The mini-computer performs certain calculations and enters
the resultant data on magnetic tape. The system generates, on- site,
a printed summary sheet of analytical data for each sample.
4..;8
-------
Se ction 5
VENTURI/SPRA Y TOWER LIME RELIABILITY TEST RESULTS
Performance and analytical data from lime reliability te sting on the
venturi/ spray tower system from 0 ctober 1974 through April 1975
are pre sented in this section, along with an evaluation of each te st
. .
and the conclusions drawn, to date. Results of lime reliability tests
prior to 0 ctober 1974 have been reported in Reference 1.
5. 1
PERFORMANCE DATA AND TEST EVALUATION
A summary of the test conditions and results of lime reliability tests
~(
on the venturi/spray tower is presented in Table 5-1. Properties
of raw materials such as lime and coal used during the tests can be
found in Appendix C. Selected operating data for tests which lasted
more than one week are graphically presented in Appendix D. Average
scrubber and clarifier overflow liquor compositions and the corres-
ponding calculated percent sulfate (gypsum) saturations are given in
I~* .
.Appendix E. An evaluation and discussion of each test is presented
in the following sections.
~(
Lime reliability runs made prior to October 1974 have been included
in this table.
**
The degree of Hquor saturation with CaS04' 2H20 at 500C was cal-
culated with the use of .the Bechtel modified Radian program. See
Reference 1 for a listing of this program.
5-1
-------
Table 5-1
SUMMARY OF LIME RELIAB'ILITY TESTS
ON VENTURI/SPRAY TOWER SYSTEM
Run No. 601-1A 602.1A 603.1A
Start-ot.Run Date 10/9/73 3111174 4/2/74
Itnd-ot-Run Date 1/8/74 4/1/74 4/19/74
On Stream Houri 2153 393 395
0.. Rate, adm @ HOoF 25,000 25.000 25.000
Spray Tower Ca. Vel. Ipi @ 1250F 6,7 6.7 6.7
Venturi/Spray TOwer 600/1200 600/1200 600/1200
Liquor Ratu, Ipm
Spray Tower 1.,/0. gal/met 60 60 60
Percent Solid. Recirculated 7-9 7.5.9.5 13.5.16
Efnuent R.8idence Time. min. 12 12 12
SoUd. Dhpol&l Sy.tem CIa rille r Only Clartl &r Intermittent ClarUI.r It Filter Clarine, It Filter Clarifier &.: rUt.,
(10/9-11/7) FIl.er (11/7-12115) (12/15.1/8)
Stoichiometric Ratio, mol.. C. 1. 01-1. 28 1. 02-1. 18 1. 04.1. 19 1. 02.1.18 1.00.1.13
add,d/mole SOZ ab.orbed
AVI" Lime UtUilation. 100" 87 91 90 91 94
molu 8°2 ,1)1. Imol. C. added
Inlet 8°2 Concentration, ppm 1600-3900 1600-4000 2100.4400 2100.3800 2100.4300
Perclnt SOZ Remoyal 68-91, 75-95 7\-95 87.97 85.98
Scrubber Inlet pH Ran,. 7,4-8.5 7.5-8.5 7.7-8.4 7.6.8.3 7.8.8.2
Scrubber Outlet pH Ran,. 4.7.5.5 4.7.5.5 4.8.5.3 4.9.5.4 4.8.5.3
Perc.nt Suilur OxtdSa.d 10-30 10.30 10.30 5.28 12.22
Loop Clolure. 'Vo SoUd. Dhch,. 20-26 20-27 42.\2 42.48 46.54
Calcv.lated '" Sulfate Saturation In 150 120 180 165 135
SCl'ubber Inlet Liquor @ 500C
Diuolved SoUd.. ppm 5700.7500 4600-7300 9800.12.300 9500 8200-10.900
Total 6P Ranae. Excludin, 11. 0-11. 5 11.0.12.0 11.7.12.3 11. 0.12. 0 11.0.12.0
Milt Eliminato!' In. H20
Venturi I1P, in. H20 9 9 9 9 9
Mill ICllmlnalor 6P. I.. H20 0.16-0.31 0.21.0.51 0.51.1.26 O. 19.0.27 O. 16.0.33
Ab.orbent Lime .1urried to 20 wt'- with makeup water and added Lime l1urried to 20 wtO!o with Lime .lurried to 20 wt'" with
10 ICHT. makeup water and added ~o makeup water and added to
ICHT. ICHT.
Milt Eliminator 10/9 - 12/151 Bottom wa.hed with avanable makeup water Bottom wa"~ed with avanable Bottom wa.hed with avanable
(""14 apm) plu. avanable Clarinld liquor (-26 ,pm). Con- makeup water ("'5 ,pm) plu. makeup water (-5 ,pm) plul
tinuou. wa.h rUe of O. 8 ,pm/ft. 12/15 - 1/81 Bottom avanable clariti.d liquor avanable clarUi.d liquor
wa.hed with avanable mak.up water (""'5 apm) plu. avanable (-3' .~m). W..h rate of 1 (-21 8~m). Wuh ro'e 0/ 1
clarineI' liquor (-45 ,pm). Wuh rate of 1 apm/tt2 on .pm/(t on oycle of... 'min Ipm/l. 0' cycle 0/-1.1/2
cycle 01 3-1/2 min on/l..l/2 min off. Aho, top wa. wa.hed o./lml. 01/. mi. 0011.1/2 mi. 01/.
once/wk with (ruh water for 5 min durin, lut 4 wk..
I Scrubblr Internah A 1 no..l88 17/heade 1') on top 3 header. .prayed downwa rd. All no..l88 on 4 heade,.. All nO&llu on , head.n
Bottom header nonlu (7) .prayed upward. .prayed downward. 7 no... .prayed downward. 7 no.-
Ilu/head.r on top 3 heade,... .lu/header on top 3 hudel'll
6 nOlll88 on bottom header. 6 no..le. on bottom h.ad.r.
Syuem Chan," Sefore Start Sy.tem (.crubber and milt eliminator) ,cleaned. Sy.tem cleaned chemically Milt eliminator cleaned.
of Run (NazC03/.u.a r/Ume.tone/
nya.h .oln. ) (ollowed by
mech. cleaninl. EHT lIaled.
lnuIlled external combu.Uon
roheate r. Chan,ed nonlu
on,bottom .pray header to
.pray downward Inuead of
UpWI rd. Capped middle
noule. on bottom header.
Method of Control Scrubber inlet pH controlled at 8.0 to. 2 SCl'Ubber Inlet pH controlled SCl'Ubber Inlet pH c~ntrolled
&I 8.0 t 0.2 .. 8.0 to. 2
! Ru. P""OIOp"y IniUally .tarted u lime reliability verlncaUon tut. Sub- Intended lon,-tum. Sealed Intended lon,-term. Rectr-
uquently, due to apparent reUabiUty of tho run. decilion EHT in attempt to reduce culatod 15% 10Uch in attempt
WI' made that tut continue U lona-term reUabiUty tut. .u]flte 'OxldaUon and thereby to reduce de,ree of .ulfate
de,ue 01 .ullate ..turation. IIturation. !:IiT ..aled.
-
Ruult. Routine in.pection on 11/7/74 .howed IYltem was generally Run terminated due to .call Degree of luUate IItunUon
clean alter 666 houri o( operation with clarifier only for (lZ5 mtll av.) and 10Udi de- wal reduced. but run wal
soUds disposal. Run was terminated on 1/8/74 due to ID polit. on milt eUminator top terminated du.e to .cate (60
fan vibration and rapidly Increasins prellure drop acrol. vane.. Sulfite oxtdation and mtll av.. I and .oUdl buildup
mist. eUm. Sulfate based .cale formed on most scrubber lulfate 'Ituratlon were not on the milt eUmtnator top
wall, and in Ilurry piping. Top of milt eliminator 800/0 reduced. Steady .tate oper- van.l.
plugged with 'olid. that fell (rom outlet duct.work. Mist aUon not achieved.
eliminator top vanea heavUy ,caled (300 mil. avg.),
5-2
-------
Table 5-1 {continued}
SUMMARY OF LIME RELIABILITY TESTS
ON VENTURI/sPRA Y TOWER SYSTEM
Run No. 604-1A 605-IA 606-IA 608-1A
Start-oC-Run Date 4/Z6/74 7/31/74 8/7174 8/Z1/74
End-oC.Run Date 7/15/74 8/6174 8/14/74 9/17/74
On Stream Hout. 18Z8 141 170 610
Gu Rate, .dm @ 330°F 25.000 Z5.000 Z5.000 Z5.000
Spray Tower Gall Vel, Cpa @ 1ZSoF 6.7 6.7 6.7 6.7
Venturi/Spray Tower min. (-100)/IZOO min. (-100)/1200 min. (~100,/IZOO 600/lZ00
Liquor Ratelll, .pm
Spray Tower L/G. gal/md 60 60 60 60
Percent Solids Rec:irculated 7.5-9.0 8.0-9.3 7.7-9.0 7.7-9.4
Effluent Re8idence Time, min. 17 17 17 IZ
SolidI Disposal System Clarifier &r Filter Clarifier &: Filter Clarifier ClarUier &r Filter
Stoichiometric Ratio. moles Ca 1. 03-1. 30 1.10-1.17 1. 10-1. 15 1.05-1.25
added/mole SOZ ablorbed
'Avg % Lime Utilization, IOOx 88 88 89 87
molee 5°2 abl. Imole Ca added
Inlet SOZ Concentration, ppm 2000- 3800 2500-3300 2400- 3200 ZOOO-3750
Percent SOZ Removal 70-92 73-81 67-79 75-95
Scrubber Inlet pH Range 7.7-8.4 8.8-9. Z 7.8-8. Z 7.6-8.4
Scrubber Outlet pH Range 4.5-5." 4.9-5..} 5.0-5. Z 4.8-5.1
Percent Sulfur Oxidized 8-30 IZ-Z8 lZ-ZZ lZ-Z8
Loop Closure, % Solids Dischg, 50-60 48-5Z 18-Z3 48-58
Calculate~ % Sulfate Saturation in 130 115 IZO 130
Scrubber Inlet Liquor @ 500C
Dissolved Solids, ppm 11,600-13,700 6.000-7,400' 5. '1>00-7.000 7,500-9. sOO
Total 6,P Range. Excluding 3.3-3.8 3.2-3.9 3.6-3.7 11.5-12.0
Mist Eliminator. in. H20
Venturi ~P. in. H20 1. 2-1. 5 (Plug 100% open) 1. 5-2. 0 (Plug 100% ODen 1. 9-2. 3 (Plug 100% open) 9
Mist Eliminatorl':..P, in. H20 0.20-1. 25 O. Z3-0. Z8 0.23..0.31 0.22-0.44
Absorbent Lime slurried to 20 wt % with Lime slurried to 20 wt% with Lime slurried to 20 wt% with Lime slurried to ZO wt% with
makeup water and added to makeup water and added to makeup water and added to makeup water and added to
scrubber downcomer. scrubber downcomer. scrubber downcomer. scrubber downcomer.
Mist Eliminator Bottom washed with available Bottom washed with available Bottom washed continuously Bottom washed with available
makeup water (-5 gpm) plus ;::~U:a~a ~~ ro~~I~p~jft8J:)' with 15 gptn (0.3 gpm/ftZ, makeup water only (-5.5 gpm
available clarified liquor raw water only. (Rate was Wash rate of 150 gpm (3 gpm/
~-'~:~~~i' on':~:~er:~:. ~f 1/2 cycle of-l min on/4 mIn. greater than available makeup ftZ) for approx. 9 mIn. every
off. water). 4 hours.
min on/I I/Z min at!.
Scrubber Internals All nozzles on -4 headers All nozzles on -4 headers All nozzles on 4 headers An nozzles on 4 headers
sprayed downward. ? noz- sprayed downward. 7 noz- spraYl!d downward. 7 noz- sprayed downward. 7 noz-
zles/header on top 3 headers. zles/headl!r on top 3 headers. zles/header on top 3 headers. zles/header on top 3 headers.
6 nozzles on bottom header. 6 nozzles on bottom header. 6 nozzles on bottom header. 6 nozzles on bottom header.
Systl!m Changes Before Start Mist eliminator and outlet System cleaned. Mist eliminator cleaned. Mist eliminator cleaned.
of Run duct cleaned. Sealed EHT Provided for Freon gas
provided with N2 gas purge. blanket over EHT.
EHT overflow blanked. Lime
slurry makeup added to
scrubber downcomer.
Method of Control Scrubber inlet pH controlled Scrubber io1et pH controlled Scrubber inlet pH controlled Scrubber inlet pH controlled
at 8.0 to. 2 at 9. 0 t O. 2 &t 8. 0 t O. 2 at 8. 0 t O. 2
Run PhUosophy [ntended 2 wh. To observe Intended long-tertp. Control Intended short-te rm. Mist Int'd 2 wks. I Z min res time,
sulfite OJC.idation and degree of at highe r pH in a ttempt to eliminator washed continuous- venturi in service. EHT seal-
sul!ate saturation with lime reduce sul!ite oxidation and ly with raw water only (at rate ed with Freon. Mist elim. on
add'n to downcomer, minimurT thereby degree of sul!ate reater than available makeup 4 hr wash cycle. Observe
slurry rate to venturi, sealed saturation. Wash mist elim- water). effects of lime add'n to down-
EHT purged with NZ gas, and inator with water only. comer and sealed E:HT (com-
8% solids recirculated. pare with Run 601-1A).
Results Degree of sul!ate saturation Run was terminated due to Run was terminated due to Run terminated due to slight
was about 130%. Solids from scale formation (up to 150 scale formation (50 mils avg.) increase in mist eliminator
outlet duct fell to top of mist mils) on top mist eliminator on top mbt eliminator vanes. 6p. Inspection revealed
eliminator. Run was tl!rmin- vanes. scale buildup (88 mils avg. )
ated due to heavy scale (500 on the mist eliminator top
m.ils avg. ) and soUds buildup vanes.
on mist eliminator.
5-3
-------
Table 5-1
( continued)
SUMMARY OF LIME RELIABIUTY TESTS
ON VENTURI/sPRA Y TOWER SYSTEM
Run No. 609-IA biO-iA 611-IA 618-IA
Start.of.Run Date 9/20/74 10/2/74 10/25/74 11/21/74
End-al-Run Date 10/2/74 10/13/74 11/11/74 12/2/74
00 Stream Hours 277 253 392 235
Gas Rate, Adm @ 3300F 25.000 25.000 25.000 25.000
Spray Tower Gas Vel. Cps @ lZSoF 6.7 6.7 6.7 6.7
Venturi/Spray Tower 600/1200 600/1200 600/1200 min (-100)/1200
Liquor Rates. gpm
Spray Tower L/G. gal/md 60 60 60 60
Percent Solids Recirculated 7.9-9.0 7.8-8.6 8.0-9.3 7.5-9.6
Effluent Residence Time. min. 24 24 6 17
Solids Disposal System Clarifier &: Filter Clarifier &: Filter Clarifier &.: Filter Clarifier
Stoichiometric Ratio. moles Ca 1. 07.1. 25 1. 10-1. 25 0.93-1. 05(" 1. 15- I. 22
added/mole SOZ absorbed
Avg % Lime Utilization, lOOx 87 85 101 '" 84
moles SOZ aba. fmole Ca added
Inlet SOZ Concentration, ppm 2250- 3600 1800- 3800 2250-3750 2600-4250
Percent SOZ Removal 80-96 87-98 96-99 57-79
Scrubber Inlet pH Range 7.6-8.6 7.8-8.4 6.9-7.2 7.0-8.3
Scrubber Outlet pH Range 4.7-5.4 4.8-6.0 5.4-6.3 4.8-5. I
Percent Sulfur Oxidized 12-30 16-26 15-28 10-28
Loop Closure, % Solids Dhchg. 47-52 43-48 44-49 16-21
Calculated % Sulfate Saturation in 110 110 45 140
Sc rubbe r Inlet Liquor @ 500C
Dissolved Solids, ppm 8,000-10,000 9,000-12,000 17,000-21,000 4,100-6,100
Total.6.P Range, Excluding Mist II. 0-11. 9 II. 0-12. 2 10.4.12.0 3.65-4.25
Eliminator, in. H20
Venturi6P. in, HZO 9 9 9 1. 8-1. 9 (Plug 1000/0 open)
Mist Eliminator {jp, in. H20 0.23-0.28 o. ZO-O. 33 0.55-0.60 0.50-0.60
Absorbent Lime slurried to Zo wt% with Lime slurried to 20 wt% with Lime slurried to 20 wt% with Lime slurried to ZO wt% with
makeup water and added to makeup water and added to makeup water and added to makeup water and added to
scrubber downcomer. effluent hold tank. scrubber downcomer. scrubber downcomer.
Mist Eliminator Bottom washed with makeup at Bottom washed with makeup at Bottom washe~continuously Bottom washed continuously
Z.7 gpm/ft2 (or -8 min every Z.7 gpm/ltZ (or """8 min every at 0.69 gpm/lt using a mix- at O. Z6 gpm/ft2 using 15 gpm
4 hrs. Simultaneous top wa sh 4 hI's. Simultaneous top wash ture o( ""5 gpm fresh water raw water (three times
with remaining makeup at with remaining makeup at and ",.35 gpm clarified liquor. required makeup water
I gpm/ft2 through a single I gpm/ltZ through a single rate).
nozzle covering about 14 ftZ. nozzle covering about 14 (t2.
Total makeup'" 5 gpm avg. Total makeup ......5 gpm avg.
Scrubber Internah All nozzles on 4 headers All nozzles on 4 headers All nozzles on 4 headers All nozzles on 4 headers
sprayed downward. 7 noz- sprayed downward. 7 noz- sprayed downward. 7 noz- sprayed downward. 7 noz-
zles/header on top 3 headers. des/header on top 3 headers. des/header on top 3 headers. zIes/header on top 3 headers.
6 nozzles on bo~tom header. 6 nozzles on bottom header. 5 nozzle. on bottom header. 5 nozzle. on bottom header.
System Change. Before Start Mist eliminator and outlet duct Relocated lime addition to System cleaned. Installed System cleaned
o( Run cleaned. A .ingle nozzle in- effluent hold tank. sloped mist eliminator and
stalled to provide top wash (or MgO (eeder. Relocated
one section o( mist eliminator lime addition to .crubber
and several holes drilled in downcomer. Effluent hold
the top vanes o( a second tank agitator lowered.
.ection.
Method o( Control Scrubber inlet pH controlled Scrubber inlet pH controlled Scrubber inlet pH controlled Scrubber inlet pH controlled
at 8.0 t o. Z. at 8.0 to. 2. at 7.0 to.Z. at 8.0 f O. Z.
R un Phil os ophy Intended 2 wk.. To ob.erve Intended 2 wks. To observe To verify the ability to run Intended I wk. To observe
the effect of mist eliminator the e((ect on sulfate satura- unsaturated with respect to rate o( scale buildup on
top wash (on one section) and tion o( lime addition to the calciwn sulfate with MgO eloped mist eliminator using
the effect o( increased resi- effluent hold tank vs addition add'n at 6 min. effluent a continuous (resh water
dence time on sullate satura- to the downcomer. residence time. bottom wash.
tion.
Results Run terminated as planned. Run terminated as planned. Run terminated as planned. Run terminated 8S planned.
Sulfate saturation reduced to Sulfate saturation 145%. Sulfate saturation 45% at a 20.250/0 of underside o( mist
110%. Mist eliminator top Mist eliminator top vanes magne.iwn Ion level of eliminator area was 50-1000/0
vanes clean where top washed. clean where top washed. 3000 ppm. plugged with mud and scale.
The underside of the mist
(aJ Total stoich. ratio (or Ca eliminator top vanes had
& Mg is 0.96-1.('8 (Avg. ......100 mils scale.
alkali util. is 98 I!/o}.
5-4
-------
Table 5"; 1 (continued)
SUMMARY OF LIME RELIABILITY TESTS
ON VENTURI/SPRAY TOWER SYSTEM
Ru. No. 619.IA 621-IA 622-IA 623-1A
Start-at-Run Dau 12/19/74 1/18/75 1/30/75 3/12/75
E.d.ol-Ru. Dltl 1/2/75 1/23/75 3/5/75 3/19/75
On Stream Houri 327 113 787 162
0.. ","t". 101m iI 1300' 25.000 25. 000 25.000 25.000
Spray Tow.. 0.. VII. /PI «I 1150, 6.7 6.7 6.7 6.7
VI.lurl/SprlY Tow.. 600/1200 600/1200 600/1200 600/1200
Liquor Ratll, Ipm
Spray Tow.. 1./0. III/mol 60 60 60 60
Perclnt SoUd, R.clrculated 7.10 8-9 7.2.8.8 7.4-8.9
B:tnulnt Ruld,nCI Tim.. min. 12 12 17 17
Solidi Dllpo..1 SYltlm Clarlfl.. ~ '111.. Clarillar ~ 'lilor Cia riner, and Cla,Uier Ie C.ntrt.tul.
CentrlfU.. (or fUUr)
Btelchiom.trto RaUo, molu Ca 1.07-1.11 1.20.1.27 I. 06-1. 20 I. 07-1.17
Iddod/molo SOa Iblorbod
A.I " I.lmo 11111100tlo.. 100. 87 81 88 89
mol.. SOa Ibl. /molo CI Iddod
1I\1.t 80. ConcentnUon, ppm 1150.4000 1600.3600 2200-3900 2700-3700
P..oo.t SO. Romo.11 70-98 82.95 71.91 74.88
Sorubbor Inlol ~ RI... 7.3.8.3 7.8.8.3 7.1-8.3 7.7-8.3
Sorubbar Oullol oH RI." 4.9.5.7 .'.2.5.6 4.7-5.3 4.85.5.1
Poroo.1 Sullllr O.ldl..d 14-34 12-26 12-28 11-21
I.oop Cloouro. " Solidi Dllobl. 53-60 57-61 50-62 53-60
Clloullted " SUllato Soluratlon III 115 130 115 105
Sorubb.. Inlol I.louor iI 100C
DI..ol.od Solidi. ODm 6400.8000 1600.6100 6500-10.000 7000.8400
Total 6p Rlnlo. Eooludlnl Mill 10.8.12.0 11.3-12,0 11.1.12.1 11.4-11.7
Eliminator. In. H.O
Vonl\lrl~. In. H.O 9 9 9 9
Mill ElImlnator6P. In. HaO 0.60.1.10 0.63.0.70 0.20.0.30 0.17-0.20
Ablorbonl I.lmo olurrlod to 20 wi "with Lime alunl.e! to 20 wt "with Lime l1unlee! to 20 wt "with Lime Ilunlee! to 20 wt ~ with
makeup "'aelr and add.d to makeup wat.r Ind added to makeup wlt.r and added to makeup wat.r and add.d to
urubb.r downcomer. .crubb.l'downcom.r. .crubb.r downcomer. Icrubber downcomer.
Mill ElImlnalor Bottom w.,hed with makeup Bottom wa .hed continuou.ly Bottom wa.hed with makeup Top wa,h.d uqu.ntlaUy with
watu at 2.6 Ipm/nl tor - 8 at 0,69 IPm/112 ullna I mix. Iwal.. at 3. 0 Ipm/112 lor trllh wat.r. ICacb no..l. (6
min ev.ry 4 bre. Total moko tun of "",,5 Ipm trllb water ....8 min .v.ry 4 bu. TolIl lotal) on 4 mill (It O. 1 Ipm/
up N 5 Ipm aVI. and NU Ipm olarlflod liquor. maklup""'! Ipm IVI. 112) wllb 76 mln oIl bo""oon
noule.. Bottom wa.hed with
remainlnl makeup at S (pml
It2 tor ....S. 5 min .v.ry 4 hu.
So rubber Intunall All n08l1.. on 4 hllder. All ft08l111 on. 4 hllde" tAll n08l188 on 4 h.ld.n All n08l1.. on 4 h.ld.u
.prayed downwlrd. 7 n08l1111 .prly.d downwlrd. 7 noul..1 .prly.d downward. 7 noul..'1 .prayed downward. 7 nOlll..
h.ad.r on. top 3 headlre. 6 hl.du on top S headl fl. 6 11.e.d.r on top S h.adl". 6 hlad.r on. top S hl.dl". 6
noul88 Oft bottom hlld.r. nOlll.. on bottom head.r. nOlll11 on bottom h.adu. noul.. on bottom h.ad.r.
y.tlm Chanlll B.fore Start Milt IUminator ol.anld in Milt .Umlnator remov.d and In.taUld nlw opln-van.. hor- Cloanoo mill ollm n&lor ona
01 Ru. plaol. Etnuonl bold tank cleanld. I.ontal mitt IUminator at an outlet duct. InttaUed milt
a.ltator railld to orilinal .levatton 1 toot bI,ber than eUminator uquenttat top...a.h
Ilvel. previoul op.n-vane, borhon- Iyltem.
tal milt eUmlnator.
~ethod of Control Scrubber inlet pH controlled Scrubber Inl.t pH controlled Scrubber inlet pH controlled Scrubb.r inlet pH controllid
It 8.0:0.2. It 8.0:0.2. al 8.0;10.2. al 8.0:0.2.
un Phtlolophy Intended 2 w}u. To obllrye Intlnded 2 wk.. To obllrye Intended 2 wkl. To IItabU.h ,Intended IonS term. To 0'0-
the rate of .eal1 buildup on the rate of .cale/.oUd. build- ball condition. tor the plr- IIrve the rate at .cale/.oUd.
.10pld milt eUminator u.ln. up on the Iloped milt IUm- formanel of the new open-yane buildup on the ml.t eUmlnator
an Intumlttant, hlah prll .ure Inator wuhed with a cantin- (of old dul,n) milt eUmlnator with bottom wa.h and IIquen-
fruh watu bottom wa.h. uou. bottomw..h u.lna all with undn'lde wa.hln, only. tlal topwa .h.
avanable makeup water and
ell. rifled Uouor.
Rllult. Run terminated,a. planned. Run terminated at planned. Run terminated a. planned. Run terminated In order to
The milt eUmlnator WI.. 25-"\ Bottom of milt eUmlnator top MI.t eUmlnator 5% re.trlcted tilt hI,he r ,a. velocltl..
30" rlltrlotld but the tilt wu yanl coatld with .0Ud. (60 by .c.le and 'oUd.. whln In,plctlon flveal,d the
InvaUd .Ine. S of the 9 milt mill 1.1. I. milt eUmlnator to b. cl.an
eUmlnatu unduwa.h noul.. with only a lisht leattered
had 10et aUsnmen.t nullns dUlt on the mitt elimln.ator
unlven wuh coveraSI. vane..
5-5
-------
Table 5-1 (continued)
SUMMAR Y 0 F LIME RELIABILITY TESTS
ON VENTURI/SPRAY TOWER SYSTEM
Run No. 6Z4-IA
Start-of-Run Date 3/19/75
End- of. Run Date 4/Z3/,.
On Stream Houri 8Z3
Ca. Rate. adm @ 330°F 30.000
Spray TowerCiu Vel. (pI @ 12SaF 8.0
Venturi/Spray Tower 600/lZ00
Liquor Ratee. gpm
Spray Tower L/c. gal/md 50
Percent Solid. Recirculated 7-10
Effiuent Ruidence Time. min. 17
SoUd. Dhpoul Sy.tem Clarifter II: Centrituae
Stoichiometric Ratio. molu C.. I. 03-1. ZO
added/mole 5°2 ab.orbed
Ava: % Lime Utilization. lOOx 90
molu 502 abl. fmole Ca added
Inlet 502 Concentration, ppm ZZ50-3750
Percent 502 Removal 70-87
Scrubber Inlet pH Range 7.8-8.3
Scrubber Outlet pH Range 4.8-5. Z
Percent Sulfur Oxidized IZ-30
Loop Clo.ure. % SoUd. Dbchg. 48-58
Calculated % SulCate Saturation in 95
Scrubber Inlet Liquor @ sooe
Diliolved Solid.. ppm 6000-10,000
Total 6,P Range, Excluding Mtet lZ. 0-IZ. 4
Eliminator. hi. HZO
Venturi 6p. in. HZO 9
Mht Eliminator 6p. in. HZO O. Z5-0. 35
Ab80rbent Lime 81urried to ZO wt '0 with
makeup water and added to
.crubber downcomer.
Mht Eliminator Top wa.hed eequentially with
fre.h water. Each nozzle (6
total) on 4 min
-------
5. 1. 1
Venturi/Spray Tower Run 609-1A
During previous reliability testing on the venturi/ spray tower, deposits
on the top vanes of the mist eliminator were observed at the end of each
run.
The mist elimination system consisted of a 316 stainless steel,
3-pass, open-vane, chevron mist eliminator with underside wash (see
Figures 3-1 and 3-3).
Run 609-1A was begun on September 20, 1974 with a clean mist eliminator.
The purposes of the test were to evaluate the effectiveness of topside
washing on the mist eliminator and to determine the effect on scrubber
liquor sulfate saturation of increasing the effluent residence time from
12 to 24 minutes.
The major test conditions selected were (see Table 5-1):
Spray tower gas velocity
Venturi liquid-to-gas ratio
Spray tower liquid-to-gas ratio
Percent solids recirculated
Effluent residence time
Scrubber inlet slurry pH (controlled)
6. 7 ft/ sec
30 gal/me!
60 gal/me!
8
24 min
8
2 >:<
During the test, the entire mist eliminator underside and a 14 ft area
on the topside were washed at high pressure (45 psig) with makeup water
* . ,
Only a small section of the topside was washed because it was felt
that entrainment from the top spray might overload the reheater and
possibly allow moisture to reach the fan. In later tests, the entire
topside was washed by resorting to sequential washing. Another
pos sible solution would be to use a second mist eliminator to' inter-
cept entrainment from the topside sprays.
5-7
-------
at a rate of 2. 7 gpm/ft2 for the underside and 1. 0 gpm/ft2 for the topside
, ,
for about 8 minutes every 4 hours.
Run 609-lA was terminated as planned after 277 hours of operation.
, *
The topside spray had drastically reduced the scale buildup on the
top mist elimina~or vanes. The washed area was essentia,lly clean,
, '
with Ie s s than 1 mil of solids accumulation, compared with an average
of 40 mils scale build~p on the rest of the topside surfaces. The bot.;.
tom vanes held a white dust film that was easily rubbed off. This
film has been observed in all runs with intermittent wash. The dust
does not accumulate.
The beneficial effect of increased residence time in reducing the percent
sulfate saturation was also observed.
For this te st with 24 minute ef-
fluent residence tim~, the calculated average ,sulfate saturat~on of
the scrubber inlet liquor (see Table 5-1) was 11 0 percent compared
with about 130 percent for Run 608-1A which had a 12 minute residence
time. This effect of re sidence time is similar to that observed for
limestone systems when supersaturated with respect to sulfate (see
Reference 1,).
5. 1. 2
Venturi/Spray Tower Run 6l0-lA
Run 6l0-lA was a short-term test to determine the effect of alkali
addition to the effluent hold tank on the scrubber liquor sulfate satura,-
tion, as opposed to alkali addition to the scrubber downcomer (Run 609-lA)~
It had been proposed that lime addition to the downcomer would correspond
*
Unless otherwise noted, scale refers to hard crystalline sulfate solids.
Solids or soft- solids refer to mud-like soft solids.
5-8
-------
to a small residence tank in series with the larger effluent hold tank
resulting in reduced sulfate saturation.
The run was started on
° ctoher 2 and continued through October 13, 1974, for a total of
253 operating hours. The system was not cleaned before the test.
Inspection at the end of the run indicated formation of new scale on all
surfaces in the spray tower below the mist eliminator. The top slurry
spray header contained scale up to 60 mils, while scale thickness on the
. walls ranged from 25 mils in the area adjacent to the top header to 40
mils on the bottom of the tower. Several slurry nozzles were plugged
and white scale covered most diffusers. Scale coverage on the wall
areas above the mist eliminator was also observed.
The venturi
flooded elbow held new scale deposits on all walls.
The washed area of the top mist eliminator vanes was still clean after
530 operating hours (Runs 609-1A and 6l0-1A), compared with an
average of 70 mils scale buildup on the rest of the topside vane surfaces.
The mist eliminator bottom v'anes held smooth white scale about io mils
thick.
The overall mist eliminator restriction had increased from 2
to 4 percent during this run.
For this run (lime added to the hold tank), the calculated sulfate satura-
tion of the inlet scrubber liquor was 145 percent at an average inlet
*
S02 concentration of 2800 ppm. This value was about 35 percent higher
*
Under the conditions for Run 61 0-lA, the scrubber inlet liquor sulfate
saturation for a lime system is a strong function of the inlet ga s 502
concentration (502 absorption rate). A 100 ppm increase in 502 con-
centration corresponds roughly to a 10 percent increase in sulfate
saturation (see Section 9- 3, Reference 1).
5-9
-------
than observed in Run 609-1A (lime added to the downcomer) at the same
inlet SOz concentration. The results of these two tests, showing a
decrease in sulfate saturation with lime addition to the downcomer,
confirmed observations in earlier lime reliability tests (see Section 9..3,
Reference 1).
5.1..3
Venturi/Spray Tower Run 611-1A
Results at the EPA pilot facility at Research Triangle Park, N. C., have
. .
shown that it is possible to .operate lime wet- scrubbing systems with
liquors unsaturated with respect to calcium sulfate, by addition of
magne siurn ion (MgO) to the scrubber liquor (see Reference 3). Run
6ll-lA was intended to verify the se re suIts at the Shawnee 10 Mw scale.
The test conditions for Run 611-1A differed from those of the previous
Run 610-IA in four respects: (1) magnesium oxide was added to the
process slurry in the effluent hold tank to maintain 3000 ppm Mg++ in
the recirculated slurry, (2) the effluent residence time was reduced
from 24 to 6 minute s (the agitator in the effluent hold tank had been
lowered before the run .started), (3) the scrubber inlet pH control point
was dropped from 8.0 to 7.0, and (4) the lim.e addition point was re-
located from .the effluent hold tank to the. scrubber downcomer.
In addition to the above changes~ the 316 stainless steel,3-pass, open-
vane, horizontal chevron mist eliminator wa s replaced by a 316 stainles s
steel, 4-pa s s, closed-vane, sloped (cone- shaped) chevron mist elim-
inator (see Figure 3-3).
The new sloped mist E!liminator was believed
5-10
-------
to have better wash liquor draining characteristics, and hence less
scaling and plugging potential. The underside of the sloped mist elim-
inator was washed continuously with approximately 40 gpm (0.69 gpm/ft2)
of diluted clarified liquor (about 5 gpm makeup water and about 35 gpm
clarified liquor) at 20 psig pressure.
The run was started on October 25 and terminated, due to an unscheduled
maintenance outage on boiler No.1 0, on November 11, 1974, after a
total of 392 operating hours.
run was started.
The system had been cleaned before the
Inspections were made after 47 and 250 operating hours and at the end
of the run.
The venturi section, flooded elbow, spray tower walls (both
above and below the mist eliminator), and spray tower outlet duct were
clean. 0 ld scale deposits remaining after the previous cleaning had
slowly disappeared.
Scale deposits on the inlet vanes' of the mist elim-
inator, ranging in thickness from 19 to 84 mils, were observed during
the first inspection, but the, scale had nearly disappeared by the end of
the run.
Channels along the lower edge of the mist eliminator not directly
contacted by the wash spray were completely filled with soft solids.
The underside of the outlet vanes were covered uniformly with 50 mils
of soft fibrous solids.
Calculated average sulfate saturations of 45 percent for the scrubber
inlet liquor and 95 percent for the scrubber outlet liquor confirmed that
the system was operating unsaturated with respect to sulfate.
The
apparent descaling effect observed during the system inspections under-
scores the beneficial effect of unsaturated operation.
5-11
-------
5. 1. 4
*
Venturi/Spray Tower Run 618-1A
Run 618-1A was begun on November 21, 1974 and continued until
December 2, 1974, for a total of 235 operating hours. The system,
including the mist eliminator, had been cleaned before the start of
the run.
The test was intended to be short term and was designed to observe the
rate of scale buildup on the sloped chevron mist elitninator under a
, continuous 15 gpm (0.26 gpm/ft2) fresh water underside wash corres-
, **
ponding to about three times the required makeup water rate. The
test conditions were chosen to permit a direct comparison with the
scale buildup rate on the open-vane, horizontal chevron mist elim-
inator during Run 606-1A (see Table 5-1 and Reference 1).
Inspection after termination of the run revealed that 20 to 2~ percent of
the underside of the mist eliminator area was 50 to 100 percent plugged
with a mixture of mud and scale. Also, the underside of the mist elim-'
inator top vane had approximately 100 mils of scale buildup. The scale'
and solids buildup on the underside of the mist eliminator may have been
due partly to insufficient coverage by the mist eliminator underspray.
The average scale growth rate on the mist eliminator top vanes was 70
>:c
Runs 612 -lA through 617 were incomplete short-term factorial tests.
They will be reported with the factorial tests scheduled for a later date.
**
This test was run under open liquor loop conditions.
, cent solids in the discharge sludge was 18 percent.
The average per-
5..12
-------
mils/week for this run as compared with 50 mils/week for the open-vane,
horizontal chevron mist eliminator during Run 606-1A (see Reference 1)
The spray tower walls above the mist eliminator were clean, but below
the mist eliminator the walls were covered with 120 mils of scale.
The
slurry nozzles had "whiskers" of white scale on the diffusers.
The
venturi section below the throat and the flooded elbow were covered with
a hard, smooth 110-mil scale.
The calculated sulfate saturation was 140 percent for the scrubber inlet
liquor and 170 percent for the scrubber outlet liquor.
The unexpectedly
high sulfate saturations observed during open loop operation may have
been due to insufficient mixing in the effluent hold tank at low agitator
position and high liquor level (17 minutes residence time at run start
and 12 minutes after November 25).
The scrubber inlet liquor pH con-
trol was also quite erratic throughout the run (see Appendix D, Figure D-4).
5.1.5
Venturi/Spray Tower Run 6l9-1A
Run 6l9-lA was begun on December 19, 1974 and continued until January 2,
1975, for a total of 327 operating hours.
The run was intended to be
short term in order to observe the rate of scale buildup on the sloped
chevron mist eliminator using an intermittent underside wash for 8
minutes every 4 hours with 150 gpm (2.6 gpm/ft2) of high pressure
(.45 psig) makeup water.
Run conditions were chosen to enable a direct
comparison with the scale buildup rate on the open-vane, horizontal
chevron mist eliminator during Run 608-1A (see Table 5-1 and Reference 1).
The mist eliminator had been cleaned in place prior to the start of the run.
5 -1.3
-------
The agitator, which had been lowered by 4 feet prio.r to Run 6ll-lA,
was raised to its original position before the start of this run.
Inspection after termination of the run revealed that approximately 25
to 30 percent of the underside of the mist eliminator area was completely
restrict.ed by solids. Much of this plugging could be attributed to mis-
orientation of three of the nine underside wash spray nozzles.
About
150 mils of scale was deposited on the underside of the outlet vanes.
The average scale growth rate on the mist eliminator top vanes was
about 75 mils /week for this run as compared with 25 mils /week for the
open~ vane, horizontal chevron mist eliminator during Run 60B-lA.
The calculated average sulfate saturations were 125 and 145 percent for
the scrubber inlet and outlet liquors, respectively.
5. 1. 6
*
Venturi/Spray Tower Run 62l-lA
Run 62l-lA was started on Janua.ry lB and terminated on January 23,
1975, after 113 hours of operation.
The purpose of the test was to
study the rate of scale / solids buildup on the sloped mist eliminator
operating with a continuous bottom wash using all available makeup
water (rv 5 gpm) and clarified liquor (1\135 gpm) at 16 psig nozzle pres-
sure.
Other te!!lt conditions were the same as for Run 6l9-1A.
The
mist eliminator was removed and cleaned prior to the startup.
* .
Venturi/ spray tower Run 620-lA was of a short duration due to opera-
tional difficulties with returning clarified liquor to the spray tower
for mist.eliminator washing.
5-14
-------
Inspection at the end of the run indicated that, in general, the continuous
underspray with a mixture of makeup water and clarified liquor was not
effective in preventing solids deposition in the mist eliminator. Large
areas were 25 to 50 percent restricted with soft solids. The outlet
vanes contained 2 to 3 mils of dust while the middle vanes were covered
with light scattered dust deposits.
It was felt that improved design of the spray system combined with proper
wash rate and cycle would reduce the rate of solids accumulation in the
sloped chevron mist eliminator.
However, because of the complexity
in the geometry of the sloped mist eliminator and the low probability that
it would become a representative design for a full scale scrubber, it was
decided to abandon further te sting of this mist eliminator in the spray
tower. The sloped mist eliminator was removed and a new 316 stainless
steel, 3-pass, open-vane, horizontal chevron mist eliminator was
>:<
installed (see Figure 3-3).
Due to the short duration of this, run, 'no representative liquor samples
could be obtained, and hence no percent sulfate saturations are reported.
5.1.7
Venturi/Spray Tower Run 622-1A
Run 622-lA was begun on January 30 and terminated on March 5, 1975,
for a total of 787 operating hours.
The run was intended to establish
base conditions,' in terms of reliability and operability, for the new
open-vane, horizontal chevron mist eliminator.
>:C
Since the original mist eliminator used prior to Run 611-lA was in
poor physical condition due to corrosion and wear, an identical one
was fabricated and installed. The new mist eliminato'r was installed
at an elevation one foot higher than the old one.
5-15
-------
The underside of the mist eliminator was washed intermittently with
high pressure (45 psig) water at 150 gpm (3 gpm/ft2) for about 8 minutes
every 4 hours.
The effluent residence time was increased from 12 to
17 minutes for this run.
Inspections were plade at 110, 275, and 574 hours and at the end of
the run after 787 hours.
Solids deposits that restricted the mist elim-
inator by 3 percent were noted at the second inspection.
By the end
of the run, the overall restriction of the mist eliminator by scale and
solids had increased from 3 to 5 percent. The top surface of the top
vanes w~s coated with scale which averaged 60 mils thick. A small
area held scale and solids up to. O. 5 inch thick on the underside trailing
edge of the top vanes.
The middle and bottom vanes held light, scat-
tered dust about 2 mils thick.
The spray tower had less scale in the lower
third of the ve ssel than it had at the end of the previous run.
The solids
deposit on the duct walls between the reheater and fan dampers averaged
150 mils thick.
The dampers were clean, but the fan blades had deposits
60 to 70 m~1s thick.
The venturi section was generally clean.
The calculated average sulfate saturation was 115 percent for the scrub-
ber inlet liquor and 13'5 percent for the scrubber outlet liquor.
These
values a.re 10 percent lower than for Run 619-1A even though the chloride
concentration was about 1000 ppm higher and the inlet gas S02 concen-
tration was about 400 ppm higher. This drop in saturation is attributed
to higher effluent residence time, i. e., 17 minutes for this run versus
12 minutes for Run 619-1A.
5-16
-------
5. 1. 8
Venturi/Spray Tower Run 6Z3-1A
Run 6Z3-1A was started on March lZ and terminated on March 19, 1975,
after l6Z hours of operation. The purpose of this run was to test the
effectiveness of a sequential top side wash system on the open-vane,
horizontal mist eliminator.
Earlier te sts (Runs 609-1A and 61 O-lA)
had shown that washing a small area of the topside of the mist eliminator,
in combination with the full underside washing, was very effective in
keeping the washed area clean.
The sequential topside wash system operated with 6 spray nozzles on
a 4 minute "on", 76 minute "off" time cycle, with only one nozzle
activated during each "on" cycle. This arrangement resulted in a
total 8 hour cycle time for the 6 nozzles. The fresh water flow rate
through one nozzle during the "on" cycle wa s set at 8 gpm (at 13 psig),
covering 16 ftZ to give a specific spray rate of O. 5 gpm/ftZ.
In addition to the sequential topside wash, the entire underside of the
mist eliminator was washed with the remaining makeup water at 150
gpm (3 gpm/ftZ) at 45 psig for about 3.5 minutes every 4' hours. The
"on" cycle was never allowed to drop below Z minutes at any time.
The system had been cleaned before the run was started. Inspection
of the mist eliminator at the end of the run showed that the combination
of sequential topside wash and intermittent underside wash was success-
ful in preventing scale and solids accumulation on the mist eliminator.
Only scattered dust a few mils thick was formed on some of the vanes.
Wall ar'eas above the mist eliminator held only scattered light dust with
5-17
-------
light scale in some areas.
The walls below the mist eliminator were
, unchanged since startup.
The vessel bottom was clean.
The calculated average sulfate saturations for the scrubber inlet and
outlet liquors were 105 and 130 percent, respectively.
5. 1. 9
Venturi/Spray Tower Run 624-lA
The combination of sequential topside and intermittent underside wash
had been successful in keeping the mist eliminator free of scale and
solids accumulation at 6.7 ft/ see gas velocity during Run 623-lA. '
Run 624-1A was started on March 19, 1975, without system cleaning, ,
to test the mist elimination system at a higher gas velocity of 8. 0 ft/ se'c.
For this run, the average wa sh time for the underside of the mist eliminator
was increased from 3.5 to 4.3 minutes every 4 hours because of the
higher makeup water rate available at the higher gas velocity. The
wash rate and cycle for the topside were the same as for Run 623-1A.
Run 624-lA was terminated on April 23, 1975, after 823 hours of opera-
tion due to a scheduled maintenance outage On boiler No.1 O.
A total of 4 inspections were made for this run, including one at the
end of the run.
The mist eliminator was found to be free of any restric-
tion during each of these inspections.
Vane surfaces washed earlier in
the wash cycle usually held 2 mils of scattered white dust, while recently
washed vane surfaces were entirely clean.
5-18
-------
Both the piping for the mist eliminator topside spray and the, corrosion
specimen rack above the mist eliminator were coated with dust.
Some
scale was noticed on parts of the spray tower wall above the mist elim-
inator and scale up to 1 inch thick encircled the spray tower outlet duct.
The spray tower wall below the top slurry spray header had less old
scale. The venturi section was almost clean and no solids had formed
in the flooded elbow.
The calculated average sulfate saturations were 95 and 120 percent
for the scrubber inlet and outlet liquors, respectively.
The low sul-
fate saturations may have been caused by the lower liquid-to-:gas ratio
at the higher gas velocity of 8. 0 ft/ see (see TCA Runs 539-2A through
543-2A and Run 545-2A, Section 6. 1).
5.2
MATERIAL BALANCES
The results of calcium and sulfur material balances for venturi/ spray
tower lime reliability Runs 610-1A and 624-1A are summarized in
Table 5-2.
The computed inlet and outlet rate s for calcium and sulfur
are in good ag reement.
This is consistent with results of earlier lime
reliability te sts. (see Reference 1).
The absorbed S02 was computed from the measured inlet gas rat e, the
inlet and outlet gas S02 concentrations, and the estimated gas outlet
rate. The added calcium was computed from the measured volumetric
rate of lime stone slurry additive and the solids concentration in the
slurry.
The discharged sulfur and calcium were computed from the
measured rate of slurry discharged from the system and the concen-
trations of sulfur and calcium in the discharge.
procedure are given in Reference 1.
Details of the calculation
5-19
-------
Table 5-2
SUMMARY OF MATERIAL BALANCES FOR SULFUR
AND CALCIUM FROM LIME RELIABILITY TESTS
Sulfur Balance Calcium Balance Average Stoichiometric Ratio.
Material Moles Ca Added/Mole SO Absorbed
Run No. Balance SO SOx in Slurry Ca in Lime Ca in $urry Based on Lime Based on
Period. Absor~ed. Discbarged. Percent Feed. Discbarged, Percent Added Slurry
hours Ib-moles/hr Ib-moles/hr Error Ib-moles/hr Ib-moles/hr Error and S02 Absorbed Analys is
610-1A 166 6.3 7.0 +10 6.1 8.3 +26 0.97 1. 19
624 -lA 165 7.4 8.6 +14 7.9 9.5 +17 1. 07 1. 10
111
I
N
o
-------
5. 3
CONCLUSIONS
5. 3. 1
Scrubber Operation
As with limestone'testing, earlier lime reliability test results have shown
that scrubber internals can be kept relatively free of sulfate (gypsum)
scale if the sulfate saturation of the scrubber liquor is kept below the
critical value of about 135 percent (Section 7.3, Reference 1). As
with limestone, this can be accomplished with increased percent solids
recirculated (Run 603-1A versus 601-1A) and/ or with increased effluent
residence time (Run 622-1A versus 6l9-lA). Lime tests have further
shown that lime addition to tb.e scrubber downcomer, corresponding to
a small residence tank in series with the larger effluent hold tank,
can substantially reduce the sulfate saturation (Run 609-1A versus
610-lA).
This permits operation at reduced solids concentration and/or
effluent re sidence time.
Run 611-1A has confirmed the findings at the EPA pilot facility that
the scrubber can be operated unsaturated with respect to sulfate by the
addition of magnesium ion (MgO) to the process slurry.
Under the con-
ditions tested, the average sulfate saturation was 45 percent for the
scrubber inlet and 95 percent for the scrubber outlet liquor, with about
3000 'ppm Mg++ concentration in the recirculated slurry. Gypsum scale,
pre sent prior to start-up, dis solved during the run.
As in earlier tests, the lime test results have shown that the sulfate
saturation of the scrubber inlet liquor is a strong function of the inlet
gas S02 concentration (S02 absorption rate).
The data have indicated
5-21
-------
that a 100 ppm increase in S02 inlet concentration corresponds roughly
to a 10 percent increase in sulfate saturation at the run conditions tested.
It should be noted that the 27 full;..cone, spiral-tipped Bete nozzles in
the spray tower have shown no signs of measurable erosion on the
stellite tips after approximately 7200 hours in 8 percent slurry service
at 10 psig nozzle pressure.
5. 3. 2
Mist Eliminator Operation
Significant improvement in the operation of the 316 stainless steel.
3-pass, open-vane, horizontal chevron mist eliminator has been achieved
during this report period.. During the earlier lime reliabilty testing
(see Reference 1), scale and solids accumulation occurred mostly on
the top surfaces of the mist eliminator when it was washed only from
the underside.
With sequential topside and intermittent underside
washing, the mist eliminator was essentially clean after 162 hours
of operation at 6. 7 ft! see gas velocity during Run 623-lA, and again
after 823 hours of operation at 8.0 ft/ see during Run 624-lA. The
mist eliminator was not cleaned between the two runs.
Future tests
with this mist elimination system will include gas velocities greater
than 8.0 ft/ see and lower wash water flow rate.
Operations with the 316 stainless steel, 4-pass, closed-vane, sloped
(cone- shaped) chevron mist eliminator have not been successful (Runs
611-lA, 618-lA, 619-lA, and 621-lA).
It is felt that improved de sign
of the spray system, in combination with proper wash rate and cycle,
would reduce or eliminate the scale and solids accumulation within the
5-22
-------
sloped mist eliminator.
However, because of the complexity in the
geometry, of this cone- shaped mist eliminator and the low probability
that it would become a representa.tive mist eliminator design for a full
scale scrubber unit, it was decided to abandon further testing of this
unit in the spray tower.
5-23
-------
Section 6
TCA LIMESTONE RELIABILITY TEST RESULTS
Performance and analytical data from limestone reliability testing on
the TCA system from October 1974 through April 1975 are presented
in this section, along with an evaluation of each te st a.nd the conclusions
drawn, to date.
Results of limestone reliability tests prior to October
1974 have been reported in Reference 1.
6.1
PERFORMANCE DATA AND TEST EVALUATION
A summary of the test conditions and results of limestone reliability
)'C
tests on the TCA system is presented in Table 6-1.' Properties of
coal and lime stone used during the te sts can be found in Appendix C.
Selected operating data for tests which lasted more than one week
are presented graphically in Appendix F. Average scrubber and Koch
tray liquor analytical data and the corre sponding calculated percent
sulfate (gypsum) saturations are presented in Appendix G. An evalua-
tion and discussion of each test is presented in the following sections.
*. .
Limestone reliability runs made prior to October 1974 have been
included in this table.
6-1
-------
Table 6-1
SUMMARY OF LIMESTONE RELIABILITY TESTS ON TCA SYSTEM
lIu' No. !I!-IA !l6-IA !l7-IA !U-IA
SIUI- ol-llu. Dol. 10/24/?! 111Z1/?! 1/18/74 1/6/ 4
End-ol-Run Dati 11/15/13 1/10/74 1/24/74 2/26/74
O. Siriom Houri 517 1190 13) 42!
a.. 110'.. ..1m 0 )Ooor 2&.000 10. !OO 10.500 10,100
a.. V.loolly. /p.4I II!Or 10.! 8.6 8.6 8.6
Llquo. 1101.. .pm 1100 1100 1200 1200
L/a. .01/11'101 60 ?I ?I ?I
P...I.I Solid. 1I..I.oulolld 14-16 14.11.5 11.16 14-16
IClnul.1 1I..ldl..1 TIll'll, 11'11., 10 10 10 12
Slol.hiomll.l. iloilo, 11'101.. Co 1.1.1. 6 1.1-1.7 I. 5.1. 9 1. I-I. 4!
oddld/moll SOl ob.o.bld
A.. " 1.111'1"'0.1 UIIII..llo., 100. ?I 69 59 78
11'101.. SO. ob.. /11'101. Co oddld
111181 SOl Co....lrI"O.. ppm 1800.4000 1600-4'00 1600-1800 1000.4000
P...I", SOl 11.11'10.01 ?I.88 U-87 15-81 79-90
S.pubb.. 111111 pH 110..1 1.1.0.1 I. 6!.1. 9 5.15.1.9 I. 7-!. 9!
S..ubb.. Oull81 pH 1\0... !.1-5.8 5.1.5.5 5. '-5. 5 5.T-5. 5
P...I.I Sui"'. O.ldlud 11-30 11-15 11-15 10-30
Solid. DI.po..1 SV.'.m Clulll.. Cluln.. Clulll.. CIa.IlI..
Loop Clo,url, " Solid. DI..II.. 11.41 15-47 34-19 15-13
Col.ulolld " Sullo'o hlu.ollo. I. 140 110 130 110
S.pubb.. 111111 Llquo. OIOoC
TOlol Dluol.od Solid.. ppll'l 7000.9600 UOO.9100 nOO-8900 .4100-6800
TOlol A Plio... Exoludlll. Mill 1.8-6.5 4.3-4.7 4.6-4.9 4.9-5.3
ICllmlllO'o, o.d Kooll TPOY. I.. HIO
MlllllllmlllOlo, ond Kooll T,oy t ~:t 1 g~m:::/:~: 1.9.1. I 1.1-3. I T.lI-T.T
II P 1\0..0. I.. H.a
Mill IIlImlllOlo, t:.P 110.", I.. HIO " O. 15-0.16 0.30-1.00 -o.1(i~o.zO
Ab.o.bl.1 1.111'10110'" .Iunlld 10 60 wi" 1.111'1..10.1 .Iunlod 10 60 wi '1'0 Limlltone .1urri,1S to 60 we" Lim..ton. l1urrttd to 60 wt "
wllh II'IOklup wol.. and oddod with makeup water and add.d w\lh II'IOklup wol.. and oddld with makeup wat.r and .dd,d
10 a:HT. 101:HT. 10 B:HT. 10 a:HT.
MI.lllllml.o'o,/Ko.II TPOY No milt eUminator wl.h. No milt IUminator ",I.h', No milt .UmiDtor With. No milt eUmlnator wl.h.
K. T. (I" wII. hll.hlll"l.ol- K. '1'. (I" wII, hll.hlll"I.OI- K. T. (3" wII. hll.hI) 1"1.01' K. T. (Z" wetr hel.ht) brl'l'-
Id willi ..ollobll maklup Id ..lIh o.ollobll moklup Id with availabl, makeup od opln-Ioop (on.o-III'ouah)
..01.. 1 ~ 9 IPm) and all 0'011- ..01.. I - 8 .pm) and 011 0'011- watt' (...., Ipm) ane! 111 avail- with 25 pm raw ""'II' only.
obi. olulliod IIquo. I'" 5 .pml. obi. .Iulliod !Iquo, (-II .pm) obll .Iulliod IIquo. I'll .pm) Bottom of Koch nay .team
Solloll'l 01 Kooh lroy .11011'1 Sollom 01 Kooh lroy 811011'1 W.. noll"I.Olod 10. I h. Ipu.ld I mln/h..
.pu..d I mlll/h,. .pu.ld I mln/h.. p.rtocS. Bottom of Koah tray
.t.am .par,.d 1 minI hr.
Sopubb.. 1111..11011 , bodl (4 ,rid.) willi 8" , bod. (4 .,ld.1 wllh 8" I bod. (3 .'111.) wllh 7 1/1" 3 bod. (4 .rld.) ..1111 5"
Iph..../bod. Top bld-nlw .ph.,1I1 bid. Top bld.nl.. .ph.rlll bId. Top bod. 5" .ph..../bed. All bod.-now
TPII .ph..... Mlddl.. HDPI: Ipll..... Mlddlo. ..o.n + II/I" now HDPII TPR .ph.....
botlom-.o.. HDPI: .pll..... bottom.wo,n HDP!C'. from .,h.rll. Bottom bld.nlw
prlyio\u r\U\. HDPII'.. Slurry nOllll. not
u..d (opon pip. onlyl 10. Ihll
,un only.
Sylloll'l ..no.,u BO 0'. y.tem (IOrubb." Kooh tray, Sy.t.m Clle'n.d. lIoploo.d lop Sy.tem not Cll.,ned. Remoyed Sy.tem ellaned. alturnld to
Slu'.ol.lIun Ind milt eliMinato, aleaa.d. bId .ph.... ..lIh nlw HDPII top ,rid .nd bid of .phl"'. 3 bed. (4 ,rld.1 with 511 nlw
Iph..... PWHT outlol (Kooh Mlddlo bld-5" HDPI: .ph.... TPR .ph....lbod. 110-
t.oy Inll\l pWPIp 1..II.hod 1.0.. from top bid + 2 1/2" nlw in.taUld inl.t "upry n08l11l.
Cefthl...1 to Hydro.ea1. HDPI:'.. Bollom bod-7 1/1" 11uta1114 !CUlot urainlr Oft
no.. HDPI:'I. RlmoYld inllt .erubblr loop. Dee ..a..4
.lurry 110..1... Ine,,'"d Koch tray weir hellM to 2".
Koch tray Wlir hlt.8ht to S".
Mollind 01 Conl,ol SOZ removal 00ft"01114 at 802 remoyal Clon'hooUld at 802 removal controllid at 802 removal controlled at
84:1'10 8401'1'0 84tl'l'o 84tl'l'o
Oyerride"
111101 pH. 5.95
Slol.h. 110110. 1. 65
lIun PIIUoloplly Intlnded 10nl.to,m. Condl- llltondod lon.-I..m. Voloclly Intlndld .hort.tlrm. To Inlondld 1 wk.. To oburve
Uon. cholln for lOft,.te,m reduold 10. reliability. HDPI determlnl wheth.. chan," any effect Oft milt eUminator
,olloblllly bo..d on .ollobll. .phe.... to be ulld until In .crubber Internal con(ll- .0Ud. and 'Oall d,poitt. with
Ity verification tuU. .tratnel" &... In.talled on u1'&tl.on could reduce .lurl'1 ra... water only fol' Koch tray
.crubber loop. .0Ud. carryover. 1"I.ollon.
Ruulu Tel'mlnated due to rapidly TIl'mlnated to replaci wOl'n Incono1u.ive. SaUd. carry. Mht eliminator and 1
-------
Table 6-1 (continued)
SUMMARY OF LIMESTONE RELIABILITY TESTS ON TCA SYSTEM
Run No. ~29.2A 130.2A 531.2A 132.2A
Start-of-Run Date 2/26/74 3/28/74 1/10/74 7/17/74
End-ot-Run Date 3/7/74 4/17/74 6/H/?4 7/29/74
On Stream Houri 213 476 1088 258
Ou Rate, .cem G !OOor 20,100 20,500 20,500 20.100
0.. V.loeltv. (pI @ 12,Oy 8,6 8. b 8,6 8. b
Liquor Rat., Ipm 1200 1200 1200 1700
L/C. .ol/mcl 73 73 73 104
Percent Sollch Recirculated 14.5.16 14.16 7.9 7.9
Etnuent auldonee Time, mtn. 1Z 12 . 12 12
Stoichiometric Ratio, mol.. C. 1. 15.1. !! 1.2.1.55 1. 3.1. 7 (5/10.26, 6/19.26) 0.88.1. ZS(bl
added/mole 9°2 ablorb,d 1. 0.1. 2(0) (5/26.6/19)
AV8 Oft 1.lmutono UtlUutlon, 100. 80 73 67 ~WY(~~Z66.~1/91'9~61 93(b)
molu SOZ ab,. Im01l C. added
Inlot 902 Concentration, ppm 2300.3900 2200.4200 1750.3750 2000.3900
Percent 502 Remoyal 79.89 78.89 71.96 96.99
Scrubber Wet pH Ran,- 5.7.5,9 5.75.5.95 5.4.6.1 5.6.6.0
Scrubber Outlet pH Ran., 5.2.5.5 5.1.5.4 4.7.5.5 5.2.5.6
Percent SUlfur Oxtdtlld 15.30 12.29 13.40 7.25
SoUd, Dllpo..l Sy.tlm CI'rUln Clarifl,r Cla,lIt., Clarilier
(Cen'rllu.e only alter 4/10)
Loop Clo.un. "SoUd. Dhen.. 30.47 30.43 35.41 32.43
Calc\llated " Sullate Saturation In 130 120 100 140
Be rubber Inlet Liquor 0 !looe
Total Dtuolvld SoUd., ppm 8400 6300.8600 25,000 45,000.60,000
Total 6P Ran.1 ExclucUn, Milt 4.9.5,3 4.8'5, I 4.3.6.6 4.5.4.8
Eliminator and Koch Tray, In, H20
Milt JCUmlnator end Koch Tray 1. 9.2. I 1.9.2. I 2.1.3.7 1.95.2.1
6P Ranle, In. H20
Milt Eliminator 6P Ran,e. In. H20 0.19.0.13 0.17.0.25 0.19.0.35 .0.15.0.19
A b. "rbent t..lme..tnn.. ..hn.,tflld tn "n wt 1\ I r.1m.,tnn,. 111\11'rled 10 (000 wt" Llmutone .1u1'1'led to 60 wt" Lime.tone .1\1nled to 60 w~
with mak.up watn and add,d with clarlft.d proce.. Hquor with ctarttlad procell liquor with clarLlled proce.. liquor
10 DlT.. and add.d to EHT. and a"ded to EHT. and added to JCHT.
Milt Eltminator/Koch Tray No milt eUmlnator wa.h. No ml.t .Uminator wa.h. No mlU'eUmlnator wa.h. Rlcycl. loop aroUDd ml.t
K. T. (2" weir hel.hl) Irrl.o'. K. T. (211 weir hellhel Irrl,al- K. T. (3" will' hll,ht) Inl.at- eUmlnator/K. T. Bottom 01
ed with avanabl. makeup .d with 8 ,pm makeup water ed with available makeup milt elim. wa.hed with 8 Ipm
water I"'" Ipm) and all avail. and 7 pm ell. rUI.d liquor. watn (-9 Ipm) and 1.11 avail. makeup water pl\11 7 &pm 1'8.
able clarified liquor ("'15 Ipm) Bottom ot Koch tray .t.am able olarttled liquor (....30 Ipm) cycle liquor. K. T. (2t! well'
Bottom at Koch tray .team .par,ed 1 mln/hr. Bottom 01 Koch tray .team ht. ) Inl.ated with" 35 8pm
.parl.d 1 mln/hr. . eper.ed I mln/hr. recyole liquor (plu. I' Ipm
milt eUm. wa.h). Bottom 01
K. T. .team .parleet 1 m1.o/hr
Scrubber Intnnab 3 bed. (4 arid.) with ':' 3 bed. (4 Irld.) with ,,, 3 bed. (4 ,rid.) with'" 3 bed. (4 .rlde) with 5"
.phull/bed. All bed.-wor .phue./ bed. All bed.-wor .pherll/ bed. All bed..worr .pherellbed. All bed.-
TPR .pher.. tram prevlou. TPR .pherll Irom prevlou. TPR .pheru tram prevlou. worn TPR .pherll Irom
run. run. run. prevlou. I"W\.
Sy.tem Chan.u Betort No cleanlnl' Sy.t.m cleaned. KochJray Sy.tem cleaned. Inltalled. Syatem cloanod. Provided lor
Sta rt. ot. Run No chan,lI. pnlphe ry ualed. PWHT MIO addlft .yltom. Lowered cloud. circuit recycle loop
outlet (Koch tray tnlet) pump .pray huder 4'. Leveled around mitt eUminator/Koch
converted trom Hydro..al to Koch tl'&Y and further "alod hay, Includlnl me.t eUmt.
Centrt.eal. Provided clarine perlph.ry. Increa.ed weir natal' underwa.h. Lowered
liquor (or lImntone .1urry hel8ht to '''. Intlalled tnlet weir hel8ht to 2". DlT and
(,ed tank. Modified plpln. '0 wolr. EHT overfiow line PWHT ..oled with C02."
obtain con.tant Koch tray blanked. pur.e.
makeup wator/Uquor ratio.
S88l.d top at EHT.
Method at Control SOZ removal controlled atz SOZ removal controlled at! S02 removal controlled 6tl Scrubber Inlet pH controlled
8H2,. 8H2% 5/10-5/13 8H2% at 5.8:0.2
Over rid,,: Overrldell 5/23-6/5 78t!%
Inlet pHS 5.95 Inlet pHS 5. 95 6/5.6119 84,2%
Stolch. Ratio!l\. 65 Stolch. Ratl061.65 6/19-6/Z6 9HZ%
Run Philo.ophy Intended 10ng~ te I'm. Tut Intended 10n,.term. EHT Intended lana-term. Attempt Intended lona~tum. Attempt
condition. .ame a. previou. ..a led to reduce oxtda.tion. to operate un.aturated with to operate unnt. with MIO
run, except Koch tray 11'1'1. and Koch tray wa.h ratio held MaO addln to naled EHT. addln to £HT (10,000 ppm
gated with all Available con.tant to ob.erve any ettect Percent .0Ud. lowered to 8%' M81. 1700 Ipm liquor rate.
makeup wlter and clarified on .01ld. buildup. to provide additional clarineI' EHT & PWHT COZ blanket.
liquor, liquor {or Koch Irrllation. mitt ellm. wa.h II milt eUm/
_u- .-- Koch tray recycle loop.
Rllult. Rtluline insp~~tion after 213 Unlble to lignlltcantly reduco Unable to maintain un.aturat. Unable to attain un.arurated
hours revealed .ome .oft oxidation or .ultate .atura. ed .u1(ate operation with 5000 .u1(ate operation with 10.000
801ld. and .light .cale buildup tion. Run terminated due to ppm Ma. Study.tate opel'. ppm MS. Run terminated due
on the mitt eUm. lower vanea. heavy .cale and .01ld. de- ation wI.. not reached. Run to Icale build-up on Koch tray
Although amount of .eale and po.U. on top 01 Koch tray. terminated due to .olid. and and 10" 01 4000 (-1/2 bod)
.0Uds wu .1Ight. it wa. poulbly eauud by low Icalo buildup on miu oUm- .pher" throush ,rid..
con.idered to be .Igniflcant (115 apm) Koch tray nu.h rato inator, Koch tray and Bottom 01 mitt eliminator
.fter only Z13 houri, and run and a clarineI' rake mallunc. bottom Rrld. Bottom 01 1.2% pluUed.
WI.. terminated. Bottom of tlon on April 8 . 10, re.ult. milt eUmtnator 750/0 plug.ed.
mist eliminator 19% plugged, ina In abnormal loUd. carry. (bl
(a) Total .tolch. Total .tolch. ratio tor Ca
over to Koch tray. Botton': ratio tor Ca & M8 Ie 1.05-1. 45 (ov8.
of milt ellmina.tor 44o/~ & M81e 1.08.1.28 (ov8. alkali utl1. II 800/0).
pluUed. alkali uti!. 8<~. .
6-3
-------
Table 6-1 (continued)
SUMMARY OF LIMESTONE RELIABILITY TESTS ON TCA SYSTEM
Run No. 5!!.2A 534.2A 53!.2A \15.29
Start-ot.Run Catl 8/6/74 9/3174 9/12/74 12/4/74
End-or.Run Date 8/21/74 9/8/74 12/4/74 12/30/74
On Stream Houri 132 100 1835 490
0... Rat., lelm G 300°,. 20,500 20,500 20,500 20,100
au V.loclty, Ip. @ 1250F 8.6 8.6 8,h 8.6
LIQuor Rate, 10m 1200 1200 1200 1200
1./0. IOI/mcl 73 73 73 73
Percent Solid. Recirculated 14,5.15.5 10.12.5 12.1'5 9.16
JCrnuent auld,nci Time, min. 12 12 1219/12.9/271. ISla/tor 9/271 1502/4.12/161. 251a/tor 12/16
Stoichiometric aatio, mol.. Ca 0.8601.31(al 1.10.1.30 1. 15.1. 70 1. 15.1. 55
addad/mola S02 ab.orbad
AVI " Ltmutono UtUtution, 100x 92la, 82 65 74
molal S02 ab.. /mola Ca addad
Inl,t S02 Concenthtion, ppm 2000.3750 2700.3600 2000.4000 1500.4900
Pucent sez Remoyal 95.99 75.90 75.88 66.94
Scrubber Inlet pH aan.. 5.7.6.0 5.65.5.85. 5.7.6.1 5.8-6. I
Scrubber OuUet pH Ran,- 5.3.5.65 5.2.5.4 5.1-5.8 5.2.5.9
Peretnt SUlfur Oxldl..d 15.23 1'.30 10-28 10-30
SoUd, J;)1.po.al Sy.tem ClarUlel' ClarUI., Clarln,r Clapilier
Loop Clooura. "Solid. Dllcha. 29-38 30-40 35.42 34-42
Calculated'" Sulfate Satuntton In 135 130 115 (9/12.10/23), 125
Scrubber Inlot L'tQuor . sOGe 105 (aftar 10/23)
Total Dtuolved SaUdi, J)J)m 53 000-58 000 7900.8500 4000-8000 4500.7300
Tota161P Ran'l Jtxcludtnl Milt 4.6.4.9 4.3-4.35 4.0-4:6 3.8-5.0
Eliminator aod Koch Tray. 10.H'0
Milt Eliminator and Koch Tray 2.0-3.8 1.8-2.0 1.9-2.0 1.8-2.2
CoP Raoao. 10. H20
Milt Ellmioator l>P Ra..a, 10. H20 0.17.0.25 O. 15-0.20 0.10-0.20 0.15.0.20
Ablol'bent Limutone l1urrled to 60 wtfo Limutone elurri,d to 60 wtCVo Lt.mutone l1\\nt.ed to 60 wtC/o Limutone l1urrt.ed to 60 wt CVo
with clarUied proce.. liquor ~tth clarl.lI.ed procu. liquor with clarUied proc... liquor with clarined proce.. liquor
aod .ddad to EHT. aod addad to EHT. aod addod to II:HT,(~/12-11/251 ..nc! added to downcomer (12/4..
and .0 dl'rWnonrnlll' .fter 11-/25. 12110 aod to EHT altar 12/I~
Milt Ellmloator/KQch Tray Rlcycl. loop .round milt Bottom of milt .Um. w".bed Bottom of milt 8Urn. w..hld Bottom at milt .Um. wa.h,d
allmlnator/K. T. Bottom of coot. with 15 apm dll. cl... coot. with 15 apm dll. cl... cont, with l! pm dUo clioI'.
milt .Um. wl..hed with 8 Ipm Uq. (.-,,8 Ipm mak'up watu + Uq. (""9 ,pm makeup "'lotII' + Uq. (""'9 ,pm makeup water +
makeup water p1\1' 7 Ipm rt.. ..7 &pm claro IIq.). K.T. ~6 apm cl... IIq.). K.T. "",6 Ipm claro Uq.). K.T.
eyel. liquor. K.T. (211 web (2" walr ht. Iinla. with.. 8 11'1'1,. with -9 ,pm clioI'. Uq. + 11'1'11' with "-'9 IPm clioI'. Uq. +
ht. ) irrl.lated with 3! &pm .pm 01&1'. Uq. + 15 Dm milt 15 apm milt eUm.wa.h. Total 15 apm milt eUm.wa.h. Total
recycle 1t.quor (p1uI 15 Dm .Um. wa.b. 8ottom ot Koch c1ar. 11q. tomilt eUm. &r K.T. c1ar. Uq. to milt .Um. Ii K. T
milt .Um. wa.h). Bottom ot tray .taam ap.raad 1 mlo/hr. 15 IPm min. Bottom at Koch 15 apm min. Steam .par.!n,
K. T. .taam a~....d I mlo/hr. tray .team..paned 1 m!n/hr. dilconUnued after 12/11.
Scrubber lnternall 3 ataa.. (4 arldal with 5 loch.. 3 lIaa" (4 arid.) with 5 Iocha 3 .ta.e. (4 gr!d').wUh 5 Inche 3 ,tag.. (4.rlh)wlth !S Inch..
.pheru/.tagl. All bad.- .phll'el/.ta.e. 1.11 bld.-worn .phlru/.ta.e. 1.11 bed.-worr. .pheru/.tage. A11 bed,..wor
new TPR .phe". TPR .phlr.. horn prevtou. TPR .phlre. trom prevlo\1I TPR .pheru from previou.
run. rWl. run.
Sy.tem Chan.u Before Sy.tem cleaned. Replaced ~.tem cleaned. Sy.tem cteaned. Seal water Removed Iteam 'parser
Start.of.RWI worn TPR .ph.ru with new removed from eoo1in, .pny (12/11). Wall walh nou1u
TPR'a. pump. WaU ",a.h n08l188 (4) (4) raplacad by .Ioala K. T.
to wa.h wa111 between Ilurry underwa.h no~.11 (12/23).
.pray header and bDttom of
Koch tray loatalled durloa
BoUer *10 outaao (10/23.
10/25).
Method of ContrC?l Scrubber Inlet pH controlled ~crubber Inlet pH controlled 1502 removal controlled at 502 remnva1 controUed at
at 5. hO. 2 ~t 5.800.2 84t2%. 84>2',.
Ove rridu, Overridul
Iolet pH~ 6.0 Inlet pH. 6.0
Stolch. Ratio ~ 1. 6 Stolch. Ratio fa 1. 6
Run Phllo.ophy Intended lonl-term. Attempt Intended 10nl-teZ'm. Diacon- Intended long-term. Tut Attempt to run at Run 535-2A
to opeZ'ate unut. with 10.000 tinue UII 01 M.O. Tut can.. condition. cholln .imllar to conditlonl with intermittant
ppm Ma cone. In EHT. 1200 dltlon. choun .Imlla r to 526.2A. burnina of Montana low lu1lur
IPm liquor rate, 15"10 .oUd., 526-2A. coal in BoUer Nt O.
C02 blanket over EHT Ii
PWHT. aod mill ollm. /KT
recycle loop.
Ruu1u Unable to attain unuturated Run teZ'minated due to .cale Run arbitrarily terminated Run terminated a. planned.
.uUUe operation with 10.000 !build-up on the Koch tray. prior to introduction of In.pectlon of 'Vltem after
pmMa. 'Run terminated due Bottom of milt eliminator Montana low .ul£\1r coal into 2325 hro (535-2A plu. 535-291
to .cale build-up on Koch tray 1-2" pluuod. boUer N:J. 10 and ruultant .howed milt eliminator bot-
nd milt eUminAtor. Bottom operational dtfftcuIUe.. 10- tom to be 8-90/'0 pluSRed with
of mtat eliminator 120/0 'pection of 'V',tem at 1835 flVa.h. The top of the Koch
luUed. hra ,howed mi.t eUminator tray Wa.1 &0% covered with
and Koch tray to be e..en- .ea.ttered .ea.le -1; mil.
(a) Total Itoich. ratio for Ca tiaUy clean (milt eliminator thick.
& Mala 1.03.1. 48 (Ava. < 5" pluuod). Wall .pra.YI
alkali utll. 801'01. kept wall a.rea a.nd bottom of
the Koch tray clean.
6-4
-------
Table 6-1 (continued)
SUMMARY OF LIMESTONE RELlABILIry TESTS ON TCA SYSTEM
Run No. !36.2A 537.2A \38.2A 539.2A
Stal't-ol.Run Date 12/31/74 1/15/75 1/24/75 3/7/75
End-ol-Run Cate 1/15/75 1/21/75 2/21/75 3/21/75
On Stream Houra 328 137 562 278
a.. Rat., aelm @ 330°F 24.000 24. 000 24.000 28.800
0.. Valoclty. 1». @ 125°F 10.0 10.0 10.0 12.0
Liquor aat., 111m 1200 1400 1400 1000
L/O. aal/mol 62 73 73 43
Perclnt SaUd. aecirculated 13.16 12.5.14 12.5.17.5 13.0.17.0
Ittnuent Relid,nce Time, min. 20 20 20 25
Stoichiometric Ratto, mol.. c. 1. 2.1. 6 1. 3.1. 6 1.3.1. 6 1. 5.1. 7
addad/mola SO. ab.o.b.d
Ava ~ Lime.tone UUU..Uon, 100. 71 69 69 62
mol.. SO" ab., Imole C. addict
Inlet S02 Concentration, ppm 1250.4250 2000.3\00 2000.4200 2000.3900
Perclnt SOa aemoyal 68.92 80-93 81.95 82.92
Scrubber Inlet pH Ran,. 5.8.6.0 5.8.6.0 5.8.6.0 5.9-6. I
Scrubber Outlet pH Ran,- 5.4.5.6 5.4.5.5 5.45.5.65 5.6.5.8
Percent Sull\1r Oxldl81d 6.30 12-26 10.30 lo.n
SoUd. Ditpo.al Syltem Clariner Cia rift. r Claritler Clarln'l'lI FUtu
Loop Cloture. .. SaUd., Dilch.. 32.43 33.40 31.40 ~40
Calculated" Bullate Saturation in 100 125 100 25
So!'Ubb.. lnIat Llouo. @ 50°C
Total Ctuolved SaUd. Dam 4200.6&00 6000.7000 4400.7400 3000- 5000
Total 6p Ransa Excludlns Milt 8. Z.5. 6 8.8.6.48 8.6.7.0 6.7.6.88
Eliminator and Koch Trav. tn. H'JO
Milt )tUmln.tor and Koch Tray 2.7.4.0 4.1.4.95 2.1.2.5 2.8.3. 6B
6P Ransa. In. H,O
MI,t EUminator 6.P Ran.e, in. HtO 0.30.0.40 0.40-0.55 0.15.0. Z! 0.33.0.50
Ab.orbent Limutone .lunied to 60 wt ¥o Limutone .lunied to 60 wt % Limutone l1unied to 60 wt eve Limutonl .luniee! to 60 wt V.
with clarittle!. prOCI.. liquor with clarified proce.. liquor with clarUied procu. liquor with clarined procell Uquor
nd addad '0 B:HT. and added to EHT. and added to EHT. and added to EHT.
Milt EliminUor/Koch Tray Bottom of milt ,Um. wa.hed Bottom of milt ,UminUor Bottom of milt eUminator Bottom of milt IUminator
cant. with con.tant U Dm wa.hed continuoualy with con- wa.hld conUnuoully with can. wa.h,d conUnuoully with can.
diluted cIaI'. lI.q. {all rnak.up .tant ZO IPm (0.4 spm/IIZ, otant ZO IPm to. 4 spm/1I2, otant Z! spm (0. 5 spm/1I2,
plu. nece..ary ciaI'. Uq). diluted clarifild Uquol' (all dUutld clarined Uquol' (all dUuted clarined Uquol' (all
Corrupond. to O. 3 .pm/ft~ makeup plu. nec.....I'Y clar. makoup plu. nece..ary etaI'. makeup plu. nece..ary clar..
Koch tray (Z" weir ht. I bri.. Iliad IIquo.). Koch tny (Zit \llld IIquo.). Koch tray (Z" Iliad IIquo.). Koch tray IZ"
with nmalnlns du. IIq. weir ht. ) ini.atld with re. wlil' ht. ) tnt.atld with 1'8- WitI' ht. lint.ated with 1'8-
Clar. Uq. UNrn 15 spm mainins clarifted lI.quor. Clar. maintnc c1ariftld Uquor. C1ar. rnatnLnc c1arifhd Uquor. C1ar.
minimum. return 17 IPm minimum. rlturn I? Dm minimum. return 22 Ipm minimum.
Scrubblr Int.rnah 3 ltaS" (4 S.ld.) with 5 Inchl 3 .taS" (4 S.ldl) with 5 Inchl 3 .taS" (4 S.ld'l wlth51ncha 3 ItaS" (4 S.ld.) with 5 Inch..
phlrll/,tace. All b,d.-worn .ph'I'I./.ta.,. All b,d.-worn .phll'l./lta,i. All.b,d.-worn .pheru/.taal. All bed. new
PR .phlru from preYiou. TPR .pherll from previou. TPR .phirll from prevlou. HDPS: .phlrel.
!'Un. !'Un. !'Un.
!Iy.tem ChanCII B,fore a cleanln.. Milt ,Umlnator No elean!na. Fifth no..te Sy.tem cteaned. Koch tray and milt IUminator
ta.t.ol.Run ottom wa.h ZO ,pm alter (ST 14 I'CNlln.tallad In eteaned.
1/7. Minimum c1arUied cent.r of IxiltLn. milt eUm.
iquor return 11 Dm after inator underwa.h hea4er.
1/10.
Method of Control SOZ removal controlled at 80Z removal controlled at 802 remo...a1 eontrd'11ed at 02 removal controlled at
84t2"'. 87t2'" 89tZ'" 89tZ'"
Overridell Ovenidlll O...erride'l Overridul
Inlat pH'" 6. 0 Inlat pH '" 6. 0 Inlat pH 6 6.0 Inll' pH ... 6. I
Stolch. RaUo" 1. 6 Stotch. Ratio 6 1. 6 Stoich. RaUo ~ 1.6 ~':tll:~' s~:t~ I~io :~-
Outlat SO. ... 1000 oom
Run Phllolophy Intended .hol't te rm. To To determine if tifth n08z1e To detlrmine.U M8her 0J0 50Z To deurmine the reUability
oburve ICJ'ubber operation on mi.t eUminator underwalh nmoval and thl fifth no..10 and operabiUty of theTCA
at 10 ft/lle 8&1 velocity. hoader ImproYII condl.tlo~ of on mist IUminator undorwa.h .y.tem at 12.0 ft/lOc 8&1
milt eliminator. header would prevent an ...e10clty.
Initially clean milt eUminator
and Koch tray from plu'Sin8.
Re.u1tt Run terminated due to warun Run terminated due to lncroa. Run terminated when routine Run terminated to determine
tna condition of milt eUmina- in, milt eUmlnator prellun in.pecUon revealed milt facton caulin. unnturated
tor and Koch tray. Bottom of d.op. Inlpectlon revealed eHminat.or to be 6CVo plu88ed operation. Milt eUminator
milt eliminator after 2657 milt eliminator .to be 31% with .0Ud.. II." pluuad altar 214 hu. 01
hu (Runl 538.ZA. 838-ZB and pluUld by 10Udl. operation. Bottom arid 60'"
836.ZA) w.. 16'" pluUad with covered with 60 mn .cale.
f1yuh (he.viut depolitt in
center of milt eUminator).
6-5
-------
Table 6-1
(continued)
SUMMARY OF LIMESTONE RELIABILITY TESTS ON TCA SYSTEM
Run No. 540.2A 541.2A 542.2A 543.2A
Start-ot.Run Date 3/21/75 3/25/75 3/28/75 4/1/75
.4.0 .Ru. Cote "..,,. 3/28/75 4/1/75 4/3/75
On Stl'lam HO\,lrl 90 65 91 47
0.. Rate o.tm lit 30001' 28 800 28,800 28.800 28,800
0.. V.l0.lty. to. lit 12501' 12.0 12.0 12.0 12.0
LI.uo. Rati, .om InM 1000 1000 1000
1./0 .11/m.1 43 43 43 43
P..u.1 Solid. R..I..ulot.d 13. 7.1!. 3 12.5.14 13. 5.1!. 5 12.9.14,9
ICmu..t R..ld.... Tim., mi.. I! I! 15 15
Stolohlometrlo Ratto. mol.. Ca 1.45.1.7 1.41.1.72 1.25.1. 55 1. 26.1. 39
Idd.d/mol. S02 Ib.o.b.d
v, ~ Llm..lo.. UIIUllllo., 100. 63 64 74 76
mol.. 502 lb., /mol. CI Iddld
InI.1 SOa Co.ol.lnllo., ppm 2100.3700 2700.4000 3100.4000 2600.3500
Pucent SOZ Remoyal 84.94 80.88 75.85 75.84
So .ubb.. InI.1 pK RI.g. 1.95.6.05 1.8.5.9 5.8.5.95 5.8.5.9
S..ubb.. Oul1ll oK RI." 5.75.5.9 5.5.5.7 5.35.1.6 5.3.5.4
~U."I S.IIIa. O.ldllid 10.\8 18.26 10.24 10.23
~.lId. Dllp...1 Syll.m Clarlll.r . J'lIlIr Clarlll.. i. 1'111.. Clarill. r . 1'111" Cl.,Ulu It rilter
Loop Clo.u.., ~ Solidi, DI..h,. "'40 N40 N 40 ... 40
~:~~~~I:~.~o~~;:~~:-~u:;:~, I. 20 45 50 135
frolll Diliolyod 801140. ....m UOO." 00 3100.4'00 3600.4200 5000.6700
~olal AP Ro.,o lI:Xoludln, MI.I 6.35.6.5 6.4.6.6 6.9.7.0 6.6.6.85
~lIml"lor o.d Xo.h Tray, I.. K20
!MllIlClImlftllo. a.d Xo.h Tny 3.65.4.0 3.6.5.9 3.1.3.2 3.0.3.15
AP RI"O, I.. KaO
MI.llClIml.llo.AP Ra.,o, I.. K20 0.50.0. 53 0.50.0.65 0.48.0.10 0.50.0.53
Ab.orbo.t Llmutone .lunled to 60 wt fo Limutone 11urrted to 60 wt '0 Llmutone dunlld to 60 wt" imuton. .lurrled to 60 wt "
with clarUled proc... liquor Iwlth .llrlll.d pro.... liquor with clarified proc... liquor Ith clarUled proc... Uquor
o.d odd.d 10 ICHT. o.d oddod 10 ICKT. I.d oddod 10 ICHT. .d Iddod 10 ICHT.
MIIIICIImI.ator/Xo.h Tray B attorn of ml.t .UmLnator' Bottom 01 milt eUmlnator Bottom of milt eUmlnator Bottom of milt eUmlnator
walbed conttnuO\1lly with con. ~a.hod contlnuou.ly with can. wa.hod contlnuoul1y with con. wa.hod conttnuCN.ly wlthZcOtI..
111.125 gpm (0.5 pm/fl2) .lanl 25 gpm (0. 5 ,pm/lt2) .10.125 gpm (0.5 pm/fl2) 110.125 gpm (0. 1 gpm/II ) ,
dllul.d .Iarlliod liquor (all dllul.d .Iarlll.d liquor (III diluted .11 rlliod liquor (all diluted clarified liquor (aU
makoup plu. nec8l.ary ciaI'. ~keup plu. noco..ary clioI'. makeup plu. noc8l.al'Y ciaI'. makoup plu. nece..ary clar.
Illod liquor)., Koch tray (2" Uied liquor). Koch tray (211 III.d liquor). Koch tray (2 II III.d liquor). Koch tray (2"
weir ht. ) Ini,ated with I'D. r.vetr ht. ) trrl,ated with 1'8. well' ht. ) Inl,ated with I'D. wetr ht. ) Inl,ated with reo.
malnin. c1Arltled liquor. Clar. malnlnl cIa rifted liquor. CIaI'. mainlnl clarified liquor. Clar. malnins clal'ltled liquor. Clar.
18turn Z2 ,pm ml.lmum. return 2Z ,pm minimum. return 22 IPm minimum. return 22 IPm minimum.
Scrubber Internall 3 01&,.. (4 grid.) .,lIh 5I..h.. 3 .Iog.. (4 ,rid.) .,llh 5 In.h.. '3 .I&g" 14 grldo).,IIh51..h" S .tal" (4 Irld.)wlth5tnchu
.phor"/III", All bod. .,0.. .phlrll/.ta,.. AU bed. worn .pheru/.ta,e. All bed. worn .pheru/.ta,l. AU bed. worn
KDPI: .phere. trom prevlou. HDPE .phl r.. from' pnvlou. HDPE .phlru tram pnvlou. HDPE .pherll from prevlou.
run. run. .... run.
Sy.tlm Chang II Blfore No chan,... ,",0 .ha.g... Undel'llde of Koch tny No chan,...
Slorl.ol.Run cleaned.
!M.lhod 01 CO'lrol S02 removal controUed at 802 removal controlled at Scrubber outllt pH controlled Scrubber outlet pH controlled
89t2" 84t2" 015.4. at 5.4.
Overrldlll Overridul
Inlol pH" 6. I 1.101 pK" 6. 0
Slol.h. Ratio "1.75 Slol.h. RIUo .1. 6
Oul1ol SO ,. 1000 oom Outl.t SO." 1 000 oom
Run Phllo.ophy Attempt to determine attoct Attlmpt to determine effect of aepeat ot Run 541.ZA except Attempt' to determine effect.
on de.ree at .u1tate .aturatton pH on'dl.rle of .ulfate ..tura- method of control chan,ed to on de,ree of .uUate eaturatto:
of reducing the effiuent 1"". tion. S02 removal contl"olled oullol pH. of ralltns the 02 content of
Idenae Ume from 25 mln to .1 8H2" 10 I.hloyo 1.lot pH 01 the tlue 81.' trom 5..7'10 to
15 mi.. 5.8.5.91.4 oul101 pK 015.4. 8.9".
5.5 (limtlar pH lnele to run.
01 high.. 1./0).
R8Iult. Run tel"mlnated a. planned. Run te rmlnated dUG to riltns Run terminated a. planned. Run terminated a. planned.
Chanl- of ruldence time had preuul'l drop Urou Koch At an averase outlet pH of Addition of air to live hlsher
no at8nlflcant effact on de.ree tray. At an averale outlet pH 5.47, deano of .ull"to nt.. 02 In fluo 8" ruulted In a
of .ullate oaturatlon. of !. 6, delrel of .ulfate ut. untlon wa. 50Cl/o. d08reo of .ullate uturaUon
uratlon wa. 45iVo. equal to 13!'o.
6-6
-------
Table 6-1 (continued)
SUMMARY OF LIMESTONE RELIABILITY TESTS ON TCA SYSTEM
Run No. 544-ZA 545-ZA
Start-ot-Run Date 414175 4115175
End-oC-Run Date 4115175 41Z1175
On Stream Houri Z69 133
0.. Rate ae!m @ 3000F ZO 500 Z8 800
Cia. Velocltv. (D, is) US°;- 8.6 1Z. 0
Liquor Rate, 8pm IZOO 1000
Llo. ga1lme! 73 43'
Percent SoHd. Recirculated 1Z. 3-15. 0 13. Z-14
Effluent Ruidence Time. min. 15 Z5
Stoichiometric Ratto. molu C. 1. Z5-1. 85 1. ZO-1. 70
added/mole 502 ab.orbed
AVB % Lime.tone Utilization. 100. 65 69
mol.. 502 .bl, Imol. C. added
Inlet SOZ Concentration. pp.m Z500-3875 Z400- 3800
Percent 5°2 aemoyal 78-90 77-89
Scrubber Inlet pH aange 5.8-6.1 5.8-6.0
Scrubber Outlet 'OH RanR. 5.4-5.6 5.4-5.6
Percent Sulfur Oxidized 1Z-40 15 -Z9
SoUd. Chpe..1 Sy.tem Clarifier Clarifier &.: Filter
Loop Clo.ure. 0/'0 Solid.. Diachg. 35-40 -40
Calculated % Sullet. Saturation in 110 90
Scrubber Inlet Liquor @ saoe
Total Diuolved SoUd., ppm 5000-8000 4000- 8000
Total COP Range Excludlns Milt 5.0-5.7 6.7-7.0
Eliminator and Koch Tray, In. H20
Milt 'Eliminator and Koch Tray Z. O-Z. Z Z. 9-3. 0
CoP Range. In. H20
Milt Eliminator oP Range, in. H20 0.15-0. ZO 0.40-0.45
Ab.orbent Limutone 8lurried to 60 wt % Limutone Ilurried to 60 wt '10
with clarified proce.. liquor with cia rUied procell liquor
and added to EHT. and added to EHT.
M18t Eliminator/Koch Tray Bottom of m18t elim. wa.hed Bottom of milt eliminator
cont. with 15-19 gpm dll. wuhed continuously with con-
cIaI'. lIq. (....9 Bpm makeup ..ant Z5 gpm (0. 5 gpmlttZ)
water + portion of claro liq.). diluted clarified liquor (all
K. T. irria. with remainina makeup plu. nec.nary cIaI'''
clar.liq. + milt eUm. walh. inod liquor). Koch tray (2"
Total cIaI'. Uq. to milt eUm. wetI' ht. ) irriaated with re-
& K.T. 15 apm minimum. maintna clarified liquor. CiaI'
return 22 gpm minimum.
crubber Interna18 3 .taaos (4 grid.) with 5 inchos 3 atagu (4 arida) with 5 inche
Iphena/.tage. All beda worn .pheru/ltage. All bed a worn
HDPE .phern from previou. HDPE .pherel from previou.
run. run.
yUem Changn Before Milt eliminator cleaned in No changn.
tart-of-Run place.
~ethod of Control 502 removal controlled Scrubber outlet pH controlled
at 84tZ'" at 5.4:0. I.
Overridn:
InlotpH 66. 0
Stoich.Ra tio 61. 6
un PhUo.ophy Run required to provide Attempt to determina whether
clarifier u'flow for Dravo .cal. formed durins Run
Corp. dudse fixation tnU. 539..2A wa. cauud by high
Condition. choun to replicate Icrubber .1urry pH (5.9..6.1
Run 535-2A to reconfirm milt inlet. 5.6- 5.8 outlat). Con..
eUminator performance. ditton. identical to Run S39-2A
except tor method of control.
uult. Run terminated alter conclu-' Run terminated prematurely
aion of .Judge fixation teaUng. when inapection revealed
No new .olld. depo.iU on mau1ve failure of the HDPE
milt eUminator .ince in place .phern (1041 operating hour8~
cleaning at .tart ot run. No Icale'on bar arid..
6-7
-------
6.1.1
TCA Run 535-2A
Run 535-2A was begun on September 12, 1974, after the system had
been cleaned.
The mist elimination system consisted of a 316 stainless
steel~ 6-pass, closed-vane, chevron mist eliminator preceded by a
Koch Flexitray used as a wash tray (see Figures 3-2 and 3-3). A
detailed description of the results of the first 786 hours of operation
for Run 535-2A has been presented in Reference 1.
This run was
continued for a total of 1835 operating hours.
It was the longest lime-
stone run made to date at the Shawnee test facility.
The major test conditions at t~e start of run were (Table 6-1):
Ga s velocity
Liquid-to-gas ratio
Percent solids recirculated
Effluent residence time
Percent S02 removal (controlled)
8. 6 ft! sec
73 gal/md
15
12 min
84
The clarified liquor return flow rate was maintained at a minimum of
15 gpm for Koch tray feed and mist eliminator wa sh to prevent high
sulfate supersaturation in the wash tray effluent liquor.
The under-
side of. the mist eliminator was washed continuously with 15 gpm
diluted clarified liquor (about 9 gpm makeup water plus about 6 gpm
clarified liquor). The Koch tray was fed with the 15 gpm mist elim-
inator wa sh plus the remaining.'V 9 gpm (minimum) of clarified liquor.
Theunderside of the Koch tray was sparged with 125 psig steam for I
minute each hour.
6~8
-------
To maintain the minimum 15 gpm clarified liquor return flow, the
slurry bleed to the clarifier was allowed to fluctuate, resulting in
only 12 to 13 percent solids at times in the recirculating slurry as
compared to the desired 15 percent.
The effluent re si.dence time wa s
increased from 12 to 15 minutes after 345 hours of operation to assure,
that sulfate saturation of the scrubber liquor would remain below
135 percent at the lower slurry solids concentration (see Figure 7-2,
Reference 1).
Inspections were made after 786, 960, 1093, 1352, and 1628 hours
of operation and at the end of the run after 1835 hours of operation.
After 786 hours of operation, the top of the Koch tray was clean and
only 1 percent of the mist eliminator was restricted with scattered solids
(mostly fly ash) on the bottom vane s.
Solids had accumulated on the
underside of the Koch tray and on the walls between the steam sparger
and the slurry spray nozzles.
The maximum deposit on one area
Approximately 30
*
mils of scale had accumulated on the TCA grids.
of the walls had reached 15 inches in thickness.
There was no mea-
surable increase in pressure drop across the beds, Koch tray, or
mist eliminator during this period of operation.
After 960 hours of operation, a two-day boiler maintenance outage
forced a scrubber shutdown.
The top of the Koch tray was still clean
and the condition of the mist eliminator was unchanged.
The underside
of the Koch tray wa s cleaner with 60 to 70 percent of the area free
>:CMaximum sulfate supersaturation occurs in the scrubber effluent.
Hence, scale formation is heaviest in the bottom TCA grid.
6-9
-------
of deposits. The bottom TCA grid generally had less scale. The
solids accumulation on the walls between the steam sparger and the
slurry spray nozzles had worsened, with the maximum deposits on
one are.a of the walls reaching 20 inches in thickness. Four wall
wash spray nozzle s, using the wa sh tray effluent liquor, were in.-
'stalled to correct this situation.
After 1093 hours of operation, the scrubber was shut down for 01;>-
servation of the effect of the four wall wash sprays.
Two walls were essentially clean, but, due to plugged spray nozzles,
the other two walls had up to 8 inche s of solids accumulation.
The
two plugged wall spray nozzles were cleaned before continuing the
run.
A second two-day boiler maintenance outage caused the scrubber
. ,
shutdown after 1352 hours of operation. The top of the Koch tray
was still clean. The mist eliminator was essentially clean with
only 2 to 3 percent restricted with solids. The underside of the Koch
tray wa s sligh~ly worse with the clean area reduced to about 50 percep.t.
About 5 to 10 percent of the steam sparger holes were plugged with
solids. Again, two wall spray nozzles were plugged, and their area
of coverage had accumulated solids. The plugged nozzles were
cleaned, and an in-line strainer was installed before the run was
re sta rted.
Scale accumulation on all TCA grids had decreased to less
than 5 mils. The average wear of the 5-gram TPR spheres, measured
during this inspection, was approximately 4 percent for 1785 hours of
service.
6-10
-------
After 1628 hours of operation, the mist eliminator and the top of the
Koch tray were still essentially clean.
The wall spray nozzle shad
remained free of plugging since the installation of the in-line strainer,
and all four walls below the Koch tray were essentially clean.
The
wall sprays were also effective in wa.shing the underside of the Koch
tray where it was covered by the sprays.
tray was about 85 percent clean.
The underside of the Koch
Run 535-2A was arbitrarily terminated on December 4, 1974, after
1835 operating hours, prior to the introduction of Montana low sulfur
coal (see Appendix C) into boiler No. 10. At the end of the run, the
top of the Koch tray was still clean and the mist eliminator was
practically clean with less than 5 percent restricted by solids.
The
underside of the Koch tray had no solids accumulation greater than
1/4 inch thick. The walls below the Koch tray were clean to the rubber
lining. The bottom TCA grid had negligible scale accumulation.
Appendix G presents average liquor compositions for the scrubber
and Koch tray inlet and outlet liquors. The data given are only for the
operating period after September 27, 1974, when the effluent hold
tank residence time was increased from 12 to 15 minutes.
The
analytical data were conveniently divided into two periods having
different sulfate saturations and dissolved chloride concentrations.
From September 28 through October 23, 1974, the calculated average
sulfate saturation was approximately 115 percent for both the scrubber
inlet and outlet liquors; for the period October 24 to December 4 these
saturations were about 105 percent.
The lower saturation values
during the second period were probably caused by the drop from 3000
6-11
-------
to 2000 ppm in the chloride concentration (with a corresponding drop
in calcium ion concentration from 1800 to 1200 ppm) in the scrubber
liquor. Asean be seen from Appendix G, all sulfate saturations for
the scrubber and Koch tray liquors were below the critical va.lue of
. .
135 percent.
During the last 200 hours of Run 535-2A, the limestone makeup slurry
addition point was changed from the effluent hold tank to the scrubber
downcomer to observe the effect on the scrubber liquor sulfate satura-
tion. Unlike lime wet- scrubbing in the venturi/ spray tower system,
the sulfate saturation in the TCA limestone system was not affected
by this change in the alkali addition point.
6. 1. 2
TCA Run 535-2B
Run 535-2B was started .on December 4, 1974 ~nd continued until
December 30, 1974, for a total of 490 operating hours. The run was
a continuation of Run 535-2A during which Montana low sulfur coal
was burned intermittently in boiler No. 10.
cleaned prior to the te st run.
The system was not
Use of both high and low sulfur coals in boiler No.1 0 re suIted in
inlet S02 gas concentrations ranging from 1500 to 4900 ppm. During
periods of low inlet S02 concentration and, therefore, reduced genera-
tion of solid products, the recirculated solids concentration had to
be decreased to maintain the minimum requirement of 15 gpm clarified
liquor return flow to the mist elimination system. ,The available
makeup water was decreased due to the reduced system sludge discharge.
6-12
-------
During burning of Montana low sulfur coal, the recirculated solids
concentration dropped to about 9 to 10 percent and the makeup water
had to be reduced to about 5 gpm.
After 165 hours of operation (2000 hours since the system cleaning
at the beginning of Run 535-2A), a five-day boiler maintenance outage
from December 11 through 15 forced a scrubber shutdown. An
inspection showed that a portion of the top of the wash tray had 12
to 17 mils of scale. The mist eliminator had an overall solids re-
striction of about 6 percent, with mist of the accumulation (up to 30
percent re stricted) in the center sections. The outlet vane tips of the
mist eliminator center sections directly under the outlet gas duct held
200 mils of fibrous scale and fly ash. The walls below the Koch tray
had a slight gain in solids. The underside of the Koch tray was es-
sentially unchanged.
The bottom TCA grid gained new scale, resulting
in about 3 percent restriction of the total free area.
The scale ac-
cumulation on the walls below the bottom grid had also increased, with
1 3/4 inches of scale at the thickest spot.
Most of the Koch tray and bottom grid scaling probably occurred
during the 1a st day (Decembe r 10) of operation before the 165 hour
inspection, when the inlet S02 concentration increased rapidly from
about 1600 to 4000 ppm during a period of low makeup water and low
recirculated solids concentration.
The sulfate saturation exceeded
135 percent during the last 3 to 4 days before the inspection.
Several changes were made before the run was restarted on December 16
to help the system accomodate the wide swings in inlet S02 concentration.
6-13
-------
To provide adequate residence time for sulfate de supersaturation dur-
ing periods of low solids concentration, the re sidence time in the
effluent hold tank was increased from 15 to 25 minutes.
In addition,
the clarifier underflow was returned intermittently to the effluent hold
tank to maintain 15 percent recirculated solids concentration during
periods of low sulfur coal. The steam sparger was removed from
service to determine if the wash liquor from the four wall sprays
*
was sufficient to keep the underside of the tray clean.
After 330 hours of operation (2165 hours since the last system cleaning),
a second inspection revealed that the amount of mist eliminator solids
deposits had apparently stabilized (about 5 percent restriction), and
that the top of the Koch tray was cleaner, with 5 to 10 mils of scale
on 5 percent of the area.
Scale on the bottom TCA grid had decreased.
The underside of the Koch tray had new deposits since the steam sparger
had been removed from service. Only 40 to 45 percent of the underside
was free of solids. All four walls below the Koch tray were clean.
To keep the underside of the Koch tray free of solids, a single under-
spray nozzle, using the Koch tray effluent liquor, was installed during
the outage.
The four wall spray nozzles were removed from service,
since the single Koch tray underspray nozzle could provide coverage
and wetting of the walls below the Koch tray.
Run 535-2B was terminated as planned on December 30, 1974, after
490 hours of operation.
The single Koch tray unde rspray nozzle had
*
In a full scale gas scrubbing unit; it would be undesirable to use steam
to clean the underside of a wash tray.
6-14
-------
been succes sful in keeping all four walls below the tray clean.
The
underside of the Koch tray still had 60 percent of the area covered
with residual scale and solids. About 60 percent of the topside of the
Koch tray was covered with scale averaging 15 mils in thickness.
Solids deposits in the mist eliminator had increased to an 8 to 9 percent
overall restriction with the heaviest deposits again confined mostly
to the center sections.
The bottom TCA grid still held a light scale
coating. The walls below the bottom grid had scale averaging 1/2
inch thick with a maximum of 1 3/4 inches.
During Run 535-2B, the calculated sulfate saturation averaged approx-
imately 125 percent in both the scrubber inlet and outlet liquors and
120 percent in the Koch tray inlet liquor.
These values are about
20 p~rcent higher than for Run 535-2A at comparable chloride con-
centrations.
This saturation increase probably re suited from the
wide variation in inlet S02 concentration (1500 to 4900 ppm) which
caused similarly wide variations in stoichiometry and recirculated
solids concentration, both of which affect saturation.
Even though there was some scale buildup during this run, it is
significant that the system was operated successfully during a period
of wide variationin inlet S02 concentration. Since the beginning of
Run 535-2A, the TCA system had operated for a total of 2325 hours
without cleaning.
The average weight losses of the 5-gram TPR spheres for the top,
middle, and bottom beds were 7.3, 6.2, and 3.4 percent, respectively,
after a total of 2757 hours of service.
Most of the spheres were dimpled.
6-15
-------
6.1.3
TCA Run 536-2A
Run 536-2A was started on December 31, 1974 and terminated on
January 15, 1975, after 328 operating hours. The objective of this
test was to evaluate the operation of the TCAsystem at the higher
ga s velocity of 10ft / sec.
No cleaning of the system was done prior
to startup. The mist eliminator and Koch tray had 2325 hours of
operation (Runs 535-2A and 535-2B) at a gas velocity of 8. 6 ft/sec.
During the run, the underside of the mist eliminator was washed con-
tinuously with 15 to 20 gpm of diluted clarified liquor (all makeup
water plus necessary clarified liquor). This wash rate resulted in
a specific spray rate of 0.3 to 0.4 gpm/ft2. The Koch tray was fed
with the remaining clarified liquor.
The clarified liquor return to the
mist elimination system was never allowed to drop below 15 gpm.
This minimum flow was raised to 17 gpm on January 10 because of
the higher slurry bleed rate available at the 10 ft/ sec ga s velocity.
The run was terminated after 328 hours when inspection revealed
the mist eliminator restriction had doubled to about 16 percent.
The major portion of the solids buildup was fly ash located on the mid-
dIe vane s in the cente r of the mist eliminator.
The to}) of the Koch
tray had acquired more scale.
tray had increased slightly.
Solids on the underside of the Koch
The calculated saturations were 100 percent for the scrubber inlet
and 105 percent for the scrubber outlet liquor.
liquor was 120 percent saturated.
The Koch tray outlet
6-16
-------
6. 1. 4
TCA Run 537-2A
Run 537-2A was started on January 15, 1975. Operating conditions
were the same as for Run 536-2A with the exceptions of an increase
in TCA slurry rate to 1400 gpm (73 gal/md) and an increase in S02
removal set point to 87 percent. These changes were made to prevent
the S02 concentration in the vicinity of the Koch tray from exceeding
the level attained during the 8.6 ft/ see gas velocity tests. In addition,
a fifth nozzle was installed on the mist eliminator underwash header
to directly cover the center portion of the mist eliminator where
plugging had occurred in the previous test. The system was not cleaned
prior to startup.
The run was terminated after 137 operating hours. At that time, the
system had operated for 2325 hours at 8.6 ft/sec and 465 hours at
10 ft/ see for a total of 2790 hours without cleaning. An inspection
showed that the overall mist eliminator restriction had increased to
31 percent from the 16 percent at the start of the run.
The scale
on the Koch tray inlet and on the adjacent walls had increased slightly.
About 90 tray valves were stuck in the open position where the tray was
clean on the inlet side and had the greater gas flow.
Thirty valves
were stuck closed.
The top of the tray and the wall above the tray
conta.ined more scale.
Additional scale had formed on the bottom. TCA grid.
corner of the grid had bridged across four grid bars.
Scale on one
Spheres above
the grid in that corner were bound by soft, wet solids and stacked
from one to six sphe re s high.
6-17
-------
The calculated sulfate s~turation was 125 percent for both the scrub-
ber inlet and outlet liquors.
6.1.5
TCA Run 538~2A
Run 538-2A began on January 24, 1975 and terminated on February 21,
after 562 operating hours. Test conditions fo.r this run were the same
as for Run 537-2A, except that the S02 removal set point was increased
to 89 percent, with a maximum allowable outlet 502 concentration of
1000 ppm during periods of high inlet 502 concentrations. Prior to
start of this run, the mist eliminator, Koch tray, and bottom TCA
grid were cleaned. The run was made to determine if higher 502
removal and the fif~h nozzle on the mist eliminator underwash would
prevent an initially clean mist elimination system from scaling and/
or plugging at the conditions tested.
A total of six inspections were made during the run.
The ove rall
restriction of the mist eliminator increased gradually to about 8 percent
in about 500 hours and appeared to level out at 6 to 8 percent at the
end of the run. The solids were predominately fly ash deposits at the
first and second bends. The rest of the scrubber system, including
the bottom TCA grid, was generally clean.
The calculated sulfate saturations were 100 percent for both the scrub-
ber inlet and outlet liquors and 110 percent for the Koch tray outlet
liquor.
The average weight losses of the 5-gram TPR spheres for the top,
middle, and bottom beds were 12.4, 14.3, and 7.1 percent, respec-
tively, in 3784 hours of service.
6-18
-------
6.1.6
TCA Run 539-2A
Run 539-2A was designed to test the operation of the TCA system at
12.0 ft/ sec gas velocity.
Both the Koch tray and the mist eliminator
were cleaned prior to start of this run.
(HDPE) spheres were used for this run.
High-density polyethylene
They had been left in the
beds after a series of pressure drop tests to define the regions of
non-flooding TCA operation (see Section 9 for results from these tests).
The run began on March 7, 1975 and terminated on March 21 after 278
hours of operation.
Because of the scrubber flooding characteristics
at 12 ft/ sec gas velocity, the liquid-to-gas ratio was limited to 43
gal/mef, corresponding to a slurry rate of 1000 gpm.
An inspection after 215 hours revealed the mist eliminator to be 11
percent restricted with a combination of fly ash and wet solids.
The
bottom TCA grid had 60 mils of scale (about 80 percent sulfite) on
60 percent of the grid bars, while the top grid had 5 mils of scale
(about 80 percent sulfite) covering 50 percent of the grid bars.
The
top of the Koch tray was scale free.
The unde'rside had 1 to 4 mils
of smooth scale plus scattered solids on 15 to 20 percent of the area.
The walls below the Koch tray had 30 mils of smooth scale.
The calculated sulfate saturations for the scrubber inlet and outlet
liquors were 25 and 35 percent, respectively.
Because of the unex-
pected gypsum-unsaturated operation and the sulfite scale formation
on the grids, it was decided to terminate the run and conduct a series
of short-term tests to determine the factors responsible.
6-19
-------
6.1.7
TCA Runs 540-2A through 543-2A
Run 540-2A was intended to determine the effect of reduced effluent
residence time (from 25 to 15 min) on the degree of sulfate saturation
of the scrubber liquor. The run was initiated on March 21 and terminated
on March 25, after 90 hours of operation. The change in effluent resi-
dence time had no significant effect on the degree of sulfate saturation
of the scrubber inlet liquor (20 percent versus 25 percent for Run
539-2A) under the conditions tested. This differs from the supersaturated
mode of operation where sulfate saturation varies inversely with resi-
dence time (see Figure 7-2, Reference 1).
Run 541-2A was made to study the effect of lower scrubber liquor
pH on the degree of sulfate saturation and on sulfite scale formation.
To achieve a lower pH, the. 802 removal set point was dropped from
89 percent to 84 percent.. The run started on March 25 and terminated
on March 28 after 65 operating hours, due to an increasing pressure
drop acros s the Koch tray.
The desired scrubber liquor outlet pH of
5.4 to 5.5 (as compared with 5.6 to 5.8 for Run 539-2A) was not achieved
during the run.
At the average outlet pH of 5.6, the sulfate saturation
of the scrubber inlet liquor was 45 percent.
After cleaning the underside of the Koch tray, Run 542-2A was sta'l:'ted
on March 28 and continued until April 1 for 91 operating hours. The
outlet pH was successfully controlled at 5.4 and the level of sulfate
saturation of the scrubber inlet Hquor was 50 percent.
Run 543-2A was intended to determine if increasing the oxygen content
of the flue gas from a range of 5 to 7 percent, as in Run 539-2A, to
6-20
-------
a range of 8 to 9 percent would significantly affect the degree of sulate
saturation. The scrubber outlet pH was still controlled at 5.4. The
run began on April 1 and terminated on April 3 after 47 operating
hours. The degree of sulfate saturation of the scrubber inlet liquor
increased to an average of 135 perc'ent during the run.
Due to time constraints, it was necessary to suspend exploratory tests
to explain the sulfate-unsaturated operation and sulfite scale formation
during Run 539-ZA. However, a similar test effort is being continued at
the EPA pilot piant facility in Research Triangle Park, North Carolina.
It was noted tha.t limestone utilization imp'roved from 63 to 76 percent
as the scrubber liquor outlet pH was dropped from 5.8 to 5.4 during
the short-term Runs 540- ZA through 543-ZA (see Table 6-1). As
expected, SOz removal dropped from approximately 90 percent to
80 percent as the scrubber liquor pH decreased.
6. 1. 8
TCA Run 544-ZA
Run 544- ZA bega,n on April 4 and terminated on April 15 after Z69
operating hours. The test was intended to be short term. It was
made to provide clarifier underflow sludge for fixation by Dravo
Corporation and to confirm the c1eanline s s of the rriist eliminator ex-
perienced during Run 535-ZA, which lasted for 1835 hours at 8.6 ft/ sec
gas velocity. The run was terminated as planned after the conclusion
of sludge fixation testing by Dravo.
6-Zl
-------
Prior to startup, the mist eliminator had been cleaned in place.
The test conditions were ide'ntical to those for Run 535-2A, except
that the mist eliminator underwash rate was 15 to 19 gpm diluted,
clarifier liquor (as compared with a constant 15 gpm for Run 535-2A),
to maintain a proper under spray pattern with the extra fifth center
spray nozzle.
An inspection after 261 hours of operation (near the end of run) showed
that the mist eliminator was essentially clean.
The top of the Koch
tray was clean, and the underside was about 90 percent clean to metal
with only a small amount of thin scale remaining from the cleanup
at the start of run. The walls below the Koch tray had less scale than
before the sta rt of run.
The bottom TCA grid was free of scale.
The frequency of soot blowing in the flue gas inlet duct had been changed
from once every four hours to once per day, beginning on March 20, 1975,
near the end of Run 539-2A.' The less frequent schedule appeared to
be adequate in keeping the inlet duct free of accumulated solids.
The run operated at a calculated sulfate saturation of 110 percent
for both the scrubber inlet and outlet liquors.
are essentially the same as for Run 535-2A.
These saturation values
6. 1. 9
TCA Run 545-2A
Run 545-2A began on April 15 and was terminated on April 21 after 133
hours of operation.
The test was part of a continuing effort to deter-
mine the cause of the gypsum-unsaturated operation and sulfite scale
6-22
-------
formation experienced during TCA Run 539-2A.
The system was not
cleaned prior to startup. Run 545-2A was performed under conditio'ns
identical to ,those for Run 539-2A (e. g., 12 ftl see gas velocity), except
that the scrubber outlet pH was controlled at 5.4, compared with the
average (uncontrolled) outlet pH of 5.75 for Run 539-2A. It was believed
that the grid scale (about 80 percent sulfite) formed during Run 539-2A
was caused by operation with high slurry pH.
The run was terminated prematurely after 133 hours when inspection
revealed massive failure of the HDPE spheres, which had been in use
for about 1100 operating hours.
TCA grids.
No scale was observed' on any o{the
The calculated sulfate saturation of the scrubber inlet liquor was about
90 percent, which is significantly higher than the 25 percent obtained
during Run 539-2A.
6.2
MATERIAL BALANCES
The results of calcium and sulfur ma.terial balances for the TCA lime-
stone reliability R~ns 535-2A and 539-2A are summarized in Table 6-2.
The computed inlet and outlet rates for calcium and sulfur are in good
agreement. This is consistant with results 0'£ earlier limestone relia-
bility tests (see Reference 1).
6-23
-------
Table 6-2
SUMMARY OF MATERIAL BALANCES FOR SULFUR AND
CALCIUM FROM LIMESTONE RELIABILITY TESTS
Sulfur Balance Calcium Balance Average Stoichiometric Ratio,
Material Moles Ca Added/Mole SOz Absorbed
Run No. Balance SOz SOx in Slurry Ca in Lime- I Ca in Slurry Based on Lime- I Based on
Period, Absorbed, Discharged. Percent stone Feed, Discharged. Percent stone Added Slurry
hours Ib-moles/hr Ib-moles/hr Error Ib-moles/hr Ib-moles/hr Error and SO" Absorbed Analysis
535-ZA . 472 5.8 6.1 +5 8.5 9.1 +7 1. 47 1. 49
539-ZA 168 .8.6 9.0 +5 15. Z 14.4 -6 1.77 1. 59
0'
I
N
oJ:>.
-------
6. 3
CONCLUSIONS
6.3. I
Scrubber Operation
Earlier limestone testing with the TCA had shown that scrubber internals
can be kept relatively free of sulfate (gypsum) scale if the sulfate satura-
tion of the scrubber liquor is kept below a critical value of about 135
percent (see Section 7. 3, Reference 1).
This can be accomplished
with the proper selection of percent solids recirculated, effluent resi-
dence time, and liquid-to-gas ratio.
Reliable operation below the
critical sulfate saturation value was demonstrated during Run 535-2A,
which continued for 1835 hours. Conditions were 12 to 15 percent solids
recirculated, 15 minutes effluent residence time, and 73 gal/me!
liquid-to-gas ratio. The average sulfate satura.tion of both the scrubber
inlet and outlet liquor was about 11 0 percent. During this run the
bottom TCA grid, where the degree of liquor sulfate saturation is the
highest, had a negligible amount of scale accumulation.
A single-nozzle underspray using Koch tray effluent liquor was used
successfully to keep the underside of the Koch tray and the scrubber
walls beneath the tray clean during the latter half Run 535-2A.
Pre~
viously, a steam sparger and four wall wash nozzles (using Koch tray
effluent liquor) had been used to prevent solids accumulations on the
underside of the tray and on the walls beneath the tray, respectively.
During Run 539-2A, the scrubber recirculation liquor was unsaturated
with respect to sulfate ("'" 25 percent saturation for the scrubber inlet
liquor), and sulfite scaling occurred on most scrubber surfaces below
6-25
-------
the Koch tray. The unsaturated operation was probably caused by the
combination of relatively high scrubber liquor pH (r>J 6. 0 at the scrubber
inlet and,.,., 5. 7 at the outlet) and relatively low liquid-to-gas ratio
~'c
(43 gal/mcf). Tests in which the scrubber liquor pH was reduced
(lower stoichiometry) resulted in increased scrubber liquor sulfate
, saturation (Runs 54l-2A, 542-2A, and 545-2A) and in the elimination
of sulfite scale formation (Run 545-2A). Supersaturated liquors were
obtained when the oxygen content in the flue gas was increased (from
- 6 percent for Run 539-2A to rJ 9 percent for Run 543-2A). The causes
for unsaturated operation during Run 539-2A are being further inves-
tiga,ted at the EPA pilot facility in Research Triangle Park, North
Carolina.
The 5-gram TPR spheres showed a weight loss of about 6 percent in
1757 hours of service at 8.6 ft/sec gas velocity. The weight loss was
about 11. 5 percent in 3784 hours of service, including 2757 hours at
8.6 it/see and 1027 hours at 10 it/see gas velocity. It is estimated
that the 5-gram TPR spheres will last at least six months at 10 ft/ see
gas velocity service before replacement is necessary.
The TPR
spheres tend to dimple, however, and can slip through the supporting
bar-grids. This may be corrected by respacing the bar-grids.
The 5-gram HDPE spheres failed after about 1100 hours of service,
including 800 hours at 12 ft/ see and 300 hours at 8.6 ft/ see gas velocity.
*
The liquid-to-gas ratio was limited to 43 gal/me! because of scrubber
flooding at the 12 ft/sec gas velocity (see Section 9).
6-26
-------
There has been no evidence of significant erosion of the 316 stainless
steel ba.r-grids in the TCA after over 9000 hours of operation.
The four 316 stainless steel slurry spray nozzles, Spraco No. 1969F,
showed no significant erosion after over 4500 hours of service with 15
percent slurry at 5 psi pressure drop.
6. 3. 2
Wash Tray/Mist Eliminator Operation
Ths most significant reliability problem encountered during the TCA
limestone reliability tests has been associated with scaling and/or
plugging of the Koch Flexitray and bottom vanes of the stainless steel,
6-pass, closed-vane chevron mist eliminator.
Earlier limestone
reliability test results have shown that the .mist eliminator and top
surface of the Koch tray can be kept relatively free of scale if the
irrigation liquor is low in sulfate saturation (see Reference 1).
Run 535-2A demonstrated long-term reliability of this mist elimination
system at 8.6 ft/ see scrubber gas velocity (5.6 ft/ see superficial gas
velocity in the Koch tray and mist eliminator areas) and 15 percent solids
recirculated.
The top surface of the Koch tray wa s entirely clean and
the mist eliminator was practically clean (less than 5 percent restricted
by solids) after 1835 hours of operation before intermittent burning of
Montana low sulfur coal in boiler No.1 0 caused operational upsets
(see Run 535- 2B).
At scrubber gas velocities of 10 ft/ see or higher, plugging of the chevron
mist eliminator by solids (mostly fly ash) became a 'problem.
At 10 ft/'sec
6-27
-------
scrubber gas velocity (6.5 ft/ see in the mist eliminator and Koch tray
areas), the overall restriction of the mist eliminator increased gradually
to about 8 percent during the first 500 hours of operation and appeared
to level out at 6 to 8 percent after 562 operating hours (Run 538-2A).
At 12 ft/sec scrubber gas velocity (7.8 ft/sec in the mist eliminator
and Koch tray areas), the mist eliminator was 11 percent plugged by
solids within only 215 hours of operation (Run 539-2A).
6-28
-------
Section 7
OPERA TING EXPERIENCE DURING LIME/LIMESTONE TESTING
This section summarizes the operating experience during lime/limestone
te sting at the Shawnee facility from 0 ctober 1974 through April 1975.
A ,summary of prior operating experience is presented in Reference 1.
7. 1
MIST ELIMINATION SYSTEMS
7. 1. 1
Venturi/Spray Tower System
A 3-pass., open-vane, 316 stainless steel, horizontal chevron mist
eliminator (see Figure 3-3) with intermittent high pressure underside
washing and sequential low pressure topside washing has operated
reliably at 8 percent slurry solids concentration and at spray tower gas
velocities up to 8.0 ft/sec (Runs 623-1A and 624-lA). The underside
was washed for"" 4 minutes every 4 hours with V\ 3 gpm/ft2 makeup
water at 45 psig nozzle pressure.
The topside was washed with makeup
water on an 8-hour sequential cycle with 1 of the 6 nozzles activated
for 4 minutes every 80 minutes. Spray rate was 0.5 gpm/ft2 at 13 psig
nozzle pressure.
This mist eliminator system will be tested at higher
ga s velocitie s after the 5-week boiler outage in May 1975.
A cone- shaped, 4-pass, closed-vane, 316 stainless steel, chevron
mist eliminator (see Figure 3-3) was unsuccessfully tested for a short
7-1
-------
period (Runs 611-lA, 6l8-lA, 6l9-lA, and 62l-lA). As it appeared
improbable that such a de sign would be applicable to a full scale unit,
testing of this mist eliminator was terminated.
7.1.2
T CA 8y stem
The TCA mist elimination system consisted of a 6-pass, closed-vane,
316 stainle s s steel, horizontal chevron mist eliminator (see Figure 3- 3)
preceded by a Koch Flexitray used as a wash tray. The underside of
the mist eliminator was continuously washed with a 60/40 mixture of
makeup water and charified liquor at 15 gpm (0.3 gpm/ft2). The Koch
tray was fed with the mist eliminator wash plus 9 gpm of clarified
liquor.
The underside of the Koch tray was continuously washed with
the Koch tray effluent liquor.
Reliability wa s demonstrated for this system during 1835 hours of
operation (Run 535-2A) at 8.6 ft/sec scrubber gas velocity and 15
percent slurry solids concentration.
At. the end of this run, the Koch
tray was clean and the mist eliminator was essentially clean with less
than 5 percent restriction by soft solids.
At scrubber gas velocities of 10 ft/ see and greater (Runs 536-2A
through 539-2A), buildup of deposits (mostly fly ash) on the mist elim-
inator have been a significant problem. Other mist elimination systems
will be tested on the TCA at scrubber gas velocities up to 12.5 ft/ see
after the 5-week boiler outage in May 1975 (see Figure 4-1).
7-2
-------
7. 2
SCRUBBERINTERNALS
7.2. 1
TCA Grid Supports
The 3/8 inch diameter, stainless steel bar-grids, installed on 1 1/4
inch centers in 0 ctober 1973, have been in slurry service for over
9000 hours with no evidence of significant erosion.
7.2.2
T CA PIa stic Sphe re s
Earlier testing indicated that 5-gram thermoplastic rubber (TPR)
spheres should have a service life of up to one year at 8.6 ft/ sec
scrubber gas velocity.
This observation has been further substantiated
by recent data which showed a 6 percent weight loss after 2757 hours
of operation at 8. 6 ft/ sec for a new batch of 5- gram TPR sphere s.
However, after an additional 1027 hours (3784 hours total) at a 10
ft/ sec scrubber gas velocity, the weight loss had increased to 11. 5
percent.
At the higher gas rate, therefore, the service life would
approach only 6 months.
The 5- gram TPR spheres tend to dimple and
can slip through the supporting grid bars.
respacihg. the bar-grids.
This may be corrected by
High-density polyethylene (HDPE) spheres lasted only 1100 hours before
a massive failure occurred.
The 1100 hours of service included 800
hours at 12 ft/ sec and 300 hours at 8. 6 ft/ sec gas velocity.
After the May 1975 boiler outage, the wear rate on new 6-gram TPR
spheres will be tested.
dimple- resistant.
The 6-gram TPR spheres should be more
7-3
-------
7.2.3
Spray Tower Nozzles
Bete No. ST48FCN stellite tipped nozzles were used in the spray
tower.
They have operated at 10 psi pressure drop with slurry con-
taining 8 percent suspended solids.
The stellite tips have shown
negligible wear after 7200 hours of slurry service, but some erosion
(15 percent weight loss) in the 316 stainless steel bases has been
observed.
7.2.4
TCA Nozzles
The four TCA slurry feed nozzles were installed in September 1974.
The se were Spraco No. 1969F, full cone, open type nozzles, made of
316 stainle s s steel.
No significant wear has been observed after 4500
hours of operation at a 5 psi pressure drop with slurry conta.ining
15 percent suspended solids.
7.2. 5
Venturi Internals
The venturi scrubber at Shawnee is a variable throat, 316 stainless'
steel venturi manufactured by Chemico Corp.
During the current
operating period both stress cracking and erosion have been noted at
several interior parts.
Inspection after shut down for the May 1975 boiler outage revealed
stress cracking on the portion of the inlet duct that extends into the
venturi; a 4- inch wide, half circle of duct had fallen off.
Also, an
8-inch hairline crack was discovered in the venturi housing at the point
7-4
-------
where the bull nozzle enters the venturi.
The stre sse racking did
not appear serious and was repaired by welding.
Severe erosion, however, has been noted on the plug shaft protection
shroud and guide vanes.
The erosion has been severe enough to require
steps to prevent damage to the plug shaft.
The most successful repair
method has been to cover the affected areas with an expendable material
that can be replaced periodically. The best material used to date
has been neoprene which has lasted slightly over 2000 hours.
7.3
HOT-GAS/LIQUID INTERFACE
The hot (300 to 3300F) flue. gas feed must be cooled before entering
the neoprene rubber-lined TCA to a temperature below 190oF, the
maximum permissible for liner protection.
Cooling of the feed ga s
is not required at the venturi scrubber inlet during normal operation
since the venturi scrubber itself is an efficient humidifying device.
The TCA flue gas cooling system, developed in early 1973 (see
Reference 1), consists of 3 spray nozzles installed at the top and side
walls within the flue gas inlet duct.
The nozzle s are fed with recir-
culating slurry.
A sootblower is provided to periodically blow off
the accumulated slurry solids into the scrubber downcomer.
The
system has been successful in eliminating solids buildup in the inlet
duct.
The sootblowing frequency was successfully reduced in March 1975
from once every 4 hours to once a day.
solids buildup has been experienced.
No increa se in the inlet duct
7- 5
-------
7.4
REHEATEES
Flue gas from the scrubber is reheated to pre.vent condensation and
corrosion in the exhaust system, to facilitate isokinetic and analytical
sampling, to protect the induced draft fans from solid deposits and
droplet erosion, and to increase plume buoyancy.
The reheater on the TCA (supplied by Hauck Manufacturing Co. ) is a
fuel-oil-fired unit with separate combustion air supply and with com-
bustion occur ring in the flue ga s stream.
This unit has been extensively
modified (see Reference 1) to facilitate operation, but burner flameout
has continued to be a problem.
An identical unit on the venturi/ spray tower system was modified in
March 1974 to incorporate a fuel-oil-fired external combustion chamber
(manufactured by Bloom Engineering Co. ).
This unit has operated
reliably with minimum flameout and equipment problems for over
7000 hours.
Inspection of the reheater on the venturi/ spray tower system during
the May 1975 five-week boiler outage revealed some cracking of the
refractory in the combustion chamber discharge section throat.
Re-
pairs were made by using a mixture of 15 percent Kaocrete and 85
percent Kruzite castable #32 refractory (A.P. Green Co. , Mexico,
Mis souri).
The reheater on the TCA will be modified during the May 1975 boiler
outage to include a Bloom external combustion chamber.
7-6
-------
7.5
FANS
The 316 stainless steel fans at the Shawnee test facility are induced
draft, centrifugal fans manufactured by Zurn Industries.
Reliability
has been good during the current operating period, with no system
downtime due to fan problems.
Previously some vibrational problems
were encountered, but these have been solved by changing pillow blocks
and greasing the fan bearings on a weekly basis (see Reference 1).
During the May 1975 boiler outage, a four-inch hairline crack was
discovered in the fan rotor shroud of the venturi/ spray tower fan.
The crack was repaired by welding with a type 347 stainless steel rod.
7.6
PUMPS
Pump problems during the current operating period (see Reference 1
for a report on prior operation) have been due mainly to pump seal
failures.
In February 1973, when most of the rubber-lined centrifugal
pumps (manufactured by Allen-Sherman-Hoff) were converted from
Hydroseal (water flushed packing) to Centriseal (air flushed packing),
several shaft failures were experienced on A-frame (50 to 100 gpm
capacity) pumps.
Hardened stainless steel shaft sleeves were installed
and shaft failures have been eliminated.
Frequent packing failure on the Centriseal pumps has continued to be
a problem on A-frame pumps since adequate purge air cannot be main-
tained without vapor locking the pump. A Tl Crane XD-lOl (316) single
seal, double hardface mechanical seal will be instalied on an A-frame
7-7
-------
pump during the May 1975 boiler outage for evaluation when the system
is restarted.
Packing failure has not been as frequent with larger pumps since the
seal purge air volume is small compared with th~ pump volume and an
adequate air flow can be maintained.
The alkali addition system pumps are positive displacement pumps
manufactured by Moyno Pump Division of Robbins & Myer Co.
They
were installed in November 1972 when the limestone system was con-
verted to provide a 60 wt % limestone slurry.
The pumps are over-
sized by a factor of two.
They are allowed to wear until the required
flow can no longer be maintained.
Typical operating life for a rotor
is 2000 hours and for a stator, 1000 hours.
7.7
WASTE SOLIDS HANDLING
7.7.1
Filte r
Due to frequent cloth failure and cake discharge difficulties, the
Maxibe1t rotary drum vacuum filter was coverted to a single roll
type with air blowback and scraper discharge in February 1975.
The filter cloth life ha s been somewhat extended but a longer period of
normal filter operation will be required to determine realistic cloth
life.
The first cloth installed after the filter modification lasted over
600 hours, but subsequent cloths have had much shorter lives due to
secondary causes (e. g., cloth deterioration during extended shutdowns
7-8
-------
or broken tension rope s resulting in the cloth catching and tearing on
the discharge scraper).
7.7.2
Centrifuge
The centrifuge was reactivated when a solids dewatering capacity greater'
than that of the clarifier alone was needed because of higher flue gas
flow rates on the TCA. The repaired centrifuge (see Reference 1 for
a description) ha,s operated satisfactorily during. 1745 hours of inter-
mittent operation.
Inspection during the May 1975 boiler outage revealed evidence of
significant wear but no maintenance was performed.
7.7.3
Clarifiers
Overloading of the TCA clarifier has occurred at times during opera-
tionat 12 ftl sec gas velocity. In an attempt to maintain clear over-
flow, the feedwell on the TCA clarifier will be extended during the
May 1975 boiler outage to provide more liquid up-flow re sidence time
and to minimize short- circuiting.
7.8
ALKALI ADDITION SYSTEMS
1. 8. 1
Lime
The lime addition system consists of a storage silo, lime slaker
(manufactured by Portec- Cahaba), a slaked lime holding tank, and
7-9
-------
as sociated feed pumps.
An analysis of the lime used can be found in
Appendix C.
Fresh water is used to slake the lime to approximately
20 to 25 weight percent.
The system has given excellent reliability in over 9000 hours of inter-
mittent ope ration.
Maintenance requirements have been minimal.
A discussion of the pump operation can be found in Section 7.6.
7.8.2
Lime stone
The limestone addition system consists of a drying-grinding system,
a storage tank, belt feeder, slurry tank, and associated feed pumps.
An analysis of the ground limestone can be found in Appendix C.
Clarified process liquor is used to slurry the limestone to 60 weight
percent.
The drying-grinding system was acquired from an earlier EPA spon-
sored dry limestone ,injection program at the Shawnee Power Station.
It has given satisfactory performance with minimum maintenance
during the three years of the alkali wet- scrubber test program.
The slurry system was modified to provide 60 wt % limestone slurry
in November 1972 and was further modified to incorporate clarified
proce s s liquor for slurrying the lime stone in March 1974.
Since March
1974 the system has operated satisfactorily in almost 7000 hours of
intermittent operation with minimal maintenance.
pump operation can be found in Section 7. 6.
A discussion of
7-10
-------
7.9
INSTRUMENT OPERATING EXPERIENCE
7.9.1
pH Meters
The main problem (see Reference 1) as sodated wi th the Uniloc Model
321 submersible pH meters has been scale formation on the probes
and subsequent measurement error.
with HCI.
The scale.is removed by rinsing
On April, 1975, a continuous ultrasonic cleaner (a Uniloc add-on)
was installed on the venturi/ spray tower inlet pH meter to aid in the
prevention of scale buildup. Although the device has operated for less
than a month, due to the unit No. 10 boiler outage, it appears to have
significantly reduced scale buildup.
Before the installation, scale
was removed daily.
With the ultrasonic cleaner, once every five
days has been sufficient.
about twice a week.
All probe s are routinely rinsed with water
7.9.2
, Flowmeters
Operation with the Foxboro magnetic flow meters in slurry service
has generally been satisfactory, but some difficulties have been ex-
perienced with deterioration of the liners in the 1 1/2 inch meters.
These meters were originally lined with Scothane. After failure they
were relined with Adiprene-L. The new liners have failed after
periods ranging from 3 to 9 months due to blister formation, subse-
quent erosion of the blister, and eventual stripping away of the liner.
7-11
-------
Larger meters (6 to 8 inch size) are lined with neoprene and. smaller
meters (1/2 inch size) are lined with Teflon.
No difficulties with liner
deterioration have been experienced with these meters.
to reline the 1 1/2 inch meters with Teflon.
It is planned
7. 10
LINING MATERIALS
Lining or coating materials for equipment at the Shawnee facility
generally consist of neoprene rubber (pipes, pumps, scrubber inter-
nal walls, and small tanks) or Flakeline 103 (effluent hold tanks and
clarifiers ).
Flakeline 103 is a bisphenol-A type of polyester resin
filled 25 to 35 percent with glass flake.
Company.
It is manufactured by Ceilcote
Both rubber and Flakeline coatings have shown very little erosion or
deterioration.
Successful repairs have been made using Epoxylite-203,
an epoxy marine coating consisting of Polypoxy 4216A plus Polypoxy
4027B produced by Tettit Co., R,ockway Beach, New Jersey.
A patch
on the venturi! spray tower effluent hold tank agitator blade has shown
little wear after over 9000 hours.
7-12
-------
Section 8
PARTICULATE REMOVAL TEST RESULTS
Presented in Tables 8-1 and 8-2 are overall particulate removal
efficiencies measured during reliability testing on the venturi/ spray
toweJ:" and TCA systems, respectively. For these tests, a modified
EPA particulate train (manufactured by Aerotherm/Acurex Corporation)
was used to measure mass loading at the scrubber inlets and outlets.
For the venturi/ spray tower system (see Table 8-1), particulate re-
movals of 99. 0 to 99. 3 .percent were obtained for spray tower gas
velocities of 6.7 to 8.0 ft/sec, venturi pressure drops of 1. 9 to 9.0
inches H20, and liquid-to-gas ratios of.5 to 30 gal/md and 50 to
60 gal/md for the venturi and spray tower, respectively.
For the TCA system (see Table 8-2), the removals were 99.0 to 99.7
percent for gas velocities of 8.6 to 12.5 ft/sec, total pressure drops
of 6. 1 to 10.0 inches H20, and liquid-to-gas ratios of 42 to 104 gal/md.
Results of particulate removal tests prior to reliabUity testing are
reported in Section 11 of Reference 1.
The current results are in good
agreement with the earlier test results.
8-1
-------
Table 8-1
OVERALL PARTICULATE REMOVAL IN VENTURI/SPRAY TOWER
DURING LIME RELIABILITY TESTS
00
I
N
Gas Spray Tower Liquor Rate. L/G. Pressure Drop. Grain Loading.
Rate. gpID gal/DJd in. HzO grains/sd Percent
Run No. Date Gas Veloc:i1y. (a ReJDoval
acfrn @ 3300F ft/sec @ IZ50F VenMri I Spray Tower VenMri I Spray Tower VenMri I Spray Tower Inlet I Outlet
604- IA 6/26/74 Z5.000 6.7 100 lZ00 5 60 1.9 3.0 Z.5Z 0.024 99.1
608-IA 9/11/74 ! ! 600 30 1 9.0 Z.Z Z.Z8 0.OZ3 99.0
610-IA 10/9/74 ! 3.Z Z.7Z O.OZI 99.Z
611-IA 1l/6/74 3.0 Z.36 O.OZI 99.1
6Z2-IA 2/18/75 3.0 3.0Z O. OZ2 99.3
6Z4-IA 3/26/75 30.000 8.0 Z5 50 4.5 1.58 0.015 99.0
6Z4-IA 3/28/75 I ~ J ~ 4.5 2.47 0.OZ2 99.1
6Z4-IA 4/4/75 4.3 Z.14 0.018 99.Z
(a) Including Dlist eliminator
-------
Table 8-2
OVERALL PARTICULATE REMOVAL IN TCA SCRUBBER
DURING LIMESTONE RELIABILITY TESTS
00
I
VJ
Gas Gas Liquor Pres sure Grain Loading,
Run No. Date Rate, Velocity, Rate, L/G, Drop, (a) grains/scf Percent
acfm @ 3000F it/see @ 1250F ga1/mcf in. H20 Inlet I Outlet Removal
gpm
531-2A 5/15/74 20,500 8. 6 1200 73 6.7 2.82 0.029 99.0
53 1 - 2A 6/12/74 1200 73 10.0(b) 3.47 0.010 99.7
532-2A 7/24/74 1700 104 6.7 3.33 0.024 99.3
535-2A 9/27/74 1200 73 6.2 2.73 0.016 99.4
535-2A 10/30/74 1200 73 6.2 2.24 0.023 99.0
535-2A 11/20/74 1200 73 6. 1 2.97 0.021 99.3
536-2A 1/9/75 24,000 10.0 1200 62 8.0 2.88 0.012 99.6
538-2A 2/13/75 24,000 10.0 1400 73 8. 7 2.18 0.018 99.2
539-2A 3/6/75 29,900 12. 5 1000 42 10.0 3.00 0.017 99.4
539-2A 3/11/75 28,800 12.0 1000 43 10.0 2.82 0.014 99.5
(a) Including mist eliminator and Koch tray.
(b) High pressure drop due to system plugging by scale and solids.
-------
A limited number of particulate tests on the TCA system to determine
removal as a function of particle size are also reported in Section 11
of Reference 1.
Future testing by EPA is planned to confirm the
validity of these results.
8-4
-------
Section 9
ANALYSIS OF TCA PRESSURE DROP DATA
This section presents a pressure drop correlation fitted to data on
the TCA system. A series of tests were made in late February and
early March 1975 to obtain pressure drop data for the four-grid,
three- bed TCA configuration. The se data were needed to define the
range of non-flooding operation as a function of gas and liquor flow rate
and sphere bed height. An earlier correlation had been developed for
the TCA system with wire mesh grids (see Reference 1) which have
since been replaced with bar-grids.
Figures 9-1 through 9-4 present the measured TCA pressure drop data
as a function of gas and liquor flow rate with 0, 5, and 7 1/2 inches of
spheres per bed.
Flooding was indicated by a rapid increase in pres-
sure drop.. This occurred at approximately 8 to 10 inches H20. Both
high-density polyethylene (HDPE) and thermoplastic rubber (TPR)
spheres were used in these tests. As can be seen in Figures 9-2 and
9-3, pressure drop does not seem to depend on which type of sphere
is used.
The following equation was fitted to the data shown in Figure 9-1 for
the four-grid TCA without spheres:
~ P = 0.221 v + O. 0355(L/A) - 1. 89
(9-1)
"
9-1
-------
where:
/::iP
=
pressure drop across four grids, inches, HZO
saturated gas velocity at 1Z50F based on tower
cross- sectional area, ft/sec
liquor flow rate per unit tower cross- sectional
area (A = 3Z ftZ), gpm/ftZ
v
=
L/A
=
Equation 9-1 accounts for 98.9 percent of the variation of the data
. *
with a standard error of eshmate of 0.075 inch HZO. The range of
variable s covered by this equation included:
Gas velocity (v): 8 to 13.5 ft/ sec
Liqu~r flow rate per unit cross-section (L/A): '25 to 45 gpm/ft2
Number of grids: 4
No spheres
The following equation was fitted tothe data shown in Figures 9-Z
through 9-4 for the four-grid TCA with spheres, for pressure drops
below 10 inches HZO.
~ P = 1. 68 + 7. 1 7. 10- 5 h , (L / A) vZ
s
(9-Z)
where:
~P
::
pressure drop across the four -grids and three beds
(5 to 7 l/Z inches of spheres per bed), inches HZO.
total static height of spheres in inches.
hs
=
):< ' .
See Appendix H for definition of statistical terms.
9-2
-------
o 3
N
I
.
c:
0..'
0
£I:
C 2
w
£I:
::>
~ ~
W
I £I:
VJ 0..
1
4
o
NO SPHERES
20,000
24,000 26,000 28,000
GAS RATE, acfm @ 275 of
32,000
30,000
22,000
I
8
I
12
I
13
I
9
I I
10 11
GAS VELOCITY, ft/sec @ 125 of
Figure 9-1.
Pressure Drop Across the Four-
Grid TC.A Without Spheres
-------
10
Cf,..
%:
.5
~.
o
~ 8
w
a:
:;)
~
w
a:
~
14
5 inches HDPE SPHERES PER BED
12
6
4
2
20,000
22,000
24,000 26,000 28,000
GAS RATE, acfm @ 275 of
30,000
I
8
I
9
I
I I
10 11
GAS VELOCITY, ft/sec @ 125 of
I
12
Figure 9-2.
Pressure Drop Across the Four-Grid, .
Three-Bed TCA with Five Inches of HDPE
Spheres per Bed
9-4
o
/
32,000
I
13
-------
10
~
:z:
.5
0.."
o
~ 8
w
II:
~
~
w
II:
0..
14
12
6
4
2
t'>~1~O/O [J 01
\.\O'UO~ :/ 0 . /
a,oO 9J'9'«\ 0 ~ /
0' ~O 0 A/
~O O~ ~A"/
-0 -------0 ,000 ~A
-0 800 6-----A
-0 -6~
-6 -
20,000
I
8
Figure 9- 3.
5 inches TPR SPHERES PER BED
I
o
22,000
24,000 26,000 28,000
GAS RATE, acfm @ 276 of
30,000
32,000
I .
9
II
10 11
GAS VELOCITY, ft/sac @ 126 of
I
13
I
12
Pressure Drop Ac'ross the Four-Grid,
Three-Bed TCA with Five Inches of TPR
Spheres Per Bed
9-5
-------
12
~
:c
.~
fl.:
o
~ 10
11.1
~
IE
16
14
8
8
4
7 1/2 Inchlt TPR SPHERES PER BED
/
o
. /0 0
o /
<1-#'/ /0 A
~~O /0 (> /
,1SI'..,p.-0 .........0 / /' A
O~~D 0 6~
. ~ ~ 0/. ~
".0 [J _ftft 0/ ~
[J ,,/ '\~ 6",.6
". O~ ~ 6"" .
,O~6~
.",. 6-----
20,000
22,000
24,000 26,000 28,000
GAS RATE, ecfm @ 276 of
I-
8
I I
10 . 11
GAS VELOCITY, ft/88C @ 126 of
I
9
30,000
I
12
Pressure Drop Across the Four-Grid,
Three-Bed TCA with Seven and One-Half
Inches of TPR Spheres per Bed
Figure 9-4.
9-6
32,000
I
13
I
6
-------
11
10
9
~8
::I:
C
0.: 7
o
a:
0
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::>
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a:
no
0
w
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u
o
w
a: 3
no
2
1
o
o
LIQUOR RATE
o
o
o
6.
1400 gpm
1200 gpm
1000 gpm
800 gpm
o
o ,0
,0 20
0
I ~
r
I
EQUATION 9-1 I
(GRIDS ONL VI; 6
/: EQUATION 9-2 .
. :~(GRIDS AND SPHERES)
t$ .
1
3 4 5 6 7 8
MEASURED PRESSURE DROP, in. H20
9
2
Figure 9- 5.
Comparison of Experimental Data and
Predicted Values of Pressure Drop for
the Four-Grid, Three-Bed TCA
9-7
10
11
-------
<-
Equation 9- 2 accounts for 97. 3 percent of the variation of the data
with a standard error of estimate of 0.35 inch H20.
variables covered by this equation included:
The range of
Pressure drop (AP) z 10 inches H20 (non-flooding region only)
Gas velocity (v): 8.5 to 13. 5 ftl sec
Liquor flow rate per unit cross-section (L/A): 25 to 45 gpm
Total height of spheres (hs): 15 to 22.5 inches
Type of spheres: HDPE or TPR hollow spheres, 1 112 inch
diameter, 5 gram average weight
Number of grids: 4
Number of beds: 3
The measured and predicted values of pressure drop from Equations
9-1 and 9-2 are compared in Figure 9-5.
9-8
-------
Se ction 10
REFERENCES
1.
Bechtel Corporation, EPA Alkali Scrubbing Test Facility: Summary
of Testing through Octob~r 1974, EPA Report 650/2-75-047, June 1975.
2.
Universal Oil Products, Air Correction Division, Bulletin No. 608, .
"UOP Wet Scrubbers, " 1971.
3.
R. H. Borgwardt, "EPA/R TP Studies Related to Unsaturated
I
Operation of Lime and Limestone Scrubbers, " Proceedings:
Symposium on Flue Gas Desulfurization - Atlanta, November 1974,
EPA Report 650/2-74-126, December 1974.
4.
R. H. Borgwardt, "Increasing Limestone Utilization in FGD
\
Scrubbers, " to be presented at the Sixty-Eighth Annual Meet~ng
of the AIChE, L~s Angeles, November 16-20, 1975~
10-1
-------
App~ndix A
CONVERTING UNITS OF MEASURE
Environmental Protect'ion Agency policy is to expres's all measurements
in Agency documents in metric units. 'When implementing this practice
will result in undue costs or lack of clarity, conversion factors are
p;rov,ided for the non-metric units used in the report.
Gene rally, this
report uses British units of meas~re.
For conversion to t~e metric
system, use the following conversions:
To' Convert From To Multiply By
scfm (600F) nm3/hr (OoC) 1. 61
cfm m3/hr 1. 70
of 0c subt'ract 32 then
. 1.8
.
ft m 0.305
ft /hr m/hr 0.305
ft / s e c m/ sec 0.305
ft2 m2 0.0929
ft2/tons per day' m2/metric tons' 0.102
per day
gal/mcf .i/m3 0.134
gpm .e / min 3.79
2 ,L/min/m2 40.8
gpmlft
gr/scf gm/m3 2.29
in. cm 2.54
in. H20 mmHg 1. 87
Ib gm 454
lb-moles gm-moles 454
lb-moles /hr gm-moles/min 7. 56
lb-moles /hr ft2 gm-moles/min/m2 81. 4
lb-moles /min gm-moles / see 7.56
A-I'
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Appendix B
SCRUBBER OPERATING PERIODS
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SCRUBBER OPERA TING PERIODS
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',:' ::: '" ,;, :", ';;,;:: :,'; ;;:: :;i' ,::i :J: I ;;; :::! . i " ~ ~ 'ii~r:rr ' ",i1~'1:1i UtH~;:T1 r:'. ;;" f;~ 1m ';:: ~h
w. ~ :::; ;:j', I!' ,,1, ',;' :'" I ,,;~ !' 11;:11 t I4r 1T!+. ~ i" I I ~. " W" :H.;I:+ TIFBtttt!
~ ,-- - :::, :;:' ,", ': ::;: :::' :.:: ;::: ::': !'! ;::lifri ~i, ',' ttH n' ~tP~' 1~ i g 1 ~ 1m ~~~.'~l~H~~ Wi ~.~~~
~ ;;;' :::: :::' ;;:i;; II' II' ;:; ;;:' ::: ;j;: ::, .. ,1m; II ~rn Ii' m', ~ , i~ '~i'Ht~ :1111tH % +at 2 ~H htt
lid ,'.. ,,;111 I'"" '01 III :,.. " , 'I'! i' 1:1' ,,, I I jill,' !l!.1' , ".' I I J !J .I:I'~:I., ,=..:: :.:! .i!~L!_L lUl!';J
I j: " . Ii I ::" ',I d ! I II:' 1" i! 1 i I!; I ,I I I ! ~ ! i I l~rr . ,r I I : I. L! !~ I It I ,r::l1. IT I d! :1 : n:; :;:! . I ; II ; ! I : rrr: :: I: ! j1 :
11.1,1,' III r 'I 'I I' ',J "1 ii. 1'1 ill" ",r-:-j'11 " '.'!11 ~ I "-\.ifH4t:- '1"11 ..." :~. :o'~ '"'1,'1 ,'-; -"g
; . ,i ~ ,;;' . I' ,:., II = I.' I . " '.' 'tj'. 1- i ~ ., I -ltili" . £ . t' P' II; ':, - I. ~: t! ~. .. i' ,.., ! ~ t, .:!.;; I
"I I,. ..:. I.:! ; IHI ;:1. IJ!." I.,~ !I:: 'jl! ;,ji ':11 I! f ttr llii j':I.i~ ! ~~ 1.1 I J. I.,i -.t; .:r:"I~'; :-;-r: ;1;: !~i J:j !.;:~ i111
:11.. .i I :1'1 p" ',' !I'I .!;i '. ,ill ". :T7:"'PPI ill: ! 'I If: TIll Tr~ 1.,'111",[1 ;"[T; 'j -: hjr !hTl ,1-r; -m'; tii ,:=1 !1t: ~~.: n.:; ~rf1 i!:~ n:'ll:i
I 'i :", ' , I! .;': :: i , II ~ i'i' I " i" I.. ' ::t [11"P. !.[: 'W I Ii ill! Hf ~ Ji tr.;.1 I rrrl iiti .Hi.' ~t @:r;';'lih,!inIHj..u.L. : T~ i~ I IT!i ~!;: : ri: I ~ : i ;m JllI
, ". ,',. ,,:,' ill, I:" :,,' ,,"", I",.., ;iT ,'I, I ilH' 1lI!J ,r,nnr:trH ,,1 11111 !Iii 1111':,; it,lli:' 't:~ 1!111Tii1 ;11. Iii,'
,; , , 01 Iii, ,,;, "" ii,' , !. "" : I ; , , . :'; ,II' , I . ;~' , h /I j 1 JiT! .. , . " .' , II 'I: ! ': III! ..:1.: ," 1 "II. lli.!:. !.J~: TTfi
I ill' I"! .:,' .,j! :11. I! .11 ,:!i ::1; rT, :I!: !: i .1 I =!: I 'n-I! iii, I ~II- I!I::11. ~ :::. i;rr~III;~: ..:! rtrt
" i:i, :.'1 ,,:' ,/I ,PI ,,! ,'" "" !:I! :;" 'I,' .1.: ',i~ 'I!: '. ,,OJ! i!,I,j ",111 . ,J1Ti[[f1 :t~i ~.r. fI~Ji.l. tr:;~~:;T: 1m
ill.. . i I !: I; III! ~ i! ~ i ; I. ! Ii!:. ; ~ I, I: .' I' 'I; I ,.:' I : I i ~ II:: I I. .: ! I; i 111 l-Hi n1: 1-:1 WI; I! ;:y: I: !7"",' 1 r; !1"P :,1i;r.m
;1 ..: ,. ,"I ill " III ::', oil; II!! "!':'III!' 01/1 Iii: , . I "ill! r.':: ~ rrr. 'I :!I, II tm..1" iTi ;:;:~:-: fttr ,TIT nit; ,: ;0':1'/11
II: i!" .'t; ;,11 III !III 1I!l1!~1i I! -dlll!:I.; 111!iI ,:1; '~ 1111 TIT; ~~I! .:1; Ii- .;rTIIP1 !il-=- "Hi ITIfllili IIli I n Tfh[ITn
lJ.//8 l4-hq '+/20 I LI/2.II'I-/2.2. 'l/23 1lJ./2fl. ILJ.j25 I tJ-!2ta 1lJ../2.7 i.J./2S 1lJ./2-Cf ' lJ-J30 T 5/' I 5/2-
IGJ15
..(
U
E-<
-------
Appendix C
PROPERTIES OF RAW MATERIALS
The following is a summary of the properties of the raw materials
used from October 1974 thro'ugh April 1975.
C. 1
COAL
Supplie r:
Old Ben Coal., Benton, Illinois
Type:
Mixture of Old Ben mines 24 and 26 either straight
from mine s or reclaimed from plant coal storage
pile'
Analysis:
9.4 to
2. 3 to
O. 03 to
14. 7 to
13.4
5. 5
0.27
27.9
wt % total moisture
wt % 'sulfur
wt % chloride
wt % ash
, Approximate Ash Analysis:
54 wt % Si02
23 wt % A1203
12 wt % Fez03
3 wt % CaO
1 wt % MgO
1 wt % SO 3
3 wt % KZ 0 ,
1 wt % Na40
3 wt % Igmtion los s
C-l
-------
Note: During Run 535-2B and isolated instances thereafter,
Shawnee Unit No. 10 burned low sulfur western coal
of the following composition:
Supplier:
Western Energy Company, Cow Creek, Montana
Type: Colstrip seam
Analysis (a 1 26.8 wt % total moisture
O. 95 wt % sulfur
O. 1 wt % chloride
10.7 wt % ash
Approximate Ash Analysis: (None made)
C.2
LIMESTONE
Supplier:
.' Type:
Analysis :
Grind:
C.3
LIME
Supplier:
Type:
Analysis:
Fredonia Quarries, Fredonia, Kentucky
Fredonia Valley White
95 wt % CaC03
1 wt % MgC03
4 wt % Inerts
97 wt % less than 325 mesh
92 wt % less than 30 microns
86 wt % less than 20 microns
53 wt % less than 6 microns
Linwood Stone Co., Davenport, Iowa
Pebble lime, unslaked
97.0
95.5
0.28
0.47
wt % CaO total
wt % CaO available
wt % MgO
wt % Inerts
(a)
Average values, from only two analyses.
C-2
-------
C.4
MAGNESIUM OXIDE
Supplier:
Type:
Analysis:
Basic Chemicals, Ft. St. Joe, Florida
MAGOX PG (pollution grade)
97. 6 wt % MgO
1. 5 wt % CaO
o. 5 wt % SiO 2
O. 4 wt % R 20 3
C-3
-------
Appendix D
GRAPHICAL OPERATING DATA FROM
VENTURI/SPRA Y TOWER LIME RELIABILITY TESTS
D-l
-------
II I BlaiN ~UN ""A IND RUN _,A I
18 18
Ii 80
'I" II
80 10
71 71
70 70
jf, ~~ PRIIIURI TAPB r
;:c 1,0
UI'1 :: --- 0.1
0.1
o I
Ii'
-~
'1 1,100
U ~: . , , , ,
I, 0 ~ 10 ~ * 100 ~ . ~ 100 a ~
TIlT TIMI, houri
Iml~I~I~lwlwl~lwlwlwl~IMIMI~I~I~I~I~I~1
CALONDAR DAV
fli
gl!~
ilt
U!
,..
',1
I.I~.
", .........-1'
',0
J~
di. :~
ul 10
~ i '0
II .1
DUI ~a ~~~L~::M ~~~~ j~AD
'1,000
J 11,000
1 11,000
11,000
~ '1,000
! ",000
;
I
II
I
i
.
. TOTAL DIBIOLVID IDLIDI
. OHLDRIDI 101 -I
o CALOIUM ICo++1
o IULPATlI1D4.1
NDTI, IIIIIOIIB WHDlI
DDNOINTRATIDNI ARI LBII
THAN 100 - ARI NOT
PLDTTID.
'0,000
0.000 .
1,000
7.000
1,000
1,000
1,000 . . . . . . .
1,00000 00
1,000 0 0 000
,. 0 0 0 0
o
o ~ 10 ~ * 100 ~
TIlT TIMB, houn
Imlwlwl~lwlwl~lwlwl_l~
CALBNDAR DAV
.
.
.
.
.
.
.
.
.
o
.
.
o
o
o
o
o
o
.~ 100 a ~
IMIMI~IMIMI~IMI~I
AU Rltl - 26.000 Iclm . 330 0 F
Uquor Rltl to Vlnturl- 800 gpm
Uquor RBtl to Spray Tower - 1200 gpm
Vlnturt IJO 30 Del/me!
Spray Tower Oel Vlloclty -8.71t1I1c
No. 01 Spray Hledl"- 4
EHT lSuled) Relldlnco
Tlml - 24 mJn
Plrclnt SolidI Recll'llulltld - 7.0.9.0 WI "
Vonturt PrlUurl Drop - 8 In H20
TolBl Prlllura Drop. Excluding Milt Ellm. - 11.0.11.86 In H20
Scrubber Inlel Liquor TOmperalura - 1215-129 of
Uquld Conductfvlty -9.000.13.000 .II. mhol/cm
DllChef1le (Cllrtner end Filter) SolidI
Conclntradon - 47.62 WI "
Umo eddltfon 10 Scrubber Downcomlr
Figure D-l.
Operating Data for Venturi/Spray
Tower Run 609-1A
D-2
4
j~
410
f
'"
I.'
".
M
',0
j~
'1,000
'1,000
'1,000
'1,000
'1,000
".
'0.
1.000
1,000
7.
1,000
1,000
1,000
1,000
1.000
I.
o
480
-------
II
I BIOIN AUN 810 .'A
LIMI8LAKIR PROILIMS
IND AUN e,o .IA
rf-
~M~
78
JO
a B ~ ::: ~
u I ~I:,,-
o.e
I
IIi
~
INLIT
I~~
n
U
.
ITAATLOW IND LOW
~~~(.? ' , , ,
o ~ ~ 1m ,~ - - - - - - ~
I ,on I 10/. 1 '011 1 'OIl 1 '017 I '011 1 'OIl 1'01'0 1 '0I,~lr,~~B1~~11 ,0/1. 1'0/11 1 '0111 I ,0i17 I '0111 I '01181 'OlIO I ,on, I
CALlNDAA DAY
"!
i'll u
gtllg :::~~
~ 1 ',0
,.,
IIi. :~
Iii :l~~
'1,000
] 'I""
'i 1..000
~ '1,000
11,000
"....
i 10,000
m 1.000..
~ 1,000
g 7.000
! 1,000
!1
S
~
~
CI
.
. .
.
. TOTAL DISSOLVID SOLIDI
o CALCIUM {Co++'
a aULPATB (S04-'
.a. CHLOA'DIICI-I
NOTIIIPECIESWH081
CONCENTRATIONIAR& Less
THAN BOO ~ ARI NOT
PLOTTED
.
.
.
.
.
..
.a..a...
....
..
..
.... .. ..
00 0
ee e
.. ..
..
1.000 .. ..
..000
1,000 0
1,000 0
ee
1.000
o
o
000
o
o
o
o
o
ee
e
e
ee
e
e
1~ 1~ - m - - - - ~
I ,on I '01' I '011 1 '0/8 1 '017 I '011 I '0/8 1'01'0 1 'O/l~Er.~~II":';;~1 1'0/1' 110/11 1'01'1 I '0/17 1 ,o/le 1 '0118 1 '0120 1 '0/2' I
CALeNDAR DAY
GIS Rete' 25,000 ecfm 03300 F
Uquor Rete to Ventu~ . 600' gpm
Uquor Rete to Spray Tower' 1200 gpm
Veny Ventu~ L/G 30 gal/mcf
Spray Tower GIS Velocity. 6,7 ftJlIC
No. 01 Spray Hl8dlll . 4
E HT (Sealed) Ruldenci
Tlml . 24 mln
Percent Solids Reclrcullted . 7.8-8.6 wt "
Vlntu~ Pressure Drop' 9 In H20
TOIII Prellurl Drop, Excluding MIl! Ellm.' 11.Q.12.2In H20
Scrubber Inlet Uquor Temperatura '128-1300 F
Uquld ConductMty '10,40Q.17,OOO jJ, mhoalcm
Dllcharge (C1a~fllr and Flltlr) Solids '
Conclntradon . 43-48 wt "
Ume addldon to EHT
Figure D-2.
Operating Data for Venturi/Spray
Tower Run 610-1A
D-3
.
10
II
10
71
JO
j '.1
'.0
~I
0.1
j~
.1,00II
r
I,.,
U
U
I,'
,.1
j~
'I,OOD
II,OOD
''',000
'1,000
'1,000
"....
10,000
e.ooo
a.ooo
7.aoo
8,000
a.ooo
'.000
1,000
z.ooo
'.000
.
.
-------
II
i
ii"
'"
IND RUN 111 ,'A I
~""A
INaPlCTIDN::t INIPICTIDN.J
'00 ~~~
118
INIPICTIDNJ
'00
II
80
80
II
II
80
10
78
~UL
ih ::
o.e --
e
Iii
78
j '.1
,.0
0.1
o.e
--
. r INL~
~~--------~. ~.......... ~
~~~
n~~V~~, ,
~o ~ 10 ~ ~ ~ - S - * - ~
1 '0/28 1 ,0117 1 '0/28 1 '0/28 I ,O/JO I '0/1' 1 11/' I 11/1 I 11~T ,;I/~I'I~ I ",e 1 11n I "" 1 "" 1 ""0 1 "'" I '1/11 1 11".1
CALiNOAR DAY
j~
..~
U!
fllu
"g ",
It 1 :: -~~~
ili
Us
011
14.000
] 12.000
't 10.000
I ,~ooo
'8,000
i 14.000
I '2,000
a '0.000
II 8.000
~
Ii e.ooo
~ 4,000
~ 2,000
o
j:::
",
'.0
o.e
:r .', rVwv~__.- j:
ot~~V O~~ 0
/j. eUL.ITIIIC",
o IUL'AnllCo.'
~ CHLDRIDIICI-I
NOTlI8PeCIES WHOaI
. ~":~=::I:::; Ll88 2O.DOO
PLDTTID. ,~ooo
,~ooo
.
. .
.
.
"'000
12.000
.
.
.
.
.
.
.
.
.
o
0 0 0
o 0
o
o 0
0
0
& 00
~"'''' ~~~6
/j. /j.
/j./j.
.
o
o
o
'''000
'2,000
o
o
o
o
o
'0.000
8.000
o
8.000
o
~
0.000
i
~ ~ i i 2~
/j. /j. .6..6.
*. - - ~ - ~ ~
1 ",. I 11,;'r ,~~~El"':':ls I 11Ie I 11n I 1118 I "" I 11/10 I "'" I '1/,. I 11/13 1
CALENDAR DAY
~
2,000
o
080
.
o .0 80 '80
I '0/21 I '0/27 1 '01" I '0/21 I '0/30 I '0/3' 1 '1/,
GI. Rete" 25,000 letm @ 3300 F
UquDr Rite to Venturi" 600 gpm
Uquor Rete tD Sprey Tower" 1200 gpm
V.nturl UG 30 gel/met
Sprey Tower GIS Velocity" 6.7 N.1e
ND. 01 Sprey H.oders " 4
EHT (Seeled) Rllidence
11me" 8 mln
Porcent Solids Roclrcullted " 6.11-9.3 WI "
Venturl PrIllU.. Drop" 9 In. H20
TOIII PrIllUI'1l Drop, Excluding MI.t Ellm. "10.4-12.0 In H20
Scrubber Inlet Liquor T.mp.retul'1l" 127.131 D F .
Uquld Conductivity" 9,2011-13,000 JL mhOl/cm
DllCherge (Crerlll.r .nd Filter) Solid.
Conc.ntretlon " 44-49 WI "
Ume Iddltlon to Scrubber Downcomer
Figure D-3.
Operating Data for Venturi/Spray
Tower Run 611-1A
D-4
-------
, INDRUN.'..'" I
II I BIGIN RUN .,..,. INIPICTION--.
10 10
811 III
i 10 10
1ft.. 71 71
70 Mfi 70
III 88
r
0..
./
- 0..
0..
I
INLET
IIi ~
~
. ~
..: t /\ 11.1\ /"\ A , 1\ . (\ r
11'1 U1J V \J'v V ~ \j "V \.j"'J ~1aI
ii:: ' , , . , . , . , , , ::
o ~ . 1m ,~ a ~ - ~ - - ~ -
Tlrr TIMI, tn
1 "/23 1 "/24 1 ,,1211 ',1211 "m 1 ,,1211 ,,121111110 I '''' I ,1/2 111/2 1 ,,,. 1 '''' 1 '''' I IIn 1 ,'" 1 1111 1 ,,,,. I,,,,, 1
CALiNDAR DAY
1.1
1.1
nl U
1i"1I' U
Btl U
".
'.1
',I
~~
',I
",
".
".
III ~lvv'\A-N
Ih
J ,.....
1 I,'"
I ......
i ','" . .
..... . .
i ..... . .
. .. .
..... 0 .. .
II 0 00
~ ~
0 0 0 0 0
Ii 2,... ~ ~ ~~ ~ ~ ~a
~ ','" a 2 0
. .
I . .
f
. TOTAL P'SSOLVIP SOLIDI
o CALCIUM (Co4'+j
o SULPATlIIO",
. CHLORIPI (CO,
NOUI SPICI!S WHOa
CONCENTRATIONS ARI LUS
THAN 800 PIIm AAI NOT
PLOnlP,
,.,...
I....
.....
','"
.....
.....
4,'"
~...
2,...
40 eo 120 110 200 240 lID
TIlT TIMB. In
1 "/23 I "/24 1"121 1 "121 1 "m I ,,1211 "121 I ,,1301 ,,,, I '1/2 I 12IJ 1 ,,,. I,,,, I ,'" I ,,,. 1 ,'" II'" 1 '1110 I ,,,,, 1
CALiNPAR PAY
120
310
....
...
','"
.
410
G.. Ritl "25.000 Icfm l1li330. F
Liquor Rete 10 Ventun" minimum (100 gpm)
Liquor Rete to Sprey TOWlr" 1200 gpm
Ventun LJG " 5 gel/mcf
Sprey TOWir Gel Velocity" 6.7 !thee
No. of Sprey Huden" 4
EHT (Sealed) Raldlnel TIml" 17 mi.
111/22.11/25).12 mln (el1er 1-1/25)
Pureent Solidi Reeireuilled " 7.5-9.8 WI"
Venlun Plug poddon 100" Open
Totll Preaure Drop. Excluding Milt Ellm. " 3.B-4.2In H20
Scrubber Inlel Liquor Temperature" 124-1300 F
Liquid Conduedvtty "4.300.5.800 .II. mhos/em
Dlscherge (Clenfier) Solidi
Coneenlredon" 18-21 WI"
Llml eddldon to Scrubber Downcomlt
'~ure
D-4.
Operating Data for Venturi/Spray
Tower Run 618-1A
D-5
-------
II
i
Ifl"
ml~ :~
i . u
u
Iii
n
U
.
~r
o
nl u
!if u "
'"
IIi
Iii
'0.000
I"
i :
11:
p~
~ ,,000
I
0.000
I,DOO
'.000
I BlaiN RUN .,..,A
fiiii CLIAN SPRAY ToweR NDZZUI
IND RUN e''''A I
.
10
:'t
711
70
I I I I I I I
~ 10 ~ ~ D - -
I '1/10 I '1/11 I '1/11 I '1/11 I '11M I '1121 1,1121 I '1/27 I ,~j,~11 ':; I '1/1' I
CAUNDAA DAY -
I I I
.. ..... ~
I ,/I I II. I ,/I 1,,1 I ,n I
u
'A
,.0
-
~~
. TOTALD&llDLVlDIOLIDI
o CA~CIUM lea+;
o IU~PATellD.'
. . CHUlRIDlICI'
. NDTI,IPIClU-
. CONCINTRATIONI ARI LI.
. .. . .. .. THANIOI_AAI-
. PUITTID.
.. ~ .. .
. .. . ..
Q) gg 00 0 0 ij8 8 88
0
0
.
.
.
.
.
00
00
o
.
o
o
oem 1. ,~ - - - -
TIlT TIMa, Houra
I '1/10 I '1/1' I '1/12 I,zm I '11M I ,11211 '1121 I '1/27 1,1/11 I '1/10 1'1/10 I '1/11 I "' I ,/I I ,/I I II. I ,/I I ,/I I ,n I
CALINDAR DAY
110
.....
GIS Rltl' 26,000 eel';' @ 330 of
Uquld Rete to Vlnturi . 600 gpm
Uquor Rete to Spray Tower' 1200 gpm
Vlnturl UG . 3D DaJ/mcf
Spray Tower l/G . 60 gal/me!
Spray Tower GIS Vlloclty . 6. 7 ftI.IC
No. 01 Spray Hledln . 4
EHT Residence Time' 12 mln
Percent Solid. Rlcirculetld' 7.10 wt"
Vlnturi Prlllura Drop' 9 In H2D
TOIII PrIllU.. Drop, Excluding Mist Ellm..10,9-12.0 In H2D
Scrubblr Inllt Uquor Tempe..tu..' 119-129 of
Uquld Conductivity. 3,70G-7,600 .II. mhos/cm
Dischlrgi (Clerifier end Filter) Solid.
Conclntratlon' 63-60 wt "
Ume Addldon to Scrubber Downcomlr
Figure D-5.
Operating Data for Venturi/Spray
Tower Run 619-1A
D-6
.
eo
.
10
,.
,.
j~
j~
4"
,..
'A
,..
u
'"
'.0
j~
'0.000
e.ooo
0.000
7.000
0.000
e.ooo
~
0.000
I,DOO
'.000
~
..,0
-------
II
: STAAT RUN 822-1A
I
r. INBPICTION
INSPICTION~
'RIUI ,"08LIM8 ~
~~ N4,
10
a
i
SS"
a:
III
71
70
88
Q
r
1,1
"I
D.4
, 1.81
m ~ 1.1
ih 0,8
0.4
:~~~, :
Ii, : Ar~~ . J:
8~\~~~-rj1
4 ~ ~.
1,100 1,100
~ I 1,000 'ODD
Ii :~~, ' , ~ :
o ~ 10 ~ * ~..~~ m - ~ ~ ~
1,111 I 1/1 1 ZII I 1/1 1 1/4 1 III 1 III 1 an I III I 1/1 I 1/10 I 1/11 I 1111 11111 1 1114 1 1111 I 1/18 11117 1 11111
CALINOAR DAY
nl
g"~
Ell
lij
Iii
"~ ====1"
::"~ ~". ::
M ~ - ~ M
1.8 1.8
~t~~rv-~~
11,000 . TOTAL DISSOL VID SOLIDI NOTIII.ICIII WHOII 11,000
o CAL.CIUM ICI++) CONCINTRATIONURI LI88 11,000
I 12.000 THAN IDO ppm ARI NOT
,0 IUL'ATlISO.1 'LOTTID.
1 11,000 . CHLORIDI (CI-I 11.000
I 10,000 . 10,000
. . . .
1,000 .. . . . 1.000
. . .
i 1,000 . . . . . .. 1,000
.
i 7,000 . . . 7,000
.
1.000 1,000
II 1.000 1,000
~ . . .. . .
4,000 . . . . .. . . . .. .. 4,000
. . . .
~ 1,000 . 0 ~8 00 1,000
. 0 0 eg (3 CC 00 gg 0 0 0 0 00 0
~ 2.000 sa 0 0 0 0 00 0 0 1,000
o 0 0 00 00 0
1,000 1,000
o 0
o ~ ID 120 180 ~ 240 21D 120 280 ~ ~ 410
I an I Tlf TIMB HOur.
11131 I 1/1 I 1/2 I 2/3 I 1/4 I 1/' I 1/1 1/1 1/1 1 1/10 I 2111 I 2111 I 2/11 I 1/14 I 211. I 211' I 1/17 I 1111 I
CALINDAA DAY
Ou Rotl " 25,000 .cfm CI 330 0 F
Uquld Rlie 10 V.nturl' 600 gpm
Uquor R.tl 10 Spray Tower" 1200 gpm
V.nturl LlO " 3D gal/me!
Spray Tower LlO' 60 gel/me!'
Spray Tower Ou Velocity" 8.7 1tI.1e
No. of Spray Hud..." 4
EHT Raldlnce Tim." 17 mln
"'relnt Solidi Rlclreulltld . 7.9 WI "
Vlnturl Praaur. Drop' 9 In H2D
TOIII Praaurt Drop, Excluding Milt Ellm, . 11.121n H2D
Scrubber Inllt Uquor Tlmplrtturt. 123-127 of
Uquld Conductivity. 9.10~9.700 AI. mhoa1cm
DllCherp (CI.rlfllr Ind Filter) Solidi
ConClntlltJon' 52-80 WI ".
Um. Addition to Scrubber DOWllcomlr
Figure D-6.
Operating Data for Venturi/Spray
Tower Run 622-1A
D-7
-------
II
IND RUN 1U.1A
€i-
80
II
70
II
n~ ::1
U; 0,1
0,.
I
II'
.~
1,100
n'" - --
Ii ~:
',100-.0 110 110 ~ ~
I 1110 I 1111 II1II I IIllc I III. I 111I I 1118 I
I I I I I I .
110 m ~ a ~ 110 m
wl~r:'~I~lmlmlml~lmlmlwl
CA~8NDAR DAV
"~
(II'"
IU::: ~
1,0
IU:~
II i '0
i 0
]
J
f
i
I
I
I
;
11,000
'I,DCO
. TOTA~ DIIIDLVID IDLIDI
o CALCIUM ICo++,
o IULPATlllDtl
. CHLORIDIIC'-I
NOTlIIPICI.8 WHOII
CONCINTRATIONURI LIII
THAN 500 ppm AA e NOT
PLOTTeD.
",DCO
10,ODD
.
.
I,DCO
1,000 .
.
.
.
.
..
.
... . .
. .
.
.
.
.
7,DCO
"ODD
8.D00
.
.
. .. ..
o 00 00
o 00 00
.,000
..
. ..
o
o 00
o 0
I,DCO
.
o
00
... . .
.
.
.
000 0 0
000 0 0
00
00
1,000 0
o
o
o
o
o
o
00
',000
o
ao lID 180 eac MO 110 720 780 BOD ~ 810 e20
I 1110 I III' I 1111 I 1111 I II.. I 1111 I IIItI I 1117 I 1I1;lr ~~II H~~ I 3/3 I 3/. I 31e I 3/1 I 3/7 I 3/1 I 3/1 I 3/10 I
CALINOAA DAV
0.. Rill. 26,000 Ie!m . 330 of
Uquld Rile 10 Venlurl . 800 gpm
Uquor Rite 10 8pray Tower. 1200 gpm
Venlurl LlO . 30 gel/me!
8pray TOWir LlO. 80 gel/me!
Spray Tower 0.. Velocity. 8.7 IImc
No. at Spray Heiden. 4
EHT Rilldlncillme . 17 mln
Percenl Solidi Recircuilled. 7,4.8.7 WI"
Vlnturl Preaure Drop. 8 In H20
TOIII Preaunl Drop. Excluding Milt Ellm..,1.IioI2.6ln H20
Scrubber Inlet Liquor Templnllure. 124012S of
Uquld Conductivity. 6,4Do.S,400 .II. mhaelcm
DllCherge (Cllrlfler end Fnllr) Solidi
Conclnlrltlon . 60.68 WI "
Ume Addilion 10 Scrubber Downcomlr
Figure D- 6.
Operating Data for Venturi/Spray
Tower Run 622-1A (continued)
D-8
10
811
10
71
70
811
jl.l
',I
0,1
0,.
r
1,000
1,800
1,000
1,100
lID
r
".
1.1
!.1
',0
j~
11,000
'1,000
",000
10,000
e,ooo
1,000
7,000
e,DCO
1.000
..000
3.000
1,000
'.000
o
lID
-------
u
I 81alN RUN Ufo'"
r-INIPICTION
r.;'NIPICTION
i
fi"
~
80
lIS
III
80
78
10
81
=II~ ::~
i t 0.1
0..
I
81
-----
r
1.2
0.1
0..
~
Iii
. ~.
~a ~~
rI ~t~~ ~
o ~ III ~ ~ ~ ~ ~ m - ~ ~ ~.
Tin TIMI. ttoul"l
1_lml_I_I~I_I_rml_I_lwlmIMI~I~lml~I~I~1
CALlNOAA OAY
"t ~"
nl U 1.1
lif :'.: ~~~~---~---' :::
y y
~n :[ ~~
I ~ a 1D
~ i 0
!11::[~v~
I~~
III 0
.
o
c
.
III
11
IIi
U
Ii
.
.. ..
.
TOTAL OII8OLVIO IOIL08
CALC'UM ICo",
IUL'AT~ 110.'
CHLOAIOI IC'-'
NOTIIIPIC'II WHOII
CONCINTAAT'ONIARI LI8I
THAN IlOO - ARI NOT
'LOTTIO.
10.000
1,000
10.000
. 1.000
.
1.000
7.000
.
.
.
.
.
.
.
.
. .
.
.
1,000
1.000
e.ooo
..
. .
. .
.
7.000
1,000
1,000
.
..
. . ..
.. . . .. . . . .
00 0 0 00 00 0 0 0 0
c 00 0 0
c Cc CC C C C
C C CC C C C
. .. "000
. . . . .. ~ooo
.
0 0 0 0 00 0 ~ooo
o Q C Cc CC
C C C C 1.000
o
m lID ~ ~ ~
"000
~ooo 0
~ooo
1,000
C
o
D
~ III ~ ~ ~ ~ ~
TIlT TIMB. Moun
1_1~lwl_I~I_I_lml_I_lwl~IMI~I~I~I~I~I~1
CALINOAR OAY
Oil Retl . 30.000 ectm " 330 OF
Uquor Rell to Venlurl . 800 gpm
Uquor Relilo 8PIIY TOWir . 1200 gpm
.Vlnturl LlO . 2& IIII/mct
8pIIY TOWir LlO . &0 IIII/met
SPIIY TOWir Oil Velocity. 8.0 Nac
No, ot SPIIY Hilde,.. 4
EHT Rnldenc,e Time. 17 mln
Perclnt SolidI Reclrculelld. 7.10 WI"
Vlnturl ,,"aull Orop . 81n H20
TOIII ,,""ure Drop. Excluding Mln Ellm. . 12.6-12.8 In H20
Scrubber Inllt Uquor Timpelltull. 12~128 of
. Uquld Conductivity. 8.10~10.000 jI. mho./cm
OllCherge ICllrltlllend Flltlll SolidI
Conclntlltlon . 48-&4 WI "
Ume Addition 10 Scrubbe; Oowncomlr
Figure D-7.
Operating Data for Venturi/Spray
Tower Run 624-1A
D-9
-------
II I RUN _1A CONTINUeD eND RUN e:l4.1A I
~r.;;;; INSPeCTIDN
10
II
i 10
81"
.. 7e '
70
II II
jl~ l r
I.'
i . o.e o.e
0.4 0,4
--.-.-. ......"-'-~-../
Ui
- r DUTLeT
--~~--------
~r
fl - .
ill 1.100
S 1.000
1.100410
I I I I
840 810 720 710
n87 TIMB. r"""
I 419 I 41'0 I 4111 I 411' I 41'1 I 4114 I 4I,e I 4/1e I 4117 I 41,e 4/,e I 4120
. CALeNDAR DA v
I
8JO
I
1180
1~
Nfj,,100
I
110
I
800
I
100
I
840
I
e20
I 41'1 I 4/JJ I 4/JJ I 4/24 I 4111 I 4128 I 4127 I
e.ooo
..
.
.
.
.
. .. .
. .
.
j:::
1.2
1,1
1.0
j:
o '
j~
10.000
IH :J
d1 "'f'
iU :r
i i ~ 10
~ ~ iI 0
ur:r
~~~
"! 0
'0.000
.
1,000
. ....
..
. ... .. .
. TOTAL DISSOLVID SOLIDS
o CALCIUM U:...)
o SULFATE 1104"'
. CHLORIDe ICI-'
NOTe: SPECIES WHose
CONCENTRATIONS ARB LESS
THAN 600 P:xn ARB NOT
PLOTTED.
e.ooo
7.000
.
.
.. ..
.
.
1,000
1,000
~1
h
~ .
s~
Ii
7.000
1,000
4.000
..
.
o
.
1,000
1,000
. .
o
00 00
o
o
o
o 00 00 0
o 00 0
000
4,000
.
.
1.000
1.000
o
o
00 00
o 0
o 0
00
00
3.000
1.000
o
410
o 0
o 0
00
00
J.ooo
'.000
8JO 110 800 840 1180 m ~ 100 '840 1180 m
I 419 I 4110 I 4/1' I 4112 I 4/13 I 4/'4 1011's I 4I'S I 41~if ~:~~e'r~~;~ I 4/20 I 4/21 I 4/22 I 4/23 1./2. I 4126 1.,26 I 4/27 I
CALIINDAR DAY
o
elO
Oel Rsts - 30.000ae!m 0 330' of
Sprey Tower 011 Velocity. 8.0 ft/lec
Uquor Retl to Venturi- BOD gpm
Uquor RBte to Sprey Tower -1200 gpm
Venturi UO '- 25 gel/me!
&prey Tower' UO - 50 gel/me!
No. 01 Sprey Heade" - 4
EHT Raldence Time - 17 mln
Percenl Solidi Reclrculetld - 7.10 WI"
Venturi Preaure Drop - 9 In H20
Total PrllSure Drop, Excluding Milt Ellm. -12.o.l2.4In H20
Scrubber Inlet Uquor Tempereture - 126-129 of
Uquld Conductivity - B,20o.14,OOO II. mhol/em
DllCherge (Clerlller end c,ntrlluge) Solidi
Concentretlon . 46-58 WI "
Ume Addition to Scrubber Downcomer
Figure D-7.
Operating Data for Venturi/Spray
Tower Run 624-1A (continued)
D-IO
-------
\
Appendix E
A VERAGE LIQUOR COMPOSITIONS FOR
VENTURI/sPRA Y TOWER LIME RELIABILITY TESTS
E-l
-------
Table E-l
AVERAGE LIQUOR COMPOSITIONS FOR VENTURI/SPRAY TOWER LIME RUN 609-lA
LiquoT Species Concentrations, mg/l Calculated Percent(b)
Sample Point pH Ca++ Total Sulfate Saturation
Sc rubbe r Inlet 8.00 2680 310 60 120 40 1440 20 4200 8870 110
Scrubber Outlet 5.00 2700 360 60 120 390 1660 5 4350 9650 125
Clarifier Overflow (a) 8.60 2200 260 60 110 30 1620 15 3930 8230 115
Notes:
The values in this table are averages for steady state operation.
Solids Disposal System: Clarifier and filter.
The following ranges of values were observed during the run.
Percent sulfur oxidized: 12-30
Loop closure, percent solids discharged: 47-52
M
I
N
(a)
Process water hold tank.
(b)
(activity Ca ++) x (activity S04 =) / (solubility product at 500C). Estimated solubility product for CaS04' 2H20
at 500C is 2.2 x 10-5 (Radian Corporation, "A Theoretical Description of the Limestone-Injection Wet
Scrubbing Proces s", NAPCA Report, June 9, 1979).
-------
Table E-I (continued)
AVERAGE LIQUOR COMPOSITIONS FOR VENTURI/SPRAY TOWER LIME RUN 610-IA
Sample Point pH H Calculated Percent(b)
Ca Total Sulfate Saturation
I?crubber Inlet 8.1 3100 ZOO 80 150 60 1350 ZO 5ZOO 10,000 110(c)
Scrubber Outlet 4.9 Z800 Z80 90 150 110 Z300 8 4300 10,000 l80(d)
Clarifier Overflow(a) 8.3 Z700 180 80 130 50 1600 ZO 4600 9500 lZO
Notes:
M
I
v..> (a)
(b)
The values in this table are averages for steady state operating period from 10/Z/74 through 10/8/74.
Solids Disposal System: Clarifier and illter.
The following ranges of values were observed during the run..
Percent sulfur arldized: l6-Z6
Loop closure, percent solids discharged: 43-48
Process water hold tank.
(activity Ca H) x (activity S04=) 1 (solubility produ';t at 50oC). Estimated solubility product for CaS04' ZHZO
at 500C is Z. Z x 10-5 (Radian Corporation. "A Theoretical Description of the Limestone-Injection Wet
Scrubbing Process", NAPCA Report, .June 9, 1970).
(c)
At an average inlet SOz concentration of Z500 ppm.
(d)
Value from one analysis.
-------
Table E-l (continued)
A VERAGE LIQUOR COMPOSITIONS FOR VENTURI/SPRAY TOWER LIME RUN 6ll-IA
Calculated Percent(a)
Sample Point Sulfate Saturation
Scrubber lnlet 7.0 3Z0 3Z00 60 80 510 11. 000 100 Z500 17.700 45(b)
Scrubber Outlet 5.85 600 3Z00 60 110 880 lZ.300 lZ Z500 18.000 95
Mist Eliminator Wash 7.55 3Z0 Z700 60 85 130 10.000 100 ZOOO 15.400 50
Notes:
The values in this table are averages for steady state operation.
Solids Disposal System: Clarifier and f"Jlter.
The following ranges of values were ,>I;served during the run.
Percent sulfur oxidized: l5-Z8-
Loop closure. percent solids discharged: 44-49
(activity Ca ++) x (activity S04=) I (solubility product at 50oC). Estimated. solubility product for CaS04. ZIIZO
at 500C is Z. Z x 10-5 (Radian Corporation. "A Theoretical Description of the Limestone-Injection Wet
Scrubbing Process". NAPCA Report. June 9. 1970).
trJ
I
~
(a)
(bl
At an average inlet SOz concentration of 3000 ppIn..
-------
Table E-l (continued)
AVERAGE LIQUOR COMPOSITIONS FOR VENTURI/SPRAY TOWER LIME RUN 6l8-lA
Calculated Percent
pH ++ SulCate Saturation
Sample Point Ca Total at 50°C
-------
tr1
I
0'
Table E-I {continued}
AVERAGE LIQUOR COMPOSITIONS FOR VENTURI/SPRAY TOWER LIME RUN 619-1A
Calculated Percent
Sample Point pH CaH Sulfate Satura-,tion
Total at 50°C a
Scrubber Inlet 7.80 1860 330 40 115 40 1830 25 2920 7200 125
Scrnbber Outlet 5.30 1930 370 40 120 630 2270 15 2900 8300 145
Clarifier Overflow 8.45 1360 320 45 110 50 1830 40 2480 6600 105
Notes:
The values in this table are averages for steady state operation.
Solids Disposal SysteJIl: Clarifier and Filter.
The following ranges of values were observed during the run..
Percent sulfur oxidized: 14-34
Loop closure, percent solids discharged: 53-60
(a)
(activity Ca ++) x (activity SO/)/(soJubility product at 50°G). Estimated solubility product for CaS04 .
at 50°C is 2.2 x 10-5 (Radian Corporation, "A Theoretical Description of "the Li.m.estone-Injection Wet
Scrnbbing Process", NAPeA Report, June 9, 1970).
2~O
-------
M
I
-J
Table E-l (continued)
A VERAGE LIQUOR COMPOSITIONS FOR VENTURI/SPRAY TOWER LIME RUN 622-lA
Liquor Species Concentrations. rng/I (pptn) Calculated Percent
Sample Point pH Ca++ SnlIate Sa~,tion
Total at 500C a
Scrubber Inlet 7.70 2440 270 60 125 50 1600 20 3850 8400 liS
Scrubber Outlet 5.00 2630 280 60 125 740 1830 10 3860 9500 135
Clarifier Overflow 7.95 2410 270 60 120 40 1660 25 3740 8300 125
Notes:
The values in this table are averages for steady state operation..
Solids Disposal System: Clarifier and Filter.
The fonowing ranges of values were observed during the run.
Percent sulfur mddized: -12-28
Lonp closure. percent solids discbarged: 50-62
(activity Ca ++) x (activity S04=)/(snlubllity product at 50°C). Estimated solubility product for CaS04'ZH20
at 50°C is 2.2 x 10-5 (Radian Corporation. "A Theoretical Description of the Limestone-Injection Wet
Scrubbing Process". NAPCA Report.-.June 9. 1970).
(a)
-------
Table E-l (continued)
A VERAGE LIQUOR COMPOSITIONS FOR VENTURI/SPRAY TOWER LIME RUN 623-lA
Liquor Species Concentrations. mg/I (ppm) Calculated Percent
Sample Point pH ea++ Sulfate Satu(:jtiOD
Total at-50oC a) -
Sc rubber Inlet 8.00 Z350 Z30 55 IZ5 50 1350 14 3460 7600 105
Scrubber Outlet 4.95 Z590 Z50 55 IZ5 640 1690 9 3600 9000 130
Clarifier Overflow 8.15 Z370 Z90 55 IZ5 45 1430 16 3Z50 7600 - llO
Notes:
The values in this table are averages for steady state operation.
Solids Disposal System: Clarifier and Centrifuge.
The following ranges of values were observed during the run..
Percent sulfur mddized: ll-Zl
Loop closure, percent solids discharged: 53-60
(activity Ca ++) x (activity SO 4 =)/(solubility product at 50oC). Estimated solubility product for CaSO .
at soGe is Z. Z ][ 10-5 (Radian CorporatiOD.. IIA'Theoretical Description of the Lilnestone-Injecnon ~t
Scrubbing Process", NAPCA Report, .June 9. 1970).
ZIIZO
M
I
00
(a)
-------
Table E-I (continued)
A VERAGE LIQUOR COMPOSITIONS FOR VENTURI/SPRAY TOWER LIME RUN 624-IA
Calculated Percent
Sample Point pH Ca++ SulCate Saturati(DJ.
Total at 500C(a)
Scrubber .Inlet 8.05 Z4Z0 Z30 55 115 65 IZZO 7 4010 8100 95
Scrubber Outlet 4.95 Z6Z0 Z60 '>0 lIS 710 1580 6 3990 9300 IZO
Clarifier Overflow 8.30 Z4Z0 Z30 SO 110 60 13Z0 8 3870 8070 100
Notes:
The values in this table are averages for the steady state operating period..
Solids Disposal System: Clarifier and Centrifuge.
The following ranges of values were observed during the run..
Percent sulfur oxidized.: 12-30
Loop closure. percent solids discharged: 48-58
(activity Ca ++) ,. (activity 504 =)/(soJubility prodoct at '>OoC). Estimated solubility prodoct forCaS04' ZHZO
at sooe is 2.. 2 ][ 10-5 (Radian Corporation. "A Theoretical Description of the LiD'lestone-Injection Wet
Scrubbing Process". NAPCA Report. June 9. 1970).
t'1
I
~
(a)
-------
Appendix F
GRAPHICAL OPERATING DATA FROM
TCA LIMESTONE RELIABILITY TESTS
F-l
-------
II
I BEGIN RUN pa,2A
I
INSPECTION =t
REHEATER BURNER CLEANING, INSPECTION3
INSPECTION ::l I
-
110
110
B8
~\V\~~:
;f
ai"
a:
110
7a
7a
70
70
0.' !
! w ~ 0.'
~;~ 0.2
i E" 0.,
o
-......--
"--
~o..
0.'
0.2
----- 0.,
o
8.8 ~8.8
. ..rINLET.
)0 8.0N~~'--~ 8.0
i!i8.l~~~~ 8.1
~ ~ ~
n~~,~~~1~
. 0 ~ 110 ~ ~ ~ w - m - ~ ~ ~
1~1_1~1~1~1~1~1_I~T:~~I_I-I_I~I_I_I_I~1
CALENDAR DAY
m ~!~ jvvJ\ . ~::
I~I ;: - . v\JV'-;:
iH :f~jvJ~~, 1:
I~~ '0 '1'0
~ ~ 0 0
'3,000 . TOTAL DISSOLVED SOLIDS
J '2.000 . <> CALCIUM ICo"1
[J SULFATE 180,.,
'i 11,000 . CHLORIOE ICI -I
NOTeISPECIE8 WHose
~ 10,000 CONceNTRATIONS ARE LESS
B.ooo THAN IDO ppm ARE NOT
::I PLoneD
~ B.OOO . . .
i!
a: . . . . .
I 7.000 . . . . .
. . . . .
D 8.000
i! e.ooo
f!
::I '.000
Iii
~ 3,000 . . . ~ . . 6
. . . ~ ~ . . . . .
0 2.000 8 8 8 @ [J S <> e <> S 8 [J i
[J e [J @ @
" '.000
'3,000
'2.000
11.000
10,000
B.OOO
8.000
7.000
8.000
e.ooo
'.000
3,000
2.000
'.000
o
Q ~ ~ 1m ,~ - ~ - - - - ~
TEr TIME houn
'~I_I~I~I~'~I~I_I~ _1_1_1_1_1~1_1_1_1~1
CALENOAR DAV
o
~
GSI RBtS . 20.600 acfm @ 300 of
LIquor Rata' 1200 gpm
UG . 73 gal/mcf
Gal Velocity. 8.8 ftllIC
EHT (SsaIBd) Resldance TlmB . 12 mln (8/12-9/271,
1 i; mln (elter 9/27)
ThraB S1IgOl, 6 In sphera!l1age
Parcent Solidi Reclrculsted . 12.16 wt %
TD1I1 Pre...re Drop, Excluding Milt Ellm.
and Koch Tray. 4.Q.4.8In H2D
Scrubber Inlot LIquor Temperatura '120.128 of.
LIquid Conductivity. 4,800.10,000 JL mhos/em
Dischsrge (Clarifier) Solidi
Concentration. 36-42 wt %
Figure F-l.
Operating Data for TCA Run 535-2A
F-2
-------
~s
i~
,
~ RUN 638.2A CONTINUED
I
INSPECTION ~
..
i
SI~
..
.
..
"
"
70
70
H~ :~
Ii' 0.2
R 0,'
o
1.0
Ui U
~
U
1.0
"800
Z.ODD
I.8OD
2,DDD
'.8OD
...
~ - - ~ - m * - ~ - I~
I ,on I '0/' I '0/1 I '0/1 I ,on I '0/1 I '0/1 I '0/'0 I ,0lliWcJ~~':;; I '0/1' I 'O/le I ,o/,e I '0117 I ,olle I '0/11 I '0120 I ,D/2, I
CALENDAR DAY
880 '.8OD
m:r-v~vJ~~J
ri"S u u
G t 1 ... \ ...
~Ii'; . ~:
ih 20 20
~~m '0 '0
9 i 0 a
. TOTAL DISSOLVED SOLIDS
'''ODD 0 CALCIUM ICI++I '2,DDD
J '''-ODD D WLFATE IS04"I '2,DDD
-' CLORIDE ICI-I
'i ".000 11,-
NOT!: SPECIES WHOSE
I . 10.000 CONCENTRATIONS ARE LEIS 'O.DOD
THAN 100 PIW" ARE NOT
::i e.ooo . PLOTTED e,ODD
i . .
I.DDD .. . . . I.DDD
i . . . . . . .
'.DOD . MI'"
g I.ODD . . "-ODD
! . .
B e,ODD "-ODD
S ',ODD . . "ODD
.. . .
i . .. . . . .
"ODD . . . "ODD
o 0 0 . .
8e .
,,-ODD
-------
h
i~
,
I RUN Ul-ZA CONTINUED
- .UNIT10 OUTAGE
INSPECTION ~
UNIT 10 OUTAGE ~ I
~..} :~~
..1.11 0.1
i I~ 0,1
°
II. ~~
r: ~r, "
- ,~ 1~ '. 1,1m 1.1~ ,~ ,~ '. '. '. ,~
1,0m I 10124 1'D/2!I 1,0/21 I 1012'/ 1,0/211,0/21 1,0/30 IIO/3,rr,,;;Mr' ~ I 11/3 I 11," 1 "/8 I 11/8 I 11n I 11/8 I 11111 I 11/10 I
CALENDAR DAV
80
lIS
;j
Q~" 80
0:
'71
70
80
~
lIS
80
71
70
""'---
J 0.'
0.'
I..
I.,
°
j I.e
0.0
I.e
I.a'
4.e
~
~
~
1~
1,&00
1,4otO
'D r
~'U 1.8 1.8
j,(U- r-\ J-~ u
dl u ~ \J . U
1,3 1~
mol sop jSO
h! 10 10
Ii! " ~. .
RS ° °
oil
13.000
J '1,000
't ,'....
~ '0,000
g 1,-
5 11,000
II
I 7""
~ 11,000
!! 11,000
I ',000
~ "000
Ii 1,000
g 1,000
.
iii
<>
°
'....
. TOTAL DISSOLVED SOLIDS
o CALCIUM ICI++, '
D SULFATE (so...'
. CHLORIDE ICI-)
NOTE: SPECIES WHOSE
CONCENTRATIONS ARE LESS
THAN 500 ppm ARI! NOT
PLonED.
13,000
'1,000
11""
10,000
.,000
e,ooo
.
. .
'. . . .
. . . . .
. .
[J [J [J
iii [J [J [J [J [J [J
~ iii 6'" 6 ~ '" 6 ~ ",iii
<> 6 <> 0 <> 00
7""
e,OOO
.
e,'"
','"
.....
iii
<>
I.'"
~
<>
I,'"
°
880 '.000 1tMO 1,om 1,120 1,183 1.200 1,240 1,280 1.320 1,380 1.400
I,om '1'0/24 1,0/111 1,0/211 10/37 1,0/211,0/211 '0/30 1 'O/3,T~~,~:M', :~/2 I 11/2 111" I 11/8 111/e 1 1m I 11/8 111/1 111/10 1
CALENDAR DAY
Figure F-I.
Gu Rete. 20,600 ecfm @ 3000 F
Liquor Retl . 1200 gpm
IIG . 73 gal/me!
Gel Velocity. 8.8 ftJlec
EHT (Seelld) Ruldenci 11me. 12 mln (9/12-9/27),
16 ml;, (efter 9/27)
Threl Sleg., 61n Iphemllt8l111
Parcent Solids Reclrculeted . 12. t 6 WI "
Tom Paraure Drop, Excluding MIlt Ellm.
end Koch Trev. 4.Q.4.8, In H2D
,Scrubber Inlet Liquor Tempereture .123-1280 F
Liquid Conductivity. 4,000.6,100 .II. mhos/cm
Dlsche,gi (Clerffler) Solidi
Concentlldan . 35-42 WI "
Operating Data for TCA R,un 535-2A (continued)
F-4
-------
o
II I RUN &a2A CONTINUED
I r UNIT 10 OUTAGE REHEATER INSPECTION :1
E BURNER CLEANING
..
.. ~
i
IfS" ..
'"
,.
7D
u~
!..} 0..
"';. 0.. -
i E. 0.'
0.0
u~
Ii': ~ET
----e
...
..... ~
n >.000
~~ .....
.....
10
..
10
7e
70
-]:
0.,
0.0
.....
.....
1.~4tO 1.- 1,1510 1,810 1.100 1.1Mo 1,180 1.720 1,780 UOO 1.1MO 1,880
nn TIMI. hn .
111/11 1",10 111,,4 I"". 111"8 111/17 I "/18 111/11 111/10 111/2' 111121 1 ",.. 1 ",.. 111/20 1'11120 111/27 111121 111121 1",10 I
. CALENDAR DAV
','"
1.820
nl
~"i
~tl
~B
~~!
~~5
o!!
::t VVj~~:;
1.8 . 1J
1A 1A
1~ 1~
~[~ ~~
'..... . TOTAL DISSOLVED SOLIDS
] '..... 0 CALCIUM ICI*)
't 11.000 0 SULFATE (S04)
.. CHLORIDE (CI'
.. to,COO NOTE: SPECIES WHOSI!
~ CONCENTRATIONS ARE LESS ALKALI ADO'N + ALKALI ADD'N
8,'" THAN 1500 ppm ARE NOT TO EHT TO DOWNCOMER
5 PLonED.
!! .....
i 7,'" . . .
. . . ..
8.... . .
. . .
!! ..... . .
II . .
::i 4,'"
Ii
~ ..... D
.& iii D D D ~~
I ..... D 6J & . . Ge . . . . .,
~ eQ:! 0 0 g 0 0 0 0 0 0
'.000 0 C(> D
D
'.....
'.....
",000
'0,'"
8,'"
.....
7,'"
1,000
. 8,000
4""
"000
~ "000
'.000
o
t.4tO 1,481 U20 1,580 1.800 1.840 Ua1 1,720 1,780 1,100 1,110. 1.880
TEST TIME, hn
I ,,,,. 111'" I '''" 111/18 111". I 11/17 111". 111110 111/10 111/2' 111121 111m 111/24 111/20 111m 111/27 111121111121111/10 I
CALENDAR DAY
o
1,120
G.. R.t. g 20.5110 acfm 11iI3000 F
Uquo, Rata g 1200 gpm
LIG g 73 gal/mcf
G.. VoIoclty g 8.61t/sac
EHT (Saled) RBSldane. TIma g 12 mln (9/12-9/27).
15 mln (afte,9127)
Threa Stages, 5 In .pheras/mge
Pa,eent Solids Reclrcul.t.d. 12-15 wt"
Tot.1 Pnaura Drop. Excluding Mist Ellm.
and Koch Tray. 4,11-4.6 In H2D
Scrubbe, Inll1 Uquor Temperatura. 115-1240 F
Uquld ConduetMty . 4.60~oOOO .... mhos/em
DlI1:ha,ge (CI.rlfl.rl Solid.
Coneantratlon. 32-411 wt "
Umastone Addition to EHT (9/12-11/281,
to Downeome, (efte, 11(26)
Figure F-l.
Operating Data for TCA Run 535-2A (continued)
F-5
-------
II
I .ND RUN UNA II .IOIN RUN""
r-INIPICTION
10
;i
Ifl"
.
10
u~ ::~
ill ~I
~o
U
Iii LI
II' I I,DGD
ii:
UNIT'OOUTAOI
10
.
10
"
10
~:
~I
~I
000
T1~
I,IQD
I,DGD
I,IQD
I,DGD
',IOD ,...
".10 ',110 ..ClOD "DIG "010 "'10 TlITT~r.-"1OO 1.140 .... I.l1O "110 "400
1 '1/1 1 '1/1 I 'II. 1 '1/1 1 '111 I II/! 1 '" I '111 I 111'0 1 '111' 1 ,11,.1 ,111.1 '11'. 1 ,11,11 '11'1 1,11" 1 ,11,.1,11,1 1 '1/10 I
CA~INDA~ DAY
101
fli 1.1
Uf u
III ~~/~
, I,DGD . TOTA~ DIIIO~VID IO~IOI
I ,,,CIOD 0 CA~eIUM ICo+;
",dco c IU~'ATI 110;'
1 . CH~~IDllel-1
I '''ClOD _I,_IU-
OONCINTIIATIONI AAI ~UI
I,DGD THAN IOD - AliI NOT.
'~TTIo.
i I,GCO .
I ',ClOD
. . .
"ClOD ..
I,DGD .
. .
I I,DGD
0
; I,DGD 0
I,DGD C ~ . ! ~.~ .
,.coo 6 0 e 0 0 00 0
.
o
.
o
101
'.1
,..
'A
'"
II,DGD
".coo
ALICA~I AOO'N + ALKALI II,DGD
AOO'N
TO_OOMIR . TO IHT
l.coo
. I,DGD
'.coo
. . .. ..
I,DGD
. I,DGD
c I,IQD
o 0 00 00 "ClOD
o I,DGD
t t U ~6 66 ,.coo
o
',110 '''' I.CIOD I.DIO I.CIO "'10 "'10 I,IOD 1.140 I.l1O I.l1O .....
1 '1/1 I '1/1 I '11. I '111 I '111 I .." 1,111 I '1/1 I IIII~f,~~~':';;;"1 ,l1li1 ,111.1,1111 I '1111 1'111' I '11111'1111 I ,I/IC I
CAUNOA~ DAY
Oal Rltl . 20,600 Iclm 11300 of
Llquer RIll. 1200 gpm
LlO . 73 gal/mcl
OIl Vlleclty . 8.8lt1aac
EHT (8Ialld) RI.ldlncl Tlml .,6 mln (through 12116),
25 mln (Iftlr 12116) .
Thm SlIIgn, 6 In Iphlres/nlga
Figure F-2.
o
1,400
Ptn:ant Selldl Racln:ulatld. 8-1,8 WI"
TOIIII Prlllurl Drep, Excluding Mln Ellm.
Ind Kech Tray. 3.8-4.8 In HiD
Scrubblr Inllt Liquor Tlmparaturl. 119-128 of
Liquid Conductivity. 3,8DQ.4,800' ... mhol/cm
Dllchlrgl (Cllrlllar) Solidi Conclntratlon . 38-42 wi "
Llm88l0nl Addition to Downcomar (through 12119).
~HT (alter 12119)
Operating Data for TCA Run 535-2A & 2B
F-6
-------
END RUN 636-29 :
~~
c-
~f
: RUN 636-29 CONTINUED
~ fiiiiilNSPECTION
DO
.J
Si~
..
..
DO
,.
10
:i"}
~;JI
!!..~
2~1!i
n
H
.....
.....
.."'"
~
.....
.....
1.400 1.440 1.480 1.120 1.5ID 1.8DD 2.840 2.88D
1 ,2/22 I ,2/23 1 1>124 I ,2/25 I .2/21 1 ,2/271 ,2/211 ,2/211 .~Er;:EI ":' I '/2
CALENDAR DAY
III.lj
g/lN U
=11 ...
. 1.2
~ii >Dr-
ih 20
n~. .0
re$
S is 0
'.....
......
I
'i
I
$ -
!
15
B
~
!
8
~
~
I 2.000
"
11,000
10,000
'.'"
.....
'.'"
.....
.....
.....
.....
'.'"
2.720 2.700 2.800 2.140
I ./3 I II. 1 ,/5 1 '/8 1 '/1 1 ./8 I '/I I
. TOTAL DISSOLVED SOLIDS
<> CALCIUM tc.++,
o SULFATE IS04)
.. CHLORIDE (CI-)
NOTE: SPECIES WHOSE
CONCENTRATIONS ARE LESS
THAN &00 ppm ARE NOT
PLonED.
.
.
.
.
.
.
.
DO
..
DO
,.
10
j 0.'
0.'
0..
0.'
o
Ju
0.0
U
0.0
...
......
.....
......
.....
'."'"
..-
r
...
U
...
...
j~
'.....
......
11,000
10,000
'.'"
.....
'.'"
.....
.....
'.'"
.....
.....
'.'"
o
"400
o
..-
.
.
o
o
o
o
o
o
o
~ ~~
o
o
.
o
~
~
~
~
~
..-
"020
.....
..-
"'20
..""
"100
"840
..-
TEST TIME, Houn
1 '2/22 I .2/23 1,2/24 1,2/25 1 ,2/211 '2/27 1 ,2/211 .2/21 I '2130 1,213, 1 .11 1 '/2 1 ./3 I "' 1 '/8 I '/8 I '/1 1 ./8 1 ,/I 1
CALENDAR DAY
Figure F-2.
"100
"410
Go. Rota' 20,500 aclm @l300 of
liquor Rota' 1200 .gpm
LtG . 73 gal/me!
Go. Valocity '.8.6 It/soc
EHT (Sealed) Residence Time '15 mln Ithrough 12/15),
25 min (after 12/15)
Throo Stages, 5 in spheres/Slago
Poreent Solid. Reclreul.ted' 11.15 wi"
Totol Pressure Drop, Excluding Mist Ellm.
and Koch Tray' 4.4-5.0 in H20
Scrubber Inlet 'Liquor Temperature" 118-126 of
liquid Conductivity. 3,600-7,600 JI. mhos/cm
Discharga (Clarifier) Solid. Concentration' 34-41 wi"
limestone Addi~on to EHT
F-7
Operating Data for TCA Run 535-2B (continued)
-------
"
z"
~~
.""
~~
0
DO
..
J
<
21#'
0'4t
:i 141
wOJ
uw"
~N~
~e~
xz
0-
13,000
j ,~ooo
t 11,000
g 10,000
o 8.000
:;
~ ~ooo
!
~ 7,000
w
=
=
:> 8.000
~
! ..000
!!
~ 4.000
iiJ 3.000
>
a ~ooo
c' '.000
40
II)
'20
. . TOTAL'DISSOlVED SOLIDS
o CALCIUM ((:.+-+,
o . SULFATE ~SO...I
. CHLORIDE (cn
NOTE: SPECIES WHOSE
CONCENTRATIONS ARE LESS
, THAN 500 ppm ARE NOT
PLOTTED.
.
.
.
..
.
.
.
.
.
.
.
.
.
.
o 0
0
~ ~ 6
o
0 40
11/, I 1/2 I 1/3
o 0 0
o 0 0
0 ~
. . 6& . ~6 6
o 0 0
DO '20 '80 200 240 2110
TEST TIME, Houn
11/4 I 1/, I' 1/8 1 1n 1,/8' 1'1/0 I '/'0 11/11 11/,2
CALENDAR DAY
Gos Rato= 24,000 aclm @300 of
Uquor Rato,. 1200 gpm . '
VG . 62 gal/me! .
Gas Volocity ~ 10.0 It/soc
EHT (Soalod) Rosidonco Timo. 20 mln
Throo 5tag.., 5 in sphores/stage
o
~ ~
o 0
...
o
...
.
o
320
.
11/,3 1,/14 1,'1,. I' '/la I ,/17 1,/10 1,/10 1
380
COO
Percont Solids Rocirculatod. 13~16 wt %
Totol Prossure Drop, Excluding Misi 'Eliminator
and Koch Tray. 5:2.5.6 in H20 .
Scrubbor Inlot Uquor Tomporet,;;. . 12O.127°F. '
'Uquid Conductivity. 3,30Q.4,900 J1 mhos/cm'
Dischargo (Clarlflor) Solids Concontration . 32-43 wt"
Umollono Addition to EHT ' ' .
r
. 1.5.
. ,.~,
. 1.3
. 1.2
j30 .
:
'3,000
,~ooo
11,000 ,
10.000
0.000
8.000 :
7,000 .
.000
..000
4.000
3,000
~ooo
'.000
Figure F-: 3.
Operating Data for TcA Run 536~2A; :-.
F-8
-------
~s
~g
a: a:
~~
o
I BEGIN RUN 5J8. 2A
I
PUMP PROBLEM ~- r; INSPECTION
REHEATER FAN
r.; CHANGE a INSPECTION
INSPECTION ~
95
.5
lvviN ~
80
80
90
.i
"
Q~"
a:
os
os
80
75
75
70
70
. W q,
~~~
w 1:1 .5.
~fi
o
~[ -1~
=~.~~~~~~£
50 ~ . -,- OUTLET j 50
~r, , , , ,~V,vr\r1~
. 0 .40 80 120 160 200 240 280 320 360 400 440 480
11128 1,/29 1,/30 1,/31 I 2/1 I 2/2 I 2J3 I 2/. I :'EIT~~E"I"U~ I 2/0 1 V9 1 2/10 12/11 I 2/12 I 2/13 I 2/1. I 2/15 I
CALENDAR DAY
a:
W>
~~ t
!;i~
n
~u'
~z
;$8
1.7
1.3
1.7
Ar-
"
1.0
1.8
nl
:i D N
~ f i 1.'
1.3
1.5
I.'
15..
~~1
ah
!Z:!!:~
WO~
UW"
a:N~
~g~
>
~.
o
10,000 . TOTAL DISSOLVED SOLIDS NOTE: SPECIES WHOSE 10,000
o CALCIUM Ie-+-+I CONCENTRATIONS ARE LESS
..000 THAN 500 ppm ARE NOT ..000
o SULFATE ISOc-' PLOTTED.
0.000 ... CHLORIDE ICI-' 0.000
.
7,000 . . . 7,000
. . .. . .
0,000 . . . 0,000
.. .
5,000 5,000
. . . .
',000 ',000
.
3,000 0 ... 3,000
~ 0 ~ ... ~ ......
~ooo D~ ~ g ...... 0 0 DO, ~ 2,000
...
... ~ ~O 0 0 0 08 0 v 0 00 ... 0
~ 0
1,000 8 fi 1,000
o
0 0
o 40 80 120 160 200 240 280 320 360 400 ... '80
TEST TIME, Haun I 2/12 I 2/13 I 2/1. I 2/15 I
V5 I 2/0 I 2n I 2/0 I 2/9 I 2/10 I 2/11
CALENDAR DAY
I 1/20 1 1/29 11/30 I 1/31 1 2/1 I 2/2 I 2/3 I 2/. I
Gas Rate. 24,000 oelm @300 of
Uquor ROl. . 1400 gpm
lJG . 73 gaI/mel
Ga. Valocity . 10.0 It/sac
EHT (Salad) RBSidon.. Timo . 20 mln
TIT... Stegas, 5 in .phores/stege
Pereonl SotldJ Rocin:ulotod. 13-17 WI"
TOIBI Prossu" Drop, Excluding Mist Elim.
and Koch T"y. 5.7-6.7 in H20
Scrubbor Inl81 Uquor Tompo"tu". 1111.125 of
Uqufd Conductivity. 3,600.5,500 .II. mhos/em
Discharge (Clorfli.r) SoIldJ Concontretlon . 31.39 WI "
UmBstono Addition 10 EHT
Figure F-4.
Operating Data for TCA Run 538-2A
F-9
-------
h
~g
",,,,
wW
L L
o
I RUN 53&2A CONTINUED I END RUN 538-2A
i INSPECTION 3 t: INSPECTI~N
--
..
J
"
N>
a !Jf
'"
v~
00
75
70
! ~}
~ ~.5
~ f~'
o
o'0r-
0.3
0.2 --
0.1
o
8.6f
r INLET
..0 -If-. ~
6.6 ~
~OUTlET
6.0
~rr~,
. 480 520
'"
w >
I~%
""Q
"'~
!;!W
n
>- ,
wU
~8
...
680 .
BOO
680
..
DO
86
00
75
70
j :::
0.2
0.1
o
..6
..0
6.6
6.0
0.6
...
600
720
TEST TIME, Houn
1_1_1_1_1_1=1=1_1~1_1=1_IMlnlml~I~I~lml
CALENDAR DAY
920
r
3.000
2.600
2.000
1.600
960
1.7
\
1.6
~-)
d.
:z: c3 N
~H
1.6
1.0
1.3
1.2
:::..
"'.."
~ ~ ~
a M~'
>-z'"
z-"
wo~
UWW
~~5
)( z
0-
~~A~v
10,000
ri
g 9.000
o
::; 8.000
~
:!t 7.000
'"
w 6,000
..-
~ i
!;!- 6.000
:!tr 0.000
!!
~ 3,000
S 2,000
>
a 1,000
;;
0
000
.
.
.
.
A ~ Q ~
8 0 0 0
620 ..., 0.. ... 0..
I 2/17 1 2/1a I 2/19 I 2/20 I 2/21 I 2/22 I 2/23 I 2/20 I
Gas Rot. . 24,000 aclm @300 of
Uquor R.te. 1400 gpm
LJG . 73 gal/me!
Gas Velocity = 10.0 hi...
EHT (Sealed) Residonc. TIm.' 20 mln
Three Stega., 5 in .pheres/slags
700
...
1.7
1..
1.6
1.4
1.3
1.2
j~
10,000
9,000
8.000
7.000
0.000
6.000
0,000
3,000
2.000
1.000
920
o
...
. TOTAL DISSOLVED SOLIDS
o CALCIUM 1C8++1
o SULFATE ISO..1
. CHLORIDE (CI-I
NOTE: SPECIES WHOSE
CONCENTRATIONS ARE LESS
THAN 500 ppm ARE NOT
PLOTTED.
760
BOO
...
...
Figure F-4.
Operating Data for TCA Run 538-2A (continued)
720
TEST TIME, Hours
_1~1=1~IMlnlml~I~I~lml
CALENDAR DAY
Percent Solid. Recirculated' 15-17 wt"
Tote! Pressure Drop, Excluding Mist Elim.
and Koch Trey = 6.~.8In H20
Scrubber Inlet Uquor Temperetu," . 120.127 of
Uquid Conductivity. 3,800.4,900 u mhos/cm
Discharge (Clariflerl Solids Concentration' 33-41 wt "
Umestone Addition to EHT
F-IO
-------
~a
~Q
a: a:
~~
o
.i
..
s~..
a:
!~}
~ 105
li;wo.."
-a:0
",~a:
o
a:>
i~i
~~
SQ
.. '
~~
~8
j BEGIN RUN 539-ZA
..
..
III
7.
70
l
0.4
0.2
o
... t INLET
..0
... ~T~E~
5.0
U
-f
3.000
UOO
2.000
1,500
o
INSPECTION
END RUN 539-ZAj
~CLAR, U'FlOW LINE PLUGGED
~
240
TEST TIME. Houn
I 31. I 310 I 3110 I 3/11 I 3/12 I 3"3 I 3/14 I 311. I 311. I 3117 I 311. I 311. I 3120 I 3121 I 3122 I 3123 I 3124 I 3125 I 3128 I
CALENDAR DAV
380
400
...
"f
!i j
~ 11 1.7
:z: c3 N
~t1 1..
1..
~~
150 ~
100
50
o
ffi..
H1
a ~rt.
~~~
~eu:
~~s
)(Z
0-
'" a: 0
;;!w:i!
11:::1.
1;~g
~~g
~s;
~
.,000
a:
~- ..000
n
11- 4.000
~~
oa: 3,000
::;g
SQ
0-' 2.000
w..
>W
8! 1,000
<;
o
o
. .
. . .
..
A A A
A'A AA
8 8g g 09 0
o
40
eo
160
200
120
.
.
.
.
..
.
.. ..
AA
AA AA
A
o AA AA og
00 00 00 0 0
o 00 00 88 0
{~
-~
~~
J~
~F
280
I
320
. TOTAL DISSOLVED SOLIDS
o CALCIUM 1C8 ++1
o SULfATE IS041
.. CHLORIDE (CI-.
NOTE: SPECIES WHOSE
CONCENTRATIONS ARE LESS
THAN 5CIO ppm ARE NOT
PLOTTED,
40 80 120 160 200 240 280 320 360 400 440
I 311 I 310 I 3110 I 3111 I 3112 I 3113 I 3114 I 311. I 3I,;E\ ;:~E1";;;' I 311. 1 3120 I 3/21 1 3122 I 3123 I 3124 I 3125 I 3128 I
CALENDAR DA V
GIS R.t. . 28,800 Ie!m @300 of
Uquor Rltl '1000 gpm
UG ~ 43 gel/me!
GIS Vllocity . 12.0 It/..c
EHT (S.llld) RBSidlncl Timl' 25 min
Thrll StlglS, 5 in sphlrlS/sllge
Figure F-5.
-\
-~
~ .---
Pertlnt Solids Rlcirculltld' 13-17 WI %
TOIII Pr.ssure Drop, Excluding Mist Elim.
.nd Koch Tr.y. 6.7-6,85 In H20
Scrubb.r Inl.t Uquor T.mp.ratura . 1 :zo.126 of
UQuid ConductMty. 3,400-5,100... inhos/cm
Discharg. (Clarlfierl Solids
Concentration II N '40Wt'"
Umostona Addition to EHT
Operating Data for TCA 539.:..2A
F-ll
..
DO
..
eo
75
70
j 0..
0.4.
0.2
o
j8.6
..0
...
5.0
4..
r
3,000
2.500
2.000
1,500
...
r
1.7
U
1..
f
]'50
100
50
o
.,000
.,000
4,000
3.000
2.000
1,000
o
...
-------
h
.. 2 ,
a: a:
lele"
o
~ BEGIN RUN 644-2A.
,
END RUN 544-2A: .
- INSPECTION.~.." ...;~
/'.,,',
" ,'. -:. .,.~ -'"
~ "., .. '.
os
..
..
..
75
10
...
j 0,0
0,4
~.2
o
18.5
8.0
...
5.0
...
r
3,000
2,500,
2,000
1,500
...
~. ,
,0 '
"a:'
a~~
~ ~~..
"...
If'
0.0 ~
0.4
0.: -
. ..,,,.. '.',.
..
."!.
, ..
v
.. ...\
f~~~\,
o ~ 00 1~ 1~ ~ ~ ~ ~
I ~5' i ..;8 I ..;7 I 4/8 1 4/9 I 4/10 I 4/11 I 4/12 I :~::r ,T1~~~ Hr:,5 I 4{18 I 4fd I 4/18 I 4/19 I 4/20 I ..i21 I 4/22 I 4/23 I
CALENDAR DAY
75
10
0,5
15>
~ ~ i 5,5
~;;j ,
5.0
1.0
~a:..'il 1,7
~ ~ '~8
i c3 N
U~ 1,5
~ 1.4
1.3
ffi..
~gl
a w~.
~!~
~~~
~e~
~!
r~
~i~ 150[-- I~~~
~ ~ g 100 V ,- ~
ffi ~ 3 60 ...
ffi..:r;; '",,' '. ... .
IL ~ g 0 I' J .
. , .
0,000
e'
.. .. .
.
.
a:
j I' 5.000
~ i 4,000
H, 3,000
Dl'g ..
~8~
~!. 1,000
C :.
.
.
.'
.
..
8. eO ~
o 0
o
o ~~ ~~ ~
t 00 00 0
2,000 0 0
~ ~o,~
, .~
. .
g 8
380
...
1,0
1.7
1,0
1.5
...
1.3
]~
j 150
~.
0,000
5.~
4,000
3,000
2,000
I.,
1,000
, 120
200
...
o
4..
. 240 280
TEST TIME, H.)urs '
I 415 I 4'0 I 4" I 4'0 I 4,. I 4"0 I 4'" I 4/12 I 4113 I 4114 I 4"5 I 4"6 I 4"7 I 4"0 I 4"9 I 4'20 I 4'" I 4'22 I 4'23 I
CALENDAR DAY
o
',0.
'" .
f. ,';' 40 '
.IIO
y';; RaIl' 20,500 a~ni @3000F
, UqUO( ~alo,~ 1200 g~m
, '" LlG' 73gal/mcl.
.: .":G.'.Voi~div .:8.6 III.... '. , .
EHT (Ssalod)' Riildonco Tim'o' 15 inln
Th..o Sla~~,,5 in 'Ph.,~jSiago "
o TOTAL DISSOLVED SOLIDS
o CALCIUM (CII1"'+1
o SULFATE 1504-'
A CHLORIDE ICI -,
NDTE: SPECIES WHOSE
CONCENTRATIONS AR E LESS
THAN 500 OIOim ARE NOT
PLOTTED.
320
380
~
""..onl Sollds'Racl..ulal8d . 12.3-15.0 wt'%
Total Prossu.. Drop, Exchiding Mist Ellm:
and Koch Tray' 5.0.5.7 In H2D , '
Scrubbor Inlol UquorTomporalura' 120.126 of
Uquid Conductivity. 3.900.8,700 .II. mhos/em
Discharge (Clarifier) Solid,' .'
Co~contration . 3~0 wt %
Umsstono Addition 10 EHT
F.ig.u're. F-- 6',
F-12
-Operating Data for TCA Run...s44-2A
-------
Appendix G
A VERAGE LIQUOR COMPOSITIONS FOR
TCA LIMESTONE RELIABILITY TESTS
G-l
-------
Table G-l
A VERAGE LIQUOR COMPOSITIONS FOR TCA LIMESTONE RUN 535-2A
Sample Point Calculated Percent
Sulfate Saturation
Scrubber Inlet
9/Z8-10/Z3/74 5.95 1800 300 55 70 70 1700 90 3000 7000 115
10/Z4-1Z/4/74 5.95 IZOO 350 50 60 90 1950 IZ5 1850 5700 105
Scrubber Outlet
9/Z8-10/Z3/74 5.40 1600 Z80 55 65 110 1750 100 Z500 6500 115
10/Z4-IZ/4/74 5.65 IZ50 300 50 60 95 1790 170 1950 5700 105
Koch Tray lolet(b)
9/Z8-10/Z3/74 7.Z0 1600 300 60 55 40 1800 70 Z700 6500 115
10/Z4-IZ/4/74 7.10 IZ30 350 50 60 30 18Z5 110 1810 5500 100
Koch Tray Outlet(c)
(;) 9/Z8-10/Z3/74 5. Z5 14Z0 180 35 35 880 1480 5 1760 5795 100
10/Z4-IZ/4/74 5. ZO IZ70 ZIO 30 45 1090 1740 35 1150 5570 105
I
N
Notes: The values in this table are averages for the steady state operating period.
Solids Disposal System: Clarifier only.
The following ranges of values were observed during the run:
Perc~nt sulfur oxidized: 10-30
Loop closure. percent solids discharged: 32-42
(a)
(activity Ca ++) x (activity 504=) / (solubility product at 500C). Estimated solubility product for CaS04' ZHZO
at sooe is Z.2 x 10-5 (Radian Corporation, "A Theoretical Description of the Limestone-Injection Wet
Scrubbing Process", NAPCA Report, June 9. 1970).
(b)
Cia rifled liquor (undiluted).
(c)
Liquor stream consists of 9 gpm of make-up water and 15 gpm of clarified liquor.
-------
Table G-I (continued)
AVERAGE LIQUOR COMPOSITIONS FOR TCA LIMESTONE RUN 535-ZB
Calculated Percent
Sample Point pH Sulfate Saturation
Ca-H- Total at 500C(a)
Scrubber Inlet 5.95 1130 410 40 65 105 Z550 110 1510 5900 IZ5
Scrubber Outlet 5.50 11Z0 390 40 75 Z30 Z600 80 1610 5900 IZ5
Kocb Tray Inlet(b) 7.30 11Z0 390 45 70 40 Z560 100 1440 5900 IZO
Notes:
Tbe values in tbis table are averages for the steady state operating period.
Solids Disposal SysteJn: Clarifier only.
The following ranges of values were observed during the run:
Percent sulfur oxidized: 10-30
Loop closure, percent solids discharged: 34-4Z
Q
I
U)
(a)
(acti'tlty Ca -H-) :II: (activity 504=) I (solnbility product at 50oC). EstiJDated solnbility PnJdnct for CaS04 . ZHZO
at 50 C is Z. Z :II: 10-5 (Radian Corporation, "A Theoretical Description of the LDnestnne-Injection Wet
Scrubbing Process", NAPeA Report, June 9, 1970).
(b)
Bottnm of mist eliminator washed with 9 gpm rnalte-up water plus 6 gpm clarified liquor. Koch tray irrigated
with 9 gpm clarified liquor plus 15 gpm mist eliminator wash (Z4 gpm total).
-------
Table G-l (continued)
A VERAGE LIQUOR COMPOSITIONS FOR TCA LIMESTONE RUN 536-2A
Calculated Percent
Sample Point pH ea++ Sulfate Saturation
at 50°cla)
Scrubber Inlet 5.95 950 400 40 40 110 Z300 ZOO 1500 5540 100
Sc rubbe r Outlet ~. 55 1000 430 40 55 nO Z350 140 lZOO 5490 105
. (b) 7. Z 10ZO 400 40 60 65 Z600 100 1150 5430
Koch Tray Inlet 115
Koch Tray Outlet 5.3 1100 Z50 30 40 1150 Z300 ZO 850 5740 lZO
Notes:
The values in this table are averages for the steady state operating period.
Solids Disposal System: Clarifier only.
- The following ranges of values were observed during the run:
Percent sulfur oxidized: 6- 30
Loop closure, percent solids discharged: 32-43
(activity Ca ++) x (activity 504=) / (solubility product at 50°C). Estimated solubility product for CaS04' ZHZO
at sooe is 2.2 x 10-5 (Radian Corporation, IIA Theoretical Description of the Limestone-Injection Wet
Scrubbing Process", NAPCA Report, .June 9. 1970).
C)
I
~
(a)
(b)
Bottom of mist eliminator washed continuously with constant 15 gpm (17 gpm after 1/10) diluted clarified
liquor (all make~ plus necessary clarified liquor). Koch tray irrigated with remaining clarified liquor.
Minimum clarified liquor return 15 gpm (ZO gpm after 1/7).
-------
Table G-I (continued)
AVERAGE LIQUOR COMPOSITIONS FOR TCA LIMESTONE RUN 538-2A
Calculated Percent
Sample Point pH CaH Sulfate Saturatioo
Total at 50oC(a)
Scrubber Inlet 5.90 1330 350 50 55 llO 18Z0 160 ZOIO 5900 tOO
Scrubber Outlet 5.55 1370 340 45 45 170 1750 190 1900 5800 100
Koch Tray Inlet(b) 7.35 1310 3Z0 40 50 30 1950 140 1880 5700 llO
Koch Tray Outlet 5.55 IZ70 ZZO 35 40 840 1850 45 IZ80 5600 llO
Notes:
The values in this table are averages for the steady state operating period.
Solids Disposal System: Clarifier ooly.
The following ranges of values were observed during the run:
Percent sulfur aridized: 10-30
Loop closure. percent solids discharged: 31-40
(activity Ca H) x (activity 504 =)/(solubility product at 50oC). Estimated solubility product for CaS04' ZHZO
at 500C is Z. Z x 10-5 (Radian Corporation. "A Theoretical Description of the Limestone-lnjectioo Wet
Scrubbing Process". NAPCA Report. June 9. 1970).
o
I
U1
(a)
(h)
Bottom of mist eliminator washed continuously with constaot ZO gpm diluted clarifier liquor (aU
makeup plus necessary clarified liquor). Koch tray irrigated with remaining clarified liquor.
Minimum clarified liquor return 17 gpm.
-------
Table G-I (continued)
AVERAGE LIQUOR COMPOSITIONS FOR TCA LIMESTONE RUN 539-2A
- Liquor Species Concentrations, mg/l (pprn) Calculated Percent
Sample Point pH ++ I ++ I + I K+ I = I = I - I - I Sulfate Saturation
Ca Mg Na S03 504 C03 CI Total at 50°c!a)
Scrubber Inlet 6.00 840 280 35 40 75 550 140 1940 3900 25
Sc rubbe r Outlet ~. 75 940 270 35 40 80 620 170 2130 4300 35
Koch Tray Inlet(b) 7.65 990 250 30 35 20 - 750 85 1860 4000 45
Koch T ray Outlet 5.70 880 170 20 25 530 780 70 1170 3600 45
o
I
0'
Notes:
The values in this table are averages for the steady state operating period.
Solids Disposal System: Clarifier and Filter.
The following ranges of values we re observed during the run:
Percent sulfur oxidized: 10-22
Loop closure. percent solids discharged: ....... 40
(activity Ca ++) x (activity 504 =)/(solubility product at 50°C). Estimated solubility product for Caso .
at sooe is 2. Z x 10-5 (Radian Corporation, irA Theoretical Description of the Limestone-Injection W4et
Scrubbing Process", NAPCA Report, June 9. 1970).
2H20
(a)
(bl
Bottom of mist eliminator washed continuously with constant Z5 gpm diluted clarifier liquor (all makeup
plus necessary clarified liquor). Koch tray irrigated with remaining clarified liquor. Minimum clarified
liquor return ZZ gpm.
-------
Table G-I (continued)
A VERAGE LIQUOR COMPOSITIONS FOR TCA LIMESTONE RUN 544-2A
Liquor Species Concentraions. rng/I (ppDl) Calculated Percent
Sample Point pH CaH Sulfate Saturation
Total at 50oC(a)
Scrubber Inlet 5.95 1400 350 40 50 100 1980 95 ZOIO 6000 IlO
Scrubber Outlet 5.50 1300 370 40 50 150 1980 Il5 1990 5900 IlO
Koch Tray InIet(b) 7.Z0 IZ30 380 35 50 90 1800 70 1990 5600 95
Koch Tray Outlet 5.40 1380 ZZO 30 30 1080 1870 9 IZ80 5900 Il5
Notes:
The values in this table are averages for the steady state operating period..
Solids Disposal System: Clarifier
The following ranges of values were observed during the run:
Percent sulfur mtidized: 12-40
Loop closure. percent solids discharged: 35-40
(activity Ca H) x (activity 504 =)/(solubility product at 50oC). Estimated solubility product for Ca504 . ZHZO
at 50°C is 2.. 2 J( 10-5 (Radian Corporation. riA Theoretical Description of the LiD'lestone-Injectian Wet
Scrubbing Process". NAPCA Report. .June 9. 1970.
o
I
-.J
(a)
(b)
Bottom of mist eliminator washed continuOl1sly with 15 to 19 gpm diluted clarifier liquor (all makeup
plus necessary clarified liquor).. Koch tray irrigated with reJDaining clarified liquor.. MiniInum clarified
liquor return 15 gpm.
-------
Appendix H
DEFINITION OF STA TISTICAL TERMS
The fraction of variation that is explained by a correlation is equal to
a *
R , where R is the correlation coefficient. Thus:
Fraction of Variation
Explained
E{Y-J~I..
= I<:~ = /- £ ('-y)1.
(H-1 )
where:
::J =
y' =
value of the independent variable for a particular data point
predicted (correlation) value of the independent variable
for the same data point
-
'J =
arithmetic average of all values of the independent variable
in the correlated set of data
The standard error of estimate is determined from the following equa-
**
tion:
Standard Error
of Estimate
=
~ (1-.1')
..
17-/(-1
(H- 2)
where:
" =
k. =
number of,data points in the correlated set of data
number of dependent variables fitted with coefficients
*
E. L. Crow, et al., "Statistics Manual, " chapter 6, page 175,
Dover, New York, 1960.
)'<:)'(
I 'Ibid., page 174.
H-l
-------
TECHNICAL REPORT DATA'
(Please read /nU/Uctlonr on the revene before completlnlJ
1. REPORT NO. 12. 3. RECIPIENT'S ACCESSION' NO.
EPA-600/2-75-050
4. TITLE AND SUBTITL.E 6. REPORT DATE
EPA Alkali Scrubbing Test Facility: Advanced September 1975
Program - First Progress Report 6. PE~FORMING ORGANIZATION CODE
7. AUTHORIS) B. PERFORMING ORGANIZATION REPORT NO.
Dr. Michael Epstein, Project Manager
9. P..ERFORMING OR8ANIZATION NAME AND ADDRESS 10. PROGRAM EL.EMENT NO.
Bechtel Corporation lAB0l3: ROAP 2lAAZ-001
50 Beale Street 11. CONTRACT/GRANT NO.
San Francisco, CA 94119 68-02 -1814
12. SPONSORING AGENCY NAME AND ADDRESS 13. TYPE OF REPORT AND PiJ~oo crl~ERED
EPA, Office of Research and Development First Proe:ress. 10 74-4 75
Industrial Environmental Research Laboratory 14. SPONSORING AGENCY CODe
Research Triangle Park, NC 27711
16. SUPPL.EMENTARY NOTES
16. ABSTRACT
The report gives results of advanced program tests on a prototype lime/
limestone wet-scrubbing S02 and particulate removal facility at TV At s ,Shawnee
Power Station. With the obJective of achieving reliable mist eliminator opera-
tion, a venturi/ spray tower was operated with lime slurry, and a Turbulent Con-
tact Absorber (TCA) with limestone. Each had 30,(000 acfm (10MW equivalent)
flue gas capacity. The venturi/ spray tower system was maintained essentially
clean in an 823-hour run at 8.0 ft/ sec gas ve1ocit1 and 8% slurry solids (the
3 -pas s, 9pen-vane chevron mist eliminator was intermittently washed on both
topside and underside with makeup water). The TCA system was operated suc-
cessfully in an 1835 -hour run at 8.6 ft/ sec gas velocity and 15% slurry solids
(the mist elimination system consisted of a Koch F1exitray, in series with a
6-pass, closed-vane chevron mist eliminator, both with underside wash). Both
scrubber systems operated with better than 99% particulate removal efficiency
and with outlet grain loadings of 0.01 to 0.03 grains/sd. A correlating equation
is presented for TCA pressure drop tests.
-
17. KEY WORDS AND DOCUMENT ANAL.YSIS
a. DESCRIPTORS b.IDENTIFIERS/OPEN ENDED TERMS c. COSA TI Field/Group
Air Pollution Coal Air Pollution Control 13B 2lD
Calcium Oxides Flue Gases Stationary Sources 7B 21B
Limestone Prototypes Particulates
Scrubbers Alkali Scrubbing 7A
Des ulfurization Venturi Spray Tower 7D
Boilers Turbulent Contact Ab- 13A
-.-
18. DISTRIBUTION STATEMENT 19. SECURITY CLASS (This Report) 21. NO. OF PAGES
Unclassified 172
Unlimited 20. SECURITY CLASS (This page) 22. PRICE
Unclassified
EPA Form 2220-1 (9.73)
H-2
------- |