v>EPA
United States
Environmental Protection
Agency
Industrial Environmental Research EPA-600/7-78-051d
Laboratory November 1978
Research Triangle Park NC 27711
EPA Utility
FGD Survey:
June-July 1978
Interagency
Energy/Environment
R&D Program Report
-------
RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories were established to facilitate further development and application of en-
vironmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:
",. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Tocioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7. Interagency Energy-Environment Research and Development
8. "Special" Reports
9. Miscellaneous Reports
This report has been assigned to the INTERAGENCY ENERGY-ENVIRONMENT
RESEARCH AND DEVELOPMENT series. Reports in this series result from the
effort funded under the 17-agency Federal Energy/Environment Research and
Development Program. These studies relate to EPA's mission to protect the public
health and welfare from adverse effects of pollutants associated with energy sys-
tems. The goal of the Program is to assure the rapid development of domestic
energy supplies in an environmentally-compatible manner by providing the nec-
essary environmental data and control technology. Investigations include analy-
ses of the transport of energy-related pollutants and their health and ecological
effects; assessments of, and development of, control technologies for energy
systems; and integrated assessments of a wide'range of energy-related environ-
mental issues.
EPA REVIEW NOTICE
This report has been reviewed by the participating Federal Agencies, and approved
for publication. Approval does not signify that the contents necessarily reflect
the views and policies of the Government, nor does mention of trade names or
commercial products constitute endorsemerit or recommendation for use.
This document is available to the public through, the National Technical Informa-
tion Service, Springfield, Virginia 22161.
-------
EPA-600/7-78-051d
November 1978
EPA Utility FGD Survey:
June-July 1978
by
M. Melia, M. Smith, W. Fischer, and B. Laseke
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
Contract No. 68-02-2603
Task No.24
Program Element No. EHE624
EPA Project Officers:
N. Kaplan J.C. Herlihy
Industrial Environmental Research Laboratory Division of Stationary Source Enforcement
Office of Energy, Minerals, and Industry Office of Enforcement
Research Triangle Park, NC 27711 Washington, DC 20460
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
-------
NOTICE
This report, (prepared by PEDCo Environmental, Inc.,
Cincinnati, Ohio, under EPA Contract No. 68-02-2603, Task No. 24)
is provided as an information transfer document. Data in this
report are supplied voluntarily by utility representatives; flue
gas desulfurization (FGD) system designers, vendors, and sup-
pliers; regulatory personnel; and others. Neither EPA nor the
designated contractor warrants the accuracy or completeness of
information contained in this report.
This report is the third of five supplementary issues to the
December 1977-January 1978 report. Supplementary issues are
cumulative, so that it is necessary to retain only the latest
issue and the December 1977-January 1978 report (EPA-600/7-78-
051a).
Initial distribution of the report (generally, one copy per
company) is limited to organizations and individuals indicating a
specific interest in the field of FGD technology. Additional
copies of this report and succeeding issues can be purchased from
National Technical Information Service, Springfield, Virginia
22151.
ii
-------
CONTENTS
Notice
Tables
Executive Summary and Highlights
Section 1 Summary List of FGD Systems
Section 2 Status of FGD Systems
Section 3 Performance Description of Operational FGD
Systems
Arizona Public Service
Cholla 1
Cholla 2
Central Illinois Light
Duck Creek 1
Columbus and Southern Ohio Electric
Conesvilie 5
Conesville 6
Duquesne Light
Elrama 1-4
Phillips 1-6
Indianapolis Power and Light
Petersburg 3
Kansas City Power and Light
Hawthorn 3
Hawthorn 4
La Cygne 1
Kansas Power and Light
Lawrence 4
Lawrence 5
Kentucky Utilities
Green River 1, 2, and 3
Louisville Gas and Electric
Cane Run 4
Cane Run 5
Mill Creek 3
Paddys Run 6
Minnkota Power Cooperative
Milton R. Young 2
11
v
vi
1
4
23
23
24
25
26
27
28
30
32
33
34
35
36
3.7
38
40
41
42
43
44
iii
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CONTENTS (continued)
Page
Montana Power
Colstrip 1 45
Colstrip 2 46
Nevada Power
Reid Gardner 1 47
Reid Gardner 2 49
Reid Gardner 3 51
Northern Indiana Public Service
Dean H. Mitchell 11 53
Northern States Power
Sherburne County Station 1 55
Sherburne County Station 2 57
Pennsylvania Power
Bruce Mansfield 1 59
Bruce Mansfield 2 61
Philadelphia Electric
Eddystone 1A 63
Public Service Company of New Mexico
San Juan 1 64
South Carolina Public Service
Winyah 2 65
Springfield City Utilities
Southwest 1 66
Tennessee Valley Authority
Shawnee 10A 67
Shawnee 10B 68
Widows Creek 8 70
Texas Utilities
Martin Lake 1 72
Martin Lake 2 73
Monticello 3 74
Utah Power and Light
Huntington 1 75
Section 4 Summary of FGD Systems by Company 76
Section 5 Summary of FGD Systems by Vendor 77
Section 6 Summary of New and Retrofit FGD Systems by
Process 79
Section 7 Summary of Operating FGD Systems by Process and
Generating Units 80
Section 8 Summary of Sludge Disposal Practices for
Operational FGD Systems 82
iv
-------
CONTENTS (continued)
Page
Section 9 Summary of FGD Systems by Process and Regulatory
Class 83
Section 10 Summary of FGD Systems under Construction 85
Section 11 Summary of Planned FGD Systems 87
Section 13 Total of FGD Megawatt Capacity by Year 90
Appendix A FGD Systems Economics A-l
Appendix B FGD Process Flow Diagrams B-l
Appendix C Definitions C-l
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TABLES
No. Page
I Number and Total MW of FGD Systems vi
II Summary of Changes: FGD Summary Report, April-May
1978 x
III Performance of Operational Units during April-May
Period xi
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EXECUTIVE SUMMARY
This report is prepared every other month by PEDCo Environmental,
Inc., under a contract to the Industrial Environmental Research
Laboratory/RTF and the Division of Stationary Source Enforcement
of the U.S. Environmental Protection Agency. Table 1 summarizes
the current status of the FGD systems addressed in this 2-month
period.
Table I
NUMBER OF TOTAL MW OF FGD SYSTEMS
Status
Operational
Under construction
Planning:
Contract awarded
Letter of intent
Requesting/evaluating bids
Considering only FGD systems
TOTAL
No. of
units
40
42
21
3
4
29
139
MW
14,480
16,834
10,708
1,960
2,255
13,232
59.469
Table II (page x) summarizes the individual units that changed
status during the reporting period.
The performance of the operating systems is summarized in Table
III (page xi). Other activity highlights during the months of
June and July are summarized below:
The present total power-generating capability of the electric
utility industry in the United States is approximately 532.4 GW.a
vii
-------
Of this total, approximately 250 GW,b representing 47 percent of
the total, is generated by coal. As indicated in Table I, 40
FGD-equipped coal-fired units, representing 14,480 MW of power
capability, are now in service. Thus, a little under 3 percent
of the total utility power-generating capacity and a little under
6 percent of the utility coal-fired capacity are controlled by
FGD. By 1986, the projected total power-generating capacity of
the electric utility industry in the United States will be
approximately 812.7 GW.a This represents an increase of 53 per-
cent over the present total and includes retirements of older
units (0.4 percent annual average based on year-end power-
generation capability). Of the 1986 total, approximately 363.2
GWa'b'c, representing 45 percent of the total, will be generated
by coal. As indicated in Table I, 139 FGD-equipped coal-fired
units, representing 59,469 MW of power capacity, are now sched-
uled for operation by 1986. Thus, approximately 7 percent of the
projected total generating capacity and 16 percent of the pro-
jected coal-fired capacity will be controlled by FGD by the end
of 1986.
HIGHLIGHTS: JUNE-JULY 1978
Arizona Public Service reported that construction began on the
limestone FGD system at Cholla 4, which is scheduled to start up
in June 1980 scrubbing 100 percent of the boiler flue gas. A
contract also was awarded for the engineering and construction of
an FGD system at the Arizona Public Service Four Corners 4 and 5
units. The startup of both units is scheduled for 1982.
The FGD system at Duck Creek 1 of Central Illinois Light became
operational on July 24, 1978, when all four modules began opera-
tions for the first time. (One of the modules had operated
intermittently from September 1976 to April 1977.) The system
however has undergone some modifications since initial startup.
The slurry transfer system was modified, after the utility dis-
covered that it was under-designed.
Louisville Gas and Electric awarded a contract to Combustion
Engineering to install FGD systems on Mill Creek 1 and 2. The
combination lime/limestone systems are scheduled to become op-
erational in early 1981 for Unit 1 and 1982 for Unit 2. Mill
Creek 3 of Louisville Gas and Electric became operational on
August 13, 1978. The FGD system is now undergoing shakedown and
debugging operations.
Nevada Power reported that during the reporting period availa-
bilities ranged from 89 to 100 percent for Reid Gardner 1, 2, and
3, while reliabilities were between 79 and 100 percent. in addi-
tion, the utility reported a modification in its original plans
to construct a new unit, Reid Gardner 4, identical to Reid Gardner
•J •
Vlll
-------
The plans for Unit 4 now call for a 250-MW unit that will be
under construction by 1980, with startup scheduled for 1983.
Construction began on the FGD system at the 400-MW Otter Tail
Power unit, Coyote 1. The dry removal FGD system is scheduled to
start up in May 1981.
Public Service of Indiana is now requesting bids for an FGD
system at Gibson 5 and expects to receive bids in September.
Initial operations are scheduled in 1982.
Utah Power and Light awarded a contract to Chemico for an FGD
system at Emery 2. This unit will be identical to Emery 1,
complete with a lime FGD system. Initial startup is scheduled in
June 1980.
A contract was awarded for an FGD system at the Columbia 2 unit
of Wisconsin Power and Light. The FGD system will treat 60
percent of the flue gas generated from the boiler that will burn
low-sulfur coal. Startup is scheduled in January 1980.
The FGD systems at Sherburne'l and 2 of Northern States Power
demonstrated total-system availabilities of 93 and 95 percent,
respectively, in June and 95 percent for both units in July-
ix
-------
Table II. SUMMARY OF CHANGES: FGD SUMMARY REPORT,
JUNE-JULY 1978
FGD status report
5-31-78
Arizona Public Service
Choi la 4
Ariiona Public Service
four corner* 4
Aritona Public Service
Pour Corners 5
Central Illinois Light
buck Creek 1
Louisville Gas and Electric
Mill Creek 1
Louievilla Get and Electric
Mill Creek 2
Louisville Cat and Electric
Hill Creek 3
Nevada Power
Keid Gardner 4
Northern States power
Cherburne 3
Northern States Power
Eharburne 4
Otter Tall Power
Coyote 1
Pennsylvania Power
Bruce Mansfield 3
Public Service of Indiana
Gibson 5
South Carolina Public Serv.
Minyah 3
Texas Utilities
forest Grove 1
Texas Utilities
Martin Lake 2
Utah Power and Light
Ebery 2
•iaeonsin Power 1 Light
Columbia 2
Total
5o7l
37
«1
*1
»1
40
— ffs —
12,862
400
425
793
14,480
Under
-S5~
43
»1
-1
-1
+1
tl
-1 .
-1
42
MV,
17,177
350
400
425
400
125
300
793
16,83*
Contract
awarded
No.
19
-1
*1
41
»1 -
+ 1
-1
*1
-r
-i
+l
+1
»i
21
H1.-;
10,606
350
755
755
330
330
860
ICO
400
Better of
intent
No.
3
-1
+1
+1
625 '
300
400
527
10,708
•1
3
mi
892
129
~ 660
•60
527
i960
Requesting/
eval- bi
16.552 •
755
755
330
330
250
650
750
13,232
Tnr'al
Hb.
136
«1
139
KV,
58,944
+125
400
59.469
-------
Table III.
PERFORMANCE OF OPERATIONAL UNITS
DURING APRIL-MAY PERIOD
Plant
Choi la 1
Choi la 2
Duck Creek 1
Conesville 5
Conesville 6
Elrama
Phillips
Petersburg 3
Hawthorn 3
Hawthorn 4
La Cygne 1
Lawrence 4
Lawrence 5
Green River
1, 2, and 3
Cane Run 4
Cane Rune 5
Mill Creek 3
Paddys Kun 6
M.R. Young 2
Colstrip 1
Colstri- ?
Reid Gardjicr 1
Reid Gardner 2
Reid Gardner 3
U.K. Mitchell
11
Eherburne 1
Sherburne 2
Bruce
Mansfield 1
Bruce
Mansfield 2
Eddystone 1A
San Juan 1
Hinyah 2
Southwest 1
Shawnee 10*
Ehavnee 10B
Hidows Creek 8
Martin Lake 1
Martin Lake 2
Monticello 3
Huntington 1
Total
FGD system
design
capaci ty
115
250
400
400
400
510
410
530
140
100
820
125
400
64
178
183
425
65
450
360
«,n
125
125
125
115
710
710
825
825
120
314
280
200
10
10
550
793
793
750
415
14,4110
FGD unit
period
115
250
400
400
400
310
410
530
820
125
400
64
178
183
425
65
125
125
125
115
710
710
825
825
120
314
280
200
10
10
793
793
250
415
11,820
No
information
per lod
140
100
4SO
360
J60
550
1960
Shutdown
period
200
500
700
FCD system
39
50
73
100
89
100
13
93
95
67
34
t
July
55
71
93
13
100
80
100
6
95
95
P ,
34
41
100
99
86
92
89
96
0
50
49
6:
July
50
28
100
99
80
99
82
80
51
98
100 |
34
43
100
100
100
96
1
50
48
96
100
79
100
4
TGD systcr
34
36
73
99
82
92
89
95
0
0
34
65
49
19
13
91
68
99
74
78
2
96
XI
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REFERENCES
a.
b.
c.
Sixth Biennial Survey of Power Equipment Requirements of the
U.S. Electric Utility Industry: 1977-1986, sponsored by the
Power Equipment Div., National Electrical Manufacturers
Association.
Policy Testing Model for Electric Utilities, Exhibit II-3,
Developed by Temple, Barker, and Sloane, Inc.
12th Annual Power Engineering Survey, Power Engineering,
April 1978.
Xll
-------
FPA UTILITY FGD SURVEY! JUNE 1978 - JULY 1<)78
COMPANY
SFCT10N 1
SUMMARY LIST OF FGD SYSTEMS
UNIT NAME
START UP DATE
REG
STATUS CLASS
ALABAMA ELECTRIC COOP
ALABAMA ELECTRIC COOP
ALLEGHENY POrtFR SYSTtM
ALLEGHENY POWER SYSTEM
A&170NA ELECTRIC PUWER COOP
ARI70MA ElECTRIC POWER COOP
ARI70NA PUBLIC SERVICE
AR170NA piibLic SERVICE
PUBLIC SERVICE
PUBLIC SERVICE
ARI70NA PUBLIC SERVICE
ARI70NA PUBLIC SERVICE
ARI70NA PUBLIC SERVICE
ARI70NA PIIBLIC SERVICE
ASSOCIATED ELECTRIC COOP
8ASIN ELECTRIC POWER COOP
BASIN ELECTRIC POWER COOP
BASTN ELECTRIC POWER COOP
BASIN ELECTRIC POWER COOP
BASIN ELECTRIC POWER COOP
BIS RTVFRS ELECTRIC
BIS RTVFHS ELECTRIC
CENTRAL ILLINOIS LIGHT
CENTRAL ILLINOIS LIGHT
CENTRAL ILLINOIS PUBLIC SERV
CENTRAL MAINE POWER
CINCINNATI GAS S FLFCTRIC
COLORADO LITE ELECTRIC ASSN.
COLORADO UTE ELFCTRIC ASSN.
COLUMBUS ft SOUTHERN OHIO ELEC.
COLUMBUS S SOUTHERN OHIO ELEC.
COLUMBUS S SOUTHERN OHIO ELEC.
COLUMBUS * SOUTHERN OHIO ELEC.
COMMONWEALTH EDISON
COOPERATIVE POWER ASSOCIATION
COOPERATIVE POWER ASSOCIATION
DELMARVA POWER * LIGHT
DUOUESNE LIGHT
DUQUESNF LIGHT
EASTERN KENTUCKY POWER COOP
GENERAL PUBLIC UTILITIES
GENERAL PUBLIC UTILITIES
GULF POWER
GULF POWER
GULF POWER
GULF POWER
HOQSIFR ENERGY
HOOSIFR ENERGY
INDIANAPOLIS POWER & LIGHT
INOTANAPULIS POWER * LIGHT
KANSAS CITY POwFR * LIGHT
KANSAS CITY PnwFK 4 LIGHT
KANSAS CITY POrtFR «. LIGHT
KANSAS POWER * LIGHT
KANSAS PUW£R * Lir.HT
KANSAS PU'IE" * LIGHT
KANSAS POWER * t f,HT
KENTUCKY UTILITIES
LAKELAND iJTILTlIES
LHUISV1LLF GAS ft FLFCTRIC
TClMBTGBtF ?
TOMBTGREF ^
PLFASANTS 1
PLEASANTS ?
APACHE 2
APACHE 3
CHOLt-A 1
CHOLLA 2
CHOLLA
-------
EPA UTILITY FSD SURVEY: JUNE 1<>78 - JULY 1" 7 fl
SECTION 1
SUMMARY LTST OF FGD SYSTf"S
COMPANY NAME
LOUISVILLE GAS S ELFCTRIC
LOUISVILLE RAS * FLECTKIC
LOUISVILLE GAS * ELECTRIC
LOUISVILLE GAS & FLF.CTRTC
LOUISVILLE GAS * ELECTRIC
LOUISVILLE GAS * ELECTRIC
LOUISVILLE GAS & FL6CTRTC
MINNESOTA POWFR S LIGHT
MINNKOTA POWER COOPERATIVE
MONTANA POWER
MONTANA POWER
MONTANA POWER
MONTANA POWER
NEVADA POWER
NEVADA POWER
NEVADA POWER
NEVADA POWER
NEVADA POWER
NEVADA POWER
NEVADA POWER
NEVADA POWER
NEVADA POWER
NEVADA POWER
NEW ENGLAND ELEC SYSTEM
NIAGARA MOHArtK POWER COOP
NORTHERN INDIANA PUB SERVICE
NORTHERN INDIANA PUB SERVICE
NORTHERN INDIANA PUB SERVICE
NORTHERN STATES POWFR
NORTHERN STATES POWER
NORTHERN STATES POWFR
NORTHERN STATES POWER
OTTER TAIL POWER
PACIFIC GAS AND ELECTRIC
PACIFIC GAS AMD ELECTRIC
PACIFIC POWER « LIGHT
PENNSYLVANIA POWER
PENNSYLVANIA POWER
PENNSYLVANIA POWER
PHILADELPHIA ELECTRIC
PHILADELPHIA ELECTRIC
PHILADELPHIA ELECTRIC
PHILADELPHIA ELECTRIC
POTOMAC ELECTRIC POWER
POWER AUTHORITY OF NEW YORK
PUBLIC SERVICE OF INDIANA
PUBLIC SERVICF OF NEW MEXICO
PUBLIC SERVICE OF NEW MEXICO
PUBLIC SERVICE OF NEW MEXICO
PUBLIC SERVICE OF NEW MEXICO
SALT RIVER PROJECT
SALT RIVER PROJECT
SALT PJVER PROJECT
S»N MIGUEL ELFCTHIC COOP
STKFSTON BO«RO OF MIINIC. UTIL.
SOUTH CAROLINA PUBLIC SERVICE
SOUTH CAROLINA PUBLIC SERVICE
SOUTHERN ILLINOIS POWER COOP
SOUTHERN ILLINOIS POWER COOP
SOUTHERN INDIANA GAS 8 ELFC
j f nPFRAl TONAL UNITS
2. MNTTS UNDER CONSTRUCTION
-5. PLANNED - CONTRACT AWARDED
UNIT NAM|_
CANE RUN S
CANE KUN 6
MILL CREEK 1
MILL CREEK 2
MILL CREEK 3
MILL CREEK u
PADDYS RUN b
CLAY BOSWELL 1
MILTON R. YOUNG 2
COLSTRIP 1
COLSTRTP 2
COISTRIP 3
COLSTRIP a
HARRY ALLEN i
HA9KY ALLEN 2
HARRY ALLEN 3
HARRY ALLEN 1
REID GARDNER 1
REID GARDNER 2
REID GARDNER 3
REID GARDNER a
WARNER VALLEY 1
WARNER VALLEY 2
BRAYTON POINT 3
CHARLES R. HUNTLFY
BAILLY 7
RAILLY e
DEAN H. MITCHELL i'
SHERBURNE 1
SHERBURNF 2
SHERBURNE 3
SHERBURNF a
COYOTE 1
FOSSIL 1
FOSSIL 2
JIM BRIDGER a
BRUCE MANSFIELD 1
BRUCE MANSFIELD ?
BRUCE MANSFIELD 3
CROMBY
EDOYSTONE 1A
FOOYSTONF IB
EDDYSTONF 2
DICKERSON «
ARTHUR KILL PLAIvT
GIBSON 5
SAN JUAN 1
SAN JUAN 2
SAN JUAN 3
SAN JUAN 4
CORONAOO 1
CORONADO 2
CDRONADO 3
SAN MIGUFL i
SIKESTON POWFR STflT
WINY AH 2
WINY AH 3
MARION t
MARION 5
A. B. BROWN 1
TART UP I
A1F ST&TUS CLASS
12-77
12-7B
1-fll
1-82
B-78
6-80
4-73
•5-flO
9-77
11-75
8-76
7-SO
7-fll
h-»5
h-Hh
h-«7
h-«h
n-7 a
H-7n
7-7h
0-S.5
ft-fil
6-S6
0- 0
0-Sci
(1- 0
0- 0
I 1 -76
^-76
u-n
F-att
n- o
•^-81
i;-8/i
O.R5
Q-79
a-76
7-77
i-flu
h-Rl)
"-75
1;
Q-7h
0-MiJ
'1-79
1
2
3
6
\
2
1
2
1
1
1
3
3
b
b
b
b
1
1
1
6
b
b
b
3
b
b
1
t
1
4
4
2
6
b
2
1
t
Z
b
1
a
b
7
7
5
1
2
3
b
2
2
6
2
2
1
3
i
b
I
B
R
B
B
R
B
C
A
B
A
A
R
B
A
A
A
A
C
C
C
C
C
R
B
B
B
B
fl
R
B
R
B
ft
B
R
R
B
n
B
A
B
B
B
R
R
B
R
t
A
A
A
A
A
A
a,
s.
6.
7.
PLANNED - I.ETTF^ OF T.^TEM siu'-fcf1
PLANNED - REQLIC:;T[irg
CONSIDERING OM Y f-Rn SYSTEM
roNSTDFKING FC,n srSTFV: AS «?LL AS A I.
T I VE METHODS
POTLFR cnNSTPucrFD SUBJECT TO FEOERAI NSPS
BOILER SUBJECT ' "> STATF STANDARD THAT TS MORE STRINGENT THAN THE FEDFRAI
IMITCr 70 SIATF STANDARD THflT IS tOU«L TO OS LESS STRINGENT THAN
CL»SS UNh NO"N
-------
EPA UTILITY FGO SURVEY: JUNE 1178 - JULY 1978
COMPANY NAME
SECTION 1
SUMMARY LIST OF FGD SYSTEMS
UNIT NAME
START UP OATF
STATUS
RFG
CLASS
SOUTHERN MISSISSIPPI ELECTRIC
SOUTHERN MISSISSIPPI ELECTRIC
SOUTHWESTERN ELECTRIC POWER
SPRINGFIELD CTTY UTILITIES
SPRINGFIELD WATER LIGHT & PWR
ST. JOE ZINC
TFNNESSEE VALLEY AUTHORITY
TENNESSEE VALLEY AUTHORITY
TFNNESSEE VALLEY AUTHORITY
TENNESSEE VALLEY AUTHORITY
TEXAS MUNICIPAL POWFR AGENCY
TEXAS POWER & LIGHT
TEXAS POWER & LIGHT
TFXAS POWER & LIGHT
TEXAS UTILITIES
TEXAS UTILITIES
TEXAS UTILITIES
TFXAS UTILITIES
TEXAS UTILITIES
TEXAS UTILITIES
UTAH POWER « LIGHT
UTAH POWER * LIGHT
UTAH POWER R LIGHT
VIRGINIA ELECTRIC & POWER
WISCONSIN POWER & LIGHT
R, D. MORROW 1
R. 0. MORROW 2
HENRY w. PERKEY i
SOUTHWEST 1
DALLMAN 3
G. F. WEATON 1
SHAWNEF 104
SHAWNEE 10R
WIDOWS CREFK 7
WIDOWS CREEK 8
GIRBONS CRFEK 1
SANDOW 4
TWIN OAKS 1
TWTN OAKS 2
FOREST GROVE i
MARTIN LAKE 1
MAPTIN LAKE 2
MARTIN LAKE 3
MARTIN LAKE a
MONTICELLO 3
EMERY 1
EMERY 2
HUNTINGTON 1
MT. STORM
COLUMBIA 2
8-78
10-78
6-83
4-77
7-80
10-78
4-72
«-72
10-80
5-77
i-82
7-80
8-83
0-84
0-81
8-77
5-78
l?-78
11-82
•5-78
12-78
fe-80
5-78
0- 0
1-80
2
2
3
1
3
2
1
1
3
1
3
3
6
b
5
1
1
2
3
1
2
3
1
7
3
A
A
A
A
A
R
r
c
c
c
A
c
A
1. OPERATIONAL UNITS
2. UNITS UNDER CONSTRUCTION
3. PLANNED - CONTRACT AWARDED
4. PLANNED - LETTFR OF TNTENI SIGNED
5. PLANNED - REQUESTING/EVALUATING RIPS
6. CONSIDERING ONLY Fr,D SYSTtVS
7. CONSIDERING FGD SYSTEMS AS /«FLI AS ALTFRN'STIVE METHODS
A. BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
B. BOILER SUBJECT TO STATE STANDARD THAT IS MORE STRIMGEMT THM THE FEDFRAL
C. BOILER SUBJECT TO STATE STANDARD THAT IS EOUAL TO OR LFSS STRINGENT THAN
0. OTHER
F. REGULATORY CLASS UNKNOWN
-------
FP« IHTLTTY
SUR\/FY: .niNt 197* - JULY 1979
SECTION ?.
STATUS OF FGD SYSTEMS
DM IT IDENTIFICATION
CURRENT STATUS
A^eAMr^ECTRTc'cnuP PFABODY ENGINEERING HAS BEEN AWARDEDi A "NTRjJCT FOR THE INSTALLATION
TO^BTGREF ? OF A LIMESTONE FliD SYSTEM ON THIS UNIT. A HIGH-EFFICIENCY ESP WILL
?js MW - Nt'1 BF INSTALLED UPSTREAM OF THE FGO SYSTEM TO PROVIDE PRIMARY
COAL 0.8 - 1 5 PERCENT SULFUR PARTICULATE CONTROL. THF FGD SYSTEM CONTAINS TWO SCRUBBING TRAINS,
PEABODY FNG NFFRTNR TREATING APPROXIMATELY 70 PERCENT OF THE FLUE GAS FOR REMOVAL OF SULFUR
,IMESTnNF DIOXIDE. STACK f,AS REHEAT WILL NOT BE REQUIRED. ERECTION OF THE SCRUBBING
STARTUP 9/78 EOUIPMENT IS NOW IN FINAL PHASE.
ALABAMA FLFCTRTC COOP
TOMBTGREE 3
?25 MW - MEW
CO»L 0.8 - l.b PERCENT SULFUR
°EA80DY ENGINEERTNP
I. IMESTDNE
STARTUP 6/79
PFAROOY ENGINEERING HAS BFEN AWARDED A CONTRACT FOR THE INSTALLATION
OF A LIMESTONE FGD SYSTEM ON THIS UNIT. A HIGH-EFFICIENCY ESP KILL
BF INSTALLED UPSTREAM OF THE FGD SYSTEM TO PROVIDE PRIMARY
PARTICULATE CONTROL. THE FGD SYSTFM CONSISTS OF TWO TRAINS, TOGETHER
TREATING APPROXIMATELY 70 PERCENT OF THE FLUE GAS FOR REMOVAL OF SULFUR
DIOXIDE. STACK GAS REHEAT WILl NOT BE REQUIRED. CONSTRUCTION ON THE UNIT J
TURBINE AND BOILER HAS RERUN AND IS 30 TO 10 PERCENT COMPLETE.
ALLEGHENY POWER SYSTFM
PLFASANTS 1
h2S MW - NEW
COAL <4.5 PERCENT SULFUR fMAX)
BARCOCK * WILCOX
I IME
STARTUP 3/79
TH£ THRFE PRINCIPAL OPERATING UTILITY COMPANIES OF THE ALLEGHENY POWER
SYSTEM ARE INSTALLING AN EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED
UNIT WHICH INCLUDES A HIGH EFFICIENCY ESP UPSTREAM OF FOUR TRAY TOWERS
EOR THE CONTROL OF PARTICIPATES AND SULFUR DIOXIDE. DESIGN REMOVAL
EFFICIENCIES FOR THIS EMISSION CONTROL SYSTEM ARE 99.5 AND 90 PERCENT
RESPECTIVELY. THE ORAVO CD. IS SUPPLYING THIOSORBIC LIME. THE CONSULTING
ENGINEERING FIRM IS UNITED ENGINEERS AND CONSTRUCTORS. CURRENTLY, EREC-
TION DF THE SCRUBBING EQUIPMENT IS IN PROGRESS.
ALLEGHENY POWER SYSTFM
PLEASANTS ?
f>25 MW - MEW
COAL 1.5 PERCENT SULFUR fMAX)
BABCOCK * WILCOX
1.1ME
STARTUP 3/SO
ARIZONA ELECTRIC POWER COOP
APACHE 2
200 MW - NEW
COAL 0.5- 0.8 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE
STARTUP 9/78
ARIZONA ELECTRIC POWER COOP
APACHE 3
200 MW - NEW
COAL 0.5- 0.8 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE
STARTUP 1/79
THE THRFE PRINCIPAL OPERATING UTILITY COMPANIES OF THE ALLEGHENY POWER
SYSTEM ARE INSTALLING AN EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED
UNIT WHICH INCLUDES A HIGH EFFICIENCY ESP UPSTREAM OF FOUR TRAY TOWERS
FOR THE CONTROL OF PARTICULATES AND SULFUR DIOXIDE. OESI6N REMOVAL
EFFICIENCIES FOR THIS EMISSION CONTROL SYSTEM ARE 99,5 AND 90 PERCENT,
RESPECTIVELY. THE DRAVO CO. IS SUPPLYING THIOSORBIC LIME. THE CONSULTING
ENGINEERING FIRM IS UNITED ENGINEERS AND CONSTRUCTORS. CURRENTLY, FOUNDA-
TION WORK ON THE SCRUBBER PLANT IS IN PROGRESS.
AEPC HAS AWARDED A CONTRACT TO RESEARCH COTTRELL FOR A LIMESTONE FGD
SYSTEM. THE UNIT WILL FIRE BITUMINOUS COAL WITH A SULFUR CONTENT OF
0.5-o.sx AND ASH CONTENT OF io.ox (HEATING VALUE - 10,000-11,OOOBTU/LBJ.
THE DESIGN INCLUDES A 22 ACRE SLUDGE POND AMD A 61 ACRE ASH POND, BOTH
UNLINED AND 10 FEET DEEP. THERE WILL BE NO REHEAT. CONSTRUCTION OF THE
SYSTEM IS NEARLY COMPLETE AND ALL FGD EQUIPMENT IS INSTALLED. THE LINERS
USED IN THE STACK AND THE DUCTS THAT LEAD TO THE STACK WILL BE A NEW
COLE BRAND CXL2000 LINING WHICH HAS A VERY HIGH HEAT RESISTANCE.
STRUCTURAL STEELWORK FOR HOT-SIDE UOP ESP'S IS COMPLETE. STRUCTURE
ERECTION OF THE SCRUBBED-ABSORBFR TOWERS IS COMPLETE. EACH SCRUBBER CAN
HANDLE 100,000 ACFM Si 870 F AND RFCIRCULATE 20,000 GPM OF SLURRY. BOILER
CONSTRUCTION HAS BEGUN. THERE ARE CURRENTLY 2 PONDS WITH A TOTAL OF 20-
YRS CAPACITY FOR THE DISPOSAL OF THE UNFIXATED SLUDGE. 2 ADDITIONAL PONDS
A"E PLANNED PROVIDING AN ADDITIONAL 20 YRS OF DISPOSAL CAPABILITY. THERE
WILL BE NO REHE'T. BECAUSE OF THE HIGH COST OF THF UNIT 2 STACK LINER,
UNIT 3 WILL USE A CEILCOTF LINING INSTEAD OF THF CXL2000 USED IN UNIT 2,
ARIZONA PUBLIC SERVICE
CHOLLA 1
115 MW - RETROFIT
COAL: o.ss* SULFUH, tox ASH
RESEARCH COTTRfLL
L JMESTONE
STARTUP 10/73
REFER TO SECTION ^ OF THIS REPORT FOR ADDITIONAL INFORMATION.
THIS LIMESTONE SCRUBBING SYSTEM WAS PLACED IN SERVICE IN OCTOBER 1973.
THE SCRUBBER PLANT CONSISTS OF TWO PARALLEL SCRUBBING TRAINS. PARTICU-
LATE CONTROL TS PROVIDER BY TWO FIOODED-DISC SCRUBBERS. 302 CONTROL IS
PROVIDED BY ONE PACKED (MIINTERS PACKING) TOWER CA-SIDE). FLUE GAS CLEAN-
ING WASTES ARE DISCHARGED TO AN EXISTING FLY ASH POND. NO WATER IS RE-
CYCLED BACK FROM THE DISPOSAL PONH. IN-LINE STEAM REHFATERS RAISE THE
GAS TEMPERATURE 10 F.
6RI/ONA PUBLIC SERVICE
CHOLLA 2
?bO MW - NtW
CO«L; o.s% SULFUR, 104 ASH
RESEARCH COTTRFLL
I IMESTONF
STARTUP d/7»
THE CONTRACT FOR THIS WET LIMESTONE SCRUBBING SYSTEM HAS BEEN AWARDED
BY THF UTILITY TO RESEARCH-COTTRELL. THERE ARE MECHANICAL COLLECTORS FOR
PRIMARY PARTICULATE REMOVAL. THE FGP SYSTEM CONSISTS OF FOUR PARALLEL
FLOODED-nlSr AND PACKED TOWER ABSORBER TRAINS. THRgF. ARE RFQiiTPFn rna FULL
LOAD CAPACITY. INITIAL OPERATIONS BEGAN IN JUNE 1978. COMPLIANT?TCQTTMr
WAS COMPLETED DURING THE SECOND WFEK OF AUGUST 1978. FULL COMMPOrr,, noFB.
AT1DNS SHOULD OCCUR BY AUGUST 1978. UL t-"MME"CtAL OPER
-------
EPA UTILITY Fr,n SURVEY: JUME i<>78 - JULY 1978
SECTION ?
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
ARIZONA PUBLIC SFRVTCF
CHOLIA MM. EOR CONTROL OF PARTICULATE AN ESP WILL HANDLE 100%
OF THF ELUfc GAS.
APS Will RF UPGRADING THE OPERATIONAL PARTICUIATE SCRUBBERS AT THF FOUR
CORNERS i, ? «ND 3 FOR ADDITIONAL soa REMOVAL. CURRENTLY, EACH UNIT HAS s
CHEMICO VENTURI SCRUBBER MODULES FOR PARTICULATF CONTROL. ROUGHLY 30% OF
THE FLUE RAS SO? CONTENT IS REMOVED AT THE PRESENT TIME IN THF VENTURIS
WITH THE HIGH ALKALINE FLYASH. NEW MEXICO APC OFFTCALS INDICATED THAT
THE 5 FOUR CORNERS UNITS WILL HE REOUTREO TO REMOVE AT LEAST 67.5% OF THE
STATION S02 (ALL 5 UMTS CONSIDERED TOGETHER), ADDITIONAL ALKALINITY WILL
BE IMPARTED TO THF SCRUBBING SOLUTION BY ADDING LIME*
ARIZONA PUBLIC SERVICE
FOUR CORNERS a
175 MW - RETROFIT
COAL 0.75 PERCENT SULFUR
CHFMTCO/APS
LIME/ALKALINF FLVASH
STARTUP O/ 0
4PS WILL BE UPGRADING THE OPERATIONAL PARTICULATE SCRUBBERS AT THE FOUR
CORNERS UNIT NOS. 1, ? AND 3 FOR ADDITIONAL S02 REMOVAL. EACH UNIT HAS 2
CHEMICO VENTUHI SCRUBBER MODULES FOR PARTTCULATE CONTROL. ROUGHLY 30% OF
THE FLUE GAS SO? CONTENT TS REMOVED AT THE PRESENT TIME IN THF VENTURIS
WITH THF HIGH ALKALINE ELYASH. NEW MEXICO APC OFFICALS INDICATED THAT
THE 5 FOUR CORNERS UNITS WILL HE REOUTRFD TO REMOVE »T LEAST 67.5% OF THE
STATION SO? (ALL S UNITS, CONSIDERED TOGETHER). AODITONAL ALKALINITY WILL
BF IMPARTED TO THF SCRUBBING SOLUTION BY ADDING LIME.
ARIZONA PUBLIC SERVICE
FOUR CORNERS 3
?a
-------
EPA UTILITY FGD SURVEY: JUNE 197ft - JULY 197ft
SECTION ?
STATUS OF FRO SYSTEMS
UNIT IDENTIFICATION
CURPF.M STATUS
RASIN ELECTRIC POWFR COOP
ANTELOPE VALLEY 2
455 MW - NEW
LIGNITE 0.68 PERCENT SULFUR
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 11/83
THE UTILITY IS TENTATIVELY TNVESTT6ATINP VAPIOuS EGO PROCFSSES FOR THIS
SECONO LIGNITE-FIRED UNIT SCHEDULED AT THE NtW STATION IQCATErt IN MERCER
COUNTY, NEAR RtULAH, NORTH DAKOTA. THIS NFrt FACILITY WILL BE KNOWN AS
T«E ANTELOPE VALLEY STATION AND WILl RE REQUIRED TO COMPLY WITH STATE AIK
EMISSION STANDARDS VIA THE REST AVAILABLE TECHNOLOGY. START-UP TS NOW
SCHEDULED FOR NOVEMRER 19*3.
RASIN ELECTRIC POWER COOP
LARAMIE RIVER 1
570 MW - NEW
COAL 0.8 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE
STARTUP «/80
RESFARCH-COTTRELL IS CURRENTLY FABRICATING THF DUAL-LOOP LIMESTONE WET
SCRUBRERS. ON-SITF CONSTRUCTION COMMENCED IN JANUARY 1978. SLUDGE WILL BE
DEWMERED TO «3X SOLIDS BEFORE LANDFILL. THE SCRUBBERS WILL 8F MADE OF
STAINLESS STEEL AND WILL HANDLE 2.3 MM ACFM AT ?86 F. L/G RATIO WILL RE
60. B*W HAS BEEN SWARDED A CONTRACT FOR TWO ESP'S. THF DESIGN DOES NOT
INCLUDE STACK GAS REHEAT. COOLING TOwFR SLOWDOWN WILL BE USED FOR MAKE-UP
IN THIS CLOSED LOOP SYSTEM. CONSTRUCTION IS NOW IS PERCENT COMPLETE.
BASIN ELECTRIC POWER COOP
LARAMJE RIVER 2
570 MW - NEW
COAL 0.8 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE
STARTUP 10/80
RESEARCH-COTTRELL IS CURRENTLY FABRICATING THE DUAL-LOOP LIMESTONE WET
SCRUBBERS. ON-STTE CONSTRUCTION COMMENCED IN JANUARY 1978. SLUDGE WILL BE
OEWATFRED TO «3% SOLIDS BEFORE LANDFILL. THE SCRUBBERS WILL BE MADE OF
STAINLESS STEEL AND WILL HANDLE 2.3 MM ACFM AT 286 F. L/G RATIO WILL BE
60. B*W HAS BEEN AWARDE" A CONTRACT FOR TWO ESP'S. THE DESIGN DOES NOT
INCLUDE STACK GAS REHEAT. COOLING TOWER SLOWDOWN WILL BE USED FOR MAKE-UP
IN THIS CLOSED LOOP SYSTEM. CONSTRUCTION IS NOW 1? PERCFNT COMPLETE.
BASIN ELECTRIC POWER COOP
LARAMIE RIVER 1
550 MW - NEW
COAL 0.8 PERCENT SULFUR
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 4/82
THE UTILITY IS STILL CONSIDERING VARIOUS FGD PROCESSES. LARAMIE RIVER
STATION WILL FIRE SUB-BITUMINOUS COAL WITH THE FOLLOWING CHARACTERIS-
TICS: 8100 8TU/LB, 0.8 PERCENT SULFUR AND 7.0 PERCENT ASH.
RIG RIVERS ELECTRIC
REID 2
250 MW - NEW
COAL 3.5-4.0 PERCENT SULFUR
AMERICAN AIR FILTER
LIME
STARTUP 12/79
THE EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED UNIT TS HFING SUP-
PLIED BY AMERICAN AIR FILTER. THE SYSTEM WILL CONSIST OF A COLO-SIDE ESP
AND TWO SPRAY TOWERS CONTROLLING PARTICULATE AND S02 TO 99.6 PERCENT AND
90 PERCENT, RESPECTTVLEY. THE B*W BOILER WILL FIRE HIGH SULFUR (3.5 TO
a.5 PERCENT) WESTERN KENTUCKY COAL. CONSTRUCTION is NOW 55 PERCENT
COMPLETE ON THE BOILER AND 27 PERCENT COMPLETE ON THE FGD SYSTEM. THE
DESIGN INCLUDES AN INDIRECT HOT AIR REHEAT SYSTEM. IUCS WILL CONSTRUCT A
SLUDGE DISPOSAL SYSTEM TO SERVICE BOTH REID 2 AMD 3.
RIG RIVERS ELECTRIC
REID 3
240 MW - NEW
COAL 3.5-4.0 PERCENT SULFUR
AMERICAN AIR FILTER
LIME
STARTUP 12/80
THE EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED UNIT IS BFING SUP-
PLIED BY AMERICAN AIR FILTER. THE SYSTEM WILL CONSIST OF A COLD-SIDE ESP
AND TWO SPRAY TOWERS CONTROLLING PARTICULATE AND S02 TO 99.6 PERCENT ANCI
90 PERCENT, RESPECTIVELY. THE BSw BOILER WILL FIRE HIGH SULFUR (3.5 TO
4.5 PERCENT) WESTERN KENTUCKY COAL. THE FGO SYSTEM WILL INCLUDE AN
INDIRECT HOT AIR REHEAT SYSTEM. IUCS WILL CONSTRUCT A SLUDGE DISPOSAL
SYSTEM TO SERVICE BOTH REID 2 AND 3. THF BOILER IS CURRENTLY UNDER CON-
STRUCTION.
CENTRAL ILLINOIS LIGHT
DUCK CREFK 1
aoo MW - NEW
COAL: 2.75* SULFUR, 8.5X ASH
RILEV STOKER / ENVIRONEF.RING
LIMESTONE
STARTUP 7/78
CENTRAL ILLINOIS LIGHT
DUCK CREEK 2
400 MW - NEW
COAL 2.5-3.0 PERCENT SULFUR
VENDOR NOT SELECTED
LIMESTONE
STARTUP 1/82
RILEY STOKER IS THE SUPPLIER OF THE FOUR VENTURI-SORBER MODULES AT THIS
UNIT. SCRUBBER TANKS AND PUMPS WILL 9F NEOPRENE LINED. A HIGH EFFICIENCY
ESP IS INSTALLED UPSTREAM OF FOUR VENTURI-SORRER SCRlJPBER MODULES FOR
PARTICULATE CONTROL. THE CONCRETE STACK IS LIMED WITH CEILCOTE FLAKFLINE
151. MO REHEAT SYSTEM IS INCLUDED. THF FIRST LIMESTONE SLURRY SCRUBBER
MODULE WAS PLACED IN SERVICE ON SEPTEMBER 9, I97h, AND OPERATED INTERMIT-
TENTLY UNTIL APRIL 1,1977. ALL FOUR MODULES BECAME OPERATIONAL ON JULY ?4,
1978.
THE UTILITY HAS NOT YEI SELECTED A SYSTEM SUPPLIER. A DECISION CONCERNING
THE STATUS OF THE BOILER AND CONTROL STRATEGY ivILI. BE ANNOUNCED IN LATE
1978. THE UTILITY WILL USF FSP'R FOR PARTICULATF CONTROL AND EITHER LIME-
STONE OR DOUBLE ALKALI FOR S02 ABSORPTION. THE UTILITY Is NOW IN THF
PROCESS OF TAKING BIOS.
-------
EPA UTILTTY FGD SURVEY: JUNE 197B - JULY
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
CENTRAL TLI INOTS PUBLIC SERV
NEWTON i
•575 MW - NEW
COAL 1.0 PERCENT SULFUR
BUFLI./ENVIROTECH
DOUBLE ALKALI
STARTUP 11/79
A CONTRACT HAS REFN AWARDED BY CTPSCd TO RUFLI XFNVIROTFCH FOR THF
INSTALLATION OF AN EMISSION CONTHOL SYSTEM ON UNIT NO. 1. THE KEY COM-
PONENTS OF THE EMISSION CONTROL SYSTEM INCLUDE: A HIGH-EFFICIENCY ESP;
FOUR PRECOOLERS, FOUR POLYSPHEHF ABSORBERS, THREE THICKENERS, TWO EX-
PERIMENTAL REHEAT SYSTEMS, «ND THREE HORIZONTAL EXTRACTION FILTERS FOR
SLUDGE OEWATERING. APPROXIMATELY (15 PFRCENT OF THF CONSTRUCTION WORK
AT THE PLANT HAS REFN COMPLETED. THE FGD SYSTEM WTU HAVE CEILCOTF-
LTNED ABSORBER MODULES.
CENTRAL MAINE POWER
SEARS ISLAND 1
600 MW - NEW
COAL SOURCE UNDETERMINED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 11/B6
BECAUSE OF THF DISCOVERY Of A GEOLOGICAL FAULT ON SFARS ISLAND, THE
UTILITY HAS CANCELLED PLANS FOR A 1150-Mnl NUCLEAR POWER PLANT. A
600-MW COAL-FTMED UNIT IS NOW BEING PLANNED PI ITS PLACE. COMMERCIAL
OPERATION IS PROJECTED FOR NOVEMBER 1986. COMPLIANCE WITH S02 NSPS WILL
BE ACHIEVED BY INSTALLING AN FGD SYSTEM. LIME AND LIMESTONE SCRUBBING
PROCESSES ARE BFING GIVEN PRIMARY CONSIDERATION. CURRENTLY, CMPCO HAS
FILED AN APPLICATION WITH THE STATE PUBLIC UTILITIES COMMISSION. AN EN-
VIRONMENTAL PERMIT APPLICATION WILL BE FILED 'rtlTHIN THE NEXT TWO YEARS.
CINCINNATI GAS & ELECTRIC
EAST BEND 2
AOO MW - NEW
CO»L
BABCOCK S WILCOX
LIME
STARTUP 1/fll
A CONTRACT HAS REFN CONDITIONALLY AWARDED TO f'SBCOCK AND WILCOX FOR A
COMMERCIAL LIME SCRUBBING SYSTEM. THE COAL SOURCE IS EXPECTED TO BE A
MID-WESTERN COAL WITH A HIGH SULFUR CONTENT. IMF THREE LIME SLURRY FGD
MODULES WILL BE PRECEDED RY AN ESP FOR PARTICIPATE CONTROL. SLUDGE WILL BE
DISPOSED OF ON-SITE USING A DRY FIXATION SYSTEM. THE A-E DESIGN FIRM IS
SARGENT AND LUNDY. FGD SYSTEM CONSTRUCTION WILL BEGIN IN EARLY 1979.
COLORADO UT£ ELECTRIC ASSN.
CRAIG 1
450 MW - NEW
COAL 0.45 PERCENT SULFUR
PEABODY ENGINEERING
LIMESTONE
STARTUP 3/79
COLORADO UTE ELECTRIC ASSN.
CRAIG 2
450 MW - NEW
COAL 0.45 PERCENT SULFUR
PEABODY ENGINEERING
LIMESTONE
STARTUP 3/79
COLUMBUS S SOUTHERN OHIO ELEC.
CONESVILLE 5
400 MW - NEW
COAL? 0,7% SULFUR, 15.IX ASH
AIR CORRECTION DIVISION, UOP
LIME (MG-PROMOTEO)
STARTUP 1/77
PEABOOY ENGINEERED SYSTEMS HAS BEEN AWARDED A CONTRACT TO DESIGN AND
SUPPLY A LIMESTONE SLURRY SPRAY TOWFR ABSORBER SYSTEM FOR S02 REMOVAL
FROM LOW-SULFUR COAL-FIRED BOILER FLUE GAS FQf> UNITS 1 AND 2. PARTIC-
ULATE CONTROL WILL BE PROVIDED BY HOT-SIDE ESP'S UPSTREAM OF THE SCRUBBER
PLANT. SLUDGE WILL BE STABILIZED AND HAULED TO A MINEFILL. THERE WILL BE
A STEAM COIL TYPE STACK GAS REHEATER INCLUDED. REQUIRED PARTICULATE AND
502 REMOVAL EFFICIENCIES ARF 99.8 AND 85 PE9C''NTf RESPECTIVELY. FGD SYSTEM
CONSTRUCTION IS NOW SOX COMPLETE.
PEABODY ENGINEERED SYSTEMS HAS BEEN AWARDED A CONTRACT TO DESIGN AND
SUPPLY A LIMESTONE SLURRY SPRAY TOWFR ABSORBER SYSTEM FOR S02 REMOVAL
FROM LOW-SULFUR COAL-FIRED BOILER FLUE GAS FC" UNITS 1 AND 2. PARTICULATE
CONTROL WILL BE PROVIDED BY HOT-SIDE ESP'S UPSTREAM OF THE ABSORBER
SYSTEM. SLUOGF WILL BE STABILIZED AND HAULED 50 A MINEFILL. THERE WILL BE
A STEAM COIL TYPE STACK GAS REHEATER INCLUOEr. REQUIRED PARTICULATE AND
502 REMOVAL EFFICIENCIES ARE 99.8 AND 85 PERCENT, RESPECTIVELY. FGO
CONSTRUCTION IS NOW SOX COMPLETE.
REFER TO SECTION 3 OF THIS REPORT FOR ADDITK
BOILER AND FSP WERE COMPLETED AND PLACED IN S
THE 8-SIOE MODULE BECAME AVAILABLE FOR SERVIC
COMMERCIAL OPERATIONS WERE ACHIEVED ON FEBRU*
CONTROL SYSTEM FOR THIS UNIT CONSISTS OF A CC
TWO LIME TCA MODULES SUPPLIED BY UOP. DRAVO >
LIME REAGENT. lues is SUPPLYING A POZ-U-TFC s
FACILITY.
"AL INFORMATION. THE
i'HVICE IN SEPT. 1976.
," IN JANUARY 1977.
'Y 13, 1977. THE EMISSION
LD-STOE FSP FOLLOWED BY
5 SUPPLYING THE THIOSORBIC
.UDGF STABILIZATION
COLUMBUS * SOUTHERN OHIO ELEC.
CONESVILLE 6
400 MW - NEW
COAL? 4.67X SULFUR, 15.IX ASH
AIR CORRECTION DIVISION, UOP
LIME (MG-PROMOTED)
STARTUP 6/78
THE UTILITY SIGNED LONG-TERM CONTRACTS WITH OfAVO FOR THE PURCHASE OF
THIOSORBIC LIME AND WITH IUCS FOR A SLUDGE FIXATION SYSTEM. CON-
STRUCTION OF THIS UNIT COMMENCED IN 1977 AND '"AS COMPLETED IN JANUARY
1978. SIMILAR TO CONESVILLE NO.5, THIS MINE hflUTH PLANT BURNS COAL
WITH 17 PERCENT ASH CONTEMT AND 4.5 TO 4.9 PERCENT SULFUR CONTENT.
THERE IS AN ELECTROSTATIC PRECIPITATOR UPSTRt. >1 OF THE FGO SYSTEM.
THE FGD SYSTEM INCLUDES TWO TCA MODULES FOR ' "E REMOVAL OF SO?. THE A-E
DESIGN FIRM IS BLACK AND VEATCH. THE UNIT BECAME OPFRATIONAL IN JUNE 1978.
COLUMBUS & SOUTHERN OHIO ELEC.
POSTON 5
375 MW - NEW
COAL 2.5 PFRCENT SULFUR
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 0/83
THIS UNIT WTLL BURN HIGH SULFUR OHIO COAL (*1 VROXIMATELY 2.5 PERCENT
SULFUR CONTENT). THE DESIGN OF THF EMISSION C^TROL STRATEGY HAS
NOT YET BEEN FINALIZED. THE PROCESS WILL EIThfR 8E LIME, LIMESTONE, OR
DOUBLE ALKALI.
-------
nrTLTTY FC.R SURVEY: JUNE
- JULY 197s
SECTION a
STATUS OF FRD SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
COLUMBUS « SOUTHERN OHIO ELEC.
POSTON 6
37S MW - NEW
CO«L 2.5 PERCENT SULFUR
VtNDnR NOT SELECTED
PROCFSS MOT SELECTED
STARTUP 0/S5
THIS UNIT WILL RURN HIGH SULFUR COAL (APPROXIMATELY 2.5 PERCENT
SULFUR rONTFNT). THE DESIGN OF THF EMISSION CONTROL STRATEGY
FOR THIS UNIT HAS NOT YET BEEN FINALIZED.
COMMONWEALTH EDISON
PUWERTON si
125 MW - RETROFIT
COAL 3.6 PERCENT SULFUR
AIR CORRECTION DIVISION, UOP
I IMEST"NF
STARTUP 3/79
THE AIR CORRECTION OIVISION OF UOP WAS AWARDED THF CONTRACT FOR A WET
LIMESTONE SYSTEM THAT WILL BE BACKFITTEO ONTO BOILER NO. 51, ONE OF TWO
IDENTICAL BOILERS SUPPLYING STEAM TO AN 850-MW TURBINE-GENERATOR. THE
SLUOGF WILL BE STABILIZED AND HAULED TO A LANDFILL. REHEAT WILL BE
PROVIDED BY A STEAM COIL WHICH WILL HEAT THE AMBIENT AIR THAT IS PUMPED
INTO THE SCRUBBER OUTLET BEFORE THE FLUE GAS ENTERS THE STACK. THE 302
EMISSION STANDARD IS I.S LB. S02/MM 8TU. CURRENTLY, EXCAVATION, BACKFILL,
AND STRUCTURAL STEEL ERECTION IS IN PROGRESS.
COOPFRATTVF POWER ASSOCIATION
COAL CREFK 1
5«5 MW - NEW
LIGNTTF - O.ft3 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME
STARTUP 2/79
THIS UNIT IS UNDER THE COMBINED OWNERSHIP OF COOP POWER AND UNITED POWER.
A CONTRACT HAS BEEN AWARDED TO COMBUSTION ENGINEERING FOR THE INSTALLA-
TION OF LIME FGD SYSTEMS ON UNITS 1 AND 2 AT THIS STATION. THE FGD SYSTEM
FOR EACH BOILER WILL CONSIST OF FOUR SPRAY TOWER ABSORBER MODULES FOR 302
REMOVAL. ELECTROSTATIC PRECIPITATORS WILL BE INSTALLED UPSTREAM OF EACH
ABSORBER TRAJN. CONSTRUCTION BEGAN EARLY IN AUGUST 1977 AND THE UNIT IS
85-9GX COMPLETE. BAD WINTER WEATHER SLOWED CONSTRUCTION SLIGHTLY.
COOPERATIVE POWER ASSOCIATION
COAL CREEK 2
515 MW - NEW
LIGNITE - 0.63 PERCENT SULFUR
COMBUSTION ENGINEERING
LI"E
STARTUP 11/79
OELMARVA POWFR (4 LIGHT
DELWARE CITY 1, 2 R 3
180 MW - RETROFIT
COKE 7-8 PERCENT SULFUR
DAVY POWERGAS
WELLMAN LORD
STARTUP a/so
niJOUFSNF LIGHT
FLRAMA POW.FR STATION
510 MW - RETROFIT
COAL? 2% SULFUR
CHEMICO
LIME
STARTUP 10/75
nuOUESNF. LIGHT
PHILLIPS POWER STATION
«10 MW - RETROFIT
COAL; 2x SULFUR
CHEMTCn
LIME
STARTUP 7/73
CENTUCKY POWFR COOP
SPIIRLOCK 2
?00 MW - NEW
THIS UNIT IS UNDER THE COMBINED OWNERSHIP OF COOP POWER AND UNITED POWER
A CONTRACT HAS BEEN AWARDED TO COMBUSTION ENGINEERING FOR THE INSTALLA-
OF LIME FGD SYSTEMS ON UNITS 1 AND 2 AT THIS STATION. THE FGD SYSTEM FOR
EACH BOILER WILL CONSIST OF FOUR SPRAY TOWER ABSORBER MODULES FOR S02
REMOVAL. ELECTROSTATIC PRECIPITATORS WILL BE INSTALLED UPSTREAM OF EACH
ABSORBER TRAIN. CONSTRUCTION BEGAN IN AUGUST 1977 AND THE UNIT IS NOW 45X
COMPLETE. THERE HAVE BEEN MINOR DELAYS BUT START-UP IS STILL SCHEDULED FOR
NOVEMBER 1979.
• •B»»WWH»«KB^B — _ • ™ • 0 » « V »B * • • » «» K •« B « V B V • V V •• V W _ _v w m w •••••_••• •
DELMARVA'S DELAWARE CITY PLANT HAS U BOILERS, 3 OF WHICH HAVE STEAM CAP»»
CITIES OF 500K L8S/HR EACH. THE BOILERS GENERATE STEAM AS WELL AS ELECTRI-
CAL POWER FOR GETTY REFINING » MARKETING. 7-8X S COKE WILL 8E BURNED IN
THE BOILERS (INSTEAD OF THE LOW-S CRUDE OIL NOW BURNED) WHEN THE CONTROL
SYSTEM GOES INTO OPERATION IN APRIL 1980. OELMARVA WILL USE VENTUBI SCRUB-
BERS FOR PARTICIPATE REMOVAL ANO WELLMAN LORD FGD SYSTEMS AT EACH BOILER
GAS EXIT FOR SO? CONTROL. PARTICULATE AND SULFUR DIOXIDE REMOVAL EFFICIEN-
CIES ARE 90 AND 85-90 PERCENT RESPECTIVELY. CONSTRUCTION IS 11X COMPLETE.
RFFFR TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE FGO SYSTEM ON THIS 1-BOILER UNIT CONSISTS OF FIVE COMMON-HEADEREO
SINGLE STAGE VENTURI SCRUBBER-ABSORBERS DOWNSTREAM FROM A MECHANICAL
COLLECTOR-ESP PARTICULATE REMOVAL SYSTEM. THE PLANT BURNS COAL WITH A
HFATING VALUE OF 11,000 BTU/LB AND SULFUR AND ASH CONTENTS OF 1.8 TO 2.2K
AND 21X RESPECTIVELY. DEWATERED SLUDGE FROM THE IUCS PLANT IS HAULED TO
AN OFF-SITE LANDFILL. THE SYSTEM INCLUDES A DIRECT OIL-FIRED STACK GAS
RFHFAT SYSTEM. DESIGNED REMOVAL EFFICIENCIES ARE 992 (PART) AND 83% (SOH),
RFFFR TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE FGD SYSTEM ON THIS ft-BOTLER UNIT CONSISTS OF ONE 2-STAGE AND THREE
SINGLF STAGF VENTURI SCRUBBER-ABSORBERS DOWNSTREAM FROM A MECHANICAL
COLLERTOR-ESP PARTICULATE REMOVAL SYSTEM. THE PLANT BURNS COAL WITH A
HEATING VALUE OF 11,000 BTU/LB AND SULFUR AND ASH CONTENTS OF 1.8 TO 2.2»
AND 2iX RESPECTIVELY, OEWATERED SLUDGE FROK THE IUCS PLANT IS HAULED TO
AN OFF-SITE LANOFILL. THE SYSTEM INCLUDES A DIRECT OIL-FIRED STACK GAS
RFHFAT SYSTFM. DESIGNED RFMOVAL EFFICIENCIES ARE 99X (PART) AND 83% (302).
A CONTRACT HAS BEEN AWARDED TO COMBUSTION ENGINEERING FOR A LIME SLURRY
FGD SYSTEM ON THE NEW 500-MW UNIT SPURLOCK 2. PARTICULATE WILL BE CONTROL-
LED BY A 99.5X FFFICIENT FSP. COOLING TOWER SLOWDOWN WILL BE THF MAKE-UP
SOURCE FOR THE FGO SYSTEM. THE DESIGNED SOS RFMOVAL EFFICIENCY IS 90X.
CO"HIISTION ENGINEERING
STARTUP
-------
FPA UTILITY FGD SURVEY: JUNE 1978 • JULY 1978
UNIT IDENTIFICATION
SECTION ?
STATUS OF FGO SYSTEMS
CURRENT STATUS
GFNFRAI PUBLIC UTII ITIFS
CCIHO 1
f»0f> MW - MEW
COAL 3.5 PERCENT SULFUR
VENDOR NOT SFLF.CTED
PROCESS NOT SELECTED
STARTUP 5/87
STARTUP OAIF WAS THANKED TO 5/87 FOR BOTH ROIIER AND OESULFURIZATtON
SYSTEM LIME AND LIMESTONE SCRUBBING ARE THE PRIMARY STRATEGIES BEING
CONSIDERED FOR COMPLIANCE WITH NEW SOURCE PERFORMANCE STANDARDS. NO
DFCISTOM HAS CIEFN MADF YET.
GENERAL PUBLIC UTILITIES
SEWAPD 7
800 MW - NEW
COAL
VENDOR NOT SELECTED
PROCESS WOT SELECTED
STARTUP 5/84
STARTUP DATF WAS CHANGED TO 5/8« FOR BOTH BOILER AND DESULFURIZAT ION
S*STEM LIME AND LIMESTUNt SCRUBBING ARE THE PRIMARY STRATEGIES BEING
CONSIDERED FOR COMPLIANCE WITH NEW SOURCE PERFORMANCE STANDARDS. NO
DECISION HAS REEN MADE YET.
RULF POWER
CRIST U * 5
150 MW - RETROFIT
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP O/ 0
EACH UNIT IS 75 MW. THt UTILITY IS STILL WAITING FOR A DECISION ON THE
EMISSION REGULATIONS THAT THEY WILL HAVE TO MEET,
GULF POWER
CRIST 6*7
B20 MW -
NEW
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 0/80
UNIT f> IS 320 MW. UNIT 7 IS 500 MW. A DECISION AS TO THE EMISSION REGULA-
TION THIS PLANT WILL HAVE TO MEET WILL BE MADE SEPTEMBER 7, 1978. THE
UTILITY EXPECTS TO SURN LOW SULFUR COAL AS A COMPLIANCE STRATEGY, IF
MORF STRINGENT EMISSION LIMITATION STANDARDS ARE IMPOSED.
GULF POWER
LANSTNG SMITH 1 S ?
305 MW - RETROFIT
COAL
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 0/80
UNIT NO. 1 IS 1?5 MW. UNIT NO. ? IS 180 MW. A DECISION AS TO THE EMISSION
REGULATION THIS PLANT WILL HAVE TO MEFT WILL BE MADE SEPTEMBER 7, 1978.
THE UTILITY EXPECTS TO BURN LOW SULFUR COAL AS A COMPLIANCE STRATEGY, IF
MORE STRINGENT EMISSION LIMITATION STANDARDS ARE IMPOSED.
GULF POWER
SCHOLZ NOS. IB & 2R
20 MW - RETROFIT
COAL 5.0 PERCENT SULFUR fMAX)
CHIYODA INTERNATIONAL
LIMESTONF
STARTUP 9/78
CHIYODA INTERNATIONAL WILL BE SUPPLYING A 20 MW PROTOTYPE UNIT TO BEGIN
OPERATION AT THIS PLANT IN SEPTEMBER 1978. THE CT-121 SYSTEM WILL INCLUDE
A NEWLY DEVELOPED JET BUBBLING REACTOR WHICH FEATURES A LARGE GAS-LIQUID
INTF.RFACIAL AREA AND PROVIDES PARTICULATE AS WELL AS 802 REMOVAL. MIST
ELIMINATION WILL BE PROVIDED BY A DOUBLE PASS VERTICAL CHEVRON. GYPSUM
WILL BE PRODUCED AND STACKED IN THE EXISTING POND. THF. STACKING CAPABIL-
ITIES OF THE GYPSUM WILL BE TESTED ALONG WITH THE GROUND WATER NEAR
THE STACK SITF. RFHFAT WON'T BE INCLUDED. CONSTRUCTION IS NEARLY COMPLETE,
HOOSIE" FNERGY
MERQM i
ago MW - NEW
COAL 3.5 PFKCtNF SULFUR
MITSUBISHI INTFRNATintjiL
LIMESTONF
STARTUP 1?/«0
HOOSTER FNFKRY
MEROM ?
490 MW - Nf'X
TiJAL 3.5 PFRCEMT SULFUR
MITSUBISHI
I TMtSTONF
STARTUP
HOOSIER ENERGY HAS AWARDED A CONTRACT TO MITSUBISHI INTERNATIONAL CORP.
FOR TWO LIMESTONE FGD SYSTEMS FOR MFROM 1 AND 2. THE NEW 490 MW COAL-FIRED
UNITS ARE PLANNED FIR LOCUTION TN SULLIVAN, INDIANA. THE FLUE GAS STREAMS
WILL BE Cl.t«NFD OF PARTICIPATES WITH ESP'S f99.4X) AND OF SULFUR DIOXIDE
WTTH GHID-TOWFR ABSORBERS (90X). SLUDGE WILL BE STABILIZED AND STOCK
PTLFU. THE GROUND WAS BROKEN FOR CONSTRUCTION IN NOVEMBER 1977, BUT DUE
TH THF BAD WINTER WFATHFR, CONSTRUCTION WAS DELAYED. CONSTRUCTION HAS
PPOrEEDEO ACCORDING TO SCHEDULE THROUGH THE SUMMER.
HOOSTFR FNKRIiY HAS AWARDED A CONTRACT TO MITSUBISHI INTERNATIONAL CORP.
FOR 1WO LIMFSTONE FRU SYSTEMS FOR MFROM 1 AND 2. THF NEW 490 MW COAL-FIRED
UNITS ARt PLANNED FOR LOCATION TN SULLIVAN, INDIANA. THE FLUE GAS STREAMS
WILL Bt CLEANED OF PARTICIPATES WITH ESP'S (99.ax) AND OF SULFUR DIOXIDE
WTIH GkTO-TOWFH ABSORBERS (90X). SLUDGE WILL BE STABILIZED AND STOCK
PTLFU. THF GROUND WAS BROKEN FOR CONSTRUCTION IN NOVEMBER 1977, BUT DUE
TO THE BAO WINTER WFATHFH, CONSTWUCTION WAS DELAYED. CONSTRUCTION HAS
ATCOWHING TO SCHEDULE THROUGH THE SUMMER.
-------
EPA UTILITY FGO SURVEY: ,IUNE 1978 - JULY l«7fl
SECTION ?
STATUS OF FRO SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
INDIANAPOLIS POWER * LIGHT
PETERSBURG 3
530 MW - NEW
COAL» 3.25* SULFUR, 9.5X ASH
AIR CORRECTION DIVISIOM. UOP
LIMESTONE
STARTUP 10/77
THE AIR CORRECTION DIVISION OF HOP SI.IPPL IFD THE IE f LIMESTONE FED
SYSTEM AT THIS UNIT. THE UNIT BECAMF OPERATIONAL ON DEC. 16,1977. AN ESP
PROVinES PRIMARY PARTICIPATE CONTROL. THF. UNIT FIRES BITUMINOUS COAL WITH
A SULFUR CONTENT OF 3.0-3.5X, AN ASH CONTENT OF 9-10X, AND A H£AT CONTENT
OF 11,000 BTU/LB. AFTFR BEING DOWN FOR PROBLEMS *ITH THE FLY ASH SYSTEM,
THt UNIT CAME BACK ON LINE TN MID-APRIL. THE UNIT WENT RACK DOWN ON JUNE
16 WHFN THE MAIN POWER TRANSFORMER FAULTED.
INDIANAPOLIS POWER & LIGHT
PETERSBURG 1
530 MW - NEW
COAL 3.5 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE
STARTUP «/82
INDIANAPOLIS POWER * LIGHT AWARDED A CONTRACT TO RESEARCH COTTRELL FOR A
LIMESTONE FGl) SYSTEM. S02 REMOVAL EFFICIENCY WILL BE AP°HOXTMA TFL Y
80 PERCENT. THIS NEW UNIT WILL FIRE HIGH-SULFUR SUBBITUMINOUS COAL WITH
A HFAT1NG VALUE OF 11,000 BTU/LB AND ASH AND SULFUR CONTENTS OF 10 PERCENT
AND 3.5 PERCENT, RESPECTIVELY. SLUDGE WILL BE DEWATERED AND MIXFD WITH
FLYASH TO PRODUCE A DRY STABILIZED PRODUCT. PLANT CONSTRUCTION BEGAN IN
DECEMBER 1977.
KANSAS CITY POWER & LIGHT
HAWTHORN 3
100 MW - RETROFIT
COAL; ?x SULFUR, 12.5% ASH
COMBUSTION ENGINEERING
LIME
STARTUP 11/72
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE SCRUBBER-ABSORBER SYSTEM ON THIS UNIT WAS CONVERTED FROM A LIMESTONE
FURNACt INJECTION AND TAIL-END SYSTEM TO A TAIL-END LIME SLURRY SYSTEM.
OPERATION IN THE LIME SCRUBBING MODE COMMENCED ON FEBRUARY 7, 1977. COM-
PLIANCE TEST RESULTS INDICATED THF UNIT MEETS THE KANSAS CITY 0.17 LB/
MM BTU PARTICULATE REG. FGD SYSTEM DESIGN INCLUDES A FINNED-TUBE STEAM
REHEATER, AN ON-SITE UNLINED SLUDGE DISPOSAL POND, AND A CHEVRON MIST
ELIMINATOR SYSTFM. THE ? FGD MODULES CAN BE BY-PASSED IN EMERGENCIES.
KANSAS CITY POWER S LIGHT
HAWTHORN 4
100 MW - RETROFIT
COAL! ?X SULFUR, 12.5X ASH
COMBUSTION ENGINEERING
LIME
STARTUP S/72
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE SCRUBBER-ABSORBER SYSTEM ON THIS UNIT WAS CONVERTED FROM A LIMESTONE
FURNACE INJECTION AND TAIL-END SYSTEM TO A TAIL-END LIME SLURRY SYSTEM.
OPERATION IN THE LIME SCRUBBING MODE COMMENCED ON JANUARY 1, 1977. COM-
PLIANCE TEST RESULTS INDICATED THE UNIT MEETS THE KANSAS CITY 0.17 LB/
MM BTU PARTICULATE REG. FGD SYSTEM DESIGN INCLUDES A FINNED-TUBE STEAM
REHEATER, AN ON-STTE UNLINED SLUDGE DISPOSAL POND , AND A CHEVRON MTST
ELIMINATOR SYSTEM. THE 2 FGD MODULES CAN BE BY-PASSED IN EMERGENCIES.
KANSAS CITY POWER * LIGHT
LA CYGNE 1
820 MW - NEW
COAL; 5x SULFUR, 25x ASH
BABCOCK & WILCOX
LIMESTONE
STARTUP 2/73
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRFD POWER-GENERATING UNIT
CONSISTS OF EIGHT SCRUBBER MODULES FOR FLY ASH AND S02 REMOVAL. EACH
MODULE INCLUDES A VENTURI SCRUBBER TN SERIES WITH A 2-STAGE IMPINGEMENT
PLATE ABSORBER. THE SCRUBBER PLANT IS AN INTEGRAL PART OF THE POWER-
GENERATING COMPLEX, ALLOWING NO FLUE GAS BYPASS. INITIAL OPERATIONS
COMMENCED IN FEB. 1973. COMMERCIAL SERVICE WAS ATTAINED BY JUNE 1973.
KANSAS POWER & LIGHT
JEFFERFY 1
680 MW - NEW
COAL 0.30 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE
STARTUP 9/78
KP&L HAS PURCHASED A COMBUSTION ENGINEERING AIR QUALITY CONTROL SYSTEM
FOR PARTICULATE AND S02 REMOVAL CONSISTING OF A COLD-SIDE ESP, I.D. FANS,
BY-PASS CAPABILITY, AND SPRAY TOWERS. AN OVERFIRE AIR SYSTEM AT THE TAN-
GENTIAL FIRED PULVERIZED BURNERS WILL CONTROL NOX EMISSIONS. THE CLEANED
GASES WILL BE VENTED To A 600 FT STACK. THE BOILER IS NOW OPERATIONAL.
THE SLUDGE DISPOSAL STRATEGY HAS NOT BEEN FINALIZED. THF FGD SYSTFM HAS
BEEN TESTED AND is wow IN THE SHAKEDOWN PHASE OF OPERATION.
KANSAS POWER & LIGHT
JEEFERFY 2
680 MW - NEW
COAL 0.30 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONF
STARTUP 6/80
KANSAS POWFR £ LIGHT
LAWRFNCE 1
125 MW - RETROFIT
COAL; O.^X SULFUR, 11X ASH
COMBUSTION ENGINEERING
LIMESTONF
STARTUP l?/68
KP&L HAS PURCHASED A COMBUSTION ENGINEERING AIR QUALITY CONTROL SYSTEM
FOR PARTICULATE AND S02 REMOVAL CONSISTING OF A COLO-SIDE ESP, I.D. FANS,
BY-PASS CAPABILITY, AND SPRAY TOWFRS. AN OVERFIRE AIR SYSTEM AT THE TAN-
GFNTIAL FTRED PULVERIZED RURNERS WILL CONTROL NOX EMISSIONS. THE CLEANED
GASES WILL PE VENTED TO A 600 FT STACK. CONSTRUCTION IS PROCEEDING ACCORD-
ING TO SCHEDULE. THE STRUCTURAL STEEL AND MOST OF THE DUCTWORK IS COM-
PIETE. ACTUAL MODULE CONSTRUCTION HAS NOT BEGUN, SLUDGE DISPOSAL STRATEGY
HAS NOT BEEN FINALIZED. THIS UNIT WILL FIRE 0.3* SULFUR WYOMING COAL.
RFFFR TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE NEW LIMESTONE FGD SYSTEM COMMENCED OPERATIONS IN EARLY JANUARY 1977.
THE NEW SYSTEM REPLACED MAWBLF-BED TOWERS WITH SPRAY TOWERS. THFRE HAVE
BEEN NO FORCED SCRUBBER OUTAGES REPORTED SINCE START-UP. CONTINUOUS S02
MONITORS HAVE RECORDED SO? REMOVAL FFFICIANCIES OF BETTER THAN 85X.
THE UTILITY REPORTED "ARTICULATE REMOVAL TS SUCH THAT NO VISIBLE PLUME
E*ITS THE STACK THE PLANT IS FIRING COAL RATED AT 10,000 RTU/LB WITH A
SULFUR CONTENT OF 0.5*.
1 0
-------
FPA UT1LTTY FGD SURVEY: JUNE 1978 - JULY 197B
SECTION ?
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
KANSAS POWER & LIGHT
LAWRENCE 5
aoo MW - NEW
COAL: o.5x SULFUR, lu ASH
COMBUSTION ENGINEERING
LIMESTONE
STARTUP 11/71
REFER TO SECTION 3 tip THIS REPORT FOR ADDITIONAL INFORMATION. THE
ORIGINAL LIMESTONF INJECTION AND TAIL-END SCRUBBING SYSTEM WAS SHUT
DOWN ON MARCH 20 SO THAT THE NEW POO-SCRUBBER AND SPRAY TOWER ABSORBER
SYSTEM COULD BE TIED INTO THE UNIT. THE NEW SYSTEM, WHICH INCLUDES TWO
MODULES, EACH CAPABLE UF HANDLING APPROXIMATELY 50 PERCENT OF THE TOTAL
BOILER FLUE GAS FLOW, CAME ON LINE ON APRIL 14, 1978. THE SYSTEM DESIGNER
AND SUPPLIER TS COMBUSTION FNGINEFRTNP. THE UNIT FIRES LOW SULFUR WYOMING
COAL WITH A HEAT CONTENT OF 10,000 BTU/LB.
KENTUCKY UTILITIES
GREEN RIVER I,?, i 3
64 MW - RETROFIT
COAL! 3.9% SULFUR, 13.5X ASH
AMERICAN AIM FILTER
LIME
STARTUP 9/75
LAKELAND UTILITIES
MCINTOSH 3
350 MW - NEW
COAL 2.6 PERCENT SULFUR
BABCOCK & WILCOX
LIMESTONE
STARTUP 10/81
RFFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE SCRUBBER PLANT INSTALLED AT THIS STATION CONSISTS OF ONE MODULE
DFSIGNEH TO REMOVE PARTICUL4TE (VARIABLE-THROAT VENTURI) AND S02 (MOBILE
-BED CONTACTOR) FROM COAL-FIRED BOILER FLUE GAS. THE SCRUBBER WAS DESIGNED
AND SUPPLIED BY AAF. SLUDGE IS DISPOSED IN AN ON-SITE UNLINED POND. THE
COAL BURNFD HAS SULFUR AND ASH CONTENTS OF 3.B AND 14 PERCENT RESPEC-
TIVELY. INITIAL STARTUP OCCURRED IN SEPTEMBER 1975. COMMERCIAL OPERATION
COMMENCED IN JANUARY 1976.
THE CITY OF LAKELAND DEPARTMENT OF ELECTRIC AND WATER UTILITIES AWARDED A
CONTRACT TO B*W FOR AN EMISSION CONTROL SYSTEM ON THE UTILITY'S NEW
350-MW POWER GENERATING UNIT, MCINTOSH 3. THE UNIT WILL UTILIZE COLD
SIDE ESP'S FOR PARTICULATE REMOVAL AND TWO LIMESTONE SCRUBBER-ABSORBER
MODULES. START-UP IS SCHEDULED FOR OCTOBER 1981. A COAL SOURCE HAS NOT
BEEN FINALIZED. THE UNIT DESIGN INCLUDES A REHEAT AND STABILIZED SLUOGE
DISPOSAL SYSTEM. CONSTRUCTION SHOULD BEGIN IN THE FIRST PART OF 1979.
LOUISVILLE GAS & ELECTRIC
CANE RUN 4
178 MW - RETROFIT
COAL» 3.75X SULFUR, 11.5Z ASH
AMERICAN AIR FILTER
LIME (CARBIDE)
STARTUP 8/76
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE FGD SYSTEM RETROFITTED ON THIS BOILER WAS DESIGNED AND SUPPLIED BY
AMERICAN AIR FILTER AND WAS FIRST PLACED IN THE GAS PATH ON AUGUST 7,
1976. THE SYSTEM CONSISTS OF TWO PARALLEL MODULES WHICH INCLUDE MOBILE
BED CONTACTORS AND OPERATE WITH A CARBIDE LIME ADDITIVE. FOLLOWING A
NUMBER OF MAJOR SYSTEM MODIFICATIONS (CHEVRON-TYPE MIST ELIMINATOR. OIL
FIRED REHEAT, PLASITE DUCT LINER, HIGHER L/G), THE SYSTEM SUCCESSFULLY
PASSED COMPLIANCE TESTING (855! 502 REMOVAL) ON AUGUST 3 AND 4, 1977.
LOUISVILLE GAS & ELECTRIC
CANE RUN 5
183 MW - RETROFIT
COAL; 3.75* SULFUR, ii.sx ASH
COMBUSTION ENGINEERING
LIME (CARBIDE)
STARTUP 12/77
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE FGD SYSTEM FOR THIS UNIT WAS DESIGNED AND SUPPLIED BY COMBUSTION
ENGINEERING. IT CONSISTS OF TWO SPRAY TOWER ABSORBERS FOR FULL-LOAD S02
REMOVAL AND UTILIZES CARBIDE LIME AS THE ABSORBING REAGENT. IN-LINE STEAM
REHEAT, A COMMON REACTION TANK, AND A THICKENER FOR SOLIDS OEWATERING
ARE INCLUDED. AN EXISTING UPSTREAM ESP PROVIDES PRIMARY PARTICULATE CON-
TROL. THE FGD SYSTEM BEGAN INITIAL OPERATION IN DEC. '77 BUT A COAL
STRIKE FORCED A PLANT SHUTDOWN. THE SYSTEM WAS RE-STARTED MARCH 21, i<>78.
LOUISVILLE GAS & ELECTRIC
CANE RHN 6
277 MW - RETROFIT
COAL 3.5 - a.O PERCENT SULFUR
ADL/COMBUSTION EQUIP ASSOCIATE
ROUBLE ALKALI
STARTUP 12/78
LOUISVILLE GAS & ELECTRIC
MILL CREEK 1
330 MW - RETROFIT
COAL 3.5- 4.0 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME/LTMFSTONE
STARTUP 1/81
THE CONTRACT FOR THIS FULL-SCALE DEMONSTRATION FGD SYSTEM HAS BEEN
AWARDED TO A.O.LITTLE/COMBUSTION EQUIPMENT ASSQC. FOR THE INSTALLATION
OF A DOUBLE ALKALI SYSTEM. THE FEDERAL EPA WILL SUBSIDIZE A MAXIMUM
$4.5 MM FOR OPERATION, RESEARCH AND DEVELOPMENT *ND REPORT WRITING FOR
A ONE-YEAR PERIOD FOLLOWING THE FIRST THREE MOhiTHS OF OPERATION (NOTElTHIS
SUBSIDY WILL NOT BE APPLIED FOR ANY CAPITAL EXPENDITURES). ENGINEERING
DESIGN WORK IS UNDERWAY. SITE PREPARATION, EXCAVATION AND FOUNDATION WORK
COMMENCED IN JULY. DUCTWORK TTE-IN TS COMPLETE,
A COMPLIANCE SCHEDULE HAS BEEN SUBMITTED TO THE JEFFERSON COUNTY AIR POt-
LUTION CONTROL DISTRICT WITH 4/81 ESTABLISHED AS THE STARTUP DATE FOR AN
FGD SYSTEM. OPERATING DATA AND INFORMATION FROU THE FULL-SCALE SCRUBBER
PLANT NOW IN SERVICE ON THE NO.4 UNIT AT CANE RUN WILL 9E OBTAINED BEFORE
THE UTILITY PROCEEDS WITH ADDITIONAL SYSTEM DESIGN WORK. A CONTRACT WAS
AWARDED TO COMBUSTION ENGINEERING FOR A LIME/LIMESTONE FGO SYSTEM.
LOUISVILLE GAS & ELECTRIC A COMPLIANCE SCHEDULE HAS BFEN SUBMITTED TO THE JEFFERSON COUNTY AIR POL-
MILL CREEK 2 LUTION CONTROL DISTRICT WITH 4/82 ESTABLISHED AS THE STARTUP DATE FOR AN
330 MW - RETROFIT FGD SYSTEM. OPERATING DATA AND INFORMATION FROM THE FULL-SCALE SCRUBBER
COAL 3.5- 4.0 PERCENT SULFUR PLANT NOW IN SERVICE ON THE NO.4 UNIT AT CANE RUN WILL BE OBTAINED BEFORE
COMBUSTION ENGINEERING THE UTILITY PROCEEDS WITH ADDITIONAI SYSTEM DESIGN WORK. A CONTRACT WAS
LIME/LIMESTONE AWARDED TO COMBUSTION ENGINEERING FOR A LIME/LIMESTONE FGD SYSTEM.
STARTUP 1/82
11
-------
EPA UTILITY FGD SURVFY: IUME 1978 - JULY 1978
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
IQUISVTLLE GAS * ELECTRIC
MILL CREEK 3
«*™ — <*a»«*i»«»«««vB«>»_<»Vw..vBm»«w*ii»«*i»«<«w«v*«*
REFER TO SECTION 1 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THIS FGO EQUIPPED UNIT WAS DECLARED COMMERCIAL IN AUGUST 1976. THE
SCRUBBING SYSTEM PROVIDES PARTICULATE AND S02 CONTROL WITH THREE SCRUB-
BER MODULES. EACH MODULE CONSISTS OF A OOWNFLOh VENTURI SCRUBBER CENTER-
ED WITHIN AN UPFLOW SPRAY TOWER ABSORBER. EACH MODULE CAN TREAT 40* OF
THE TOTAL BOILER FLUE GAS AND THE MODULES CANNOT BE BYPASSED. THE UN-
STABILIZED SLUDKE IS OISPOSFD IN AN ON-SITE LINF.D DISPOSAL POND. IN-LINE
STEAM RFHFAT ANfl CLOSED WATER LOOP CAPABILITY ARE INCLUDED IN THE SYSTEM.
A CONTRACT FOR THE INSTALLATION OF TWO ADDITIONAL LIME/ALKALINE FLYASH
SCRUBBING SYSTEMS HAS HFEN AWARDED TO A.D. LITTLE/COMBUSTION EQUIPMENT
ASSOCIATES. THESE SYSTEMS WILL BE INSTALLED ON UNITS 3 AND 1 OF THE
COLSTRIP POWER STATION. COLSTRIP UNITS i AND a ARE BOTH EQUIPPED WITH
OPERATIONAL LIME/ALKALINE FLYASH SCRUBBING SYSTEMS FOR THE REMOVAL OF
PARTICULATES AND SULFUR DIOXIDE.
-------
FPA UTILITY FGO SURVFY: JUNE 1978 - JULY 1978
SECTION ?
STATUS OF FRI) SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
MONTANA POWER
COI STRIP 4
700 MW - NEW
COAL 0.7 PERCENT SUl.F'IK
A CONTRACT FOR THF INSTALLATION OF TWO ADDITIONAL LIME/ALKALINE FLYASH
SCRUBRiNG SYSTEMS HAS HFEN AWARDED TO A.D. LITTLE/COMBUSTION EQUIPMENT
ASSOClATtS. THESE SYSTEMS W?LL IE INSTALLED ON UNTTS 3 AND 1 OF THE
COLRTRTP POWER STATION. COL^TRIP UNTTS 1 AND 2 ARE BOTH EQUIPPED WITH
ADL/CUM8IISTinN EQUIP ASSOCIATE OPERATIONAL L IMF/ALK Al INE FLYASH SCRUBBING SYSTEMS FOR THE REMOVAL OF
i IME/ALK.ALINE FLYASH PARTICUI.ATES AND SUIFUR DIOXIDE.
STARTUP
NFVAOA POWFR
HARRY ALLEN 1
son MW - NF.W
COAL
VENDOR NOT SFLECTEO
PROCFSS NOT SELECTED
STARTUP h/«5
CONSIDERING HOT STOF FSP IN CONJUNCTION WITH AN FRO SYSTEM. SPECIFICA-
TIONS HAVF NOT YET REFN PREPARED.
NEVADA POWER
HARRY ALLEN 2
500 MW - NEW
COAL
VENDOR NOT SELECTED
PROCFSS NOT SELECTED
STARTUP
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGO SYSTEM. SPECIFICA-
TIONS HAVF NOT YET REEN PREPARED.
NEVADA POWFR
HARRY ALLEN 3
500 MW - NEW
COAL
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP f>/«7
CONSIDERING HOT SIOF FSP IN CONJUNCTION WITH AN FED SYSTEM. SPECIFICA-
TIONS HAVF MOT YET BEEN PREPARED.
NEVADA POWFH
HARRY ALLEN t
500 MW - MEW
COAL
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 6/R8
CONSIDERING HOT SIDF FSP TN CONJUNCTION WITH AN FGD SYSTEM. SPECIFICA-
TIONS HAVE NOT YET SEEN PREPARED.
NEVADA POWER
REID GARDNFR 1
125 MW - -RETROFIT
COAL; o.sx SULFUR, sx ASM
AOL/COMB'ISTION EQUIP ASSOCIATE
SODIUM CARBONATE
STARTUP '4/7U
NEVADA POWFR
REID GARDNER 2
125 MW - BETROFIT
cuALr o.sx SULFUR, a% ASH
ADL/CUMHUSTJOlM EQUIP ASSOCIATE
SODIUM CARBONATE
STARTUP 'l/7
-------
EPA UTILITY FGD SURVEY: JUNE i"78 - JULY i<»78
SECTION 2
STATUS op FGD SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
NEVADA POWER NEVADA P? COMPANY HAS SCRAPPED THIFR ORIGINAL PLANS TO MAKF UNIT « A
REID GARDNER 4 COPY OF UNIT 1. THE NFw PLANS CALL FOR A 250-MW UNIT TO BE IN OPERATION
250 MW - NEW BY 1983. THF UTILITY IS PREPARING SPECIFICATIONS AT THIS TIMF. CONSTRMC-
COAL 0-5- 1.0 PERCENT SULFUR TION IS SCHEDULED TO START IN 1980.
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 0/83
NEVADA POWFR
WARNFR VALLEY 1
250 MW - NEW
COAL
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 6/84
SPECIFICATIONS ARE BEING PREPARED FOR A SCRUBBING SYSTEM. NEVADA POWER
HAS NOT YFT ANNOUNCED PLANS FOR THIS UNIT'S EMISSION CONTROL STRATEGY.
NEVADA POWER
WARNER VALLEY 2
250 MW - NEW
COAL
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 6/85
SPECIFICATIONS ARE BEING PREPARED FOR A SCRUBBING SYSTEM. NEVADA POWER
HAS NOT YET ANNOUNCED PLANS FOR THIS UNIT'S EMISSION CONTROL STRATEGY.
NEW ENGLAND ELEC SYSTEM
BRAYTON POINT 3
650 MW - RETROFIT
FUEL OIL, LOW SULFUR
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP O/ 0
THE UTILITY IS INVESTIGATING VARIOUS ADVANCED REGENERABLE FLUE GAS DESUL-
FURIZATION SYSTEMS WHICH OFFER A BREAKTHROUGH IN OPERATING COSTS AND
PRODUCE ELEMENTAL SULFUR AS AN END PRODUCT. THE UTILITY IS CURRENTLY
INVOLVED IN BENCH AND LABORATORY SCALE INVESTIGATIONS OF SULFUR RECOVERY.
THE NO. 3 UNIT IS CURRENTLY OPERATIONAL. FIRING LOW SULFUR FUEL OIL.
NIAGARA MOHAWK POWER COOP
CHARLES R. HUNTLEY 6
100 MW - RETROFIT
COAL 2.5-1.5 PERCENT SULFUR
ATOMICS INTERNATIONAL
AQUEOUS CARBONATE
STARTUP 0/80
A CONTRACT WAS AWARDED TO ATOMICS INTERNATIONAL FOR THE DESIGN AND IN-
STALLATION OF AN AOUEOUS CARBONATE FGD SYSTEM. THIS DEMONSTRATION SYSTEM
WILL PRODUCE END-PRODUCT SULFUR. FUNDS ARE BEING PROVIDED BY THE USEPA
AMD THE EMPIRE STATE ELECTRIC ENERGY RESEARCH CORP. THE DESIGN S02 RE-
MOVAL EFFICIENCY WILL 8E 90 PERCENT. GROUND BREAKING FOR CONSTRUCTION WILL
8E IN LATE FALL 1978.
NORTHERN INDIANA PUB SERVICE
BATLLY 7
190 MW - RETROFIT
COAL 3 PERCENT SULFUR
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP O/ 0
NORTHERN INDIANA PUBLIC SERVICE IS CURRENTLY CONSIDERING A LIME OR LIME-
STONE SCRUBBING UNIT FOR BAILLY 7 AND 8. THEY ARE ALSO WAITING FOR
PERFORMANCE RESULTS OF THE WELLMAN LORD/ALLIED CHEMICAL UNIT IN SERVICE
AT DEAN H. MITCHELL 11. LOW SULFUR COAL MAY BE EMPLOYED TO COMPLY WITH
302 EMISSION REGULATIONS. APPLICABLE INDIANA S02 REGULATIONS ARE STILL NOT
FIRMLY ESTABLISHED.
NORTHERN INDIANA PUB SERVICE
BAILLY 8
«oo MW - RETROFIT
COAL 3 PERCENT SULFUR
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP O/ 0
NORTHERN INDIANA PUBLIC SIRVICE IS CURRENTLY CONSIDERING A LIME OR LIME-
STONE SCRUBBING UNIT FOR BAILLY 7 AND 8. THEY ARE ALSO WAITING FOR
PFRFORMANCE RESULTS OF THE WELLMAN LORD/ALLIED CHEMICAL UNIT IN SERVICE
AT DEAN H. MITCHELL 11. LOW SULFUR COAL MAY BE EMPLOYED TD COMPLY WITH
soa EMISSION REGULATIONS. APPLICABLE INDIANA so? REGULATIONS ARE STILL NOT
FIRMLY ESTABLISHED.
N INDIANA PHB SERWICfc REFER TO SECTION 3 OF THIS REPORT FOH ADDITIONAL INFORMATION.
DEAN H. MITCHELL 11
! 15 MW - RETROFIT
COAL; 3.5Z SULFUR, 10% ASH
DAVY POWFRGAS
WELLMAN LORD
STARTUP 11/76
THIS FGD SYSTEM IS AN INTEGRATION OF THE WELLMAN-LORD S02 RECOVERY PROCESS
OFFERED BY DAVY POWERGAS AND THE SO? TO SULFUR REDUCTION PROCESS DE-
VELOPED BY ALLIFD CHEMICAL. DAVY POWERGAS is THE DESIGN AND CONSTRUCTION
FIRM AND ALLIED CHEMICAL is SYSTEM OPERATOR AND PRODUCT MARKETER.
PERFORMANCE TFSTS WFRE SUCCESSFULLY COMPLETED ON SEPTEMBER 14, 1977. A
DEMONSTRATION YFAR COMMENTED ON SEPTEMBER 16, 1977.
1 H
-------
FPA UTILITY FGD SHRVFY: JUNE iQ7s - JULY 1978
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
NORTHERN STATES POWER
SHERBURNF 1
710 MW - NEW
COAL? O.flj; SULFUR, 9X ASH
COMBUSTION ENGINEERING
LIMESTONE/ALKALINE FLYASH
STARTUP 3/76
REFER TO SECTION 1 OF THIS REPORT FDR ADDITIONAL INFORMATION.
FULL COMMERCIAL OPERATION OF THE SYSTEM BEGAN ON MAY 1, 1976. THE SCRUB-
BING SYSTEM FOR THIS UNIT CONSISTS OF 12 MODULES. EACH SCRUBBING MODULE
INCORPORATES A VENTURT-ROO SECTION AND A MARBLE 8FD ABSORBER FUR PAR-
TICULATE AND SULFUR DIOXIDE REMOVAL. » FORCFD OXIDATION SYSTEM CONVERTS
ALL THE CALCIUM SULFITE TO SULFATF PRIOR TO DISCHARGE TO A CLAY-LINFD
SETTLING POND. STACK GAS PEHEAT IS PROVIDED BY IN-LINE HOT WATER TUBES.
NORTHERN STATES POWER
SHFR8U9NE ?_
710 MW - NEW
COAL; o.ax SULFUR, 9* ASH
COMBUSTION ENGINEERING
LI"ESTONF/ALKALINE FLYASH
STARTUP a/77
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE SHERBURNE NO. 2 AIR QUALITY CONTROL SYSTEM IS IDENTICAL IN DESIGN TO
THE SYSTEM IN OPERATION ON' THE NO. 1 UNTT AT THIS STATION. TWELVE 2-STAGE
PARTICULATt SCRUBBER (VFNTURI-ROD SCRUBBER) AND SULFUR DIOXIDF ABSORBER
(MARBLE-BF.O ABSORBER) MODULES ARE PROVIDED FOR FLY ASH AND SO? CONTROL.
ELEVEN MODULES ARE REQUIRED FOR FULL GENERATING CAPACITY OPERATIONS.
THE CALCIUM SULFITE IS FORCIBLY OXIDI7ED TO SULFATE PRIOR TO DISCHARGE TO
THE DISPOSAL POND. IN-LINE HOT WATER TUBES PROVIDE STACK GAS REHEAT.
NORTHERN STATES POWER
SHFRBURNE 3
SfeO MW - NEW
COAL 0.8 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE/ALKALINE FLYASH
STARTUP 5/84
TWO ADDITIONAL COAL-FIRED POWER-GENERATING UNITS ARE SCHEDULED TO BE IN-
STALLED AT NSP'S SHERBURNE COUNTY GENERATING STATION IN BECKER MINNESOTA,
COMBUSTION ENGINEERING WAS AWARDED A CONTRACT FOR LIMESTONE SLURRY SPRAY
TOWER FGO SYSTEMS ON THE 860 MW UNITS 3 & 4. THE 2- STAGE SCRUBBING SYSTEM
WILL REMOVE PARTICULATE (99.5%) & 302 (BOX). THE BOILER CONTRACT HAS BEEN
AWARDED TO BABCOCK AND WILCOX AND THE TURBINE WILL RE SUPPLIED BY GENERAL
ELECTRIC. START-UP HAS BEEN DELAYED TO MAY 1984.
NORTHERN STATES POWER
SHERBURNF 4
860 MW - NEW
COAL 0.8 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE/ALKALINE FLYASH
STARTUP O/ 0
TWO ADDITIONAL COAL-FIkED POWER-GENERATING UNITS ARE SCHEDULED TO BE IN-
STALLED AT NSP'S SHFRBURNE COUNTY GENERATING STATION IN BECKER MINNESOTA.
COMBUSTION ENGINEERING WAS AWARDED A CONTRACT FOR LIMESTONE SLURRY SPRAY
TOWER FGD SYSTEMS ON THE 860 MW UNITS 3 & 4. THE 2-STAGE SCRUBBING SYSTEM
WILL REMOVE PARTICULATE (99.5X) S 302 (80%). THE ROILF.R CONTRACT H*S BEEN
AWARDED TO BABCOCK AND WILCOX AND THE TURBINE WILL BE SUPPLIED BY GENERAL
ELECTRIC. THE UNIT WILL POSSIBLY START-UP IN 1907 OR 1988.
OTTER TAIL POWER
COYOTE 1
400 MW - NEW
LIGNITE 0.9 PERCENT SULFUR
WHFELABRATOR-FRYE/A.I.
AQUEOUS CARBONATE
STARTUP "1/81
PACIFIC GAS AND ELECTRIC
FOSSIL 1
800 MW - NEW
COAL 0.8 PERCENT SULFUR
VENDOR NOT SELECTED
LIMESTONE
STARTUP 0/8a
THIS NEW COAL-FIRED STATION IS JOINTLY OWNED BY FIVE UTILITIESo OTTER
TAIL POWER TS THE MAJOR OWNFR AND CONSTRUCTOR. MONTAN6-DAKOTA UTILITIES
IS THE FACILITY OPERATOR. THIS PLANNED UNIT WILL FIRE LOW SULFUR LIGNITE
FROM THE MERCER COUNTY ARFA IN A B&W CYCLONE BOILER. THE CONTRACT FOR THIS
ARUEOUS CARBONATE/FABRIC FILTER 302 SCRUBBER-ABSORBER WAS AWARDED TO
WHEELABRATOR-FRYE AND ATOMICS INTERNATIONAL. THE DRY REMOVAL SYSTEM COM-
BINES AT'S AOUEOUS CARBONATE PROCESS IN A W-F FABRIC FILTER. FGD CON-
STRUCTION HAS JUST BEGUN. START-UP TS SET FOR M4Y 81.
PG&E ANNOUNCED PLANS TO BUILD TWO 800-MW COAL-FIRED POWER GENERATING
UNITS IN NORTHERN CALIFORNIA. THE FIRST UNIT WILL BURN COAL WITH A HEAT-
ING VALUE OF 12000 BTU/L8, 0.8X SULFUR AND 10X \SH CONTENTS. THE SECOND
UNIT WILL BURN COAL OF EQUAL OR BETTER QUALITY. THE EMISSION CONTROL
SYSTEM WILL CONSIST OF AN ESP OR BAGHOUSE AND * LIMESTONE FGO SYSTEM.
SLUDGF WILL BE DISPOSED OF IN A LANDFILL. STAR"'-UP DATES ARE 1984 AND 1965
FOR NOS. 1 AND 2 RESPECTIVELY.
PACIFIC GAS AND ELECTRIC
FOSSIL Z
BOO MW - NEW
COAL 0.8 PERCENT SULFUR
VENDOR NOT SELECTED
LIMESTONE
STARTUP 0/85
PG&E ANNOUNCED PLANS TO BUILD TWO 810-MW COAL-FIRED POWER GENERATING
UNITS IN NORTHERN CALIFORNIA. THE FIRST UNIT WILL BURN COAL WITH A HEAT-
ING VALUE UF 12000 BTU/LB, O.RX SULFUR AND 10X 6SH CONTENTS. THE SECOND
UNIT WILL BURN COAL OF EQUAL OR BFTTE" QUALITY. THE EMISSION CONTROL
SYSTEM WILL CONSIST OF AN ESP OR BAGHOUSE AND ft LIMESTONE FGO SYSTEM.
SLUDGE WILL BE DISPOSED OF IN A LANDFILL. START-UP DATES ARE 1984 AND 1985
FOR NOS. 1 AND ? RESPECTIVELY.
PACIFIC POWER * LIGHT THE AIR CORRECTION DIVISION OF U0° WAS AWARDED A CONTRACT FOR AN FGD
JIM BRTDGER « SYSTEM AT THIS NEW-509 MW COAL-FIRED UNIT. THF FGD SYSTEM WILL CONSIST OF
509 MW - NEW PARALLEL TRAY TOWER ABSORBER MODULES, EACH TREATING ONE-THIRD OF THE
COAL 0.56 PERCENT SULFURfAVG.) BOILER FLUE GAS AT FULL LOAD. AN ESP WILL PROVIDE PRIMARY PARTICULATE
AIR CORRECTION DIVISION, UOP CONTROL. A CETLCOTE-LINED WFT/DRY STACK IS INCLUDED IN THE SYSTFM. PPL'S
SODIUM CARBONATE PILOT STUDY INSPECTION REVEALED SCALE FORMATION PROBLEMS. TESTS ARE BEING
STARTUP 9/79 CONDUCTED TO RESOLVE THIS PROBLEM. TO DATE, THE FOUNDATION IS IN AND
VESSEL ERECTION IS 28 PERCENT COMPLETE.
15
-------
FP4 UTILITY FGD SURVFY: JUNE 1978 - JULY 1978
SECTION 2
STATUS PF FGD SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
PENNSYLVANIA PO«FH
BRIICF "AMSFIFLD 1
8gS MW - NEW
COAL! «.7I SULFUR, 12,5"* ASH
CHFMlcn
LIME
STARTUP «/7fe
PENNSYLVANIA POWER
BRUCE MANSFIELD 2
825 MW - NEW
COAL: 4.7X SULFUR, 12.5X ASH
CHFMICO
LIME
STARTUP 7/77
REFER in SECTION 3 OF THIS REPORT FOR AOOITONAL INFORMATION.
THIS EMISSION CONTROL SYSTEM WAS DESIGNED TO REMOVE FLYASH AND 808 FROM
.5.35 MM ACFM OF FLUF GAS USING THIOSORBIC LIME »S A SCRUBBING ABSORBENT.
THE INITIAL SHAKEDOWN AND DEBUGGING PHASE OF OPERATION BEGAN FOR PART Of
THb SYSTEM IN DFCFMBER 1975. PARTIAL COMMERCIAL OPERATION COMMENCED IN
APRIL 197ft. THE UNIT WAS CERTIFIED FULL-LOAD COMMERCIAL IN JUNE 197*.
THE FGD SYSTEM HAS EXPERIENCED OPERATIONAL PROBLEMS SINCE IT HAS BEEN IN
SFRVICE REQUIRING A NUMBER OF SYSTEM REPAIRS AND DESIGN MODIFICATINS.
RFFFR TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THIS EMISSION CONTROL SYSTEM WAS DESIGNED TO REMOVE FLYASH AND 802 FROM
3.35 MM ACFM OF FLUE GAS USING THIOSORBIC LIME AS A SCRUBBING ABSORBENT.
SIX SCRUBBING TRAINS, EACH INCLUDING TWO VENTURI SCRUBBERS IN SERIES
ARRANGEMENT, ARE PROVIDED FOR FULL-LOAD OPERATION. THE INITIAL SHAKEDOWN
AND DEBUGGING PHASE OF OPERATION BEGAN FOR THREE TRAINS IN JULY, 1«77.
FULL COMMERCIAL OPERATION FOR THE ENTIRE SYSTEM COMMENCED ON OCTOBER I,
1977.
PENNSYLVANIA POWER
BRUCF MANSFIEL" 3
825 MW - NEW
COAL 4.7 PERCENT SULFUR
PULLMAN KELLOGG
LIME
STARTUP 1/80
A CONTRACT WAS AWARDED TO PULLMAN KELLOGG FOR THE F6D SYSTEM AT THIS UNIT,
THE EMISSION CONTROL SYSTEM FOR THIS UNIT WILL CONSIST OF ESP'S UP-STREAM
OF FIVE WEIR HORIZONTAL CROSSFLOW WET SCRUBBING MODULES. SLUDGE WILL BE
DISPOSED OF BY THE EXISTING SYSTEM AT THE BRUCE MANSFIELD PLANT. LINER IN
THE CHIMNFY WILL BE AN INCONEL 625 MATERIAL. THE UNIT IS CURRENTLY UNDER
CONSTRUCTION WITH ESP'S 70-80 PERCENT COMPLETE AND THE F60 SYSTEM JO
PERCENT COMPLETE. UNIT START-UP WILL BE IN APRIL 1980.
PHILADELPHIA ELECTRIC
CROMBY
150 MW - RETROFIT
COAL 2-a PERCENT SULFUR
UNITED ENGINFERS
MAGNESIUM OXIDE
STARTUP 6/80
THE UTILITY PLANS TO RETROFIT ONE OF THE TWO BOILERS AT CROMBY KITH AN
FGO SYSTEM. HOWEVER, A FINAL DECISION HAS NOT BFEN MADE. THE SYSTEM
BEING GIVEN PRIMARY CONSIDERATION IS MAGNESIUM OXIDE. ENGINEERING DESIGN
WORK IS SCHEDULED TO COMMENCE SOON. TENTATIVE FGD SYSTEM START-UP IS
SCHEDULED FOR JUNE 1980. CURRENTLY, PECO IS CONTINUING PROCESS EVALUATION
STUDIES AT THE EDDYSTONE EXPERIMENTAL UNIT.
PHILADELPHIA ELECTRIC
FDDYSTONE 1A
120 MW - RETROFIT
COAL! 2.5X SULFUR, 12% ASH
UNITED ENGINEERS
MAGNESIUM OXIDE
STARTUP 9/75
PHILADELPHIA ELECTRIC
EDDYSTONE IB
240 MW - RETROFIT
COAL 2.5 PFRCENT SULFUR
UNITED ENGINEERS
MAGNFSIUM nxiDF
STARTUP 6/80
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF THREE PARALLEL
SCRUBBING TRAINS FOR THE CONTROL OF PARTICULATE AND SULFUR DIOXIDE.
THE C-SIDE SCRUBBING TRAIN INCLUDES AN 802 ABSORBER MODULE IN SERIES
WITH A PARTICULATE SCRUBBER. APPROXIMATELY ONE-THIRD OF THE BOILER FLUE
GAS is SCRUBBED WITH MAGNESIUM OXIDE SLURRY FOR soa REMOVAL. THE SPENT
SLURRY IS REGENERATED AT THE ESSEX SULFURIC ACID PLANT IN NEWARK, N.J.
THE REGENERATED MAGOX IS RETURNED TO THE PLANT FOR 302 SCRUBBING SERV1CI.
THE INSTALLATION OF AN FGD SYSTEM ON THE BALANCE OF THE FLUE GAS FROM
THIS UNIT WILL FOLLOW PENDING THE OUTCOME OF THE PERFORMANCE OF THE EXPER-
IMENTAL SCRUBBING UNIT WHICH HAS BEEN INSTALLED AND CURRENTLY OPERATIONAL
ON THIS UNIT. CURRENTLY, 3 PARTICULATE SCRUBBERS ARE TREATING THE FULL
GAS LOAD FROM THIS UNIT.
PHILADFLPH1A ELECTRIC
EDDYSTONE 2
336 MW - RETROFIT
<"0»L 2.1 PERCENT SULFUR
UNITED ENGINEERS
MAGNESIUM OXTOE
STARTUP 6/80
THE UTILITY IS AWAITING PERFORMANCE RESULTS FROM THE EXPERIMENTAL FGO
SYSTEM INSTALLED ON UNIT 1 AT THIS STATION BEFORE PROCEEDING WITH THE
DESIGN OF AN FGD SYSTEM FOR THIS COAL-FIRED BOILER. THE SYSTEM BEING
GIVFN PRIMARY CONSIDERATION IS MAGNESIUM OXIDE, DESIGNED JOINTLY BY
UNITED ENGINEERS AMD PHILADELPHIA ELECTRIC. ENGINEERING DESIGN WORK SS
SCHEDULED TO COMMFNCE SOON. TENTATIVE FGO SYSTEM START-UP IS SCHEDULED
FOR JUNE 1980.
POTOMAC ElF.CTWTC POWER
DICKFKSCIN a
800 MW - NfW
COAL ?.0 PFKCENT SULFUR
VFMOOH NOT SFLFCTfO
PR^CFSS NOT SffLETTFO
•STARTUP "5/flb
THERE ARE NO FIRM PLANS FOR INSTALLATION OF AN FGD SYSTEM. STARTUP DATE
OF THE ROILFR IS PLANNED FOR 1985. THIS UNIT WILL BURN 2 PERCENT SULFUR
COAl WITH A HFATJNG VALUE OF 11,000 BTU/L9.
-------
FPA UTILITY FGH SURVEY! JUNE 1978 - JULY 1978
SECTTUN ?
STATUS OF FGU SYSTEMS
OMIT
CURRENT STATUS
POWFR »UTHOUTtY OF NFw
ARTHUR KILL PLANT
701 MW - MF.W
CO»L - 3* SULFIIW - RFFHSF
VENDOR W01 SFLFCTFH
PROCESS MOT SI-LECTEO
STARTUP
THf UTILITY IS CONSIDERING ROTH RFGFNERABLE AND LIMESTONE FGD PROCESSES.
FRO TECHNOLOGY TS 3F1NG CONSIDERED FOR A FOSSIL FUEL BURNING UNIT WHICH
MLl FfPLOY COAL 6S THE PRIMARY FUEL AND OIL AS BACKUP, REFUSE WILL 9E
PRUVIOED AS ft SUPPLEMENTAL FUEL SUPPLY. THE PREFERRED PLANT 3ITF IS THE
AR1HUR KIIL FACILITY LOCATED ON STATEN ISLAND. THE PROJECT DESIGN ENGI-
NFfRIMl, Flh'M 15 SARGEMT AMU LUNDY. PUBLIC SERVICE COMMISSION HEARINGS
ARt IN PttOGRESS.
PUBLTC SERVICE OF TMD14NA
r-IRSON 5
650 MW - MEW
COAL 3.3 PFRCENT SULFUR
VENDOR NOT SFLFCTEP
PROCESS NOT SELECTED
STARTUP 0/«2
PUBLIC SERVICF TO OF TNIANA ANNOUNCED PLANS FOR THE CONSTRUCTION OF THIS
NFw 6SO-MK CUAL FTKFO POWER GFNERATIQNG UNIT AT GIBSON STATION. THE
UTILITY HAS COMPLFTFO .SPEC IF 1C AT IONS AND IS CURRENTLY REQUESTING BIDS.
PSI EXPECTS TO RECIFVE BIOS SOMETTMF IN SEPTEMBER. THE FGD PROCESS IS
STILL UMOFCTDEO. INITIAL START-UP IS SCHEDULED FOR 5982.
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN 1
31 u MW - NEW
COAL; O.BX SULFUR, 2.2% ASH
OA»Y POWERRAS
WELLMAN LORD
STARTUP 1/78
THIS FGD SYSTEM IS AN INTEGRATION OF THE WELLMAN LORD 802 RECOVERY PROCESS
OF DAVY POWFWGAS »NO ALLIED CHEMICAL'S S02 REDUCTION TO SULFUR PROCESS.
A HOT STOF FLFCTROSTATIC PKECTPTTATOR PRECEDES THE FGD SYSTFM. OF THE
FOUR ABSORBFR TOWERS INSTALLED THREF ARE NEEDED TO CARRY THF. FULL LOAD.
MOLTEN SULFUR WILL BE STORED (IN THE PLANT SITE. THE INSTRUMENTATION
CONTROL PROBLEM PREVIOUSLY REPORTED HAS BEEN SOLVED. CONSTRUCTION 18 NOW
COMPLETE. FLUE GAS FIRST ENTERED THE FGD SYSTEM APRIL 8, 1978.
PUBLIC SERVICE OF NEW MEXICO
SAM JUAN 3
706 MW - RETROFIT
CCSL 0.8 PERCENT SULFUR
DAVY POWFRGAS
«ELLM»t>' LORD
STARTUP 7/78
CONSTRUCTION IS WEARING COMPLETION. START-UP IS WOW SCHEDULED FOR JULY
197*. THIS* FGf> SYSTEM IS SN INTEGRATION OF THE WELLMAN LORD S02 RECOVERY
PROCESS OF DAVY POftERGAS ANO ALLIED CHEMICAL'S S0^ REDUCTION TO SULFUR
PROCESS. A HOT SSDE ELECTROSTATIC FRECIPTTATOR WILL PRECEDE THE FED SVS-
TFM. FOUR ABSORBER TOWERS WILL BE INSTALLED FOR THIS UNIT. THREE WILL
CARRY THE FULL LOAD. MOLTEN SULFUR WILL BE STORED ON THE PLANT SITE,
START-UP DELAY WAS CAUSED BY A BOILF.R EXPLOSION, THE POWER PLANT HAS NOW
RFTURNEO TO SERVICE.
PUBLIC SERVICE OF ^EW MEXICO
SAN JUAN 3
'468 MW - ME«
COAL 0.8 PFRCENT SULFUR
DAVY PnwFRfiAS
STARTUP 1/B1
TH£ UTILITY AWARDED A CONTRACT TO DAVY POWERGAS FOR
ONE MODULF WHICH WILL BRING THE UNIT INTO COMPLIANCE WITH NSPS 8V JAN.
197°. THE FGD SYSTEM FOR THE REMAINDER OF THE FLUE G4S FROM THIS 500-MW
UNIT HAS NOT BEEN SELFCTED. PRIMARY PARTICUIATE CONTROL WILL BE EFFECTED
BY AN UPSTRFAM FSP. THE SINGLF MODULE S3 CURRENTLY UNDER CONSTRUCTION,
CONTRACT NEGOTIATIONS ARE CURRENTLY UNDERWAY FOR THE BALANCE OF THE UNIT
3 FGO SYSTEM AND FOR THF FNTIRE UNIT 4 SYSTEM,,
PUBLIC SERVICE OF MEW MEXICO
SAN JUAN a
872 MW - MEW
COAL O.fl PFRCENT SULFUR
DAVY PnwFRGAS
WELLMAN LORD
STARTUP 1/82
THE UTILITY HAS PLACED A HOLD ON FURTHER ENGINEERING DESISN WORK AT THF.
PRESENT TIMF. THE PRESENT PLANS INCLUDE A WELLMAN LORD 302 RECOVERY
PROCESS. AN ESP WILL RE PROVIDED UPSTREAM OF THE FGD SYSTEM FOR PRIMARY
PARTICIPATE CONTROL. CONTRACT NEGOTIATIONS ARE CURRENTLY UNDERWAY IN
CONJUNCTION WITH UNIT 3. THE PROJFCTED START-UP DATE FOR UNIT <• IS MAY
SALT RTVFH PROJECT
CORUNADO 1
•^50 MW - NEK
COAL l.U PFRTENT SULFUR O&X1
PULLMAN K
1/79
STARTUP
THIS NEW UNIT WILL BURN LOW SULFUR WESTERN COAL. A MAXIMUM OF 80X OF THE
FLIIF GAS WILL BF SCRUBBED TO MEET SULFUR DIOXIDE EMISSION REGULATIONS.
PULLMAN/KELLOGG WILL PROVTDF ? WETR HORIZONTAL SPRAY TOWERS UTILIZING
LIMESTONE SI URRY FOR SO? CONTROL. THE SYSTEM WILL UTILIZE RUBBER-LINED
SLURRY RtCYCLF PUMPS, EACH RATED AT 9800 GPM, RIGIFLAKE-LINED SCRUBBER
MODULES, VER1TCAL HFIL MIST ELIMINATORS AND A MINIMUM OF 20 PERCENT
RFHFAT. THE SLUDGE WILL BE PONDED. THE FOUNDATION IS IN AND STRUCTURAL
WORK IS 70 PtRCFNT COMPLETE.
SALT WTVFK PROJECT
MW - Mt !/
1.0 PFkCFNI SULFUR (MAX)
1/10
THIS NEW UNIT WILL BURN LOW SULFUR WESTERN COAL. A MAXIMUM OF SOX OF THE
FLUF GAS WIIL BF SCRUBBED TO MEET SULFUR DIOXIDE EMISSION REGULATIONS.
PULlMAN/KFLIOGG WILL PROVIDE ? WEIR HORIZONTAL SPRAY TOWERS UTILIZING
LIMESTONE SIURRY FOR SO? CONTROL. THE SYSTEM WILL UTILIZE RUBBER-LINED
SI U»RY Rf.CYCLF PUMPS, bACH RATED AT 9BOO GPM, RIGIFLAKE-LINED SCRUBBER
MnoUlES, VERTICAL HFIL MIST ELIMINATORS AND A MINIMUM OF 20 PERCENT
KFHFAT. THE SLUDGE WILL BE PONDED. THE FOUNDATION IS IN AND STRUCTURAL
WORK IS 50 PERCENT COMPLETE.
1 7
-------
EPA UTILITY FGr> SURVEY: .TUNE 1978 - JULY 1978
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
SALT RIVER PROJECT
CORONAdO 3
350 MW - NEW
COAL 1.0 PERCENT SULFUR (MAX)
VENDOR NOT SELECTED
LIMESTONF
STARTUP 0/87
THIS NEW UNIT WTLL BURN LOW SULFUR WESTERN COAL. 80 PERCENT OF THE
GAS WILL BE SCRUBBED TO MFET SULFUR DIOXIDE EMISSION REGULATIONS.
THE UTILITY IS CURRENTLY CONSIDERING THE INSTALLATION OF TWO HQPI70NTAL
SPRAY TOWERS EMPLOYING 6 LIMES10NE SCRUBBING SOLUTION TO REMOVE 302 FROM
THE FLUE GAS. SCHEDULED COMMERCIAL OPERATION DATE IS 1987. PLANS FOR
AN EMISSION CONTROL SYSTEM HAVF NOT BFEN FINALIZED. SLUDGE WILL PROBABLY
BE PONDED.
SAN MIGUEL ELECTRIC COOP
SAN MIGUEL 1
aoo MW - NEW
LIGNITE 1.67 PERCENT SULFUR
BABCOCK S WILCOX
LIMESTONE
STARTUP fe/80
THE EMISSION CONTROL EQUIPMENT FOR THF COAL-FIREO RADIANT BOILER WILL
CONSIST OF AN ESP UPSTREAM (IF FOUR LIMESTONE SCRUBBING MODULES.
THE SCRUBBER FLUt GAS CAPACITY TS NOMINALLY DESIGNED AT 1.579 MILLION
ACFM (302 F). DESIGN SO? REMOVAL EFFICIENCY IS 86 PERCENT FOR 1100 PPM
S02 INLET. L/K RATIOS ARE 10 AND 45 FOR QUENCHER AND ABSORBERf RESPEC-
TIVELY. RESEARCH COTTRELL HAS BEEN AWARDED THE SLUDGE DISPOSAL CONTRACT.
FGD SYSTEM FOUNDATION AND STRUCTURAL STEEL WORK IS COMPLETE. INITIAL
START-UP IS SCHEDULED FOR LATE SUMMER 1978.
SIKESTON BOARD OF MUNIC. UTIL,
SIKESTtlN POWFR STATION
235 MW - NEW
COAL 2.8 PERCENT SUFUR
BABCOCK & WILCOX
LIMESTONE
STARTUP b/81
BHW WAS AWARDED A CONTRACT FOR THE BOILER AND AIR QUALITY CONTROL SYSTEM.
THE AQCS WILL CONSIST OF 2 F.SP'S FOLLOWED BY 3 FGD MODULES, EACH CAPABLE
OF HANDLING SOX OF THE BOILER LOAD; ONE WILL BE ON STAND-BY AT ALL TIMES.
THE UNIT WILL BURN A 2.8X SULFUR COAL. THE SIKESTON STATION WILL FEATURE
A DOUBLE-LINED STACK, 2 PONDS (ONE FOR FLY ASH, ONE FOR SCRUBBER SLUDGE/
BOTTOM-ASH DISPOSAL), AND a AXIAL FLOW FANS. NO STACK G»S REHEAT TS
PLANNED. MAXIMUM FLUE GAS CAPACITY IS 7«B,390 ACFM 3 288 F. CONSTRUCTION
COMMENCED IN MAY 1978.
SOUTH CAROLINA PUBLIC SERVICE
WINYAH 2
280 MW - NEW
COAL; i.ox SULFUR, i9x ASH
BABCOCK t. WILCflX
LIMESTONE
STARTUP 7/77
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF A 100X CAPACITY ESP
FOLLOWED BY A SOX CAPACITY LIMESTONE FGD SYSTEM. ONE FGD MODULE, CONSIST-
ING OF A VENTURI SCRUBBER AND TRAY TOWER ABSORBER, REMOVES 70X OF THE
INLET 302. REHEAT IS SUPPLIED BY FLUE GAS BYPASS. THE SCRUBBING WASTES
ARE DISCHARGED TO AN ON-SITE, UNLINED DIKED POND. THE NO. 2 UNIT
COMMENCED INITIAL OPERATION IN JULY 1977. THE ACCEPTANCE TEST FOR COM-
MERCIAL CERTIFICATION WAS SUCCESSFULLY COMPLETED IN DECEMBER 1977.
SOUTH CAROLINA PUBLIC SERVICE
WINYAH 3
300 MW - NEW
COAL 1.7 PERCENT SULFUR
BABCOCK K WILCfX
LIMESTONE
STARTUP 5/80
A CONTRACT HAS BEEN AWARDED TO BABCOCK AND WILCOX FOR THE INSTALLATION
OF THE FGD SYSTEM ON THIS UNIT. PARTICULATE REMOVAL WILL BE PROVIDED
BY RESEARCH COTTRELL ESP'S. THE BOILER is COAL-FIRED DRY-BOTTOM UNIT
WHICH WILL BURN COAL WITH A 1.7X SULFUR CONTENT AND HEAT VALUE OF 11,500
BTU/LB. THE GENERATING EQUIPMENT IS BEING SUPPLIED BY RILEY STOKER. 100*
OF THE FLUE GAS WILL BE SCRUBBED. FGD SYSTEM CONSTRUCTION WILL BEGIN
IN DECEMBER 1978. START-UP IS SCHEDULED FOR MAY 1980.
SOUTHERN ILLINOIS POWER COOP
MARION a
184 MW - NEW
COAL 3.0 PERCENT SULFUR
BARCOCK X WILCnx
LIMESTONE
STARTUP 9/78
THE EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRFO BOILER CONSISTS OF AN
ESP FOR PARTICULATE CONTROL FOLLOWED BY 2 SPRAY TOWFRS FOR S02 CONTROL.
LIMESTONE SLURRY WILL BE USED AS THE SCRUBBING REAGENT. SIPC IS NOT PLAN-
NING TO UTILIZE FLUE GAS REHEAT AND IS CURRENTLY PLANNING ON A BRICK
LINING FOR THE STACK. STPC INTENDS TO USE A LANDFILL WITH ASH STABILIZA-
TION OF HASTE FOR SLUDGE DISPOSAL. CONSTRUCTION IS NEARLY 100X COMPLETE
AND THE SYSTEM HAS BEEN AIR TESTED. START-UP IS SCHEDULED FOR AUGUST 1978.
SOUTHERN ILLINOIS POWER COOP
MARION 5
300 MW - NEW
COAL 3.0 PFWCENT SULFUR
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 0/8«
SOUTHERN ILLINOIS POWER COOP TS PLANNING A NEW COAL-FIRED UNIT FOR ITS
MARION STATION, MARION 5. THE FGD PROCESS HAS NOT BEEN DECIDED. THE UNIT
WILI FIRE 3.0% SULFUR COAL AND MAY START UP AS EARLY AS 1983. THE UTILITY
IS WAITING FUR THE FINALIZATION OF THF S02 REGULATIONS THEY WILL HAVE TO
MFET.
SOUTHERN INDIANA GAS & El.EC
A. B. PRflwN 1
250 MW - NEW
COAL 3.75 PERCENT SULFUR
FMC CORPORATION
DOUBLE ALKALI
ST«RTUP 1/7S
THE UTILITY HAS AWARDED A CONTRACT TO FMC FOR THE INSTALLATION OF A
DOUBLE ALKALI SCRUBBING SYSTEM UTTLI/CTNG SODA ASH AND LIME. THIS UNIT IS
A PART OF A NEW POwFW STATION LOCATED IN WEST FRANKLIN, INDIANA. THE
SYSTEM WILL PRODUCE FILTER CAKE AS A WASTE PRODUCT WHICH WILL BE DIS-
PnsFD OF IN AM niM-STTF LANDFILL. THF PARTICULATE EMISSIONS WILL BE CON-
TROLLED BY A BUFLL-FNVIROTECH COLD-SIDE FSP. THE CONSTRUCTION WOHK AND
ENGINEERING IS N£4RI Y 10X COMPLFTF.
-------
FPA UTILITY FGD SURVEY: JUMP 1979 - JULY 197B
SECTION ?
STATUS OF FGO SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
SOUTHERN MISSISSIPPI ELECTRIC
R. D. MORROW 1
180 MW - MEW
COAL 1.0 PERCENT SULFUR
PII EY STOKFR / EWVTRONEERING
LIMESTONF
STARTUP 8/78
A CONRTACT WAS AWARDED BY SME TO RHEY RTOKER/ENVIRONEER1NG FOK THIS FGD
SYSTEM. PAKTICULATES WIIL BE CONTROILFO BY A HIGH-EFFICIENCY ESP UPSTREAM
OF THF. FGD SYSTFM. DESIGNED S02 AND PARTICULATE REMOVAL EFFICIENCIES ARE
85 AND 99.6 PERCENT, RESPECTIVELY. A WATER SPRAY HAS BEFN ADDED IN THE
BY-PASS DUCT TO PROTECT THE LTNFR FROM TEMPEKATURF EXCURSION. SLUDGF WILL
BF STABILIZED WITH FLYASH AND DISPOSED OF UN-SITE. CONSTRUCTION OF THE WET
LIMESTONE SCRUBBING SYSTEM TS COMPLETE.
SOUTHERN MISSISSIPPI ELECTRIC
R. D. MORROW s
180 MW - NEW
COAL J.O PERCENT SULFUR
RILEY STOKER / ENVIRONEERI^G
LIMESTONE
STARTUP 10/78
SOUTHWESTERN ELECTRIC POWER
HENRY W. PFRKEY 1
720 MW - NEW
LIGNITE
AIR CORRECTION DIVISION, UOP
LIMESTONE
STARTUP 6/83
A CONTRACT WAS AWARDED BY SME TO RILIY STOKER/ENVIRONEERING FOR THIS FGD
SYSTEM. PARTICULATES WILL BF CONTROLLED BY A HlfiH-EFFTCtENCY ESP UPSTREAM
OF THE FGD SYSTEM. DESIGN SULFUR OIOXTDE AND PARTICULATE REMOVAL EFFI-
CIENCIES ARF «5 AND 99.fe PERCENT, RESPECTIVELY. A WATFR SPRAY HAS
BFEN ADDED IN THE BY-PASS DUCT TO PROTECT THE LINFR F»OM TEMPEKATURE
EXCURSION. SLUDGE WILL BE STARILI7ED WITH FLYASH AND DISPOSED ON THF PLANT
SITE. CONSTRUCTION OF THE rtET LTMESTONE SCRUBBING SYSTEM IS 80 PERCENT
COMPLETE.
A CONTRACT FOR THE EMISSION CONTROL SYSTEM HAS 9EEN AWARDED TO THE AIR
CORRECTION DIVISION OF UOP. THE SYSTEM DESIGN INCLUDES TWO COLD-SIDE ESP'S
FOR PARTICULATE REMOVAL UP-STREAM FROW 4 SPRAY TOWERS WHICH UTILIZE LIHE-
STONE SLURRY FOR SO? CONTROL. SLUDGE DISPOSAL WILL 86 HANDLED BY AN IUC3
SYSTEM. START-UP IS EXPECTED BY JUNF !983,
SPRINGFIELD CITY UTILITIES
SOUTHWEST 1
200 MW - NEW
COAL? 3.5X SULFUR, 152 ASH
»IR CORRECTION DIVISION, UOP
LIMESTONF
STARTUP 0/77
SPRINGFIELD WATER LIGHT & PWR
DALLMAN ?
190 MW - MEW
COAL 3.0-4.3 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE
STARTUP 7/80
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED UNIT CONSISTS OF A
FOUR-FIELD HIGH EFFICIENCY ESP C99.6X DESIGN) AND s TURBULENT CONTACT AB-
SORBER MODULES (SOX DESIGN) FOR THE CONTROL OF PARTICULAR'S AND S02, BOTH
THE ESP AND LIMESTONE FGD SYSTEM «RE SUPPLIED 3Y UOP. THE SCRUBBING
WASTES ARE DEWATERED BY A ROTARY DRUM VACUUM FILTER AND THE FILTER CAKE IS
HAULED AWAY TO A LANDFILL. TNTTIAL OPERATION OF THE FGD SYSTEM OCCURRED IN
APRIL 77. IN SEPT. 77, THE UNIT SUCCESSFULLY COMPLETED COMPLIANCE TESTING.
A CONTRACT HAS BEEN AWARDED TO RESEARCH COTTSELL FOR THE INSTALLATION Of
A LIMFSTONE FGO SYSTEM, REQUIRED SULFUR DIOXIDE REMOVAL EFFICIENCY
IS 90 PERCENT. A SLUDGE DISPOSAL STRATEGY H*S NOT BEEN FINALZZEDt BUT
THE UTILITY IS CONSIDERING EITHER PONDING OP LANDFILL. CONSTRUCTION OF
THE FGO SYSTEM SHOULD COMMENCE IN LATE 1978,, FGD START-UP IS SCHEDULED
FOR JULY 1980. BOILER OPERATION IS SCHEDULER TO COMMENCE IN JUNE 1<»78.
ST. .JOF 7INC
6. F. WEATON i
60 MW - RETROFIT
COAL 3.0 PERCENT SULFUR
BUREAU OF MINES
CITRATE
STARTUP 10/78
CONSTRUTTTON CONTINUES ON THE CITRATE PROCESS SCRIBING SYSTEM WHICH
WILL CONTROL SO? EMISSIONS FROM A 60-MW COAt.-FJREO POWER GE^4ERAT^NG
UNIT AT ST. JOE MINERALS, THIS UNIT PROVIDED POWER FOR THE LOCAL UTILITY
GRID. FGD SYSTEM START-UP IS SCHEDULED FOR OCTOBER 1978. THE REGENERABLE
FGD SYSTEM WILL PRODUCE ELEMENTAL SULFUR AS 4 BY-PRODUCT.
TENNESSEE VALLEY AUTHORITY
SHAWNEF 10A
10 MW - RETROFIT
COAL: 2.9% SULFUR, is.ex ASH
AIR CORRECTION DIVISION, UOP
LIME/LTMESTONE
STARTUP 4/72
REFER TO THF BACKGROUND INFORMATION IN SECTION 3 OF THIS REPORT. THIS
TURBULENT CONTACT ABSORBER (TCA) LIME/LIMESTONE SCRUBBING SYSTEM HAS BEEN
OPERATIONAL SINCE APRIL 197?. THIS TEST PROGRAM IS FUNDED BY THE EPA WITH
TVA AS THE CONSTRUCTOR AND FACILITY OPERATOR THE 8FCHTEL CORP. OF SAN
FRANCISCO IS THE MAJOR CONTRACTOR, TEST DIRECTOR, AND REPORT WRITER.
DURING THE REPORT PERIOD, OPERATIONS WERE CONDUCTED WTTH MGO ADDITION TO
BOTH LIME AND LTMFSTONE SLURRY CIRCULATTNG THROUGH THE UNIT.
TENNESSEE VALLEY AUTHORITY
SHAWNEF 10B
10 MW - RETROFIT
COAL! ?.9Z SULFUR, 15.8X ASH
CHEMICO
LIME/LTMESTONE
STARTUP 4/72
REFER TO THE BACKGROUND INFORMATION IN SECTION 3 OF THIS REPORT. THIS
VENTURI/SPRAY TOWER LIME/LIMESTONE SCRUBBING SYSTFM HAS BEEN OPERATIONAL
SINCE APRIL 197?. THIS TEST PROGRAM IS FUNDED BY THE EPA WITH TVA AS THF
CONSTRUCTOR AND FACILITY OPERATOR. THE RECHTEL CORP. OF SAN FRANCISCO IS
THE MAJOR CONTRACTOR, TFST DIRECTOR, AND REPORT WRITER. DURING THF REPORT
PERIOD, FORCED OXIDATION WAS EVALUATED ON FLY ASH-FREE FLUE GAS WTTH
LIME AND LIMESTONE SLURRY AS THE SCRUBBING AGENT.
19
-------
FPA UTILITY Ft;n SURVEY: JUNE 197« - JULY 197ft
SECTION 2
STATUS OF FGO SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
TENNESSEE VALLFY AUTHORITY
WIDOWS CREFK 7
•575 MW - RETROFIT
ro»L 3.7 PFHCENT SULFUR
COMBUSTION ENGINEERING
I IMfcSTONE
STARTUP 10/BO
TENNESSEE VALLEY AUTHORITY ANNOUNCED THAT A CONTRACT HAS BEEN AWARDED TO
COMBUSTION ENGINEERING FOR A LIMESTONE SLURRY SPRAY TOWER F6D SYSTEM. THf
FGD SYSTEM WILL TREAT HIGH SULFUR COAL FLUE GAS. THE SPRAY TOWER ABSORBED
WTLl RE CONSTRUCTED OF ^17L STAINLESS STEEL. THE NO. 7 UNIT FIRES COAL
WITH THE SAME CH AR ACTF.R 1ST ICS AS THE COAL FIRED IN THE NO. 8 UNIT.
INITIAL OPERATIONS ARE SCHEOULEO FOR OCTOBER 1980.
TFNNFSSEF VALLFY AUTHORITY
WIDOWS CREEK 8
550 MW - RETROFIT
COAL; 3.7Z SULFUR, 17X ASH
TENNESSEE VALLEY AUTHORITY
LIMESTONE
STARTUP 5/77
TEXAS MUNICIPAL POWER AGENCY
RIBBONS CREEK 1
000 MW - MEW
LIGNITE - 1.06 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE
STARTUP
TEXAS POWER 8 LIGHT
SANDOw 4
545 MW - NEW
LIGNITE
COMBUSTION ENGINEERING
LIMESTONE
STARTUP 7/80
HFFER TO SECTION * OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE EMISSION CONTROL SYSTEM FOR THIS 550-MW COAL-FIRED POWER-GENERATING
UNIT CONSISTS OF EXISTING ELECTROSTATIC PRECIPITATQRS FOLLOWED BY FOUR
PARALLEL SCRUBBING TRAINS, EACH CAPABLE OF HANDLING 25 PERCENT OF THE
BOILER FLUE GAS FROM UNIT 8. EACH TRAIN INCLUDES A RECTANGULARTHROAT
VENTURI SCRUBBER AND A GRID-TOWER ABSORBER SUPPLIED BY POLYGON. THE GRID
TOWER CAN BE CONVERTED TO A MOBILE-BED TOWER IF GREATER S02 REMOVAL IS
REQUIRED.
COMBUSTION ENGINEERING WAS AWARDED A CONTRACT TO DESIGN AND SUPPLY
A aOO-MW LIGNITE-FIRED BOILER, ESP, AND FGD SYSTEM AT GIBBONS CREEK
STEAM ELECTRIC STATION UNIT NO. 1. THE BOILER WILL BURN 1.06X SULFUR
LIGNITE. FLUE GAS WILL BE CLEANED OF PARTICULATES BY A COLD-SIDE ESP
(99.73X EFFICIENCY). S02 WILL BE REMOVED BY 3 SPRAY TOWER MODULES UTILIZ-
ING A LIMESTONE SLURRY (72.5 TO 87.5X EFFICIENCY). A CONTRACT HAS BEEN
AWARDED TO IUCS FOR 3LUOGF DISPOSAL. COMMERCIAL START-UP HAS BEEN SET FOR
JANUARY 1982.
COMBUSTION ENGINEERING HAS BEEN CHOSEN AS THE BOILER AND FGD VENDOR FOR
THIS UNIT. BOILER CONSTRUCTION BEGAN ON SEPTEMBER 9, 1977. PARTICULATE
REMOVAL EQUIPMENT WILL BE LOCATED ON THE COLO-SIOE OF THE AIR HEATER.
SOMF PORTION OF FLUE GAS WILL BYPASS THE SCRUBBER FOR REHEAT. THE SPENT
SLURRY WILL BE PONDED AND WATER RECYCLED. FGO CONSTRUCTION IS SCHEDULED
TO BEGIN NOVEMBER 1978.
TEXAS POWER & LIGHT
TWIN OAKS 1
750 MW - NEW
LIGNITE
VENDOR NOT SELECTED
LIMESTONE
STARTUP 8/flJ
THIS UNIT WILL BE JOINTLY OWNED BY TP8L AND ALCOA. A FIRM DECISION HAS
NOT BEEN MADE WHETHER TO INSTALL FGD FACILITIES. THIS IS PRIMARILY
DUE TO THE FACT THAT SUCH A DECISION IS NOT YET REQUIRED IN THE
UTILITIES PLANNING TIMETABLE.
TEXAS POWER * LIGHT
TWIN OAKS a
750 MW - NEW
LIGNITE
VENDOR NOT SELECTED
LIMESIONF
STARTUP 1/80
THIS UNIT WILL BE JOINTLY OWNED BY TP8L AND ALCOA. A FIRM DECISION HAS
NOT BEEN MADE WHETHER TO INSTALL FGO FACILITIES. THIS IS PRIMARILY
DUE TO THE FACT THAT SUCH A DECISION IS NOT YET REQUIRED IN THE
UTILITIES PLANNING TIMETABLE.
TEXAS UTILITIES
FOREST GROVE 1
750 MW - NEW
LIRNITF
VENDOR NOT SFLECTEO
PROCESS NOT SELECTED
STARTUP 0/81
TEXAS UTILITIES IS PLANNING A NEW 750-MW UNIT AT THE FOREST GROVE SITE.
TWO ESP'S WILL BE INSTALLED FOR PARTICULATE CONTROL,, THE UTILITY IS
CIIRRENTL* REQUESTING BIDS FOR AN FGD SYSTEM. START-UP IS SCHEDULED FOR
L«TF 1981. THE BOILF-W WILL BE SUPPLIED BY THE BABCOCK * WILCOX COMPANY.
TFXAS UTTLTTTES
MAPTIN L»KF 1
793 MW - NEW
COAL; i.0% SULFUR
RESEARCH COTTKFLL
I I"ESIOWF
STARTUP A/77
THIS NfW 79^-MtM POWFR GENERATING UNTT FTRFS TFXAS LIGNITE WHICH CONTAINS
0.9? SULFUR CAVG) AMD e.ax ASH CAVG). IN ORDER TO MEET FEDERAL NSPS THE
UNIT HAS BEEN EQUIPPED WITH AN EMISSION CONTROL SYSTEM WHICH INCLUDES
COLD-SIDE ESP'S AND A LIMESTONE FGO SYSTEM BOTH SUPPLIED BY RESEARCH-COT-
TRELI . THE FGD SYSTEM CONSISTS OF 6 PACKED/SPRAY TOWER ABSORBERS WHICH
TREAT 75* OF THE TOTAL BOILER FLUE GAS. THE REMAINING FLUE GAS IS BYPASSED
FOK RFHFAT. TOTAL 302 REMOVAL EFFICIENCY IS 70.5X. THE FLUE GAS CLEANING
»KF S1AHTLTZFD AND DISPOSED IN AN ON-SITE, LINED POND.
?0
-------
UTILITY FGD SU&VFY: JUNE 1978 - JULY
STATUS OE FRO SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
TFXAS IITTI TT TES
MARTTN LAKF ?
793 MW - Nfc V
CO/il.; l.o* S»I_FUP
RESEARCH
I IMESTONF
STARTUP
TFXAS uiTLITTtS
MARTTN LAKF ^
79^ u|W - MFW
COAL 1.0 PERCENT SULFI.IW
RESEARCH COTTRPLL
LIMESTONE
STARTUP 1?/7S
TEXAS UTTLTTTES
MARTIN LAKE i
79? MW - NEW
COAL 1.0 PERCENT SULFUR
RESEARCH COTTKFLL
IIMESTONE
STARTUP 11/8.2
THIS NEW 797~Mrt POftFR (jFNFRATTNG UNIT FTKFS TEXAS LTGMTF CONTAINING
0.9* SULFUR (AVG.) ANO K% ASH (AVR.1. TO MfET FEDERAL NSPS, THE UNIT WILL
HF FtiinopFD ATTH AN EMISSION CONTROL SYSTEM CONSISTING OF COLD-SIDE ESP'S
A"'L/ A LTUFSTfjNE FRO SY&TfM, HOT" SLfPPLIFD BY RESE4RCH-C<">TTRELl. THE FGO
SYSTEM CONSISTS UF h PACKED/SPRAY TOwFR ABSORBERS WHICH WILL TREAT 75* OF
THE. TOTAL HIRER Ftllt GAS. THF RpMATNTNG RAS WIIL BE BYPASSED FOR RFHFAT.
TOTAL DFSTbN SO? RE.MUVAI FFFICIFMCY IS 7u.5*. THE FLUE RAS CLEANING WASTES
MLl RE STARII I?cn AND DISPOSED IN AN ON-SITE. LINED POND.
THIS New 79^-Mw POWER fjFNFRATTNG UNIT WILL FIRE TEXAS LIGNITE CONTAINING
<).
-------
EPA UTILITY FGD SURVEY: JUNE i"J7s - JULY
UNIT IDENTIFICATION
SECTION ?
STATUS OF FRO SYSTEMS
CURRENT STATUS
WISCONSIN POWER * LIGHT
COLUMBIA a
587 MM - NEW
COAL 0.8 PERCENT SULFUR
CHEMICO
LIME/ALKALINF FLYASH
STARTUP 1/80
A CONTRACT HAS REFN AWARDED TO CHEMTCO FOP A LIME/FLYASH FGD ?YS-
TEM. IT WILL CONSIST OF TWO SPRAY MODULES WITH A HOT-SIDE ESP FOR PAR-
TICIILATE REMOVAL . A CLOSEn LOOP WATER SYSTEM IS ANTICIPATED WITH FLYASH
STABILIZATION OF THE SLUDGE. A SLUDGE DISPOSAL POND LOCATED OFF-SITE IS
BEING CONSinERED. THE FGD SYSTEM TS BEING DESIGNER TO TREAT bOI OF THE
FLUF GAS RESULTING FROM THE COMBUSTION OF LOW SULFUR COLSTRIP COAL. THE
REMAINING 10X WILL RE BYPASSED FOR REHEAT. CURRENTLY, THE UTILITY IS
MAKING TESTS TO STUDY ALTERNATE S02 COMPLIANCE STRATEGIES.
-------
FPA UTILITY FGD SURVEY: JUNt 1978 - JULY 1978
SECTION 3
PFRFORMANCt DESCRIPTION FnR OPERATIONAL I-GD SYSTEMS
UTILITY NAME
UNIT NAMF
UNIT LOCATION
UNIT HATING
ARIZONA PUBLIC SERVICE
CHOLLA 1
JOSEPH CITY ARIZONA
115 MW
FLIFL CHARACTERISTICS COAL: 0.55* SULFUR, 10* ASH
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
EFFICIENCY:
PARTICULATES (ACTUAL)
(DESIGN)
S02 (ACTUAL)
(DESIGN)
WATER MAKE UP
SLUDGE DISPOSAL
RESEARCH COTTRFLL
LIMESTONE
RfTROFTT
10/73
99.7 PERCENT
99.7 PERCENT
50-60 PERCENT
58.S PERCENT
OPEN LOOP 1.04 GPM/MW
IINSTABILTZFD/FLYASH POND
OPFRATING EXPERIENCE UPDATE:
RELIABILITY (X)
MONTH MODULE A MODULE B
JAW. 78 97 91
FEB. 78
99
88
MAR.
APR.
MAY
JUNE
JULY
78
78
78
7«
78
7«
100
87
100
99
74
100
98
100
100
COMMENTS
THE FLOUDED DISC SCRUBBER TANK HFAOER FOR SLURRY LIMF.STONE WAS
REPAIRED AFTER BF1NG D»MAGFD DURING THE OVFRHAUL. THE BOILER
WAS OPFRATFD ONLY 135 HRS. DURING JANUARY AS THE OVERHAUL HAD
F.XTENOFD INTO THIS MONTH. THE A-SIDE AND B-SIDE SERVICE HOURS
WERE 131 AND 1?3 HOURS RESPECTIVELY.
SOME MINOR LEAK REPAIRS AFTER THF OVERHAUL/CLEANING TOOK PLACE
DURING FEBRUARY. SF.RVTCF HOURS WERE: BOILFR = 642, A-SIDE =
63ft, B-SIDF = 561.
ONE FORCED SHUTDOWN OCCURRED ON THE A-SIDE. SERVICE HOURS WERE!
BOILF.K = 744, A-SIOE = 714, P-SIDE = 735.
A MINOR LEAK RFPAIR WAS NECESSARY AFTER AN OVERHAUL/CLEANING.
SERVICF HOURS WERE: BOILER = 7?o, A-SIDE = &f>7. R-SIOF = 720.
THFRE WfcRE NO SIGNIFICANT PROBl EMS REPORTED. ONLY GENERAL
MAINTENANCE WAS PERFORMED ON THE SYSTEM DURING HAY.
NO PROBLEMS WERfc NFPOHTEn FOR JUNE.
ONLY ROUTINE MAINTENANCE WAS RFUUIRED ON THE FGD SYSTEM DURING
JULY.
-------
FPA UTILITY FGH SURVEY: .JUNE 1978 - JULY 1978
SFCTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
UTILITY NAME ARIZONA PUBLIC SERVICE
UNIT N»ME CHOLLA a
UNIT LOCATION JOSEPH CITY ARIZONA
UNIT RATING 250 MW
FUEL CHARACTERISTICS COAL; 0.5X SULFUR, 10X ASH
FGD VENDOR RESEARCH COTTRELL
PROCESS LIMESTONE
NEW OR RFTROFIT NEW
START UP DATE 6/78
EFFICIENCY:
PARTICULATES (ACTUAL)
(DESIGN) 99.7 PERCENT
SOa (ACTUAL)
(DESIGN) 75.0 PERCENT
WATER MAKE UP OPEN LOOP
SLUDGE DISPOSAL UNSTABILIZED/SLUDGE POND
OPERATING EXPERIENCE UPDATE!
APRIL-MAY 1976 - THE SCRUBBER ON UNIT a IS NOW WORKING MOST OF THE TINE AND IS THEREFORE CONSIDERED
TO BE OPERATIONAL. SOME PROBLEMS HAVE OCCURRED WITH VIBRATIONS THROUGH THE SYSTEM. THE EPA HAS
GRANTED THE UTILITY AN EXTENSION FOR COMPLIANCE. THE COMPLIANCE TEST SHOULD BE COMPLETED BY AUGUST
15 WHICH IS THE DATE THAT HAS NOW BEEN SET FOR COMERCIAL START-UP.
JUNE-JULY 1978 - UNIT 2 IS STILL UNDERGOING SHAKEDOWN AND DEBUGGING OPERATIONS. THE SLURRY RECYCLE
PIPING HAS EXPERIENCED CONTINUAL VIBRATION. THE CONTRACTOR HAS BEEN INJECTING NITROGEN (CAS) INTO
THE LINES TO DAMPEN THE VIBRATIONS (AIR WAS NOT USED BECAUSE THE SULFITE WOULD BE OXIDIZED TO
SULFATE AND RESULT IN SCALE FORMATION IN THE SYSTEM). A PROBLEM HAS ALSO OCCURRED WITH PEELING OF
THE CORROSION RESISTANT COATING IN THE DOWNCOMER AREA IN ONE OF THE ABSORBER MODULES.
-------
EPA UTILITY FGD SURVEY: JUNE 1978 - JULY 1978
SECTION 3
PERFORMANCE DFSCRIPTlnN FOR OPERATIONAL FRO SYSTEMS
UTILITY NAME CENTRAL ILLINOIS LIGHT
UNIT NAMF OUCK CREEK i
UNIT LOCATION CANTON ILLINOIS
UNIT RATING 400 MW
FUFL CHARACTERISTICS CO'LJ ?.75X SUI FUR, p.SX ASH
FGn VfMDOR RHEY S10KER / fVVIRONFERING
PROCESS LIMESTONE
NEW OR RETROFIT MEW
START UP OATF 7/7"
EFFICIENCY:
PARTICULATES (ACTUAt) 99.fl PERCENT
(OFSTGN) 99.B PERCENT
Stl2 (ACTUAL) 91. * PERCENT
(DESIGN) a^.o PERCENT
WATER MAKE UP CLOSED LOOP
SLUDGE DISPOSAL IINSTABTL IZF.D/SLUOGE POND
OPERATING EXPERIENCE UPDATE:
JUNE-JULY 1978 - ALL « MODULES BECAME OPERATIONAL ON JULY ?4. THE SYSTEM HAS OPERATED INTERMIT-
TENTLY THROUGHOUT THE PERIOD. MODIFICATIONS WERE M«PE TO THE SLURRY TRANSFERr SINCE IT WAS FOUND
TO BE UNDER DESIGNED. A PLUGGING PROBLEM OCCURRED IN THE FGD SYSTEM DUE TO COAL FINES BEING MIXED
IN KITH THE SLURRY. THIS RESULTED FROM THF USF OF COMMON UNLOADING SYSTEMS FOR THE COAL AND
LIMESTONE.
-------
FP» n i u i T v rb'1 SURVEY:
1Q7» - U'LY 1Q/'
PFHFiiRl-ANCh OFSTRIPT tnui FOR nPt R AT J ON AL FGI) SY
111 T| IT Y NAME
UNIT NAMF
UNIT LOCATION
IINTT RATING
COI iJMhHS 14 SnuTHFRN nuTU El.hr.
rnMtsviLiF 5
rONESVTLLE UHin
«oo MW
FUFl. CHARACTEHTSTICS COAL: a,7% SULFUR, IS. IX ASH
FGD VENDER AIR CORRECTION DIVISION, HOP
PROCESS LIME (MG-P
NEW OR RFTRQF1T NEW
START IIP OATF 1/77
FFFiriFNCY!
PARTjrULATfS (ACTUAL)
sna (ACTUAL)
fDFSIUM) 80. 5 PERCENT
WATE" MAKE UP OPFN LOOP; i.2"5
SLIIDRE DISPOSAL si»BiLTZFn/LANnFTLi
EXPERIENCE UPDATF:
PERIOD
OPERATION TIME (HR5
BOILER A-STOF B-SIOE
JAN. 78 0
ALL INDEX VALUES - 0 PERCENT
FEB. 76
ALL INDEX VALUES - 0 PERCENT
MAR. 78 379 72
AVAILABILITY IX) = 20
OPERA8TLITY f%) - 19
RELIABILITY (X) - ha
UTILIZATION (z) = 10
APR. 7« 7tfe 41fl
AVAILABILITY m - h?
OPFR««ILTTY (x) - SP,
RELIABILITY C%1 - 61
60
If.
5 a
R
fcS
COMMENTS
IMF UNIT WAS SHUTDOWN FOR OVERHAUL THROUGH FEBRUARY AND
STARTED IIP ON MARCH !&„
IMPURITIES IN LIME HAVF CAUSED PLUGGING PROBLEMS. PH
CONTROLS AND 502 ANALYSERS H&VE GIVEN SOME OPERATIONAL
PROBLEMS.
THF SYSTEM riAS DOWN DIJF TO AN1 EXCESS OF FLOCCULAWT
TM THE THICKFNER. THIS CAUSED 6 HIGH AMOUNT OF SOLIDS
IN THE OVERFLOW THAT RFSULTEO IN PLUGGING PROBLEMS IN
THF ABSURHF.R MODULES.
MAY 7R 7?0
AVAILABILITY (% )
npFKABTLITY (XI :
RELIABILITY f%l :
UTILIZATION (X) =
JUNE 7fl 7?0
AVAILABILITY I H )
RELIABILITY (zi
UTILIZATION ui
JULY 7« 7?7
AVAILABILITY (?
OPFRABTLITY (X)
RELIABILITY (X)
UTILTZATTOM (X)
as
aa
an
77
77
«78
fib
50
51
30
30
30
37
37
3?
THF SYSTFM WAS TAKFN OUT OF SERVICE RECALISF OF CONTINUED
PHHRLtMS KvTTH THF FLOCHULANT FEED SYSTEM. THE THICKENER
WAS EMPTIED TO RESTORE PROPER FLOCCULANT BALANCE.
FLOCCULANI WAS CLEANED OUT.
AN FRP PIPING FAILURE TN THE MIST ELIMINATOR WASH
SYSTFM OCCURRED IN JUNE.
OUTAGE TIME HAS DIJF TO PLUGGING IN THE MIST FLIMINATOK
»iMD SCRUPBFR HALL REGIONS.
-------
FPA UTILITY FGn SURVEY! JUNE 1978 - JULY 197fl
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FRO SYSTEMS
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
COLUMBUS S SOUTHERN OHIO ELEC.
CONESVTLLE 6
CONESVTLLE OHIO
400 MW
FUFL CHARACTERISTICS COAL: 4.67X SUIFUH, 15.1? ASH
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FFFICIFNCY:
PARTICUI.ATES (ACTUAL)
(DESIGN)
S02 (ACTUAL)
(DESIGN)
WATER MAKE UP
SLUDGE DISPOSAL
AIR CORRECTION DIVISION, UOP
LIME (MG-PROMQTEO)
MEW
6/7S
99.6 PERCENT
89.5 PERCENT
OPEN LOOP
STABILIZED/LANDFILL
OPERATING EXPERIENCE UPDATE:
OPERATION TIME (HR)
PERIOD BOILER A-STDE B-SIDE
JUNE 78 524 173 !7S
AVAILABILITY (X) = 56 44
OPFRABTLITY (X) = 49 33
RELIABILITY (X) = 51 34
UTILIZATION (X) = 42 30
JULY 7« 502 1*6 96
AVAILABILITY m = 83 70
OPERA8TLTTY (X) = 37 19
RELIABILITY (X) = 63 33
UTILIZATION (2) = 25 13
COMMENTS
CONTROL OF THE LOUVERED DAMPER OF THE BYPASS SYSTEM
WAS LOST. THE RESULT WAS A BACK PRESSURE BUILD UP
THAT AUTOMATICALLY TRIPPED THE BOILER OFF. SCRUBBER
CONTROLS WERE NOT OPERATING PROPERLY AND NEEDED ADJUST-
MENT.
THE LOUVERED DAMPER PROBLEM CONTINUED. SCRUBBER
CONTROLS HERE ADJUSTED. THE FRP TRANSFER LINE FROM
THF THICKENER TO THE IOCS SYSTEM RUPTURED AS A RESULT
OF A WATER HAMMER IN THE LINES AND HAD TO BE REPAIRED.
THE LINE BECAME PLUGGED AT A "Y" VALVE DURING DOWN TIME.
27
-------
UTILITY
MlRVFYt
1Q7B -
1 « /
S F C T I n N 3
PERFORMANCE DESCRIPTION FOK OPERATIONAL H50 SYSTEMS
IITTLITV NAME
IIMTT N«MF
IINTT LOCATION
UNIT RATING
nuOUESNE LIGHT
FLRAMA POWER STATION
FLRAMA PENNSYLVANIA
S10 MW
FUFL CHARACTERISTICS CO«L: ?% SULFUR
Fen VENDOR
PROCESS
MEW OR RETROFIT
START UP P»TE
FFFIflFNCY:
PARTICULATES (ACTUAL)
302
fDFSIGN)
(ACTUAL)
(DESIGN)
WATER MAKE UP
SLUDGE DISPOSAL
CHFMICO
LIME
RETROF n
10/75
99.0 PERCENT
99.0 PERCENT
75 + PERCENT
83.0 PERCENT
OPEN LOOP
STAHILTZFD/LANDFTLL
OPERATING EXPERIENCE UPDATE:
PERIOD
JAN, 78
OPERATING HOURS
BOILER SCRUBBER-ABSORBER VESSELS
101
-------
nunUFSNE LTGHT
PERIOD
APR. 7ft
MAY 78
OPERATING HOURS
RUILFK SCHUSHER VESSFLS
101 201 301 401 SOI
JUNE 78
JULY 7«
EPA UTILITY FGD SURVEY! JUNE 1978 - JULY 1978
ELRAMA POWER STATION
BOILER 3 IS STILL BEING OVERHAULED. ALL FGO SYS-
TEM CONSTRUCTION IS COMPLETE AND COMPLIANCE TEST-
ING WILL TAKE PLACF IN JULY WHEN UNIT 3 is PUT IN
SERVICE. THE PRFLTMINARY TESTING CONDUCTED DURING
THE PERIOD VERIFIED SYSTEM SOS REMOVAL EFFICIENCY.
NO HOURS WERE REPORTED DUE TO IRREGULAR SYSTEM
OPERATION DURING THE TESTING. THE AVAILABILITY
FOR ALL TRAINS WAS BOX.
MODULE 301 WAS PULLED OFF FOR A MAJOR CLEANING
OVER THE PERIOD. THE UTILITY HAS EXPERIENCED
MIST ELIMINATOR PLUGGING APPARANTLY AS A RESULT
OF LOW PH. THE CHRONIC INABILITY TO CONTROL
CHEMISTRY (PH3 IS DIRECTLY RtLATED TO GRIT BUILD-
UP IN THE LIME HANDLING AND SLURRY PREPARATION
SYSTEM. THE UTILITY IS CURRENTLY STUDYING HAYS TO
TIGHTEN THE WATER BALANCE BY TAKING THICKENER
SUPERNATE FOR THE MIST ELIMINATORS INTERMITENTLY
WITH CLEAR SERVICE WATER. THE COMPLIANCE TEST
SHOULD TAKE PLACE DURING THE NEXT REPORT PERIOD.
-------
FPA UTILITY F(;r> SURVEY: IUMF 1Q7« - IUIY l°7«
SFCTT.ON $
PERFORMANCE DESCRIPTION Hit* OPERATIONAL FRO h Y S T f-
UTILITY NAME
UNIT NAMF
11N T T LOCATION
UNIT RATING
LH-.HT
PHILI- 1 pb P'1|*FH STAT1M.J
SOIIIM HEIGHT PFNMSVL"A
41 U MW
FUFL CHAPACTFRTSTICS COAL: ?* SULFUR
FGD VENDOR
PRHCFSS
NFW OR RETROFIT
START UP OATF
CHFMTCn
LIME
RETROFIT
7/73
FFFICIFNCY:
PARTICULATES (ACTUAL) 99.0 PERCENT
(DESIGN) 99.0 PERCENT
S02 (ACTUAL) 7S+
(DESIGN) 83.<
WATER MAKE UP OPEN LOOP
SLUDGE DISPOSAL ST AB IL T ZF D/L ANDMLL
FXPt'RIEMCE UPOATF:
OPEHATTNT, HOURS
MONTH
1
ROTLF.R
3
SCRURBER-ARSORBER
101 ?01 301
401
JAN. 7« 6?7 57
-------
OUOUESNE LIGHT
EPA UTILITY FGO SURVEY! JUNE 1978 - JULY 1978
PHILLIPS POWER STATION
JUNE 78
JULY 78
THE INTERNAL MIST ELIMINATOR ON MODULE ?oi WAS REMOVED AND CLEANED OVER THE PERIOD. THE
FGO SYSTEM HAS ACCUMULATED APPROXIMATELY ?4,000 HOURS OF OPERATION OM ALL FOUR MODULES SINCE
START-UP. THERE HAVE BEEN WATER BALANCE PROBLEMS AT THE UNIT WHICH CONTRIBUTED TO THE OCCUR-
RANCE OF LOW PH AND EVENTUALLY MIST ELIMINATOR PLUGGING. THE MIST ELIMINATOR PLUGGING TS
ALSO RELATED TO LOW PH RESULTING FROM LIME HANDLING AND SLURRY PREPARATION SYSTEM FAILURE.
GRIT BUILD UP HAS BEEN THE MAJOR SOURCE OF THE REAGENT HANDLING SYSTEM FAILURES. THE
UTILITY IS CURRENTLY STUDYING WAYS TO TIGHTEN THE WATER BALANCE BY TAKING THICKENER
SUPERNATE FOR THE MIST ELIMINATORS INTERMITTENTLY WITH CLEAR SERVICE WATER. THE COMPLIANCE
TEST SHOULD TAKE PLACE DURING THE NEXT REPORT PERTOO.
-------
FPA UTILITY Fc;o SURVEY: JUNE 1<>7K - JULY i<>7fl
SECTION i
DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
UTILITY NAME INDIANAPOLIS POwEK * LIGHT
UNIT IMAMF PETERSBURG 3
UNIT LOCATION PETERSBURG INDIANA
UNIT RATING 510 MW
FUFL CHARACTERISTICS COAL: 1.25* SULFUR, 9.5% ASH
FGD VENDOR AIR CORRECTION DIVISION, UOH
PROCFSS LIMESTONE
NEW OR RETROFIT NEW
START UP DATE 10/77
EFFICIENCY:
PARTICUIATES (ACTUAL)
(DESIGN) 99.1 PERCENT
S02 (ACTUAL)
(DESIGN) BO.O PERCENT
WATER MAKE UP CLOSED LOOP,- 1.6* GPM/MW
SLUDGE DISPOSAL STABTLIZED/SLUDGF POND
OPERATING FXPERIENCE UPDATE:
DECEMBER-JANUARY 197B - OPERATION OF ALL FOUR MODULES WAS INITIATED IN DECEMBER J977. A SUCCESSFUL
?1-HOUR RUN WAS COMPLETED ON DEC. 16 AND 17 WITH MODULES "B", "C" AND "D" IN OPERATION. "A" MODULE
HAD AN INOPERATIVE RECYCLE TANK AGITATOR. REPAIR OF THE AGITATOR WAS COMPLETED ON DEC. Zi.
AND MODULF A WAS PLACED IN INITIAL OPERATION. A SO-DAY RUN SCHEDULED TO BEGIN JAN. 11 WAS POST-
PONED UNTIL MID-MARCH PENDING RESOLUTION OF PROBLEMS ASSOCIATED WITH THE FLY ASH REMOVAL SYSTEM.
THF COID WFATHFR NECESSITATED THE ERECTION UF TEMPORARY ENCLOSURES AROUND SEGMENTS OF THE FGD SYSTEM
UNTIL THF INSTALLATION OF HEAT TRACING COULD BF COMPLETED.
FEBRUARY-MARCH i9?fl - THF MODULES DID NOT OPERATF DURING FEBRUARY AS REPAIRS WERE MADE TO LINES AND
VALVFS DAMAGED BY FRFtZE-UPS DURING THF WINTER. DURING MARCH SOME SCHEDULED REPAIRS
WERE MAOF WHTCH INCLUDED INSTRUMENTATION WORK, INSULATION INSTALLATION AND REPAIR OF A BROKEN PINION
GEAR ON THF THICKENER. SYSTEM START-UP IS STILL BEING DELAYED BY PROBLEMS WITH THE ELY ASH HANDLING
SYSTFM AND IS NOW EXPECTED TO RE IN MJO-APRIL.
APPII-MAY 1978 - THE UNIT CAME BACK ON LINE IN THE MIDDLE op APRIL AFTER PROBLEMS WITH THE FLVASH
HANDLING SYSTEM W£"E CORRECTED. THE SYSTEM OPERATED UNTTL THE MAIN POWER TRANSFORMER FAULTED,
PAUSING THF SY.STFM 10 GU UOwN. THE OUTAGE LASTED UNTIL JUNE 16. PROBLEMS HAVE ALSO BEEN EXPERI-
FNCED ",>ITH ALL CONTROL VALVES AND PIPING. THE VALVES HAD TO BF SENT HACK TO THE FACTORY FOR MODI-
FICATIONS.
JUNE-JULY i97e - THE UNIT is STUL PROCEEDING WITH SHAKEDOWN AND DEBUGGING OPERATION AS FINAL DESIGN
MODIFICATIONS ARF BEING MADE. PREPERATIONS ARF BEING COMPLETED FOR THE COMPLIANCE TEST WHICH HAS
MOT YtT TAKEN
-------
FCA UTILITY Fsn SlJRVFY: JUNE 1178 - JULY 1978
r inrj MIK ul'b P «T IOM/IL 1-fU) SYSTI-MS
HITLTTV "U^E KANSAS CTI" POWER » IIPHT
MiMTl M«|.'F MASTHiiRK) 3
MM I L"C«ITOK' KANSAS C1TV MTbSDLIKT
MHJT I K«! INl^ 1 OU Mil
irs ru'i. r =< SULFUP, IP.CX ASH
rOMtlMSTIHM f N(, TfvFh P [ NK
I IMh
Mfw nw WFIRUFIT RfTROKTT
STAKT MP U«IF 11/7?
PARTiriJLATES fArillAI) 99.0 PfRCFM
(I)FSTGN) f<3.
fOESI&N) 70. n PtRCFNT
MAKh UP OPEN LHOP 7.0 RC
SLUDGE DISPOSAL LINST AB ILIZED/Sl UnGF PONU
nPFMATTNR FXPbRIFNCE UPDA1F:
FSI) SYSTEM
MONTH PLRIOD MRS. bPILEP. HKS. FG" SYSTEM H9S. UTILt/ATTON (X)
FER. 78 fr7? 187 Ifr7 3«i
"A». 7R 7 UOb Sfc
DIIHTNR FERMIARY IHt UNIT WAS DOWN FnuP. TIMES HITH ECONOMIZER ANn WATER WALL LEAKS COUTAGE
TTM= APUOV. 50a HBS1. A Twn WtFK OMTAGF WAS SCHEDULED CURING MARCH FOR SEASONAL MAINTENANCE.
KATFk rt«LL Lfc»K HFPAIR AS rtFLI- «S AT1D TLFANlNli OF THE ROTLFH CSUSED ADDITIONAL OUTAGE TIME
DURING THF LAST «FbK IN MAKCH.
APR. l» 7^n 5"8 ^?I3 7h
MAY 7« Tin i 103 t?
AM AIR PHFnEATER FIPp DTSPOVtRtn ON M4Y 1? PAMSFQ DAMAGES THAT FORCED MODULE A TO BE DOWN THE
UFST OF THE MONTH.
-------
EPA UTILITY F6D SURVEY! JUNE 1978 - JULY 1978
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
UTILITY NAME KANSAS CITY POWER * LIGHT
UNIT NAME HAWTHORN. 4
UNIT LOCATION KANSAS CITY MISSOURI
UNIT RATING 100 MW
FUFL CHARACTERISTICS COAL? 2X SULFUR, 12.5X ASH
FGD VENDOR COMBUSTION ENGINEERING
PROCESS LIME
NEW OR RETROFIT RETROFIT
START UP DATE 8/72
EFFICIENCY!
PARTICIPATES (ACTUAL) 99.0 PERCENT
(DESIGN) 99.0 PERCENT
802 (ACTUAL)
(DESIGN) 70.0 PERCENT
WATER MAKE UP OPEN LOOP 7.0 GPM/MW
SLUDGE DISPOSAL UNSTABILIZEO/SLUDGE POND
OPERATING EXPERIENCE UPDATE:
FGD SYSTEM
MONTH PERIOD HRS. BOILER HRS. F60 SYSTEM HRS. UTILIZATION («)
FEB. 78 672 198 196 30
MAR. 78 744 471 471 63
THE UNIT MAS DOWN THREE TIMES DURING FEBRUARY FOR NON-SCRUBBER RELATED PROBLEMS. TWO OTHER
OUTAGES WERE THE RESULT OF A FUEL SAFETY TRIP PROBLEM AND GENERAL SCRUBBER MAINTENANCE. IN
MARCH THEOE HERE THREE ECONOMIZER LEAK OUTAGES (APPOX. 231 HRS) AND THE SCRUBBER REQUIRED AN
ADDITIONAL 32 HRS OF OUTAGE TIME FOR MAINTENANCE.
APR. 78 720 288 2SB 40
MAY 78 744 421 327 44
FGD OUTAGE IN MAY WAS DUE TO CLARIFIER PLUGGING. APRIL OUTAGE TIME WAS SCHEDULED FOR
ROUTINE MAINTENANCE AND GENERAL CLEANING.
-------
EPA UTILITY FGD SURVEY: JuNF 1 9 7 R - .IllLY 1978
SFCT10N 3
PERFORMANCE DFsrmpTioN FOR OPERATIONAL pro SYSTLMS
UTTLTTY NAME KANSAS CTTY POWER R LIGHT
UNTT NAMF LA CYGNE 1
IINTT LOCATTON LA CyGNt KANSAS
UNIT RATING B?0 MW
FUFL CHARACTERISTICS COAL! SX SULFUR, 2SX ASH
FGO VENODR BABCOCK * W1LCOX
PROCESS LIMESTONF
MEW OK RETROFIT NEW
START UP HATE 2/73
FFFICIFNCY:
("ARTICULATES (ACTUAL) 98.? PERCENT
(DESIGN) 9R.o PERCENT
S02 fACTIIAL) 80.1 PERCENT
fDFSTGN) 7ft.0 PERCFNT
WATER MAKE UP OPFN LOOP l.« GPM/Ww
.SLUDGE DISPOSAL UNST AB IL I ZED/SLUDGE POND
npFRATTNG FXPERIENCE UPDATE:
PERCENT AVAILAFULITY-BY MODULE
MONTH BOILER HOURS ABCDEFGH AVFRAGE
FER. 7S ?78 92 03 9? 9« 91 97 9h 93 9fl
MAR. 7R 7i|l 95 «5> 90 95 9U 95 «9 93 93
FGD OPERATIONS AT LA CYRNF W£R£ CONDUCTED DURING THF REPORT PERIOD WITH NO MAJOR PROBLEMS
ENCdUNTFRFO.
APR. 7« h20 91 ">£ 9^ 91 90 92 9! 91 91
THE HOILER WAS DOWN A TOTAL OF 100 HOURS IN APRIL. THIS TIME INCLUDED THREF OUTAGES DUE TO
BOILER LEAKS AND LACK OF I OAD RETIREMENT. MODIFICATIONS TO THE FGD SYSTEM WERE PERFORMED
DURTNf, THE OUTAGES WHICH INCLUDED CHANGING THF REHEAT IUBF BUNDLES.
MAY IK 593 89 92 9? 93 9? 91 93 Rb 91
IN MAY THF HOILFR WAS DOWN TWICE FOR A TOTAL OF isi HOURS. OIJTAGFS WFRF AGAIN CAUSED BY
B"iLtR LtAKS. GENERAL MATNTENANCF AND REPAIRS ON THE FGO SYSTEM WERE CONTINUED.
JIJNt 71 IS
JULY 7" '"ll 88 97 9? 94 6« 93 93 95 93
THE UWJT WAS INLY UP FOR is HOURS IN JUNE. IN THE FIRST PART OF JUNE THERE WFRE BOILER TUBE
LFAKS. FROM JUNE 8 TO JUNE 17 4 ROTLFR OIIHGF WAS NECESSARY FOR GENERATOR REPAIR. THE UNIT
THROUGHOUT JULY.
35
-------
EPA UTILITY FGf) SURVEY! JUNE 1978 - JULY I«t78
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS
UTILITY NAME KANSAS POWER & LIGHT
UNIT NAME LAWRENCE 4
UNIT LOCATION LAWRENCE KANSAS
UNIT RATING 125 MW
FUEL CHARACTERISTICS COAL? 0.5X SULFUR, 11X ASH
FGO VENDOR COMBUSTION ENGINEERING
PROCESS LIMESTONE
NEW OR RETROFIT RETROFIT
START UP DATE 12/68
EFFICIENCY:
PARTICULATES (ACTUAL) 99+ PERCENT
(DESIGN) 98.9 PERCENT
S02 (ACTUAL) 90+ PERCENT
(DESIGN) 73.0 PERCENT
WATER MAKE UP OPEN LOOP
SLUDGE DISPOSAL UNSTABILIZED/SLU06E POND
OPERATING EXPERIENCE UPDATE:
FEB. 78 THE FGD SYSTEM OPERATED DURING THE REPORT PERIOD WITH NO MAJOR PROBLEMS. THE THICKENER
MAR. 78 UNDERFLOW LINE IS STILL FROZEN AND TWO 3 INCH DIAMETER FIRE HOSES ARE BEING U8EO TO PUMP
THE UNDERFLOW SOLIDS TO THE POND.
APR. 78 THE UTILITY REPORTED THAT THE FGD SYSTEM AND THE BOILER RAN WITHOUT ANT OUTAGES DURING
MAY 78 THIS PERIOD.
JUNE 78 THE BOILER AND FGD SYSTEM BOTH OPERATED THROUGHOUT THE PERIOD. THE UTILITT
JULY 78 REPORTED THAT THE OPERATING HOURS EQUALED THE HOURS IN THE PERIOD.
-------
EPA UTILITY FGD SURVEY! JUNE 1978 - JULY 1978
SECTION 3
PERFORMANCE DESCRIPTION f-OR OPERATIONAL FGD SYSTEMS
HIILI1Y NAME KANSAS POWER & LTGHI
UNT-T NAMF LAWHFMCE 5
UNIT LOCAIIOM I AWkFNCF KANSAS
IJNTT RATTNG 100 MV
FUFL CHARACTERISTICS CO«L; O.SX SULFUR, 11Z ASH
FGO VENDOR COMBUSTION fcMGTNFtRING
PROCESS LIMESTONE
NEW OR RETROFIT NEW
START IIP 0*TF 11/71
EFFICIENCY:
PARTICUI.ATES (ACTUAL)
(DESIGN) 9R.9 PERCENT
S02 (ACTUAL)
(DESIGN) 5P.O PERCENT
WATER MAKE UP OPEN LOUP
SLUDGE OISPOSAL UNSTABIL TZED/Sl.UOGE POND
OPERATING EXPERIENCE UPDATE:
OPERATING HOURS
MONTHS HOTLFR FRO MODULES
FEB. 78
MAR. 7fl
THE ORIGINAL FGO SYSTEM KAS PULLEO OFF LINE ON MARCH 20 SO THAT THE NEW SCRUBBER-ABSORBER
SYSTEM COULO BE TIEO TNTO THE GAS P
-------
EPA UTILITY FGD SURVEY: JUNE 1"7P - .JULY |Q7R
SECTION 3
PERFORMANCE DESCRIPTION FOK OPERATIONAL FGn
UTILITY NAME KI-NTUCKY UTII.ITIFS
HNTT NAME GREEN RIVER 1,2 R ?
HNTT LOCATION CENTRAL CITY KFNTUTKY
UNIT RATING M MW
R1FL CHARACTERISTICS COAL; 3.9% SULFUR, H.5% ASH
FGO VENDOR AMERICAN AIR FILTER
PROCESS LIME
NEW OR RFTROFIT RETROFIT
START IIP DATE 9/7S
EFFICIFNCY:
PARTICIPATES (ACTUAL) 99.7 PERCENT
(OFSIGN) 99.7 PERCENT
S02 fACTHAL) 80-91) PERCENT
(DESIGN) ao.o PERCENT
WATER MAKE UP OPEN LOOP i.?o GPM/MW
SLUORE DISPOSAL UNSTABILTZEO/SLUOGF POND
OPERATING EXPERIENCE UPDATE:
TOTAL BOH ER MODULE MODULE CALLED HR. MODULE
PERIOD PERIOD (HW) OPERATION (HR) AVAILABILITY (HR) TO OPERATE (HR) OPERATED
JAN. 7R 7«a 537 722 537 170
AVAILABILITY = 2?Z
RELIABILITY = X2X
OPERABILITY = 32X
UTILIZATION = 23?
DURING THE MONTHS OF DECEMBER AND JANUARY NUMEROUS FREEZE-UPS OCCURED. AS ONE COMPONENT
WAS THAWEO ANOTHER WOULH FREEZE. THE ABSORBER WAS AVAILABLE FOR FGD OPERATIONS BUT COULD NOT
RE UTILIZED BECAUSE TH£ SIURRY LINE TO THE POND FROZE. THE UNIT WENT DOWN AFTER ABOUT 170
HOURS OF OPERATION IN JANUARY. BECAUSE OF EMERGENCY CONDITIONS THE UTILITY CHOSE TO CONCEN-
TRATE THEIR MAINTENANCE CREWS ON POWER GENERATION RATHER THAN FGD OPERATION. UNDER NOR-
MAL CONDITIONS THF RELATIVELY MINOR FGD SYSTEM PROBLEMS WOULD HAVE BEEN SOLVED MORE QUICKLY.
IN LIGHT OF THIS THF SYSTFM COULD HAVE BEEN CONSIDERED AVAH ABLE THROUGHOUT MOST OF THE
PFRIHO CONCERNED.
FEB. 7fl hi? hi? b!2 0 0
AVAILABILITY - 100X
RELIABILITY = UNDEFINED
OPERABILITY - 0%
UTILIZATION - OX
DURING THE FREEZE UP NUMEROUS GASKETS WERE TORN THROUGHOUT THE SYSTFM. THE SYSTEM WAS SHUT
DOWN COMPLETELY FOR REPAIR WORK.
MAR. 78 ll\U 669 1UI\ 0 0
AVAILABILITY = 100X
RELIABILITY = UNDEFINED
DPERA9ILITY r Oj;
UTILIZATION - OX
REPAIR WORK rtILL CONTINUE UNTIL LATF APR1I 78 nHEN THE SCRUBBER-ABSORBER SYSTFM IS EXPECTED
BACK DIM LINE.
APR. 7* 720 295 2<,fe ?45 2q6
AVAILABILITY - 4tX
RELIABILITY = 995:
DPERABILTTY - 995!
UTILIZATION = 4IX
-------
EPA UTILITY FGD SURVEY: JUNE 1978 - JULY 1978
KENTUCKY UTILITIES 6REFN RIVER 1,2 & 3
TOTAL BOILER MODULE MODULE CALLED HR. MODULE
PERIOD PERIOD (HR) OPERATION (HR) AVAILABILITY (HR) TO DPFRATF (HR) OPER«TFD
MAY 78 744 471 474 473 474
AVAILABILITY = t>4X
RELIABILITY = 100*
nPERABTLTTY = 100X
UTILIZATION = MX
THE SCREENS ON THE SUCTION SIDE OF THE PUMPS THAT PUMP THE SLURRY FROM THE PREP ROOM TO THE
NOZZLFS EXPERIENCED PLUGGING PROBIEMS. THE SCREENS GET PI UGGF.D WITH LARGF GRIT IN THF SLURRY
AND ARE SUCKED OUT OF POSITION RY THE PUMPS. THE UTILITY REPORTED THAT THIS TENDS TO BE A
RE-nCCURRTNG PROBLEM.
JUNE 78 720 525 524 S24 5?4
AVAILABILITY = 73*
RELIABILITY = 100X
OPERABILITY = 100X
UTILIZATION = 73X
BOILER AND FGD SYSTEM OUTAGES DURING JUNE WERF FOR ROUTINE MAINTENANCE.
.JULY 78 744 103 99 99 99
AVAILABILITY = 13X
RELIABILITY = tOOX
OPERABILUY = 96X
UTILIZATION = 13X
BOILER AND FGD SYSTEM OUTAGES DURING JULY WERF FOR ROUTINE MAINTENANCE.
-------
FPA UTILITY FGH SURVEY! TUNE 1978 - JULY 197S
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
UTILITY NAME LOUISVILLE &AS ft ELECTRIC
IINTT NAMF CANE HUN 1
UNIT LOCATION LOUISVILLE KENTUCKY
IINTT RATING 178 MW
FUFL CHARACTERISTICS COAL: 3.751 SULFUR, 11.5% ASH
FGO VENDOR AMERICAN AIR FILTER
PROCESS LIME (CARBIDE)
NEW OR RETROFIT RETROFIT
START IIP D»TF
EFFICIENCY.'
PARTICULATES (ACTUAL) 99.0 PERCENT
(DESIGN) 99.0 PERCENT
302 (ACTUAL) 8h-89 PERCENT
(DESIGN) 85.0 PERCENT
HATER MAKE UP OPEN LOOP
SLUDGE DISPOSAL STABILIZED/SLUDGE POND
OPERATING EXPERIENCE UPDATE:
PERFORMANCE FACTORS (*)
PERIOD HOURS BOILER (HR) FGH SYSTEM (HR) OPFRA8TLITY UTILIZATION
FEB. 78 67? 00 00
M»p. ;« 7i)« 249 34
THE UNIT WAS OOWN THE ENTIRE MONTH OF FEBRUARY DUE TO THE COAL SHORTAGE AND A LACK OF AVAIL-
ABLE LIME RFSULTING FROM THE SEVERE WINTER WEATHER. THE UNTT CAME BACK ON LINE MARCH 21
AFTER WHICH TIME THE FGH SYSTEM WAS ON LINE DURING 95X OF THE BOILER HOURS THROUGH THE END OF
MARCH.
APR. 7fi 720 303 303 100 47
DURING APRIL THF BOILER WAS DOWN FOR REPAIRS. THE UTILITY REPORTED THAT THE AVAILABILITY
AND RELIABILITY WFRE BOTH 100X.
MAY 7« 704 3S2 115 35 12
THE BOILER WAS DOWN AGAIN IN MAY FO" REPAIRS. DURING THE BOILER OUTAGE A NUMBER OF MODIFICA-
TIONS nFRF MADt TO THF DAMPFWS IN THE FGD SYSTEM. THE UTILITY REPORTED THAT THE FGD SYSTEM
HAS BEEN RUNNING WELL SINCE THE MODIFICATIONS TOOK PLACE. THE AVAILABILITY AND RELIABILITY
FDR MAY WFRF 31 AND 35 PERCENT RESPECTIVELY.
JUNE 7fl 720 7?U 715 99 99
JULY 78 7UU b«7 fe78 99 91
40
-------
EPA UTILITY FGO SURVEY: JUNE 1978 - JULY 1978
.SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FRO SYSTEMS
UTILITY NAME
UNIT NAMF
UNIT LOCATION
UNIT RATING
LOUISVILLE GAS & ELECTRIC
CANE RUM 5
LOUISVILLE KENTUCKY
1«3 MW
FUEL CHARACTERISTICS COAL: 3.75? SULFUR, 11.5* ASH
COMBUSTION
LIME (CARBIDE)
RETROFIT
12/77
VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
EFFICIENCY:
PARTICULATES fACTUAL)
(DESIGN)
803 (ACTUAL)
(DESIGN)
WATER MAKE UP
SLUDGE DISPOSAL
99.0 PERCENT
8">.o PERCFNT
CLOSED LOOP
STABILIZED/SLUDGE POND
OPERATING EXPERIENCE UPOATF:
DECEMBER-JANUARY 1978 - OPERATION OF THE FGD SYSTEM AT CANE RUN ^ REGAN ON DECEMBER 29. INITIAL
OPERATIONS WERE NOT CONTINUOUS. DURING OPERATION SOME OF THE CONTROLS WFRE NOT WORKING PROPERLY
AND MODIFICATIONS WERE NECESSARY.
FEBRUARY-MARCH 1978 - THF PL«NT REMAINED OFF LINE THROUGHOUT FEBRUARY AND THEN RF-STARTEO ON MARCH
24. THE BOILER OPERATED APPROXIMATELY 18? HOURS THROUGH THE END OF MARCH WITH THE FGO SYSTEM
OPERATING APPROXIMATELY ° 1 HOURS. VARIOUS INITIAL START-UP PROBLEMS WFRF STILL BEING ENCOUNTERED
CAUSING FGO SYSTEM OUTAGES.
APRIL-MAY 197fl - DURING APRIL THF BOILER WAS ON I INE 6ft9 HOURS, AND THE FGD SYSTEM OPERATED 6«8 OF
THOSF HOURS. DURING MAY THF. BOILER AND FGO SYSTEM OPERATED 432 ANO 364 HOURS, RESPECTIVELY. FGD
SYSTEM MODIFICATIONS HAVF BEEN TAKING PLACE TN PREPARATION FOR THE PERFORMANCE TESTS. THE ONLY
PROBLEM THAT OCCURRED DUPING TESTING WAS A POOR JOB OF DATA GATHERING BY THE DATA CREWS. THEY DID
NOT ACCURATELY FOLLOW THF EPA TEST METHODS. THE UTILITY is CONFIDENT THAT THE UNIT WOULD HAVE
PASSED HAD THF CREW TAKEN THEIP DATA PROPERLY. THE UNIT IS NOW IN ITS PREOPERATIONAL PHASE.
PERIOD HOURS BOILER THR) FGO SYSTEM
PERFORMANCE FACTORS (X)
OPEHAHILITY UTTLT/ATION
JUNE 78 720 feaS 590 Bfa 82
JULY 78 Ian hi? 506 80 f.8
THE UNIT EXPERIF.NftO RtHEATFR PROBLEMS OVFK THb PFRTOO. THE REHEAT COIL (STEAM) INSTALLATION
HAS BFEN A CHRONIC PROBLEM ARFA. THE BANK OF TIIBFS AROUND THE DUCT HAS WELDS AT EACH END,
WHERt THE COIL FORMS « "U". THFSE WfcLDS HAVE BFEN FAILING EVFR SINCE INITIAL OPERATIONS.
-------
EPA UTILITY FGO SURVFY: IUNE IP/P - .H'LY iQ78
SFCTiniM J
PERFORMANCE OFSCrtTPTiriN t-OW ClPt P AT 1 flNAL FG(J
IITTLTTY NAME LUMISVTLIF 6»S & RLE
IINTT N4MF MILL CREFK i
UNIT LOCATION IUMISVTLLE KFNTIJCKY
UNIT RATING a?5 MW
FUFL CHAPACTFKIbTICS COAL; 3.7bX SULpllk. 11.bX ASH
FGD VEMDHM AMERICAN Alk FILTER
PROCFSS LIME (CARBIDE)
NEW OR RETROFIT NEW
START UP DATE fl/7fl
FFFICIFNCY:
P^RTIrUI_ATES (ACTUAL)
(DESIGN) 90 PERCFNT
502 (ACTUAL)
(DESIGN) as PERCENT
WATER MAKE UP
SLUDGE DISPOSAL SIABILIZFO/SLUOGF POND
OPERATING EXPERIENCE UPDATF:
AUGUST 1978 - THE UNIT BFCAMF OPERATIONAL DN AUGUST 13, 1978 AND IS CURRENTLY UNDERGOING SHAKEDOWN
AND DEBUGGING OPERATIONS.
-------
FPA UTILITY FGF1 SURVEY: JUNE 197ft - JULY 1978
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGl) SYSTEMS
UTILITY NAME LOUISVILLE GAS 8 ELECTRIC
UNIT NAME PADDYS RUN 6
UNIT LOCATION LOUISVILLE KENTUCKY
UNIT RATING 65 MW
FUEL CHARACTERISTICS COAL; 3.75X SULFUR, 11.5* ASH
FGO VENDOR COMBUSTION ENGINEERING
PROCFSS LIME (CARBIDE)
NEW OR RETROFIT RETROFIT
START UP DATE a/7?
EFFICIENCY!
PARTICULATES (ACTUAL) 99.0 PERCENT
(DESIGN) 99.0 PERCENT
SOa (ACTUAL) 80-99 PERCENT
(DESIGN) 80.o PERCENT
WATER MAKE UP OPEN LOOP 0.7 GPM/MW
SLUDGE DISPOSAL STABILIZED/LANDFILL
OPERATING EXPERIENCE UPDATE:
SEP. 77
THROUGH
MAR. 78 PADDY'S RUN NO. 6 DID NOT OPERATE THROUGH THIS PERIOD DUE TO A LACK
OF POWER REQUIREMENT.
APR. 7«
MAY 7fl THIS PtAK LOAD UNIT WAS ONLY ON LINE A FEW HOURS DURING THE PERIOD.
NO PROBLEMS WERE REPORTED.
JUNE 7S
JULY 7« "THIS UNIT RAN INTERMITTENTLY FOR ABOUT 8 TO 10 DAYS OVER THE PERIOD
AMD IS EXPECTED TO OPERATE SIMILARLY THROUGH SEPTEMBER.
*MOTfc: THIS UNIT WILL BF RETIRED SOON AFTER THE MILL CREEK 3 UNIT
BFCOMFS FULLY OPERATIONAL.
-------
FPA UTILITY FGO SURVEY: .TUNE 1978 - JULY 197P
SFCTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
UTILITY NAME MJNNKOTA POfcER COOPERATIVE
UNIT NAMF MILTON R. YOUNG ?
UNIT LOCATION CENTER NORTH DAKOTA
UNIT RATING 450 MW
FIIFL CHARACTERISTICS LIGNTTF; 0.7* SULFUR, 7.SX ASH
FGD VENDOR ADL/COMBUSTION EQUIP ASSOCIATE
PROCESS LIME/ALKALINE FLYASH
NEW OR RETROFIT NEW
START IIP DATE 9/77
EFFICIENCY:
PARTICULATES (ACTUAL)
(DESIGN) 99.6 PERCENT
S02 (ACTUAL)
(DESIGN) 75.0 PERCENT
WATER MAKE UP CLOSED LOOP
SLUDGE DISPOSAL UNSTABILIZED/LANDFILL
OPERATING EXPERIENCE UPDATF:
FEBRUARY-MARCH 1978 - BOTH THE BOILERS AND FGD SYSTEM CAME BACK ON LINE FEB. 21 AFTER COMPLETION
OF THE TURBINE REPAIRS. ONE SCRUBBER-ABSORBER FORCED DRAFT FAN HAD AN OIL LEAK AND A SHAFT ALIGN-
MENT PROBLEM. IT WAS TAKEN OFF THE LINE AND SHIPPED TO BUFFALO FORGF CO.'S PLANT FOR REPAIRS, THE
AFFECTED MODULE WAS DOWN FROM FEB. 23 THROUGH APRIL 10, WHEN THE REPAIRED UNIT WAS RE-INSTALLEO.
THF VACUUM FILTER ON THE SECOND SCRUBBER-ABSORBER WAS MALFUNCTIONING, ALLOWING LARGER SIZE
PARTICLES TO ESCAPE THF FILTER. THIS CAUSFD THE RUBBER LINING DOWNSTREAM TO PEEL WHICH, IN
TURN, CREATED A PLUGGING PROBLEM. EIMCO ENGINEERS ARE PRESENTLY STUDYING THE PROBLEM
AND HOPE TO INCORPORATE MODIFICATIONS TO IMPROVE THE PERFORMANCE OF THE FILTERS. THE COMPLIANCE
TEST HAS AGAIN BEEN RESCHFDULEn WITH THE EPA FOR THE END OF MAY.
APRIL-MAY 1978 - COMPLIANCE TESTING TuOK PLACE DURING THE WEEK OF JUNE 5. THE REPORT SHOULD BE
AVAILABLE TO THE UTILITY BY THE END OF JUNF. THE UNIT IS CURRENTLY DOWN WITH DAMPER PROBLEMS (DOWN
ON THE 24TH OF JUNE). APPARENTLY THE CHAINS THAT PULL THE GUILLOTINE DAMPERS WERE UNDEROESIGNED.
THFY ARE BEING REPLACED.
-------
FPA IJTTLTTY FGD SURVEY: JUNE J978 - JULY 1978
, SFCTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
UTILITY IMAMt MON1ANA POWtR
UNIT NAMF COLSTRTP 1
UNIT LOCATION COLSTRIP MONTANA
UNTT RATING JfeO MW
FUFL CHARACTERISTICS COALT 0.8X SULFUR, 1?% ASH
FGO VENDOR AOL/COMBUSTION EQUIP ASSOCIATE
PROCFSS LIME/ALKALINE FLYASH
NEW OR RETROFIT NEW
START UP DATE 11/75
EFFICIENCY:
PARTICIPATES (ACTUAL) 9
-------
FPA UTILITY FGD SIIRVFY: .UJNt 1"7« - .IUI Y 1 9 7 «
HFKFURMANPt UFSCKTPTin^ FOk (IP t R A T ] HIM* L F-K
UTILITY NAME MONTANA POWLR
UNIT NAMF roi.STRTH d
UNIT LnCATTUM TOLSTRTP MONTANA
UNIT RAITNn JMj MM
FUFl. C^APACTEWTST ITS TOALr 0.«X SULFUR, 1?X ASH
FGn VfcNLlOR AOL /COMBUSTION hnuTP ASSOCIATE
PROCFSS LIME/ALKALINF FL^ASH
NEW OR RETROFIT NEW
START UP DATF 8/7C,
FFFICIFMCT:
PARTICULATES (ACTUAL) 99.5 PERCENT
(OESIGNl <»9.S PERCENT
SO? (ACTUAL) 7S.O PERCENT
(DFSIGN) bO.O PtRCFNT
WATER MAKE UP CLOSED LOOP
SLUDGE DISPOSAL STABILIZED/SLUI^CF PONO
OPERATING EXPERIENCE UPDATE:
J»N. 7«
FEfl. 7«
MAR. 70
NO INFORMATION WAS REPORTED BY~THE UTILITY FOR THIS PERIOD.
APR. 7»
MAY 7«
THE UNIT WAS nOWN FOR MOST OF THE SPRING FOR * SCHEOULEO OVERHAUL.
lib
-------
EPA UTILITY FGfl SURVFY! JUNE 1978 - JULY 1978
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
UTILITY NAME NEVADA POWER
UNIT NAME REID GARDNER 1
UNIT LOCATION MOAPA NEVADA
UNIT RATING 125 MW
FUFL CHARACTERISTICS COAL: 0.5X SULFUR, 8X ASH
FGO VENDOR AOL/COMBUSTION EQUIP ASSOCIATE
PROCESS SODIUM CARBONATb
NEW OR RETROFIT RETROFIT
START UP DATE 4/74
EFFICIENCY:
PARTICULATES (ACTUAL) 99* PERCENT
(DESIGN) 99.0 PERCENT
SH2 (ACTUAL) 85-90 PERCENT
(DESIGN) 85.0 PERCENT
WATER MAKE UP OPFN LOOP 0.40 GPM/MW
SLUDGE DISPOSAL UNSTABILIZED/SLUDGF POND
OPERATING EXPERIENCE UPDATE:
HR.
BOILER MODULE CALLED
TOTAL OPERATION AVAILABLE UPON TO OPERATION
PERIOD (HR.) (HR.) (HR.) OPERATE (HR.)
FEB. 78 672 589 654 309 292
AVAILABILITY = 97%
RELIABILITY = 94%
OPFRA8TLITY = 75X
UTILIZATION = 43%
THE SCRUBBER-ABSORBER SYSTEM WAS OFF-LINE FOR APPROXIMATELY 18 HOURS DURING FEBRUARY DUE TO
PLUGGED SENSING LINES AND A DUCT HI-10 PRESSURE TRIP. THE BOILER WENT OUT OF SERVICE ON
ON FEBRUARY 17 FOR A THREE WEEK OUTAGE.
MAR. 78 744 355 207 355 207
AVAILABILITY = 28*
RELIABILITY = 5«x
OPERA8TLITY = 58X
UTILIZATION = 28%
THE BORER CAME BACK ON LINE MARCH t6 BUT PROBLEMS WITH THE GUILLOTINE SWITCHES DELAYED
START-UP OF THE FGD SYSTEM UNTIL MARCH 22. FGD DOWNTIME WAS APPROXIMATELY 537 HOURS.
A PROBLEM WAS ALSO ENCOUNTERED WITH TH£ REHEAT STFAM REGULATOR DURING MARCH.
APR. 7ft 720 560 720 "541 541
AVAILABILITY = 100*
RELIABILITY = 1002
OPFRABTLTTY r 97%
UTILIZATION = 75%
THERE WERE NO FGD SYSTEM FORCED OUTAGES. ALL DOWNTIME WAS BOILER RELATED (179 HRS.).
MAY 78 744 630 721 605 582
AVAILABILITY = 97X
RELIABILITY = 96%
"PFRABTLTTY = 92*
UTILIZATION = 78%
THE UNIT WAS DOWN 132 HOURS FOR A PRODUCTION CONTROL OUTAGE, 7 HOURS FOR REPAIRS TO THE
CONDENSER, AND 23 HOURS DUE TO HIGH TEMPERATURE ON T.D. FAN BEARING. (OUTAGES WERE BOILER
RELATED.)
47
-------
FPA UTILITY FGO SURVEY: .niNt 197* • JULY
NEVAHA PONFR PETD GARDNER 1
BOHFR MODULE HR. CALLED
TOIAL OPERATION AVAILABLE UPON To OPERATION
PERinn (HR.) (HR.) (HR.) OPERATE (HR.)
JUNE 7R 7?U 7?0 6'J« hut 614
AVAILABILITY = ft
-------
EPA UTTLTTY F6n SURVFY: JUNE 1978 - JULY 1978
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
UTILITY NAME NEVADA POWER
UNIT NAME REID GARDNFR Z
UNIT LOCATION MOAPA NEVADA
UNIT RATING l?b MW
FUFL CHARACTERISTICS COAL: O.SX SULFUR, fl* ASH
FGD VENDOR ADL/COMBUSTION EnulP ASSOCIATE
PROCESS SODIUM CARBONATE
NEW OR RETROFIT RETROFIT
START IIP DATE H/70
EFFICIENCY:
PARTICIPATES (ACTUAL! 99+ PERCENT
(DESIGN) 99.0 PERCENT
S02 (ACTUAL) 85-90 PERCENT
(DESIGN) 85,0 PERCENT
WATER MAKE UP OPEN LOOP O.aO GPM/MW
SLUDGE DISPOSAL UNSTABILIZFD/SLUDGE POND
OPERATING EXPERIENCE UPDATE!
HR.
BOILER MODULE CALLED
TOTAL OPERATION AVAILABLE UPON TO OPERATION
PERIOD (HR.) (HR.) (HR.) OPERATE (HR.)
FEB. 78 672 M6 bZb f<3? 585
AVAILABILITY = 9351
RELIABILITY = 92»
OPERABILITY = 93%
UTILIZATION = 87*
FGD DOWNTIME DURING FF6RUAKY WAS APPROXIMATELY
-------
FPA UTILITY FGD SURVEY: JUNK 1Q7« - iui. Y iQ'fl
NEVADA POWFK Wf-TI) GAKONFrt
H01LER Munul t- MR. CALIkl'
TOTAL OPERATION AVAILABLE UPU"' TU ()PF. "?A T ION
PERIOD (HH.) (MR.) (Hk.) (IPEPATH (UK.)
.IUNE 7" 7?0 7?n 7 IB ^b^ 6M
AVAILABILITY - in ti?
REI. I»HTLTTY = 1 oOX
MTTLTZA1 TON - °?X
THt^E WFKF TWO scHhnuLEn pen nufARt-s TU UNPI un THF TRAYS AND TU CHANGE THF OIL ON THE i.n.
F»N. A FORCEO FGO OUTAGE OCrUKREH WMFN HIGH OuCI PRESSHKF PAUSED A flOILfcR TRIP.
JULY 78 7«'( h76 5Q6 701 5S4
AV&ILARIL TV = ^ux
REI IAHTLITY = 795!
npFRABTLTTY = *?7.
UTILTZATTOM = 71X
THE BOILER WAS OUT OF SERVICE UHE TH A ROTLFR IUBF LEAK. THERE WAS ALSO A BOILER TRIP DUE TO
A HTGH nuCT PRESSURE. THIS WAS CAUSED RY A FAULTY POSITIONER ON THE I.n. FAN CONTROLLER,
THE I.I). FAN EXPANSION JOINT DIM THE STRUBPER WAS REPLACED. ANOTHER FGD OUTAGE OCCURRED WHEN
A ROLT, rtHlCH FELL FROM THE FAM, CAUSED VIBRATIONS. A SECOND BOILER TRIP DURING JULY W«S
CAUStO flY AN UNDETERMINED SOURCE. THF SUC1IUN LINE FROM THE VENTURI DISCHARGE LINE TO
THE tFFLUENT PUMPS WAS CLEANED OUT, WHEN PLUGGING OCCURRED.
50
-------
EPA UTILITY FGD SURVEY! JUNE 1978 - JULY 1978
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FRO SYSTEMS
UTILITY NAME NEVADA POWER
UNIT NAME REID GARDNER 3
UNIT LOCATION MOAPA NEVADA
UNIT RATING 125 MW
FUEL CHARACTERISTICS COAL! O.SX SULFUR, 8* ASH
FGO VENDOR ADL/COMBUSTION EQUIP ASSOCIATE
PROCESS SODIUM CARBONATE
NEW OR RETROFIT NEW
START UP DATE 7/76
EFFICIENCY!
PARTICULATES (ACTUAL) 99+ PERCENT
(DESIGN) 99.0 PERCENT
S02 (ACTUAL) 85-90 PERCENT
(DESIGN) 85.o PERCENT
WATER MAKE UP OPEN LOOP 0.40 GPM/MW
SLUDGE DISPOSAL UNSTABILIZED/SLUDGE POND
OPERATING EXPERIENCE UPDATE:
HR.
BOILER MODULE CALLED
TOTAL OPERATION AVAILABLE UPON TO OPERATION
PERIOD (HR.) (HR.) (HR.) OPERATE (HR.)
FEB. 78 672 619 642 618 588
AVAILABILITY = 96*
RELIABILITY = 95*
nPERABILITY = 95*
UTILIZATION = 88*
DURING FEBRUARY FAULTY WIRING CAUSED A HIGH VENTURI TFMPERATURE RESULTING IN AN INITIAL \b
HOUR FGf> SYSTEM OUTAGE. THFRE WAS A SECOND OUTAGE OF 13 HOURS TO CHECK THE VENTURI TFMPLRA
TURF. INDICATOR. A THIRD OUTAGE WAS CAUSED BY PLUGGING OF THE MIX TANK WHICH MADE IT TMPOS
SIBLE TO MIX CHEMICALS.
MAR. 78 744 711 724 738 718
AVAILABILITY = 97*
RELIABILITY = 97*
OPERABILITY = 97*
UTILIZATION = 96*
THE MIX TANK PROBLEM CONTINUED INTO MARCH CAUSING THE ONLY FGD DOWNTIME FOR THE MONTH
(APROX. 20 HOURS). A FURNACE HI-LO PRESSURE TRIP CAUSED A BOTLER OUTAGE OF 6 HOURS.
APR. 78 720 704 699 650 629
AVAILABILITY = 97*
RELIABILITY = 97X
OPFRABTLTTY = 89*
UTILIZATION = 87*
THE FGD SYSTEM WAS DOWN APPROXIMATELY 21 HOURS FOR REPAIRS ON THE VENTURI EMERGENCY SPRAY
SYSTEM. THE BOILER WAS DOWN APPROXIMATFLY 70 HOURS DURING APRIL.
MAY 78 744 646 724 514 494
AVAILABILITY = 97X
RELIABILITY = 96*
OPF.RABILITY = 77*
UTILIZATION = 66*
THERE WAS A SCHEDULED OUTAGF OF 230 HOURS FOR BOILER MAINTENANCE, AND A FORCED OUTAGE OF
20 HOURS DUE TO A FAULTY TEMPERATURE PROBE «T THE VFNTURI DURING MAY.
51
-------
FP4 UTILITY FbO SURVFY: JUNE 1«»7S - JULY l<>7fl
NEVADA POWEN REID GARDNER 3
SOILt" MOOliLE HR. CAULtD
TOTAL OPERATION AVATLABIE UPON' TU OPERATION
JUNE 7R 7?0 715 7?0 715 6R6
AVA1LAHJIITY - 1 " tl *
RELIABILITY - p <> x
OPFHAHTLTTY - OfeX
MTTLTZATTON - Q5X
A srHEOULFD FGO OUTAGE OCCURRED WHEN THF FJRE SPRAY SYSTEM WAS OUT OF SERVICE. THERE HAS
ALSO \ BOILER TRIP CHT-IO FURNACE PRESSURE TRIP).
JULY 7fl 74« 75fc 7Hi» 583 58J
AVAILABILITY = inox
RELIABILITY - 100*
OPEKABTLITY - SO*
UTILIZATION = 78Z
LOW VFNTUPI FLOW CAUSED ONE OF THREE SCHEDULED FGD OUTAGES. THIS WAS CORRECTED WHEN THE
NOZZLES ON THF RACt TRACK WERE CLEANED. ANOTHER OUTAGE OCCURRED WHEN AN INSPECTION OF THE
VFNTURI TANK AND RACt TRACK WAS RFQU1RED. THE TANK AND RACE TRACK NOZZLES WERE CLEANED AND
THE RIIBREW LINING ON THF VENTURI SPOOL WAS REPLACED. A THIRD OUTAGE WAS REQUIRED TO CLEAN
THE VFNTURI RACE TRACK. A SCHEDULED OUTAGE, WHICH WAS NOT FGO SYSTEM RELATED, TO CLEAN THE
TURBINE LUBE OIL COOLERS ALSO OCCURRED DURING JULY.
•52
-------
EPA UTILITY FGO SURVEY: JUNE 1978 - JULY 1978
SECTION i
PERFORMANCE DESCRIPTION FOK OPT-RATIONAL FGO SYSTEMS
UTILITY MAME
UNTT NAMF
UNIT LOCATION
UNTT RATING
NORTHERN INDIANA PUB SERVICE
OEAN H. MITCHELL 11
GARY INDIANA
115 MW
FUEL CHARACTERISTICS COAL: 3."5% SULFUR, 10% ASH
FGD VENDOR DAVY POwFRGAS
PROCESS WELI.MAN LORD
NEW OR RFTRoVlT RETROFIT
START UP DATF 11/76
EFFICIENCY:
PARTICUL.ATES (ACTUAL)
(DESIGN)
S02 (ACTUAL)
(DFSIGN)
WATER MAKE UP
SLUDGE DISPOSAL
99.5 PERCENT
99.s PERCENT
91.o PERCENT
90.0 PERCENT
CLOSED LOOP
ELEMENTAL SULFUR PRODUCT
OPERATING EXPERIENCE UPDATE:
MONTH
HOURS
IN PERIOD
HOURS
AVAILABLE
HOURS
CALLER ON
TO OPERATE
HOURS
OPERATED
AVAILABILITY RELIABILITY UTILIZATION
MOV. 77 720 «531 596 428 71 72 90
THF FGD IINTT OPERATED FOR 18 CONSECUTIVE DAYS, AVERAGING 90X S02 REMOVAL WITH ?85 LONG TONS OF
SULFUR RECOVERED. FGD OPERATION WAS INTERRUPTED 6Y A UNIT 11 BOILFR TUBE LEAK AND RESUMPTION OF FGD
OPERATION WAS FURTHER DEI AYEO BY MAINTENANCE IN THF EVAPORATOR SECTION. MAINTENANCE WAS ALSO PER-
FORMED ON THF FLUE GAS ISOLATION DAMPER, El UF GAS BOOSTER BLOWER, AND S02 REDUCTION SECTION.
DEC. 77 768 37" ^^ 2 0 41 0 0
THE FGD SYSTEM rtAS NOT OPERATED PURING THIS PERIOD DUE TO ABNORMAL BOILER OPERATING CONDITONS
RELATED TO HIGH SILICA LFVFLS TN THE I-FEP WATER. THE HIGH SILICA LEVELS RSULTED FROM HIGH MAKE-UP
WATER REQUIREMENTS DUE IN PART TO A HIGHFR THAN NORMAL FGD PLANT USAGE, AS WELL AS UNIT 11 COAL FEED
PROBLEMS AND A PRECIPITATOR MALFUNCTION. MAINTENAMCF WAS PERFORMED ON THE FG ROOSTER BLOWER AND
THE ABSURBFR SOLUTION REGENERATION SECTION.
JAN. 7« 720 S/6 0 0 SO 0
THE FGP SYSTEM REMAINED DOWN THROUGHOUT JANUARY AS HIGH SILICA LFVFLS IN THE UNIT 11 BOILER FEED
WATER PE"STST£0. MAINTENANCE ''-'AS PERFORMfP ON THE UNIT 11 PRECIPITATOR, THE FG BOOSTER BLOWFR AND
THF FGD SYSTEM SOd COMPRESSOR,
FEB. 7fl 720 336 0 0 a7 0
THF F6D SYSTEM WAS NOT OPERATED DUF TO ABNORMAI BOTLFR OPERATING CONDITIONS RELATED TO HIGH SILICA
iEVEI s IM THE ROTLF.W FEEH WATER, COUPLFD WITH UNIT n CO«L FEEP PROBLEMS, STOP VALVE PROBLEMS, PRE-
CIPITATljR MAI FUNCTION AND A LFAKTNR RUTLFW TUBF AUP WORK ON THE FLUE GAS ISOLATION DAMPER. MAIN-
WAS »LSU PFHFURMFD ON THF FG BHOSTFH BLOWER, THE EVAPORATOR CIRCULATING PUMP AND THE sos
PIPING.
MAR. JH 7jj(| t,un Hft] ,?15 9P 77 30
THE FGO SYSfFM OPERATE" FUR TEN DAYS.* OPERATION flAS INTFRRUPTFU BY SHUTDOWN UF THE IJNI1 11 BOILER
F0° PEPATR Up COAL GRINDTNC MILlS AMP PHFC 1P I T & TORS. PRHPF.N CONPITIONS CQIILO NOT BE HF-F ST APLI SHED
F09 Ofc-STAPT OF FGH npFRATTOw ^EPAUSF "F COAL FfPD AND GRINIiI.NG PROBLEMS CAUSED BY EXTREMELY POOR
OIJALTTY CUAl . MAIMTFfjANCF WAS PFRFuRrFD OM THF FG I'OOSIFH BtOWtR AND OPFRAUNG PROBLEMS WERF
FN/rtlM'jTCP(-0 '*11H THf. n.UF GAS TS'HATTtiN OA^PFR.
-------
FPA I'TTlTTY FGD SURVEY: TijME 1°7« - JULY
NORTHERN iMr'TA")A HUBLIC SFRVTCF
FE.A.-J M. "ITCHEIL
MONT H
HOURS
1 M PERIOD
HOURS
AVATLABIF
CALLED n;j
10 OF^K A I F
OPFK A T Eli
AVAIL ABU 1TY KEt.lABTt.TIV
u
n
£ R f* o o u
THF FQ HOOSIFk ti( U^ER WAS OUT OF bFKVirt F OK THIS FUTJPL PERTH" FrjP REBLADTNG. THF FGP SYSTEM WAS
TNOPFufAHLE. A FHIURE OF THF FLUE G A b ISOLATION 1)4 hPl^ AL^il IJCfMBPED. A Nf l'.« SUPPIV OF HIGH 5ULFUR
COAL WAS oRTAiMen sNm surcFssFiu. L Y TFSTtn nm IJ\IIT 11 tiiuif-. R. THTS C^AI is txpFCTEf TO AILEVTATE
PAST DTFFICUITTES HITH THE COAL FtFO A^!L) SRINUTNR SYSTFI-1. M A 1 N TFN ANTE hAS AISO PeRFOWMfO ON IHt
90TLEK in FANS, ri)AU FFEniN'G AMI) GRINDTlM^ SySTFc. AM[j T HE f CD ABSnWBb".
MAY78 7d" ^b« b?9 ^6i bl ^0 37
THF so? PETUVERY POKTIDN OF THF FGP SYSIFM OPEPATFO FOR ?h HAYS. THF TOMPLETF FGD SYSTEM OPFHAIFO
FOR 11 DAYS. npFXATTON WAS TNTEPWIIPTfn By FAtlURt UF THF FLUt GAS ISOLATION UAMPEf. PROBLFMS WITH
WET COAL WHICH RFOIIIRFn THAT THE UNIT 11 BOILER OPFWATF ON LD'A SIILFOR COAL FOR A SHQPT PFRTOn AND
PLHGRIMG OF AN ENTRAPMENT SEPARATOR IN THE so? REDUCTION UNIT.
,IU"E 7fl 720 97 S?l 3 1 * 1 0
OPERATION DF THE FGU SYSTfM WAS LIMITED Ry FAILURE OF THF FG BOOSTFR Bl 0>"ER DkTVF TUPBTNE AMD
INABILITY OF THE FR ISOLATION DAMPFR TO npFRATF. THF FGD PWOCFSS FACILITIES. CONSISTING OF THE
ABsoRBFH, FVAPORAIOR, so? REOUCTTON AND PURGF TKEATMFNT UNTIS, WERF AVAILABLE FO" OPEKATTON FOR
FSSENTIAILV THF ENTIRE PFRTOD.
JULY 7" 720 4? i>»3 17 t- 4 ?.
OPERATION OF THE FGD SYSTEM WAS LIMITED BY IMBALANCE OF THE FG BOOSTER BLOWER. DUE TO INABILITY
OF THE FG ISOLATION DAMPFR TO OPFh'ATE, THIS CONDITION COULD NOT BE CORRECTED UNTIL POWER DEMANDS
PERMITTED A SHUT DOWN op UNIT 11 BOILER. RECURRTNR FLUCTUATIONS IN THF PRESSURE OF THF MAIN
STFAM SUPPLY TO THE FGD SYSTFM ALSO RESTRICTED OPERATION. FG BOOSTER BLOWER PROBLEMS INCLUDED
LOW OIL PRESSURE, LEAKING BEARING OIL SEALS AND DRIVE TURHTNE GOVERNOR MALFUNCTION. THE FGD
PROCESS FACILITIES WFRF AVAILABLE FOR OPERATION FOR THE ENTIRE PERIOD.
-------
EPA UTILITY FGD SURVFY: JUNE 1978 - JULY 1978
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
UTILITY NAME NORTHERN STATES POWER
UNIT NAME SHERBURNE 1
UNIT LOCATION BECKFR MINNESOTA
UNIT RATING 710 MW
FUFL CHARACTERISTICS COAL; 0.8X SULFUR, 9X ASH
FGD VENDOR COMBUSTION ENGINEERING
PROCESS LIMESTONE/ALKALINE FLYASH
NEW OR RETROFIT NEW
START UP DATE 3/76
EFFICIENCY:
PARTICULATES (ACTUAL) 99 + PERCENT
fDESIGM) 99.0 PERCENT
S02 (ACTUAL) 50-55 PERCENT
(DESIGN) 50.0 PERCENT
WATER MAKE UP OPEN LOOP 1.13 GPM/MW
SLUDGE DISPOSAL UNSTABILTZED/ SLUDGE POND
OPERATING EXPERIENCE UPDATE:
BOILER OPERATION TIME AND MODULE OPERARILITY (X)
BOILER
PERIOD HR. 101 102 103 104 105 106 107 toa 109 no 111 112
FEB. 78 636 0 93 "2 89 74 85 89 88 7fa 86 88 87
TOTAL SYSTEM AVAILABILITY = 92 PERCENT
MEGAWATT-HOURS GENERATED = 366,200
MODULE 101 WAS DOWN IN FEBRUARY FOR MODIFICATIONS TO THE SPRAY TOWER ABSORBER. A BULK
ENTR4INMENT SEPARATOR WAS INSTALLED ALONG WITH A KOCH WASH TRAY. SPRAY NOZZLES WERE
REPLACED. THE 2 IN. OTA. ss RODS IN THE PRIMARY CONTACTOR WERE REPLACED WITH 6 5/a IN. DIA.
CERAMIC COATED C.S. RODS. THE CEKAMIC SLEEVFS ARE 9/16IN. THICK. MODULES WHICH ARE SHOWING
AVAILABILITY OF LESS THAN ao PERCENT, ARE THOSE IN WHICH THE STRAINER MODIFICATIONS WERE
PERFORMED.
MAR. 78 676 71 83 64 89 90 83 62 89 97 71 79 90
TOTAL SYSTEM AVAILABILITY = 92 PERCENT
MEGAWATT-HOURS GENERATED = 123,220
STRAINER MODIFICATIONS CONTINUED THROUGH MARCH AFFECTING THE AVAILABILITIES OF MODULES 101,
103, 107 AND 110.
APR. 78 713 92 87 87 44 81 85 91 86 92 91 87 52
TOTAL SYSTEM AVAILABILITY = 95 PERCENT
MEGAWATT-HOURS GENERATED = 464,520
THE REASON FOR LOW AVAILABILITY ON MODULE 104 AND 112 TN APRIL RESULTED FORM THE OUTAGE TIME
NECESSARY FOR THE INSTALLATION OF STFEL STRAINER SCREENS.
"AY 7« 635 61 86 85 86 89 64 62 83 82 71 87 79
TOTAL SYSTEM AVAILABILITY = 95 PERCENT
MEGAWATT-HOURS GENERATED = 3so,oio
THFRF WERE NO MAJOR FGD RELATED OUTAGES DURING MAY.
JUNE 78 717 50 84 85 85 62 78 55 83 8fl 82 72 95
TOTAL SYSTEM AVAILABILITY = 93 PFRCtNT
MEGAWATT-HOURS GENERATED = «i«,670
JULY 78 694 82 76 71 74 75 52 75 63 62 72 66 73
TOTAL SYSTEM AVAILABILITY = 95 PERCENT
MEGAWATT-HOURS GENERATED = 394,510
55
-------
FPA UTTLTTY FG.H SURVEY1. JUNE 1Q7R - JULY 197«
STATES POWE" SHFRRURNE 1
THF UTILITY TS IN THF PROCESS OF RFMOVTNG THE OLD 7URN DUPLEX STRAINERS AND REPLACING THEM
WITH 316 STAINLESS STEFL PTPFS. THE OCCURANCfc OF PLUGGING PROBLEMS IN THE MIST ELIMINATORS
AND REHEATFR HAS BFEN MORE FREQUFMT THBN NORMAL. THE UTILITY is EVALUATING NEW RUBBER LINED
PUMPS tanoo GPM) AND STAINLESS STEFL MTST ELIMINATOR WASH LANCES (TO REPLACE OLD FTBERGLAS
I.ANCFSI. THE Fr,n SYSTEM HAS BEEN EXPERIENCING PRIMARY CONTACTOR WALL AND MARBLE BED WEAR.
THF UTILITY TS PRtPARIMG FOR THE STATE COMPLIANCE DEADLINE ON NOV. 1. CURRENTLY TESTING
HAS BtFN PROCEEDING ON DIFFERENT MODULES IN AN EFFORT TO FINE TUNE THE SYSTEM.
-------
EPA iiTTLirv FGO SURVEY: JUNE 197B - JULY 1978
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
UTILITY NAME NORTHERN STATES POWER
UNIT NAME SHERBURNE ?
UNIT LOCATION BECKER MINNESOTA
UNIT RATING 710 MW
FUEL CHARACTERISTICS COALl O.R% SULFUR, 9X ASH
FGD VENDOR COMBUSTION ENGINEERING
PROCESS LIMESTONE/ALKALINE FLYASH
NEW OR RETROFIT NEW
START UP 0»TE »l)Pt FRtnuFN* TH4M FORMAL. TH^ UTILITY IS EVALUATING NEW RUBBER LINED
PUMPS (nOHO ^PM) AND STAINLESS Slfl-L MIST rI.TMlN»TnR WASH I ANCFS (TO REPLACE OLD FIBFRGLAS
LANCES). THF FGD SYSTEM HAS BEEN EXPERIENCING PRIMARY CONTACTOR WALL AND MARBLE BED WEAR.
-------
FP» UTILITY FGH SURVFY: juwt i«»7« - JULY i«?«
NORTHERN STATES POWER
THE U1TLTTY IS PREPARING hOK 7HF STATh CHMPLTANCF HEAO LTNF ON NOV. 1.
HAS RtFN PROTEFOIIMR ON oTFFk'PENT MODIII.FS IN 1^ EFFORT Tu FINF TUNE THE SYSTfW.
-------
EPA UTILITY FGD SURVEY: JUNf 1978 - JULY l<)7fl
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
UTILITY NAME
UNIT NAMF
UNIT LOCATION
UNIT RATING
PENNSYLVANIA POWFR
BRUCE MANSFIELD t
SHIPPINGPORT PENNSYLVANIA
825 MM
FUEL CHARACTERISTICS COAL! 4.7X SULFUR, 12,5X ASH
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
EFFICIENCY:
^ARTICULATES (ACTUAL)
(DESIGN)
S02 (ACTUAL)
(DESIGN)
WATER MAKE UP
SLUDGE DISPOSAL
CHEMICO
LIME
NEW
4/76
99.9 PERCENT
99.8 PERCENT
95.0 PERCENT
9P.1 PERCENT
OPEN LOOP
STABILIZED/LANDFILL
OPERATING EXPERIENCE UPDATE:
MONTH
BOILER
OPERATING HOURS
FGO MODULES
BCD
NOV. 77 720 682 713 657 000
FGO AVAILABILITY FACTOR X 95 99 91 0 0 0
FGO OPERABILITY FACTOR X 95 99 91 0 0 0
FGO UTILIZATION FACTOR X 95 99 91 0 0 0
TOTAL FGD LOST GENERATION FACTOR = 5P.5X
REMOVAL OF THE OLD COATING AND PRIMINS OF THE FLUE LINING IN FLUE IB IS PROCEEDING
SLOWER THAN ANTICIPATED. IT is EXPECTED THAT TOTAL WORK ON THE FLUE WILL NOT BE COMPLETED
UNTIL FEBRUARY OR MARCH 1978.
DEC. 77 626* 677 592 675 0 0
FGO AVAILABILITY FACTOR X 100 93 99 0 0
FGO OPFRABTLITY FACTOR X 100 94 100 0 0
FGO UTILIZATION FACTOR X 91 79 91 0 0
TOTAL FGP LOST GENERATION FACTOR = 61 X
SANDBLASTING OF UNIT 1-R FLNE IS NEARING COMPLETION.
CXL-2000.
THE FLUF WILL BE RELINED WITH
JAN. 78 331* 433 0 43? 000
FGO AVAILABILITY FACTOR X 100 0 100 0 00
FGO OPFRABTLITY FACTOR X 100 0 100 0 00
FGO UTILIZATION FACTOR 58 0 58 0 00
TOTAL FGO LOST GENERATION FACTOR = 60X
THERE WERE PROBLEMS WITH IB FAN WHICH NECCESITATED EXTENSIVE REPAIRS. LINING ABRASION AND
OTSBONDMENT IN FAN CAUSED CORROSION OF UNDERLYING SUPPORT MFTAL. THE UNIT TRIPPED SEVERAL
TIMES DUE TO DIFFICULTIES IN BURNING WET STOCKPILE COAL.
FEB. 78 514* 534
FGD AVAILABILITY FACTOR X 79
FGO OPFRABILTTY FACTOR X 100
FGD UTILIZATION FACTOR X 79
TOTAL FGO LOST GENERATION FACTOR
410 551 0 00
61 82 0 00
80 100 000
61 8? 0 00
= 54X
EXTENSIVE REPAIRS TO 1B I.D. FAN AND THE EMERGENCY NEED FOR LOAD FROM THE PLANT DURING THE
COAL STRIKE TEMPORARILY OVERLOADED 1A AND 1C TRAINS. THE MIST ELIMINATOR WILL BE REPLACED ON
JC TRAIN AS A RESULT OF THIS. IB FLUF RELINING CONTINUES.
59
-------
FPA IITTLTTY Fr,n SURVEY: JUNE 197* - JULY 1978
PbMNSYl VAMA Pn«FR
BRIICF MANSFIELD 1
OPERATING HOURS
MONTH SORE"
MAP. 78 6H9
FGO AVAILAHII ITY FACTOR X
FGO OPFRABTI.TTY FACTOR X
FG" MTTLTZATTON FACTOR x
TOTAL Fc;n LOST GFNFRATTON
REPLACEMENT UF THF
FGO MODULES
A
324
43
47
43
FACTOR
LINING
B
678
91
98
91
= 54%
IN IB
c
670
90
97
90
CHIMNFY
n
485
65
70
65
WITH
F
376
SO
54
SO
CXL ?000
F
449
60
65
60
WAS COMPLETED. REPAIRS WERE DONE ON
A, S, AND C FAN HOUSINGS.
APR. 78 720
FGO AVAILABILITY FACTOR x
FGD OPFRABILTTY FACTOR X
FGO UTILIZATION FACTOR X
TOTAL FGD LOST GENERATION
MISCELLANEOUS LEAK
MAY 78 457
FGO AVAILABILITY FACTOR x
FGO OPERABTLITV FACTOR X
FGD UTILIZATION FACTOR X
TOTAL FGO LOST GENERATION
EXTENSIVE REPAIRS
JUNE 78 0
FGD AVAILABILITY FACTOR X
FGO OPFRABILITY FACTOR X
EGO UTILIZATION FACTOR X
TOTAL FGD LOST GENERATION
530
74
74
74
FACTOR
REPAIRS
44?
98
97
59
FACTOR
632
88
88
88
= 18X
WERE
0
0
0
0
- 21X
WFRE MADE ON
n
0
0
0
FACTOR
0
0
0
0
= ox
357
49
49
49
DONE ON
443
98
97
50
630
87
87
87
FAN
389
91
85
52
THF 18 FAN.
0
100
0
0
0
100
0
0
697
97
97
97
HOUSINGS
394
92
A4
52
678
9«
94
94
AND DUCTS.
395
9?
8h
53
ANNUAL BOILER INSPECTION OUTAGE BEGAN ON MAY 20.
0
100
0
0
0
100
0
0
UNIT OUTAGE TTMF WAS FOR BOILER INSPECTION AND GENERATOR STATOR COOLER REPAIRS.
*NOTE: AN ATTEMPT IS ALWAYS MADE TO BEGIN OPERATION OF THEDOILER AND FGD SYSTEM SIMULTANEOUSLY AT
BRUCE MANSFIELD. OCCASIONALLY PROBLEMS DELAY BOILER START-UP MAKING IT POSSIBLE FOR MONTHLY
FGD MOOIILF HOURS TO EXCEED ACTUAL BOILER HOURS.
-------
EPA IITTLITY FGF1 SURVEY! JUNE 197B - JULY 197B
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL
SYSTEMS
UTILITY NAME
UNIT NAMF
UNIT LOCATION
UNIT RATING
PENNSYLVANIA POWER
BRIICF MANSFIELD ?
SHTPPINGPORT PENNSYLVANIA
8?5 MW
FUFL CHARACTERISTICS COAL! 4.7X SULFUR, 1?.5X ASM
FGO VENDOR CHFMICO
PROCESS LIME
NEW OR RETROFIT NEW
START UP DATE 7/77
EFFICIENCY!
PARTICULATES (ACTUAL)
(DESIGN)
Sni (ACTUAL)
(DESIGN)
WATER MAKE UP
SLUDGE DISPOSAL
99.9 PERCENT
99.8 PERCENT
95.0 PERCENT
9?.i PERCENT
OPEN LOOP
STABILIZED/LANDFILL
OPERATING EXPERIENCE UPDATE:
MONTH
BOILER
OPERATING HOURS
FGD MODULES
B C tl
NOV. 77 581* 598
FGf> AVAILABILITY FACTOR X 100
FGO OPERABILITY FACTOR X 100
FGO UTILIZATION FACTOR X 83
580
96
100
81
533
SB
9?
71
331
07
57
46
304
55
5?
4?
546
31
TOTAL FGO LOST GENERATION FACTOR = 27X
PROBLEMS ASSOCI/ITFD WITH THE STATION POWER TRANSFORMERS CAUSED LIMITATION IN LOAD ON UNIT E.
THREE OF THE SIX STATION TRANSFORMERS FOR UNIT ? WERE DESTROYED.
DEC. 77 607* 469
FGO AVAILABILITY FACTOR V. 70
FGO OPERABILITY FACTOR X 77
FGD UTILIZATION FACTOR X 63
638
99
100
86
618
98
100
8?
614
100
100
86
513
89
85
565
99
93
76
TOTAL
GO LOST GENERATION FACTOR = i.itt
COLO WEATHER CRFATEO SOMF FREEZING PROBLEMS WTTH PNOCFSS PIPING.
JAN. 78 391« ?28 b6« ?18 b?l ilSl 375
FGD AVAILABILITY FACTOR 7. 95 100 96 9U 99 99
PCD OPERABILITY FACTOR X 58 100 56 100 100 96
FGO UTILIZATION FACTOR X 31 76 <>9 70 61 50
TOTAL FGO LOST GENERATION FACTOR =
-------
Fpft UTILITY Fi,n SURVEY: MIME IQ?P - mi v
PENNSYLVANIA F-.lwFk
"ANSF IF 1.0
MONTH
fcR
(IPf- w« [ TNT, HllMf.
F[.n M|jr>i|l i S
t: n
MAR. 7« a<*'J*
FGH 4VAUAH1LITY FACTOR 1.
FGn OPFRAttlLTIY FACtOM 7.
FGP UTILIZATION FAC10R %
TOTAI FGD I.OSI GENFkAtTON
A HOHE.R TH'Jt LEAK
WFkF PtRFOk^tn ON
APR. 7H 71 ^
Fr;n AVAIIABJIJTY FACTOR t
Ft,n OPERAHTITTY FAC1OR 'I.
FG" OTILT/AIIUM FACTOR •/.
TOTAL FGO iosi GENERAITON
"ill? 449
1 o n o ?
1 o n 01
o7 M)
FAClOk - If
C AIISF D AN f
•HE ^^ FAN.
1 o n i n o
HP H^
81 «1
FACT ok - jaz
M fc b n 4 'i / 'i
in 100 4^
:Ok SFVFkAL
1 OH
CHIMNEY FLUE LINING RFPATKS BtC-AN
1 b
1 b
APRIL
1 01
1 'I
14
10
FxTtNSTVF T.n. FAN HOUSING
1 5
1 i
1 i
nFRF DQNt ON THF ?C I.I).
FAN. IHt f- Mv WAS
FkOM MARCH h THWPUGH
MAY 7fl
FGO AVAILABILITY FACTOR i
FGO opFRARTLiTY FACTOR a,
FGn UIILT7ATTON FACTOK 'I.
TOTAL FGO LOST GENERATION
^n STACK FLUE LTNTNG RF.PATkS ruNiiNiien. THE UIMII WAS
THE 2C 1.0. FAN. IHE FAN HOUSING >MA?> CIAO WITH
?7f>
i on
i on
47
FACTOR
i
?7fr
1 on
1 00
57
0
0
0
0
n
n
0
0
0
0
0
D
JUNE 7fl ai7* So? 501
FGO AV'IIAPILITY FACTOR * 7n (,<)
FGD npFR»biLTTY FACTOR 1 100 ino
FG" UTTLI2ATION FACTOR % 7n f,9
TOTAL FGH IOSI GENERATION FACTOR = 6ft%
-------
EPA UTTLTTY FGD SURVEY: JUNE 1978 - JULY
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS
UTTLITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
PHILADELPHIA ELECTRIC
EDDYSTdNE 1A
FODYSTONF PENNSYLVANIA
120 MM
FUEL CHARACTERISTICS COAL: a."5X SULFUR, 1?X ASH
F6D VENDOR UNITED ENGINEERS
PROCESS MAGNESIUM OXIDF
NEW OR RETROFIT RETROFIT
START UP DATE 9/75
EFFICIENCY:
PARTICULATES (ACTUAL)
(DESIGN)
S02 (ACTUAL)
(DESIGN)
MATER MAKE UP
SLUDGE DISPOSAL
99.9 PERCENT
99.9 PERCENT
95-97 PERCENT
90.0 PERCENT
OPEN LOOP 1.1 GPM/MW
ACID PLANT REGENERATION
OPERATING EXPERIENCE UPDATE:
FEB. 78 THE TURBINE OVERHAUL CONTINUED DURING THE REPORT PERIOD. DURING THE SHUTDOWN PERIOD IT
MAR. 78 WAS FOUND THAT SOME HIGH PRESSURE STEAM TUBES WERE CRACKED, SO UNIT MAINTENANCE HAS TAKEN
LONGER THAN EXPECTED. SOME MINOR FGO SYSTEM MODIFICATIONS HAVE BEEN INCORPORATED IN THE
COURSE OF THE SHUTDOWN PERIOD. START UP IS EXPECTED IN MID-APRIL 78.
APR. 7B THE UNIT JUST CAME BACK ON LINE JUNE 1 AFTER AN EXTENSIVE SYSTEM MODIFICATION OUTAGE
MAY 7« WHICH PEGAN DECEMBER a?. THE UNIT WAS EXPECTED BACK ON LINE IN MID-APRIL, BUT THERE WAS
A PROBLEM WITH A SUPER PRESSURE STEAM TURBINE.
JUNE 78 DURING JUNE THE SCRUBBER-ABSORBER SYSTEM ACHIEVED A fl9X OPERABILITY. OPERABILITY FOR JULY
JULY 78 WAS 51X. PROBLEMS OTCURREO THE LAST WEEK OF JUNE WITH THE MGS03 SLURRY CIRCULATION PUMP
WHEN THE UTILITY DISCOVERED THE RUBBER LINER WAS TORN AWAY. THERE HAVE BEEN SOME PROBLEMS
WITH THE MGO SECTION WHERE THE MGO MIXES WTTH THE SYSTEM LIQUOR. FIRE BRICK WAS REMOVED
FROM THE FLUID BED KFACTPR CHAMBER TO REPLACE THE ACID BARRIOR PLATES WHICH WERE FAILING.
THE FIRE BRICK WAS THEN REPLACED. THE SLOW PIECE BY PIECE PROCEDURE WAS TIME CONSUMING
AND ACCOUNTED FOR MOST OF THE REGENERARLE FACILITY DOWN TIME (MOST OF JUNE AND JULY).
MAJOR PROBLEMS WERE SOLVED ON THE REGENERATIVE FACILITY OVER THE PERIOD RESULTING IN
IMPROVED AVAILABILITY OF THE FACILITY.
-------
FPA IITTLTIY FGO SURVEY: JUNE 1978 - JULY
SFCTION 3
HFkFU^MMMCt DFSCkTPTIOlj FOR OPERATIONAL FGO SYSTfcMS
UTILITY WA^E PUBLIC SFRVICL OF NEW Mtxico
UNIT NAMF SAN JUAN 1
UNIT LOCATION WATERELOW NEW MEXICO
UNIT RATING 311 hW
FuFL CHARACTERISTICS COAL: 0.8X SULFUR, 2?X ASH
FG" VEMDOR DAVY POWFRGAS
PROCESS WELLMAN LORD
MEW Ok RETROFIT MEW
START UP DATE 1/78
EFFICIENCY:
PARTICUI ATES (ACTUAL)
(DESIGN) 99.8 PERCENT
so? (ACTUAL)
(DESIGN) 8^.0 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL ACID PLANT REGENERATION
OPERATING EXPERIENCE UPDATF:
FEBRUARY-MARCH 1978 - INITIAL SO? ABSORPTION AT SAN JUAN NO. 1 BEGAN ON APRIL B, 1978. FULL COMMER-
CIAL OPERATION IS EXPECTED BY LATE JUNE. THF FGO SYSTEM IS CURRENTLY IN SERVICE WITH TWO OF THE
UNIT'S FOUR ABSQRRFR CELIS OPERATING CONTINUOUSLY. A THIRD CELL IS TO BE BROUGHT ON LTNF LATER.
THREF CELLS WILL BF REQUIRED FOR FULL LOAD nllH A FOURTH INCLUDED FOR SPARE FfcD CAPACITY. THE CUR-
RENT MOljF TS TO KEEP i CELLS IN SERVICE AT ALL TIMES AND f. OUT OF SERVICE. ?/3 OF THE FLUE GAS
TS HFING TREATED WHILE 1/3 IS RETNG BYPASSED. THE UNIT IS IN COMPLIANCE AT PRESENT WITH RESPECT TO
SO? WITH ONLY ? CELLS RUNNING BECAUSE THF RISULFITF CONCFNTRATTON HAS NOT YET RUILT UP IN THF ABSOR-
BENT LIQUOR. WHFN THt SYSTEM REACHES EQUILIBRIUM WITH RFSPECT TO RISULFITF dex BISULFITE) THF UNIT
WILL BE READY TO BEGIN REGENERATING OPFRATTQNS. RFGFNFRATTON is EXPECTED TO BEGIN BY APRIL 27.
COMPLIANCE TESTING MAY TAKF PLACF AS EARLY AS THE FIRST WEFK OF MAY.
APRIL-MAY ISTB - OVER THE PERIOD THE UTILITY ACCUMULATED a? DAYS OF DATA DURING WHICH THE BOILER
WAS nuWN FOR 7 HOURS AND THE ABSORBERS WERE OOWiM FOR 2« HOURS (UNSCHEDULED). THE UNIT IS STILL NOT
STABILIZED SO USEFUL FIGURES FOR WATER REQUIREMENTS ARE UNAVAILABLE. THF CHEMICAL PLANT RFMAINS IN
ITS START up
JUNE-JULY 1978 - THE UNIT FXPEPIFNCED A VERY HTbH PRESSURE DROP ACROSS THE VENTURIES DURING THIS
PERIOD. CONSEQUENTLY, THE VOLUME OF FLUF GAS FLOWING ACROSS THE VENTURIES WAS NOT AS GRFAT AS
TS MFCFSSARY. THE FGU SYSTEM HAS NOT Y£T MET THF STAIF REGULATION HUT SHOULD MEET IT RY NOVEM-
BER ?a, 197t*.
-------
FPA UTTLTTY FGD SURVFY: JUNE 197S - JULY 1978
. S F C T I 0 M i
PERFORMANCE DESCRIPTION f-OK OPERATIONAL FGI) SYSTEMS
UTTLITY NAMR SOUTH CAPOI IMA PUBLIC SERVICE
UNIT NAMF WIMYAH 2
UNIT LOCATION GEORGETOWN SOUTH CAROLINA
UNIT RATING gflO MW
FUFL CHARACTERISTICS COAL: 1.0% SULFUR, 10% ASH
FGO VENUOR BABCOCK R W1LCOX
PROCESS LIMESTONE
NEW OR RETROFIT NEW
START UP D*1E 7/77
EFFICIENCY:
PART1CUI ATES (ACTUAL) 99.« PERCENT
(OESIRNJ gq.a PERCENT
sna (ACIUAI) s'i.o PERCENT
(DESIGN) 69.0 PERCENT
WATER MAKE UP OPFN LOOP
SLl'OGE DISPOSAL STABTLIZFD/SLU06F PONU
OPEWATINR EXPERIENCE UPDATF:
FEB. 7« DURINR THE FfB-MAR PERIOD THE FGO SYSTEM WAS BYPASSED ONCF FOR SEVERAL DAYS TO ALLOW
MAR. 7« SYSTEM CLEANING. THIS WAS IN PREPARATION FOR TESTS THAT BA8COCK AND WILCOX WILL SOON
8F PERFORMING, AND FOR WHICH THFY HAVF SET UP TFMPORARY ON-SITE LABORATORY FACILITIES.
OTHERWISE, THF SYSTEM RAN WELL DURING THE PEHTOO WITH ONLY A FEW MINOR PLUGGING AND SPILL-
ARE PROBLEMS IN VARIOUS SLURRY LINES.
APR. 7« THE SYSTEM WAS OPERATIONAL FOR MOST OF THIS PFRTOO. THE ONLY PROBLEM ENCOUNTERED WAS
MAY 7« MINOR SCALING, BUT TT DTD NOT CAUSE AN OUTAGE. THE UTILITY DID NOT HAVE ANY PERFORMANCE
FACTORS TO REPORT FOR THIS PERIOD.
JUNE 7fl THERE fflFRE NO FGD RFLATFD OUTAGES DURING THF PERIOD. THE BOILER AND FGD SYSTEM RAN FOR
JULY 78 679 AND 7?2 HOURS FOR JUNE AND JULY, RESPECTIVELY. THERE WFRF THREE BOILER OUTAGES DURING
THE PERTOn, ONE OF WHICH WAS A SCHEDULED OUTAGE.
-------
UITI.UY run SU&VFY: IUNE IQ/P - lui v i»/-
.s F c M n N
PFHFIIRN-ANCI- DFsn, TPT i Hi, i
UPI- jn OF APRIL.
7«
THE UNIT FXPE&IFNCED AM FRP LIIMFR FAILUPE AS WELL AS A PUMP FAILURE DURING THE PERIOD.
CURRENTLY ONLY ONF SCRUBBFR-ABSOKHER MdDULt IS RUNNING. THF EXPANSION -IOTNT FAILURE
MENTIONED PREVIOUSLY WAS DIRECTLY RELATED TO THE OAMPFR FAILURE nlHICH ALLOWED THE BOILER
TO CONTINUE PUMPING GAS TO THF SEALFD OFF FGD -SYSTEM.
JUNE
JULY
I*
A-MODIILF HAS BEFN RUNNING STEADILY FOR PVFK 11 HAYS. H-MOOULF is STILL DOWN WITH THE EXPAN-
STOM JOINT FATLUWF. THF FXPANSTON JCITNT WILL HE REPATRFD WITHIN THF NEXT i TO f> WEEKS
DURING A SCHEDULE" UNTT OUTAGF. THF MIST tLIMINATO"? WASH SYSTEM WAS ALTERED FROM A SEPARATE
CLUSI-D LOOP FOw K.ACH MODULE wHITH CIRrillATED CUNIINHOUSLY UNTIL THE SOLIDS LEVEL REACHED
SPECIFIED LFVFL AND W«S BLOWN DO.MN. THF NEW WASH SYSTE" IS COMMON TO BOTH MODULES. THF
NF« SYSTEM TAKfcS SUPERNATF F«OM [HE inp OF THF THICKENER FOR ^IST ELIMINATOR SPRAY, THIS
SYt.Th'-' IOFJ, NOT HAVE THF r-HRONIC PROBLEMS tVIDENT IN THF ORIGINAL SYSTEM BUT THERE IS SOMF
CONCERiV THAT THF I.«C K UF PEDUMOANCY 1 ^l THF M.F. SYSTEM WOULD RESULT IN A COMPLETE FGD SYSTEM
SHUT DOWN IN THF FVFNT THAT M.fc. WASH FAIIS. THERE A«E STILL INSTRUMENTATION PROBLEMS. PH
PRORtS HAVF I3FEN I OS!, THF MAG-FLOw MFTFR FOR LTMFSTONF SLURRY HAS FAILED AND THE AUTOMATIC
GAS AMALY7ERb HAVE NEVER OPFRATFD PROPERLY. PIPING HAS rtFEN1 PLUGGING BECAUSE OF NEOPRtNE
PI IIG PEELING FROM VALVES. THF SLiiur-t SYSTEM FXPF.RIFNCED SOME FILTER BELT PROBLEMS BUT THESE
tifUF WEPATWFO.
ftfe
-------
FPA UTILITY FGP) SURVEY: JUNE 197« - JULY 1<»78
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
UTILITY NAME TENNESSEE VALLFY AUTHORITY
UNIT NAMF SHAWNEF 10A
UNIT LOCATION PADUCAH KENTUCKY
UNIT RATING 10 MW
FUEL CHARACTERISTICS COAL: ?.9* SULFUR, 15.«X ASH
FGH VENDOR AIR CORRECTION DIVISION, UOP
PROCESS LIME/LIMESTONE
NEW OR RETROFIT RETROFIT
START UP DATE 4/7?
EFFICIENCY:
PARTICULATES (ACTUAL)
(DESIGN) EXPERIMENTALLY CONTROLLED
803 (ACTUAL)
(DESIGN) EXPERIMENTALLY CONTROLLED
WATER MAKE UP EXPERIMENTALLY CONTROLLED
SLUDGE DISPOSAL EXPERIMENTALLY CONTROLLED
OPERATING EXPERIENCE UPDATE:
RFFFR TO OPERATING EXPERIENCE UPDATE FOR SHAWNEE NO. 10B.
-------
FPA
ITLTIY Fc;n SURVFY: TUNE
- .HH.Y 1978
SECTION 3
DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
MITLITV NA"E
llfoTI NAMF
UNIT LOCATION
1INTT RATING
TENNFSSEF VALLFY AUTHORITY
SHAwMtF 10R
PADUCAH KENTUCKY
10 MK
FUEL CHARACTERISTICS COAL: ?.9% SULFUR,
FGD VENDOR CHFMICO
PROCESS LIME/LTMFSTONE
NEW OR RETROFIT RETROFIT
START UP DATE a/7?
.a* ASH
EFFICIENCY:
PARTICULATES (ACTUAL)
(DESIGN)
302 UC1HAL)
(DESIGN)
WATEP MAKE UP
SLUDGE DISPOSAL
EXPERIMENTALLY CONTROLLED
EXPERIMENTALLY CONTROLLED
EXPERIMENTALLY CONTROLLED
EXPERIMENTALLY CONTROLLED
OPERATING FxPERIENCE UPDATF:
APR.
M4Y
FEB. 7« MAJOR SYSTEM DOWNTIMES DURING THE PERIOD INCLUDED: JANUARY 36 THROUGH FEBRUARY 4 FOH THE
MAR. 7« VENTUWI/SPRAY TOWER AND JANUARY ?6 THROUGH FEBRUARY ?. FOR THF TCA SYSTEM DUE TO FREEZING
WEATHER, AMD MARCH 6 THROUGH MARCH i? FOR BOTH SYSTEMS DUE TO BOILER OUTAGE.
THF EFFECT OF THE SLURRY LFVEL IN THF AIR SPARGED OXIDATION TANK WAS INVESTIGATED IN THE
Tnn SCRUBBER LOOP VENTPRT/SPRAY TOWER SYSTEM WHICH is OPERATING ON LIME SLURRY WITH HIGH
FLY ASH LOADING. NEAR COMPLETE SULFITE OXTUATTON (98 PERCENT) WAS ACHIEVED WITH 1« FOOT
AND 1B FOOT OXTOATION TANK LEVELS AT AN AIR STOICHTOME TR 1C RATIO OF 1.8 ATOMS OXYGEN/MOLE
SO? ABSORBED. AN AIR ST OICHI OME TR TC RATIO UP TO ABOUT i.8 WAS NEEDED TO YIELD NEAR COM-
PLFTF OXIDATION WHEN THE TANK LEVEL WAS DROPPED TO 10 FEFT.
A NEW TEST HLUCK WAS STARTFD ON MARCH i ON THE VFNTURI/SPRAY TOWER SYSTEM. MAGNESIUM
OXIDE WAS ADDED TO THE SPRAY TOwFR SLURRY LOOP IN A TWO SCRUBBER LOOP OPFRATTON WITH
FORCFD OXIDATION IN THF VEN1URT LOOP. THE SYSTEM WAS OPERATED IN A LIMESTONF SLURRY MODE
WITH HIGH FLY ASH LOADING. THE PRIMARY OBJECTIVE OF MAGNESIUM ADDITION is TO IMPROVE THE
so? REMOVAL EFFICIENCY. BECAUSE UF THE SHORTAGE OF COAL CAUSED BY THE COAL MINERS'
STRIKE, COALS FRPM DIFFERENT SOURCES WFRE BU&NFD IN THF BOTLFR. AS A RESULT, INLET sos
CUNCFNTRATIUN FLUCTUATED AS MUCH AS TENFOLD (550-3500 PPM), CAUSING PROBLEMS IN SYSTEM
CONTROL.
TC» rtAS npFRiTFu WITH BOTH LIMF ANPI LIMESTONF. AND WITH MAGNESIUM OXTDE ADDITION.
FLUfc GAS rtlTM HIGH Fl Y ASH LOADING nAS USED. THFSE TESTS WERE CONDUCTED PRIMARILY TO
RESOI.VF SUMt OF THF INCONSISTENT RESULTS OBTAINED DURING EARLIER LIME/MGO AND LIMESTONE/
wr,n TE^IS MADE IN APRII -MOVFMQFR i
-------
FHft IIITLTTY FGO SURVEYS JUNE 1978 - JULY 1978
TENNFSStF VALLFY AIUHORITY SHAWN'EF 1 OB
TOWfcP. M^n WAS ADDED To THE tFFlUFNT HOLD TANK TO MAINTAIN AN EFFECTIVE MG + + ION CQNCEN-
THMTON OF sown PPM. A si URPY STKFAM WAS TAKEN FROM THE SCRUBBER OOWNCOMER AND SENT TO
AN OXIDATION TANK INTO WHICH AIR WAS SPARGED. A RECYCLE STREAM OF ABOUT 30 6PM WAS SENT
RACK FROM THE OXIDATION TANK TO THE FFFL.UENT HOLD TANK TO CONTROL PH IN THE OXID6TTUN TANK
AND TO PROVIDE GYPSUM SEFDS IN THE SCRUBBER SLURRY. FTNAL SYSTEM PLPEO was WITHDRAWN FROM
THF OXIDATION TANK. AT AN AVERAGE OXIDATION TANK PH OF 6, SIILFITE OXIDATION AVERAGED 98
PtRCFNT. FILTFR CAKF SOLIDS CONTENT WAS 85 PERCENT, SIMILAR TO THAT OBTAINED WITH TWO
SC&UR8FR LOIJP OPERATIONS. HOWFVFH, THF SLURRY SOLIDS SETTLING RATF. WftS ONLY ABOUT
O.a CM/MTN, CU^PARFD TO ABOUT 0.« CM/MTN FOR THE TWO LOOP OPERATION, SETTLING HATF FOR
IINOXTOrZED SLURRY TON!AIMING MAGNESIUM ION NORMALLY DIP NOT EXCEED 0.1 CM/KIN WITH 50 TO
-------
FPA UTILITY FGO SURVEY! JUNE 197fl - JULY 197«
SFCT10N 3
PFRFoRMANCt DESCRIPTION FOR OPERATIONAL
MTTLTTY NA"E
IINTT N'MF
UNIT LOCATION
UNIT RATING
TENNFSSEF VALLEY AUTHORITY
WIDOWS CRfcFK 8
BRIDGE-HURT ALABAM4
550 MW
FUEL CHARACTFKTSTirS COAL: *.7X SULFUR, 17X ASH
FGD VENDOR
PROCESS
NEW OR RETROFIT
START IIP D»TF
TENNFSSEF VA1LFY AUTHORITY
LIMtSTONF
RETROFIT
5/77
EFFICIENCY:
PARTICULATES (ACTUAL) 99.S + PERCENT
(OF.SIGN)
S02 CACTIIAl)
fDFSTGN)
WATER MAKE UP
SLUDGE DISPOSAL
99.s PERCENT
8^-9(1 PERCENT
80.0 PERCENT
STABTLIZED/SLUDGF POND
OPERATING EXPERIENCE UPDATF:
MONTH BOTLEH A-STDE
171
OPERATING HOURS
B-SIDE C-SIDF D-SIOE
COMMENTS
401
370
THE OUTAGE TTMF FOR TRAINS A AND B WAS REQUIR-
ED TO REPLACF THF RUBBER LINERS IN THE DOWN-
COMER AREA WITH STAINLESS STEEL. THIS WILL BE
DONE TO THF REGAINING TWO TRAINS AS WELL.
FEB. 78 safe
AVAILABILITY = 55
OPF.RABTLITY = SUX
RELIABILITY = 61X
UTILIZATION = 47X
* THE UTILITY REPORTED THAT THFY COULD NOT ACCURATELY DETERMINE RELIABILITY BECAUSE OF THEIR
INABILITY TO CALCULATE UNIT LOAD DEMAND ON A DAILY BASTS. GFIMERALLYr TT IS ASSUMMED THAT SYSTEM
FORCED OUTAGE HOURS PLUS THE HOURS FGD SYSTEM OPERATED WILL GIVE ROUGHLY THE HOURS THE SYSTEM WAS
CALLFD UPON TO OPERATE. IN THIS WAY, RELIABILITY CAN BE CALCULATED INDIRECTLY. HOWEVER, IN THIS
CASE, TWO TRAINS AT A TIME HAVE BEEN DOWN ON A SCHEDULED OUTAGF FOR NECESSARY MODIFICATIONS. PART
OF THIS OUTAGE TIME LIMITED ROILFR OPERATION SO THAT THE UNIT COULD NOT RUN AT FULL LOAD WHEN THERE
WAS A DEMAND FOR FULL LOAD. FOR THIS CALCULATION IT WAS ASSUMMED THAT THERE WAS A DEMAND FOR FULL
I DAD DURING THE FNTIRt SCHEDULED OUTAGE SO THAT ALL OK IHE TRAINS WOULD HAVE BEEN CALLTD THE ENTIRE
SCHEDULED OUTAGE. THfc RESULT WAS A VERY CONSERVATIVE FSTIMATE OF RELIABILITY WHERE HOURS CALLED
= SYSTEM FOKCF.O OUTAGE HOURS * SYSTEM SCHEDULED OUTAGE + HOURS THE FGD SYSTEM OPERATED.
NOTE: THIS is A PEDCO ESTIMATE.
MAR. 7« f>aa 5
AVAILABILITY 6rtX
OPFRABILITY = ftbX
RELIABILITY - S9X *
UTILIZATION : -58X
34
-------
TENNESSEE VALLEY AUTHORITY
MONTH BOILFN A-STDE B-SIDE C-STDF D-SIDE
AVAILABILITY = b^X
OPERABILTTY = 8JX
RELIABILITY = hit *
IITILAZATTON = f>2*
464
576
EPA UTILITY FGD SURVEY! JUNE 197B - JULY
WIDOWS CREEK H
fOMMFNTS
AT THE BEGINNING OF THIS MONTH» DURING A HRIFF
INSPECTION OF THF SCRURBFR, SOLIPS OEPOSTfTOM
WAS NOTICED TN THE ENTRAIWMENT SFPARATOR
SECTTON OF Ai.L TRAINS RfCAUSF OF PLURGTIMG THAT
HAH OCCURRED IN .SEVERAL OF THE ENTPAINMENT
SEPARATOR SPRAY NOTZLES, TWAIN n WAS NOT IN
OPFHATTON FQR )? UAYS, DURING THIS PERIOD THE
ENTRAPMENT SEPARATOR WAS r11 S3 ASSF M8I E 0 RY
SECT TUNS AMD CLEANED. A STATNLESS STFF.L LTNFR
WAS INSTALLED ON THE SLOPING ARE»S OF TuF
ABSORBER AND VFNTURI. STAINLESS STEFL PLATES
WERE INSTALLED OVER THF ENTRf DOOM OPENINGS
70 TRAIN D INLET, OUTLE1, AND BYPASS GUILLO-
TINE DAMPERS TO REDUCE GAS LEAKAGE FROM THF
ENTRY DOOR OPENINGS. 3TAINLFSS STEEL CUVtRS
WERE INSTALLED AROUND THF FIVE EXPANSION
JOINTS ON TRAIN D, TWO EXPANSION JOINTS ON
TRAIN 4, AND OME EXPANSION! JOINT OW TRAIN B,
TO RFDUCE C,AS LEAKAGE TO TH£ ATMOSPHFRF.
THFRE CONTINUES TO BE A WEAR PROBLEM WITH PUMP
LINERS AT THE PALL MILL, NO CAUSE OR SOLUTION
OF THE PRORLFM HAS BEEN ASCERTAINED AS YET.
71
-------
FPA nrtLTTY FGO SURVEY: JUNE i«7« - JULY 197?
SECTION 3
PFWFORMANCt DESCRIPTION FOR OPERATIONAL FRO SYSTEMS
UTILITY NAME TEXAS UTILITIES
UNIT N«MF MARTIN LAKF i
UNIT LOCATION TATUM TEXAS
UNIT RATING 79.5 MW
FUFL CHARACTERISTICS COAL: l.OX SULFUR
FGH VF.NDOK RESEARCH COTTRFLL
PROCFSS L1MESTONF
NEW OR RETROFIT NEW
START UP 041E 8/77
EFFICIENCY:
PARTICULATES (ACTUAL)
(DESIGN) 99.a PERCENT
SOa (ACTUAL)
(DESIGN) 70.5 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL STABIL IZF.U/SLUnGF POND
OPFRATINR F.XPERIFNCE UPDATE:
FERRUARY-MARCH i«'7fl - CERTIFICATION WAS RECEIVED FROM THF EPA FOP THIS UNIT. THE BOILER AND
SCRUBBER-ABSORBER SYSTFM OPERATEn THROUGHOUT THE PERIOD. THE UTILITY TS STILL HAVING SOME PROBLEMS
WITH THE SLURRY HANDLING SYSTEM, AND SOME FQRCFD OUTAGE TIME OCCURRED.
APRII-MAY 1978 - NO INFORMATION WAS REPORTED BY THE UTILITY FOR THIS PERIOD.
JUNE-JULY 1978 - THE SYSTEM IS NOW RUNNING COMMERCIALLY. THF UTILITY HAS ENCOUNTERED SOME PROBLEMS
SINCF INITTAl OPERATION. THF HAMPERS FOR FACH ABSORBER MODULE WERE NOT FUNCTIONING PROPERLY. IT
HAS BEFN IMPOSSIBLE TO ISOLATE INDIVIDUAL MODULES FOR REPAIRS (THE ENTIRE SYSTEM WOULD HAVE TO BE
SHUTDOWN IF REPAIRS WERE REQUIRED ON ONLY ONE MODULE). THERE HAS ALSO BEEN A PROBLEM WITH THE PH
METERS. THE METERS HAVE NOT OPERATED PROPFRLY FOR SOME TIME NOW.
-------
FPA UTILITY FGD SURVEY: JUNE 1978 - JULY 1978
SFCTIOfv 3
PFKFOPMANCt OFSCR THT I a
-------
EPA UTILITY FGD SURVFY: JUNE
- JULY 1
-------
EPA UTILITY Ftn SuRVFY: JUNE 19f« - JULY 1978
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
« *
UTILITY NAME UTAH POWER & LIGHT
UNIT NAME HUNTTNGTON i
UNIT LOCATION PRICE UTAH
UNTT RATING 415 MW
FUFL CHARACTERISTICS COAL? O.SX SULFUR
FGH VENDOR CHEMTCO
PROCFSS LIME
NEW OH RFTROFIT NEW
START UP DATE S/7B
EFFICIENCY:
PARTICULARS (ACTUAL)
(DESIGN) 9<9.5 PERCENT
SP2 (ACTUAL)
(DESIGN) 8o.o PERCENT
WATER MAKE UP CLOSED LOOP
SLUDGE DISPOSAL STABILIZED/SLUOGE POND
OPERATING EXPERIENCE UPDATE!
JPPIL-MAY 1978 - INITIAL OPERATIONS BtGAN MAY 10 AT THIS PLANT. CUMMFHCIAL START-UP IS EXPECTED
SOMETIME IN JULY.
JUNE-JULY 1978 - THE UTILITY REPORTED THAT THt UNIT OPERATFD MOST OF THE PERTOP WITH BOILER HOURS
(IF 72U AND 731 FOR JUNE AND JULY RESPECTIVELY. THE FGD SYSTEM WAS ON-LINE «7l) AND 7M HOURS fOR
JUNE AND JULY RESPECTIVELY.
-------
FPA UTILITY FGD SURVEY: JUNE I97fl - JULY 1978
SECTION 4
SUMMARY OF FGD SYSTEMS BY COMPANY
UTILITY
ALABAMA ELECTRIC COOP
ALLEGHENY POWFR SYSTEM
ARIZONA ELECTRIC POWER COOP
ARI70MA PUBLIC SERVICE
ASSOCIATED ELECTRIC COOP
BASIN ELECTRIC POWER COOP
8TG RIVERS ELECTRIC
CENTRAL ILLINOIS I IGHT
CENTRAL ILLINOIS PUBLIC SERV
CENTRAL MAINE POWER
CINCINNATI GAS * ELECTRIC
COLORADO UTE ELECTRIC ASSN.
COLUMBUS * SOUTHERN OHIO ELEC.
COMMONWEALTH EDISON
COOPERATIVE POWER ASSOCIATION
OFLMARVA POWER ft LIGHT
DMQUESNE LIGHT
EASTERN KENTUCKY POWER COOP
GENERAL PUBLIC UTILITIES
GULF POWER
HOOSIFR ENERGY
INDIANAPOLIS POWER a LIGHT
KANSAS CITY POWER & LIGHT
KANSAS POWER * LIGHT
KENTUCKY UTILITIES
LAKELAND UTILITIES
LOUISVILLE GAS S ELECTRIC
MINNESOTA POWER & LIGHT
MINNKOTA POWER COOPERATIVE
MONTANA POWER
NEVADA POWER
NEW ENGLAND ELEC SYSTEM
NIAGARA MOHAWK POWER COOP
NORTHERN INDIANA PUB SERVICE
NORTHERN STATES POWER
OTTER TAIL POWER
PACIFIC GAS AND ELECTRIC
PACIFIC POWER & LIGHT
PENNSYLVANIA POWER
PHILADELPHIA ELECTRIC
PUBLIC SERVICE OF INDIANA
PUBLIC SERVICE OF NEW MEXICO
SALT RIVER PROJECT
SAN MIGUEL ELECTRIC COOP
STKFSTON BOARD OF MIINIC. UTIL.
SOUTH CAROLINA PUBLIC SERVICE
SOUTHERN ILLINOIS POWFR COQP
SOUTHERN INDIANA GAS * FLEC
SOUTHERN MISSISSIPPI FLFCTRTC
SOUTHWESTERN ELFCTRIC POWER
SDRTNGFTELD CITY UTILITIES
SPRINGFIELD WATER LIGHT & PWR
ST. JDE ZINC
TENNESSEE V*LIEY AUTHORITY
TFXAS MUNICIPAL POWER AGENCY
TFXAS PnwFR a LIGHT
TFXAS UTILITIES
UTAH POWER R LIGHT
WISCONSIN POWER S LIGHT
TOTAL
NO MW
2
2
^
B
1
5
2
2
1
1
1
2
4
1
2
i
2
i
2
1
2
2
3
4
1
1
8
1
1
4
10
1
1
3
tl
1
2
1
3
4
1
4
3
1
1
2
2
1
2
1
1
1
1
4
1
3
6
3
1
450.
1250.
400.
2804.
670.
2600.
490.
800.
57S.
600.
600.
900.
1550.
425.
1090.
180.
920.
500.
1600.
20.
980.
1060.
1020.
1«65.
64.
350.
2283.
500.
450.
2120.
3125.
650.
100.
705.
3140.
400.
1600.
509.
247S.
846.
650.
1560.
1050.
400.
235.
580.
08U.
250.
360.
720.
200.
190.
60.
1145.
400.
2045.
467?.
1215.
527.
OPERATIONAL CONSTRUCTION CONTRACT
AWARDED
NO MW NO MW NO MW NO
0
0
0
2
0
0
0
1
0
0
0
0
2
0
0
0
2
0
0
0
0
1
3
2
1
0
4
0
1
2
3
0
0
1
2
0
0
0
2
1
0
1
0
0
0
1
0
0
0
0
1
0
0
3
0
0
3
1
0
0.
o.
0.
365.
0.
0.
0.
400.
0.
0.
0.
0.
800.
0.
0.
0.
920.
0.
0.
0.
0.
530.
1020.
525.
64.
0.
851.
0.
450.
720.
375.
0.
0.
115.
1420.
0.
0.
0.
1650.
120.
0.
314.
0.
0.
0.
280.
0.
0.
0.
0.
200.
0.
0.
570.
0.
o.
2336.
415.
0.
2
2
?.
1
0
2
2
0
1
0
0
2
0
1
2
1
0
0
0
1
2
1
0
2
0
0
2
1
0
0
0
0
0
0
0
1
0
1
1
0
0
1
2
1
1
0
1
1
2
0
0
0
1
0
0
0
1
1
0
450.
1250.
400.
350.
0.
1140.
490.
0.
575.
0.
0.
900.
0.
425.
1090.
180.
0.
0.
0.
20.
980.
530.
0.
1360.
0.
0.
772.
500.
0.
0.
0.
0.
0.
0.
0.
400.
0.
509.
825.
0.
0.
306.
700.
400.
235.
0.
184.
250.
360.
0.
0.
0.
60.
0.
0.
0.
793.
400.
0.
0
0
0
2
1
0
0
0
0
0
1
0
0
0
0
0
0
1
0
0
0
0
0
0
0
1
2
0
0
2
0
0
1
0
0
0
0
0
0
0
0
1
0
0
0
1
0
0
0
1
0
1
0
0.
0.
0.
1510.
670.
0.
0.
0.
0.
0.
600.
0.
0.
0.
0.
o.
0.
500.
0.
0.
0.
0.
0.
0.
0.
350.
660.
0.
0.
1400.
0.
0.
100.
0.
0.
0.
0.
0.
0.
0.
0.
468.
0.
0.
0.
300.
0.
0.
0.
720.
0.
190.
0.
575.
400.
5a5.
793.
400.
527.
0
0
0
3
0
3
0
1
0
1
0
0
2
0
0
0
0
0
2
0
0
0
0
0
0
0
0
0
0
0
7
1
0
2
2
0
2
0
0
3
1
1
1
0
0
0
1
0
0
0
0
0
0
0
0
z
I
0
0
PLANNED
MW
0.
0.
0.
579.
0.
1460.
0.
400.
0.
600.
0.
0.
750.
0.
0.
0.
0.
0.
1600.
0.
0.
0.
0.
0.
0.
0.
0,
0.
0.
0.
2750.
650.
0.
590.
1720.
0.
1600.
0.
0.
726.
650.
472.
350.
0.
0.
0.
300.
0.
0.
0.
0.
0.
0.
0.
0.
1500.
750.
0.
0.
TOTALS
1 ?9 59429. /JO 14400. 42 16834. 21 10708. 36 17«47.
- PLANNED STATUS INCLUDES LtTTFR OF INTENT SIGNED, REQUESTING/EVALUTING BIDS.
irjn cuMSTi)FKTNG ONLY FC,O SYSTEMS
76
-------
FPA tITTLTTY FGO SURVEY! JUNE 1978 - JULY 1978
stcriuN s
OF H*r> SYS1FMS HY VFNOOR
TOTAl
STATUS — «
OPERATIONAL CONSTRUCTION CONTRACT
MANUFACTURER /PROCESS
AOL/COMBUSTION EQUIP ASSOCIATE
DOLIRLF ALKALI
LTMF/ALKAl.INt FlYASH
soiiTUM CARBONATF
TOTAL -
AIR CORRECTION DIVISION, UOP
LIMF CMG-PROMOTED)
LTMF/LfMESTONF
LTMFSTONE
SOOHIM CARBONATE
TOTAL -
AMFRTCAN AIR FILTER
LIMF
LIMF fCARBlOfc)
TOTAL -
ATOMICS INTERNATIONAL
AOUFOUS CARBONATE
TOTAL -
RAPCOCK * WJLCOX
LIME
LIMESTONE
TOTAL -
RUFLL/FNVIROTECH
DOURLF ALKALI
TOTAL -
BUREAU OF MINES
CITRATE
TOTAL -
CHFMICO
LTMF
LIME/ALKALINE FLYASH
LTMF/LIMESTONF
LIMESTONE
TOTAL -
CHIYOUA INTERNATIONAL
LTMFSTONE
TOTAL -
fuMHMSTIOiM tNGTNFEfRING
LIMF
LTMF (CAHRJOEl
LTMF/LIMtSIONF
LTMTSTIIME
LTwrSTuNf/ALKALINF FLYASH
TOTAl -
NAVY pnwFKRAS
WFLIMAIM \_r\Hri
TOTAL -
FMC rilPPOK A 1 TM,".|
OHDPLF ALKAI. i
TIJTAI -
NO.
1
5
3
9
2
1
4
1
8
4
2
6
1
1
3
7
10
1
1
1
1
7
1
1
1
10
1
1
b
2
2
7
2
16
b
5
1
1
MW
277.
257 u.
375.
?2?2.
800.
10.
1875.
509.
3194.
1049.
603.
1652.
100.
100.
1850.
2569.
4419.
575.
575.
60.
60.
3785.
527.
10.
750.
5072.
20.
20.
1 790.
24tt.
660.
*405.
1 4?0.
7b?3.
1 58J.
1383.
250.
250.
NO.
0
f
3
f-
2
1
?
0
5
1
?
^
n
0
0
?
?
0
0
0
n
5
0
1
1
7
0
n
?
?
0
?
?
a
?
?
p
n
M'W
0.
1170.
375.
1545.
800.
10.
730.
0.
1540.
64.
603.
6fa7.
0.
0.
0.
1100.
noo.
0.
0.
n.
n.
2985.
0.
10.
7bO.
3745.
0.
0.
200.
?48.
0.
525.
1 "20.
-------
IITTLT1Y FGO SUHVFY! JUNh
- U'lY
s t r i T n N s
SUMMARY (!F Fbn SY"irM<; '*Y VFhl'H)!'
TOTAL OPFRAT 1 Ol «L
MANMFACTMPEP/PRncFSS
TOTAL -
PEAHOLJY FNGlNEEHTtoG
LTMP/AI.KALINF. FI YASH
LTMFSTuNF
TOTAL -
PULLMAN KtLLDGG
LIMF
LTMFSTllNF
TOTAL -
RESEARCH COITHFLL
LIMFSTOME
TOTAL -
PILtY STDKFk / ENVTRONFERING
LTMFSTONE
TOTAI -
TENNFSSEF VALLFY AUTHORITY
LIMFSTONE
TOTAL -
IINITFO ENGTNFERS
MAGNESIUM OXIDE
NDT SFLFCTEH
TOTAL -
WHFELARKATDR-FRYF/A.T.
AQUFOHS CARBONATE
TOTAL -
fjn. Mrt
a SRO.
1 500.
4 1 3^0.
5 1HSU.
1 8?b.
3 1370.
4 ?195.
13 614?.
13 6147.
3 760.
5 76U.
1 550.
1 550.
1 120.
2 1510.
3 1 630.
1 400.
1 400.
MU.
0
n
0
n
fl
0
0
4
a
1
t
1
1
1
0
1
0
0
M'/!
0.
0.
0 .
0.
o.
0.
n .
1951 .
1951.
400.
400.
550.
550.
120.
0.
120.
0.
0.
NO.
2
1
4
5
1
2
3
7
7
2
^
0
0
0
0
0
1
1
Mpj
SR».
500.
1 350.
1rt50.
SP5.
/no.
15?5.
321 3.
3213.
360.
360.
0.
0.
0.
0.
0.
400.
400.
CONTN AC T
(•ill.
0
0
0
0
0
1
1
?
?
0
0
0
0
0
2
2
0
0
Ml"
0.
0.
0.
0.
0.
670.
6/0.
983.
983.
0.
0.
0.
0.
0.
1510.
1510.
0.
0.
103 419K2.
40 14440.
42 16834.
21 10708.
7H
-------
FPA IITKTTY FGD RURVFY: JUNt 1978 - JULY 1978
SECT TON ft
SUMMARY OF NEW ANO RbTrtDFTT Ff,U SYSTEMS BY PHOCFSS
NEW OR OPERATIONAL CONSTRUCTION CONTRACT
PROCFSS RETROFIT
IIME
LIMt (CARBIDE)
LIME (MG-PROMOTEO)
LIME/ALKALINE FLYASH
LIME/LTMFSTONE
1 JMESTONF
LIMESTONF/ALKALINE FLYASH
SUBTOTAL - LIME/LIMESTONE
SQIIEOUS CARBONATE
CITRATE
DOUBLE ALKALI
MAGNESIUM OXTDE
NOT SELECTED
SODIUM CARBONATE
WELLMAN LORD
TOTALS
LIMF/LIMESTONE t Op TOTAL MW
N
R
M
R
N
R
N
R
N
R
M
R
N
R
N
R
N
R
M
R
N
R
N
R
M
P
N
P
N
R
N
P
N
R
NO
3
5
1
3
e>
0
3
0
0
2
10
3
2
0
?1.
13.
0
0
0
0
0
0
0
1
0
0
1
2
1
1
23.
17.
. MM
2065
1184
425
126
800
0
1170
0
n
20
521f-
790
1420
0
11096.
2420.
0
n
0
0
0
0
0
120
0
0
125
250
314
115
11535.
2905.
96
83
NO
9
0
0
n
0
0
i
0
0
0
22
2
0
0
32.
2.
1
0
0
1
2
1
0
0
0
0
1
0
0
?
36.
6.
MW
4550
0
0
0
0
0
500
0
0
0
8782
445
0
0
13832.
445.
400
0
0
60
825
277
0
0
0
0
509
0
0
486
15566.
1268.
89
35
PI.ANNFO
A *v A R 0 E 0
NO.
3
0
0
0
0
0
3
0
0
2
8
1
0
0
14.
3.
0
1
0
0
0
0
0
0
0
2
0
0
1
0
15.
6.
Si
MW
1500
0
0
0
0
0
1927
0
0
660
3968
S75
0
0
7395.
1235.
0
100
0
0
0
0
0
0
0
1510
0
0
468
0
7863.
2845.
!|
J
NO
1
0
0
0
0
0
0
3
0
0
6
0
2
0
9.
3.
0
0
0
0
0
0
0
3
17
3
0
0
1
0
27.
9.
MH
455
0
0
0
0
0
0
579
0
0
3850
0
1720
0
6025.
579.
0
0
0
0
0
0
0
726
8405
1240
0 .
0
472
0
14902.
?5'J5.
40
?3
TOTAL NO.
OF
NO
16
5
1
3
2
0
7
3
0
4
46
6
4
0
76.
21.
1
1
0
1
2
1
0
4
17
5
2
2
3
3
101.
38.
PLANTS
MW
8570
1 1 U4
425
426
800
0
3597
579
0
630
21816
1810
3140
0
38348.
4679.
400
100
0
60
825
277
0
846
84U5
2750
634
250
1254
601
49866.
9563.
77
49
79
-------
FPA IJTTLTTY FGO SllRVFY: JUMfc 1Q7« - JULY t<>78
SECTION 1
SUMMARY OF OPERATING FRD SYSTEMS BY
ANPI GENERATING UNITS
P&UCESS/GFNFRA T TNG UNITS
LIMF
BRuff MANSFTELU 1
BPUTE MANSFIELD 2
ELRAMA POWER STATION
GREFM KTVFK 1,2 * 3
HAWTHORN 3
HAWTHORN 4
HUNTINGTON 1
PHHLTPS POWER STATION
LIMF (CARBIDE)
CANF RUN 4
CANF RUN 5
MILL rRFEK ?
PADOYS RUN 6
LTMF (MG-PWOMOTFO)
CONFSVILLF 5
CONFSVILLF 6
LTMF/ALKALINE FLYASH
COLSTRIP 1
COLSTRIP 2
MILTON R. YOUNG 2
LTMF./LJ.MESTONF
SHAWNFE 10A
SHAWNFE 10B
LIMFSTONE
CHOLLA 1
CHOLLA f
OMCK r-RFEK 1
LA TYGNF 1
LAWRENCF «
LArtR£NCF S
MARTIN LAKE 1
MARTIN LAKE 2
MOMTITELLO *>
PFTFRSBURP 3
SOUTHWEST 1
WIDOWS CRFEK fl
W TIM YAH ?
LTMFSTONE/ALKALINF FLYASH
SHFRHMkNe 1
SHERHIIWMF f.
FGn/MIN
825
825
510
ba
100
1 00
ais
am
V*9.
178
183
«25
bS
851.
aoo
400
800.
3faO
360
45ft
1170.
10
10
?0.
115
?50
«00
820
12^
400
79^
793
750
530
200
550
28"
600fa.
710
710
STARTUP EXPFHIENCEIMO.
4-7b
7-77
10-7S
9-75
11-72
fl-72
5-78
7-73
8-76
l?-77
8-78
4-73
1-77
6-78
11-75
8-76
a-77
4-72
a-72
10-73
6-78
7-78
2-73
1P-68
11-71
8-77
S-78
5-78
10-77
a-77
S-77
7-77
3-76
a-77
?7
12
33
34
68
71
2
60
307
33
7
0
63
93
18
1
19
32
2 j
10
65
75
75
ISO
57
1
0
65
115
80
11
2
2
9
15
1 4
12
383
?8
15
03
MAGNESIUM OXIDE
EnijYSTnrvt 1A l^O Q-75 34
-------
FPA UTILITY FGP SURVEY! JUNE 1978 - JULY 1978
SECTION 7
SUMMARY OF OPERATING FRO SYSTEMS HY
PROCESS ANtl GENERATING UNITS
PROCESS/GENFHATING UNITS
RFin
RFin
DFAN
SAM
SODIUM CARBONATE
GARDNER 1
GARDNER ?
GARDNER 1
WFLLMAN LOHD
H. MITCHFLL 11
JUAN 1
FGlV/Mw STAKTUP EXPFKIENCFCMO.
ISO. 14
12S «-74 51
135 4-74 51
125 7-76 24
375. 1?6
115 11-76 30
314 4-78 3
4^9.
-------
FPA "Ttl IT* Hlx 'illP'iM: I •:•'(• l^if - I!:l 1
,r L i in... „
PiVAr T I T, "5 t i,|v npFK s i Tii»!,\l F(,P ^YSH-i'S
--SMinbF-- --SI..UIH4F-- PuNI)--- PUND---
17tT> UNSTAHll T7£n LTNFU UNLINH1
LIME
MANSFIELD 1 "
-------
FPA UTTLTTY FGD SU&VFY! JUNE 1976 - JULY 1978
SECTION 9
SUMMARY OF FGO SYSTFMS RY PROCESS AND RFGULATORY CLASS
REGULATORY OPERATIONAL
PROCESS CLASS
LIME
LIME (CARBIDE)
LIMEiCMG-PROMOTEO)
LIME/ALKALINE FLYASH
LIME/LTMESTONE
LIMESTONE
LIMESTONE/ALKALINE FLYASH
SUBTOTAL - LTMF./LIMESTONE
SQllEnuS CARBONATF
CITRATE
DOUBLE ALKALI
"ARMFSTIJM MXTDF
* *
A
B
C
D
E
A
B
C
D
E
A
B
C
D
E
A
B
C
0
E
A
B
C
D
E
A
B
C
0
E
A
B
C
0
E
A
B
C
0
E
A
B
C
0
E
A
R
C
D
E
A
H
r
D
t
A
B
C
!>
fc
NO.
1
6
1
0
0
0
3
1
0
0
0
2
0
0
0
2
i
0
0
0
0
0
2
0
0
1
4
2
0
0
0
2
0
0
0
10.
18.
ft.
0.
0.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
•"' ' n .:'
1
n
n
0
MM
415
2770
61
0
0
0
7S6
65
0
0
0
600
0
0
0
720
450
0
0
0
0
0
20
0
0
3746
890
1370
0
0
0
1420
0
0
0
4881.
7116.
1519.
0.
0.
0
0
0
0
0
0
0
0
0
0
0
0
u
0
0
0
120
0
0
•J
CONSTRUCTION
NO.
7
a
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
11
11
2
0
0
0
0
0
0
0
19.
13.
2.
0.
0.
0
1
0
0
0
0
1
0
0
0
2
\
0
0
0
0
0
0
0
0
MM
3230
U20
U
0
0
0
0
0
0
0
0
0
0
0
0
500
0
0
0
0
0
0
0
0
0
3932
4850
445
0
0
0
0
0
0
0
7662.
6170.
445.
0.
0.
0
400
0
0
0
0
60
0
0
0
«?5
277
0
" 0
0
0
0
0
0
C
CONTRACT
AWARDED
NO.
1
0
0
0
n
0
0
0
0
0
0
0
0
0
0
1
2
0
0
0
0
2
0
0
0
8
0
1
0
0
0
0
0
0
0
12.
4.
1 .
0.
0.
n
0
i
0
0
0
f]
n
0
0
0
0
(1
n
n
0
n
n
n
n
MM
1500
0
0
0
0
0
0
0
0
0
0
0
0
0
0
527
1400
0
0
0
0
660
0
0
0
3968
0
575
0
0
0
0
0
0
0
5995.
2060.
575.
0.
0.
0
0
100
0
0
0
0
0
0
0
0
0
n
0
0
f!
0
n
0
0
PLANNED
NO,
0
i
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
0
0
0
0
0
0
0
0
3
3
0
0
0
0
2
0
0
0
3.
9.
0.
0.
0.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
0
0
0
Mh
0
455
0
0
0
0
0
0
0
0
0
0
0
0
0
0
579
0
0
0
0
0
0
0
0
1900
1950
0
0
0
0
1720
0
0
0
1900.
4704.
0.
0.
0.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
7?fe
0
0
u
TOTAL NO.
PLANTS
NO. MM
11
9
1
0
0
0
3
1
0
0
0
2
0
0
0
4
6
0
0
0
0
2
2
0
0
29
18
5
0
0
0
4
0
0
0
44.
44.
9.
0.
0.
0
1
1
0
0
0
1
0
u
0
2
1
0
(J
0
0
4
0
0
0
5145
4545
64
0
0
0
786
65
0
0
0
BOO
0
0
0
1747
2429
0
0
0
0
660
20
0
0
13546
7690
2390
0
0
0
3140
0
0
0
20438.
20050.
2539.
0.
0.
0
400
100
0
0
0
60
0
0
0
825
277
0
0
0
U
fl«fe
0
0
0
-------
I IT T i I T ' t- b 1 S U ° V F V :
1 Q 7 K - .1 LI L Y 1 Q / S
SE.CTTON 0
OF FSD SYSTEMS RY PROCESS AMU RFGIJLATOKY CLASS
REGULATORY OPERATIONAL
PROCESS rt'ss
NOl SELECTED A
8
c
D
E
SODJIIM CAKHONATE A
B
C
0
E
WELLMAM LORD A
B
c
D
E
TOTALS A
B
C
0
E
LIME/STONE 51 OF TOTAL MW A
8
C
D
E
CONSTRUCTION
CONTRACT
PLANNED
AWARDED
ND
n
0
n
n
0
*
0
n
0
n
0
1
i
0
0
1?
20
7
0
0
MW
0
0
0
U
0
375
0
0
0
0
0
314
lib
0
0
. 5256.
. 7550.
. 1634.
0.
0.
93
94
•?i
0
0
MO
0
0
0
0
0
0
1
0
0
0
0
1
1
0
0
21
18
3
0
0
MW
0
0
0
0
U
U
509
0
0
0
0
30h
IRQ
0
0
. R4fl7.
. 7732.
. 625.
0.
0.
90
80
71
0
0
NO.
0
?
0
0
0
0
0
0
0
0
0
\
0
0
0
12.
7.
2.
0.
0.
Mlv
0
1510
0
n
0
0
0
0
0
0
0
uea
0
0
0
5995.
403B.
675.
0.
0.
100
51
85
0
0
NO.
13
a
3
U
0
0
0
0
0
0
0
1
0
0
0
16.
17.
3.
0.
0.
Mw
6650
1755
1240
0
0
0
0
0
0
0
0
172
0
0
0
8550.
7657.
1200.
0.
0.
22
61
0
0
0
TOTAL NO.
PLANTS
NO
13
6
3
0
0
3
1
0
0
0
0
a
2
0
0
62.
62.
15.
0.
0.
Mn,
6650
3265
1240
0
0
375
509
0
0
0
0
1560
295
0
0
28288.
26967.
«174.
0.
0.
72
74
61
0
0
A. ROTLFK CHNSTWOCIF.!) SIIR.JECI rn FEDERAL MSPS
H. ROUFH SIIHIECI TO STATE STANDARD THAT TS MHKF STRINGENT THAN THE FEDERAL NSPS
c. RUTLFR SUBJECT m STATE STANDARD THAT TS EQUAL TO OR LESS STPINGF.NT THAN NSPS
n. flTHFW
F. RERUI ATO^Y CLASS UNKNOWN
-------
FPA UTTLTTY FGn SURVEY: JUNE 1978 - JULY 1978
SFCTiniM JO
SUMMARY OF FGn SYSTEMS UNDER CONSTRUCTION
UTILITY COMPANY
POWFR STATION
ALABAMA ELECTRIC COOP
TOMBIGBF.E d
ALABAMA ELECTRIC COOP
TOMBIGBEE 3
A4.LFGHEMY POWER SYSTEM
PLEASANTS 1
ALLEGHENY POWER SYSTEM
PLEASANTS 2
ARIZONA ELECTRIC POWER COOP
APACHE 2
ARI70NA ELECTRIC POWER COOP
APACHF. 3
ARI70NA PUBLIC SERVICE
CHOLLA 4
BASTN ELECTRIC POWER COOP
LARAMTE RIVER 1
BASIN ELECTRIC POWER COOP
LARAMIE RTVFR 2
816 RIVERS ELECTRIC
RF.IO 2
BIG RIVERS ELF-CTRIC
RFID 1
CENTRAL ILLINOIS PUBLIC SERV
NEWTON 1
COLORADO UTF ELECTRIC ASSN.
CRAIG 1
COLORADO 1ITE ELECTRIC ASSN.
CRAIG 2
COMMONWEALTH EDISON
POWERTON 51
COOPERATIVE POWFR ASSOCIATION
COAL CRFEK 1
COOPERATIVE POWFK ASSOCIATION
COAL CREEK 2
DELMARVA POWtR * I IGHT
DFLWARE CITY 1 , 2 & 3
GULF POWER
SCHOL7 MOS. IB * 2B
HOOSIEH ENERGY
MFWOM 1
HOuSIFR ENERGY
MFROM
-------
EPA UTILITY FGO SURVFY: JUNE 197* - JULY l°7S
SECTION in
SUMMARY OF FGO SYSTFMS UNDER CONSTRUCTION
PROCESS/VENDOR
UTILITY COMPANY
POWER STATION
KANSAS POWER t L IGHT
JFEFEREY ?
N b W OR
RETROFIT
N
STZF OF FKI)
UNIT CMW)
START-LIP
DATF
LOUTSVILLF PAS R ELECTRIC
CANE RUN b
LOUTSVILLF GAS R FLFCTRIC
MILI CRFEK 1
MINNESOTA POWER & LIGHT
CLAY RUSWFLL 846COCK S WTLCOX
LIMFSTUNE
?3? BABCOCK & WILCOX
LIMESTONE
18a 8ABCOCK 8 WILCOX
LIMFSTONE
250 EMC CORPORATION
DOUBLE ALKALI
180 RILFY STOKER / ENVIRONEEHING
LIMESTONE
180 RILFY STOKER / FNVIRQNEFRING
LIMESTONE
60 BUREAU OF MINES
CITRATE
793 RESEARCH COTTRELL
LIMESTONE
100 CHEMICO
LIME
6/80
12/78
h/flO
•i/BO
5/B1
a/ao
7/78
1/79
1/80
6/80
b/Bl
9/78
8/78
10/76
10/78
12/78
-------
FPA UTILITY FGP SURVEY! JUNE 1978 - JULY 1978
DI TLT i Y COMPANY
POwFK STATION
SECTION l|
OF PI ANNEO FGD SYSTEMS
NbW Ok
UFTRUF1T
ST2F OH FR)
UN II
VLNUHR/HROrESS
START-UP
DATE
CONTRACTS
AHI70NA PUBLIC. SERVICE
FOUR CORNERS 4
ARIZONA PUBLIC SERVICE
CORNERS "5
ASSOCIATED ELECTRIC COOP
THOMAS HILL 3
CINCINNATI GAS * ELECTRIC
FAST BEND i -•
EASTERN KENTUCKY POWER COOP
SPURLOCK ?
LAKFLANn UTILITIES
MCINTOSH 3
LOUISVILLE GAS & ELECTRIC
MILL CREEK 1
LOUISVILLE GAS S ELECTRIC
MILL CRFF.K ?
MONTANA POrtER
COLSTRIP 3
MONTANA POWER
COLSTRIP 'I
NIAGARA MOHAWK POWER COOP
CHARLES R. HUNTLEY 6
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN 3
SOUTH CAROLINA PUBLIC SERVICE
WINYAH 3
SOUTHWESTERN FLFCTKTC POWFH
HENRY W. °ERKFY 1
SPRINRFTELO WATER LIGHI & PWH
DALLMAM 3
TENNESSEE VALLEY AUTHORITY
WIDOWS CRFEK 7
TEXAS MUNICIPAL POWFK AGtNCY
GTBHONS CRtEK 1
TEXAS POrtFW *. LIGHT
SAN1DW 0
TFXAS UTILITIES
LAKt a
755
75S
670
hOO
500
350
330
330
700
700
100
4M
300
7,0
190
S7S
UNITED ENGINEERS
NOT SELECTED
UNITED ENGINEERS
NOT SELECTED
PULLMAN KFLI.OGG
LIMESTONE
BABCOCK & wILCOX
LIME
COMBUSTION ENGINEERING
LTME
BABCOCK & WILCOX
LIMESTONE
COMBUSTION ENGINEERING
LIME/LIMESTONE,!
i-fl*
COMBUSTION ENGINEERING
i. TME/LIMESTONF.
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH
ATOMICS INTERNATIONAL
AQUEOUS CARBONATE
[JAVY POWERGAS
WFLLMAN LORD
bABCUCK & WTLCOX
LIMESTONE
AIR CORRECTION DIVISION, UOP
LIMESTONE
RFSEARCH COTTRELL
LTMESTQME
COMBUSTION ENGINEERING
0/82
0/82
10/81
1/81
3/80
10/81
1/81
1/S2
7/80
7/81
0/80
1/81
5/80
6/83
7/80
10/flO
UTAH
«00
S'lS
400
LIMESTONE
C'lMRUSTIUN FNGINEFRINT,
'LTMFSTONE
COMBUSTION FNGlNfcEKING
LIMESTONE
KFSFARCH COTTRELL
LTMFSTONt-
:LTMF
7/80
fe/80
^Pj»Fk .1 LIGHT
COL I 'Ml I A
LTMF/ALKAt IME FLYASH
OF
SIA1F.S H"ivFH
5
COMBUSIIUN F
LIMFSTOME/AL K ALTIMF FLYASH
-------
FPA nriLTTY Fgn SURVEY: ,tu*'t. i"J/fl -
IITILTTY CUMHANY
STATION
SUIFS
U
PHILADELPHIA FLFCTkTC
EODYSTONE 1R
.->FCTir>N 11
SUMMARY OH PI ANIMFH t-r,o SYS
NEW OR >STZF OF FRO VENDOR /PROPt PS START-UP
RF1WUF1T MNTT (Mw) DATE
IV XhO COMBUSTION FN^INtEKING O/ 0
I TMFSTUNF./AI.KALINE FLYASH
k ?flO UNITtD ENGINEFKS 6/*0
MAGNESIUM OXIDE
KFQUESTTNG/FVALUATlNb
BASIN ELECTPIC POWER. COOP
ANTFLOPF VALLEY 1
CENTRAL ILLINOIS LI6HT
DUCK CREEK 2
PUBLIC SERVICE OF INDIANA
GIBSON 5
TEXAS UTILITIES
FORFST GWOVF 1
CONSIDERING FGO SYSTEM
ARIZONA PUBLIC SERVICE
FOUR CORNERS 1
ARIZONA PUBLIC SERVICE
FOUR CORNERS 2
ARIZONA PUBLIC SERVICE
FOUR CORNFRS 1
BASIN ELECTRIC POWER COOP
ANTFLOPF VALLEY 2
BASIN ELECTRIC POWER COOP
LARAMIE RTVER 3
CENTRAL MAINE POWER
SFARS ISLAND 1
COLUMBUS R SOUTHERN OHIO ELEC.
POSTON 5
COLUMBUS & SOUTHERN OHIO FLEC .
POSTON ft
GENERAL PUBLIC UTILITIES
COHO 1
GFNFRAL PUBLIC UTILITIES
SFWARD 7
NFVADA POWER
HARRY ALLFN 1
NEVADA POWER
HARRY ALLFN 8
NFVAOA POWER
HARRY AI.LFN 3
NFVADA PQWtR
HARRY ALLFN 4
NFVADA POWER
NFVADA POWER
W«kNER VAI.LFY 1
ass
ton
650
750
175
J75
?2<9
055
550
600
375
375
800
800
SOO
500
500
500
250
?50
NOT SELECTED
LIMF
NOT SFLFCTEO
LIMFSTONE
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
CHEMICO/APS
LIME/ALKALINE FLYASH
CHEMICO/APS
LIME/ALKALINE FLYASH
CHEMICO/APS
LIME/ALKALINE FLYASH
NOT SELECTED
NOT SELECTED
NOT 3ELFCTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SFLFCTEO
NOT SELECTED
NOT SELECTED
11/81
1/82
0/83
0/81
O/ 0
O/ 0
O/ 0
11/83
«/88
11/86
0/83
0/85
5/87
5/84
6/85
6/86
6/87
6/88
0/83
6/B«
-------
FPA UTILITY FGD SUPVEY: JUNE 1978 - JULY 1978
SECTION 11
SUMMARY OF PLANNED FGD SYSTEMS
UTILITY COMPANY
POWER STATION
NEVADA POWER
WARNER VALLEY 2
NFW ENGLAND ELEC SYSTEM
BPAYTON POINT 3
NORTHERN INDIANA PUR SERVICE
BAILLY 7
NORTHERN INDIANA PUR SERVICE
BAILLY 8
PACIFIC GAS AND ELECTRIC
FOSSIL 1
PACIFIC SAS AND ELECTRIC
FOSSIL 2
PHILADELPHIA ELECTRIC
CROMBY
PHILADELPHIA ELECTRIC
EODYSTONE 2
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN a
SALT RIVER PROJECT
CORONADO 3
SOUTHERN ILLINOIS POWER COOP
MARION 5
TEXAS POWER & LIGHT
TWIN OAKS 1
TEXAS POWER « LIGHT
TWIN OAKS 2
NEW OR
RETROFIT
N
R
R
R
N
N
R
R
N
N
N
N
N
SIZF OF FRD
UNIT (MW)
S50
650
190
400
BOO
800
150
336
«72
350
300
750
750
VENDOR/PROCESS
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIMESTONE
NOT SELECTED
LIMESTONE
UNITED ENGINEERS
MAGNESIUM OXIDE
UNITED ENGINEERS
MAGNESIUM OXIDE
DAVY POWERGAS
WELLMAN LORD
NOT SELECTED
LIMESTONE
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIMESTONE
NOT SELECTED
LIMESTONE
START-UP
DATE
6/85
O/ 0
O/ 0
O/ 0
o/ea
0/85
6/80
6/80
1/82
0/87
0/84
8/83
9/84
89
-------
FP« UTILITY FGD SIIPVFY: JUNE i<»7fl - JULY i°7R
SFCllON 13
TOTAL FGO MFGAflATT CAPACITY BY YEAR *
YFAR NO. UNITS MFGAWATTS
196B
1971
1972
1973
1974
1975
1976
1977
1978
1979
1980
1981
1982
1985
1984
1985
1986
1987
1988
UNDEFINED
1
1
(I
a
?
a
6
10
20
15
25
11
10
5
t>
U
2
3
1
7
125
400
220
1410
250
1054
2313
4921
7252
5399
10838
5448
5635
2550
3760
1925
1100
1650
500
2679
* TOTALS DISPLAYED DO NOT INCLUDE TERMINATED OR INACTIVE SYSTEMS.
90
-------
APPENDIX A
FGD SYSTEMS ECONOMICS
A-l
-------
INTRODUCTION
The cost of flue gas desulfurization (FGD) systems for the
control of sulfur dioxide emissions is an area of intense inter-
est and substantial controversy. As a result, many computer
models have recently been developed to estimate capital and
annual costs. As part of an effort by the U.S. Environmental
Protection Agency to provide meaningful economic data concerning
FGD systems, reported economic data have been incorporated into
the EPA Utility FGD Survey report. This information has appeared
as a separate appendix of the report since October 1976. Until
January 1978, this cost appendix consisted entirely of data
reported by the utilities with little or no interpretation pro-
vided by PEDCo Environmental, Inc. Beginning with the May 1978
report, the format and content of the cost appendix were revised
to include reported and adjusted costs for the operational FGD
systems.
The rationale for including adjusted as well as reported
costs stems primarily from the lack of comparability of the
reported costs. Many of the reported cost figures, both capital
and operating, are largely site-sensitive values that cannot be
accurately compared because they refer to different FGD battery
limits and different years in which the expenditures were made.
As a result, an analysis of the cost data was made for the opera-
tional units since these systems offer the potential of having
complete and accurate economic data. The adjustments were made
to provide comparable, accurate cost data for the sulfur dioxide
portion of the emission control system. This, in effect, will
eliminate much of the confusion that exists concerning the re-
ported data, and it will provide a common basis for the reported
costs.
A-2
-------
APPROACH
In March 1978, each utility having at least one operational
FGD system was given a cost form containing all available cost
information then in the PEDCo files. The utility was asked to
verify the data and fill in any missing information called for
on the form. A follow-up visit by the PEDCo Environmental staff
was arranged to assist in data acquisition and to insure com-
pleteness and reliability of information. Results of the cost
analysis were forwarded to each participating utility for final
review and comment.
The cost data were treated solely to establish the accurate
costs for FGD systems, on a common basis, not to critique the
design or reasonableness of the costs reported by any utility-
Adjustments focused primarily on the following items:
0 All capital costs were adjusted to July 1, 1977, dol-
lars using the Chemical Engineering Index. All capital
costs, represented in dollars/kilowatt ($/kW), were
expressed in terms of gross megawatts (MW) Actual
costs were reported by utilities in dollar values for
years 1970 to 1980. These values are represented in
terms of the year of greatest capital expenditures.
0 Gross unit capacity was used to express all FGD capital
expenditures because the capital requirement of an FGD
system is dependent on actual boiler size before de-
rating for auxiliary and air quality control power
requirements.
0 Particulate control costs were deducted. Jince the
purpose of the study was to estimate the incremental
cost for sulfur dioxide control, particulc e control
costs were deducted using either data cor^ ined in the
cost breakdowns or as a percentage of the otal direct
cost (capital and annual). The percentag reduction
varied depending upon system design and o, cation.
A-3
-------
The capital costs associated with the modification or
installation of equipment not part of the FGD system
but needed for its proper functioning, were included
(e.g. - stack lining, modification to existing ductwork
or fans, etc.).
Indirect charges were adjusted to provide adequate
funds for engineering, field expenses, legal expenses,
insurance, interest during construction, allowance for
startup, taxes, and contingency.
All annual costs, represented in mills/kilowatt-hour
(mills/kWh), were expressed in terms of net megawatts
(MW).
Net unit capacity was used to express all FGD annual
expenditures because the annual cost requirement of an
FGD system is dependent on the actual amount of kilo-
watt-hours (kWh) produced by the unit after derating
for auxiliary and air quality control power require-
ments.
All annual costs were adjusted to a common capacity
factor (65 percent).
Replacement power costs were not included since only a
few utilities reported such costs and these were pre-
sented using a variety of methods.
Sludge disposal costs were adjusted to reflect the
costs of sulfur dioxide waste disposal only (i.e.,
excluding fly ash disposal) and to provide for disposal
over the anticipated lifetime of the FGD system. This
latter correction was necessary since several utilities
reported costs for sludge disposal capacity that would
last only a fraction of the FGD system life. The
adjustments were based on a land cost of $2000/acre
with a sludge depth of 50 ft in a clay-lined pond (clay
is assumed to be available at the site).
A 30-year life was assumed for all process and economic
considerations for all new systems that were installed
for the life of ths unit, & 20-year life was assumed
for all process and economic considerations for retro-
A-4
-------
fit systems that were installed for the remaining por-
tion of the life of the unit.*
0 Regeneration and by-product recovery facility costs
were added for those regenerable systems not reporting
such costs.
To the extent possible, all cost adjustments were made using
the previous assumptions developed by PEDCo Environmental. When
cost data were inadequate, adjustments were made using process
design data in conjunction with the previous cost assumptions.
In some cases, no adjustments were possible because of in-
sufficient data.
* The use of a 30-year service life for new units coincides with
the conclusion of the National Power Survey of the Federal
Power Commission which recognized this value as reasonable for
steam-electric plants. A 20-year service life was assumed for
all retrofit units even if the remaining life of the units is
l-itfs than this value. Thus, two different rates are used and
should be noted when making comparisons between new and retro-
fit systems.
A-5
-------
DESCRIPTION OF COST ELEMENTS
Capital costs consist of direct costs, indirect costs, con-
tingency costs, and other capital costs. Direct costs include
the "bought-out" cost of the equipment, the cost of installation,
and site development. Indirect costs include interest during
construction, contractor's fees and expenses, engineering, legal
expenses, taxes, insurance, allowance for start-up and shake-
down, and spares. Contingency costs include those costs result-
ing from malfunctions, equipment alterations, and similar un-
foreseen sources. Other capital costs include the nondepreciable
items of land and working capital.
Annual costs consist of direct costs, fixed costs, and over-
head costs. Direct costs include the cost of raw materials,
utilities, operating labor and supervision, and maintenance and
repairs. Fixed costs include those of depreciation, interim
replacement, insurance, taxes, and interest on borrowed capital.
Overhead costs include those of plant and payroll expenses. The
various capital and annual cost components are discussed and
defined in greater detail in the following paragraphs.
The direct capital costs include the following elements:
0 Equipment required for the FGD system. Table A-l
provides a summary of the major process equipment used
in regenerable and nonregenerable systems.
° Installation of equipment, including foundations; steel
work for support, buildings, piping and ducting for
effluents, slurries, sludge, and make-up water, control
panels, instrumentation, insulation of ducting, buildings,
piping, and other equipment, painting and piling.
9 Site development may include clearing and grading,
construction of access roads and walkways, establish-
ment of rail, barge, and/or truck facilities, and
parking facilities.
A-6
-------
TABLE A-l. MAJOR FGD SYSTEM EQUIPMENT SUMMARY
Category
Description
Material handling-
raw materials
Feed preparation-
raw materials
Sulfur dioxide
absorption
Flue gas reheat
Gas handling
Sludge disposal
Utilities
By-product
handling
Equipment for the handling and transfer of
raw materials includes unloading facilities,
conveyors, storage areas and silos, vibrators,
atmospheric emission control associated with
these facilities, and related accessories.
Equipment for the preparation of raw material
to produce a feed slurry consists of feed
weighers, crushers, grinders, classifiers,
ball jnills, mixing tanks, pumps, agitators,
and related accessories.
Equipment for treating the flue gas includes
absorbers, mist eliminators, hold tanks,
agitators, circulating pumps, pond water re-
turn pumps, and related accessories.
Equipment required includes air, steam, or
hot water heaters, condensate tanks, pumps,
soot blowers, fans, fuel storage facilities,
gas bypass equipment, and related accessories.
Equipment to handle the boiler flue gas in-
cludes booster fans, ductwork, flue gas by-
pass system, turning vanes, supports, plat-
forms, and related accessories.
Nonregenerable FGD systems require solids/
water separation equipment such as clarifiers,
vacuum filters, centrifuges, sludge fixation
equipment, and related accessories.
Equipment to supply power and water to the
FGD equipment consists of switch-gear, break-
ers, transformers, piping, and related
accessories.
Equipment for processing the by-product of
regenerable FGD systems may include a rotary
kiln, fluid bed dryer, conveyor, storage silo,
vibrator, combustion equipment and oil stor-
age tanks, waste heat boilers, hammer mills,
evaporators, crystallizers, el rippers, tanks,
agitators, pumps, compressors, ev* If uric acid
absorber and cooling, mist elxidnator, pumps,
acid coolers, tanks, etc.
(continued)
A-7
-------
TABLE A-l. (continued)
Category
Description
Regeneration
Purge treatment
Auxiliary
Equipment for regeneration of the absorbing
medium of an FGD system may consist of re-
actor vessels, material handling system,
storage, weigh feeder, conveyor, rotary kiln,
fluid bed calciner, dust collector, storage
silo, vibrator, combustion equipment and oil
storage tanks, waste heat boiler, hammer
mill, evaporators, crystallizers, strippers,
tanks, agitators, pumps, compressors, sul-
furic acid absorber and cooling, mist elimi-
nator, pumps, acid coolers, tanks, etc.
Equipment for the removal of purge material
(e.g. sodium sulfate) includes refrigeration,
pumps, tanks, crystallizer, centrifuge,
dryer, dust collector, conveyors, storage,
and related equipment.
Equipment not directly related to the
FGD system, but which may require design or
modification to accommodate an FGD system
may include such items as existing fans,
ducts, or stack. If new fans, ducts, or
stacks are added to improve boiler perfor-
mance and accommodate the FGD systen, the
costs are prorated to the boiler and FGD
system.
A-l
-------
Indirect capital costs include the following elements:
° Interejst accrued on borrowed capital during construction,
e Contractor ' _s_ fee and expenses , including costs for
field labor payroll; field office supervision; person-
nel; construction offices? temporary roadways? railroad
trackage; maintenance and welding shops; parking lot?
communications; temporary piping and electrical and
sanitary facilities; safety security (fire, material ,
medical, etc.); construction tools and rental equip-
ment; unloading and storage of materials; travel ex-
penses? permits? licenses; taxes; insurance; overhead;
legal liabilities; field testing of equipment; start-
up; and labor relations.
° Engineering costs, including administrative , process,
project, and general; design and related functions for
specifications; bid analysis? special studies; cost
analysis? accounting; reports; consultant fees; pur-
chasing; procurement; travel expenses; living expenses;
expediting; inspection; safety; communications? model-
ing; pilot plant studies (if required because of pro-
cess design or application novelty) ; royalty payments
during construction; training of plant personnel; field
engineering; safety engineering; and consultant ser-
vices.
e Legal expenses, including those for securing permits,
rights -of -way, etc.
° Taxes , including sales, and excise taxes.
0 Insurance covering liability for equipment in transit
and at site; fire, casualty, injury, and death? damage
to property; delay; and non compliance.
0 Allowance for start-up and shakedown includes the cost
associated with system start-up.
° Spare parts including pumps, valves, controls, special
piping and fittings, instruments, spray nozzles, and
similar items.
Other capital costs include the following elements:
0 Land required for the FGD process, waste disposal, re-
generation facility, and storage.
- capital , including the total amount of money
invested in raw materials and supplies in stock,
finished products in stock, and unfinished products
A~9
-------
in the process of being manufactured; accounts re-
ceivable; cash kept on hand for payment of operating
expenses such as salaries, wages, and raw materials
purchases; accounts payable; and taxes payable.
Annual cost of an FGD system includes the following direct,
fixed and overhead charges:
0 Direct Charges
Raw materials, including those required by the FGD
process for sulfur dioxide control, absorbent regenera-
tion, sludge treatment, sludge fixation, flocculants,
etc.
Utilities, including water for slurries, cooling and
cleaning; electricity for pumps, fans, valves, lighting
controls, conveyors, and mixers; fuel for reheating of
flue gases; and stream for processing.
Operating labor, including supervisory, skilled, and
unskilled labor required to operate, monitor, and
control the FGD process.
Maintenance and repairs, consisting of both manpower
and materials to keep the unit operating efficiently.
The function of maintenance is both preventive and
corrective to keep outages to a minimum.
Byproduct Sales; credit from the sale of byproducts
regenerable FGD processes (e.g. sulfur, sulfuric acid)
is a negative charge deducted from the annual direct
cost to obtain the net annual direct cost of the FGD
system.
0 Fixed Charges
Depreciation - the annual charge to recover direct and
indirect costs of physical assets over the life of the
asset.
Interim, replacement - costs expended for temporary or
provisional replacement of equipment that has failed or
malfunctioned prematurely.
Insurance, including the costs of protection from loss
by a specified contingency, peril, or unforeseen event.
Required coverage could include losses due to fire,
personal injury or death, property damage, explosion,
lightning, or other natural phenomena.
A-10
-------
Taxe.s, including franchise, excise, and property taxes
levied by a city, county, state, or Federal government.
• Interest on borrowed funds.
0 Overhead
Plant and administrative overhead is a business expense
that is not charged directly to a particular part of a
project, but is allocated to it. Overhead costs in-
clude administrative, safety, engineering, '.legal and
medical services; payroll? employee benefits; recrea-
tion? and public relations.
Table A-2 provides a summary of the means used to determine
the missing cost elements if ths costs were not reported or
insufficient information prevented their actual determination.
The assumptions and cost bases for determining the capital and
annual costs of FGD systems were developed by the PEDCo staff
based upon previous economic studies conducted for the U,S. EPA
(Flue Gas Desulfurization Process Cost Assessment, May 1975;
Simplified Procedures for Estimating Flue Gas Desulfu- ization
System Costs, June 1976, EPA-600/2-76-150,- Particulate and Sulfur
Dioxide Emission Control Costs for Large Coal-Fired Boilers *
March 1978, EPA-600/7-78-032) .
A-ll
-------
TABLE A-2. COST ELEMENT FACTORS
Category
Value
Indirect capital costs:
Interest during
construction
Field overhead
Contractor's fee and
expenses
Engineering
Taxes
Spares
Shakedown allowance
Other capital costs:
Contingency
Direct annual costs:
Raw materials:
Fixation chemicals
Lime
Limestone
Magnesium oxide
Sodium carbonate
Salt cake (credit)
Sulfur (credit)
Sulfuric acid (credit)
Utilities;
Electricity
Water
Steam
Operating labor:
Direct labor
Supervision
10% of total direct capital costs
10% of total direct capital costs
5% of total direct capital costs
10% of total direct capital costs
2% of total direct capital costs
1% of total direct capital costs
5% of total direct capital costs
20% of total direct and indirect
capital costs
$2/ton
$40/ton
$10/ton
$150/ton
$80/ton
$50/ton
$65/ton
$25/ton
25 mills/kWh
$0.20/103 gal
$0.80/106 Btu
$8.50/man-hour
15% of direct labor costs
Contingency costs are used only when the cost data supplied are
incomplete (such as equipment costs or direct costs only) and a
contingency cost must be factored in to give an accurate estimate
of the total capital cost.
(continued) A-12
-------
TABLE A-2. (continued)
Category
Maintenance:
Labor and materials
Supplies
Overhead;
Plant
Payroll
Fixed annual costs:
Depreciation
Interim replacement'
Taxes
Insurance
Capital costs
Value
b
4% of total direct capital costs
15% of labor and materials costs
50% of operation and maintenance costs
20% of operating labor costs
3.33% or 5% (new or retrofit)
0.7% or 0.35%
4%
0.3%
9%
b
Some system components have life spans less than the expected
service life of the system. Interim replacement is an allow-
ance factor used, in estimating annual revenue requirements to
provide for the replacement of these short-lived items. An
average allowance of 0.35% of the total investment is normally
provided and used for systems with an expected service life of
20 years or less, A higher allowance of 0.70% of the total
investment is provided and used for systems with an expected
service life of 30 years or more.
A-13
-------
DEFINITION OF COST ELEMENTS
The costs displayed in Appendix A are accompanied by a
series of alphabetic characters summarizing data presented for
each FGD system. These relate to the cost elements described
earlier in this section and identify what has been included and
excluded for reported and adjusted capital and annual costs, The
alphabetic characters, along with their titles, are briefly de-
scribed in Table A-3.
A-14
-------
TABLE A-3. DESCRIPTION OF COST
Code
Title
Description
Particulate control (required for FGD pro-
cess) included in capital cost.
Particulate control (included in FGD
process) included in capital cost.
Total direct capital costs included.
Partial direct capital costs included.
Total indirect capital costs included.
F Partial indirect costs included.
I
Chemical fixation of sludge included in
capital cost.
Dry sludge disposal included in capital
cost.
Off-site landfill area included in
capital cost.
Sludge pond included in capital cost.
Additional sludge disposal capacity
added for life of system.
Stack included in capital cost.
Modifications to stack, ducts, and/or
fans included in capital cost.
Total regeneration facility cost included
in capital cost.
Partial regeneration facility cost in-
cluded in capital cost.
R i D costs included in capital cost.
Particulate precollection device (ESP,
fabric filter, venturi) prior to FGD
system required for proper operation of
S0_ control system.
Particulate collection equipment (venturi
scrubber) is included in the PGD Bysteau
Complete cost of all PGD equipment, the
labor and materials required for equip-
ment installation, and interconnecting
the system is included in the total
capital cost.
One or a number of direct cost items, or
the cost associated with one or e. number
of direct cost items, are excluded from
the total capital cost.
Complete cost of all the indirect cost
elements, including interest during con-
struction, contractor's fees, engineer-
ing, legal expenses, taxes, insurance,
allowance for start-up, and spares, is
included in total capital cost.
One or a number of indirect cost items,
or the cost associated with one or a
number of indirect cost items, are ex-
cluded from the total capital cost.
The cost of e chemical fixation process
which stabilises the flue gas cleaning
wastee prior to disposal is included in
the total capital cost.
The cost of a secondary dewatering or
treatment method, much as filtration, cen-
trifugation, or forced oxidation, which
ultimately produces a dry sludge cake
for final disposal, is included in the
total capital cost.
The cost of an off-site area used as a
landfill for flue gas cleaning wastes is
included in the total capital cost.
The cost of an on-site disposal area for
ponding of treated or untreated flue gas
cleaning wastes is included in the total
capital cost.
The cost of additional SO, waste disposal
capacity required for FGD system operation
over the anticipated service life of the
unit is included in the total capital cost.
The cost of the stack is included in the
total capital cost.
Modifications to existing equipment (stack,
fans, ducts, etc.) which are required be-
cause of inclusion of an FGD system.
Complete cost of entire regeneration
facility included in total capital cost.
Part of the cost associated with the re-»
generation facility included in the total
capital cost.
Bench scale or pilot plant studies to de-
termine process and design characteristics.
(continued)
A-15
-------
TABLE A-3. (continued)
Code
Title
Description
W
X
Costs underwritten by system supplier in-
cluded in capital cost.
Excess reagent supply costs included in
capital cost.
Total direct annual costs included.
Partial direct annual costs included.
Total fixed annual costs included.
Partial fixed annual costs included.
Overhead cost included in total annual
cost.
Particulate control costs included in
direct annual cost.
Sludge disposal service costs (contract)
included in direct annual cost.
Replacement energy costs included in
total annual costs.
Capital expenditures underwritten by the
system supplier for system repairs or
modifications for optimization of perfor-
mance or R « D programs.
Capital expenditures for reagent supply
exceeds the amount required for the period
of initial operation.
Complete cost of all raw materials,
utilities, operating labor and maintenance
and repairs is included in the total
annual cost.
One or a number of direct annual cost items,
or the cost associated with one or a number
of direct annual cost items, are excluded
from the total annual cost.
Complete cost of all fixed cost elements,..
including depreciation, interim replace-
ment, insurance, taxes, and interest, is
included in the total annual cost.
One or a number of fixed annual cost items,
or the cost associated with one or a
number of fixed annual cost items, are ex-
cluded from the total annual cost.
Plant and payroll overhead costs are in-
cluded in the total annual cost.
The cost of operating particulate collection
equipment included in the FGD system is in-
cluded in the total annual cost.
The treatment and disposal of flue gas
cleaning wastes that are handled by an
outside firm.
The cost of additional power-generating
capacity required to compensate for power
used by the PGD system.
A-16
-------
RESULTS OF COST ANALYSIS
The results of the operational FGD system survey are
summarized in Tables A-4 and A-5. Table A-4 summarizes the re-
ported and adjusted capital and annual costs for all the
operational FGD systems addressed in the survey. Table A-5 pro-
duces a summary of a categorical analysis of the reported and ad-
justed capital and annual costs for the operational FGD systems
addressed in the survey- Included in this categorical analysis
are the ranges, means, and standard deviation for all the various
types and categories of FGD systems examined.
A-17
-------
TABLE A-4. REPORTED AND ADJUSTED CAPITAL AND ANNUAL
COSTS FOR ALL OPERATIONAL FGD SYSTEMS
Cholla 1
Conesville 5
Elrama 1-4
Phillips 1-6
Petersburg 3
Hawthorn 3-4
La Cygne 1
Green River 1-3
Cane Run 4
Cane Run 5
Paddys Run 6
M.R. Young 2a
Colstrip 1-2
Reid Gardner 1-2
Reid Gardner 3
D.H. Mitchell 11
Sherburne 1-2
B. Mansfield 1-2
Eddystone 1A
Winyah 2
Southwest la
Widows Creek 8
Reported
Capital
$/kW
52.0
55.6
113.5
107.0
99.5
29.3
53.7
70.3
66.6
62.4
52.9
86.0
77.1
42.9
113.6
_.
49.3
120.7
156.8
47.5
77.3
98.2
Annual
mills/kWh.
2.19
4*71
5.31
7.83
8.40
1.70
14.35
2.75
0.27
2.10
2.10
1.99
13.18
1.61
2.99
Adjusted
Capital
$/kW
56.0
70.8
127.2
140.6
100.6
87.3
68.0
77.6
80.6
67.5
76.5
93.1
77.3
60.9
107.9
71.5
102.2
233.3
66.5
117-7
113.2
Annual
mills/kWh
2.58
7.42
7.81
8.5-7
6.56
4.35
3.78
5.24
8.64
5.56
6.51
5.55
4.06
3.20
4.38
2.77
7.67
2.92
6.17
5.28
a Annual costs were not reported by the utility for this system
because of the lack of meaningful data due to recent operating
status.
b Annual costs were not reported by the utility for this system
because of the lack of meaningful data due to peak load status
of unit.
c Reported and adjusted cost data are being assembled by project
participants.
d Annual cost data are being assembled by the utility.
A-18
-------
TABLE A-5. CATEGORICAL RESULTS OF THE REPORTED AND ADJUSTED
CAPITAL AND ANNUAL COSTS FOR OPERATIONAL FGD SYSTEMS
All
New
Retrofit
Nonregen-
erable
Regenerable
Limestone
Lime
Alkaline/fly
ash/limestone
Alkaline fly
ash/line
Sodlua
carbonate
MaRnealun
oxide
Reported
Capital
Range, $/kH
27.0-156.8
47.5-120.7
27.0-156.8
27.0-120.7
156.8
57.5-99.5
27.0-120.7
49.3
77.1-86.0
42.9-113.6
156.8
Avg.,
77.6
78.0
77.2
73.7
156.8
71.4
75.1
49.3
81.6
78.3
156.8
a
32.2
26.8
37.8
27.3
23.7
31.7
6.3
50.0
Annual
Range ,
fillls/kUh
0.27-14.35
0.27-13.18
2.10-14.35
0.27-14.35
1.61-3.00
2.75-14.35
1.99
0.27
2.10
Avg.,
nllla/kWh
4.77
3.65
5.74
4.77
2.13
8.08
1.99
0.27
2.10
0
4.32
4.41
4.28
4.32
0.64
4.34
Adtusted
Capital
Range, $/kH
56.0-233.3
66.5-117.7
56.0-233.3
56.0-149.7
233.3
56.0-117.7
67.5-149.7
71.5
77.3-93.1
60.9-107.9
2.33.3
Avg.,
S/kM
95.8
87.6
103.4
89.0
233.3
87.0
94.1
71.5
85.2
84.4
233.3
o
40.1
18.9
52.5
25.4
26.7
29.3
11.2
33.2
Annual
Range ,
milla/kUh
2.58-9.54
2.77-7 67
2.58-9.54
2.58-9.54
2.58-6.56
4.09-9.54
2.77
4.06-5.55
3.20-4.38
Avg..
mllla/kUh
5.53
5.13
5.92
5.53
4.55
7.03
2.77
4.81
3.79
0
2.09
1.79
2.38
2.09
1.69
1.81
1.05
0.83
-------
APPENDIX B
F6D PROCESS FLOW DIAGRAMS
THIS APPENDIX COMPRISES BOTH ACTIVE AND INACTIVE UNITS
ARRANGED ALPHABETICALLY ACCORDING TO UTILITY
"SUPPLEMENTAL EDITION"
CHANGES/ADDITIONS
B-l
-------
STACK
NJ
COAL SUPPLY-
FEEDER
PULVERIZER
-I.D. FAN
STACK GAS
IR HEATER
DEM1STER
MARBLE BED
TACK GAS REHIIATER
STACK'
GAS
SCRUBBER
Kansas Power and Light
Original Operational FGD System at Lawrence No. 4.
RECYCLE
WATER
-------
LIMESTONE MATCH
HOPPER HUBSriPtC
OILUTIOII MATER (FRO"
MOITIH STORAGE RECIRCUUTION TANM
T»H« tO 5011 OS
W
I
U)
ADDITIVE
DILUTION
i T T""
r ADD1TM
^( *
SCRUBBER
NODULE
ONE OF TWO MODULES
t~
T
F
f
ADDITIVE
(FROM MILL)
/
1
OUTLET DAMPER
J STACK s~\ l.U. ^A«S (2)
\-S t
BYPASS ^
r 1 , v
LUE SAS FROM ^ |
IK PKtHLAItR IHLET \ |
DAMPER \
\°
t
« ^ c
|i
MAKEUP ^
1 UATER 9
T It
ROD SCRUBBER i!o
| SPRAY PUMP n| f
O — i_?l *
r o jj
t
—l\ r-REHEATER
1^3 •« REHEATER BLOWER
PS
B-E-S- _ . MIST ELIMINATOR
ABSORBER STRAINER WASHER
/(TYP.)
J / STRAINER HASH
/ 1 1 !NF ITtf }
H r 9 ' O
fll ? T ABSORBER
b, JU<1
1EACTION !,
TMK 1 r —0
TRAINERS:
u
Q- ^L ADDITIVE ibcomiNUTOR
STORAGE TANK ^
FEEB
PUHP5(2)
BLEED j
PUMP —
™y L_ -TO PONO
Kansas Power and Light,
Lawrence No. 4 Operational FGD System
Simplified Process Flow Diagram
-------
STACK
•I.D. FAN
ro
i
COAL SUPPLY-
FEEDER
PULVERIZER
•STACK GAS REHEATER
AIR HEATER
DEMSTER
RECYCLE
WATER
STACK'
GAS
SCRUBBER
Kansas Power and Light
Original FGD System Installed at Lawrence No. 5:
Simplified Process Flow Diagram.
-------
DILUTION HATER
(FROM RECIRQIUTION TANK)
SLURRY PUMPS
TO OTHER
SCDUMER NODULE
I
Ul
ONE OF TWO MODULES
BYPASS
•Q
7 ROD
Q/////
GAS •- >
nriirflTFR *
ntnt" 1 L" _
/ MIST
/ELIMINAT
SPRAY
TOWER
AD^nDDETD
VANES
BLOWERS
I. D. FAN
\
ORS
STACK I POND RETURN
I (MAKE-UP)
I WATER
BLOWERS
TO STRAINER]
WASHERS ~"~^
. |
HASH
PUMP
RECIRO
PUMPS
RECI
TANK
WEIR
OVERFLOW
TO
•SETTLING
POND
Kansas Power and Light,
Lawrence No. 5 Operational FGD System
Simplified Process Flow Diagram
-------
SCRUBBER INLET
TEST PORT LOCATION
PRECIPITATOR
INLET TEST
PORT LOCATION
W
I
TOP OF STACK
ELEVATION 1645'
8" ABSORBER
NODULE
TEST PORT
ELEVATION 1516
L_TOP OF OUTLET BREECHING
ELEVATION 1372'-2 3/8"
UTOP OF BYPASS BREECHING
ELEVATION 1307'- 8 1/2"
BYPASS DUCT \
GRADE ELEVATION 1261'
A" ABSORBER
MODULE
c«u
(HIKED WITH
RJMH
LMWIU
SCRUBBER INLET
TEST POST LOCATION
Springfield City Utilities, Southwest No. 1:
Simplified Process Diagram
-------
APPENDIX C
DEFINITIONS
C-l
-------
DEFINITIONS
Boiler Capacity Factor:
Boiler Utilization Parameter:
Efficiency:
Particulates
SO,
FGD Viability Indexes
(kWh generation in year)/
maximum continuous generating
capacity in kW x 8760 hr/yr).
Hours boiler operated/hours in
period, expressed as a percen-
tage.
The actual percentage of
particulates removed by the
emission control system (mech-
anical collectors, ESP, or
fabric filter and FGD) from
the untreated flue gas.
The actual percentage of SO-
removed from the flue gas by
the FGD system. Design removal
efficiency values are presented
for nonoperational systems for
which actual removal data are
not available.
Several parameters have been
developed to quantify the
viability of FGD system tech-
nology. Various terms such as
"availability," "reliability,"
"operability," and "utilization"
are used to accurately repre-
sent the operation of any FGD
system during a given period.
The above-mentioned parameters
are defined below and dis-
cussed briefly. The objectives
of this discussion are to make
the reader aware that several
different definitions are
being used and to select
appropriate parameters that
can be used for reporting
purposes so that reasonably
consistent comparisons can be
made.
C-2
-------
DEFINITIONS
Availability Index
Reliability Index
FGD Operability Index
Hours the FGD system is avail-
able for operation (whether
operated or not) divided by
hours in period, expressed as
a percentage. This parameter
tends to overestimate the
viability of the FGD system
because it does not penalize
for election not to operate
the system when it could have
been operated. Boiler down-
time may tend to increase the
magnitude of the parameter
because FGD failures generally
cannot occur during such
periods.
Hours the FGD system was
operated divided by the hours
the FGD system was called upon
to operate, expressed as a
percentage. This parameter
has been developed in order
not to penalize the FGD
system for elected outages,
e.g., periods when the FGD
system could have been run but
was not run because of chemi-
cal shortages, lack of manpower,
short duration boiler operations,
etc. The main problem in
using this formula is the
concise determination whether
or not the system was "called
upon to operate" during a
given time period. In addition,
an undefined value can result
when the FGD system is not
called upon to operate for a
given period (e.g., turbine or
boiler outage when FGD system
is available).
Hours the FGD system was opera-
ted divided by boiler operating
hours in period, expressed as
a percentage. This parameter
indicates the degree to which
the FGD system is actually
used, relative to boiler
C-3
-------
FGD Utilization Index
FGD Status:
Category 1
Category 2
Category 3
operating time. The parameter
does not reflect the extent of
exertion on the FGD system,
that is, the magnitude of the
parameter has little or no
correlation with FGD system
operating time. Also, the
parameter is penalized when
options are exercised not to
use the FGD system in periods
when the system is operable.
In addition, an undefined
value can result when the FGD
system is not called upon to
operate for a given period
(e.g., turbine or boiler
outage when FGD system is
available).
Hours that the FGD system
operated divided by total hours
in period. This parameter is
a relative stress factor for
the FGD system* It is not a
complete measure of FGD system
viability because the para-
meter can be strongly influ-
enced by conditions that are
external to the FGD system
(e.g., infrequent boiler
operation will lower the value
of. the parameter although the
FGD system may be highly
dependable in its particular
application).
Operational - FGD system is in
service removing SO-.
Under Construction - ground
has been broken for installa-
tion of FGD system, but FGD
system has not become opera-
tional.
Planned, Contract Awarded -
contract has been signed for
purchase of FGD system but
ground has not been broken for
installation.
C-4
-------
Category 4
Category 5
Category 6
Category 7
Category 8
FGD Vendor
Fuel Characteristics
New
Nonregenerable
Planned, Letter of Intent
Signed - letter of intent has
been signed, but legal con-
tract for purchase has not
been awarded.
Planned, Requesting/Evaluating
Bids - bid requests have been
released but no letter of
intent or contract has been
issued.
Considering only FGD Systems -
an FGD system is proposed as a
means to meet an SO- regula-
tion.
Considering an FGD system as
well as alternative methods.
Nonoperational - FGD system
has been in service in the
past but has been shut down
permanently or for an extended
indefinite period of time.
A firm which fabricates and
supplies FGD systems, most
notably the flue gas treating
and ancillary equipment.
Type of fuel, average gross
heating value in Btu/lb.
average percent ash and average
percent sulfur content for
fuel as fired.
FGD unit and boiler were
designed at the same time or
space for addition of an FGD
unit was reserved when boiler
was constructed.
The SO,, removed from the flue
gas is not recovered in a
usable or marketable form and
resulting sulfur-bearing waste
products must be disposed in
an environmentally acceptable
fashion.
C-5
-------
Operational Experience
Process
Regulatory Class
Regenerable
Retrofit
Sludge Disposal
C-6
Summary of FGD status and
description of current month's
progress.
Company name if process is
patented. Generic name if
several companies have similar
processes.
A. New boiler constructed
subject to Federal New
Source Performance Stan-
dards.
B. Existing boiler subject
to State Standard that is
more stringent than the
Federal New Source Per-
formance Standard (NSPS).
C. Existing boiler subject
to State Standard that is
equal to or less strin-
gent than NSPS.
D. Other (unknown, undeter-
mined) .
The S02 removed from the flue
gas is recovered in a usable
or marketable form (e.g.,
sulfur, sulfuric acid, gypsum,
ammonium sulfate, sodium
sulfate).
FGD unit must be added to an
existing boiler not specifi-
cally designed to accommodate
FGD unit.
Disposal method for nonregen-
erable systems producing
sludge including: lined
or unlined ponds, stabilized
or unstabilized sludge, and
on- or off-site disposal,
disposal type (minefill,
landfill, structural fill).
For the regenerable systems,
the form or method of sulfur
recovery is provided (e.g. -
molten elemental sulfur,
sulfuric acid plant).
-------
Start-up Date
Total FGD System Lost
Generation Factor
Unit Cost
Unit Location
Unit Name
Unit Rating
Date when initial SC>2 removal
began or is scheduled to
begin.
The total monthly lost genera-
tion hours due to FGD train
outages divided by the total
monthly expected generation if
the FGD trains would have been
available for operation,.
expressed as a percentage.
Capital Cost in $/kW includ-
ing: SC>2 absorption and
regeneration system,, SQ2
recovery system, solids dis-
posal y site improvements,
land,, roads, tracks,, substa-
tion, engineering costs,
contractors fee and interest
on capital during construc-
tion,
Annualized Cost in mills/kWh
including fixed and variable
costs„ Fixed costs includes
interest on capital, deprecia-
tion, insurance, taxes, and
labor costs including over-
head. Variable costs include:
raw materials, utilities, and
maintenance.
City and State listed in
mailing address.
Unit identification as it
appears in Electrical World -
Directory of Electrical Util-
ities, McGraw-Hill - Current
Edition - or as indicated by
utility representative for
installations in planning
' stages.
Operational - Maximum con-
tinuous gross generation
capacity in MW; Preopera-
tional - maximum continuous
design generation capacity in
MW,.
C-7
-------
Utility Name Name of corporation as it
appears in Electrical World -
Directory of Electrical Util-
ities, McGraw-Hill - Current
Edition - as space permits.
Water Make-Up Gallons per minute of make-up
water required per MW of
capacity.
C-8
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-600/7-78-051d
2.
3. RECIPIENT'S ACCESSION NO,
4. TITLE AND SUBTITLE
EPA Utility FGD Survey: June-July 1978
5. REPORT DATE
November 1978
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
M.Melia, M.Smith, W.Fischer, and B.Laseke
8. PERFORMING ORGANISATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDFtESS
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
10. PROGRAM ELEMENT NO.
EHE624
68-02-2603, Task 24
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13, TYPE OF REPORT A.ND PERiOD COVERED
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES E pA project officers are N. Kaplan
2556) and J. C. Herlihy (DSSE, 202/755-8137).
report jg ^ updated supplement to EPA-600/7-78-051a and should be
used in conjunction with it. It presents a survey of utility flue gas desuliurization
(FGD) systems In the U.S. , summarizing information contributed by the utility indus-
try, process suppliers, regulatory agencies, and consulting engineering firms. Sys-
tems are tabulated alphabetically, by development status (operational,, under con-
struction, in planning stages,, or terminated operations), by utility company, by pro-
cess supplier, by process, by waste disposal practice, and by regulatory class. It
presents data on system design, fuel sulfur content, operating history, and actual
performance, It discusses problems and solutions associated with the boilers and
FGD systems. Process flow diagrams and FGD system economic data are appended
to the report.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Group
Pollution
Flue Gases
Desulfurizatior
Electric Utilities
Waste Disposal
Boilers
Maintenance
Pollution Control
Stationary Sources
Utility Boilers
13B
21B
07A,07D
15E
13A
8. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (ThisReport)'
Unclassified
21. NO. OF PAGES
136
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
C-9
------- |