EPA-600/2-77-165
August 1977
Environmental Protection Technology Series
MAGNESIA FGD PROCESS TESTING
ON A COAL-FIRED POWER PLANT
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Research Triangle Park, North Carolina 27711
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RESEARCH REPORTING SERIES
Research reports of the Off ice of Research and Development, U.S. Environmental Protec-
tion Agency have been grouped into nine series. These nine broad categories were
established to facilitate further development and application of environmental tech-
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2 Environmental Protection Technology
3 Ecological Research
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5 Socioeconomic Environmental Studies
6 Scientific and Technical Assessment Reports (STAR)
7 Interagency Energy-Environment Research and Development
8 "Special" Reports
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This report has been assigned to the ENVIRONMENTAL PROTECTION TECHNOLOGY
series. This series describes research performed to develop and demonstrate instrumen-
tation, equipment, and methodology to repair or prevent environmental degradation from
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nology required for the control and treatment of pollution sources to meet environmental
quality standards.
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This report has been reviewed by the participating Federal Agencies, and approved for
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constitute endorsement or recommendation for use.
This document is available to the public through the National Technical Information
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EPA-600/2-77-165
August 1977
MAGNESIA FGD PROCESS TESTING
ON A COAL-FIRED POWER PLANT
by
Diane K. Sommerer
York Research Corporation
• One Research Drive
Stamford, Connecticut 06906
Contract No. 68-02-1401
Tasks No. 1, 10, 24, and 25
Program Element No. 1AB013
ROAP No. 21BAV
EPA Project Officer: Charles J. Chatlynne
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, N.C. 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, D.C. 20460
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ABSTRACT
This field measurement program was initiated with the overall ob-
jective of determining the operability and reliability of the
Chemico magnesium oxide venturi scrubber in operation at Potomac
Electric Power Company's Dickerson Generating Station, located in
Frederick , Maryland.
To achieve this objective, a continuous source-monitoring station
was installed at the scrubber, and was complemented by a field
analytical laboratory intended for the measurement and analysis
of various process streams. These facilities continuously monitor-
ed process and emission variables during a four month period between
October 1974 and January 1975; and later during the month of August
1975.
Scrubber operation was evaluated during periods of steady-state opera-
tion, and transient operation. The latter included periods of start-
up, shutdown, and malfunction. During the test period, the scrubber
was available for approximately 48 percent of the time. This per-
cent availability included all levels of operation, steady-state
and transient alike. It is estimated that of the time that the sys-
tem was available, approximately 80 percent was steady-state where
the system was operating normally.
This test program showed that, although scrubber availability was
not all that was desired due to problems with logistics in supplying
raw materials (MgO), and to mechanical problems mainly attribu-
table to under-design in such areas as piping, slurry pumps, and
other auxiliary equipment, the basic scrubber concept and design was
one that should meet critical criteria once these problems are
remedied.
111
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ACKNOWLEDGEMENTS
York Research Corporation wishes to express its appreciation to
the Potomac Electric Power Company's Dickerson Generating Station
personnel for their cooperation during the test program. Appre-
ciation is extended also to Dr. Charles Chatlynne and Mr. Robert
Hendriks of the Industrial Environmental Research Laboratory -
Research Triangle Park (IERL-RTP), and to,the Chemical Construc-
tion Company (Chemico).
-iv-
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CONTENTS
Page
ABSTRACT iii
ACKNOWLEDGEMENTS iv
FIGURES Vii
TABLES viii
SUMMARY ix
1.0 INTRODUCTION 1
2.0 PLANT DESCRIPTION 3
3.0 FGD SYSTEM PROCESS DESCRIPTION 5
3.1 First Stage - Flyash Removal 9
3.2 Second Stage - SO2 Removal 9
3.3 Solids Concentration 10
3.4 Drying 10
3.5 Dry Solids Storage 10
3.6 Calcination 10
3.7 Scrubber Process Control 11
4.0 TEST PROGRAM 13
4.1 Test Methods 13
4.1.1 Continuous Monitoring Program 13
4.1.2 Measurement of Process Streams 15
4.1.3 Manual Testing of Gaseous Emissions 19
4.1.4 Instrument Calibration 19
4.1.5 Operational Data 20
4.2 FGD System Availability 21
4.3 Boiler and ESP Availability 22
5.0 TEST RESULTS 25
5.1 Boiler and ESP 25
5.2 Scrubber: Steady-State Operation 25
5.2.1 Scrubber First Stage 25
5.2.2 First Stage Bleed 29
5.2.3 Thickener Overflow 31
5.2.4 Thickener Underflow 31
5.2.5 Scrubber Second Stage 32
5.2.6 MgO Slurry 35
5.2.7 Second Stage Bleed 36
5.2.8 Centrifuge Cake 38
5.2.9 Mother Liquor 38
5.2.10 Dryer Product 39
5.3 Scrubber: Transient Operation 40
5.3.1 Startups 40
5.3.2 Shut-Downs 42
5.3.3 Malfunctions 42
5.3.4 Leaks 46
5.3.5 Centrifuge Outages 46
-v-
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5.3.6 First Stage Outages
5.3.7 Second Stage Outages
50
50
6.1.2
6,
6,
6.1.5
,1.3
,1.4
6.0 ENGINEERING EVALUATION 53
6.1 Operability 53
6.1.1 Scrubber First Stage 53
Solids Removal Section for the First
Stage 57
Scrubber System Second Stage 57
MgO Slaking and Recycle 59
Solids Removal Section for the 60
Second Stage
6.1.6 Process Control 66
6.2 Optimization 67
6.2.1 Second Stage Absorber 67
6.2.2 MgO Slaking 80
6.2.3 Solids Removal System 82
6.i) Performance 84
6.3.1 SO2 Removal Efficicney 84
6.3.2 Particle Removal Efficiency 85
6.3.3 Duration of Scrubber Performance 86
7.0 CONCLUSIONS 87
REFERENCES 89
APPENDICES
A. SCHUBBER EQUIPMENT LIST AND EQUIPMENT
SPECIFICATIONS
B. TABULATION OF DATA
C. DAILY OPERATING LOGS
D. METHODOLOGY
E. TR*NSIENT CONDISTIONS
F. LIST OF SCRUBBER MALFUNCTIONS AND MAINTENANCE
-VI-
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FIGURES
Page
3-1. SCHEMATIC DIAGRAM OF CHEMICO WET 6
SCRUBBER SYSTEM
3-2. BOILER-SCRUBBER CONFIGURATION 7
3-3. FLOW DIAGRAM OF THE FGD SYSTEM 8
4-1. SAMPLING LOCATIONS 14
5-1. DRYER PRODUCT Fe203: 11/10/74 41
6-1. S02 REMOVAL EFFICIENCY DURING CENTRIFUGE OUTAGE
(11/15/74) 62
6-2. LIQUID FLOW RATE VARIATION; 12/17/74 71
6-3. HIGH GAS FLOW; 1/27/75 73
6-4. UNREACTED MgO IN CENTRIFUGE CAKE AS A FUNCTION
OF TEMPERATURE
81
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TABLES
Page
4-1. SCRUBBER CHARACTERIZATION TESTING PROGRAM 16r-18
4-2. VALIDATION OF INSTRUMENTAL DATA 20
5-1. BOILER OPERATING PARAMETERS 26
5-2. SCRUBBER FIRST STAGE OPERATING PARAMETERS 27-28
5-3. SCRUBBER SECOND STAGE OPERATING PARAMETERS 33-35
5-4. PERCENT S02 REMOVAL AT SHUT-DOWN 43
5-5. SUMMARY OF MAJOR TRANSIENT CONDITIONS 44-45
5-6. LEAKS NOV., DEC. '74; JAN., AUG. '75 47
5-7. CENTRIFUGE REPAIR 48
5-8. CENTRIFUGE PERFORMANCE 49
5-9. FIRST STAGE OUTAGE 50
5-10.SECOND STAGE OUTAGE 51
6-1. LEAKS OF THE SCRUBBER SYSTEM * 55
6-2. FIRST STAGE OUTAGE; DEC. 7, 1974 56
6-3. SECOND STAGE OUTAGE; DEC. 16, 1974 59
6-4. BOILER/SCRUBBER DATA; NOV. 15, 1974 63
6-5. PERCENT SOLIDS 64
6-6. CENTRIFUGE REPAIR 65
6-7. BOILER/SCRUBBER DATA 68
6-8. BOILER/SCRUBBER DATA 69
6-9. LIQUID FLOW RATE CHANGES; DEC. 17, 1974 72
6-10.BOILER/SCRUBBER DATA 74-75
6-11.TEST RESULTS; DEC. 17, 1974 77
6-12.BOILER/SCRUBBER DATA 78-79
6-13.ALTERATION OF Ap 80
6-14.SOLIDS REMOVAL EFFICIENCY DATA 83
CONVERSION FACTORS: BRITISH TO SI UNITS 90
-viii-
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SUMMARY
This report presents the results of a five-month study of an 95 MW
MgO Demonstration FDG System on a coal-fired utility boiler. The
site chosen for this study was the Dickerson Generating Station
which is operated by Potomac Electric Power Company. This facility
had been fitted with a Chemico/Basic Two-Stage MgO Venturi scrubber.
This test program showed that, although scrubber availability was
not all that was desired due to problems with logistics in supply-
ing raw materials (MgO), and to mechanical problems mainly attribu-
table to under-design in such areas as piping, slurry pumps, and
other auxiliary equipment, the basic scrubber concept and design was
one that should meet critical criteria once these problems are
remedied.
This report discusses scrubber operation during steady-state and
transient operating conditions, and the basic chemical character-
istics of the process streams. Recommendations are provided re-
lative to the unit's operation and maintenance from the viewpoint
of improvements in mechanical design to improve the availability.
Due to the limited availability during the test program which did
not provide the opportunity for full system characterization and
optimization, and to the system's indicated strengths, recommenda-
tion is given that further testing of the MgO FGD System be carried
out in order to better characterize the process.
-ix-
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-x-
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1.0 INTRODUCTION
York Research Corporation (YRC) was contracted by the Industrial
Environmental Research Laboratory - Research Triangle Park (IERL-RTP)
of the Environmental Protection Agency (EPA) to perform a test pro-
gram upon a Magnesia Flue Gas Desulfurization (FGD) process on a coal-
fired utility boiler. The objectives of the program were to charac-
terize both emissions from, and the process operation of, the FGD
system under both steady-state and transient operating conditions.
This was to be achieved through the installation and operation of
a continuous emission monitoring program, which was supplemented by
manual emission measurements using standard EPA techniques, and
by the sampling of certain process streams.
The site chosen for the test program was the Dickerson Generating
Station, operated by the Potomac Electric Power Company (PEPCO).
This station had been equipped with a Chemico/Basic MgO FGD demon-
stration scrubber system.
Mr. Roland Glenn of Combustion Processes, Inc. was involved in the
program as a field consultant for the purpose of assisting with
process evaluation.
During the test program, PEPCO plant operators and the Chemical
Construction Company were responsible for the operation, optimiza-
tion, repair, and maintenance of the demonstration system. Data
presented in this report are results of YRC's observations and
measurements made during the program.
The test program commenced in October 1974 and ran continuously
until the end of January 1975. At that time, there was a scheduled
-1-
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outage for boiler repairs. Dior ing this period, a considerable amount
of repair work was performed upon the FGD system. In August 1975,
the test program was resumed and ran until the end of the month,
at which time it was terminated due to lack of further committment
on the part of PEPCO to supply the additional necessary maintenance
funds. The U.S. EPA did have funds allocated for the continuation
of the operation of the regeneration facility.
The objectives of the program were to characterize scrubber emissions
and variations in emissions, as well as the performance factors
of the FGD process during:
• Steady-state operating conditions
• Transient operating conditions
Steady-state conditions are defined as being in effect when the flue
gas flow, boiler operating conditions, and fuel constituents were
not fluctuating, and when scrubber process streams were in an equili-
brium state.
Steady-s*:ate conditions were determined to be in effect when after
startup, the scrubber had settled down into its normal operating
process condition. Conversely, transient conditions were when this
mode of operation was not in effect (e.g., during scrubber startup,
shutdown, or malfunction).
-2-
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2.0 PLANT DESCRIPTION
The No. 3 boiler at PEPCO's Dickerson Generating Station is a
tangentially fired, pulverized coal-fired unit rated at 190 MW
(maximum continuous rating). It was installed by Combustion
Engineering in 1962 and is designed to produce 1,300,000 pounds
of steam per hour at 2480 Ibs /in at 1000°F superheat. The unit
incorporates a separated twin furnace design with economizers,
waterwalls and generating surfaces, two stage superheat with spray
attemperation, reheat, and provision for dry bottom ash removal.
Four Raymond Bowl Mill Pulverizers feed 32 tangential burners;
i.e., one burner at each of the four levels at each furnace corner.
The boiler is equipped with two steam coil air heaters, and two
Ljungstrom rotary air heaters for combustion air preheat. There
are two forced draft (FD) and induced draft (ID) fans for con-
trolling furnace pressure and airflow, two forced circulation
pumps to maintain water flow, and a Bailey combustion control
system. The boiler is also provided with pilot and warmup oil
torches (No. 2 Oil) which can be used as load carrying burners dur-
ing periods of firing low volatile or wet coal.
A Research Cottrell electrostatic precipitator (ESP) is installed
in the exhaust gas network of boiler Unit No. 3 downstream of the
combustion air preheater. This unit consists of two Opzel plate
precipitators in the same housing,, separated by an internal partition,
Each precipitator is divided into 2 units containing 3 sections of
6 foot plates along 21 ducted segments, with discharge electrodes
(wires) suspended between parallel plate collectors. Twelve Syntron
vibrators are used on the discharge electrodes and 24 magnetic im-
pulse rappers (continuous cycle) are used on the collection plates
to dislodge collected matter. Each unit is designed for a particle
removal efficiency of 97.5 percent, at design flow rate of 492,000
-------
cubic feet per minute (CFM) at 245 p. Boiler exhaust qases typi-
cally contained the following:
• 13.0 percent C02
• 0.2 percent CO
• 6.0 percent Q^
• 6-10 percent moisture
A typical analysis of the bituminous coal which is fired at the
Dickerson Station shows the following:
Heat Content
Nitrogen
Carbon
Hydrogen
Chlorine
Sulfur
Oxygen
Moisture
Ash
12,154 Btu/lb.
0.96%
71.30%
4.20%
0.10%
1.60%
4.90%
1.40%
15.42%
-4-
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3.0 FGD SYSTEM PROCESS DESCRIPTION
The Chemico/Basic Magnesium Oxide Flue Gas Desulfurization (FGD)
system (Figure 3-1) was designed to accomodate approximately one-
half (295,000 ACFM at 259°F) of the exhaust gas from Unit No. 3.
This FGD system incorporated the following major processing steps:
• Flyash removal
• SO2 removal
• Solids concentration
• Drying
• Dry solids storage
• Calcination
The first five of the above steps were accomplished within the
system, while the last was carried out at the Essex Chemical
Company's sulfuric acid plant in Rumford, Rhode Island.
The total boiler-scrubber system configuration is shown in Figure 3-2,
where it is noted that appropriate by-passes were provided such
that gas flows to both the scrubber and ESP could be adjusted to
control the flow through each unit.
In its operating mode, the flue gas from the boiler was drawn into
the scrubber by means of an induced draft (ID) fan which was regulated
by the scrubber operators. This permitted adjustment of the volume
of flue gas entering the scrubber inlet. Design flow of the scrub-
ber was approximately 295,000 ACFM, which was about one-half of the
full load gas flow of the boiler. The flow diagram for the entire
scrubber is shown in Figure 3-3.
The FGD system was designed as a two stage system, with the first
stage providing flyash removal and the second stage SO2 removal.
-5-
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FLUE GAS IN
SCRUBBING
WATER iW
PLUMB SOS
DRYER EXHAUST GAS
CENTR/FU6ESOL/OS OUT
MOTHER
LIQUOR
OUT
Mg SO,
TO STORAGE
TO STACK SILO
1 1
DILUTION
TANK
CLEAR WATER
\ \
L~~
1
SETTLING
POND
SCHEMATIC DIAGRAM OF CHEMICO WET SCRUBBING SYSTEM
UNIT NO. 3, PEPCO-DICKERSON
Figure 3-1
-6-
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STACK
BOILER
PRECIPITATOR
; SCRUBBER
FAN
BOILER-SCRUBBER CONFIGURATION
FIGURE 3-2
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nastAu
scuun
i
oa
I
tarniw
HIW noa
FLOW DIAGRAM OF THE FGD SYSTEM
FIGURE 3-3
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3.1 First Stage - Flyash Removal
The first stage was an adjustable throat venturi, where
the flue gas was cooled from 250°F to 120°F and saturated
with water vapor. This stage was used for flyash (particle)
control only, and its re-circulating liquid stream was
separate and independent from that of the second stage.
Ash-laden water was circulated at a nominal 2 percent
solids concentration. The adjustable venturi automatically
controlled the first stage pressure drop/ which was main-
tained at 11 inches (H2O). Design particle removal ef-
ficiency was 99.0 percent.
A 980 gal /min (GPM) bleed stream from the first stage
recycle line carried ash to the thickeners. A flocculant
was used to aid settling in the thickeners. Thickener
underflow (20 GPM at 40 percent solids) was discharged to
a dilution tank where water was added, and the mixture
pumped back to a settling pond. The overflow cascaded
through a total of four ponds in series, and the water
from the lowest pond was then pumped back to the dilution
tank. The thickener overflow was pumped back into the
scrubber's first stage. This closed-loop operation was
maintained within first stage operation.
3.2 Second Stage - SO, Removal
Flue gas, after leaving the first stage, passed upward
through an annular mist eliminator, and then downward
through the scrubber's second stage. Within the second
stage, magnesium oxide (MgO) was added to the scrubbing
water. This allowed the S02 in the flue gas to diffuse
into the water droplets, thus removing it from the gas
stream. In this process, the S02 chemically reacts with
the MgO, forming hydrated magnesium sulfites (MgSC^^nH-O) ,
and to a lesser degree, magnesium sulfate (MgS04).
Flue gas and entrained liquor entered the separator
— 9 —
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portion of the absorber through a central downcomer.
The liquor fell to the lower section of the separator
which served as an integral storage reservoir, while
the gas passed upward through the second stage mist
eliminators and was exhausted through the stack to the
atmosphere.
3.3 Solids Concentration
A 170 GPM bleed from the absorption system entered a
36 inch by 72 inch solid bowl centrifuge where hydrated
magnesium sulfite and magnesium sulfate crystals, and un-
reacted MgO were separated from the mother liquor. The
mother liquor was returned to the second stage absorption
system, and the centrifuged wet cake entered the dryer.
3 o 4 Drying
The wet cake containing hydrated magnesium sulfite,
magnesium sulfate, MgO and surface moisture was dried
by direct firing to remove free and combined moisture.
Exhaust gas from the dryer passed through a cyclone dust
collector, and back into the scrubber's second stage.
3.5 Dry Solids Storage
The anhydrous MgSO^ and MgSO^ material was conveyed from
the dryer to a storage silo (capacity: 200 tons) where
it was kept until it was transported to the sulfuric-acid
plant for calcination.
3.6 Calcination
The dry cake was transported to the Essex Chemical
Company's sulfuric acid plant in Rumford, Rhode Island
for calcination. Regenerated MgO was returned (with
make-up) and stored in the MgO silo (capacity: 100 tons),
The MqO slurry was prepared using regenerated MgO, make-
up MgO, and mother liquor. This MgO slurry was added as
make-up to the absorption recycle liquid circuit (second
stage).
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3.7 Scrubber Process Control
The control process for this FGD system was relatively
simple. Basically/ the liquid flow rates through the
scrubber were constant and independent of gas load. The
first stage of the venturi was automatically adjusted to
maintain an 11 inch (I^O) pressure drop across the venturi.
MgO additive feed rate was varied to maintain the slurry
pH at a preset point; generally about 7. The pH was
measured at the discharge of the second stage re-circulation
pump. A downward pH trend triggered the addition of MgO
to the system from the MgO make-up tank.
—11 —
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-12-
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4.0 TEST PROGRAM
During the five months that YRC test personnel were on-site, the
followina types of testing were performed:
• Continuous monitoring of scrubber emissions
• Measurement of process streams
• Manual testing of gaseous emissions.
Figure 4-1 illustrates the sampling points.
In the planning stage of the project, it was decided to continuous-
ly monitor CO, C02, and 0? as indicators of the status of boiler
operation, and to provide information regarding leaks in the FGD
system. Once the program was underway, it became evident that CO/
concentrations were maintained at a level so low that instrumental
analytical values were unreliable. Thus, after the first few weeks,
monitoring of this parameter was discontinued. Oxygen, on the
other hand, proved to be a reliable indicator since its level was
well maintained within tight bounds in the combustion zone.
4.1 Test Method
4.1.1 Continuous Monitoring Program
Gaseous effluent from the scrubber was continuously
monitored during the program to obtain data related
to the scrubber's performance during steady-state and
transient operating conditions. A continuous monitor-
ing trailer was installed at the base of the scrubber
approximately 45 feet from the ducting where the probes
were situated. Flue gas, after passing through a series
of filters, was carried to the continuous monitoring in-
struments by means of a heated sample line. The gas
flow was conditioned (where moisture was removed) in the
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COAL
BOILER
PRECIPITATOR/SCRUBBER - ABSORBER
ADDITIVE SYSTEM FOR SO^ RECOVERY
SCHEMATIC PROCESS FLOW SHEET
**^~
• FUEL BURNERS
• STEAM COIIS
TO DRY ASM HANDLING SYSTEM HOT FAN
RECYCLED
POND WATER
MgO FROM ACID PLANT
MgSOj TO ACID PLANT
SAMPLING LOCATIONS
FIGURE 4-1
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trailer before passing to the instruments. Flue gas
samples were drawn alternately and sequentially from the
inlet and outlet of the scrubber for periods of between
5-20 minutes each. Switching from one location to another
was done automatically by a timer-solenoid switching sys-
tem. The sampling duration from either inlet or outlet
were manually adjustable by the trailer operator. This
feature allowed shorter sampling times per point during
transient conditions than during steady-state conditions.
The parameters measured and the measurement principles
were as follows:
Parameter Method Instrument
S02 Pulsed Fluorescence Thermo Electron
Model 40
NO Chemiluminescence Thermo Electron
Model 10B
CO2, CO NDIR Infra-Red Model 703
09 Paramagnetic Cleveland-Kent
Model CKA-1A
Flow - - Teledyne-Hastings
Temperature; Thermocouple - -
Detailed information concerning instrument operation
appears in Appendix D.
4.1.2 Measurements of Process Streams
The sampling and analytical program included the col-
lection of data relative to the performance and relia-
bility of the process itself. All of the major process
streams were studied and, in addition, some special
investigations were made to study various secondary reac-
tions and products. Table 4-1 illustrates the scope of
this part of the program. Detailed information concern-
ing the analytical methods used appears in Appendix D.
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TABLE 4-1.
SCRUBBER CHARACTERIZATION TESTING PROGRAM
Sampling Location
Parameter
Location** Sampling Frequency
Analytical
Method (Appendix
Bleed
Thickener Overflow
Thickener Underflow
SECOND STAGE
Bleed
Mother Liquor
pH
Magnesium
Suspended Solids
Chloride
Sulfate
Sulfite
Suspended Solids
pH
Chloride
Suspended Solids
pH
Chloride
pH
% Solids
% Mg S03-6 H20
% Mg S04
% MgO (Solids)
% MgO (Total)
Density
% Solids
% Mg S03.6 H20
% MgO (Solids)
% MgO (Slurry)
Density
8 hours
it
Tl
II
tl
II
IT
It
tf
II
4 hours
it
it
Tt
tt
tt
tt
tt
tt
tl
Electrode
Volumetrically
Gravimetrically
Turbidimetrically
Colorimetrically
Volumetrically
Gravimetrically
Electrode
Turbidimetrically
Gravimetrically
Electrode
Turbid imetrically
Electrode
Gravimetrically
Volumetrically
Colorimetrically
Volumetrically
Volumetrically
Gravimetrically
Gravimetrically
Volumetrically
Volumetrically
Volumetri cally
Gravimetrically
Sampled only during the last month of scrubber evaluation (Aug. 1975).
Determined during first portion of the program only (Oct., 1974 through Jan., 1975)
Sampling Location - See Figure 4-1
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TABLE 4-1. SCRUBBER CHARACTERIZATION TESTING PROGRAM fCONT'O.)
Sampling Location
Parameter
Location** Sampling Frequency
Analytical
Method (Appendix D)
MgO Belt
Centrifuge Cake
Dryer Product
SPECIAL ANALYSES
Dryer Product
Second Stage Slurry
Scrubber 1st Stage
% MgO
% Mg
Density
% Combined Water
% Free Water
% Mg S03
% Mg SO 4.
6
7
4 hours
Tt
% MgO
% Water
% Mg S03
% Mg S04
% MgO
Density
Iron Content
Trihydrate-
Hexahydrate Study
Time Dependance of pH
Sulfate
Sulfite
Chloride
Iron
Magnesium
pH
tl
tl
It
Tt
ft
tl
tt
tt
tl
tt
tt
November 10,11,1974
2 Hour intervals
Dec. 1974, Jan. 1975
Dec., 1974
Jan. 10, 1975
tt
Gravimetrically
Colorimetrically
Gravimetrically
Moisture Balance
Gravimetrically
Volumetrically
Colorimetrically
Volumetrically
Moisture Balance
Volumetrically
Colorimetrically
Volumetrically
Gravimetrically
Colorimetrically
Volumetrically
Electrode
Colorimetrically
Volumetrically
Turbidimetrically
Colorimetrically
Volumetrically
Electrode
**
Sampling Location - See Figure 4-1.
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TABLE 4-1.
SCRUBBER CHARACTERIZATION TESTING PROGRAM rCONT'O.)
oo
I
Sampling Location
Centrifuge Cake
Dryer Product
FIRST STAGE
Process Water
SECOND STAGE
Scrubber Inlet
Scrubber Outlet
Parameter
Water Content
Inert Material
Magnesium
Chloride
Iron
Chloride
SO 2
co2
°2
Flow
Temperature
SO2
CO 2
°?
Flow
Temperature
Location**
7
7
1
1
4
4
9
9
9
9
9
10
10
10
10
10
Sampling Frequency
August, 1975
August, 1975
August, 1975
August, 1975
August, 1975
August, 1975
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Analytical
Method f Appendix D)
Moisture Balance
By Difference
Volume tri cally
Turbid imetrically
Colorimetrically
Turbidimetrically
Pulsed Fluorescent
NDIR
Paramagnetic
Pulsed Fluorescent
NDIR
Paramagnetic
** Sampling location - See Figure 3-1.
-------
4.1.3 Manual Testing of Gaseous Emissions
Testing of the scrubber at its inlet and outlet was
performed periodically during the test program using
EPA Standard Methods. This was carried out to validate
the results obtained from the continuous monitoring in-
struments. Table 4-2 summarizes the comparative data
obtained in this manner. More detailed information
appears in Appendix D.
4.1.4 Instrument Calibration
All analyzers were calibrated daily in the manner spec-
ified by the manufacturer of the instrument. Calibration
gas was stored in the rear of the York Research Corpora-
tion Monitoring trailer and was injected at specifically
controlled rates from the master control panel located
within the trailer proper.
In addition to the standard calibration methodology, the
calibration gas was injected up an auxiliary sample
carrying line into the probe and then returned to the
analyzers through the usual passageways. Utilizing this
method, York engineers could determine if probe or sample
line leakage existed.
As a final check on the instruments, York Research per-
formed wet chemical testing under strict EPA guidelines.
Samples were taken simultaneously at the inlet position
and the trailer's analyzer lead-in, and then again at the
outlet position and the trailer's analyzer lead-in. The
following methods were used to verify instrumentation:
• Sulfur Dioxide: EPA Method #6
• Nitrogen Oxide: EPA Method #7
• Carbon Dioxide, Oxygen, and Carbon Monoxide:
EPA Method #3.
-19-
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TABLE 4-2. VALIDATION OF INSTRUMENTAL DATA
Parameter (Location)
so2
so2
°2
°2
co2
co2
(Enlet)
(Outlet)
(Inlet)
(Outlet)
Clnlet)
(Outlet)
No. of
Tests
10
13
2
1
2
1
Avg. Concentration
Manual
1028.
490.
6.
6.
13.
11.
8 ppm
3 ppm
3 %
4 %
0 %
6 %
Instrumental
1035.
488.
6.
6.
13.
12.
0 ppm
7 ppm
4 %
8 %
1 %
7 %
4.1.5 Operational Data
In addition to the test programs described, consider-
able attention was paid to the acquiring of operational
data for the boiler, the electrostatic precipitator, and
the scrubber. Logs similar to those compiled in the con-
trol rooms were kept by York Research personnel. These
data obtained include:
• Boiler Load (MW)
• Steam Temperature
• Superheater Temperature
• Reheater Temperature
• Pulverizer Mill Outlet Flow
• Pulverizer Mill Temperature
• Burner Tilt Position
• Combustion Air Temperature
• Coal Feed Rate
• Supplemental Oil Rate
• Coal Composition
Notivication of malfunctions
Mist eliminator pressure drop
-20-
ESP
Scrubber
-------
• Dryer draft
• Outlet temperature
• Product temperature
• Absorber pressure drop
• Inlet temperature
• Slurry temperature
• Circulation rate
• Centrifuge feed rate
• MgO slurry feed
• Recycle pump speed
• Centrifuge torque
• MgO tank level
• pH
• S02 inlet
• S02 outlet
• Induction fan speed
Each month a report was compiled containing the following:
• Statement of Program Progress
• Statement of Program Problems
• Discussion of data
• Raw emission data (Instrumental)
• Boiler operating parameters
• Scrubber operating parameters
• Chemical analysis of scrubber process streams
• Graphical representations of data and trends
• Daily log
This information is summarized in Appendix B (Hourly Data).
A Daily Log of the unit's operation as well as the monitor-
ing program is presented in Appendix C.
4.2 FGD System Availability
For the purposes of this evaluation, system availability
has been defined as:
Availability (%) = (tQ/t ) x 100
Where: t = Total hours system operated
t = Total hours in test program
-21-
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Based upon data taken from the operating logs, the above
relationship shows that the scrubber was available dur-
inq approximately 48 percent of the test period. Availa-
bility includes all levels of operation; transient and
steady-state alike. It is estimated that of the time the
system was available, approximately 80 percent of that
was steady-state where the system was operating normally.
There were several occasions in which one or the other of
the two stages was operating separately. These are con-
sidered to be transient conditions. It should be noted
that a portion of the outage time was due to lack of
MgO supplies, as well as the fact that MgO slurry feed
pumps were inadequate for handling full flow. The per-
cent of availability then, could have been much higher
had these deficiencies not existed.
4.3 Boiler and ESP Availability
Oxygen and carbon dioxide levels were constantly re-
corded at the scrubber inlet as indicators of boiler
operating status and/or leaks in the ductwork (which
would affect SC>2 concentrations in the flue gas) .
The levels of these two constituents remained very con-
stant throughout the test program. This was due to the
use of the excess G>2 monitor located in the plant control
room which allowed operators to regulate the level of 02
in the boiler within tight limits (generally 3-4 percent)
The boiler availability was good during the test program.
The boiler ran at varied loads due to changes in demand
or operation, but for most of the program it was in the
range of full load.
The ESP also operated smoothly. There are few records
in the operator's log of any ESP shut-down or upset
during the test period. All of the flue gas from Unit
No. 3 passed through the ESP before entering the first
stage of the scrubber. A duct to by-pass the ESP was
-22-
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constructed, but this feature was very rarely used
because very heavy grain loading was considered to be a
strain on the demonstration unit's hardware. This type
of operation was restricted to a few demonstrations.
-23-
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-24-
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5.0 TEST RESULTS
5.1 Boiler and ESP
The scrubber was designed to perform under a variety of
boiler operating levels, and in practice it did this
well. Unit No. 3 had a good performance record. Table
5-1 presents the operating parameters of the boiler.
5.2 Scrubber: Steady-State Operation
During the test program, the scrubber handled greater
than 100 percent of the design flow on several occasions,
but for the most part it ranged between 50 percent and
90 percent of its design capacity. On occasions when the
boiler load was reduced because of wet coal or a loss of
coal feeders, the scrubber seemingly operated independ-
ently of this reduction. The only effect was a drop in
the S02 inlet concentration of approximately 200 ppm (or
15 percent). The second stage slurry pH values rose
slowly in this case, and the MgO feed rate was lessened
to compensate. Otherwise, this drop in load would not
notably effect the scrubber.
The particle removal efficiency of the scrubber with-
out the ESP preceeding it ranged between 99.2-99.7 percent.
With the ESP in line, the scrubber's particle removal
efficiency was between 94.1-99.5 percent.
5.2.1 Scrubber First Stage
Flue gas entered the first stage from the air preheater.
Table 5-2 lists the ranges for the operation and chemical
analyses performed on this stage.
-25-
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TABLE 5-1. BOILER OPERATING PARAMETERS
Parameter
Range
Average
Load MW (gross)
Average Capacity Factor
Burner ^ilt (degrees off vertical)
Super heciter Steam Flow ( Ubs/hr)
Flue Gas; Temperature (°F)
Flue Gas; Flow Rate (ACFM) (full load)
Excess Oxygen (%)
Combustion Air Temperature (°F)
Coal Consumption (tons/hr)
Heat Input ( 10 Btu/hr)
Coal Composition
Heat Cor.tent (Btu/hr)
Sulfur (%)
Carbon (%)
Nitrogen (%)
Oxygen (%)
Hydrogen (%)
Ash (%)
Moisture (%)
Flue Gas Composition (inlet to scrubber)
88-190
+12 to -8
3-4
510-585
10,100-12,600
1.20-3.30
59.0-72.90
0.87-1.50
2.7-9.50
3.4-4.8
13.8-21.7
0.4-2.5
Oxygen (%)
Carbon Dioxide (%)
Nitrogen Oxides (ppm)
Sulfur Dioxide (ppm)
Moisture (%)
Grain Loading (ESP on)(gr/SCF)
Grain Loading (ESP off)(gr/SCF)
Duct Temperature (°F)
5.0-10.0
11.0-17.0
340-520
660-1680
5.1-8.7
0.09-0.25
2.60-4.40
81
1,300,000
259
590,000
74.5
1744
11,000
1.74
66.6
1.30
5.35
3.89
17.2
1.3
0.3
3.0
240
-26-
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TABLE 5-2. SCRUBBER FIRST STAGE OPERATING PAKAMF.TKRS
Parameter
Minimum Maximum Avg,
Inlet Gas Temperature (°F)
Inlet Gas Flow (ACFM)
First Stage Pressure Drop (inches 1^0)
Mist Eliminator Pressure (inches 1^0)
Recycle Rate (gpm)
Bleed Rate (gpm)
Compositions
First Stage Bleed
PH
Suspended Solids (mg/1)
Magnesium (mg/1)
Chloride (mg/1)
Sulfite (mg/1)
Sulfate (mg/1)
Thickener Overflow
Recycle Line (gpm)
Suspended Solids (mg/1)
Suspended Solids Removal Efficiency(%)
PH
Chloride (mg/1)
Thickener Underflow
Suspended Solids (mg/1)
Suspended Solids Removal Efficiency(%)
PH
Chloride (mg/1)
250 265
100,000 300,000
11.4 12.5
0.1 1.3
2850 3100
1.1
0.5
11.8
7.5
0.1
35.0
6.1
966
113.9
2550
0.5
4340
*0.5
8.2
1.1
7.5
<0.5
1.6
1.3
11.0
317
83.9
6.4
2550
376
93.0
6.3
2550
980
20
-27-
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TABLE 5-2. SCRUBBER FIRST STAGE OPERATING PARAMETERS (CONT.)
Parameter Minimum Maximum Avg,
Particle; Removal Efficiency
With E,SP in line (%) 94.1 99.5
Without ESP in line (%) 99.2 99.7
Sulfur Oxides Removal Efficiencies (%) 5.0 10.0
-28-
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5.2.2 First Stage Bleed
The first stage bleed was the liquid sent to the
thickeners for clarification after being circulated
through the venturi throat along with the flue gas
and had impacted the solid particulate matter. The
samples were collected at the distribution box where
the liquid from the bleed line was separated. The
parameters determined were chosen to characterize
the first stage recycle liquid for corrosiveness and
to determine the amount of spill-over from the second
stage absorber.
A pH as high as 6.1 occurred when a very light gas flow
passed through the inlet. The pH always dropped with
the length of time the scrubber was in operation be-
cause of the formation of acids (sulfuric, sulfurous,
hydrochloric and some nitric from the absorption of
gases in the water). An equilibrium pH value of 1.1-
1.4 was reached after the longest run for which these
data were obtained (84% hours).
In order to determine if there was any cross-over con-
tamination from the second stage's scrubbing water to
that of the first, testing was performed to determine
the magnesium ion (Mg ) concentrations in the first
stage. The Mg levels in the first stage bleed ranged
between 11.8-113.9 mg/1. Contributors could have been
the make-up water, the flyash, or contamination from
the second stage. It seems that the make-UD water
was the most likelv source of Mg in view of the
magnitude of the maximum (113.9 mg/1). When tested in
August 1974, the make-up water indicated levels of Mg
ranging between 71.0-102.6 mg/1. Any reasonable increase
in the Mg concentration over these values could be
attributed to the recycling of the process water through
the first stage.
-29-
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The suspended solids level in this bleed line was a
measure of thickener efficiency. Naturally, the level
was low shortly after start-up, but rose to a high of
nearly 1000 mg/1 as operation was continued. As the
thickener achieved an equilibrium operating state, the
suspended solids level would drop from this maximum.
The presence of chloride and its associated corrosion
problems was also investigated. The chloride ion
concentrations were generally quite high, because the
liquid was recycled, and the levels would increase as
scrubber operating time increased.
The coal tested during a baseline study showed a
chloride content of between 0.03-0.14 percent. Un-
doubtedly this was the primary origin of this ion in. this
first stacre recycle bleed liauid, as it was absorbed
from the flue eras or flyash, It is unlikely that
this chloride level could have been introduced from the
river water used for make-up because other parameters
which were measured in this make-up water were very
low. The iron, sodium, copper, mercury, phosphate and
fluoride, when tested earlier were present in quantities
low enough for the river water to be considered a re-
latively non-polluted surface water. The resulting cor-
rosiveness could have been responsible for the occurrence
of leaks in the first stage piping. Sections 6.0 and 7.0,
and Appendix F describe these in detail.
The levels of SO^ (sulfite) and SO^ (sulfate) were
approximately those which would be expected. They
originated from the minimal absorption of sulfur oxides
from the flue gas into the first stage liquid. Previous
testing had shown that the concentration of SO., in the
flue gas ranged between 0 and 55 ppm. SO^ levels averaged
about 1000 ppm in the stack gas. The first stage of the
scrubber normally removed between 5 and 10 percent of the
SOj in the flue gas, which formed sulfuric acid as it
-30-
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dissolved in the liquid. The highest level of S04 measured
was 3738 mg/1 which is equivalent to a 0.1 normal sulfuric
acid solution.
Thus the corrosive nature of this recycling bleed was
established, and was considered to be sufficiently
high to breakdown even No. 316 stainless steel. (R. Glenn,
Weekly Technical Report, January 27, 1975).
5.2.3 Thickener Overflow
The thickener overflow was the clarified water from the
thickener tanks. After being mixed with make-up
water, this overflow was returned to the scrubber first
stage. Make-up water was added to the system to replace
that portion of the liquid going into the thickener under-
flow, and that lost due to evaporation.
Testing of this stream was done to determine the levels
of suspended solids, chloride ion, and pH. The suspended
solids remained in a range which indicated an adequate
performance of solids removal by the thickener system.
When the first stage recycling system reached equili-
brium, the solids in the overflow ranged between 20-80
percent of the suspended solids level in the bleed line.
The pH and chloride ion levels paralleled those of the
first stage bleed as these concentrations were unaffected
by the addition of flocculant to the liquid, or settling.
5.2.4 Thickener Underflow
This stream was the slurry product of the thickener
flocculation process. The slurry was pumped to a transfer
tank, and thence to a series of settling ponds. The
water from the settling ponds was subsequently used to
dilute the thickener underflow slurry in the trans-
fer tank. Suspended solids, chloride ion levels, and pH
were generally similar to those of the overflow samples.
The efficiency of the thickener was minimal at low solids
-31-
-------
concentrations (1.6 percent); however, it increased to a
high of 93.0 percent removal when the incoming slurry
(first stage bleed) had a high suspended solids content.
More definitive observations could have been made if the
duration of periods of scrubber operation had been longer
during this study of the first stage. Chloride concentra-
tions were still climbing when the scrubber shut down due
to a build up of product in the dryer. Other trends in
solids removal may have become more evident during a longer
operating period.
5.2,,5 Scrubber Second Stage
After passing through the mist eliminators the gas was
processed in the MgO absorber of the second stage. The
dryer off-gas was also scrubbed in this section to re-
move any sulfur oxides and other pollutants generated from
the oil combusted to heat the dryer. Table 5-3 lists the
operating ranges of the various parts of this stage.
-32-
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TABLE 5-3. SCRUBBER SECOND STAGE OPERATING PARAMETERS.
Parameter
Inlet Gas Temperature (°F)
MgO Storage Silo capacity (tons)
MgO Belt feed rate (#/min)
% MgO
% MgS04
MgO Slurry feed rate (gpm)
MgO Slurry temperature (°F)
Pressure Drop total (inches H20)
-absorber (inches H20)
-mist eliminator (inches H20)
Absorber circulation rate (gpm)
Second Stage Bleed rate (gpm)
Second Stage Bleed Composition
PH
MgS03'6H20 (%)
Suspended Solids (%)
SO| (filtrate) (%)
MgO in solids (%)
Density (g/ml)
Outlet Gas Flow (ACFM) *
Outlet Gas Composition
Particulate (gr/SCF @ 12% C02)
02 (%)
C02 (%)
Minimum
110
15
85.0
0.01
6
120
0.4
0.4
0.1
4600
5.5
0.07
0.16
0.5
0.06
0.99
81,800
0.0009
5.0
10.4
Maximum Average
120
100
25
96.2 90.1
12.57 2.75
25
165
13.0
4.0
1.0
5500
170
8.0
11.74
19.79
22.1
41.86
1.34
159,000
0.020
10.0
16.0
*Includes dryer off gas flow, which is added into Second Stage
-33-
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TABLE 5-3. SCRUBBER SECOND STAGE OPERATING PARAMETERS (CONT.)
Parameter
S02 (ppm)
NOX (ppm)
Moisture (%)
Outlet temperature (°F)
S02 Removal Efficiency (%)
Centrifuge feed rate (gpm)
Centrifuge Cake Composition
Density (g/ml)
Combined Water (%)
Free Water (%)
MgS03 (%)
MgS04 (%)
MgO (%)
Mother Liquor Composition
Solids (%)
MgS03'6H2O (%)
MgO (% in solids)
MgO (% total)
Density (g/ml)
Dryer Outlet temperature (°F)
Dryer Product composition
Water (%)
MgS03 (%)
Minimum
63
320
7.5
111
61.0
90
1.00
42.0
7.0
40.0
3.0
0.75
0.08
0.16
0.20
0.01
1.01
200
0.2
60.0
Maximum Average
350
450
13.0
145
93.0
132
1.60
47.0
15.0
45.0
6.0
7.0
12.62
11.58
21.96
4.05
1.34
450
15.0
75.0
-34-
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TABLE 5-3. SCRUBBER SECOND STAGE OPERATING PARAMETERS (CONT.)
Parameter
Dryer Product Composition (Cont.)
MgS04 (%)
MgO (%)
Density (g/ml)
MgS03 Silo Storage capacity (tons)
Minimum
5.0
2.0
0.45
Maximum
10.0
10.0
0.70
Average
200
5.2.6 The MgO slurry was prepared by mixing a weighed amount
of MgO from the storage silo with the mother liquor from
the centrifuge. The weigh feeder belt delivered between
15 and 25 Ib./min. of MgO. The accuracy of this belt was
not as dependable as was expected. This made the addition
of MgO slurry into the scrubber difficult and caused a pro-
blem for the operators who were attempting to regulate the
pH by this method.
During October, 1974, 200 tons of MgO were used. This
was a mixture of virgin and regenerated MgO in a ratio
of approximately 1.5:1. In November, 73 tons of additional
virgin MgO were added to the silo. The rest of that month
the scrubber operated using regenerated MgO. Later in
December and January, some small quantities of virgin MgO
were added to the silo to replenish the MgO that was lost
in operation and in transportation.
Throughout the test program, the MgO was analyzed for
MgS04 and MgO content. The samples ranged between 85.0-
96.2 percent MgO and 0.01-12.57 percent MgSO4-
The amount of MgO indicated the purity of the product used.
No specific analyses for impurities were performed by York
Research chemists, however, so the percent difference be-
tween the total of the percent MgO and percent MgSO. from
-35-
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100 percent was assumed to provide the amount of foreign
material present. These impurities could have originated
from the flyash which was carried through the system into
the second stage, or from corrosion and/or erosion pro-
ducts in the scrubber itself. Since this product was
effectively recycled, these impurities increased with
each absorption-recalcination cycle. Ultimately, these
impurities could have reduced the reactivity of the MgO
so as to render it useless.
The MgO slurry was mixed with the mother liquor and
heated by a steam sparger. The slurry was then pumped into
the second stage nozzles above the venturi. The stack gas
and the MgO slurry proceeded through the venturi together.
The scrubbed gas flowed through the mist eliminators to
the scrubber outlet and the stack. The slurry dropped to
the bottom of the second stage and was recycled through
this process.
5.2.7 Second Stage Bleed
A small portion of the slurry containing unreacted MgO
and the product MgSO^ was bled off at a rate of 120 gpm
and processed in the centrifuge. Make-up water was
added to the absorber to maintain the proper consistency
of the slurry. Fresh MgO slurry was added at a rate reg-
ulated by the operator to adjust pH. An ideal pH was
between 6.8-7.2, because this range maximized the SO2 ab-
sorption process without producing a build-up of crystals
in the absorber. This also assisted the centrifuge and
dryer to attain optimum performance. However, due to the
difficulty in regulating the pH by MgO addition, normal
operation included pH values ranging from 5.5 to greater
than 8.0.
The lower pH values were indicative of problems that
developed in the MgO slurry feed or recycle systems.
These problems had the effect of reducing the amount
-36-
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of MgO being pumped into the scrubber to a level that was
lower than that required to react with most of the S02
present. The presence of excess S02 increased the acidity
of the slurry. When the pH was allowed to drop below 6.8,
corrosion of ductwork and piping could have become acute.
The higher values occurred shortly after the scrubber
startup, before the S02 in the stack gas had been thoroughly
mixed with the absorbent MgO slurry. At this time the pH
was as high as 9.4.
The solids content of this bleed slurry ranged between
0.16-19.79 percent. The different levels were due to
changes in the MgO slurry feed rates, and the variations
in flue gas flow into the scrubber. Both of these rates
were manually set by the scrubber operators. The low values
represented the initial operation shortly after the start
up when the scrubber operated with reduced gas flow from
the boiler. Values ranging from 3-8 percent were typical
of favorable MgO feed rates and a proper pH level in the
absorber slurry. Solids above 18 percent were not de-
sirable because the pumping system from the absorber to
the centrifuge could not adequately handle the crystals
in the absorber slurry which forced the gas load to be
reduced until the crystals could be freed.
The composition of these solids was studied to determine
the amount of product (MgSO.,) formed in the absorber.
Naturally, the higher this percentage, the more efficient
the operation. The range for the test program was 0.07-
11.74 percent MgSO.,. Another component of the solid
portion of this slurry was MgO (range 0.09-19.6 percent).
The difference was composed of impurities and insoluble
sulfates.
The slurry density was also measured. This measurement
gave a rough indication of the type of slurry that was
introduced to the centrifuge. Operational changes could
have been made using this parameter to obtain a more con-
-37-
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sistent product and reduced wear on the system.
5.2,,8 Centrifuge Cake
The slurry was introduced to the centrifuge to separate
the solid and liquid portions. The centrifuge cake
(solid portion) was analyzed to determine the character
of the product. The bulk density was measured to in-
dicate the free water in the cake. As the percent water
increased the density decreased/ which meant that the
centrifuge efficiency had decreased. A very wet cake
put a strain on the screw conveyor and dryer.
During August, the amount of free water was as high as
29.8 percent. The chemical analysis of the cake was
comparable to past cakes; therefore, the cause of the
high water content was possibly due to centrifuge per-
formance. The centrifuge weir heights, which controlled
the degree of liquid/solid separation, were adjusted dur-
ing the August 26, 1975 outage but no chemical analyses
were performed after this date to determine if the cent-
rifuge was the problem.
The percent MgO was measured to determine the amount of
unused reactant leaving the absorber. Low MgO concen-
trations (less than 3 percent) reflected good absorption
in the second stage. High values (above 6 percent) re-
flected a high pH in the absorber, low gas flow, low
reactivity of the MgO, or decreased slaking due to fail-
ure of the steam lines to the MgO slurry make-up tank at
certain times.
5.2.9 Mother Liquor
The liquid separated by the centrifuge was returned to
the process to be recycled. Most of it was pumped
directly into the second stage of the scrubber below
the venturi. A small portion was used with the MgO
to make up the MgO slurry.
-38-
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The solids concentration in this liquor varied inversely
with the efficiency of the centrifuge. A determination
of the reacted product MgSCU was made to observe the amount
that was recycled. The percent MgO was also monitored.
High MgO readings may have resulted from a high second
stage pH, unreactive MgO, or decreased slaking in the
MgO slurry tank.
5.2.10 Dryer Product
The dryer prepared the centrifuge cake for storage and
shipment to the calcination facility. Final composition
analyses were performed on this product. Water content
ranged between 0.2-15.0 percent. MgSO^ content was nor-
mally within 60-75 percent and the unreacted MgO levels
were between 2.0-10.0 percent.
The percent MgO in the dryer product was analyzed in
order to determine how much unreacted material was
being carried through the system and being shipped out for
regeneration. A low percent MgO reading was desirable
because it reflected good S02 absorption and economical
operation of the system. Among the factors that may have
effected high MgO readings are a high pH in the second
stage slurry, unreactive MgO, and decreased slaking due
to failure of steam lines to the MgO make-up tank. Varia-
tions in MgO content could be attributed to pH fluctuations
in the absorber, changes in the volume of flue gas pro-
cessed, the type of coal burned, the percent of MgO in
the slurry, and centrifuge efficiency.
The bulk density of the dryer product was measured as an
indication of the character of the product. This would
have been an aid in determining the volumes and weights
of the product for shipment and bucket elevator performance,
In January 1975, a high percentage of 1^0 in the dryer
product was deliberately induced in order to determine
the effect of percent H~0 on the bulk density. It was
-39-
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found that increased in I^O did increase the bulk density.
This was significant because shipping and handling costs
could definitely be affected by the moisture content of
the dryer product.
A question was raised regarding the iron content of the
system. All of the existing pipes leading from the
second stage back to the dryer system were composed of
carbon steel. After a lengthy outage, October 26 to
November 10, 1974, the iron content of the system was
measured by analysis on the dryer product solids at two-
hour intervals. Upon start-up, the iron in the first dryer
product sample was determined to be 3.77 percent Fe203.
Within a twentyfour-hour running period, the iron content
diminished to the 200 ppm (0.2%).Fe203 and held constant
at that level for a sustained period. .The results are
plotted in Figure 5-1.
Chloride concentration in the coal was found to be 0.02-
0.20 percent at this time. (Chlorine from the coal com-
bustion forms HCl gas which reacts with the MgO (aq.)
forming soluble MgCl2« It was believed that the Cl'tMgC^)
concentration continually increased with on-line time
since the soluble MgCl2 was circulated through the system
continually via the mother liquor.
5.3 Scrubber: Transient Operation
Transient operation occurred during scrubber start-ups,
shut-downs and malfunctions. The major point of interest
in the documentation of these conditions was their effect
on emissions.
5.3.1 Start-Ups
Before starting the scrubber induced draft fan (ID), it
was necessary to prepare the scrubber to receive stack
gas. The MgO slurry for use in the second stage of the
-40-
-------
O
CM
0)
z
w
w
00
02
04
06
08
16
10 12 14
TIME OF DAY
DRYER PRODUCT Fe203 (11/10/74)
FIGURE 5-1
18
20
22
-------
scrubber was mixed in the slurry make-up tank. This
slurry was then pumped in and circulated through the second
stage. First stage liquid, which was a combination of
the thickener overflow liquid and make-up water, was also
circulated through the scrubber. As the scrubber ID fan
was started, dampers on the inlet and outlet to the scrub-
ber were opened, allowing the stack gas to circulate.
When a sufficient amount of MgS03 crystals had formed in
the second stage, the centrifuge, dryer, and solids hand-
ling equipment were placed in service.
Within a few minutes the SO- removal efficiency was typi-
cally 70-80 percent. Additional information on S02 con-
centration and percent SC^ removal during several start-
ups is included in Appendix E.
5.3.2 Shut-Downs
Prior to stopping gas flow to the scrubber, SOj removal
efficiencies were observed between 70-80 percent. Table
5-4 shows typical shutdown data. More detailed informa-
tion is presented in Appendix E.
5.3.3 Malfunctions
Table 5-5 summarizes the overall effect of several major
transient conditions. Generally, if equipment failure
caused shutdown of major components such as the centri-
fuge, or required major changes in liquid or gas flows,
then SO- removal was significantly reduced.
Generally, many of the malfunctions, and the leaks dis-
cussed in the following Section, were attributable to the
delivery of off-specification pipe and fittings during
construction, and to the use of off-specification nuts,
bolts, hanger rods, and nozzles. In addition, in some
cases, stainless steel was of an improper grade, and
rubber linings were too thin and poorly bonded.
-42-
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TABLE 5-4. PERCENT S02 REMOVAL AT SHUTDOWN.
Boiler
Load
Date Time (MW)
11/11/74 0145
0200
0215
0230
0245
11/16/74 2045
2100
2115
2135
i 2145
*>.
CJ
' 0800 140
12/23/74 0900 169
0930
1900 188
1915
11/12/75 1930
1945
2000 185
0730
0745
11/24/75 0800 147
0815
0830
0845
Scrubber Ap
2nd Stage
(in. H20 }
1.0
0.0
0.0
8.0
6.2
—
4.9
6.8
5.5
6.4
0.0
Inlet
Scrubber SO 2
pH (ppm)
6.0
1175
5.6 1200
7.4 1000
1000
7.0 880
7.2 860
— —
7.1
920
900
7.0
900
7.3 900
850
Outlet S02 Removal
S02 Efficiency
(ppm) U)
220
250
1200
210
210
1000
160
160
—
185
150
OFF SCALE
190
190
850
78.0
78.7
0.0
79.0
79.0
0.0
81.8
81.4
0.0
80.2
83.3
78.9
78.9
0.0
-------
TABLE 5-5. SUMUIRY OF MAJOR TRANSIENT CONDITIONS
Condition
Centrifuge Repair - Cover
leak erosion of carbon
steel
Centrifuge Diversion-Main-
tenance procedure - wash
out the chute
Centrifuge Diversion -
Clogged hopper-wet centrifuge
cake, possibly due to im-
proper weir height
1st Stage Outage - Leak - 1st
Stage recycle lines. Breaks
in rubber lining exposed
carbon steel pipe to low pH/
high abrasive content liquid
of 1st Stage
2nd Stage Outage - Leak in
discharge header-abrasive
action of the solids laden
slurry
2nd Stage outage-Repair re-
cycle header-20" pipe very
thin due to abrasive action*
holes easily formed
2nd Std<,e Outage
Time of
Transient
Condition
11/15
1000-1500
0430-0515
1/14
0100-0145
12/28
1200-1250
12/7
1300-1400
12/16
1000-1200
12/19
1900-2000
8/26
Transient Previous* Transient
Previous* Transient Previous* Condition % SO? Condition
2nd Stage Condition SO2 Out- SO 2 Outlet Removal * SO?
Ap Ap let(ppm) (ppm) Eff. Removal Eff
8.0 4.1 125 175 85.6 75.9
NA NA 160 160 84.0 84.3
NA NA SO 70 90.9 91.9
9.3 3.0 169 230 80.9 74.2
6.2 0.0 168 683 82.2 23.1
8.4 NA 206 300 82.1 75. 0
3.4 0.8 302 1075 73.2 4.4
Slurry feed
flow rate
had to be
reduced and
scrubber
init could
not handle
design gas
flow. Un
treated por-
tion was by
passed to
stack
Scrubber
unit could
not handle
design flow.
Untreated
portion was
bypassed to
stack
* Refers to steady-state conditions in existence prior to the transient condition.
-------
TABLE 5-5. SUMMARY OF MAJOR TRANSIENT CONDITIONS (COMT) .
U1
I
Condition
Boiler load was reduced-
Wet coal-high surface
moisture reduced pulver-
ized mill outlet temper-
atures to below the ISOop
minimum needed to maintain
an adequate drying cake.
Rising Boiler Load -
Partial alleviation of
wet coal problem
Coal feed problem required
reduced boiler load - Wet
coal - agglomeration of
coal particles before the
pulverizer
Tine of
Transient
Condition
1500-0800
12/8-12/9
0900-2400
12/9
2200-2000
12/20-12/21
Transient Previous *
Previous* Transient Previous* Condition % SOj
2nd 'Stage Condition SC>2 Out- SC>2 Outlet Removal
Ap Ap let(ppm) (pptn) Ef f .
8.5 4.1 143 273 85.4
4.1 5.4 273 207 75.3
6.2 3.6 232 232 81.7
Transient
Condition
« SO,
Removal Eff
75.3
77.6
78.2
Gas flow
through the
scrubber was
reduced and
SO 2 emissions
were used
under the
period .
Refers to steady-state conditions in existence prior to the transient condition.
-------
The scrubber's absorption efficiency was not unusually
sensitive to gas flow because the venturi design provided
greater than 70 percent of S02 removal even though Ap
was reduced by 50 percent and gas flow was 70 percent of
the normal rate.
5.3.4 Leaks
Table 5-6 details the frequency with which individual
leaks occurred. Apparently there were twice as many
leaks causing shutdown in the first stage of the scrubber
as in the second stage. The rubber-lined pipes in the
first stage sustained more mechanical damage because
they were subjected to extraneous material (such as
pieces of weld), which might have been carried in
with the flue gas. In addition, extensive corrosion
and erosion were noted from tests performed. Both
chemical and visual observations to this affect were
performed.
5.3.5 Centrifuge Outages
Approximately 1.6 percent of the total recycle of the
second stage was taken from the discharge of the recycle
pumps to the centrifuge. The centrifuge normally re-
moved 50 percent of the solids in this liquid stream.
During the course of the scrubber study, the centrifuge
had to be diverted numerous times because of clogging
or leaks that developed in its cover. Consequently, no
solids were removed during these periods.
-46-
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TABLE 5-6.
LEAKS NOV., DEC. '74; JAN., AUG. '75
Affected Component
First stage bleed line
First stage recycle lines
First stage headers
"A" 1st stage pump
Reducer, Nozzle lines, and pump
Second stage bleed lines
Second stage recycle line
Second stage discharge headers
Second stage drain connection
"B" discharge pump
Centrifuge Cover
Occurrences
7
9
6
2
4
1
2
5
1
1
9
Number
Inducing
Shutdown
3
4
1
2
1
1
1
1
1
1
Duration
of
Outage
150 hrs.
153*
41 hrs.
h hr.
66 hrs.
28 hrs.
2J$ hrs.
81 hrs.
2 hrs.
* This excludes a 14 day outage begun August 27, 1975 to replace
the lines.
-47-
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The effect of a typical centrifuge malfunction requiring
shutdown for repair is summarized below:
TABLE 5-7. CENTRIFUGE REPAIR
Condition
Second Stage
AP PH
S02 Outlet
Concentration
(ppm) .
SO-, Removal
Efficiency
Steady-S4:ate
Condition Before
the Centrifuge
Repair
(0400-0900,11/15)
Centrifuge Repair
(1000-1500,11/15)
8.0
4.1
7.5
7.0
125
275
85.6
75.9
Centrifuge shutdown occurred at 0940. To prevent build-
up of excess solids, gas flow to the unit was reduced at
1000. It was further reduced at 1030 when no progress
was made on the repair. The second stageAp had been
8.0 inches of water. As a result of the reduced gas
flow and Ap of 4 inches, S02 removal efficiency dropped
from 85.6% to 75.0%. It eventually bottomed at 73.8%
removal, but because of continued reduced gas flow, it
did not stabilize until 1500 hours when the removal
efficiency averaged 78.9%.
-48-
-------
Increased liquid/gas ratio somewhat off-set reduced gas
velocity through venturi yielding a somewhat lower S02
removal efficiency during the repair period. The lower
pre-repair levels of S02 outlet emission were reached a
few hours later. Lower gas flows were continued beyond
the return of the centrifuge to operation so a reduction
in the accumulated solids might be effected. Excessive
solids build-up in the system placed undue strain on
pumps and increased erosion. When a problem with the
centrifuge required a diversion, gas flow to the unit
was reduced before and during the Outage to reduce solids
build-up.
MgO slurry feed was reduced and the lessened gas flow
continued until accumulated solids had been separated
as shown below:
TABLE 5-8. CENTRIFUGE PERFORMANCE
Time
0800
1200
1600
Second Stage
Bleed (% Solids)
6.9
8.25
3.96
Mother Liquor
(% Solids)
1.16
3.99
1.33
The result of the 2-hour and 40 minute outage was a 5*s
hour period of higher than steady-state emissions.
Although stability was attained at the end of this time
period, emissions still had to fall to attain prior
steady-state levels. It is concluded that continuous
reliable centrifuge separation of solids is important
to effective scrubber operation.
-49-
-------
5.3.6 First Stage Outages
A leak of the first stage recycle lines on December 7,
1974 necessitated a complete first stage shutdown. The
first stage was down for 50 minutes, from 1200 to 1250
hours. The effect is summarized in Table 5-9.
TABLE 5-9. FIRST STAGE OUTAGE
Comparison of Parameters
Second Stage S02 Outlet % SO- Removal
Condition A P pH (ppm) Efficiency
Steady-State Period
Prior to Outage
(0100-1000,12/7) 9.3 7.1 169 80.9
First Stage Outage
(1200-1250,12/7) 3.0 7.5 230 74.2
Gas flow to the FGD unit was reduced and efficiency of
SOo removal was reduced. Additional data are presented
in Appendix E.
5o3.7 Second Stage Outages
December 16, 1974 the second stage was shutdown at
approximately 1255 to weld a leak in the discharge
header. As shown in Table 5-10, gas flow to the scrubber
was reduced and the second stage Ap, which had been 6.4
at 1200, dropped to zero. Efficiency decreased from 83
percent at 1200 to 23 percent at 1322, and stayed in the
low 20's until start-up at 1510. This Table compares
the parameters from the steady-state period prior to the
outage with those of the transient condition.
-50-
-------
TABLE 5-10. SECOND STAGE OUTAGE
Condition Second Stage SOj Outlet % SO- Removal
AP PH Concentration Efficiency
(ppm)
Steady-State
Period Before
Outage (0500-
1200, 12/16) 6.2 7.2 168 82.2
Second Stage
Outage (1300-
1400, 12/16) 0.0 8.0 683 23.1
This is typical of the efficiency reduction associated with
a second stage outage. Two other such outages occurred,
and detailed data are presented in Appendix F.
-51-
-------
-52-
-------
6.0 ENGINEERING EVALUATION
Three primary goals can be outlined for the Magnesia FGD demon-
stration unit. The first goal was to construct and operate the
system according to design specifications, for extended periods of
time. The second goal was to study the sub-systems of the process
and optimize their performance in order to optimize the over-all
system performance. The third goal was to vary the flue gas com-
position and flow rate to the system and observe the overall
system performance. The following engineering evaluation of the
process is divided into these three sections. The sections dis-
cuss (1) the operability of the process as it was designed,
(2) the optimization efforts undertaken, and (3) the over-all
performance of the system.
6.1 Operability
The operability of the system is discussed separately
for the first and second scrubber stages along with their
individual sub-systems. These sections discuss the mal-
functions, repairs, and maintenance performed during the
test program. Appendix F lists each malfunction and the
type of maintenance performed in chronological order.
These data were compiled from the Chemico Operator's Log
and from the Weekly Technical Reports prepared by Mr.
Roland Glenn. The August 1975 listings in Appendix F are
solely from Mr. Glenn's reports as no scrubber operator's
log was available.
6.1.1 Scrubber System First Stage
Throughout the scrubber testing program, the system
operation was hampered by malfunctions. A majority of
-53-
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these malfunctions occurred in the first scrubbing stage
due to leaks in the pipes, valve liners, and headers. The
areas most vulnerable to leaks were areas where the flue
gas changed direction within the scrubber or where rapid
slurry velocity increases occurred in piping such as at
elbows, reducers, and orifice plates. Rubber liners in
the pipes and valves were torn and gouged by stray pieces
of metal in the system. These breaks in the liner exposed
the steel pipe to the highly corrosive liquid of the first
stage. Table 6-1 is a compilation of the leaks encountered
in the first and second stage during the periods of Novem-
ber and December, 1974, and January and August, 1975.
On January 18, 1975, after an inspection of the inside
of the first stage vessel, it was reported that six of
the ten tangential spray nozzles were missing. The
probable cause of these stainless steel nozzle failures
was the high concentrations of chlorides, low pH of the
recycle slurry, and off-specification stainless steel.
Chloride from the combustion of the coal in the boiler
aided in the corrosion by pitting and etching the steel,
exposing surface area to sulfuric acid attack. The pit-
ting was more prevalent on the outside of the nozzle
where acid mist had settled. The use of acid resistant
coatings, rubber or plastic pipes and nozzles in this
location should be considered.
Available data indicate that leaks adversely affected
scrubber efficiency.when the repair undertaken.required
alterations in scrubber operating parameters. A case in
point was provided by the data of December 7, 1974 when
a leak of the first stage discharge header caused the shut-
down of the entire first stage.
-54-
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TABLE 6-1. LEAKS OF THE SCRUBBER SYSTEM
Nov.,Dec.'74; Jan.,Aug.'75
Scrubber Component
Affected
Occurrences
Number
Inducing
Shutdown
Emission Control
Time Lost to
Outages (Approx.)
First Stage bleed line
First Stage recycle lines
First Stage discharge
headers
First Stage recycle
pumps
First Stage piping
7
9
3
4
150 hrs.
489 hrs.*
41 hrs.
% hr.
reducers and nozzles
Second Stage bleed lines
Second Stage recycle line
Second Stage discharge
headers
Second Stage drain
connection
Second Stage recycle
pumps
Centrifuge cover
4
1
2
5
1
1
9
1
1
1
1
1
1
66 hrs.
28 hrs.
2*s hrs.
81 hrs.
2 hrs.
* This includes a 14 day outage begun August 27, 1975 to replace
the lines.
-55-
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On this occasion, the first stage was down for 50 minutes,
from 1200 to 1250 hours. The short duration permitted
but one set of wet test readings for the outage which
appear in Table 6-2. Also included are the average
parameters for the steady-state period immediately before.
The drop in efficiency induced by the first stage shut-
down was approximately 7 percent. S(>2 outlet concentra-
tions increased by 36 percent. Scrubber operators re-
duced inlet flows during the outage and the second stage
pressure drop decreased. This, in turn, contributed to
reduced performance. The pH was also affected by the
lower gas flows. In this case it was a combination of
lower flows and insufficient reduction in the MgO slurry
feed rate that led to a higher pH reading.
Inspection of the demister in the first stage indicated
TABLE 6-2. FIRST STAGE OUTAGE
December 7, 1974
Condition
Inlet
Plow
ACFM*
Comparison of Parameters
% so2
Second Stage S02 Outlet Removal
Ap pH (ppm) Efficiency
Steady-State
Period Prior
to Outage
(0100-1000,12/7) 230,000 9.3 7.1 169 80.9
First Stage
Outage
(1200-125D,12/7) 140,800 3.0 7.5 230 74.2
* At the inlet to the first scrubber stage.
that there was no problem with solids deposit formation.
The principal problem with the demisters appeared to be
from physical abuse from being walked on during in-
spections. There was no apparent reduction, however, in
the performance of this equipment.
-56-
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6.1.2 Solids Removal Section for the First Stage
Generally, there were few problems in the operation of
the solids removal section of the first scrubber stage.
This can be attributed to two operating conditions that
existed during the test period. The first was the flue
gas which came directly from the electrostatic precipi-
tator the majority of the time. As a result there was not
a very heavy load placed upon the solids removal equipment.
The second condition that existed were dual particle
removal systems which allowed each thickener to operate
independently of the other. Consequently, there was only
one instance where the solids removal equipment forced a
shutdown of the scrubber system. This occurred on Janu-
ary 19, 1975 and was the result of a restriction in the
first stage bleed line.
The thickener overflow and underflow were not sampled
on a routine basis until August 1975. During August, the
longest sustained operating period was 85.5 hours. Since
complete test data are lacking, nothing more can be said
about the operability of this section other than to note
the few failures which occurred in the list of scrubber
malfunctions in Appendix F.
6.1.3 Scrubber System Second Stage
Malfunctions in the absorber section of the second stage
were not as numerous as those in the first stage where the
pH was very low. Leaks in the second stage recirculation
piping were caused by abrasion, where the solids in the
slurry eroded and finally destroyed the piping. From
thickness measurements made by Chemico personnel with an
ultrasonic thickness measurement instrument on the second
stage lines, the pipes showed excessive erosion on sur-
faces where maximum abrasion would be expected. These
areas were primarily the elbows, reducers, and places
where a change in flow direction occurred. The MgO
slurry contained up to ten percent solids under normal
operating conditions. This accounts for the abrasiveness
-57-
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of the slurry, especially on unlined steel piping.
Decreases in liquid velocities slowed this wear, but
installing abrasion resistant rubber liners would have
been more desirable.
There were three second stage outages during the scrubber
study: December 16, 1974, December 19, 1974, and August
26, 1975. On December 16, 1974 the second stage was shut
down at approximately 1255 to weld a leak in the discharge
header. (The first stage was still operational). Scrubber
inlet gas flow was reduced and second stage Ap, which had
been 6.4" H20 at 1200, dropped to zero. Efficiency de-
creased from 83 percent at 1322, and stayed in the low
20's range until startup at 1510. Table 6-3 compares
the parameters from the steady-state period prior to
the outage with those of the transient condition itself.
The steady-state period was from 0500 to 1200 hours on
12/16.
During this outage the S02 removal efficiency remained
at approximately 20 percent for an hour and 45 minutes
after the second stage was off-line. Apparently, the
MgO slurry remaining in the absorber without being cir-
culated absorbed a small amount of S02 until the surface
became saturated. Normally, the first stage removed be-
tween 5-10 percent of the S02 in the flue gas. This was
measured when the second stage was not only inoperable
but empty as well.
-58-
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TABLE 6-3. SECOND STAGE OUTAGE
December 16, 1974
Condition ACFM*
Second Stage
AP PH
S02 Outlet
Concentra-
tion (ppm)
% so2
Removal
Efficiency
Steady-State
Period Before
Outage (0500-
1200,12/16) 146,000 6.2 7.2 168 82.2
Second Stage
Outage (1300-
1400,12/16) 74,800 0 8 683 23.1
* At the inlet to the first scrubber stage.
6.1.4 MgO Slaking and Recycle
The MgO slaking equipment used in preparing the MgO
slurry operated relatively trouble free. The MgO belt
experienced problems with slippage, but these were re-
medied by adjustments. The steam line to the MgO tank
clogged once and the controller had one malfunction, but
repairs were made without a shutdown. On August 11, 1975,
a crack developed in the steam control valve. During the
period when the steam line was not in use, a higher than
normal amount of unreacted MgO was found in the second
stage bleed. When the steam line was put back into use,
the amount of unreacted MgO returned to normal. Further
discussion of MgO slaking is covered in Section 6.2.2
where its effect on system optimization is illustrated.
The two rubber lined pumps (one operating and one stand-
by) used for MgO slurry transfer and recycle of the second
stage slurry normally operated reliably. However, with
one pump on the line it was not possible to maintain full
design gas flow through the unit. In order to provide
sufficient slurry at design gas flows and SO^ loadings it
was necessary to operate both pumps together.
-59-
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Leaks in the pumps were generally remedied by repacking
or adjusting the seals. The main problem experienced by
the pump inlet and outlet lines was clogging because of
an accumulation of MgO. This may be remedied by being
able to isolate the individual pumps and lines when they
are not in service. They could then be cleared through
a series of wash-out valves. The cleaning of these pumps
and lines could be part of a routine maintenance schedule.
6.1.5 Solids Removal Section for the Second Stage
Centrifuge cover leaks and clogging of the centrifuge chute
were the major problems with this equipment throughout
the test program. The leaks in the cover were probably
caused by the abrasive material in the centrifuge feed
water which wore away the carbon steel. The centrifuge
chute required almost continual attention at times, de-
pending on the consistency of the centrifuge cake. On
days when the cake was wet or sticky, the chute would re-
quire periodic cleaning during each shift in order to
prevent clogging. The angle of the chute was changed once
during the program and the vibrators were adjusted for
continual operation but these changes had little effect
on the clogging problem. As the test program progressed,
The operators started to wash the chute on a regular basis
during their shift to prevent this problem. Using a dif-
ferent configuration or type of equipment may eliminate
these problems in future designs.
Approximately 1.5 percent of the total recycle of the se-
cond stage was taken from the discharge of the recycle
pumps to the centrifuge. The centrifuge normally re-
moved 50 percent of the solids in this liquid stream.
During the course of the scrubber study, the flow to the
centrifuge had to be diverted numerous times due to clog-
ging of the centrifuge chute at higher gas flow and SO?
loading conditions. To initiate the assessment of the
effects of these diversions, data taken during the centri-
-60-
-------
fuge repair on 11/15 were plotted in Figure 6-1 when the
centrifuge was out of service for about 2 hours and 40
minutes. The centrifuge shutdown occurred at 0940. To
prevent build-up of excess solids, the scrubber operators
reduced the gas flow to the unit at 1000. It was further
reduced at 1030 when no progress was made on the repair.
The accompanying data sheet (Table 6-4) displays the
second stage Ap and inlet gas flow experienced during
this outage. As a result of the operator action, SC>2 out-
let levels jumped from 120 ppm at 0900 to 250 ppm by 1000,
for a rise of over 100 percent. They eventually peaked
at 340 ppm, but because of continued reduced gas flow,
they did not stabilize until 1500. The lower pre-repair
levels of SC>2 outlet emissions were reached several hours
later.
Reduced gas flows were continued beyond the return of
the centrifuge to operation so that a reduction in the
solids that had accumulated might be affected. Excessive
solids build-up on the system placed an undue strain on
the pumps and exposed pipes to erosion. When a problem
with the centrifuge necessitated diversion, operators
attempted to circumvent the situation by first reducing
the flow of gas to the unit before and during the outage
to prevent solids build-up, and then by continuing this
reduced gas flow afterwards to work down the accumulated
solids. Along with the reduction in flow, the operators
decreased the MgO slurry feed.
The centrifuge outage caused a reduction in S02 removal
efficiency because of the need to reduce the gas flow as
part of the remedial action. Thus the two hour and 40
minute outage also caused a substantial build-up of
solids in the system, especially in the mother liquor,
which normally received centrate directly from the cen-
trifuge. This is illustrated in Table 6-5.
-61-
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I
0\
ro
100
NOFM&L GEERKPION
50
07 08 09 10
11 12
13
14
15 16
17 18 19 20
•ELMS OF DRY
REM3V&L EFFIdQ^CT DUREN3 CBUKEFUGE CX715VGE (11/15/74)
FIGUFE 6-1
-------
TABLE 6-4. BOILER/SCRUBBER DATA (NOV. 15, 1974)
Time Boiler Load
(MW)
0700
0800 169
0900
0930
; Outage
us
Cn
S
•H
•P
c
0)
u
'0945
1000 180
1015
1030
1045
1100
1115
1130
1145
1200 178
1215
1230
1245
^1300
1400 178
1500
1600 173
1700
1800 174
1900
2000 178
Scrubber A p Slurry
(2nd Stage) pH
7.4
8.0 7.4
7.4
5.8 6.4
7.3
3.0 7.1
7.3
3.0 7.0
7.1
5.2 7.1
7.0
5.2 7.0
7.2
7.0 6.9
S02 (ppm)
inlet/outlet
900/125
900/125
780/176
-
780/100
1150/250
1150/250
1450/340
1300/340
1300/340
1200/270
1100/275
1100/265
-
1050/210
1050/240
1050/270
900/190
900/190
900/180
900/170
800/160
800/160
SOj Removal
Efficiency (%)
86.1
86.1
77.1
-
87.2
78.3
78.3
76.6
73.8
73.8
77.5
75.0
75.9
-
80.0
77.1
74.3
78.9
78.9
80.0
81.1
80.0
80.0
-63-
-------
TABLE 6-5. PERCENT SOLIDS
Time
0800
1200
1600
Second Stage Bleed (%)
6.9
8.25
3.96
Mother Liquor (%)
1.16
3.99
1.13
The increase in solids measured in the mother liquor from
0800, which was before the centrifuge diversion, to 1200,
was 240 percent. By 1600 hours that afternoon, or by 3%
hours after the centrifuge was back on line, the solids
had been decreased to its previous level. In the case of
the second stage bleed, the increase at 1200 was not quite
as dramatic, but the solids were reduced by 50 percent by
1600.
Analysis of these results is somewhat hampered by the time
lag between test measurements. If it had been possible
to follow more closely the rapidity of solids build-up
during the centrifuge outage, it might have been feasible
to extrapolate relationships between duration of outage,
extent of solids build-up, and minimum time necessary to
work down accumulated solids. The four hour readings did
not provide any continuous assessment.
The final result of the two hours and 40 minute centri-
fuge repair on 11/15, then, was a five and one-half hour
period of higher than steady-state emissions. Although
stability was attained at the end of the repair outage,
the emission level took several more hours to return to
thr prior steady-state concentration. This effect is
shown in Table 6-6.
-64-
-------
TABLE 6-6. CENTRIFUGE REPAIR
Average Parameters
Condition
Second Stage
Ap pH
S02 Outlet
Concentration
(ppm)
% so2
Removal
Efficiency
Steady-State
Condition Before
the centrifuge
repair (0400-
0900, 11/15) 8.0 7.5 125 85.6
Centrifuge
Repair (1000-
1500, 11/15) 4.1 7.0 275 75.9
Because of the centrifuge repair, S02 removal efficiency
fell almost 10 percent, to 75.9 percent. Correspondingly,
S02 outlet concentrations increased by 120 percent. The
large drop in second stage Ap contributed substantially
to the efficiency decrease. It should be noted, however,
that second stage pH dropped from 7.5 to 7.0. This was
due to a cutback in MgO slurry feed in order to curtail
the accumulation of additional solids.
It is apparent that its capacity as a solid extractor
makes the centrifuge important for effective scrubber
operation. The exact time period the scrubber can operate
without the centrifuge was not discernible from the data
of 11/15/74.
Other malfunctions that occurred in the solids handling
equipment were due primarily to centrifuge cake con-
sistencies which interfered with the dryer, the screw
conveyor and the bucket elevator operation. The dryer
would clog when fed exceptionally wet cake; however,
this problem would normally clear up if the centrifuge
flow was diverted for a short time. On one occasion
the scrubber was shut down because the dryer became so
clogged it had to be cleared manually.
-65-
-------
The bucket elevator operations were not always reliable
during the project. An extremely wet or dry dryer pro-
duct would cause the elevator to become ineffective.
A wet product would overload the elevator and a very dry
product would be dusty and difficult to handle. Buckets
were changed once during the program, but became dis-
torted and bent after a short time.
One final malfunction that occurred in the solids handling
equipment concerned the dryer ID fan belts which burned
out on November 12, 1974. When the belts were replaced,
the fan would not start because of the water accumulated
in the fan housing. After this incident the draining of
this housing was performed regularly as a maintenance
function. The water condensed and accumulated in this area
whenever the dryer off gas temperature was below 212°F.
6.1.6 Process Control
The process control of the scrubber system was relatively
simple and thus created little problem in keeping the
system functioning. The liquid flow rates through the
scrubber were constant and independent of gas load. The
MgO additive feed rate was varied to maintain the slurry
pH at a preset point, about 7. The main problem in the
control room was with the pH meter which measured the pH
at the discharge of the second stage re-circulation pump.
During the test program the pot for the meter developed
leaks and had to be patched. In addition, the meter be-
came plugged at times with crystals and had to be manually
cleaned.
Other control equipment that required maintenance included
the S02 analyzer probe which was replaced because it was
badly eroded. Some of the flow rotometers froze and
burst. These were replaced or bypassed with spool pieces,
when replacements were not available. The MgO weigh feeder
was also found to be inaccurate and had to be recalibrated.
-66-
-------
Control dampers were installed as indicated in Figure 3-2
(Section 3 - Process Description) to regulate the amount
of gas going through the scrubber. Throughout the test
period of October, 1974 to September, 1975, the dampers
were frozen in position. This left the ID fan after the
scrubber as the only control device for varying the gas
flow rate through the scrubber system.
6.2 Optimization
In order to properly optimize the individual components
within the process, the system should have been capable
of operating at steady-state conditions for extended
periods of time. As can be seen from the previous section
on operability, steady-state conditions were not attain-
able for very long periods during the study. The system
was operated for a maximum duration of 120 hours before
a shutdown was required due to equipment malfunctions.
However, several attempts were made throughout the study
to try and optimize various components within the system.
Discussion of the optimization efforts of the FGD process
centers on the second stage of the system. Except for
problems with materials of construction, the first stage
of the scrubber performed very well during the testing
program. As a result no efforts were made to optimize
the components of the first stage.
6.2.1 Second Stage Absorber
To provide a better assessment of the influence of certain
operating parameters, experiments were conducted at
Dickerson modifying selected parameters and recording the
results. The first operating parameter to be changed was
the re-circulated liquid flow rate to the tangential
sprays and cones of the second stage. These experiments
were conducted on the 14th and 17th of December, 1974.
Data collected for the variation of liquid flow rate
appear in Tables 6-7 and 6-8.
-67-
-------
TABLE 6-7. BOILER/SCRUBBER DATA
I
CTi
00
I
Date: 14 December 74 Time Span: 1400-1500 Test Condition:
Boiler ScrubberA Flue Gas Inlet
Load
Time (MW)
1400 146
1415
1430
1500
2nd Stage Flow* Scrubber S02
(in.H20) (ACFM) L/G pH (ppm)
6.2 159,700 31.9 6.0 1150
6.4 159,700 31.9 6.9 1140
6.4 159,700 31.9 6.9 1140
6.0 159,700 36.9 7.0 1190
Variance of Liquid Flow Rate
Outlet SO^ Removal 2nd Staqe
SO2 Efficiency
(ppm) %
205 82.2
200 82.5
200 82.5
195 83.6
Liquid Fli
(gpm)
5100
5100
5100
5900
* At the inlet to the first scrubber stage.
-------
TABLE 6-8. BOILER/SCRUBBER DATA
I
CTi
Date:
Time
0900
0950
1000
1035
1100
1130
1150
1200
1225
1245
1300
1320
1400
17 December 74 Time Span: 0900-1400
Boiler
Load
(MW)
151
162
174
182
182
182
ScrubberA
2nd Stage
(in. H?O)
3.7
8.2
8.2
8.0
8.7
7.4
6.2
6.0
6.6
8.3
8.5
9.5
9.7
Flue Gas
Flow
(ACFM) *
130,600
159,700
159,700
140,800
159,700
165,900
165,900
180,200
180,200
197,600
196,600
173,100
180,200
L/G
42.0
36.9
36.3
52.5
42.6
31.3
24.1
22.8
27.7
25.3
25.3
33.5
32.2
Test Condition:
Scrubber
PH
7.2
7.1
7.1
7.0
7.0
7.0
7.0
7.1
7.2
7.3
7.1
7.2
Inlet
SO2
(ppm)
790
1050
1050
1020
950
900
850
960
880
810
810
805
790
Experiments changing the liquii
flow rate in the scrubber 2nd
stage.
Outlet
S02
(ppm)
165
170
170
135
135
170
195
180
180
120
135
110
110
SO Removal
Efficiency
%
79.1
83.8
83.8
86.8
85.8
81.1
77.1
81.3
79.5
85.2
83.3
86.3
86.1
Liquid Flow
Rate
(gpm)
5500
5900
5800
7400
6800
5200
4000
4100
5000
5000
5000
5800
5800
* At the inlet to the first scrubber stage.
-------
The experiment conducted on December 14 was run under
normal scrubber operating conditions. As can be noted in
Table 6-7, a liquid to gas ratio (L/G) of 31.9 was main-
tained until the last point where it increased to 36.9.
The Chemico scrubber design specified an L/G ratio in
units of gallons/(1000 ft3) at 117°F as 20 for the
first stage and 40 for the second. It is apparent that
the second stage venturi was operated below the design
specifications during this experiment. However, as the
L/G ratio approached 40, an increase in the scrubber
efficiency was observed.
In order to further evaluate the effect of the L/G ratio
and determine optimum value, further studies were conduc-
ted on December 17, 1974. The difficulty in interpreting
these results lies in the fact that the Ap across the
scrubber second stage was not generally held constant.
In order to better depict the flows and efficiencies of
the 17th, Figure 6-2 is presented. Figure 6-2 shows how
the S02 removal efficiencies followed the re-circulating
flow variations produced during the experiment. As the
liquid flow rate increased so did the SO2 removal efficiency
By isolating the four readings in Table 6-7 from 1035 to
1150 the interaction of re-circulating flow and S02 re-
moval efficiency at constant pH can be studied. As is
shown during this period in Table 6-9, the pH of the ab-
sorber remained constant at 7.0. The re-circulation rate,
however, was steadily decreased from the 7000 gpm level
at 1035 to the 4000 gpm mark at 1150, the result was a
drop in efficiency of almost 10 percent. The second A P
also dropped reflecting the fall in the re-circulaion rate.
-70-
-------
Missing
Data Points
0900
1000
1100
1200
1300
1400
LIQUID FLOW RATE VARIATIONS
12/17/74
FIGURE 6-2
-71-
-------
TABLE 6-9.
LIQUID FLOW RATE CHANGES
December 17, 1974
Time
1035
1100
1130
1150
7
7
7
7
pH
.0
.0
.0
.0
Gas
Flow
(ACFM)
140
159
165
165
,800
,700
,900
,900
Second
StageAp
8
8
7
6
.0
.7
.4
.2
Liquid
Flow
Rate
(gpm)
7400
6800
5200
4000
S02
Removal
Efficiency
L/G
52.
42.
31.
24.
5
6
3
1
86.
85.
81.
77.
%
8
8
1
1
The second operating parameter to be changed on the second
stage was the pressure drop across the throat of the
venturi scrubber. Since the throat of the scrubber is of
a fixed size and the liquid flow rate is normally at a
constant volume, the only other parameter which affects
the pressure drop across the throat is the volume of gas
flowing through the venturi. With this in mind> tests
were conducted on January 27, 1975 to assess the affects
of varying gas flows at a constant re-circulating rate
of 5000 gpm.
Gas flow rates approximately equal to the design specifi-
cations were run through the scrubber for approximately
one hour, and were then maintained at lower levels for
five additional hours. Higher SOj removal efficiencies
were obtained during the operation at high flows. Data
shown on Table 6-10 indicate that with lower gas flows in
the 100,000 ACFM range, the SO2 removal efficiencies were
approximately 80 percent. When the gas flow increased to
290,000 ACFM the efficiency rose to over 90 percent.
The close correlation that exists between flue gas flow
rate, second stage Ap, and the unit's efficiency through-
out this period of high gas flows is illustrated very well
in Figure 6-3. At 0900, when the flue gas flow rate was
above 290,000 ACFM, second stage Ap was 13.0 inches H20
-72-
-------
w
09 ID 1.
HOUR OF DAY
HIGH GAS FLOW
1/27/75
FIGURE 6-3
12
13
14
-73-
-------
TABLE 6-10. BOILER/SCRUBBER DATA (1/27/75)
Time
0600
0700
0800
0900
0915
0930
0945
1000
1015
1030
1045
1100
1115
1130
Boiler Load
(MW)
116
163
176
162
116
138
Scrubber Ap
(2nd Stage)
0.7
1.8
0.2
13.0
10.8
10.2
Flue Gas
Flow Slurry
(ACFM) pH
169,400 7.4
188,300 7.4
141,200 7.5
291,800 7.5
291,800
291,800
291,800
242,200 7.4
255,000
255,000
255,000
242,200
242,200
222,400
SO2 (ppm)
inlet/outlet
1000/280
1000/280
900/240
900/63
-
900/63
900/50
910/80
900/75
-
900/90
940/105
900/110
—
SOo Removal
Efficiency (%)
72.0
72.0
73.3
93.0
-
93.0
94.4
91.2
91.7
-
90.0
88.8
87.8
—
-------
TABLE 6-10. BOILER/SCRUBBER DATA (1/27/75)(Continued)
Boiler Load Scrubber Ap
Time (MW) (2nd Stage)
1145
1200 174 8.0
1220
1235
, 1250
^_ t
^ 1305 175 7.8
1320
1345
1400 174 8.0
Flue Gas
Flow Slurry
(ACFM) pH
218,100
207,400 7.2
207,400
207,400
200,400
207,400 7.3
207,400
197,600
218,100 7.1
SO2 (ppm)
inlet/outlet
1000/120
1020/130
1000/120
-
1000/120
1020/125
1000/130
-
1020/125
SC>2 Removal
Efficiency (%)
88.0
87.3
88.0
-
88.0
87.7
87.0
-
87.7
-------
and the unit efficiency was a very high 93 percent. How-
ever, once the gas flow was decreased to 242,200 ACFM at
1100, second stage Ap fell to 10.2 inches H-O and the
efficiency dropped to 88 percent.
It would have been valuable if the rapidity of solids
build-up in the absorber could have been monitored when
the gas flow was high. It would have provided some measure
of the requirements to be placed on the centrifuge, and
possibly delineated a constraining factor on continued high
gas flow operation. From the data available it is known
that the solids iji the second stage bleed were 1.39 percent.
Solids levels rose to 7.51 percent at 1200, when the
efficiency was 88 percent. Greater solids formation at
higher efficiencies was observed. It can only be spec-
ulated as to what the solids build-up amounted to at 0930
when efficiency was 93 percent, but if above 10 percent,
it probably placed undue strain on the pumps and pipes.
This possibility would have to be investigated fully in
conjunction with the ability of the centrifuge to work
down the solids before making a final assessment on the
benefit of a high gas flow for this demonstration plant.
The data from the December 17th tests (Table 6-8) also
demonstrated that efficiency rises by increasing gas
flow and maintaining the liquid flow rate constant. The
readings for 1225 and 1245, reproduced below, show the
same liquid flow rates of 5000 gpm, but differing gas
flows. Since the gas flow at 1245 was higher than at
1225, second stage Ap increased, and S02 removal ef-
ficiencies rose by almost 6 percent in 20 minutes.
-76-
-------
TABLE 6-11. TEST RESULTS - DEC. 17, 1974
Flue Gas Second Liquid Flow SO, Removal
Time Flow (ACFM) StageAP Rate (gpm) Efficiency(%)
1225
1245
180,200
197,600
6.6
8.3
5000
5000
79.5
85.2
In concluding the experiment on liquid flow rate changes
(Table 6-8), high gas flows were combined with high
liquid flow rates, and higher efficiencies were the re-
sult. At 0950, a 5900 gpm liquid flow rate and an 8.2
inch H20 A P produced an 83.8 efficiency, whereas at
1320 a 5800 gpm liquid flow rate and a 9.5 inch H2O A?
produced an 86.3 percent efficiency. It was the higher
gas flow rate at 1320 that increased the second stage A P
and produced the greater efficiency.
The third parameter that was changed on the absorber was
the restrictor in the throat of the second stage venturi.
During the boiler shutdown between February and August
1975, several modifications were made to the system, one
of which was the removal of the restrictor in the second
stage venturi throat. This change was made by Chemico
in order to provide data on operation at a reduced pres-
sure drop while maintaining a design gas flow rate.
In order to demonstrate the effect of removing the throat
restriction, Table 6-12 provides data from a test run on
August 26, 1975. It is seen that there is a dramatic de-
crease in the A P for a given flow rate with a correspond-
ind decrease in SC>2 removal efficiency. The data in
Table 6-13 are extracted from Tables 6-8 and 6-12 to demon-
strate this point.
-77-
-------
TABLE 6-12. BOILER/SCRUBBER DATA
oo
I
Date: 26 August
Boiler
f — -a
xjucKa
Time (MW)
0400 176
0415
0500 183
0515
0600 180
0700 176
0710
0715
0716
0717
0718
0719
0720
0730
0800 177
0815
0900 ,176
1000 178
1030
1045
1100 180
1200 184
1230
75 Time Span: 0400-1400
Scrubber A p Flue Gas
Secund St
-------
TABLE 6-12. BOILER/SCRUBBER DATA (CONT.)
Date:
Time
1245
1300
1330
1345
1400
* At
i
10
: 26 August 75 Time Span: 0400-1400 Test Condition: Rapid Velocity Chanc
Boiler Scrubber A p Flue Gas Inlet Outlet
Load Second Stage Flow Scrubber SO2 SO2
(MW) (in.H20) (ACFM)* pH (ppm) (ppm)
173,000 7.1 1200 370
185 173,000 1200 350
198,700 1120 320
198,700 1100 300.
185 3.6 198,700 6.8 1100 . 300
the inlet to the first scrubber stage.
SOo Removal i
Efficiency
69.2
70.8
71.4
72.7
72.7
-------
TABLE 6-13. ALTERATION OF Ap
Date
L2/17/75
8/26/75
Time
1035
1100
Ap
8.0
1.6
Gas (ACFM)
140,800
140,800
SO2 Removal Eff.
86.8
67.2
Without additional details to describe the design of the
venturi, further extrapolations as to the energy required
Ln the form of a pressure drop across the venturi to pre-
dict S02 removal efficiency cannot be made.
6.2.2 MgO Slaking
No deliberate attempts were made to change any of the para-
meters in the MgO slaking operation. The control system
was set up so that the pH of the second stage recycle line
was maintained at approximately 7 throughout the test program.
On August 11, 1975 the malfunction of the steam control
valve on the MgO slurry tank provided the opportunity to
observe the effect of reducing the amount of steam to the
slaking process. A result of this heat reduction was a de-
crease of the efficient usage of MgO. This is clearly illus-
trated in Figure 6-4 which shows the percent of unreacted MgO
appearing in the centrifuge cake during a period of normal
heating, and during a period when the heating system was in-
operable.
The large amount of MgO in the centrifuge cake eventually
created a major problem in the dryer. On August 15, 1975,
the dryer was plugged with a rock-hard material.
Subsequent analysis of this material indicated the existence
of a large concentration of inerts, which were hypothesized
to be oxysulfate. An oxysulfate cement is formed by the re-
action of magnesium oxide which has been produced by the
calcination of a magnesium compound, with a solution of
magnesium sulfate of suitable concentration . Since
-80-
-------
16
g 8
w
W
O<
08 16
1/12/75
MgO SLURRY TANK TEMPERATURE: 155 F
00
08 16
1/13/75
DATE & TIME
00
08 16
1/14/75
i
00
MgO SLURRY TANK TEMPERATURE: 114~F
n
08 16
8/11/75
08 16
8/12/75
UNREACTED MgO IN CENTRIFUGE CAKE AS .A FUNCTION OF TEMPERATURE
FIGURE 6-4
08
-------
a large amount of free water was present during this run
and available MgO was present, the 10-20% concentration
of MgSO. -71^0 in the free water reacted with the available
MgO to form the oxysulfate cement.
As a result of the problems incurred with the breakdown
of the steam control valve and the evaluation of the re-
sultant data collected, it becomes evident that the MgO
slurry tank must be operated at some optimum temperature
from an economical and operational standpoint. The object
in maintaining this temperature is to arrive at an optimum
amount of MgO of sufficient activity in the re-circulation
lines and especially in the centrifuge cake. Since these
observations were made at the end of the testing program,
insufficient time was available to study this problem fur-
ther.
602.3 Solids Removal System
Throughout the operating period of the scrubber system,
there was no control system to regulate the solids con-
centration in the second stage absorber. Samples were
collected, however, at 4-hour intervals to monitor the
percent solids for purposes of analyzing the perfor-
mance of the system.
Upon reviewing the data collected prior to the comple-
tion of the scrubber testing in January, 1975, Chemico
stated that they wished to operate the centrifuge at a
different rotational speed to determine removal effici-
ency at a second separational force. Table 6-14 shows the
data collected on December 6-8, 1974 from operations at a
higher torque, and from August 12-14, 1975 from operations
at lower torque. No definite statements can be made con-
cerning the solids removal efficiency at rates greater
than 24 g's; however, as the separation force decreases
from this point, the efficiency also definitely decreases.
-82-
-------
TABLE 6-14. SOLIDS REMOVAL EFFICIENCY DATA
Data for Dec. 6-8,'74 and Aug. 12-14,'75
00
OJ
Higher Torque Operation
Mother
2nd Bleed Liquor
% Solids Torque % Solids
% E
Lower Torque Operation
Mother
2nd Bleed Liquor
% Solids Torque % Solids
% E
12/6
MidN.
12/7
12/8
9.
7.
7.
8.
11.
13.
10.
10.
11.
9.
10.
14.
10.
11.
11.
11.
12.
11.
07
62
04
32
92
29
36
06
18
34
90
57
89
98
17
88
08
95
58
40
40
50
52
46
46
50
50
40
40
45
44
44
40
44
24
27
8.91
2.72
3.79
3.14
2.75
3.20
5.24
3.92
4.08
3.08
3.70
4.01
5.36
5.49
4.18
4.22
NA
3.68
1.
64.
46.
62.
76.
75.
49.
61.
63.
67.
66.
72.
50.
54.
62.
64.
—
69.
7
3
2
2
9
9
4
0
5
0
1
4
8
2
6
5
2
8/12 3
MidN . 4
3
4
3
6
8/13 7
7
8
7
7
9
8/14 8
19
2
2
3
4
.5
.0
.14
.20
.01
.81
.19
.76
.25
.23
.97
.28
.83
.79
.56
.61
.07
.77
22
26
24
28
32
45
52
43
42
32
36
32
8
OFF
3
1
2
14
2.92
0.39
0.39
NA
0.67
0.88
2.87
1.91
2.23
2.51
2.82
3.35
7.03
3.45
2.29
2.59
3.32
4.39
16.6
90.3
87.6
—
77.7
87.1
60.1
75.4
73.0
65.3
64.6
63.9
20.4
82.6
10.5
0.8
—
8.0
Average
10.76
43
4.20
6.33
26
2.59
-------
A second parameter that is of importance in the operation
of the centrifuge is the amount of magnesium sulfite that
is in the hexa-hydrate form as opposed to the trihydrate
form. The hexa-hydrate form has a large crystalline
structure which allows the centrifuge and dryer to operate
more efficiently. Experimental studies were conducted by
YRC to determine the percent combined H20 in the centrifuge
cake that was of the hexa-hydrate as opposed to the tri-
hydrate form of magnesium sulfite. The test results indi-
cate that at least 80% of the product in the centrifuge
cake was of the form
Observations that were made on a similar magnesium oxide
scrubber at Boston Edison's Mystic Station indicated
that the tri-hydrate form of magnesium sulfite was the
predominant form of the product. To further investigate
this reaction, the U.S. EPA commissioned Radian Corpora-
tion to study the kinetics and equilibrium of the hydrate
formations. The report on this study will soon be pub-
lished.
6.3 Performance
The Dickerson MgO system was capable of removing 90% of
the sulfur dioxide produced when burning coal containing
2% sulfur.
6.3.L SO2 Removal Efficiency
From the beginning of full scale testing on October 15,
1974 to the completion of testing on January 27, 1975
the scrubber system was normally able to attain effi-
ciencies of between 78-83%. Maximum efficiencies of 96-
97% were obtained at high flue gas flow rates on short
duration runs of several hours, but difficulties in
running the MgO feed system and solids separation sys-
tem for the second stage at high flow rates necessi-
tated that the system generally be run at 75% of the de-
signed flue gas flow rate.
-84-
-------
During the down period of January 27, 1975 to August 11,
1975, the restrictor plate in the venturi throat was re-
moved to observe the performance at a lower A p. From
August 11, 1975 to September 27, 1975, an average ef-
ficiency of between 70-75% was attained. No attempts
were made to run the system at high gas flow rates due
to the problems with the feed system and the solids sep-
aration system for the second stage.
The parameter that affected the SO- removal efficiency
the most was determined to be the pressure drop across
the venturi throat. This parameter is a measure of energy
usage required to make the system work. In order to reach
efficiencies greater than 90%, a pressure drop of at least
11 inches of H20 was required. This value was achieved
with close to design gas flow rates flowing through the
venturi at an approximate L/G of 20. A second parameter
that was studied was the liquid to gas ratio. It was
found that doubling the volume of recirculating slurry at
a pH of 7.0 increased the SO- removal efficiency by only
10 percent at lower gas flow rates; however, an increase
of 10 to 20% in the SO2 removal was incurred by increasing
the pressure drop across the venturi throat with higher
gas flow rates.
6.3.2 Particle Removal Efficiency
The provision to by-pass the ESP and send flue gas with
a heavy concentration of particles to the scrubber worked
very well in demonstrating the ability of the FGD system
to attain a high particle removal efficiency in excess of
99%. One concern that is coupled with this high removal
efficiency is the possible build-up of inert flyash in
the second stage solids. Since the FGD system was not
operated enough to attain a high recycle rate of MgO,
no data were recorded that indicated that there was a
flyash build-up problem. As with all power plant scrubber
-85-
-------
particle removal systems, the problem of the ultimate
disposal of the flyash slurry from the first stage must
be given careful consideration due to its low pH and high
chloride concentration.
6.3,3 Duration of Scrubber Performance
Throughout the full scale testing program time period
of October 18, 1974 to January 27, 1975 and August 11,
1975 to September 27, 1975, the scrubber was operating
approximately 53% of the time. Many of the scrubber
outages were the result of leaks which developed in the
first and second stage recycle systems, and also due to
the lack of MgO raw material make-up. In order for a
system of this size to operate without interruption, at
least twice as much material storage must be available
to counteract the shipment problems which occurred
throughout the project. On-site storage was only 100
tons which at design conditions was about a month's
supply. A second storage problem arose with the dis-
posal of the magnesium sulfite product. A 200 ton stor-
age silo was employed at the Dickerson site which proved
to be inadequate due to the erratic operation of the MgO
regeneration station in Rumford, Rhode Island, which would
certainly not be representative of a commercial unit.
As a result of experiencing these storage problems, it is
apparent that a reliable regeneration facility is neces-
sary to make the MgO FGD process a viable system.
-86-
-------
7.0 CONCLUSIONS
The test program has shown that the S02 removal efficiency of the
MgO venturi scrubber is principally dependent upon both the pressure
drop, and the liquid to gas ratio of the second stage venturi ab-
sorber. Removal efficiencies of over 90 percent were attained with
an 11 inch (H-O) pressure drop.
The particle removal efficiency of the first stage was greater than
99 percent when the flue gas was taken directly to the scrubber from
the boiler, and not pre-conditioned by the ESP.
The overall performance of the scrubbing system was satisfactory,
aside from difficulties experienced with materials and equipment
(which have been documented herein). During transient operation,
operational problems and high emission levels were generally
normalized soon after the upset occurred. Sustained operation
was never experienced, and as a result data obtained are only
representative of those short periods studied.
Availability percentages were rather low but this was only partially
due to the basic scrubber design. The distance and nature of the
MgO recovery operation often caused scrubber shut-downs due to lack
of raw materials. Low availability was also due to:
• Lack of proper recirculation systems.
• Lack of pipe linings.
• Auxiliary equipment problems.
• Lack of sufficient number of operators.
• Boiler shut-downs.
-87-
-------
If these deficiencies were corrected, efficiency and availability
would have been significantly improved.
The aforementioned problems also reduced the time and effort that
should have been spent on experimentation and optimization of the
process. For the most part, work done to test the operation proved
successful. An example of this would be the study of liquid to gas
ratios, and high gas flows. Unfortunately, there were not enough
such investigations to fully characterize and optimize the process.
It is recommended that consideration be given to further testing of
the MgO process in order to better characterize the system under
longer term operation and to demonstrate commercial availability.
-88-
-------
REFERENCES
1. YRC Report 4-8864: Preliminary Report for the Evaluation
of Particulate Emission Control at PEPCO's Dickerson
Station. PEPCO Report dated 10/31/75.
2. Federal Register, Vol. 37, No. 247, Dec. 23, 1971.
-89-
-------
Conversion Factors: British to SI Units
To Convert
From
To
Length
Mass
Voluire
inch (in.)
foot (ft.)
pound (Ib.)
ton
grain
cubic foot
(CF, ft3)
gallon (gal)
meter (m)
meter (m)
kilogram (kg)
kilogram (kg)
kilogram (kg)
cubic meter(m )
cubic meter(m )
Energy
British thermal
unit (Btu) calorie (cal)
Temperature
Fahrenheit(°F) Celsius (°C)
Celsius ( C) Kelvin (K)
multiply by 0.0254
multiply by 0.3048
multiply by 0.4535924
multiply by 907.1847
mulitply by 0.0000648
multiply by 0.02832
multiply by 0.003785
multiply by 251.9958
°C = 5/9 (°F - 32)
K = °C + 273.16
-90-
-------
APPENDIX A
SCRUBBER EQUIPMENT LIST
AND
EQUIPMENT SPECIFICATIONS
-Al-
-------
Scrubber Equipment List
Item Description
MgO Make-Up Tank
Dust Collector-MgO Silo
Thickener
Transfer Tank
Distribution Box
Sump Tank
Mother Liquor Tank
Dust Collector-Dryer
MgO Storage Silo
MgSOs Silo
MgO Feed Pump
First Stage Recycle Pump
Second Stage Recycle Pump
Underflow Pump
Transfer Pump
Sump Pump
Mother Liquor Pump
Induced Draft Fan
MgO Agitator
Mother Liquor Agitator
MgO Weigh Feeder
Dryer Feed Conveyor
Dryer Discharge Conveyor
Dryer Discharge Elevator
MgS03 Weigh Feeder
Two-Stage Venturi Scrubber
Mist Eliminator
Variable Speed Coupling
Centrifuge
Rotary Dryer
Dryer I.D. Fan
Instrument Air Dryer
Code No.
G-101
G-102
G-201 A,B
G-202
G-203
G-204
G-301
G-401
1-101
1-401
J-101 A,B
J-201 A,B
J-202 A,B,C
J-203 A,B,C,D
J-204 A,B
J-205
J-301 A,B
K-201
M-101
M-301
0-101
0-401
0-402
0-403
0-405
R-201
R-202
R-203
R-301
R-401
K-402
V-101
Quantity
1
1
2
1
1
1
1
1
1
1
2
2
3
4
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Motor Horse-
power (HP)
10
350
250
125
30
20
3500
5
3
1
2
2
200
40
100
-A2-
-------
GENERAL SPECIFICATIONS - SG>2 REMOVAL SYSTEM
EQUIPMENT
1. MgO System
MgO Make-Up Tank (G-101)
MgO Storage Silo (1-101)
MgO Feed Pumps and Motors (J-101 A & B)
Agitator (M-101)
One paddle type agitator (Denver, or equal), including enclosed
reducer with coupling, shaft, three 8" deep horizontal paddle
arms 7' diameter and 45 degree angular paddle in tank conical
section, beam type superstructure V-belt drive, drive guard
5 HP, 900 rpm-TEFC motor and motor base. Includes seal and
seal plate to mount on tank cover around the shaft. Paddle
speed 8 rpm, reducer ratio 48 to 1; wetted parts mild steel
construction.
MgO Weighing System (0-101)
One gravimetric feeder which provides a continuous measurement
of weight through a scale; compares the measurement signal with
the set point through suitable control instrumentation, and
actuates a hopper gate to provide a constant feed of material. A
section of the constant speed weight belt is weighed by means of
mechanical levers and a scale beam. Beam deflection is trans-
mitted mechanically via a link connection to a regulator that
adjusts the feed gate. Unit includes self contained belt feeder
mechanical weight control loop, totalizer, totally enclosed pulley
transmissions, and static test weights, capacity 0.5 to 1.5
Standard Tons Per Hour (STPH).
MgO Supply Conveyor (0-102)
One conveyor handling 25 STPH of magnesium oxide with bulk density
of 25 Ibs/cu.ft. from the truck unloading hopper to the silo
feed elevator.
2. Absorption System
1st Stage Recycle Pumps and Motors (J-201 A,B)
2nd Stage Recycle Pumps and Motors (J-202 A,B,C)
I.D. Fan and Motor (K-201)
Scrubber (R-201)
3. Centrifuge System
Mother Liquor Tank (G-301)
Mother Liquor Pumps and Motors (J-301 A,B)
Centrifuge (R-301)
One 36" x 72" carbon steel solid bowl continuous centrifuge,
(Bird or equal), including 200 HP, 460 volt, 3 phase, 60 cycle
-A3-
-------
TEFC motor with high thermal capacity. A main bearing forced
oil circulating system is provided with pump, drive motor, oil
filter, heat exchanger, pressure switch and gauge, and oil
reservoir. An outlet chute is included.
4. Dryer System
MgS03 Silo (1-401)
Rotary Dryer (R-401)
Size of dryer
Shell plate
Feed end head
Number of riding rings
Riding rings
Support rollers
Thrust, roller
Hammers
Feed end chamber
Dryer Dust Collector (G-401)
Description
One rotary dryer, to produce
the anhydrous products MgSOs,
MgSC>4 and MgO as follows:
8'0" diameter x 50'0" long
V
5' - 0" diameter x V plate
2
8'10" diameter x 7" face
20" diameter x 9" face
16" diameter x 2V face
2 sets of 8
Breaching where the feed con-
veyor enters the dryer
One cyclone with scroll outlet for 97% removal, plus rotary
discharge valves. The fines collected by the collector will re-
turn directly to the dryer product conveyor.
Dryer I.p. Fan (K-401)
One induced draft fan, with inlet and outlet flanges, inspec-
tion door, drain, dampler, V-belt drive, drive guard, and 100 HP,
3 phase, 60 cycle, 230/460 volt, 1,800 rpm, TEFC, motor.
Fan Performance Data
Volume
Static Pressure
Speed
Dryer Combustion Chamber
26,500 CFM @ 400 F
8" S.P.
1,800 rpm
One direct fired air heater approximately 6' - 0" O.D. x 18 '-0"
long, etnd designed to operate with the following:
Maximum Heat Release
Inlet Temperature
Combustion Chamber Temp.
Site Elevation
Operating Furnace Pressure
Fuel
Maximum Oil Viscosity
Type Fuel Oil Atomization
Burner Turndown
Insurance Requirements
26.3 10° Btu/hr
70°F
1,600 F
Sea Level
Balanced
No. 2 fuel oil
40 SSU, constant
Air
5:1
F.I.A.
-A4-
-------
Fuel Oil Supply for Combustion Equipment (R-401)
A duplex fuel oil pumping and straining set, designed to meet
the following conditions will be provided to supply fuel oil to
the air heater burner:
Fuel Oil No. 2
Design Capacity 3 gpm
Pump Discharge Pressure 125 psig
Maximum Suction Plus 30 psig
Minus 13" Hg
Electric Service 440 volt, 3 phase, 60 cycle
Dryer Feed Conveyor (0-401)
One 12" diameter x 5'0" long heavy duty ribbon feeder conveyor,
complete with 3 HP drive.
Dryer Discharge Elevator (0-403)
One elevator which elevates 5 STPH of dried magnesium sulfite
with a density of 50 Ibs/cu.ft. discharging from the dryer to
the magnesium sulfite bin.
SCRUBBER INSTRUMENTATION AND CONTROLS
The system has two separate control panels as follows:
1. The scrubber/absorber control panel (SCP) located in the
prefab building south of the mist eliminator vessel.
2. Main control panels (VB and BB) located in the main control
room of the existing powerhouse building.
Scrubber/Absorber System Control Panel
The following controls are located on the control panels located
in the prefab building and their names and functions are des-
cribed.
PDR-1 pressure drop recorder for first stage of scrubber
absorber
FRI, 1,2 first stage recycle liquor flow rate indicator
LIC 1 level indicator - controller for first stage scrubber
LIC 11 level indicator - controller for transfer tank
HIC 10 manual loader for bleed from first stage to dis-
tribution box
WI 28,29 torque indicators on thickener rakes A and B
PDR 3 pressure drop recorder for second stage of scrubber/
absorber vessel
FIC 5 flow indicator - controller, MgO slurry to scrubber
HIC 4 manual loader for bleed from second stage to centri-
fuge
LIC 2 level indicator - controller scrubber 2nd stage
WR 11 torque recorder, centrifuge
LIC 7 level indicator - controller,MgO make up tank
LIC 8 level indicator - controller, mother liquor tank
FR 20 flow recorder, mother liquor to MgO tank
-A5-
-------
TR 8
TIC 8
PIC 12
FR 23
TJR 4
WCIQ 18
TISH 1A,1B
FI 7
PDI 2
PDI 4
FI 6
FI 4
FI 3
AIC 1
AR 2
AI 2
WCIQ 17
TISH 9
II 9A,IJ
ZI - 1A
HS 9
II 10A,B,C
HS 14
HS 15
HS 5
temperature recorder, dryer outlet gas
temperature indicator - controller, dryer outlet gas
pressure indicator - controller, dryer outlet gas
flow recorder, fuel oil flow to dryer
six point temperature recorder:
1. flue gas, dryer exit
2. product discharge, dryer
3. cyclone inlet, dryer
4. spare
5. spare
6. spare
controller, totalizer MgSO-j feeder
temperature indicating switches, 2nd stage scrubber
inlet
flow indicator, make up liquid to 1st stage from
transfer pumps
mist eliminator pressure drop, 1st stage
mist eliminator pressure drop, 2nd stage
flow indicator, centrifuge feed
flow indicator 2nd stage scrubber, upper cone,
recycle loop
flow indicator 2nd stage scrubber, lower cone,
recycle loop
SC>2 inlet/outlet concentration indicator
pH recorder, bleed to centrifuge
pH indicator, bleed to centrifuge
controller totalizer, MgO weigh feeder
temperature indicating switch, dryer combustion
chamber outlet
ammeters, 1st stage scrubber recycle pumps
scrubber cone position indicator
transfer pump selector switch
ammeters, 2nd stage scrubber recycle pumps
mother liquor pumps, selector switch
MgO makeup pumps, selector switch
hand selector switch, recycle pumps, 1st stage
Main Control Panel
The following controls are located in the control room in the
main building. Their names and functions are given belowt
PDA 1 plumb bob position and pressure differential,
1st stage
PAL 20 low pressure alarm ID fan fluid drive
TAH 5 high temperature alarm ID fan drive bearings
TAH 10 high temperature alarm ID fan fluid drive
accessories
XAH 7 alarm, ID fan vibration
IA 8 ID fan motor trip
FALL 2B low low flow, scrubber recycle, first stage
FALL 7B low low flow scrubber makeup, first stage
TAHH 2B high high temperature, gas inlet 2nd stage
ZI IB position indicator, plumb bob
-A6-
-------
HS 12 auto manual station, plumb bob
HS 4 precipitator mode selector switch
HS 17 raise lower switch, plumb bob
TISH 5 alarm annunciator motor, fan and fluid drive bearings
II 7 ammeter, ID fan motor
HS 22 start, stop switch ID fan
PDIC 1 pressure indicator controller, plumb bob, 1st stage
HS 6 hand selector switch, recycle pumps, 2nd stage
HS 16 selector switch, pond water return pump
-A7-
-------
-A8-
-------
APPENDIX B
DATA TABULATION
-Bl-
-------
DATA TABULATION
These tables represent the hourly data obtained during the
testing period. When data are missing, an (NF) or an asterisk
(*) appears. An NF indicates that the instrument used to measure
the parameter was not functioning. The asterisk indicates that
the datum was not obtained, usually for a reason explained in
the footnote, or otherwise unknown.
-B2-
-------
HOURLY DATA
I
W
U)
Inlet
Date Time
1974
11-1 Scrubber
11-2 SiTubbiT
11-3 Scrubber
11 -'I Scrubber
11-5 Scrubber
11-0 Scrubber
U-7 Scrubber
11-8 Scrubber
11-9 Scrubber
11-10 Ol'lS
0220
01(10
03U5
0'1'IS
OS'IS
OO'IS
07 'IS
08 'IS
09 US
10'IS
11US
12US
13US-19US
20US
21U5
22U5
23'IS
11-11 OOUS
01U5
0220
Scrubber
ACFM x 2nd
MW JJ100 ^ P
Down,
Down
Down
Down
Down
Down
Down
Down
Down
178
J78
158
IU8
151
151
ISO
151
101
173
17 U
172
170
100
173
17 'I
108
105
1'|7
1'I7
138
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
*
NF
NF
NF
NF
NF
NF
NF
U.O
'1.8
O.S
0.5
5.5
5.5
'1.9
0.2
0.0
0.2
1.0
1.0
3.5
*
2.0
'1.2
'1.2
5.0
5.0
1.0
0.0
Stage
Nr1
Nr
Nr
0. 3
o.u
o.o
7.3
7.0
7.0
o.s
0.8
0.8
7.1
*
0.9
7.0
0.8
7.0
O.S
0.0
5.0
S02
ppm
Nr
Nr
NC
000
080
7 '10
700
700
1050
Nr^
900
920
970
Nl'3
1050
lO'lO
1020
1000
1000
1000
1200
INI
NOX
ppm
Nr
Nr
Nr
uoo
'100
380
390
390
UOO
MI-
NT
NT
NT
NF
390
too
390
380
380
370
220
,cr
C<>2
. Nr
Nr
NT
11.75
13.5
15.5
15.0
1 S.O
.10.0
NT
.15.3
1'I.S
13.0
Nr
1'l.S
Ib.S
10.5
It. 5
15.0
I'l.O
Nr1'
OUTLET % SOp
02
%
Nr
NT
NF
7.0
0.8
0.0
7.0
0.0
0.8
NT
7.8
7.7
7.3
NT
9.5
9.5
9.0
10.0
9.0
9.2
NT
S02
ppm
NT
150
125
ISO
100
100
150
I'll)
195
NT
I'lO
185
210
NI'
220
220
220
225
220
220
1000
NOX
ppm
NT
300
.350
UOO
UOO
380
UOO
380
UOO
NT
Nr
Nr
Nr
NF
330
300
350
3 tO
3 to
NF
NF
C02
NF
12.2
13.0
12.5
13.5
10.0
15.0
1'I.S
10.5
Nr
10.5
11.0
11.5
Nr
13.0
15.0
15.5
13.9
I'l.O
NF
NF
02
%
Nr
8.5
8.7
7.0
0.8
7.0
7.0
0.8
0.8
NT
>10.0
HO.O
9.5
NF
>10.0
10. 0
9.8
9.8
9.8
NF
NF
Removal
Efficiency
-
-
-
77.3
70.5
78. U
78.0
80.0
Bl.U
-
8U.U
79.9
78. U
-
79.0
78.8
78. U
77.5
78.0
78.0
-
•I pll olpctrodp broken; Start up
2 Watnr In sample lines
3 Wator tn analyzer lines
'' Smibbpr down 0220; Watpr leaks
-------
HOURLY DATA
Date
11-12
11-13
11-14
Aiu.tii_ GUJE uuDcr •*• *'"*-* •*-'•*-
ArFM x 2nd Stage SO2
Time
MM
Scrubbrr
2010
2030
2130
2230
2330
0030
0130
0230
0330
0430
0530
0630
0730
0830
0930
1010
1130
1230
1330
1130
1530
1630
1800
1900
2000
210C1
2200
2300
2400
183
182
183
182
18 "1
181
183
183
183
182
184
185
177
180
180
179
136
173
183
180
181
165
173
176
172
177
176
171
173
1 QOf
Down
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
) 4P
_
G.O
G.O
6.0
6.0
6.0
0.8
1.8
3.0
3.0
3.0
*2
3.0
*
3.0
*
6.5
*
5.0
*
5.2
*
3.0
7.0
*
7.0
*
8.3
*
8.0
.pH
Start
NF*
NF
8.0
*
7.2
*
r>.7
*
7.6
7.6
*
7.6
*
7.5
*
7.0
*
7.1
*
6.9
*
6.9
7.0
*
7.2
*
7.3
*
7.1
ppm
up at
NF
550
725
1100
1200
1250
1300
1100
900
975
900
90(1
850
650
900
925
900
925
f,50
500
NF
1000
1000
900
875
925
900
900
900
NOX
ppm
2010
NF
460
440
440
440
460
450
380
380
380
400
420
420
420
460
460
380
420
400
400
NT
420
380
400
•400
400
370
400
400
C02
%
NF
13.0
13.5
13.8
14.0
14.0
15.5
12.0
10.0
11.0
15.0
1M.O
13.5
11.5
1«4.0
16.0
15.5
15.0
NF
NF
Nr
16.5
16.0
15.5
15.0
14.0
16. 0
15.0
17.0
02
%
NF •
7.6
7.6
9.0
9.0
8.4
8.0
9.2
9.8
8.0
NT
NP
NF
MF
NF
NF
Mr
NF
NF
NF
NF
NF
6.6
6.5
6.6
9.0
6.6
6.6
6.6
S02
ppm
NF
180
160
180
280
280
240
310
320
.300
350
320
280
250
125
145
150
NF
115
95
NF
180
130
150
120
130
110
140
135
ULUL,t,l
NOX
ppm
NF
440
440
440
400
420
400
240
320
310
360
380
390
390
420
400
340
NF
390
390
NF
360
375
360
350
370
360
360
360
C02
%
NF
12.0
13.3
13.5
13.5
12.5
13.5
9.0
8.5
11.0
13.5
13.0
13.0
13.0
13.5
15.0
15.0
NF
NF
NF
NF
11.5
13.0
15.0
14.0
12.0
15.0
14.5
15.5
02
-3L
NF
7.8
7.6
>10.0
8.6
8.4
9.0
>10.0
>10.0
9.0
NF
NF
NF
NF
NF
NF
NF
NT
NF
NF
NF
NF
7.9
7.4
7.8
9.0
7.6
7.8
7.6
% SO2
Removal
Efficiency
_
f.7 . 3
77.9
83.H
76.7
77.6
81.5
71.8
64.4
69.2
61.1
64.4
67.1
61.5
86.1
84.3
83.3
-
82.3
81.0
-
82.0
87.0
83.3
86.3
85.9
87.8
84.4
85.0
1 Sample line leak
2 Flow problems until 1800
reading suspect until 1400, 11-15
-------
HOURLY DATA
Date
11-15
I
OJ
cn
I
11-10
Time
01 00
0200
0300
U400
0501)
0000
0700
0800
0900
1000
lion
1200
1 300
1 400
1500
1 000
1700
1800
J9I10
2000
2100
2200
2300
2400
01(10
0200
0300
0400
0500
0600
0700
0800
Al
MW
105
105
157
107
160
109
171
109
175
180
182
178
178
178
182
J73
170
174
108
178
179
179
179
179
171
174
109
174
175
177
17 3
175
Inlet
inon
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
SS^fefjfe
A P
*
12.2
*
8.0
*
8.0
*
8.0
*1
5.8
*
3.0
*
3.0
*
5.2
*
5.2
*
7.0
*
7.0
*
7.0
*
9.4
*
12.0
*
13.0
*
12. S
pH
0.5
7.2
7.5
7.5
7.5
7.5
7.4
7.4
7.4
6.4
7.3
7.1
7.3
7.0
7..1
7.1
7.0
7.0
7.2
6.9
7.0
7.1
6.9
•7.0
7.1
7.2
7. 3
7.4
7. 4
7.4
7 . 4
7.3
INLET
S02
PPm
900
800
920
1000
910
900
900
700
1150
1300
1100
.1 050
J050
900
900
900
900
800
800
850
800
800
850
800
840
800
900
850
900
900
900
N(JX
PPm
41.0
420
400
425
395
420
440
420
420
440
440
438
420
460
450
420
420
400
400
420
430
430
430
420
430
430
420
430
430
420
430
400
C02
%
10.0
15.5
16.0
10.5
10.5
17.0
17.0
15.8
J5.9
15.5
J5.8
1.5. 3
10.5
11.0
11.0
11.0
11.8
J1.3
11.5
10.5
11.5
13.0
12.5
12.5
13.5
13.5
13.5
13.5
14.0
14.0
J2.5
11.0
02
6.6
6.8
6.4
6.6
5.4
6.2
6.4
6.6
6.4
6.5
6.8
0.9
0.7
6.8
0.7
7.6
6.4
6.2
0.7
6.8
6.8
6.8
7.0
6.8
6.8
0.8
0.8
8.4
0.4
6.6
7.0
7.8
S02
pprn
160
180
160
130
J35
128
125
125
120
250
340
265
240
270
190
190
180
170
160
160
150
130
150
170
140
180
120
110
90
110
100
100
OUTLET
NOX C02
pprn
370
360
390
390
380
390
390
400
400
400
360
360
360
290
390
400
360
350
360
380
400
400
400
390
420
418
'400
420
420
420
410
400
JL
15.0
14.5
15.0
15.5
15.8
16.0
16.0
J5.4
15.5
14.3
13.4
13.2
14.5
10.0
11. I
10.5
11.0
11.0
10.5
9.8
10.5
12.5
12.0
12.0
12.5
12.5
12.0
13.0
14.0
12.5
J2.5
H.5
02
% S<>2
Removal
% Efficiency
7.4
7.8
8.0
7.8
7.4
7.8
7.6
7.5
7.6
8.0
9.5
8.8
8.8
8.5
7.9
8.0
8.0
8.4
8.2
8.0
8.0
7.8
8.0
7.8
7.8
7.8
7.6
8.0
7.0
7.4
7.2
8.0
82.2 ,
80.0
80.0
85.9
80.5
85.9
80.1
86.1
82.9
78.3
73.8
75.8
77. 1
74.3
78.9
78.9
80.0
8J.I
80.0
80.0
82.4
83.8
81.3
80.0
82.5
78.6
85.0
87.8
89.4
87.8
88.9
88.9
Ceritr.i Fugo rc-pair 0940
-------
HOURLY DfeTft
Inlet SCRUBBER
ACFM x 2nd Stage S02
Date
1.1-16
(Contd)
11-17
11-18
11-19
11-20
Time
0900
1000
1100-1800
1900
2000
2100
2135
MW i nnn
17 'i NF
175 NF
180 NF
177 NF
178 NF
179 NF
A P
*
11.5
*
*
1.2
*
0
pH ppm
7.] 850
* 1 NF
* 2 NF
7 . 4 1000
7 . 4 1000
7.4 1 000
Scrubber
INLET
NOX C02
ppm %
•120
•100
NF
'100
380
120
down;
6.5
NF
NF
13.0
9.5
10.0
02
JL
6.5
NF
NF
7.0
7.4
8.0
S02
ppm
70
NF
NF
250
230
210
OUTLET
NOX C02 02
ppny
'400
390
NF
260
290
300
JL JL
9.0 7.8
NF NF
NF NF
9.5 10.0
7.5 10.0
8.5 10.0
% S02
Removal
Efficiency
91.8
_
-
7S.O
77.0
79.0
pinch valve ruptured
Scrubber Down
Scrubber Down
1740
1800
1900
2000
2100
2200
2300
2400
0100
0200
0300
0400
0500
0600
0700
0800
0900
1000
1100
174 *
173 NF
173 NF
182 NF
170 NF
173 NF
174 NF
174 NF
174 JJp
175 g£
173 NF
176 NF
174 NF
175 NF
177 NF
175 NF
174 NF
175 NF
170 NF
*
*
*
*
9.5
*
7.0
*
9.2
*
*
*
*
*
10.0
*
*
*
Scrubber
* 3 300
* 200
7.3 NF
* 800
7.1 7SO
* 800
6.8 800
* 800
7.1 800
800
800
800
800
800
7.2 800
* 950
6.9 1000
* 1100
start
450
4'IU
NF
460
4GO
460
460
460
440
440
440
430
440
430
440
410
•120
380
up
13.5
13.8
NF
1M.O
14.5
1M.O
m.o
13.5
I'l.O
1U.O
I'l.O
14.0
14.0
14.5
11.5
14.5
15.1
20.5
10.0
7.0
NF
7.0
6.8
6.8
6.4
6.4
6.4
6.2
6.2
6.2
6.2
6.4
6.8
6.0
6.0
4.0
220
150
NF
130
100
90
100
150
120
150
90
90
90
120
175
110
120
135
430
420
MF
420
430
400
400
380
380
380
380
380
390
400
400
380
370
370
13.5 6.8
I'l.O 7.0
NF NF
13.0 7.6
14.0 7.8
13.5 8.2
13.5 8.2
12.5 8.2
13.0 8.2
13.0 8.0
13.5 8.0
13.5 8.0
13.5 8.2
14.0 8.0
14.0 7.8
14.1 7.1
15.2 7.2
Ifl.G 702
26.7
25.0
-
83.8
86.7
88.8
87.5
81.3
85.0
81.3
88.6
88.8
88.8
85.0
78.1
88.4
88.0
87.7
Centrifuge diverted 1230 - 13.30
Analyzers having flow problems
Faulty solenoid valve on Inlet sampling line
-------
HOURLY DATA
Date
11-20
(Contd)
11-21
I
CO
Time
1200
1 I'll)
1400
1 500
J 000
1700
18 00
1900
2000
2.1 00
2200
2300
2400
OHIO
0200
(HOO
0400
0500
0000
0700
0800
0900
1000
1100
1200
1300
1400
1500
1600
Inlet
ACFM x
MW 1000
173
173
171
173
180
184
177
180
1.7 S
175
17 S
17 S
17 S
173
176
174
172
160
160
160
102
183
177
177
177
182
178
175
177
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
SF
NF
NF
NF
NF
NF
NF
NF
SCRUBBER
2nd
-AP
8.0
*
8.5
*
1.0.0
*
*
*2
*
*
*
*
*3
*4
7.2
*
7.2
*
7.2
*
' 8.9
*
10.2
*
11.7
*
1 1.4
*
10.0
Stage
pH
7.1
7.2
7.1
7.1
7. I
7.0
7.0
7.0
7.0
7.0
7.0
7.2
7.1
7.0
7.0
('.8
0.9
7.0
7.1
7.1
7.2
7.2
7.1
7.1
7.1
7.1
7.0
7.0
7.0
S02
ppm
1100
1000
Nr
1050
1.0 SO
1010
1000
Nr
1100
iioo
1100
900
Nr
1150
1100
1100
1100
1200
1100
1100
950
990
875
875
900
900
950
900
900
INLET
NO*
ppm
400
400
400
410
450
420
420
420
410
4.10
420
400
*
420
420
420
420
190
400
400
410
440
400
450
460
460
450
160
160
C02
18. S1'
12.5
12.0
12. S
12.0
12.5
12.5
11.5
32.5
12.0
12.5
12.5
Nr
Nr
Nr
Nr
11.0
11.0
9.5
10.0
10.5
10.0
10. 5
12.0
12.0
12.5
12.5
12.5
12.5
02
%
6.0
6.0
0.0
5.8
S.S
0.4
6.6
6.0
6.2
6.4
0.2
6.6
6.0
S.S
S.S
6.0
6.0
0.0
5.8
6.0
6.0
6.6
6.6
6.2
5.8
6.4
6.0
6.0
6.0
S02
ppm
140
ISO
Nrl
165
140
140
160
Nr
180
180
170
160
Nr
190
190
240
240
260
240
230
200
160
ISO
155
160
170
175
165
180
OUTLET
NOX
PPm
350
340
380
400
410
400
400
400
400
400
380
390
*
380
380
380
380
340
360
380
370
420
130
410
418
430
430
430
430
C02
%
21. H"
8.5
11.0
10. S
11. 5
9.5
10.5
.10.0
11.0
11.4
1.2.8
12.5
NT
Nr
Nr
Nr
10.0
9.5
10.5
10.5
10. S
11.0
11. S
12.0
12.5
11. S
12.0
11.5
1.1.5
02
%
7.0
8.2
7.0
7.0
7.2
8.4
7.4
7.0
7.2
7.0
6.8
7.0
7.0
7.8
7.8
7.2
7.0
6.8
7.0
7.0
7.0
7.0
7.2
7.0
6.8
6.9
6.8
6.8
7.0
% S02
Removal
Efficiency
87. 3
85.0
84. 3
86.7
86. 1
84.0
83.6
83.0
84. S
82.2
83
82
78
78
78
78
79
78
83.8
82.9
82. 1
82.2
81.1
81.6
81.7
80.0
1 SOg Analyzer maintenance
2 SOj Analyzer maintenance
^ 303 Ana.lyzor maintcMiaiicc
'* C02 Analyzer malfunction
-------
HOURLY DATA
Date
11-21
(Contd)
11-22
11-23
11-24
11-24
I
03
00
I
inlet SCRUBBER
ACFM x 2nd Stage
Time
1700
1800
1900
2000
2100
2200
2300
2400
MW 1000
184 . NF
189 NF
188 NF
185 NF
IB 5 ' OFF
183 OFF
170 OFF
174 OFF
3BFR DOWN
SCRUBBER DOWN
0239
0300
0400
0500
0600
0700
0800
0900
1000-1500
1530
1600
1700
1800
1900
2000
2100
2200
2300
2400
Scrubber
148 NF
150 NF
149 NF
147 NF
148 NF
147 NF
*2 NF
4P pH
* 7.0
9.6 7.0
* 7.1
*! 7.0
OFF OFF
OFF OFF
OFF OFF
OFF OFF
Boiler
Start Up
0.5 7.7
2.5 7.7
2.4 7.4
4.2 7.4
4.8 7.4
5.5 7.3
* *
S02
ppm
900
900
920
OFF
OFF
OFF
OFF
OFF
INLET
NOX
ppm
4(40
440
450
OFF
OFF
OFF
OFF
OFF
C02
12.0
12.5
12.5
OFF
OFF
OFF
OFF
OFF
02
%
6.8
7.0
6.8
OFF
OFF
OFF
OFF
OFF
S02
PPm
180
180
185
830
840
840
840
850
OUTLET
NOX
ppm
M20
420
Mil)
480
M80
M20
"420
420
C02
15.5
12.5
13.0
13.0
13.0
12.5
13.0
13.0
02
_2L
6.8
7.0
6.8
6.4
6.4
6.4
6.4
6.«4
% S02
Removal
Efficiency
80.0
80.0
79.9
_
-
-
_
-
Down 2300, tube leak
800
875
810
800
900
900
850
380
440
440
440
460
460
90
11.4
12.4
11.5
11.6
12.4
13.4
NF
6.7
6.0
6.8
6.8
5.2
5.4
NF
150
240
250
210
200
190
850
340
too
"420
420
'440
'480
440
9.0.
11.0
10. S
10. M
11. '1
12.5
9.8
8.0
6.8
7.3
7.5
0.9
6.1
7.6
81.3
72. f,
69.1
73.8
77.8
78.9
O
SCRUBBER DOWN
178 NF
178 153. t
178 153.6
178 180.2
180 218.1
180 218.1
169 218.1
178 218.1
181 218.1
156 NF
4.4 7.1
7.0 7.1
7.0 7.0
8.0 7.0
8.0 7.0
9.5 7.2
10.0 7.2
9.4 7.1
9.6 7.0
10. 0 7.0
900
910
900
900
880
900
900
900
900
NF
460
460
450
440
440
460
440
430
430
NF
13.5
1«4.5
13.8
14.0
14.0
13.5
14.0
14.0
14.3
NF
6.4
5.8
6.2
5.9
5.8
6.0
6.0
6.4
6.0
170
160
170
160
160
150
140
160
150
150
380
400
420
•420
(420
440
mo
420
(420
395
12.6
12. U
13.0
12.5
12.8
12.5
13. U
13.0
13.0
13.3
7.0
8.0
7.4
7.0
7.2
7.4
6.8
7.0
7.0
6.1
-
82.2
81.3
82.2
82.2
83.0
84.4
82.2
83.3
83.3
1 Trailer sampling outlet only. Scrubber down mt 2000
2 Scrubber down 0855, problem with bushing on screw c'onveyor
3 Scrubber start up, Inlet flow problem*
-------
HOURLY DATA
Date
11-25
I
W
vo
I
Jl-20
Inlet
SCRUBBER
ACFM x 2nd
Time
01 00
0200
0:100
0>IOO
0500
0000
07 00
0800
OfJOO
1000
1 100
1200
1300
I'lOO
1500
ir.oo
1700
1800
1900
2000
2100
2200
2300
2400
0100
0200
0300
O'lOO
0500
0000
0700
0800
MW
151
152
1.51
1'I7
150
153
1.70
170
182
182
183
181
183
180
182
182
180
181
180
179
181
180
180
173
180
180
181
175
175
109
180
179
1000
207.4
82.9
91.1
91.1
146.4
180.2
173.1
140. C
165.9
188.4
197.6
197.6
197.6
197.6
197. C
197.6
197.6
165.9
NF
165.9
165. S
155. S
153.6
159.7
159.7
159.7
159.7
165.9
165.9
165.9
165.9
165.9
4I_
9.0
2.'l
2.4
2.4
5.0
7.0
6.8
0.0
0.5
8.5
8.5
8.5
8.5
8.5
8.8
9.0
'J.I
'J.I
9.1
9.1
9.1
9.1
9.2
8.8
9.0
9.0
10.0
9.5
9.5
9.5
9.0
9.0
Stage
plj_
7.2
7.3
7.3
7. '4
7.3
7.2
6.9
_
7.1
7.0
_
7.0
7.1
7.1
7.1
7.2
7.1
7.1
7.0
7.0
7.0
0.9
7.0
7.0
7.1
7.1
7.1
7.1
7.1
7.1
7.3
7.2
S02
PPm
910
925
900
900
900
900
900
880
900
990
880
850
900
820
880
900
800
900
850
850
800
775
750
810
900
900
900
900
875
900
NI'2
NP
INLET
NOX
PPm
i|i|0
'130
440
'HlO
440
"WO
M60
l|i)0
1480
480
•480
'180
480
"400
450
'400
MOO
'100
'400
'400
"400
IIGO
'460
'4'40
470
470
400
440
450
450
NT
NF
C02
%
14.0
13.5
13.8
13.8
14.2
14.5
14. 0
12.8
11.8
13.2
13.5
13.5
13.4
13.5
12.2
13.2
14.0
14.0
13.0
13.5
13.9
13.8
13.8
13.4
13.4
13.0
13.0
13.0
13.4
13.0
NP
NP
02
%
5.3
0.4
6.4
r..5
5.9
5.7
0.2
0.2
0.4
O.I
0.0
0.1
0.2
0.4
0.2
0.5
0.4
0.4
7.0
0.4
0.6
G.6
6.0
0.6
0.8
0.9
6.9
0.5
0.8
0.8
NF
NF
S02
ppm
170
245
255
255
220
190
190
185
190
165
175
180
170
165
185
120
150
NFl
NF
130
140
150
160
120
140
140
120
140
150
135
110
120
OUTLET
NOX
PPm
380
340
'350
340
380
390
400
390
420
420
430
420
430
410
420
350
420
NF
NF
420
410
400
400
400
420
420
440
410
400
410
430
430
C02
%
10.5
11.2
11.2
11.0
12.2
12.3
12.4
U.2
11.0
11.9
12.2
13.4
11.3
13.2
13.4
7.03
12.4
NF
NF
12.5
12.4
12.0
12.0
12.2
12.2
12.0
11.9
11.9
12.4
12.0
12.0
12.4
02
%
8.7
8.8
8.9
9.1
8.0
7.0
7.2
7.8
7.6
7.6
7.0
7.6
7.6
7.8
7.7"
G.ti
7.8
NF
NF
7.6
6.6
7.6
8.0
7.8
7.8
8.0
7.8
7.9
7.7
7.9
8.0
7.8
% S02
Removal
Efficiency
8.1.3
73.5
71.7
71 .7
75.0
78.9
78.9
"79.0
80.8
83.3
80.1
78.8
81.1
79.9
79.0
80.7
82.0
-
-
84.7
82.5
80.0
78.7
85.2
84.4
84.4
86.7
84.4
82.9
85.0
-
-
J Probo cLcanpil
2 Restriction in sampln line
^ CO, Analyzer malfunction
-------
HOURLY DATA
I
M
O
Date
11-20.
(Contd)
11-27
Time
0900
1000
1100
1200
1300
I'lOO
1500
1000
1700
1800
1900
2000
2100
2200
2300
2'IOO
OHIO
0200
0300
0'400
0500-1200
1300
1400
1500
1600
1700
MW
182
1.81
179
180
181
179
182
182
182
182
182
180
179
179
181
179
182
182
178
183
180
178
178
170
181
177
Tnloh
ACFH X
1000
165.9
165.9
159.7
165.9
NF
165.9
159.7
159.7
159.7
165.9
173.1
165.9
159.7
159.7
165.9
165.9
NF2
401.4
401.4
401.4
NF3
159.7
153.6
159.7
153.6
146.4
eK-mjnnc-p INLET
2nd
^ P
9.0
'J.O
9.0
9.0
*1
9.'l
9.2
8.9
8.9
9.0
9.2
9.0
8.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
9.0
Stage
pH
7.2
7.1
7.0
7.0
*
6.8
7.0
7.0
6.9
7.0
7.0
7.0
7.0
7.0
7.0
7.0
6 .9
7.0
7.1
7.1
7.1
7.1
7.0
7.0
7.1
*
S02
NF
900
900
900
NF
9 MO
900
1000
1000
950
1000
1000
1000
760
800
800
Nl'2
980
900
875
NF3
NF1*
NF
NT
NF^
NT
NOX
ppm
NF
460
'* SO
'ISO
NF
'ISO
'160
•460
•160
190
•(80
'ISO
500
«*MO
'ISO
'|i|0
NF
'160
•430
M30
NF
NF
NF
NF
NF
NF
C02
Nl
1U.I4
13. "4
13.3
NF
13.6
13.6
13.7
13.8
13.6
13.0
1'*.0
I1*. 2
i"4.8
13.4
1U. 2
NF
1'».2
12.0
12.5
NF
NF
NF
NF
NF
NF
02
NF
6.2
6.8
6.6
NF
6.2
6.8
6.8
6.1*
6.8
6.6
6.7
6.7
6.9
6.8
6.6
NF
6.8
6.8
6.8
NF
NF
NF
NF
NF
NF
S02
ppm
150
150
170
150
I'lO
1'45
165
182
155
165
180
195
185
120
1'I5
1U5
NF
l'*5
130
120
NF
160
173
170
170
170
UUTLtT % S02
NOX
ppm
it'll)
i*i*0
'*20
M30
i*30
'130
U20
•*30
M20
'430
•41*0
•120
•ISO
•420
•430
•120
NF
'130
MOO
MOO
NF
400
NF
NF
NF
NF
C02
%
12.3
12. 'I
12. '1
12. '1
12.6
12.0
12.7
12.8
12.8
12.8
12.5
13.0
13.3
13.7
13.'l
12.8
NF
13.1
11.8
11.8
NF
12. •*
12.'*
12.5
12.6
12.0
Oj
%
7.9
7.9
7.9
7.9
7.8
7.9
7.6
7.6
7.6
7.9
7.9
7.9
7.7
_
7.8
7.8
NF
7.6
7.8
7.6
NF
NF
NF
NF
NF
NF
Removal
Efficiency
_
83. 3
81. 1
83. H
8U.6
81.7
81.8
8'4. 5
82.6
82.0
HO. 5
81. S
8M.2
81.9
81.9
_
8S.2
85.6
86.3
_
-
-
-
-
-
Outlet S<>2 Wrt tosting
^ Clean sample linos
3 t\imp out on trailer sampling system
'' Insufficient flow for inlet, NO,, and Oj readings
Coal feeder problems
-------
HOURLY DATA
Date
1 1-28
H-29
11-30
12-1
Time
Inlet
ACFM x
MW 10QO
SCRUBBER
2nd Stage
4P pll
Nil DATA TAKKN - TIIANKSIil VJNC,
NO DATA TAKF.N - TIIANKSKlVTNi;
O'lOO1
1000
1.100
1201)
1300
1400
1 500
1600
170(1
1800
1900
2000
2100
2200
2300
2401)
0100
0200
0300
0400
0500
0600
0700
0800
0900
1000
HOO
1200
180
175
108
172
182
182
182
181
176
170
178
178
170
175
175
176
177
172
174
1.78
174
178
179
177
179
177
170
179
197.6
197.6
228.4
NF2
NF
NF
228.4
218.1
242.2
242.2
228.4
242.2
242.2
NF2
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
215
215
NF
NF
S.2
0.7
*
5. 5
*
6.5
0.8
6.4
6.8
0.7
0.0
0.8
0.8
*
*3
*
*
6.0
*
6.5
*
6.5
*
6.5
*
6. 5
*
6.5
6.8-
7 . 4
*
7.0
*
7.0
7.0
7.1
0.9
7.0
7.0
7.0
7.0
*
*
*
*
7.0
*
0.9
*
7.0
*
7.0
*
7.0
*
7.1
S02
ppm
INLET
NOX
ppm
C02
HOMDAY .
02
%
S02
ppm
OUTLET
NOX
ppm
C02
02
HOLIDAY
950
1000
970
900
Nl'
NF
1000
1010
1000
1.000
1000
1010
1010
900
900
900
900
900
Nr
Nr
Nr
NT
Nr
Nr
1000
1000
900
900
420
450
440
Np2
Nr
NF
440
450
460
400
420
400
470
450
455
440
440
400
Nr
Nr
Nr
Nr
Nr
NF
440
440
'180
400
12.8
1.3.1
13.4
Nr
13. 3
13.5
13.0
12.9
13.5
13.5
13.5
13.3
13.5
13.2
13.2
13.3
13.2
Nr1'
NF
Nr
Nr
NF
Nr
Nr
12.9
13.4
12.0
12.6
6.8
7.0
6.7
Nr
7.0
6.8
7.0
7.0
6.9
6.7
0.8
7.0
0.7
0.8
Nr
Nr
Nr
Nr
NT
Nr
Nr
Nr
NF
NF
6.6
6.5
6.4
6.3
240
240
220
250
Nr
Nr
150
160
165
170
185
185
185
160
160
160
160
160
Nr
Nr
Nr
NF
NF
Nr
200
200
200
200
390
390
400
Nl'
NF
NF
410
410
410
410
400
410
410
410
405
400
400
415
NF
NF
NF
NF
NF
NF
400
400
405
405
12.0
12.0
12.0
NF
12.0
12.0
11.0
11.0
12.0
12.1
12.0
12. I
12.0
12.0
12.0
J2.0
12.0
NF
NF
NF
Nr
w
Nr
Nr
11.9
11.8
11.4
11.4
8.5
8.5
H 2
NF
8.0
8.0
8.0
8.0
7.5
7.8
8.0
8.0
8.0
7.9
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
8.1
7.9
7.5
7.5
1 lie-nan at 0900 afti>r holiday
2 rlow problems
^ 02 Recordor down
'• Flow probJ cms nut il O')00
Removal
Efficiency
74.7
76.0
77. 1
72.2
85.0
84.2
83.5
83.0
8)
81
81
82
82
82.2
82.2
82.2
80.0
80.0
77.8
77.8
-------
HOURLY DATA
inlet JjCKUBBER
Date
12-1
(Contd)
Time
1300
1401)
1500
1 600
1700
1800
1900
2000
2050
MW
179
179
168
180
178
178
176
177
183
ACFM >
NF
NF
NF
NF
NF
NF
NF
NF
NF
4P
*
0.5
*
6.0
*
0.2
*
5.4
*1
stage
pH
*
7.1
*
7.1
*
7.1
A
7.1
*
S02
ppm
900
900
900
900
900
900
900
900
900
INLbT
NOx
ppm
450
450
440
440
450
440
435
450
500
C02
12.3
12.3
12.6
12.6
12.5
12.3
12.3
12.0
12.2
02
_2L
6.3
6.3
6.2
6.2
6.3
6.3
6.2
6.5
>10.0
S02
ppm
200
260
18U
200
210
210
210
210
210
OUTL
NOX
ppm
405
MOO
'400
390
405
400
400
400
MOO
ET
C02
11.2
11.1
11. 1
10.8
U.3
11.1
11. 1
10.6
NF
02
7.6
7.6
7.3
7.6
7.M
7.5
7.5
7.7
6.3
% S02
Removal
Efficiency
77. R
71.1
80.0
77.8
76.7
76.7
76.7
76.7
76.7
I
CO
H-
N)
12-2
12-3
12-M
12-5
12-6
SCRUBBER DOWN
SCRUBBER
SCRUBBER
17002
1800
190(1
2000
2100
2200
2300
2400
moo
0200
0300
0400
0500
0600
0700
0800
0900
1000
1100
1200
1300
165
167
173
175
175
174
177
175
179
182
178
176
176
178
178
180
180
180
180
180
178
DOWN
DOWN
51.2
56.3
58.9
110.1
110.1
105.0
179.2
165.9
179.2
179.2
179.2
179.2
117.8
179.2
230.4
197.1
240.6
240.6
240.6
230.4
240.6
0.8
0.8
2.8
2.8
4.5
3.3
5.2
4.8
5.0
5.0
5.0
5.0
M.O
•4.5
M.O
0.3
8.2
8.0
8.0
8.0
8.5
7.1
7.1
7.2
7.1
7.2
7.2
7.1
7.2
7.0
7.0
7.0
6.9
7.2
7.2
7.2
7.0
7.0
7.0
7.0
7.0V
7.1
900
950
-940
910
950
950
900
950
950
1000
1000
1000
950
1000
900
900
990
990
900
930
1000
430
'420
425
'130
425
440
425
460
'420
430
420
420
400
420
400
440
460
460
470
* 390
460
14.8
14.9
14.3
14.4
15.0
15.0
15.3
15.2
15.0
l't.8
15.2
1M.5
15.0
15.2
15.0
15.0
13.8
13.8
13.7
13.6
l't.5
7.0
7.2
7.4
7.2
6.8
5.8
6.0
6.6
6.0
6.0
6.2
5.6
7.2
6.4
6.6
6.6
6.8
6.8
6.9
7.0^
6.8
230
228
250
250
220
280
230
230
220
220
230
240
230
225
160
155
210
170
160
145
450
385
380
410
420
420
420
440
400
380
400
380
400
340
350
360
400
410
450
460
; 360
420
13.0
13.1
12.5
13.5
15.4
15.0
15.0
13.5
13.0
13.0
12.0
14.0
12.0
13.0
14.0
14.0
12.5
13.5
13.5
12.5
13. S
8.5
8.4
7.8
7.9
7.0
5.8
7.1
8.2
8.6
8.6
9.0
7.4
9.6
9.0
9.0
8.8
8.0
7.M
7.5
8.0
7.3
71.4
76.0
73.4
72.5
76. 8
7CI.S
7 '4 . 'I
75.8
76.8
78. 0
77.0
76.0
75.8
77.5
82.2
82.8
78.8
82.8
82.2
84.4
SS.O
Scrubber down 20SO, Irak in scrubber bleed lines
Scrubber start up
-------
HOURLY DATA
OJ
I
Inlet
ACFM x
Date Time
12-6 1400
(conttl) 1500
1000
1700
1800
1900
2000
2100
2200
2300
2400
12-7 0100
0200
0300
0400
0500
0000
0700
0800
0900
1000
1100
12002
1300
1400
1500
1000
1700
1800
1900
2000
2100
MW
179
175
180
178
178
172
179
178
176
177
179
177
170
170
170
170
170
170
173
173
176
179
179
179
179
175
180
177
177
178
179
177
1000
240.6
207.4
197.6
165.9
188.4
180.2
180.2
180.2
188.4
188.4
188.4
288.4
228.4
228.4
228.4
228.4
228.4
228.4
207.4
207.4
207.4
135.7
140. B
146.4
173.1
*3
NF
188.4
188.4
188.4
188.4
197.6
SCRUBBER
2nd
A P
8.5
8.5
8.5
8.8
9.0
8.5
8.5
8.9
8.5
8.6
8.5
9.0
9.0
9.0
9.0
9.5
9.5
9.5
9.5
9.5
9.5
7.0
3.0
5.0
7.5
*3
*
8.0
8.8
8.6
8.6
8.6
Stage
pH
7.0
7.1
7.1
7.0
7.0
7.0
7.1
7.1
7.1
7.1
7.1
7.1
7.1
7.1
7.1
7.1
7.2
7.2
7.2
7.1
7.1
7.0
7.5
7.4
7.3
*
*
7.0
7.1
7.1
7.1
7.0
SO2
ppm
1000
1000
1000
1000
1000
1000
1000
1000
800
880
850
850
900
920
900
900
900
900
800
900
800
800
890
11.40
875
NT
NF
960
1020
980
1020
1020
INLET
NOx
PPm
400
400
450
400
460
460
460
400
430
440
440
440
430
430
440
440
440
440
4 '40
460
440
420
420
NF
420
NF
NF
425
440
440
430
440
CC>2
%
14.5
14.3
13.8
14.2
14.0
13.8
14.0
14.2
14.3
14.0
14.0
14.0
14.0
13.5
14.0
13.5
13.5
13.5
14.0
14.0
13.5
13.5
13.3
NF
14.5
NF.
NF
13.4
12.9
13.1
12.9
12.7
02
%
0.8
6.8
6.8
6.6
0.6
0.8
0.0
0.5
6.6
6.6
6.6
6.4
0.4
0.4
0.4
0.6
6.6
6.4
6.6
6.5
0.8
0.8
7.0
NF
6.7
NF
NF
6.8
6.7
6.6
6.6
6.6
S02
ppm
NT1
150
170
168
200
208
165
160
170
180
180
170
175
190
175
180
180
170
150
150
150
150
230
252
120
NF
NF
210
190
145
115
135
OUTLET
NOx
ppm
NF
420
410
420
415
410
420
420
400
410
410
420
390
400
400
420
420
410
420
430
410
400
400
380
390
NF
NF
380
400
400
400
395
C02
JL
NF
12.5
12.6
12.5
12.5
13.0
12.6
12.1
13.0
12.7
13.0
13.0
13.0
12.5
12.5
12.5
12.5
12.7
12.8
12.8
12.8
12.5
12.2
13.0
12.5
NF
NF
12.2
11.8
12.0
12.2
12.4
02
NF
8.0
7.8
8.0
8.0
7.8
7.8
7.6
7.8
7.8
7.8
7.8
7.8
8.0
7.8
7.6
7.6
7.6
7.6
7.6
7.6
7.8
8.3
8.2
8.2
NF
NF
7.4
7.4
7.3
7.4
7.2
% 502
Removal
Efficiency
.
85.0
83.0
83.2
80.0
79.2
83.5
84.0
78.8
79.5
78.8
80.0
80.0
79.3
80.0
80.0
80.0
81.1
81.3
83.3
82.6
81.3
74.2
77.9
86.3
_ .
_
78.1
81.4
85.2
88.7
86.8
Outlet probe cleaned
2 1st Stage outage, leak in recycle header
3 F\imp outage on sampling ay Stem
-------
HOURLY DATA
Date
12-7
(oontd)
12-8
tB
M
*>.
I
12-9
Inlet
ACFM x
Time
2200
2300
2UOO
0100
0200
0300
OMOO
0500
OOOO2
0700
0800
0900
1000
1100
1200
1300
I'lOO
1500
1000
1700
1800
1900
2000
2100
2200
2300
2MOO
01(10
0200
0300
OMOO
HW
175
176
179
181
179
179
180
180
180
179
177
IMft
l'IU
1M3
137
129
110
111
106
102
103
96
97
102
102
100
102
101
101
101
101
1000
188 .
188.
188.
188.
188.
NF
188.
188.
188.4
188.4
188.4
188.4
180.2
180.2
173.1
165.3
165.9
146.4
146.4
153.6
153.6
180.2
188.4
188.4
188.4
188.4
188.4
188.4
188.4
188.4
138.4
SCRUBBER
2nd
AP
8.8
8.G
8.G
8.5
*1
*
8.5
8. 5
8.5
fl.5
fl.5
8.3
8.1
8.1
7.3
0.0
6.2
3.5
3.5
3.8
5.6
3.8
3.9
3.9
3.5
3.8
'l.O
'1.2
'I.')
4.4
4.4
Stage
pll
7.0
6.9
7.0
7.0
*
*
7.1
7.0
7.0
G.9
r,.8
fi.7
r..9
6.9
6.9
0.9
ft. 9
f>.9
7.2
7.0
7.0
7.0
7.L
7.1
7.2
7.2
7.0
7.0
7.0
7.0
7.0
S02
ppm
1000
1000
1000
900
1000
NF
1000
1000
1000
950
1000
12110
1100
1200
1100
1200
1100
1100
1.050
1050
1020
1020
1020
1100
1000
1050
1100
1200
1200
1200
1200
INLET
NOX
ppm
MGO
U50
UUO
1,1,0
U50
NF
UMO
i|50
M80
'ISO
M60
M10
"100
MOO
U20
"120
"120
MOO
MOO
M10
M20
MM5
M30
M20
MOO
380
410
MHO
MMO
4MO
, 420
C02
%
13.0
13.1
13.0
13.0
13.0
NF
13.0
13.0
13.0
13.0
13.2
13.0
13.0
12.6
12.5
13.0
NF
12.5
12.7
13.0
12.0
12.7
12. H
11.7
12.7
11.5
13.0
13.0
13.0
13.0
13.0
02
%
6.M
O.M
6.2
6.6
6.6
NF
6.2
0.2
6.2
6.2
0.2
0.2
6.0
5.8
5.8
6.M
NF
6.5
7.0
6.2
7.8
7.0
6.M
7.2
6.6
8.0
6.4
6.0
6.4
6.6
6.6
S02
ppm
1MO
1M5
1MO
140
NF
NF
150
150
135
140
180
200
200
200
220
2MO
220
240
250
250
260
260
270
280
240
280
290
290
280
290
280
OUTLET
NOX
ppm
MOO
"*00
MOO
MOO
NF
NF
330
MOO
t|l|Q
I'll)
MOO
MOO
360
360
360
380
360
360
3MO
380
MOO
MOO
390
390
380
360
360
MOO
400
400
380
C02
%
12. 3
11.8
12.0
12.5
NF
NF
12.0
12.0
12.0
12.5
12.2
12.2
12.0
12.0
12.5
12.0
12.7
12.3
11.0
10.5
10.6
10.5
11. 1
10.0
11.3
11.4
11.5
12.2
12.5
12.0
11.7
02
%
7.4
7.4
7.2
7.4
NF
NF
7.6
7.6
7.6
7.4
7.0
7.2
7.0
7.0
6.8
7.0
6.8
8.0
8.M
8.9
9.0
8.9
8.4
9.0
8.M
fl.M
8.0
7.M
7.6
7.8
7.8
% S02
Removal
Efficiency
86.0
85.5
86.0
SU. M
85.0
85.0
8(>. 5
85.3
82.0
83.3
81.8
83. 3
80.0
80.0
80.11
78.2
76.2
76.2
7H.5
7'I. 5
73.5
7«l.5
76.0
73.3
73.0
75.8
76.7
75.8
76.7
Outlet probe blocked
2 Drop in load, wet coal
-------
HOURLY DATA
Date
12-9
(rontd)
CO
12-10
Time
0000
0000
07(M)J
0800
0900
1000
1100
1200
1.300
1400
1SOO
loon
1700
1800
L900
2000
2100
2200
2300
2400
0100
0200
0300
0400
0500
0600
0700
0800
0900
1000
1100
1200
MW
110
10J
100
9 9
101
IBS
IBS
185
105
170
172
LO')
182
190
189
l')3
182
183
1.75
173
176
174
164
148
147
174
156
LSI
178
183
184
180
Inlet
ACFM x
1000
188.4
188.4
188.4
188.4
197.6
197.6
197.6
218.1
218.1
218.1
207.4
207.4
207.4
218.1
228.4
218.1
228.4
228.4
228.4
228.4
228.4
228.4
228.4
242.2
228.4
228.4
228.4
228.4
228.4
228.4
218.1
173.1
SCRUBBER
Zna
AP
4.2
4.4
'l.'l
'1.3
4. 5
'l!s
1.3
4.7
5.8
5.8
5.1
4.0
5.8
S.7
6.2
0.0
6.0
6.2
6.2
5.8
6.0
6.0
6.0
7.0
7.0
6.5
7.0
6.8
5.4
'1.8
3.8
2.2
Stage
pll
7.0
7.0
7.1
7.1
7.1
7.0 ,
6.9
6.9
6.8
7.0
7.1
7.1
7.0
6.9
7.0
7.0
0.9
0.9
6.9
7.2
7.1
7.0
6.8
6.9
6.9
6.9
7.0
7.1
7.1
6.9
6.2
7.2
S02
ppm
1200
1200
1200
1050
1100
900 >
850
850
920
900
900
900
900
900
950
900
920
950
980
980
1000
950
1000
900
850
800
800
800
800
800
800
800
INLET
NOX
PPm
400
440
400
420
380
420
400
410
400
4GO
460
445
440
430
410
420
420
400
420
420
400
360
400
400
380
380
380
400
420
410
400
400
C02
%
13.0
12.0
13.0
13.0
13.2
12.5
12.5
12.8
12.5
12.8
13.0
12.7
12.9
13.3
13.6
13.4
13.2
13.5
13.8
12.5
14.0
13.5
14.0
13.5
12.5
13.5
13.5
I'l. 3
l't.3
13.7
14. 3
12i7
02
X
6.4
7.0
7.0
0.8
6.M
7.2 ;
7.3
6.0
7.0
0.0
6.4
6.6
6.6
6.4
6.4
6.4
6.4
6!4
0.0
6.8
5.2
6.4
5.8
6.2
7.5
6.5
6.5
6.0
6.4
6.8
6.2
7.0
S02
ppm
310
310
320
220
230
220 \
185
175
190
185
200
195
175
190
180
220
225
280
290
180
190
220
230
240
220
200
200
170
150
200
240
230
OUTLET
NOX
ppm
380
380
360
380
320
370
360
380
420
400
400
370
400
400
380
380
370
360
390
380
380
350
380
370
360
340
.340
360
370
380
380
320
C02
%
12.5
13.0
11.5
12.5
12.5
11.0
12.2
11.5
12.0
13.0
12.8
11.0
11.2
11.8
11.9
11.6
12.1
12.0
12.5
12.0
12.0
12.5
12.5
13.0
11.0
13.0
12.5
12.0
12.3
12.3
12.0
10.0
02
7.2
6.9
8.4
7.3
6.8
8.7
8.4
8.4
8.0
6.8
6.9
8.2
8.0
7.7
7.8
8.2
7.6
7.4
7.2
7.6
7.8
7.5
7.5
6.8
8.8
7.4
7.6
7.8
7.8
7.8
8.0
>10.0
% SO 2
Removal
Efficiency
74.2
7'I. 2
73.3
79.0
79.1.
75.6
78.2
79.M
79.3
79.4
77.8
78.3
80.6
78.9
81. I
75.6
75.5
70.5
70.4
81.6
8J.O
76.8
77.0
73.3
74.1
75.0
75.0
78.8
81.3
75.0
70.0
71.3
1 Rising Boiler load
-------
HOURLY DATA
I
CO
Inlet
ACFM x
Date
12-10
(fontd)
12-11
12-12
12-13
Time
1300-1600
1700
1800
190(1
200(1
2100
2200
2300
2UOO
0100
0200
0300
O'lOO2
0500^
HIM)'1
1 UOO
J8101'
1900
2000
2100
2200
2300
2<400
MW
17 S
170
170
178
177
177
160
108
153
10"!
102
1 (>2
1.03
103
170
172
120
118
111
116
113
108
107
1000
NF
207.4
207.4
207.4
207.4
218.1
228.4
228.4
228.4
242.2
242.2
242.2
180.2
180.2
197.6
197.6
228.4
228.4
242.2
228.4
242.2
242.2
228.4
SCRUBBER
2nd
A?
*1
M.'l
't.O
M.O
'4.2
"4. '1
5". 5
5.6
6.0
6.0
6.0
6.0
1.0
0
'4.0
0
1.'4
3!2
2.7
2.7
5.3
5.0
5.2
Stage
pll
7.3
7.1
6.9
7.0
7.0
7.0
7.0
7.0
7.0
7.0
6.9
6.9
7.2
7.1
7.2
7.1
7.2
7.2
7.1
7.1
0.8
7.1
7.1
S02
ppm
NF
980
1020
1050
1090
1100
1120
1100
1100
1100
1100
1100
1100
1100
1200
MTS
1250
1250
1180
1200
1250
1200
1100
INLET
NOX
ppm
Nr
IIMO
M30
M20
"100
MOO
510
UOO
380
uno
'400
"400
•4in
300
380
Nr
395
390
390
mo
•100
•42(1
•450
C02
NF
13. M
13.3
12. '1
13.0
13.3
1U.5
13.1
13.5
13.5
13.2
13.5
13.0
11.0
1H.6
NT
15.0
I'l.O
13.9
13.3
13.6
13.8
1.3.14
02
NF
6.2
6.6
7.0
6.8
6.2
5.«4
6.3
6.0
6.0
G.2
6.2
7.0
9.0 '
6.5
NF
5.0
5.7
5.5
3.2
6.2
6.0
6.3
SO 2
ppm
NF
225
230
235
2UO
2>45
260
220
220
220
2'IO
220
>lf)00
305
308
55
285
290
275
235
225
210
OUTLET
NOX
ppm
NF
390
360
350
360
360
370
360
360
360
390
390
360
1420
360
360
90
320
320
320
350
380
390
C02
%
NF
10.0
12.3
11.2
11. '4
12. 3
12.6
12.1
12.0
12.0
13.5
12.5
12.0
12.5
16.1
10.9
3.2 >
11.5
11.6
10.7
13. M
13.6
12.6
02
NF
8.9
7.8
8.G
8.7
7.8
7.G
7.7
7.8
7.8
6.6
7.2
8. "4
7.0
5.G
6.7
•10.0
8.8
8.0
8.7
7.6
7.U
7.8
% 502
Removal
Efficiency
77.0
77.5
77.6
78.11
77.7
70.8
81.8
81.8
81.8
78.2
8.1.8
78.2
-
7 "1.0
-
95.0
77.2
75.'4
77.1
81.2
81.3
80.9
Pump out on sampling apparatus
2 1st Stage outage, dropprd hammer
3 Scrubber shut clown - O'l25
** Scrubber start up - 1230
5 Sciiibber slint down - 1'I20
c Scrubber start up - 1810
-------
HOURLY DATA
Date
12-14
I
CO
12-15
Inlet
ACFM x
Time
0100
0200
037)0"^
" 0400
0500
0600
0700
0800
0900
1000
1100
1200
1300
14001
1500
1600
1700
1800
0100
0200-1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
MW
102
100
101
102
102
102
1(12
102
101
103
121
133
135
135
140
140
144
147
140
*3
175
170
178
179
176
178
135
151
168
172
173
10QP
153.0
153.6
153.0
153.0
153.6
153.0
153.6
153.0
159.7
146.4
159.7
159.7
165.9
159.7
153.6
120.3
153.6
153.6
165.9
*
159.7
159.7
140.8
188.4
197.6
197.6
140.8
140.8
140.8
159.7
159.7
SCRUBBER
2nd
4JL
5.3
5.4
5.4
5.3
5.3
5.3
5.3
5.5
5.5
0.4
6.5
6.5
0.2
6.2
0.0
2.4
*2
*
7.2
*
6.7
6.5
6.5
0.5
8.2
7.3
0.0
8.0
7.0
7.0
6.7
Stage
pH
7.2
7.1
7.1
7.0
7.0
7.0
7.1
7.1
7.1
7.2
7.1
7.1
7.1
7.0
7.0
7.1
*
*
7.1
*
7.0
7.0
6.9
7.0
7.0
7.0
6.8
7.0
7.0
7.0
7.0
S02
ppm
11.00
1100
-------
HOURLY DATA
I
CD
M
00
I
Inlet
ACFM x
Date Time
12-16 0100
0200
0300
0400
0500
0600
07 OU
0800
0900
loon
1100
12001
1300
1MOO
1500
16002
1700
1800
1900
2000
2100
2200
2300
2400
12-17 0100
0200
^s^^OSne^
omno
0500
MW
155
172
170
15(1
1S5
171
168
160
145
143
145
146
146
143
140
140
140
142
142
140
138
1 MO
145
156
160
160
160
160
1000
159.7
130.6
159.7
153.6
153.6
140.8
146.4
146.4
140.8
140.8
153.6
159.7
74.8
74.8
82.9
74. B
140.8
140.8
165.9
165.9
165.9
165.9
165.9
165.9
159.7
159.7
159.7
159.7
159.7
SCRUBBER
2 iid
j& P
6.5
6 .0
7.0
fi.2
6.0
6.0
6.0
6.0
6.5
O.I
6.3
6.4
0
0
0
1.8
6.0
5.4
8.2
8.2
8.2
8.3
8.4
8.4
7.8
7.5
7.5
7.5
7.5
Stage
pll
7.0
7.1
7.1
7.0
7.1
7.2
7.3
7.3
7.3
7.3
7.2
7.2
7.5
y 8
>8
7.5
7.1
7.1
6.9
6.9
7.0
7.1
7.1
7.1
7.1
7.1
7.2 (
7.1
7.2
SOa
ppm
1040
10MO
1000
1000
1000
1100
moo
1000
885
850
800
940
890
885
900
770
800
790
780
860
840
800
840
820
820
840
800 •
800
INLCT
NOX
ppm
390
420
M10
380
MOO
MOO
400
MOO
380
370
380
370
350
3M5
350
360
360 "
370
360
360
360
380
380
380
380
380
380
380
380
C02
14.0
14.8
14.8
13.2
13.8
14.8
14.8
14.0
13.8
13.8
13.7
14.0
13.6
14.0
13.9
14.0
14.0
12.0
13.5
14.5
12.5
14.0
15.5
12.5
13.4
14..0
13.5
14.5
13.5
02
%
6.8
6.2
6.8
7.8
7.0
6.4
6.8
6.2
5.8
5.7
5.8
5.7
6.0
6.0
6.0
6.4
6. 4
7.3
6.4
6.2
6.4
6.0
5.9
6.5
6.8
6.2
6.501
6.2
6.6
S02
ppm
185
200
200
210
190
200
180
150
140
150
175
160
685
680
135
150
140
140
140
120
130
140
140
130
120
120
13 tr
130
120
OUTLET
NOX
ppm
360
390
380
340
330
360
330
350
340
340
350
350
320
320
210
260
260
340
320
330
340
340
325
325
340
340
340
340
340
C02
%
12.0
12.6
12.2
13.4
14.2
13.5
11.5
13.0
12.0
12.5
12.7
13.8
12.9
12.5
9.5
11.0
11.5
13.0
13.0
12.5
11.5
11.7
13.5
12.5
12.5
12.5
12.5
12.5
12.5
02
8.0
7.8
8.4
7.5
7.5
7.8
8.4
8.0
7.2
7.2
6.4
6.2
7.0
6.5
10.8
9.4
7.8
7.2
7.4
7.2
7.2
7.4
7.0
7.8
7.8
8.0
7.5
7.5
7.8
% S02
Removal
Efficiency
82.2
80.8
80.0
79.0
81. 0
81.8
82.0
85.0
R'1.2
82.4
78.1
83.0
23.0
23.2
85.0
80.5
82.5
82.3
82.1
86.0
84.5
82.5
83. 3
84.1
85.4
85.7
83.8
83.8
85.0
1 Scrubber 2nd Stage out for repairs
2 Coal feeder problems - Unit #3
-------
HOURLY DATA
W
Date
12-17
(oontd)
12-18
Time
0000
07 OO1
0800
090H2
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
0100
0200
0300
0400
05003
0600
0700
0800
0900
1000
1100
MW
160
158
145
151
162
174
182
182
182
181
182
181
180
181
163
174
180
182
182
174
188
190
190
190
185
190
172
175
174
174
Inlet
ACFM x
10QO
159.7
159.7
95.2
130.0
159.7
159.7
180.2
197. C
180.2
165.9
165.9
180.2
180.2
188.4
197.6
197. C
197. C
188.4
180.2
188.4
188.4
188.4
IBS. 4
138.4
138.4
138.4
XF ^
.)F
SCRUBBER
2nd Stage
AP pH
7.8
7.H
1.1
3.7
8.2
8.7
0.0
8.5
9.7
"J.8
10.0
10.1
10.1
10.3
12.0
10.1
10.0
10.1
10.0
10.5
9.8
9.8
9.8
9.8
10.2
10.5
9.5
9.8
0.8
9.8
7.2
7.1
7.3
7.2
7.1
7.0
7.1
7.1
7.2
7.1
7.1
7.2
7.0
7.1
7.0
7.0
7.1
7.1
7.0
7.0
7.1
7.1
7.1
7.2
7.0
7.0
7.0
7.1
0.9
6.9
S02
ppm
800
840
780
790
1050
950
960
810
790
800
800
840
800
800
800
800
800
900
950
950
930
900
930
900
1080
1020
1100
1020
1020
1140
INLET
NOX C02
ppm %
380 13.2
380 12.5
320
380
365
395
470
460
460
MOO
M65
400
420
410
MOO
M05
MOO
MMO
MOO
420
440
460
'480
460
460
450
440
MMO
M40
450
.13.8
14. 0
11.8
13.0
13.6
12.7
13.5
13.5
14.5
14.0
13.5
14.5
14.5
1M.5
14.5
14.0
14.0
14.0
14.2
14.2
14.8
14.4
14.4
14.2
15.0
15.5
14.5
14.5
02
JL
6.8
6.8
6.2
6.5
6.4
6.8
6.1
6.5
6.3
6.4
5.9
5.2
5.9
6.0
5.8
5.8
5.8
5.6
3.6
5.4
5.6
5.6
5.6
5.6
5.6
5.8
5.0
5.0
5.4
5.4
S02
ppm
110
140
200
165
170
135
180
135
110
102
120
110
120
110
120
125
125
100
170
160
150
160
150
138
174
174
186
168
204
192
OUTLET
NOX C02
ppm %
340 12.2
340 12.1
340
345
340
380 ,
440
450
450
410
410
400
390
400
340
380
360
400
380
380
400
400
440
420
410
380
380
MOO
390
400
13.5
13.9
11.9
12.3
12.7
12.9
12.7
12.6
13.0
13.0
13.0
13.0
14.0
14.0
13.0
11.5
12.0
13.0
12.7
12.7
13.7
13.5
14.0
13.5
15.0
14.0
13.0
13.0
02
JL
7.8
7.8
6.0
6.7
7.8
7.2
7.0
6.7
6.7
7.4
6.4
6.8
5.0
6.4
5.4
6.8
5.2
6.8
6.8
6.6
7.0
6.8
6.5
6.5
6.5
6.5
6.6
5.6
6.4
6.4
% S02
Removal
Efficiency
80.3
83.3
7M.4
79. J
83.8
85.8
81.3
83.3
86.1
87.3
85.0
80.9
85.0
86.3
85.0
84.4
84.4
88.9
82.1
83.2
83.9
82.2
83.9
84.7
83.9
82.9
83.1
83.5
80.0
83.2
Coal feeder problem
2 Change liquid flow rate
3 SO2 readings from OuPont unit
* Testing using inlet ports
-------
HOURLY DATA
10
O
I
Date
12-18
(contd)
12-19
„
^
Time
1200
1300
1400
1500
1GOO
1700
1800
J900
2000
2100
2200
2300
2MOO
OJ Ofll
0200
0300
JIUOO
- 0500'
0000
0700
08 OO2
0900
1000
1100
1200
1300-1500
10003
1700
1800
Inlet
ACFM 3:
SCRUBBER
2nd Stage S02
MW 1000 -AP
174
174
174
173
174
173
174
173
171
171
172
172
167
166
166
JOO
160
162
162
158
J57
157
157
156
152
143
150
143
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
188.4
188.4
188.4
188.4
188.4
188.4
197.6
197.6
207.4
159.7
165.9
165.9
SCRUBBR*
173.1
188.4
197.6
7.8
9.0
9.8
9.8
9.8
9.2
9.8
9.0
9.0
8.5
8.0
8.0
8.2
8.2
8.2
8.2
8.5
8.5
8.5
8.5
8.5
8.M
*
*
*
DOWN
2.8
6.0
6.2
pH pprn
7.U 11MO
7.1 11 HO
7.U II'IO
7.0 1200
7.0 11«U)
7.0 ll'lfl
7.0 11"IC
7.0 11«IU
7.0 II'IO
6.9 11MO
7.0 1140
7.0 II'IO
6.9 II'IO
6.9 II'IO
7.0 1140
7.0 II'IO
7.0 12GU
6.9 11UO
7.0 1080
7.0 1080
7.0 1200
7.0 1200
* 1200
* 1200
* 1200
- 2nd Stage
7.0 1200
7.1 1300
7.1 1200
INLET
NOX
Ppm
410
460
440
440
440
MMO
MMO
MMO
MOO
400
MOO
MOO
400
400
400
MOO
'ISO
430
MMO
M20
400
420
460
450
440
recycle
440
420
430
C02
%
12.8
I'l.O
1M.2
14.5
14.0
14.2
13.5
14.2
14.0
14.2
14.0
14.0
13.7
14.5
14.3
14.3
14.5
14.1
14.0
m. 5
!•». 3
15.0
15.0
13.5
14.0
header
13.5
12.0
15.0
02
%
0.8
5.'l
5.4
5.M
5.0
5.5
5.8
5.4
5.8
5.6
5.9
5.6
6.0
5.M
5.5
5.0
5.5
5.M
6.0
5.8
5.8
5.8
5.8
G.2
6.0
had to
5.8
G.O
5.0
S02
OUTLET
NOX
ppm ppin
210
192
192
192
200
200
200
200
200
200
200
210
192
192
192
192
210
204
192
210
400
400
400
390
MOO
MOO
MOO
MOO
360
360
360
360
360
380
360
300
390
380
380
360
234 360
230
300
300
300
be
300
220
228
360
360
350
340
repaired
390
370
380
C02
JL
12.5
12.5
13.2
12.5
12.5
12.5
12.5
12.5
13.0
13.0
13.2
12.3
13.0
12.0
12.0
12.0
12.6
12.9
13.2
12.5
12.5
12.0
11.5
12.0
11.0
12.5
11.0
13.0
02
7.2
6.6
6.4
6.M
6.6
6.8
6.8
6.8
7.0
7.0
6.8
7.0
6.8
7.0
7.0
6.8
6.8
6.8
6.8
6.8
6.8
7.2
8.0
8.0
8.0
7.0
7.6
7,0
% SO2
Removal
Efficiency
8l.fi
83.2
83. 2
RM.O
82.5
82.5
82.5
82.5
82.5
82.5
82.5
81.6
83.2
83.2
83.2
83.2
83.3
82.1
82.2
80.6
80.5
80.8
75.0
75.0
75.0
75.0
83.1
81.0
1 SOp readings from DuF'ont unit
2 2nd Stage outage (for repairs)
3 Scrubber start up
-------
HOURLY DATA
I
03
N>
Inlet
ACFM x
Date
12-19
(contd)
12-20
Time
1900
2000
2100
2200
2300
2MOO
01001
0200
0300
OMOO
0500
060I)2
0700
0800
0900
1000
1100
1200
1300
1MOO
1SUO
1600"
1700
1800
1900
2000
2100
2200
2300
MW
1MO
IMG
IMS
1M<)
IMS
129
100
100
100
100
100
90
90
99
98
9M
88
90
89
91
89
95
102
102
106
US
12M
128
120
1000
197.6
197.6
197.6
197.6
197.6
197.6
197.6
207.4
207.4
207.4
105.0
105.0
99.3
91.1
99.3
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
95.2
95.2
99.3
95.2
SCRUBBER
2nd
A P
G.M
6.M
6.0
0.0
O.M
3.M
3.6
3.7
3.9
3.5
3.8
3.5
3.5
3.M
3.0
3.0
3.0
3!a
3.8
3.8
3.8
3.8
3.8
3.2
3.0
3.0
3.0
2.8
3.0
Stage
pH
7.1
7.1
7.1
7.1
7.0
7.1
7.2
7.1
7.0
7.0
7.0
7.0
7.0
7.0
' 7.0
7.0
7.0
7.2
7.2
7.2
7.1
7.0
7.0
7.0
7.0
7.0
7.1
7.1
7.1
S02
ppm
1320
1320
1200
1280
1200
1200
11MO
HMO
1180
1200
HMO
1080
1180
1200
1180
1180
1020
900
900
960
'• 930:
' 8 MO ',
. 960
, 8 MO .,
1000
980
1020
980
980
INLET
NOx
ppm
MOD
420
MOO
MOO
M20
MSO
MSO
M.30
M90
M90
M25
.390
MOO
M30
MOO
M70
MOO
M80
MMO
500
'180
M80
MSO
M70
M60
MOO
380
380
380
c<>2
1M.O
12.5
13.0
12.5
13.5
12.8
12. M
.1.2.3
12.5
12. M
12.8
NF
NF-^
NI-
13.5
13. M
12.5
12.5
13.0
13.5
15.0
12.5
1M.O
13.0
13.0
12.5
13.0
12.5
12.5
02
%
6.0
5.8
5.8
6.0
6.1
5.7
6.0
5.2
5.9
5.9
6.2
7.2
6.3
7.2
6.2
6.8
7.0
6.M
6.2
7.1
6.0
6.1
6.0
6.0
6.1
6.2
6.0
6.0
6.0
S02
ppm
210
2MO
238
2MO
2MO
2MO
252
252
282
282
252
255
280
285
2MO
2MO
200
186
192
192
198
190
210
200
2MO
200
200
230
2MO
OUTLET
NOX
ppm
330
370
3MO
300
360
350
370
M05
Ml 5
Ml 5
370
350
380
350
360
370
MOO
M10
390
M20
M20
MOO
M10
360
370
3 MO
3UO
320
320
C02
%
13.0
11.5
11.7
11.5
12.5
11.6
11.8
10.7
11.5
11.3
11.2
NF
NF
NF
13.0
12.2
11.5
11.0
11.5
12.5
1M.O
11.5
12.5
12.0
11.0
11.0
11.0
11.0
11.5
02
%
7.0
7.0
7.0
7.M
7.0
8.0
7.5
6.8
7.0
6.9
7.5
8.5
7.5
8.1
8.1
7.8
8.2
8.2
8.0
7.3
6.3
7.8
7.5
7.2
8.0
8.0
8.0
8.1
7.6
% S02
Removal
Efficiency
83.0
81.8
80.2
8J .3
81.0
80.0
77.9
77.9
70.1
70.5
77.9
70. M
70.3
70.3
79.7
79.7
80. M
80.0
80.0
80.0
78.7
77. M
78.1
76.2
76.0
79.6
80. M
76.5
75.5
S02 readings from IhiPont unit
2 Cn2 Analyzer not working
3 Boiler feed problem wet coal
** S02 readings from TECO unit resumed
-------
HOURLY DATA
I
W
ACFM x
Date
12-20
(contd)
12-21
12-22
Time
2UUO
OlflU
0200
0300
O'lOO
0500
0600
0700
0800
0900
1000
11(10
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
0100
02UO
0300
0400
0500
0600
0700
MW
130
129
131
131
133
125
122
130
129
131
HI
131
131
132
132
132
132
138
141
144
144
146
147
147
148
149
137
113
111
115
111
110
1000
82.9
105.0
115.2
130.6
135.7
135.7
130.6
125.4
140.8
140.8
NF
NF
NF
NF
NF
NF
NF
NF
NF
125.4
125.4
125.4
125.4
130.6
135.7
130.6
140.8
140.8
140.8
140.8
135.7
135.7
2nd
A P
2.8
4.5
4.5
5.8
0.2
5.8
5.5
5.5
6.4
5.4
6.6
6.0
6.6
6.6
6.6
6.8
6. 4
6.4
6.4
6.4
6.4
6.4
6.4
6.4
6.5
6.7
6.5
6.7
0.7
6.3
6.5
6.8
Stage
pH
7.1
7.0
7.0
7.0
6.9
7.0
7.1
7.1
7.1
7.0
7.0
7.0
6.8
6.9
6.9
6.9
7.1
7.1
7.1
7.1
7.1
7.0
7.1
7.0
7.2
7.2
7.1
7.2
7.2
7.2
7.1
7.1
S02
ppm
720
820
800
840
960
950
940
920
860
860
980
1000
1160
1180
1160
1220
1000
1000
1000
920
1080
1080
1080
1080
920
900
900
1100
1100
940
1080
1000
NOX ~C02
ppm
380
380
375
420
405
420
390
370
375
400
400
400
390
390
300
390
300
300
300
300
280
250
250
230
230
220
215
445
430
370
390
380
5«
12.5
12.0
12.0
13.9
13.5
13.5
14.1
14.4
. 13.5
12.6
13.5
13.5
12.5
13.0
14.5
14.5
13.0
13.0
13.0
13.0
13.0
13.0
14.0
14.0
14.3
13.3
16.4
14.5
14.7
13.7
14.0
14.3
02
%
6.2
7.3
6.3
6.3
6.4
6.8
5.8
5.7
0.0
6.4
6.1
6.4
6.4
6.2
0.2
5.8
6.1
6.1
5.9
6.0
5.8
5.8
5.4
5.6
5.4
6.0
5.4
6.0
6.7
6.6
6.7
6.6
S02
ppm
190
170
160
190
140
160
150
160
110
120
160
160
140
200
200
420
240
240
280
180
200
220
200
200
150
140
120
220
210
190
220
260
OUTLET ">* sn-i
NO^ C02
Ppm
340
340
335
365
380
375
350
350
320
364
300
360
350
300
260
260
260
260
260
260
240
230
220
210
195
195
190
400
370
360
340
360 '
_2L
11.5
11.8
11.7
12.5
12.4
12.3
12.0
12.5
11.0
12.0
12.5
12.5
12.5
13.0
13.5
14.0
12.0
12.5
11.5
12.0
12.5
12.0
13.0
13.0
12.7
12.5
13.8
13.3
13.8
12.7
12.5
13.4
02
%
7.5
7.3
7.4
7.8
7.6
7.5
7.6
7.8
8.4
7.2
7.2
7.0
7.0
7.4
7.6
5.2
7.2
7.2
7.2
7.0
7.0
7.1
7.0
7.0
6.8
7.0
7.7
7.3
7.3
8.3
8.4
7.5
Removal
Efficiency
73.0
79.3
80.0
77.4
85.4
83.2
84.0
82.6
87.2
86.0
83.7
84.0
87.9
83.1
82.8
65.6
76.0
76.0
72.0
80.4
81.5
79.6
81.5
81.5
83.7
84.4
86.7
80.0
80.9
79.8
79.6
74.0
-------
HOURLY DATA
I
to
ro
to
I
Inlet SCRUBBER
Date
12-22
(rontd)
12-23
12-24
12-25
12-26
ACFM x 2nd
Time MW 1000 Ap
08001 136 135.7 6.2
0900-1000 SCRUBBER OUT
11002 174 140.8 6.2
1200 173 140.8 f'.3
13(10 174 140.8 0.3
1400 175 146.4 7.0
1500 170 146.4 6.2
lf.00 176 146.4 0.6
1700 177 146.4 7.0
1800 17'l 140.8 0.8
1900 179 140.8 f'.M
2000 181 140.8 6.4
2100 180 135.7 0.'4
2200 178 140.8 0.4
2300 170 140.8 <>.'!
2400 100 165.9 8.3
0100 141 NF3 8.8
0200 116 180 2 9.2
0300 108 130*2 9.2
0400 108 188.4 9.2
0500 109 180.2 9.2
0600 110 180.2 8.8
0700 119 180.2 9.0
0800 140 173.1 8.0
0900H 169 146.4 6.2
SCRUBBER DOWN
SCRUBBER DOWN
NO DATA TAKEN - Crew
Stage
_£H_
7.1
7.2
7.2
7.2
7.1
7.2
7.1
7.1
7.1
7.1
7.2
7.2
7.1
7.1
7.0
6.9
6.9
7.0
7.0
7.0
7.0
7.0
7.0
7.2
still
S02
PPm
980
890
800
800
880
800
800
760
800
8HIJ
880
930
840
880
840
NF3
780
840
800
810
850
1000
880
860
INLET
NOX
PPm
400
440
440
400
440
440
440
420
420
400
400
420
400
400
400
NF
400
400
405
400
385
380
360
350
C02
JL_
14.0
12.5
12.5
13.5
14.5
13.0
J2.5
12.5
12.5
13.0
13.0
13.0
13.0
13.0
13.0
NF
13.0
13.5
13.0
13.5
12.6
13.0
12.5
12.0
02
JL
6.0
OJ8
6.8
6.5
0.4
0.8
6.8
7.0
7.0
7.0
7.0
7.0
7.0
6.8
6.9
NF
7.3
7.2
7.2
7.2
8.0
7.0
6.8
7.2
S02
PPm
180
128
140
200
200
200
100
160
160
200
200
220
200
210
140
NF
150
150
100
140
160
160
160
160
OUTLET % SOp
NOX
pprn
360
'390
390
380
380
380
380
380
360
360
360
360
360
360
360
NF
380
380
380
375
340
340
320
320
C02
JL
12.5
12.6
12.0
13.0
12.5
13.5
11.5
11.0
11.5
11.5
11.0
11.0
12.0
11.5
12.0
NF
12.0
12.0
12.4
12.5
12.0
13.0
12.0
11.0
02
JL
7.6
8.1
8.1
8.0
8.0
8.0
8.1
8.5
8.2
8.1
8.5
8.6
8.4
8.2
8.2
NF
8.4
8.2
8.2
8.0
8.4
7.0
7.8
8.2
Removal
Efficiency
81.0
85.6
82.5
75.0
77.3
75.0
80.0
78.9
80.0
77.3
77. 1
76.3
70.2
76.1
83.3
-
80.7
82.1
80.0
82.7
81.2
84.0
81.8
81.4
on holiday
Sorubber down to repair leaks
^ Scrubber start up
3 Plugged sample line
** Sombber shut down - repair leaks
-------
i«X)RLY DATA
Date
12-27
I
CO
NJ
it*
I
12-28
Inlet SCRUBBER
ACFM x 2nd
Time
08 HO1
0900
JOOO
1100
1200
1300
J400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
oinn
0201)
0300
0400
0500
0600
0700
0800
0900
1000
1100
J200
1300
1400
1500
MW
1M2
174
177
179
1RI
179
177
17 S
175
172
171
172
172
180
179
17 f,
174
17 S
175
135
135
134
134
158
109
174
170
167
16 M
164
103
138
1000 AP
180.2 6.0
180.2 5.6
NF 5.4
NF 5.7
NF 5 i|
NF 7^
NF g.O
NF 9.0
228.4 8.7
228.4 9.3
228.4 g.s
228.4 9.5
228.4 9^5
218.1 8.8
228.4 9.3
228.4 9.3
228.4 9.3
228.4 9.3
228.4 9.3
242.2 10.2
242.2 10.2
242.2 10.2
242.2 10.2
218.1 9.8
228.4 10.0
228. 9.6
228. 10.1
228. 10.0
228. 10.1
228. JO.O
228.4 10.0
228.4 11.0
Stage
pH
7.0
7.0
7.1
7.1
7.1
7.2
7.1
7.0
7.0
7.0
7.1
7.0
7.0
7.1
7.1
7.1
7.0
7.0
7.1
7.0
7.0
6.9
6.9
7.0
7.0
6.8
7.0
7.0
7.0
7.1
7.1
7.0
S02
ppm
1000
108 U
960
960
1040
1040
960
960
940
920
900
900
900
860
800
870
880
860
820
920
920
920
960
1100
1160
1160
1120
1080
1180
1020
loon
1160
INLET
NOX
PPm
460
480
480
480
480
460
460
460
430
430
435
430
440
440
470
440
450
450
440
450
450
440
440
440
4'40
440
440
380
350
370
380
370
C02
%
13.8
13.0
14.0
14. U
14.0
13.0
14.0
14.0
12.8
13.4
13.2
13.5
13.3
13.0
14.3
14.2
14.5
14.2
14.2
13.4
14.5
14.2
14.4
14.3
14.3
14.3
14.0
14.0
14.0
14.0
14.0
15.0
02
5.2
6.4
6.0
G.O
G.O
7.0
6.0
G.O
6.4
G.O
6.3
6.3
6.3
6.6
6.2
6.9
5.8
6.2
6.2
6.5
6.2
6.2
6.0
6.4
6.2
6.0
6.0
G.I
6.0
6.0
6.0
5.0
S02
PPm
160
240
200
200
180
240
200
200
120
130
110
100
110
110
110
80
80
70
70
80
100
80
90
100
160
140
120
220
240
120
140
120
OUTLET
NOX
420
420
420
420
420
420
380
380
410
370
380
385
400
400
420
405
410
410
400
420
400
400
400
400
•400
410
380
350
320
340
360
360
CU2
%
12.0
12.0
11.5
11.5
11.3
12.5
13.0
13.0
11.5
12.8
12.4
12.0
12.1
12.4
12.8
12.9
12.8
13.8
13.6
13.4
14.0
13.4
13.4
13.8
13.5
13.0
13.3
13.0
13.0
13.0
13.0
12.5
02
%
8.0
8.0
8.4
8.5
8.0
8.0
6.0
6.2
7.8
7.0
7.6
7.5
7.4
7.3
7.4
7.4
7.4
7.0
7.0
6.5
7.0
7.0
7.0
6.8
7.0
7.2
7.2
7.0
7.0
7.0
7.1
7.8
% S02
Removal
Efficiency
84.0
77.8
79.2
79.2
82.7
76.9
79.2
79.2
87.2
85.9
87.8
88.9
87.8
87.2
86.3
90.8
90.9
91.9
91.5
91.3
89.3
91.3
89.5
90.9
86.2
87.9
89.3
79.6
79.7
89.2
80. 0
89.7
*• Crr-w began talcing data
-------
HOURLY DATA
I
CO
to
(Jl
I
Inlet SCRUBBER
Date
12-28
(contri)
12-29
12-3U
12-31
Time
IfiOO1
1700
1800
1900
2000
2100
2200
2300
2400
0100
0200
0300
O'ino
osoo
(16002
0700
0800
0900
1000
1100
1200
1300
moo
1500
1000
17 OO3
1800
MW
135
172
172
179
176
179
178
176
13'l
135
135
135
135
135
135
135
ll'l
102
101
101
127
156
1S7
145
137
148
153
SCRUBBER
SCRUBBER
ACFM x <*nd
IflJlfl. 4JL.
242.2 11.0
228.4 9.6
228.4 9.8
228.4 9.0
228.4 9.0
228.4 9.5
242.2 0.6
242.2 *».6
266.2 10.0
255.0 9.8
255.0 10.0
255.0 10.2
255.0 10.2
255.0 10.2
255.0 10.2
255.0 10.2
266.2 11.0
266.2 10.4
228.4 3.3
153.6 3.3
146.4 3.6
159.7 3.0
146.4 2.8
159.7 2.6
165.9 3.5
130.6 0
130.6 0
IX)WN
DOWN
Stage
pll
7.0
7.0
7.0
7.0
7.1
7.1
7.0
7.0
7.0
6.9
6.9
6.9
6.9
6.9
6.9
7.0
7.0
7.0
7.3
7.2
7.0
6.9
7.0
6.9
7.1
7.7
*
S02
ppm
1020
1000
960
960
940
1000
1050
10SO
1020
1080
1020
1020
1020
1080
1080
1080
1020
920
1200
1300
1340
1240
1520
1520
1680
200
200
INLET
NOX
ppm
3.90
380
WO
400
400
395
390
385
390
UOO •
'100
iMIO
440
440
420
380
370
300
360
3 MO
350
380
380
370
370
270
190
C02
JL_
114.0
13.7
].i|. 5
lit. 6
13.9
13.9
1U.3
I'l.O
13.8
13.8
14.0
1U.8
14.8
14.8
1'l.fl
15.0
I'l.O
13.0
12.5
12.5
I'l.O
13.0
13.0
13.3
13.2
10.2
7.1
02
_2L
0.6
6.0
0.0
0.1
0.2
0.2
5.9
0.2
0.8
6.7
6.0
0.0
0.0
6.0
0.0
5.8
7.0
7.2
8.0
7.2
6.5
0.8
6.2
0.0
5.5
8.<4
10.0
S02
ppm
108
132
120
120
130
138
132
144
144
138
132
120
126
132
138
132
128
16"4
144
210
300
280
320
300
300
1600
*
OUTLET
NOX
PPm
300
350
370
370
380
370
365
355
370
380
360
mo
400
'100
400
380
340
330
320
290
310
310
320
320
330
380
*
C02
JL
13.1
12.9
13.3
13.4
12.8
12.5
13.4
13.3
13.3
13.0
13.8
13.5
14.2
14.2
13.8
14.0
12.5
11.5
12.0
11.0
11.0
11.0
11.5
12.0
11.4
12.5
*
02
JL
7.4
7.4
7.4
7.2
7.4
7.2
7.0
7.0
7.0
7.5
6.8
7.0
6.8
6.8
7.0
6.8
8.0
8.5
8.5
9.0
9.0
8.8
8.4
8.0
7.8
6.8
*
% S02
Removal
Efficiency
89. 'I
86.8
86.9
87.5
80.2
80.2
87. '1
86.3
8S.9
87.2
87.1
87.0
87.0
87.8
87.2
87.8
87.0
82.2
89.0
82.4
77.0
77.4
78.9
70.3
82.1
-
Readings for SO-, after 1000 arc from IhiPont unit
2 Boiler cut to three coal feeders, 0000-1300
3 Scrubber down at 1645, leak in olbow
-------
HOURLY DATA
Time
Inlet
ACFM x
MW 1000.
SCRUBBER
2nd Stage
.AP pH
S02
ppm
INLET
NOX C02
pptn %
02 S02
OUTLET
NOX C02
PPM %
02
% 502
Removal
Efficiency
I
01
to
l-'l
1-5
1-6
1-7
1-8
DOWN
SCRUBBER DOWN
ScrubbcT operating with 1st stage only
21001 171 266.2 0 OFF 900 'I'lO 1U.2
22002 171 266.2 0 OFF 840 120 II.8
SCRUBBER DOWN - 1st Stage off line at 0835
SCRUBBER IK)WN
SCRUBBER IK1WN
5.8
5.8
960
835
WO
1420
1U.8
1M.8
5.8
5.8
0
.0
1735
2000
2100
2200
2300
2'400
0100-0200
0300
O'lOO
0500
0600
0700
0800
0900
1000
1100
1200
1300
1100
1st
183
179
178
182
180
*'l
183
181
180
177
175
178
182
178
176
181
180
181
Stage only
121-8
loo . z
279.6
266. 2
266.2
266.2
*
266.2
266.2
266.2
266.2
266.2
266.2
266.2
266.2
266.2
266.2
266.2
120.3
3.3
3.5
3.5
3.i|
3.1
*
0
0
0
0
0
0
0
0
0
0
0
0
OEF NF3
OFF NF
OEF NF
OFF 1080
OFF 1120
* NF
OFF 1080
OFF 1120
OFF 1120
OFF 1120
OFF 1160
OFF 1280
OFF 1280
OFF 12'40
OFF 1210
OFF 1350
OFF 1350
OFF H80
420
375
350
370
720
NF
680
620
620
620
620
5HO
130
'410
110
100
370
390
12.6
13.0
12.7
12.5
13.5
NE
13.0
13.0
14. 0
13.5
1'4.0
12.5
13.8
13.5
13.5
13.8
1'4. 5
1'4.0
7.2
f>. 5
7.2
7.0
6.8
NF
6.8
7.0
6. *4
6.8
C.2
7.2
6.5
5.8
5.8
5.9
5.9
6.2
NF
NE
NE
1000
NF
NE
NF^
9GO
1080
1080
1080
1120
1160
11'40
1200
1200
1210
1290
390
320
3>40
380
670
NE
NF
600
600
600
590
520
•420
•400
370
390
360
380
12.8
13.2
13.1
12.8
NE
NF
NF
12.0
13.0
13.0
14.0
12.5
13.8
13. S
11.2
14.0
I'l.O
13.6
7.2
8.6
8.0
7.0
NF
NF
NF
8.0
7. '4
7.«
6.1
7.14
6.8
6.2
6.M
6.2
6.1
6.2
-
_
_
7. "I
-
-
_
1<4.3
3.6
3.6
6.9
12.5
9.M
8.1
3.2
11. 1
10. «4
6.5
Trailer on line
2 Trailer off linn due to pump failure
•j Trailer on line; SOp TBCO unit down
* Sample line repair
5 First Stage only operating
-------
HOURLY DATA
I
0)
Date Time
1-8
Inlet
ACFM x
MW 1000
(oontd) 1405-1600
17001
1800
1900
2000
2100
2200
2300
2400
1-9 01002
0200
0300
0400
0500
0600
0700
0800
0900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
176
179
179
181
180
183
*
*
184
183
184
184
178
179
179
179
170
154
154
149
149
149
149
147
140
130
133
128
125
126
129
124
SCRUBBER
2nd
AP
Stage
First Stage down
180.2
255.0
291.8
291.8
291.8
291.8
291.8
438.3
291.8
291.8
266.2
291.8
291.8
291.8
291.8
291.8
291.8
291.8
291,8
291.8
291.8
291.8
291.8
291,8
266.2
291.8
291.8
291.8
291.8
266.2
266.2
266.2
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
S02
INLET
NOX
Ppm
C02
02
%
S02
ppm
OUTLET
NOX
ppm
C02
_*_
02
% S02
Removal
Efficiency
for repairs
1300
1320
1300
1380
1390
1390
1430
1430
1300
1400
1390
1390
1500
1360
1300
1300
1070
1080
1080
1050
980
900
900
780
750
790
710
710
840
820
800
810
380
375
380
355
350
345
330
330
300
300
300
280
280
280
240
245
420
420
420
450
440
440
460
460
520
470
450
500
400
460
440
480
14.2
12.6
12.7
13.4
14.1
13.5
13.6
. 13.5
13.0
13.0
13.2
13.0
12.2
13.5
13.8
13.8
13.8
13.8
13.8
13.0
13.5
13.2
13.4
13.3
12.1
11.8
12.2
12.2
13.8
13.3
12.5
13.0
6.4
5.8
5.8
5.8
5.4
5.5
5.3
5.5
5.2
5.2
5.4
5.4
5.6
5.4
5.4
5.4
5.6
5.8
5.8
5.5
5.4
5.6
5.8
5.7
6.5
7.0
0.5
6.0
5.3
5.6
5.9
6.0
1220
1290
1290
1340
1260
1280
1340
1340
1300
1380
1360
1360
1380
1300
1300
1200
990
950
900
900
900
850
BOO
720
620
710
680
630
730
730
740
730
370
375
350
350
340
335
320
320
300
280
280
280
280
260
240
220
410
410
410
440
420
420
440
440
400
470
440
SOO
455
420
430
460
12.4
12.3
14.0
12.4
12.5
13.2
13.0
13.0
13.0
12.8
13.0
12.8
12.0
13.5
13.5
12.5
13.8
13.5
13.2
13.0
13.2
13.2
13.4
12.8
12.8
12.3
12.3
11. '»
11.8
12.0
12.4
12.0
6.5
6.2
5.6
6.0
5.9
6.0
5.8
6.0
5.8
6.1
6.0
6.0
6.0
6.0
6.0
6.0
6.1
5.8
5.8
5.8
5.4
5.8
5.8
5.8
5.6
6.5
6.2
7.4
6.8
6.7
6.4
7.0
6.2
2.3
2.3
2.9
9.4
7.9
6.3
6.3
0.0
1.4
2.2
2.2
8.0
4.4
0.0
7.7
7.5
12.0
16.7
14.3
8.2
5.6
11. 1
7.7
17.3
10.1
'1.2
11.3
13.1
8.2
7.5
9.9
1 First Stage only on line
2 First Stage only operating
-------
HOURLY DATA
Date
1-10
1-11
I
00
tsi
00
I
1-12
Time
moo
0200
0300
0400
0500
0000
0700
0800
0830
1340
1400
1500
1000
1700
1800
1900
2000
2100
2200
2300
2400
01 OO1
0200
0300
0400
0500
0600
0700
0800
0900
1000
MW
120
119
119
119
119
119
119
119
Inlet
ACFM x
1000
266.2
266.2
266.2
266.2
242.2
242.2
266; 2
266.2
SCRUBBER
2nd Stage SO2
AP pH ppm
0 OFF Bin
0 OFF 800
o OFF sno
0 OFF 800
0 OFF 800
0 OFF 8 00
0 OFF 800
0 OFF 900
Complete scrubber shut
Complete scrubber start
174
178
177
169
179
177
176
176
177
17 S
135
12S
125
126
126
127
114
108
109
109
119
146.4
180.2
197.6
197.6
197.6
140.8
197.6
197.6
197.6
218.1
218.1
218.1
242.2
242.2
218.1
218.1
218.1
207.4
207.4
207.4
197.6
1.5 7.8 1100
2.5 7.9 1100
5.0 7.4 NF
4.0 f..9 1000
5.5 7.0 1000
3.2 7.2 990
0.0 7.2 1000
6.6 7.1 1000
6.0 7.0 1000
6.0 6.9 1000
7.2 7.1 1140
7.2 7.0 1100
7.4 6.9 1100
7.4 7.0 1200
7.4 7.1 1J40
7.4 7.0 1140
6.3 7.2 1100
6.3 7.1 900
5.8 7.1 1080
O.'l 6.9 1080
6.2 7.0 1420
INLET
NOX
ppm
390
460
460
460
440
440
440
440
clown
up
410
430
450
450
450
440
440
420
440
440
440
450
440
450
450
440
410
400
420
420
430
C02
13.8
13.4
13.0
1.3.0
13. '1 '
13!'»
13.4
13.8
12.5
14.4
14.2
13.0
13.0
J3.0
14.0
in. 2
14.2
in. 3
13.5
14.0
14. 0
J4.0
13.6
13.0
13.5
13.5
14.2
13.5
1"4.0
02
%
6.0
0.4
6.6
6.6
6.4
6.4
6.2
6.0
6.8
5.8
5.0
6.2
6.2
7.0
6.2
6.4
6.4
6.4
6.0
6.0
6.2
6.0
6.4
6.5
6.6
6.4
6.4
6.4
5.8
S02
PPm
760
770
720
720
720
720
720
800
340
240
NF
140
140
180
170
120
120
120
140
140
140
160 ,
135
130
145
130
150
280
230
OUTLET % Sf>2
NOX
ppm
450
440
440
440
470
420
420
440
380
390
450
440
•440
400
400
380
380
380
380
•410
410
420
110
410
380
385
380
390
380
C02
%
J 3 . 4
12.8
13.0
12.8
12.8
13.0
13.4
13.5
13.4
12.8
11.4
13.0
13.0
11.5
13.5
13.0
13.5
13.0
13.0
12.5
12.6
12.5
13.0
12.5
12.0
12.4
12.4
13.2
13.1
02
JL
6.8
7.0
6.8
7.0
6.8
6.8
6.8
6.8
6.8
7.8
6.8
6.8
6.8
8.0
6.8
7.2
7.2
7.8
7.8
7.2
7.0
7.2
7.U
7.2
7.8
7.8
7.5
7.5
7.2
Removal
Efficiency
0.2
3.8
10. 0
10. n
10.0
10.0
10.0
11.1
69.1
7fl.2
_
86.0
8C.O
8.1.8
83.0
88.0
88.0
88.0
87.7
87.1
87.3
86.7
88.2
88.6
86. 8
85.6
80.1
7"4.1
«3.8
Coal feeder problems
-------
HOURLY DATA
I
to
ro
vo
I
Inlet
ACFM x
Date Time
1-12 1100
(contcl) 1200
1300
1400
ISOO
1000
1700
1800
1900
2000
2100
2200
2300
2MOO
1-13 0100
0200
0300
0400
0500
0600
0700
0800
O'JOO
1000
1100
1200
1300
1400
ISOO
1600
1700
1800
1900
2000
MW
127
127
129
131
132
131
133
J33
133
133
133
133
132
125
118
120
119
119
119
120
124
127
130
128
128
129
129
128
129
128
129
129
130
128
1000
197.6
197.6
197.6
188.4
188.4
197.6
197.6
197.6
197.6
218.1
207.4
207.4
218.1
207.4
207.4
197.6
207.4
207.4
207.4
207.
207.
207.
207.
207.
207.4
207.4
197. C
197.6
197.6
207.4
207.4
207.4
207.4
207.4
SCRUBBER
2nd
AP
6.5
6.1
6.0
6.0
6.0
6.0
G.O
6.0
6.0
G.O
0.0
0.0
0.0
0.0
0.2
0.2
0.2
0.2
6.2
6.4
6.0
6.2
5.8
6.1
6.3
6.2
6.2
6.5
6.5
6.0
6.4
0.6
6.6
6.6
Stage
pH
7.0
7.0
7.0
7.1
7.1
7.1
7.1
7.1
7.2
7.2
7.2
7.1
7.1
7.1
6.9
7.1
7.1
7.1
7.1
7.1
7.1
7.2
7.2
7.3
7.2
7.1
7.2
7.2
7.1
7.1
7.0
7.0
7.0
7.0
S02
ppm
1580
1580
1000
1640
1040
1600
1500
1400
1400
1500
1450
1400
1380
1380
1400
1350
1300
1300
1300
1300
1400
1300
1150
1100
1050
1000
1000
1000
1000
1000
1000
1000
1000
1000
INLET
NOX
ppm
420
425
420
425
400
410
400
400
400
400
400
395
380
380
390
390
380
380
380
380
380
380
370
380
3flS
380
380
380
390
380
390
390
380
420
C02
_2L_
13.5
14.6
14.0
.14.6
13.4
14.5
14.5
14.5
14.5
14.5
14.5
14.5
14.5
14.0
12.5
13.0
13.5
13.5
13.0
13.5
13.7
14.4
14.3
14.1
13.2
13.7
14.3
14.1
13.8
14.3
14.5
14.0
14.5
14.5
02
6.3
5.9
5.8
5.6
6.0
5.8
6.0
6.0
6.0.
5.8
5.8
5.8
S.8
6.2
6.5
6.3
0.2
0.2
6.2
6.0
5.8
5.6
5.6
5.6
5.5
5.6
5.5
5.5
5.8
5.5
5.5
5.7
5.5
5.5
S02
ppm
270
200
260
200
270
280
226
250
250
270
270
250
250
250
250
250
230
240
230
230
240
245
235
210
200
205
175
150
140
160
170
130
175
150
OUTLET
NOX
ppm
390
390
380
380
370
370
370
370
380
380
380
340
340
340
340
340
350
370
340
330
340
340
340
330
340
340
340
340
340
340
3 SO
340
350
370
C02
%
12.8
13.1
13.2
13.5
12.8
13.5
12.5
12.5
12.5
12.5
13.0
12.5
12.5
12.0
11.5
11.5
12.0
12.5
11.8
12.5
12.5
13.0
12.5
12.5
12.3
12.2
12.5
13.0
12.8
12.8
13.0
12.7
13.0
13.2
02
_*_
7.0
7.0
7.2
6.8
7.2
7.0
7.2
7.2
7.0
7.0
7.0
7.0
7.0
7.2
7.6
7.6
7.3
7.2
7.3
7.0
6.8
6.8
7.0
6.8
6.7
7.0
6.8
7.1
7.2
7.1
7.0
7.2
7.0
7.0
% S02
n 1 '
Removal
Efficiency
82.9
83.5
83.8
84.1
83.5
82.5
84.9
82.1
82.1
82.0
81.4
82.1
81.9
81.9
82.1
81.5
82.3
81.5
82.3
82.3
82.9
81.2
79.6
80.9
81.0
79.5
82.5
85.0
86.0
84.0
83.0
87.0
82.5
85.0
-------
HOURLY DATA
Date
(Contd)
1-14
U)
o
I
1-1S
1-16
1-17
1-18
Time
2100
2200
2300
2400
0100
0200
0300
0.400
0500
0600
0700
0800
0900
1000
1100
1200
1300
1'KJO
1500
1GUO
1640
1330
1>400
1500
1600
17002
MW
Inlet SCRUBBER
f*FM 3C
1000 2nd
4£_
207.
207.
207.
207.
207.
207.
207.
207.
207.
207.
207.
6.8
7.0
7.0
6.8
6.8
6.8
6.8
6.8
6.8
6.8
6.8
218.1 6.8
218.1 6.8
218.1 6.7
218.1 6.5
218.1 6.6
218.1 6.6
153.6 2.0
218.1 6.8
22M..4 7.0
Stage
pH
7.0
7.0;
7.0
7.0
7.0
6.9
6.8
7.1
7.2
7.1
7.1
7.0
6.9
7.1
7.3
7.2
6.9
7.0
7.3
7.2
S02
£pm
1000
1000
1000
1050
1000
1000
1000
1020
1050
1050
1000
1050
NFl
1300
1280
1260
1270
1250
1280
1280
TMT !"•••
INL
NOX
ppm
400
420
400
390
380
380
380
380
370
380
380
360
NF
360
350
360
360
350
360
360
C.1
C02
Ji_
14.5
I'l.O
1M.O
13.9
13.7
13.9
13.7
13.7
13.9
13.8
13. 8
11.3
NF
13.7
13.6
13.7
14.5
13.0
13.9
13.9
02
_2L
5.5
6.0
6.0
6.0
6.0
5.8
6.0
6.0
6.0
6.0
6.2
NF
NF
6.2
6.1
6.0
6.0
6.5
5.9
6.3
S02
ppm
130
170
180
350
200
180
160
160
150
150
150
100
225
255
260
230
250
270
220
NF
nt |1*T t-*f
OUIL
NOX
ppm
360
360
340
350
350
340
340
340
340
340
340
330
310
310
320
320
330
290
330
NF
C.1
CO2
_2L
13.0
12.0
12.0
12.2
12.0
13.7
12.5
12.7
12.7
12.7
12.5
12.3
12.5
12.2
12.4
12.4
12.7
10.1
12.3
NF
02
JL
7.
7.
7.
7.
7.
7.
7.
7.
7.
7.
7.
7.
7.
7.
7.
7.
7.
8.
7.
NF
1
6
6
4
2
2
5
3
4
4
4
4
4
2
2
2
5
9
5
127
SCRUBBER DOWN - out of MgO
SCRUBBER DOWN
SCRUBBER DOWN
SCRUBBER DOWN
SCRUBSF.R On-Mne
126 197.S 5.6 7.5 800
150 188.4 4.2 7.2 940
178 188.4 5.4 7.3 900
* * * * *
420 13.3 6.0 I'M) 390 12.6 6.7
450 12.5 6.8 160 425 12.3 6.7
460 13.0 6.5 140 390 11.0 8.4
*******
% S02
Removal
Efficiency
87.0
83.0
82.11
66.7
80.(I
82.0
84.0
84. 3
85.7
85.7
85.0
84.8
80.4
79.7
81.7
80.3
78.4
82.8
82.5
83.0
84.4
*• Sample line frozen
2 Scrubber shut down 1730, 1.1), fan down
-------
HOURLY DATA
Date
1-19
1-20
1-21
1-22
1-23
I
to
1-2M
Time
1130
1200
1300
1'fOO
1MM5
1500
1600
1700
1800
1900
2000
2100
2200
2300
2MOO
0100
0200
0300
OMOO
0500
0000
0700
0800
0900
1000
1100
1200
1300
Inlet
ACFM x
MW 100,0 1
SCRUBBER
177 180.2
175 173.1
*1 NF
SCRUBBER DOWN
SCRUBBER DOWN
SCRUBBER DOWN
SCRUBBER
2nd
A P
Stage
pH
On-Line
3.M
M.M
0
7.5
7.2
*
S02
PPm
10MO
1020
1000
INLET
NOX
PPm
M70
M50
MMO
C02
13.0
12.5
12.5
02
%
6.M
6.8
7.0
S02
ppm
200
210
*
OUTLET
uox
PPm
M50
M20
*
C02
JL
12.5
12.0
*
02
%
7.0
7.0
*
SCRUBBER On-Lim?
181 78.8
178 74.8
170 120.3
178 87.0
178 67.0
178 110.1
181 46.1
177 87.0
171 99.3
172 99.3
179 120.3
176 153.6
176 153.6
168 140.8
168 140.8
108 140.8
170 120.3
175 146.4
176 188.4
17 1| 207.4
178 207.4
175 218.1
176 146.4
1.8
2.0
3.2
2.0
2.0
1.2
1.2
2.M
3.M
M.5
3.6
M.O
3.8
3.8
3.8
3.8
3.8
M.'l
5.7
7.5
8.0
8.5
0
7.7
7.6
6.9
7.1
7.0
6.9
7.1
7.2
7.3
7.2
7.2
7.2
7.1
7.0
7.0
7.0
7.1
7.1
7.3
7.M
7.3
7.3
7.5
1180
1120
1200
1150
1150
1200
1100
1200
1180
1180
1200
1200
1200
1250
1300
1300
1150
1100
870
1050
1020
1080
1070
M50
MMO
M60
MMO
MMO
M30
'100
MMO
M20
M20
MMO
MMO
MMO
MMO
MOO
M20
MOO
M20
•420
M50
M50
M50
MMO
13.1
12.5
13.0
13.5
13.5
1M.O
13.11
13.8
13.0
13.5
13.5
13.5
13.5
13.5
1U.5
13.5
13.5
13.3
1M.1
1M.M
1M.3
1M.2
13.7
6.6
7.2
6.M
5.6
6.5
6.2
7.1
6.M
6.6
6.2
6.M
6.2
6.M
6.M
M.8
6.M
O.M
6.2
6.8
6.8
6.5
7.0
110
300
280
320
300
290
290
270
250
290
2MO
2MO
. 2MO
200
2MO
250
270
200
120
120
115
120
255
370
M20
MMO
MOO
MOO
380
380
3 MO
360
380
380
380
380
390
380
360
3 MO
370
360
M.O
M10
M20
260
10.8
12.0
11.8
11.8
13.0
13.0
12.5
11.5
11.5
U.5
11.5
11.5
11.5
12.5
12.0
12.5
12.0
12.2
12.9
12.5
13.2
13.6
9.1
8.6
8.0
7.M
7.14
7.2
8.0
8.0
9.0
8.0
8.0
8.M
8.2
8.M
7.8
8.0
8.2
8.M
7.8
7.8
8.2
8.2
7.8
10.0
% S02
Removal
Efficiency
80.8
79.M
90.7
73.2
76.7
72.2
73.9
75.8
73.6
77.5
78.8
75.M
80.0
80.0
80.0
8M.O
81.5
80.8
76.5
81.8
86
88
88
88
76.2
Scnibbor down at 1MOO, 1st stage overflow
-------
I
w
CO
CO
SCRUBBER
Date
1-24
(Contcl)
1-25
Time
1400
1500
J600
1700
1800
1900
2000
2100
2200
2300
2UOO
0100
0200
0300
OUOO
0500
0600
0700
0800
0900
1000
1100
1200
1300
I'lOO
1500-2400
Inlet
ACFtl x
MW 1000
172 135,7
175 197.6
176 242.2
176 255.0
J82 266.2
176 279.6
1R3 266.2
178 207.4
178 218.1
17M 218.1
174 218.1
175 218.1
178 2^8.4
179 228.4
172 242.2
141 228.4
140 255.0
138 255.0
158 218.1
177 228.4
176 NF
175 218.1
177 197.6
175 188.4
177 197;. 6
2nd Stage
.AP
1.0
4.5
3.4
3.2
3.0
3.4
3.0
8.0
8.0
8.0
7.5
7.6
9.0
9.0
9.5
9.5
9.5
9.5
6.5
8.8
9.0
9.0
8.8
8.8
8.8
SCRUBBER DOWN
pH
7.3
7.2
7.5
7.2
8.3
7.8
7.8
7.3
6.9
7.1
7.1
7.1
7.2
7.1
7.0
7.1
7.1
7.1
7.2
7.2
7.1
7.0
7.1
7.1
7.1
S02
PPii
1060
1050
1050
1000
970
980
940
920
920
950
950
900
900
900
900
900
900
1000
980
1050
1000
1000
1000
1010
1020
- Leaks In
HOURLY DATA
INLET
MOX CO2
ppm
415
440
440
420
420
430
420
420
420
430
410
410
410
400
400
410
440
440
420
430
420
420
400
400
410
•%
13.5
13.8
14.5
16.0
13.5
14.5
14.5
14.0
13.0
13.5
12.5
12.2
12.0
13.5
13.5
11.5
14.0
13.5
12.7
15.6
13.5
13.5
13,7
14.5
13.0
02
JL
6.8
6.7
6.5
6.0
7.0
6.4
7.0
6.6
6.8
6.4
6.6
6.4
7.0
6.4
6.6
6.4
6.4
6.4
6.9
6.2
6.1
6.2
6.3
6.4
6.2
S02
ppm
300
310
310
680
700
6RO
690
130
130
140
120
120
120
100
100
100
110
140
130
120
115
120
120
120
120
OUTLET
NOX C02
ppm
370
420
420
410
420
420
410
360
360
360
360
360
360
360
360
380
410
400
370
380
380
370
360
370
370
%
12. 3
13.7
13.5
15.5
13.5
14.0
14.0
11.5
12.0
11.5
11.5
11.5
11.2
12.0
12.0
14.0
13.0
12.5
11.3
11.2
11.7
11.5
12.6
12.5
11.9
02
_2L
8.8
7.2
7.0
8.0
7.0
7.0
7.0
8.5
8.0
8.2
8.0
8.0
8.0
8.0
7.8
6.8
7.8
8.0
7.6
8.1
7.2
7.6
7.8
7.7
7.6
% S02
Removal
Efficiency
71.7
7(1.5
70.5
32.0
27.8
30.6
26.0
85.9
85.9
85.3
87.il
86.7
86.7
88.9
88.9
88.9
87. R
86.0
86.7
88.6
88.5
88.0
88.0
88.1
88.2
1st stage
1-26
1-27 0100-0500
06001
0700
SCRUBBER DOWN
SCRUBBER DOWN
116 NF .7 7.4
163 NF 1.8 7.4
1000
1000
400
440
13.8
12.0
7.0
7.2
280
280
310
380
12.5
11.5
8.0
8.6
72.0
72.0
1 Start up 0525
-------
HOURLY DATA
I
CD
to
U)
I
Date
1-27
(contd)
1-28
1-29
1-30 to
8-11
8-12
Time
0800
09001
1000
1JOO
1200
1300
moo
15002
1000-2400
8/10
0100-1300
1M3&3
15004
1000
1700
1800
1900
2000
2100
2200
2300
2UOO
0100
Inlet SCRUBBER
ACFM x 2nd Stage
MW 1000 4P pH
176 nF 0.2 7.5
162 309.2 13.0 7.5
116 255.0 10.8 7.<4
138 242.2 10.2 7.2
17'l 207.4 8.0 7.2
175 207.4 7.8 7.3
17M 228.4 8.0 7.1
173 108.4 2.2 7.2
SCRUBBER DOWN
SCRUBBER DOWN
SCRUBBER DOWN
INLET •
S02
ppm
9UO
900
910
9"4<)
1020
1020
1020
1010
- Test
- Test
Boiler and Scrubber
185 87.0 1.7 *3
185 100.2 1-8 *
182 180.2 2-7 *
185 207.4 3.0 *
182 218.1 2.6 7.7
182 218.1 3.3 *
183 218.1 3-t 7.3
18'« 218.1 3.3 *
183 218.1 3.'» 7.1
183 218.1 3.2 *
183 218.1 3.2 7.0
18'l 218.1 3.2 *
10
660
700
700
670
680
680
680
700
6'IO
600
600
NOX
C02
ppm %
mo
'110
•400
'•60
510
520
520
U80
crew
crew
13.0
13.5
13.5
14.1
13.3
13.2
13.3
1«4.S
parked up
left site-
02
_2L
7.0
7.5
6.9
6.2
7.0
8.5
6.7
7.0
S02
ppin
240
63
80
105
130
125
125
160
OUTLET
NOX
ppm
380
UOO
390
M60
'150
M50
U50
<420
C02
JL
ii.i
12.2
12.9
13.3
12.0
11.8
11.5
12.7
02
_*_
8.5
8.6
7.8
6.7
8.5
8.5
6.7
7.0
% S02
Removal
Efficiency
73. 3
93.0
91.2
88. R
87.3
87.7
87.7
8U.2
equipment
down for maintenance
NF
Nr
NF
NT
NF
NF
NF
NF
NF
NF
NF
NF
.5
12.0
12.5
12.3
12.5
12.5
12.5
12. S
13.0
13. 0
13.0
12.5
*
*
6.0
6.2
6.2
6.1
6.0
6.0
6.0
6.1
6.0
6.0
and repairs
590
130
130
130
110
110
itro
110
110
100
100
90
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
11.5
12.M
12.2
10.0
10.5
10.5
10.5
10.5
10.5
10.5
10.5
10.5
*
*
6.8
8.8
8.6
8.U
8.5
8.6
8.5
8.6
8.7
8.8
-
80.3
81. H
81.14
83.6
83.8
85.3
83.8
814.3
BM.M
83.3
85.0
1 High c;as Flow 0815
2 Scrubber down 15<40
3 Trailer readings suspect until 1000, 8/12
" Scrubber start up
-------
HOURLY DATA
Date
8-J2
(Con td)
03
W
**
I
8/13
Tnloh
ACFfi x
Time
0200
0300
0400
0500
OGOO
07 (JO1
08002
0900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
0100
0200
0300
0400
0500
OGOO
0700
MW
162
I'll
151
177
ISO
ISO
183
184
186
187
185
185
185
184
185
184
184
183
185
183
184
181
184
179
185
181
180
155
1G4
186
1000
242.2
242.2
218.1
228.4
242.2
228.4
188.4
197.6
197 < 6
197.6
197.6
197.6
197.6
197.6
188.4
197.6
197.6
197.6
197.6
197.6
207.4
207.4
207.4
197.6
197.6
197.6
218.1
210.1
207.4
207.4
RrnimRER INLET
2nd Stage
A P
3.7
3.7
3.7
3.3
3.3
3.3
4.0
2.9
2.5
2.9
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.2
2.8
2.8
2.8
3.5
3.6
3.2
3.2
pH
7.0
*
7.0
*
7.0
*
0.8
*
6.8
*
7.1
*
7.0
*
7.1
*
7.1
*
7.1
*
6.8
*
7.0
*
7.0
*
7.0
*
7.1
*
S02
ppm
600
590
550
GOO
GOO
NF
780
NF
1020
NF
1080
NF
10RO
NF
1140
NF
1140
NF
1140
NF
1140
NF
1140
NT
1140
NF
1200
NF
1200
NF
NOX
ppm
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
C02
12.5
13.0
13.0
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
02
*
5.9
G.O
5.6
5.8
5.8
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
SOj
ppm
90
90
90
80
90
NF
294
NF
300
NF
300
NF
300
NF
300
NF
300
NF
300
NF
300
NF
300
NF
262
NF
300
NF
300
NF
GliTLiM
NOX
ppm
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
C02
_2L
in. 5
10.5
11.0
NF
NF
NF
NF
NF
NF
.NF
NF
NF
NF
NF
NF
NT
NF
NT
NF
NF
NF
NF
NF
NT
NF
NF
NF
NF
NF
NF
02
JL
8.6
8.6
8.3
8.4
8.3
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
*j s
-------
HOURLY PATA
U)
Ul
I
Inlet
ACFH x
Date
8/13
(Contd)
8/14
Time
0800
0900
1000
1100
1200
1300
1400
1500
1000
1700
1800
1900
2000
2100
2200
2300
2400
oiooi
0200
0300
0400
0500
0600
0700
0800
0900
1000
1100
1200
1300
1400
MW
184
184
182
183
180
183
182
181
183
184
185
184
187
184
184
184
188
183
186
170
150
151
150
178
183
186
184
181
181
178
178
1000
218.1
218.1
218.1
218.1
218.1
210.1
207.4
207.4
207.4
207.4
218.1
213.1
207.4
207.4
207.4
207.4
120.3
120.3
135.7
66.6
66.6
66.6
66.6
66.6
82.9
87.0
82.9
82.9
82.9
82.9
02.9
SCRUBBER
2nd Stage
j&P
3.3
3.3
3.3
3.0
3.6
3.0
3.0
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
3.8
2.8
1.4
1.4
2.0
0.4
0.4
0.4
0.3
0.8
0.8
0.8
0.8
0.8
0.8
0.8
pH
7.0
*
7.0
*
7.1
*
7.0
*
7.1
*
7.1
*
7.1
*
0.9
*
7.1
*
7.2
*
7.4
*
7.3
*
7.1
*
7.1
*
7.1
*
7.1
S02
ppm
1140
NF
1140
NF
1080
NF
1.170
NF
1200
NF
1260
NF
1260
NF
1260
NF
1200
NT
1260
NF
1080
NF
1080
NF
1080
NF
1080
NF
1020
NF
1020
INLET
NOX
PPm
NF
NF
NF
NF
NF
NF
NF
NF
NF
NT
NT
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
C02
%
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NT
NF
NF
NF
NF
02
JL
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
S02
ppm
294
NF
294
NF
2'40
NF
270
NF
300
NF
300
NF
300
NF
300
NF
360
NF
360
NF
180
NF
180
NF
240
NF
240
NF
240
NF
240
OUTLET
NOX
ppm
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NT
NF
NF
NF
NF
C02
JL
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NT
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NT
NF
NF
NF
NF
02
JL
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
% S02
Removal
Efficiency
74.2
_
74.2
_
77.8
-
76.9
.
75.0
_
76.2
_
76.2
_
76.2
_
71.4
_.
71.4
_
83.3
_
83.8
_
77.8
_
77.8
_
76.5
-
76.5
DuPont SOj readings
-------
HOURLY DATA
I
CO
u>
Inlet SCRUBBER
Date
8-14
(Contd)
8-15
8-16
8-17
8-18
8-19
8-20
8-21
8-22
Time
1SOO
1000
1700
1800
1900
2000
2100
2200
2300
2400
oiooi
02002
03003
0400-2400
0100-1400
14301*
15003
1GOO
17 00&
ACFM x «?nd
MW j&aa. 4?
179 32.9 0.8
179 32.9 0.8
177 105.0 1.3
177 110.1 1.3
178 140.8 2.3
179 140.8 2.4
183 165.9 3.0
178 165.9 3.0
178 130.2 3.5
179 180.2 3.5
181 188.4 3.6
178 188.4 3.8
178 207.4 4.1
SCRUBBER DOWN
SCRUBBER DOWN
SCRUBBER DOWN
SCRUBBER DOWN
SCRUBBER DOWN
SCRUBBER DOWN
SCRUBBER DOWN
SCRUBBER DOWN
176 * 1.5
175 153.6 2.0
177 165.9 2.0
179 173.1 2.0
Stage SO2
pH
*
7.1
*
7.0
*
6.9
*
7.0
*
7.1
*
7.2
*
*
*
7.4
*
ppm
NT
900
NF
900
NF
1020
NF
1020
NF
1020
NF
1080
NF
NF
1150
1200
1190
INLET
•NOx
ppm
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
C02
_*_
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
13.0
13.5
14.5
02
_2L
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
6.0
6.0
6.1
S02
ppm
NF
240
NF
240
NF
240
NF
240
NF
240
NF
240
NF
NF
370
350
340
OUTLET
NOX —
ppm
NF
NF
NF
NF
NT
NF
NF
NF
NF
NF
NF
NF
NF
NF
NT
NF
NF
CO2
_2L
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
13.0
12.5
12.7
02
_2L
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
7.8
7.3
7.2
% S02
Removal
Efficiency
75.0
-
75.0
-
76.5
-
76.5
-
76.5
_
77.8
-
_
67.8
70.8
71.4
1 DuPont SO2 readings
' Dryer plugged
3 Scrubber down 0400 - dryer pluggrd
'* Scrubber start up
* Trailer on line
^ Velocity increase 1630
-------
HOURLY DATA
Date
8-22
(Contd)
8-23
W
CO
Inlet
ACFM x
Time
1800
1900
2000
2100
2200
2300
2400
0100
0200
0300
0400
0500
06001
0700
0800
0900
1000
1100
1200
1300
1400
1500
16002
1700
1800
1900
2000
21003
2200
2300
2400
MW
184
180
177
181
178
176
178
184
181
170
138
117
116
115
116
125
171
177
181
176
180
174
171
170
182
181
174
180
178
174
158
1UUO
207.4
207.4
207.4
207.4 .
197.6
197.6
197.6
197.6-
180.4
218.1
228.4
228.4
228.4
228.4
223.4
218.1
207.4
207.4
207.4
197.6
207.4
207.4
207.4
207.4
197.4
207.4
207.4-
207.4
146.4
146.4
120.3
SCRUBBER
2nd
>4 P
3.2
3.4
3.4
3.4
3.4
3. 4
3.4
3.4
4.2
4.2
4.2
4.2
4.2
4.2
4.2
4.2
3.7
3.7
3.7
3.7
3.7
3.7
3.5
3.2
3.2
3.2
3.2
3.2
1.5
1.0
1.0
Stage
pH
7.3
*
7.2
7.2
*
7.0
*
7.0
*
6.9
*
6.9
*
6.9
*
7.1
*
7.1
*
6.9
*
6.9
*
7.0
*
7.0
*
7.0
*
*
S02
ppm
1150
1090
1100
1095
1100
1000
1000
1100
1040
1025
1090
1075
1020
NF
1140
NF
1200
NF
1200
NF
1380
NF
1380
NF
1440
NF
1500
NF
1080
NF
NF
INLET
NOX
ppm
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
C02
%
13.5
13.7
12.5
13^0
12.5
13.4
13.4
13.3
13.2
•13.3
13.0
13.1
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
02
%
5.6
6.2
6.2
6.2
6.5
6.4 •
6.4
6.5
6.7
6.5
6.7
6.9
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
S02
ppm
300
290
300
300
295
270
280
290
300
270
250
250
180
NF
300
NF
300
NF
300
NF
420
NF
390
420
400
400
410
400
500
470
500
OUTLET
NQX
Ppm
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
C02
%
12.5
12.0
12.3
12.0
11.9
12.5
12.6
12.6
12. .6
12.7
12.5
12.5
NF
NF
NF
NF
NF '
NF
NF
NF
NF
NF
12.0
12.6
12.6
12.8
12.8
12.7
12.3
12.4
12.3
02
%
6.6
7.2
7.2
7.3
7.4
7.4
7.2
7.3
7.6
7.4
7.5
7.7
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
7.4
7.0
6.8
6.8
6.6
6.7
7.8
7.0
7.6
% S02
Removal
Efficiency
73.9
73.4
72.7
72.6
73.2
73.0
72.0
73.6
71.2
73.7
77.1
76.7
82.4
-
73.7
-
75.0
-
75.0
-
69.6
_
71.7
-
72.2
-
72.7
-
53.7
' -
-
•*• DuPont SOj readings, conditioners malfunctioned
2 Outlet mode of trailer on-line
3 Centrifuge Clog
-------
HOURLY DATA
tfl
U)
00
I
Date Time
ACFM x
MW 1000
8-24 SCRUBBER DOWN -
8-25 • SCRUBBER DOWN -
1330
14001
15002
1600
1700
1800
1900
2000
2100
2200^
2300
2400
8-26 0100
0200
0300
04001*
0500
0600
0700
0800
0900
1000
1100
1200
1300
1400
184
175
178
182
180
176
177
175
182
173
171
180
177
179
182
176
183
180
176
177
176
178
180
184
185
185
173.1
173.1
180.2
180.2
180.2
173.1
180.2
188.4
188.4
188.4
188.4
188.4
138.4
.188.4
197.6
197.6
197.6
125.4
125.4
120.3
120.3
146.4
146.4
173.1
197.6
2nd
Stage S02
pH ppm
0305
0100-1300
0.0
1.8
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
0.7
3.4
0.8
0.9
0.9
0.8
1.6
1.6
2.8
3.6
7.3
*
7.3
*
7.3
*
7.3
*
7.0
*
7.0
*
6.9
*
6.9
*
6.9
*
7.2
*
7.1
-*
7.1
*
6.8
1080
NF
1140
NF
1140
NF
1140
NF
1250
1325
1325
1275
1200
1175
1300
1200
1300
1350
1300
1325
1300
1225
1200
1150
1050
NOX C02
ppm • %
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NT
NF
NF
NF
NF
NF
NF
NF
• NF
NF
13.0
13.7
12.8
12.6
12.6
12.5
12.5
12.5
12.5
13.0
13.0
13.5
12.9
1U.O
14. 4
14.6
14.5
02
-3L
NF
NF
NF
NF
NF
NF
NF
NF
5.8
5.8
5.8
5.8
5.3
5.8
6.1
6.6
5.9
6.5
6.6
6;6
6.8
6.2
6.3
6.0
5.9
S02
PPm
360
NF '
310
320
340
310
310
340
350
375
380
380
350
360
390
400
400
400
425
480
425
400
400
300
290
NOX
PPffl
NF
NF
NF
; NF
NF
NF
NF
NF
NF
NF
NF
NF
KF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
NF
C02
NF
NF
13.0
12.9
11.5
12.5
12.5
12.7
12.5
13.0
11.6
11.6
11.5
11.5
12.0
10.5
11.8
11.0
12.0
12.2
11.5
12.7
13.5
13.3
14.0
02
NF
NF
6.7
7.4
7.4
7.4
7.0
C.8
7.0
6.8
6.9
6.9
7.1
7.0
7.0
9.0
7.1
7.0
8.6
8.4
8.7
8.0
7.2
7.2
6.7
Removal
Efficiency
66.7
_
72.8
-
70.2
_
72.8
_
72.0
71.7
71.3
70.2
70.8
69.4
70.0
66.7
69.2
70.4
07.3
63. B
67.3
67.3
67.7
73.9
72.4
1 DuPont SOg .inlet readings
2 Scrubber start up
3 Trailer On-line
Velocity change
-------
HOURLY DATA
OJ
VD
I
Inlet SCRUBBER
Date
8-26
(contd)
8-27
Time
1500
1600
1700
18001
1900
2000
2100
2200
2300
2400
0100
0200
0300
0400
0500
0600
0700
0800
0900
1000
1100
1200
1300
14002
1500
1530-2400
ACFI1 x
-------
-B40-
-------
APPENDIX C
DAILY OPERATING LOGS
-Cl-
-------
-C2-
-------
NOVEMBER 1974
-C3-
-------
1974
Nov. 1 - The scrubber was not in operation. The hub for the "B"
MgO pump was not available; operators settled for reboring
the old hub and reassembled the pump. A new 3HP motor
was installed on dryer conveyor. Some attention and
effort was placed on reducing the spillage when loading
MgS03.
Nov. 2 - The centrifuge cover was installed as was the vibrator
on the MgSC>3 silo. Work was completed on the pipe
line, and the 14 inch discharge line at the "B" recycle
pump (first stage) was finished. Installation of a
pump coupling on the "B" MgO slurry pump was accomplished
and a truck load of MgO was received.
Nov. 3 - Sunday
Nov. 4 - Welding contractor began repairing various pipes. The
man-way on the first stage was opened.
Nov. 5 •- Inspected first stage inner cone. One break in the
lining in compression ring of inner skirt under the
modules was noted but no repairs were initiated. The
rod below the hanger was fine as was the plumb bob.
The vortex breaker showed signs of erosion or etching.
The hangers supporting the first stage cone were
acceptable.
Nov. 6 - The first stage man-ways were closed. An outboard
bearing on the top of the bucket elevator was worn
out. Repairs were made on leaHs in the steam line
and on the top of the scrubber. All bearings were
lubricated and the oil levels checked. The plumb bob
was operated as a check.
Nov. 7 - Work was done on cutting out and cleaning the "A" MgO
line. A leak was fixed in the sump pump discharge line.
The car of MgO was unloaded. Completed work on Suction/
Discharge headers except for "patches" or overlay
pieces, which still needed welding.
Nov. 8 - Installed bearing on top of the bucket elevator. Work
on the MgO pumps and lines has been completed; pump
performance will be tested. The fir^t stage was filled
and leak tested.
Nov. 9 - The centrifuge was started for pre-run time. The MgO
storage tank was heated. The thickeners were refilled.
The weigh belts were recalibrated and zeroed. All
solids handling equipment was test run. Water was
introduced into the second stage- At 1600 hours the
"B" MgO pump stopped. An electrician was called to
install a larger heater in the switch. By 2000 hours
-C4-
-------
the pump was back in service. The "A" MgO line was
well flushed with hot water. The level of MgO was
lowered to 20% and the first batch was prepared at
2100 hours. The man-ways on the gas ducts were closed.
Nov. 10 - At 0140 hours the fan was started but it tripped out
because the damper did not open. At 0145 the fan was
started again and gas went through the scrubber. At
0300 hours the flow was raised to 148,000 ACFM. The
pH was erratic due to the malfunctioning of the meter
in the scrubber control room. At 0800 hours the
solids handling equipment was put on line. The MgO
slurry in the tank turned to putty at 0930, and the
load was reduced to 94,000 ACFM. A new batch of MgO
was made and at 1245 hours the load was brought to
118,000 ACFM. Since the pH was not held constant during
this period of operation, many changes in flow were
experienced. At 1645 the steam control valve on the
MgO tank failed to control the temperature, the steam
to the tank was then put on manual control. At 2300
hours, a hole was discovered in the mother liquor
return line on the second stage of the scrubber.
The continuous monitoring trailer experienced some
problems after start up. Probe filters had to be
altered as they were restricting flow. Temperatures
in the conditioning system had to be changed due to
moisture reaching the analyzers. S02 readings from
0220 to 0745, 02 readings from 2045 through midnight
and CC>2 readings all day may be incorrect because of
these problems.
Nov. 11 - At 0245 hours the stack gas was routed out of the
scrubber, so repairs could be made. The following
problems were noted at this time: a broken electrode
and a leak in the pH meter system, a plugged MgO line
to the absorber, and the recycle slurry line from the
absorber to the centrifuge was parted at the discharge
header. The steam controller on the steam line to the
MgO tank was found to be operating properly, but it
appeared the check was sticking. A mechanic was not
available today from either Pepco or Hurley.
Nov. 12 - The MgO tank was drained and flushed in an attempt
to find the restriction in the line to "B" pump. The
instrumentation department worked on the temperature
monitor and steam control check valves. Changes were
made in the continuous monitoring system so the SO-
unit could automatically change scales for inlet/
outlet modes.
Nov. 13 - Four mechanics from Hurley reported for work in the
morning. The thermocouple for temperature monitoring
in the circulation line was placed in the vertical
-C5-
-------
position for more effective readings. Gas was routed
into the scrubber at 2010 hours. The pH meter was still
not functioning correctly but the steam line to the MgO
tank was working properly. The loading was increased
to 148,000 ACFM at 2130.
A probe blow-back system for the continuous monitoring
trailer was installed and made operative. This should
reduce flow problems caused by probe plugging. The
sampling site for mother liquor samples was changed in
order to take a more representative sample. York
Research personnel were asked to take pH readings
every 15 minutes as the scrubber plant pH meter was
not working properly.
Nov. 14 - The scrubber operated all day. The batch of MgO appears
to have had low reactivity. Research is needed to
evaluate the quality of the MgO effect on slurry tank
temperature and its reaction with mother liquor to
determine why the slurry jelled again as it did on
Nov. 10th. The centrifuge drop-out hopper plugged up
and had to be cleaned out. The "B" thickener dump
valve fully opened causing the dilution tank to over-
flow. Electricians were called to make repairs to the
MgO Belt indicator, heat tape, rake lowering mechanism
and MgSC>3 weigher motor. The steam line valve to the
MgO tank was shut off to observe the effect.
The continuous monitoring system was operational but
some problems developed with leakage and outlet probe
blockage. These were corrected during the day. The
SO? readings from 0530 to 0830, C>2 until 0830 hours
and C02 readings may have been incorrect,,
York personnel were performing pH tests every half hour
in order to check the accuracy of the scrubber plant pH
meter.
Nov. 15 - The scrubber was operated all day today. Early in the
day the flow had to be reduced to 110,000 ACFM from
160,000 ACFM due to foreign material plugging the weigh
feeder belt. The flow was brought back up when the
problem was corrected.
The centrifuge cover was removed and the hopper was
cleaned out. There was no spout extension for use
when loading MgSCK, as was requested on Nov. 1. There-
fore, approximately 1.5 tons of MgSOo were spilled.
When stripping the crystals which had accumulated in
the absorber while the centrifuge was being repaired,
it was found the maximum flow to the centrifuge was
55 gpm. This may be a limiting factor in the amount of
gas sent to the absorber. The pH meter had to be
repaired and was working properly by 1600 hours. The
-C6-
-------
north thickener was put into operation as a leak
developed in the cone of the south thickener.
Holland Glenn requested York chemists to take two
centrifuge cake samples per day and prepared them
for shipping to Rumsford, Rhode Island. (Essex
Regenerating Plant)
The C02 readings for the entire day are probably in-
correct due to an electrical problem within the monitor.
Nov. 16 - York chemists were asked to verify the buffer solution
used for the pH meters. Both meters (bench and con-
tinuous) were found to be about 0.3 pH units high.
The MgSC>3 conveyor at the top of the silo tripped and
the centrifuge was diverted. The MgSOo weigh belt
broke and was placed on by-pass. The bucket elevators
and centrifuge product screw malfunctioned in late
afternoon and had to be reset. The bucket elevator
kept malfunctioning during the evening and had to be
dug out and reset numerous times. At about 1800 hours
the flow was reduced due to a low pH and the problems
with the bucket elevator. A 6 inch pinch valve to the
tangential spray ruptured at 1930 hours. Gas was
taken out of scrubber at 2135 hours. The second stage
was operated until 0400 Nov. 17 to strip out the
solids.
The continuous monitoring trailer was operating until
'1000 hours when it was shut down to replace the outlet
probe with one of better design. The sample lines
also had to be flushed out. Monitoring continued at
1900 hours. The C02 readings are probably inaccurate.
Nov. 17 - The scrubber was not in service today. The equipment
downstream of the scrubber was washed out. The screw
conveyor from the dryer to the bucket elevator was
inspected. The gear box needs to be inspected more
carefully as it is very noisy. The south thickener
finished draining during the day.
Nov. 18 - The scrubber was not in service today. Three Hurley
mechanics were in working on a first stage line. It
was found the key in the drive sheave of the dryer
screw conveyor was loose and worn, and it was repaired.
PEPCO operators removed the bolts from the centrifuge
cover and the second stage discharge header was found
to be drained.
Nov. 19 - The scrubber was not in service at the start of the day.
The agitator on "A" dilution tank was hooked up elect-
rically and filled with oil. It was then ready for
service. The mechanical seal on "B" pump was leaking
badly when it was started. The liner was removed and
replaced in the centrifuge divert valve. Eleven bolts
-C7-
-------
in the "B" thickener were found to be nearly decomposed
and were replaced. Gas went to the scrubber at 1740
hours. The centrifuge cover was still leaking.
Continuous monitoring trailer was operating well after
the first two hours of operation. A bad solenoid
valve caused false readings until approximately 2030
hours. The CC>2 readings are probably inaccurate.
Nov. 2C - The scrubber operated all day. At the start of the
day, the flow had to be reduced to remove some debris
from the MgO belt. By 0100 hours the load had been
increased to 82% of design. The impeller was removed
from "A" recycle pump and Chemico personnel requested
PEPCO to order a back-up one. The bearing on the
inside of Dryer #2 conveyor to the silo had come apart.
This was what probably caused the conveyor to trip on
Nov. 16. A new leak developed in the centrifuge cover
during the day.
The continuous monitoring trailer was semi-operational,
with the S02 unit output very low and the CC>2 unit
down (C02 readings were taken by EPA Method 3).
The chemical trailer operation was normal. Some special
analyses were performed on the sump discharge, the
process water and the second stage bleed. Also some
changes were made in analytical procedures due to the
detection of interferences in some of the samples.
Nov. 21 - The scrubber operated most of the day. At 0110 hours
the bucket elevator tripped. The load reduced by about
45,000 ACFM at 0130 hours to reduce the build-up of
crystals. The temperatures associated with the dryer
did not appear correct but this may have been due to one
of the thermocouples having been located near an air
leak from outside the dryer. The front rappers fell
off the dryer in the morning, causing the thermocouples
to the fire box to be ripped out. The centrifuge
hopper had to be washed out and an attempt was made
to weld the holes in the centrifuge cover. At 1520
hours the flow was reduced to 187,000 ACFM to reduce
crystal formation. At 2000 the belts on the dryer ID
fan burned off, and the gas was removed from the scrubber,
A mechanic was called out to replace the belts.
The continuous monitoring trailer was semi-operational.
The S02 and CO2 units were repaired during the day.
Meetings were held by York, PEPCO and Chemico repre-
sentatives.
Nov. 22 - The scrubber did not operate today. An electrician
was called in at 0030 hours to check the fan. The
housing was half filled with water; it was drained,
-C8-
-------
but it still would not perform at the proper speed.
The duct and dryer man-way covers were removed and the
#2 screw conveyer was inspected. The mechanics re-
moved the dryer fan pulley for replacement. The
centrifuge cover was welded again today. Two trucks
each removed a load of MgSC>3. An unsuccessful attempt
was made at cleaning the second stage overflow line.
Nov. 23 - The scrubber did not operate. The work on the rappers
and on the dryer ID fan was completed.
Nov. 24 - The .scrubber operated for part of the time. At 0240
hours, gas entered the scrubber. At 0830 hours,
the gas was taken out of the scrubber as the sheave
bushing in the dryer gear box was the wrong size.
The sheave was replaced and the scrubber was started
at 1445 hours at 153,600 AFCM. By 1900 hours the flow
was up to 218,100 ACFM.
Nov. 25 - The scrubber operated all day. The flow was cut back
to 82,900 ACFM. The bucket elevator and screw conveyor
had to be cleaned out. By 0400 hours the load had
been increased to 91,100 ACFM. At 0945 hours the flow
stabilized at 175,000 ACFM.
The continuous monitoring trailer operated well except
for some outlet flow problems which were corrected as
soon as they occurred.
Nov. 26 - The scrubber operated all day with a flow of 165,000
ACFM. Repair work began on the south thickener valves.
During the day the cover and hopper from the centrifuge
had to be washed out. A leak developed in a 6 inch
water recycle line on the first stage and it was
sealed with a rubber lined clamp-on band.
The continuous monitoring trailer had some flow
problems. These were attributed to icing in an un-
heated part of the sampling line. Heating tape was
installed to correct the problem.
Nov. 27 - The scrubber operated all day. The level control on
the first stage and MgO tank were not working properly
and had to be repaired. The maintenance department
finished installing the valve on the south thickener.
Variations in pH during the day have been attributed
to coal feeder problems in the plant, which affect the
inlet SC>2 concentrations.
The continuous monitoring trailer was not operational
during most of the day because of a pump failure.
Several unsuccessful attempts were made to repair the
pump. Before the pump failure, an SO- comparison test
had been made on the duct, trailer ana analyzer. The
readings differed by 6%.
-C9-
-------
Nov. 28 - The scrubber operated all day but with some problems.
A leak developed in the first stage ball nozzle dis-
tribution header and had to be patched. The drain
nipple on the bottom of the sump pump discharge line
also started to leak. The feed was diverted because
the dryer drum had become over-loaded. This was re-
flected in the very wet consistency of the centrifuge
product. The centrifuge case started leaking worse
than it had been and the continuous pH meter was not
operating properly.
One York chemist was on hand during the day shift
during this holiday period.
Nov. 29 - The scrubber operated all day. A leak developed in the
line from the first stage to the distribution box. The
load was reduced in order to maintain the pH while the
boiler output was reduced. Patch clamps were installed
in the 6 inch bleed line, recycle line, and on the
discharge header of the first stage. The dryer became
overloaded again and the centrifuge feed had to be
diverted to allow the dryer to clear out. At 1745
hours the load was increased. The south thickener was
filled with water and placed on standby.
The sampling pump on the continuous monitoring trailer
was replaced during the day and the trailer was made
operational.
Nov. 30 - The scrubber operated all day. Some problems were en-
countered maintaining pH due to boiler fluctuations.
The centrifuge hopper had to be washed out during the
day. The load was increased to 228,400 ACFM at 1020
hours.
The continuous monitoring trailer was operational but
some flow problems developed.
-CIO-
-------
DECEMBER, 1974
-Cll-
-------
Dec. 1 - The scrubber operated most of the day but had many
problems. The torus sprays in the southwest corner
gave way. At 0800 hours flow was stopped to the
torus sprays but the Chemico operator was unable to
remove the flange bolts to insert the blind. The
flow was restored to the sprays but at a reduced rate.
The 6 inch scrubber bleed to thickener line developed
another leak but no pipe clamps were available to
patch it. The gas was taken from the scrubber at 2200
hours because the first stage level could not be con-
trolled.
The continuous monitoring trailer operated part of the
day. The down time was attributed to flow and electrical
problems. These were corrected by 0900 hours.
Dec. 2 - The scrubber did not operate today.
Dec. 3 - The scrubber did not operate. Blanks were installed
in two lines at the top of the scrubber. While cleaning
the pre-mix tank, the laborers dropped a bar into the
down-comer and it had to be drained to remove the bar.
The 1 inch mother liquor line to the pre-mix tank broke
and had to be replaced. A rubber insert was to be used
on the 6 inch line to the thickener until a new section
of line was ready (approx. Dec. 9). A first stage
elbow section of line was removed from the top of the
scrubber; a replacement was made and will be ready for
rubber lining tomorrow.
York chemists performed special analyses while the con-
tinuous monitoring trailer personnel performed mainten-
ance and read data.
Dec. 4 - The scrubber did not operate. The work on the 6 inch
bleed line for the first stage was completed. Work
was perfomred on the mother liquor to pre-mix tank
line and on the pH meter. The second stellited re-
stricting orifice plate was removed from the bleed line
to the thickener. An attempt was made to start the
centrifuge but it kept tripping off. A broken shear
pin on the centrifuge was found.
A new inlet probe was installed for the continuous
monitoring trailer.
Dec. 5 - The scrubber was operated during the later part of the
day. The centrifuge had to be flushed with steam and
water before it was freed. The mother liquor to pre-
mix tank line repairs were completed. The pre-mix tank
holding spring booster and the "A" second stage pump
discharge valve were replaced. At 1630 hours flow at
51,200 ACFM entered the scrubber. A second leak developed
in the first stage discharge header. Both leaks are
-C12-
-------
in a welded joint area. By 2130 hours the load was
increased to 110,100 ACFM. The recycle rate to the first
stage dropped from 4500 gal/min. to 3500 gal/min. at
2200 hours, but came back up by itself by 2330 hours.
The continuous monitoring and chemical analysis trailers
resumed analyses.
A stearing committee meeting was held with representatives
from EPA, Rumsford, Basic, PEPCO, Chemico and York.
Dec. 6 - The scrubber operated all day. Early in the day the
centrifuge cake became very wet and sticky. A vibrator
had to be kept on almost continually which caused low
instrument air pressure. At 0435 hours a large clump
of MgO plugged up the weigh feeder. The flow was cut
to 117,800 ACFM because the pH started dropping. After
the belt was cleared the load was increased. The flow
was at 230,400 ACFM by 0700 hours and later increased
as high as 240,600 ACFM. The centrifuge hopper required
almost constant attention due to plugging. The grease
fittings on the elevator belt were replaced. All of the
stellited orifices were removed from the bleed line to
the thickeners because the pipe failures in this area
were attributed to the velocity increases across the
plates. The DuPont SC>2 analyzer was repaired by the
instrumentation shop.
There were no outlet readings at 1400 while the probe
assembly was inspected.
Dec. 7 - The scrubber operated all day. The leaks in the first
stage discharge header became much worse during the day.
An unsuccessful attempt was made to patch the leaks
with polyethylene. At 1100 hours the load was being
reduced in order to install a blind in the first stage
recycle line header. By 1700 hours the load was up to
188,400 ACFM. A leak developed in the spool piece in
the first stage recycle line at the pinch valve
location, and had to be patched.
The continuous monitoring trailer operated all day but
had some pump and flow problems which were corrected
as soon as they occurred. There were no 1500 and 1600
hour readings because of the pump outage.
Dec. 8 - The scrubber operated all day. The MgO weigh feeder
belt ran off its track and had to be repaired. An-
other leak developed in the 6 inch spool line on the
first stage recycle line and had to be patched. At
1530 hours Unit #3 had wet coal problems, and the
scrubber load was cut to 146,400 ACFM from 188,400 ACFM.
The centrifuge cake was still very wet and required much
attention.
-C13-
-------
The continuous monitoring trailer had some problems
with flow on the outlet mode. The probe had to be
washed out, therefore the 0300 hour reading was
omitted.
Dec. 9 - The scrubber operated all day. Early in the day the
transition pipe between #1 and #2 feed screws plugged
and the centrifuge feed was diverted long enough for
the line to be freed. The impeller on the "B" pump
had to be replaced. A piece of rubber in the north
thickener bleed valve could not be freed so the tank
was drained.
Dec. 10 - The scrubber operated all day. The continuous pH
monitor was fluctuating but this was due to the coal
feeder problems in the plant. New overload heaters
of the correct rating were installed in the "B" MgO
pump. The rotometer for the demister spray was re-
moved and was found to be broken and frozen. The first
stage recycle pumps were shut down to replace a 14 inch
elbow. The elbow on the 6 inch plump-bob line was re-
moved but a new one was not installed. A new leak
developed in the centrifuge cover.
The continuous monitoring trailer was operational most
of the day. No readings were taken from 1300 to 1600
hours due to a sample pump outage.
The chemical trailer performed a special study on pH
vs. time, because of the differences between the con-
tinuous and bench meters. Results indicate the time
between sampling and bench measurement was sufficient
for the pH to increase 0.3 pH units.
Dec. 11 - The scrubber was operated only for a short time due to
a planned shut down. At 0300 hours new leaks were
noticed around the patches on the first stage bleed
line to the thickener. The MgO tank was diluted and
the flow was cut back in preparation for shut-down.
At 0425 hours the I.D. fan was turned off. The north
thickener was allowed to finish pumping out. The
mother liquor pump valves were repaired and a new
lined elbow was installed on the plumb-bob line. The
blind was then removed from the top of the scrubber.
The scrubber was ready for operation at 1600 hours but
no PEPCO operators were available for work.
Dec. 12 -• The scrubber was operated for only 2 hours today
because a patch came off after start up. The rubber
was cleared from the bleed valve in the north thickener
and refilling began. Flue gas entered the scrubber at
1230 hours but at 1430 a high level was noted in the
first stage, even though the bleed valve was completely
open. Due to the high back pressure the patch on the
6 inch bleed line parted. The gas was routed out of the
-C14-
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scrubber at this time. The rakes on the thickeners
were checked and found to be satisfactory.
York Chemists were informed they would have to move
their laboratory.
Dec. 13 - The scrubber was put on-line at 1800 hours today. R.
E. Donovan maintenance crews were on site in the
morning. A 20 foot section of 6 inch rubber lined
pipe was installed in the first stage bleed. The
balance of the pipe was inspected and was found to
have a baseball size blister in one section. A new
section of pipe was fabricated to replace this section.
A test of the pumps and first stage showed there was a
restriction between the thickeners and scrubber. An
inspection of a valve showed a ruptured liner. A
liner was used from the north thickener valve to re-
pair it. Gas entered the scrubber at 1810 hours at
228,400 ACFM. The flow was increased again at 1850
and was at 242,200 ACFM by 2200. The scrubber load may
be limited as the boiler experienced wet coal con-
ditions. The mother-liquor agitator kept malfunctioning.
The problem was located in the motor or gearbox.
The York chemical lab was moved into a 36 foot trailer.
Dec. 14 - The scrubber operated all day. A leak developed in
the spool piece that was installed at the 6 inch pinch
valve location on the first stage recycle line. Main-
tenance personnel removed the gear box from the mother-
liquor tank agitator. At 1600 hours the flow was cut
to 120,300 ACFM, so that repair work to the lines
could be performed. At 1705 hours the load was in-
creased again to 153,600 ACFM.
The continuous monitoring trailer operated most of
the day. An electrical short caused the main sampling
line to burn out. A temporary replacement was installed.
There are no 1800 to 2400 readings because of this
electrical short.
The move of the chemistry laboratory was completed.
Dec. 15 - The scrubber operated all day. The centrifuge and its
hopper had to be flushed out during the day. A leak
developed in the second stage discharge header. At
1645 hours the flow was increased to 188,400 ACFM. At
2030 hours the flow was cut by 48,000 ACFM because the
MgO tank nozzle plugged up and had to be cleared.
The flow was maintained at 140,800 ACFM for the rest of
the day.
The continuous monitoring trailer was semi-operational.
The temporary sample line had intermittent freeze-up
problems. An insulated line was put into service in
-CIS-
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the evening. No readings were taken until 1400 hours.
Dec. 16 - The scrubber operated all day. Electricians were
called when the "B" second stage recycle pump mal-
functioned. They installed new overload heaters. The
flow was dropped to 74,800 ACFM so the welder could re-
pair leaks in the discharge header. At 1530 hours
the boiler unit lost all coal feeders. The flow was
cut to 80,000 ACFM. By 1840 hours the load was up to
165,900 ACFM.
Dec. 17 - The scrubber operated all day. Leaks developed near
the top of the first stage vessel. Blanks were in-
stalled in the tangential nozzle lines to stop the
leaks. A new leak developed in the second stage dis-
charge header. During the afternoon the flow was in-
creased to 197,600 ACFM, and a series of tests was
carried out.
Three York Research personnel came in from Connecticut
to perform particle mass testing.
Dec. 18 - The scrubber operated all day. The load was cut at
0830 hours because of the build up of very wet
centrifuge cake in the dryer. The flow to the centri-
fuge was cut at this time so leaks could be welded in
the centrifuge cover. A new leak developed in the
second stage discharge header. While loading MgSC>3,
approximately 1 ton was spilled due to a faulty gate.
At 1930 hours, clumps of product started coming loose
in the dryer. The load was cut and the centrifuge feed
rate was reduced in order to clean the dryer.
The continuous monitoring trailer was semi-operational.
The SC>2 unit went off-line at 0400 hours. The elec-
tronics technician from York Research was in contact
with a Thermo Electron representative throughout the
day attempting to fix the unit.
The stack testers from York Research performed four
particle mass tests during the day.
Dec. 19 -• The scrubber operated part of the day. At 1000 hours
the second stage circulation was stopped so that
second stage discharge header leaks could be welded.
The gas was routed out of the scrubber at 1300 hours.
While the scrubber was down, the dryer was cleaned with
water. At 1535 hours the scrubber was back on-line at
173,000 ACFM and later flow was increased to 197,600 ACFM.
The dryer discharge conveyor tripped and had to be reset.
There continued to be a large build up in the dryer.
The continuous monitoring trailer was on-line except
for the S02 monitor. (DuPont readings were used on the
data sheets). A representative from TECO was scheduled
-C16-
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to fix the analyzer.
No stack testing was performed due to unsteady operating
conditions.
Dec. 20 - The scrubber operated all day. A leak developed in the
first stage vessel at the tangential spray nozzle level.
The front band of rappers on the dryer were not hitting
the drum. Attempts to tighten the rappers were un-
successful. A 20 foot section of pipe to the upper pond
developed a leak; it was replaced by a hose.
The continuous monitoring trailer was on-line too, but
the S02 monitor was still not working. The CC>2 analyzer
was down from 0600 to 0900 hours. The TECO SC>2 unit was
back in service in late afternoon.
No particle mass tests were performed because the boiler
load was too low.
Dec. 21 - The scrubber operated all day. At 0220 hours the flow
was increased to 130,600 ACFM. Two leaks developed on
stage nozzle distribution lines. The 8 inch pinch valve
liner on the first stage tangential nozzle line failed.
The stack testers from York Research left today with
plans to return in early January.
Dec. 22 - The unit was operated all day with one brief outage.
At the start of the day, a leak developed in the first
stage recycle line to the plumb bob on the north side
of the scrubber. The scrubber was taken off-line at
0910 hours, and the pinch valve was repaired. The
scrubber was on-line again at 1020 hours at 140,800 ACFM.
The flow was increased to 146,400 ACFM by 1500 hours.
Dec. 23 - The scrubber operated in the beginning of the day.
The liner in the pinch valve of the first stage
recycle line ruptured. A leak also developed in a
second stage discharge line. The gas was diverted from
the scrubber at 0900.
York Research personnel departed for the holiday at
0900 hours.
Dec. 24 - The scrubber was not operated today. Shutdown procedures
were completed during the day.
Dec. 25 - The scrubber was not operated today.
Dec. 26 - The scrubber came on-line at the end of the day. The
second stage discharge header was welded, and the first
stage spool piece with an orifice plate was installed.
The pre-mix tank was cleared out during the day. An
-C17-
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electrician was called to check a relay on the second
stage recycle pumps. Gas entered the scrubber at 2140
hours.
Dec. 27 - The scrubber operated all day. During the morning the
load was cut so the pre-mix tank could be cleared. A
mechanic adjusted the packing on the first stage and
transfer pumps. The flow was increased throughout the
day and was at 228,000 ACFM at 1900 hours.
York Research personnel resumed their testing at 0800
hours.
Dec. 28 - The scrubber operated all day. The centrifuge had to
be diverted so the bucket elevator and the centrifuge
hopper could be cleared. A leak developed on the first
stage pump elbow and was plugged. Leaks also developed
in the pH meter probe assembly and second stage suction
header.
The SC>2 monitor in the York Research trailer was not
working properly; DuPont readings were used from
1700 hours on.
Dec. 29 - The scrubber was operated for part of the day. A
second hole on the first stage elbow had to be plugged.
At 1000 hours the bucket elevator tripped; the inlet
flow was reduced to allow the system to clear itself.
At 1345 hours an upset occurred in the mother liquor
and pre-mix tank. The gas was routed out of the
scrubber at this time to repair the elbow leak for a
third time. The ID fan would not restart because of
a damper problem.'
The SC>2 analyzer in the continuous monitoring was re-
paired and on line at 1050 hours.
Dec. 30 -• The scrubber did not operate today. Final shut-down
operations were carried out. The second stage suction
header was removed, the water valve on the centrifuge
deck was replaced, the gasket on the dryer ID fan was
replaced, and the leaky elbow on the first stage was
removed for repair.
-C18-
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JANUARY, 1975
-C19-
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Jan. 1 - The scrubber was not in operation today. The inside
of the second stage was inspected and a large amount
of crystals and dirt was found. It was concluded
that some of the spray nozzles were plugged. The first
stage elbow was replaced during the day.
Jan. 2 - Maintenance continued.
Jan. 3 - At the start of the day, maintenance was still being
performed on the scrubber. Two of the flow meters
froze; replacements were ordered. Gas entered the
scrubber at 1545 hours and was at a flow of 266,200 ACFM
by 2100 hours.
A new sample line for the continuous monitoring trailer
was installed during the day. Leaks in fittings on the
new line were eliminated but readings on the TECO unit
appeared very low. The probable cause was a bad ampli-
fier. Pump problems were encountered in the evening;
therefore the readings for the day were inaccurate.
Jan. 4 - The scrubber operated until 0840 hours. A 3 inch drain
valve on the second stage was plugged. The rake on
the thickener was placed in service today.
The continuous monitoring trailer was not in operation.
Jan. 5 •• The scrubber was not operated today. One of the second
stage demisters was freed, and maintenance continued.
Jan. 6 -• The scrubber was not operated today. Maintenance
continued.
Jan. 7 - The scrubber was not operated until late in the after-
noon. The second stage was inspected and found to have
no leaks. The valves to the second stage cone and
tangential sprays were blocked. The mother liquor
agitator was repaired and re-installed. At 1735 hours
gas entered the first stage. The second stage was not
operated. The load was increased to 255,000 ACFM and was
up to 279,200 ACFM by 2200 hours.
The continuous monitoring trailer had many problems.
The sample pumps failed and part of the sample line
burned out and had to be replaced.
Jan. 8 - The first stage was operating at the start of the day.
At 1405 hours the gas was removed so a leak in the "B"
discharge line could be repaired. The first stage was
back on-line at 1600 hours and flow was up to 180,200
ACFM by 1700 hours.
At 1825 the load was raised 291,800
-C20-
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The continuous monitoring trailer operated well after
0300 hours. The NOx readings in the later part of the
day were inaccurate due to a blocked capillary, which
was discovered the next day.
Jan. 9 - The first stage of the scrubber operated until 1600
when the load was reduced because of coal feeder
problems. A lubrication program was carried out during
the day.
The continuous monitoring trailer operated with only
small flow problems. The blocked capillary on the NOx
monitor was corrected at 0900 hours.
Jan. 10 - The scrubber was operated until 0830. The gas was re-
moved and repairs were made on the rubber lined elbow
on the "B" first stage pump. A leak developed on an
inner cone line and had to be repaired.
Jan. 11 - Repair work continued. A leak was found in the second
stage bleed to the centrifuge. The first and the
second stages of the scrubber came on-line at 1340
hours at 146,400 ACFM. The load increased to 197,600
ACFM at 2100. The centrifuge cover was leaking by the
end of the day.
The continuous monitoring trailer operated well, except
that the SO2 readings for 1600 were not taken because
the analyzer was being repaired.
Jan. 12 - The scrubber operated at a decreased load because of
problems with the coal feeders in the station. At
1530 hours the MgO "A" pump suddenly lost pressure and
the load was cut back to 188,400 ACFM; while cleaning
and changing to the line "B" pump. The flow was then
increased to 218,100 ACFM. The MgO weigh feeder was
suspected to be incorrect.
Jan. 13 - The scrubber operated at this same level all day. Tests
were performed to evaluate the accuracy of the MgO
weigh feeder and it was found to be 25% high. A first
stage inner cone developed a leak and was repaired. New
leaks were noticed in the centrifuge cover.
The continuous monitoring trailer operated all day except
for the outlet stack temperature monitor.
Jan. 14 - The scrubber operated between 202,000 and 220,000 ACFM
until 1640 hours when it was shut down because the MgO
supply had been exhausted. A number of problems were
encountered before the shut-down. Among them were the
centrifuge hopper constantly plugged, the first stage
level controller froze up, the pre-mix tank partially
solidified, and the wash hose for the centrifuge hopper
froze.
-C21-
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The continuous monitoring trailer operated all day.
No readings were taken at 0900 because the sample line
was frozen. This problem was immediately corrected.
Jan. 15 •• The scrubber did not operate. The first stage was kept
running to prevent it from freezing. New test buckets
were installed on the bucket elevator. Maintenance and
freeze-up precautions were carried out.
Jan. 16 - The first stage was again kept running to prevent a
freeze-up. A leak was discovered on the pH meter
probe assembly. Three loads of MgO arrived during
the night shift.
Jan. 17 - The first stage was operated without gas to prevent
its freezing. The "B" first stage pump failed to
work correctly and was inspected. An 18 inch section
of broken-off tangential spray nozzle was found in the
pump. A new leak developed at the 10 inch tee to the
tangential spray. At 1545 the first stage was shut
down to save wear on the scrubber.
Jan. 18 - The first stage, without flue gas, was operated to avoid
a freeze-up. The 10 inch line with the leak was
removed. The ten tangential nozzles were inspected and
the results were: six of the nozzles were completely
missing, two were about to break and the other two were
in fair condition. Because of the low plant output,
60 MW, the scrubber could not start up until 1315 hours.
At 1400 the load was at 197,600 ACFM. At 1600 hours
the dryer was fired but the screw conveyor at the top
of the MgS03 silo kept tripping out. The operator was
unable to inspect the screw because of the ice on the
scaffolding. Flue gas was routed out of the scrubber
at 1730 hours.
The continuous monitoring trailer operated properly for
the time the scrubber was on-line.
Jan. 19 - The scrubber was operated for a brief period. The
problem with the MgSC>3 conveyor was corrected and gas
entered the scrubber at 1130 hours. At 1345 the flows
and levels in the first stage could not be controlled
due to a plugged line. At 1400 hours the gas was turned
off.
Jan. 20 - The scrubber did not operate. Maintenance was per-
formed on a valve liner.
Jan. 21 - The scrubber did not operate. The pumps and solids
handling equipment were operated hourly to prevent
a freeze-up.
-C22-
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Jan. 22 - The scrubber did not operate. Maintenance and freeze-
up prevention were carried out throughout the day.
Jan. 23 - The scrubber came on-line during the afternoon. Before
start-up work was completed on the thickener bleed line
that plugged on Jan. 19. Gas entered the scrubber at
1445 hours. At 1615 hours the flow was at 120,300 ACFM.
Problems developed in the MgO feeder and the flow had
to be reduced to 87,000 ACFM to maintain the pH. At
2245 hours the flow was raised to 99,300 ACFM.
Jan. 24 - The scrubber operated all day. During the day leaks
developed in the torus spray and in the first stage
tangential spray header. At 0630 the flow was cut to
120,300 ACFM because of the low pH. By 0900 hours the
flow was increased to 207,400 ACFM. Experiments with
restricted flows were carried out on the second stage.
The centrifuge hopper plugged and the load had to be
cut to 135,700 ACFM but it was raised to 255,000 ACFM
by 1600. At 1650 the bucket elevator tripped. The
belts on the top of the elevator had to be replaced.
The scrubber operated at 218,100 ACFM for the rest of
the day.
Jan. 25 - The scrubber operated most of the day. The centrifuge
hopper was washed out to avoid plugging. The gas was
removed at 1500 hours to insure that the scrubber
would be able to operate for a visit by Chemico
management on Jan. 27.
Jan. 26 - The scrubber did not operate. Leaks were patched and
new belts were installed on the bucket elevator. Pumps
and solids handling equipment were operated hourly to
prevent a freeze-up.
Jan. 27 - The scrubber was operated for part of the day. Gas
entered the scrubber at 0525 hours. The load was
changed many times during the day; the maximum load
was 309,200 ACFM. The scrubber was operated in both
Mode I (gas after precipitator) and Mode II (gas
before the precipitator). When in Mode II it was noted
the centrifuge cake was very dirty from carry-over
fly ash. At 1540 the gas was removed from the scrubber.
The continuous monitoring trailer operated well; except
that the inlet velocity readings before 0900 are
inaccurate because of a crimped pitot line.
Jan. 28 - The scrubber did not operate. Final scrubber shut-down
procedures were carried out.
The boiler (Unit #3) was shut down for a major turbine
overhaul which took several months. The scrubber did
not operate until August 11, 1975, when operation was
planned for only 3 to 4 weeks to consume the MgO on hand,
-C23-
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The supply of MgO was limited due to the shut-down of
the Essex Regeneration Facility in Rhode Island.
Jan. 29 •- The buckets that were installed on Jan. 15th were
removed and inspected. They were found to be bent out
of shape to the extent that they were ineffective.
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AUGUST-OCTOBER, 1975
-C25-
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Aug. 11 - The scrubber began operating at 1403 hours; however,
due to the outlet damper sticking, the gas flow was
shut off. At 1435 gas entered the scrubber at 87,000
ACFM. When steam was admitted to the MgO slurry tank,
the control valve cracked; and operation continued
without steam. The scrubber operated the rest of the
day at 218,100 ACFM.
The continuous monitoring trailer had many problems.
Water in the gas conditioning system overflowed and
flooded the sample lines.
NOTE: Due to limited manpower, scrubber operating
parameters were taken only every 2 hours.
Aug. 12 - The scrubber operated all day except for a brief shut-
down. The outage was to replace some first stage bleed
lines.
The continuous monitoring trailer experienced more
flooded lines because the condensers failed during
the night.
Aug. 13 - The scrubber operated most of the day at between 197,600
and 218,100 ACFM.
The continuous monitoring trailer was off line because
of the problems with excessive moisture in the sampling
lines.
Aug. 14 - The scrubber operated all day. At the start of the day,
the flow was cut to 120,300 ACFM and then further
reduced to 82,900 ACFM because of a build up of dryer
product. By 2400 hours it had been raised to 180,200
ACFM.
The continuous monitoring trailer was not on line because
of gas conditioner malfunctions.
Aug. 15 - The scrubber operated for only a short time today. The
flow was increased to 207,400 ACFM by 0225 hours. Because
of a build up of the dryer product, the flow was reduced
and at 0400 the scrubber was shut down.
Repair work continued on the continuous monitoring
trailer.
Aug. 16 - Repair work was initiated oh the dryer drum. The boiler
developed a tube leak at 0018. Repairs on the boiler
tube were complete at 2010.
Aug. 17 - Repair work on the scrubber continued.
Aug. 18 - Repair work on the scrubber continued.
-C26-
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Aug. 19 - Repair work on the scrubber continued.
Air conditioning maintenance people repaired the
condensing units on the continuous monitoring sample
system.
Aug. 20 - Repair work on the scrubber continued. The boiler
developed a reheater tube leak at 0100. This was re-
paired by midnight.
Aug. 21 - Repair work on the scrubber continued.
Aug. 22 - Repair work on the scrubber was completed. Gas entered
the scrubber at 1430 hours at 153,600 ACFM. The flow
was raised to 197,600 ACFM by midnight.
The continuous monitoring system operated well after
start up.
Aug. 23 - The scrubber was at a flow of between 197,600 and 228,400
ACFM for most of the day. At 1800 hours the bucket
elevator tripped several times but was finally restarted.
At 2300 hours, centrifuge clogging problems forced a
scrubber shut-down.
The continuous monitoring trailer was shut down at
0500 because of moisture problems. The outlet mode
only was operational from 1600 hours.
Aug. 24 - The centrifuge hopper was washed out.
Aug. 25 - The centrifuge cleaning and repair was completed. Gas
entered the scrubber at 1330 at 173,100 ACFM. By 1600 the
load was increased to 180,200 ACFM.
Air conditioner repair people serviced the conditioning
units on the continuous monitoring trailer. The outlet
mode was operational at start up and the inlet mode
on-line at 2200 hours.
Aug. 26 - The scrubber was operated until 1830. At this time
it was decided to shut the second stage down and adjust
the weir height in the centrifuge. It was hoped that
this would produce a dryer centrifuge cake. The first
stage was operated the remainder of the day.
The continuous monitoring system operated all day. At
2030 hours it was placed on outlet mode only for the
night.
Aug. 27 - The first stage of the scrubber operated until 1530
hours when it was taken off line to repair leaks in
the first stage recycle lines.
-C27-
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The continuous monitoring trailer operated on outlet
mode only until 1200 hours. Repairs on the inlet
conditi cner were completed and inlet/outlet monitoring
resumed.
Aug. 28 •- Shut-down procedures were carried out on the scrubber
and continuous monitoring trailer.
Aug. 28-
Sept. 11 Repairs on scrubber continued.
Sept. 11 -• Scrubber operation was limited to the first stage in
order for the plant to conduct a study on particle re-
moval using both the electrostatic precipitator and the
scrubber. The first stage began operation at 0925 and
shut down 12 hours later for repairs on the boiler and ESP,
Sept. 12 -
Sept. 18 Particle removal study continued.
Sept. 19 - Repairs planned on stirrer bearing on MgO slurry tank
Sect 20 agitator. First stage in operation for a total of 84
p * hours during study
Oct. 19 - Wait for delivery of bearing.
Oct. 20 - Scrubber startup of both stages. The centrifuge was com-
pletely "cemented" with product and during the startup the
pins were sheared. Maintenance and further repair of the
unit was judged too costly by the plant representatives
and the program was terminated.
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APPENDIX D
METHODOLOGY
-Dl-
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-D2-
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CHEMICAL ANALYSES
METHODOLOGY
-D3-
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% FREE WATER ON CENTRIFUGE CAKE
A portion of the sample was weighed in a tared vessel. Several
aliquots of acetone were added to wash the sample which was stirred
and separated. The sample was transferred to a tared watch glass,
oven-dried for 30 minutes and re-weighed to obtain the oven-dried
sample weight.
Calculation: % Free water = 100 - % solids
where: % Solids = wt. of oven-dried sample
wt. of original sample
% COMBINED H?0 on CENTRIFUGE CAKE AND DRYER PRODUCT
A 10.0 gr portion of the oven-dried sample was placed on an
OHAUS moisture balance for 50 minutes. When complete, % moisture
was read from the calibrated scale.
pH
The pH of the samples was taken using a Corning Research pH
meter. The meter was first standardized using two standard buffer
solutions; and temperature compensated. Readings on the meter were
then takein + 0.01.
DENSITY DETERMINATION ON MOTHER LIQUOR, 2nd STAGE BLEED, MgO SLURRY
A 10.0 ml (2 ml ) sample was placed in a tared graduated tube
and weighed on an analytical balance. This analysis was always
performed in triplicate.
Calculation: wt. sample = Density in ms/ml
ml sample
APPARENT DINSITY; CENTRIFUGE CAKE AND DRYER PRODUCT (As Received)
A 100 ml plastic cup was tared and filled loosely with sample to
the mark. The weight was taken on the triple beam balance and
evaluated:
grans/100 ml = weight/100 ml
SUSPENDED SOLIDS (mq/1)
200 mis of sample filtered through a tared millipore filter, dried
in an oven for 1 hour @ 125°F and weighed.
Calculation: mg/1 S.S. = mgs S. solids x 5
200 mis sample
-D4-
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% MgO IN MOTHER LIQUOR, MgO SLURRY AND SECOND STAGE BLEED
A portion of the sample was collected into a graduate centrifuge
tube. The exact volume was noted and the sample was analytically
transferred to a beaker. A reaction with 3% H202 was induced by
boiling and a quantity of H2SC>4 was added.
For MgO slurrys add 25 ml of 2.512N H2S04
For Mother Liquor, 2nd stage bleed add 10 ml of 2.512N H2S04
The solution was stirred and boiled for 5 minutes, then diluted.
When cooled, a methyl purple indicator was added and the solution
was titrated with NaOH to a distinct green endpoint.
Calculation: % MgO = (ml H2S04 x N) - (ml NaOH x N)
mis sample
% MgO DETERMINATION ON CENTRIFUGE CAKE (OVEN DRIED) , DRYER PRODUCT
2nd STAGE BLEED SOLIDS, MOTHER LIQUOR SOLIDS, MgO BELT
These samples were prepared as above except the quantity of
H2S04 which was added.
For MgO Belt sample add 25.0 ml of 2.512 N H2SO4
For the rest add 50.0 ml of 0.50 N
Calculation: % MgO = (mis H?S04 x N) - (mis NaOH x N) 0 n, ,
1 i — .-" JC £• • \) J. 0
sample wt.
CHLORIDE
Liquid, Homogeneous
A portion of the sample was treated with an aliquot of HN03
and AgN03 and allowed to become turbid. The concentration
of chloride was calculated from the turbidimetric calibration
curve, FIGURE D-l and the turbidity reading on the meter.
Solids and Slurrys
A weighed sample was treated with an aliquot of HN03 and
heated to complete dissolution. The contents were then
diluted to a known volume and an aliquot was treated with
AgN03 . The resultant turbidity was read on a meter and
calculated from the calibration curve, FIGURE D-l.
Calculation: % Cl- = mg/1 x vol.
rooo x
wt. x 1000
-D5-
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I
a
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Percent Magnesium
The percent magnesium was determined by a titration with a
standard solution of disodium ethylenediaminetetraacetic
acid solution (EDTA). The pH was adjusted to 10 + 0.05. A
suitable sample volume was chosen, the pH adjusted and titrated
with EDTA solution. The end point of the titration was deter-
mined by the addition of Eriochrome Black T, because the
indicator color was red in the presence of magnesium and blue
when the cations are completely complexed with the EDTA.
Calculations were made from the amount of titrant consumed
by the sample. The amount of magnesium was determined on the
filtrate portion of the samples. Calcium was first precipi-
tated out of solution as the oxalate. The magnesium was
calculated from the amount of EDTA consumed and reported in
gr/1.
Magnesium content in solids was determined by treating a
weighed portion of the sample with 1:4 HNC>3 and heated until
dissolution was complete. The solution was then diluted and
an aliquot treated with NH4O4, oxalic acid and filtered.
The solution was buffered to a pH of 10.0 + 0.02 and titrated
as above.
Calculation: % Mg = mg/1 x vol. x IQO%
1000
wt. x 1000
% SOLIDS (GRAVIMETRIC) ON 2nd STAGE BLEED AND MOTHER LIQUOR
An aliquot of the sample was placed in a preheated, tared
bottle and weighed. The sample was shaken, filtered, and
re-weighed. The filter was then washed repeatedly with
portions of acetone and dried in an oven at 135°F for 30
minutes. The sample was then re-weighed and calculated as
follows:
% Solids = wt. dry solids ,nn
— — <\— , X -L U U
sample wt.
% MgSOa on 2nd STAGE BLEED FILTRATE
The filtrate saved from the % solids analysis was allowed to
sit for 1-2 hours to allow any solids to settle out. 10.0
mis was pipetted into a tared vessel, and weighed. From this
the density equalled 0.1 x weight of 10 ml.
Calculation: The % MgSO^ is then read from the graph on the
following page (data from Perry's Engineering Handbook).
(Figure D-2)
-D7-
-------
I
o
oo
I
2S -
20
5 '
DENSITY OF
SOLUTIONS
(ref. Perry's Handbook)
1 .0(1
1.05 1.10 1.15 1.20
Density
1.25
1.30
-------
Sulfate
Sulfate was determined on a filtered sample because
particulate matter interferes with the gravimetric
method. Determinations made on solid samples were per-
formed after the potassium carbonate fusion (1.2) and
dissolution. The clarified sample was acidified to a
pH of 4.5-5.0, an additional amount of hydrochloric
acid was then added. This solution was heated to boil-
ing and, while being stirred gently, a solution of
barium chloride was added slowly until precipitation
appeared complete; then a 2 ml excess of barium chloride
was added. The precipitate was digested at 80-90°C,
and to insure proper crystallization of the BaSC>4 the
solution was let to stand overnight. The precipitate
was filtered and washed with distilled water until free
of chloride. The BaSC>4 crystals and the filter were
dried and ignited at 600°C for one hour, cooled in a
dessicator and weighed. The amount of sulfate present
in the sample was calculated from the equation:
mg 804/1 = mg BaSO* x 411.5
ml of sample
% MgS04 in DRYER PRODUCT, CENTRIFUGE CAKE (OVEN-DRIED) AND
MgO BELT SAMPLES
A weighed portion of sample was diluted and treated with an
aliquot of 1:1 HC1 and boiled for several minutes. The hot
solution was filtered analytically. A portion of the cooled
solution was treated with a HACK Sulfaner reagent and placed
in a colorimeter cell. The solution was allowed to react
and then shaken. The absorbance was then read on the color-
imeter, and calculated from the calibration curve (Figure D-3)
Calculation: % MgS04 = meter reading x 0.3133
-D9-
-------
o
I
125
100
3
3
(A
-H44-4--W4WW -H-J4I H
SULFATE
BY
SULFAVER IV
30 40 50 60 70 80 90 100
-------
% MgS03 IN CENTRIFUGE CAKE AND DRYER PRODUCT
The percent sulfite in the solid samples was determined titri-
metrically. A weighed portion of the sample was treated with a
normal solution of sodium and diluted with water. Immediately
before titration with 0.1N solution of sodium thiasulfate, an
aliquot of 1:1 HC1 was added. The solution was titrated to a pale
yellow and a few drops of starch indicator added. The titration
continued until a clear endpoint was obtained.
Calculation: % MgSOj = (ml 12 x N l2)-(ml Na2S;)03 x NH S?C>3)x5.215
sample wt.
% MgS03.6H2O in SECOND STAGE BLEED AND MOTHER LIQUOR
A portion of the sample was collected in a graduated centrifuge
tube and the exact volume noted. The contents were transferred
analytically, diluted, and treated with 2.5 normal H2S04 dropwise
to a pH of 4.5-5.0. An aliquot of Kl-starch indicator was added
and the solution titrated with standard KI03 solution to a faint
blue color. The solution stirred with a magnetic stirrer and
titrated carefully to a deep blue endpoint.
Calculation: % MgS03.6 H2O = ml KIO3 x NKI03 x 7 . 08
ml sample
% Sulfite
As above with the following calculation:
%S03 = ml KI03 x NKI03 x 2.668
ml sample
-Dll-
-------
-D12-
-------
CONTINUOUS MONITORING
SAMPLING PROCEDURES AND
WET TEST RESULTS
-D13-
-------
MONITORING HARDWARE
The mobile emissions measuring laboratory consisted of six
separate monitoring devices for continuous 24 hour measurement
of sulfur dioxide, nitrogen oxides, carbon dioxide, carbon
monoxide, oxygen, and inlet velocity pressure. Each unit was
selected for its accuracy, reliability, and applicability. In
addition to these units, inlet duct, outlet duct and sample
line temperature were monitored with chromel-alumel thermocouples
and digital readouts. All of the above systems had Rustak strip
chart recorders operating continuously. A brief description of
each of the emissions monitoring instruments follows.
-D14-
-------
THERMO-ELECTRON CORPORATION MODEL 10B CHEMILUMINESCENT NO-NOX
ANALYZER
The TECO NO-NOX Gas Analyzer provides a sensitive and accurate
means of continuously measuring the concentrations of nitric
oxide (NO) and total oxides of nitrogen (NO + N©2) in stack
gases. The heart of the analyzer is the cylindrical reaction
chamber Figure D-4 where sample gas containing NO molecules
mixes with 03 molecules from the ozone generator. Electronically
excited N02 molecules are created which emit light (chemilumines-
cense) as the orbital elecrons decay to their ground state.
Specifically:
NO + 03 *• N02 + 02 + hj/
In operation, dry filtered air is drawn into the instrument and
a portion is converted to 03 in an ozone generator. Separate
capillary tubes carry the mixture of 02 and 03 and sample gas
into the reaction chamber where mixing occurs. A vacuum pump
keeps the reaction chamber pressure at a constant -25 inches of
mercury. The chemiluminescent signal in the reaction chamber is
deflected by a high sensitivity photomultiplier tube; the de-
flection of which is limited to the narrow wavelength band pro-
duced only by the NO-03 reaction. The signal as it leaves the
tube enters an electrometer amplifier which further amplifies
the signal and converts it to voltage. The amplifier voltage
output powers the meter and the strip chart recorders.
To measure NO concentrations, the sample gas to be analyzed is
blended with 03 in the reaction chamber. The resulting chemi-
luminescence is monitored through an optical filter by a high
sensitivity photomultiplier position at one end of the reactor.
The output from the photomultiplier is linearly proportional to
the NO concentration.
To measure NOX concentrations the sample gas is diverted through
a stainless steel heated coil which converts any N©2 to NO before
the sample enters the reaction chamber. The chemiluminescent
response is linearly proportional to the NOX concentration
entering the converter.
-D15-
-------
EXHAUST
NO MODE
FILTER
DRY AIR
OR
OXYGEN
PHOTO-
MULTIPLIED
NO OR NO
SAMPLE
NOX - NO
.CONVERTER
NOX MODE
STRIP CHART
RECORDER
(OPTIONAL)
POWER
SUPPLY
FIGURE D-4
Chemiluminescent NO-NOX Gas Analyzer Conceptual Schematic
-D16-
-------
INSTRUMENT CALIBRATION
All analyzers were calibrated daily in the manner specified by
the manufacturer of the instrument. Calibration Gas was stored
in the rear of the York Research Corporation Monitoring trailer
and was injected at specifically controlled rates from the
master control panel located within the trailer proper.
In addition to the standard calibration methodology, the
combination gas was injected up an auziliary sample carrying
line into the probe and then returned to the analyzers through
the usual passageways. Utilizing this method, York engineers
could determine if probe or sample line leakage existed.
As a final check on the instruments, York Research performed
wet chemical testing under strict EPA guidelines (Tables D-l
through D-5) . Samples were taken simultaneously at the inlet
position and the trailer's analyzer lead-in, and then again at
the outlet position and the trailer's analyzer lead-in. The
following methods were used to verify instrumentation:
Sulfur Dioxide: EPA Method #6
Nitrogen Oxide: EPA Method #7
Carbon Dioxide, Oxygen, and Carbon Monoxide: EPA Method #3
The S02 sampling and analysis was performed in accordance with
the specifications outlined in the Federal Register, Vol. 36,
No. 247 - Thursday, December 23, 1971, and designated as Method
6 - "Determination of Sulfur Dioxide Emissions From Stationary
Sources". This method basically consists of pulling the stack
gas sample through a heated, glass-lined probe and bubbling it
through a series of four midget impingers, reference Figure 1.
The first impinger contains 15 ml of isopropanol, which will
scrub the SOj and ^304 out of the sample gas stream. The next
two impingers each contain 15 ml of hydrogen peroxide, which
is used to oxidize the S02 to S03 and react with the 503 to
form H2SO^j. The fourth impinger remains empty. The S02 samples
were analyzed on-site by titration to a pink end-point using
standardized barium chloride.
Nitrogen Oxides
Nitrogen oxide samples were taken using Method 7 - "Determination
of Nitrogen Oxide Emissions From Stationary Sources" as printed
in the Federal Register, Vol. 36, No. 247 - Thursday, December 23,
19-1. The procedure for obtaining the sample is to evacuate a
two liter glass flask to approximately 26 inches of mercury.
The flask, containing 25 ml of a sulfuric acid - hydrogen
peroxide solution, is evacuated and leak- tested. Stack gas is
then pulled into the flask by vacuum and a complex of H2S04/N02
-D17-
-------
is formod. Any NO that is present in the stack gas is oxidized
to N02 with available oxygen from the hydrogen peroxide. See
Figure !>.
Analysis of the sample is performed by reaction with phenoldi-
sulfonic acid in a basic medium. A yellow nitrate is formed
which has a color proportional to the concentration. The ab-
sorbanco is then read by a spectrophotometer at 400 nm.
-D18-
-------
TABLE D-l. EMISSION TESTING WITH CONVENTIONAL EQUIPMENT
Date
11-26-74
12-6
12-9
12-10
12-14
12-17
12-18
12-19
12-8
12-18
12-20
12-21
1-7-75
1-8-75
1-9-75
1-10-75
Parameter
S02
so2
02, C02 and CO
TT
TI
S02
so2
S02
so2
S02
so2
so2
02 and C02
TT
n
TT
TT
t!
4 particulate mass
2 " it
2_ it IT
so2
S02
so2
so2
Location
Outlet (Duct)
Outlet (Trailer
Outlet (Duct)
Outlet (Trailer)
Outlet (Instruments)
Inlet/Outlet
Inlet/Outlet
Inlet
Inlet/Outlet
Inlet/Outlet
Inlet
Inlet/Outlet
Inlet (Duct)
Outlet (Duct)
Inlet (Trailer)
Outlet (Trailer)
Analyzer (Inlet)
Analyzer (Outlet)
Inlet/Outlet
IT
tT
IT
TT
H
TT
Method
EPA # *
6
6
3
3
3
6
6
6
6
6
6
6
3
3
3
3
3
3
5
5
5
6
6
6
6
* Fcick-ral Resistor. Doc. 23, 1971, Vol. 37, No. 247
-D19-
-------
TABLE D-2. WET CHEMICAL VERIFICATION OF INSTRUMENTS
S02 - EPA Method 6, 11/26/74
1300: Outlet at Duct - 170 ppm
Teco Model 40 - 150 ppm
1330: Outlet at Trailer - 161 ppm
Teco Model 40 150 ppm
0;>, C02, CO - EPA Method 3, 11/26/74
% 02 % C02 %CO
1400:
1430:
Inlet at Duct
Inlet at Trailer
Inlet at Instruments
Outlet at Duct
Outlet at Trailer
Outlet at Instruments
6.5
6.6
6.2
8.0
8.0
7.9
13.8
13.5
13.6
12.5
12.4
12.6
0.0
0.0
0.0
0.0
0.0
0.0
-D20-
-------
TABLE D-3. INSTRUMENT CALIBRATION - JANUARY 1975
Date
1/8/75
1/10/75
1/11/75
1/12/75
1/14/75
1/24/75
1/25/75
1/27/75
Type of
Time Reading
0840 Desired
Actual
Difference
0025 Desired
Actual
Difference
1200 Desired
Actual
Difference
0025 Desired
Actual
Difference
0125 Desired
Actual
Difference
Desired
Actual
Difference
0505 Desired
Actual
Difference
0525 Desired
Actual
Difference
S02
(ppm)
1000
1000
1000
1000
1000
1000
1000
910
-90
1000
1000
1000
1100
+100
1000
1000
1000
950
-50
(ppm)
520
620
+100
500
540
+40
520
520
500
500
520
515
-5
500
500
500
420
-80
CO2
15.0
14.0
-1.0
15.0
13.5
-1.5
15.0
15.0
15.0
16.0
+1.0
15.0
14.0
-1.0
15.0
15.0
15.0
11.0
-4.0
*2
5.0
6.2
+1.2
5.0
4.8
-.2
5.0
5.0
5.0
5.0
5.0
5.0
5.0
4.9
-0.1
5.0
5.0
-D21-
-------
TABLE D-4. GAS ANALYSES - EPA METHOD #3*
December 8, 1974 Time; 1415 hrs.
Location
::nlet
Duct
Outlet
Duct
Trailer
Inlet
Trailer
Outlet
Analyzer
Inlet
Analyzer
Outlet
% C02
12.0
12.0
12.3
11.8
11.5
11.5
12.0
12.0
11.8
11.8
11.8
11.5
12.5
12.7
% 02
6.0
6.5
5.5
6.0
6.5
6.8
6.5
6.5
5.5
6.3
6.5
6.8
6.5 (1500 hrs)
6.8 (1400 hrs)
* Federal Register (Vol. 37, No. 247, December 23, 1971)
-D22-
-------
TABLE D-5. SC>2 WET TESTS - EPA METHOD #6*
Date
12/6
12/9
12/10
12/14
12/17
12/18
12/19
*
**
***
****
ppm
S02
Wet Test
Time Inlet
1200 945
1000 1030
1300 1166
0300 1185
0300 833
0200 ***N
0500 1122
Method 6 - Federal
December 23, 1971)
Leak in main sample
Not in service
Not sampled
ppm
SO 2
Wet Test
Outlet
154
270
N
228
122
132
193
Register,
line
X
ppm N ppm
DuPont
In
***
1020
—
1140
840
N
1140
(Vol.
Out
*
234
N
216
132
156
204
37, No
TECO
In
930
VL050
800**
1200
800
N
^"
. 247,
Out
145
'(220^
N
230
130
150
^
-D23-
-------
TABLE D-6. WET TESTS - JANUARY 1975
Date
1/7/75
1/7/75
1/7/75
1/8/75
1/9/75
1/10/75
Time
0330
0600
2300
1830
0200
0400
SO 2 ppm
Wet*
Inlet
1042
1137
1147
1286
892
791
SO 2 ppm
TECO
Inlet
1050
1160
1160
1300
900
800
SO 2 ppm
Wet*
Outlet
126
1140
1032
1299
824
716
SO 2 ppm
TECO
Outlet
133
1160
1040
1320
825
700
* Metho3 6 - Federal Register (Vol. 37, No. 247, Dec. 23, 1971)
-D24-
-------
APPENDIX E
TRANSIENT CONDITIONS
-El-
-------
SlirMAKY OF BOILER RELATED TRANSIENT CONDITIONS
Condition
Pre- Tran- Pro- Tran- Pre- Trnn-
vious sient vicnis* sient vious* sient
Ihir.itJon SOj In- Coud. S02 Cond. % S02 Com!.
of Tran- lot SOj In- % Outlet SOj Out- % Removal ?< SO^
Date sicnt Coml. (ppm) let (ppm) Change (ppm) let (ppm) Change Efficency Kcm.Ef F. Chang
1
w
ro
I
D rop in
Boiler load
wet conl
Rising
Boiler
Load
Coal Feeder
Problem
Wet Conl
Coal Feeder
Problem
Coal Feeder
Problem
in SO in SO
f™:isoo.
1.2/8 12/8-12/9 080 1109 + 13% 1.'I3 273 + 91°* 85. U
I'l hrs.
(O'IOO-2'IOO,
12/9 12/9) 1109 925 - 10. tt& 273 207 -2'l% 75.3
21 hrs.
(2300-2000,
12/20 12/20) 1269 IOGO -16.5% 232 232 - 81.7
2 hrs.
12/17 (0800-0900,
12/17) Rl'l 78S -.1.0% 12U 183 +'17.696 8M.7
10 hrs.
1712 (2UOO-0900,
in
Eff .
75. T -10.1%
77. f. +2.3*
78.2 -3.556
75.7 -9.0*
1098
+-9.09^
111 155
+9.9"/
85.8
85.8
* Previous refers to steady state conditions existing before the transient condition.
-------
.Condition
Date
W
U>
I
Centrifuge Repair Ll/lS/VU
Centrifuge Diversion l/l't/75
Centrifuge
Diversion 12/28/7'(
1st Stage Outage .12/7/74
2ml Stage Outage 12/16/7'»
2nd Stage Outage 12/19/7 4
Drop in boiler load 12/8/74
Rising Boiler Load 12/9/74
Boiler feed problem 12/20/7'»
TRANSIENT CONDITIONS - CAUSES
Cause
Cover leak - abrasive matorial in centrifuge
feed wearing on the carbon steel
Maintenance procedure - wash out the clwte
to prevent clogginy
Clogged hopper - wet centrifuge cake,
possibly due to improper weir height
Leak - 1st Stage recycle lines. Breaks in
rubber lining exposed carbon steel pipe to
low pU/high abrasive content liquid of 1st
stage
Leak in discharge heailer - abrasive action
of the solids laden slurry
Repair recycle header - 20" pipe very thin
due to abrasive action; holes easily formed
Wet coal - high surface moisture that
reduced pulverized mill outlet temperatures
to below the 1SO°F minimum needed to main-
tain an adequate drying cake.
Partial alleviation of wet coal problem
Wet coal - agglomeration of coal particles
before the pulverizer
Scrubber Operator Response
Reduction in fan rpms and MgO
slurry feed flow
None
None
Initial reduction of fan rpras
(1 hr.), and -then complete
first stage shutdown
Tan rpms reduced and complete
second stage sliutdown
Fan rpms reduced and complete,
second stage shutdown
Boiler operators reduced fan
rpms
Fan rpms increased
Fan rpms reduced
-------
DURATION OF TRANSIENT CONDITIONS
Duration of
Transient
Period of
Condition
Centrifuge Repair
Centrijfuge
Diversion
Centrifuge
Diversion
1st Stc.ge Outage
2nd Stage Outage
2nd Stage Outage
Date
11/15/74
1/14/75
12/28/74
12/7/7 U
12/16/74
12/19/74
Condition
2 hrs. 40 min.
for repair
< 1 hr.
< 1 hr.
SO min. actual
outage time
1 hr. 15 min.
outage time
3 hrs. of 2nd
Emission Influence
5% hrs.
-0-
-0-
3 hrs.
3 hrs.
Stage
2nd Stage Outage 8/26/74
Drop in boiler
load-wet coal 12/8/74
Rising Boiler Load 12/9/74
outage, then complete
scrubber shutdown for
2 hrs. 6 hrs.
y 6 hrs., 2nd stage
out until end of
testing on Aug. 27 > 6 hrs.
2'l hrs.
2 hrs. for boiler
load to reach
previous levels
Coal Fee'der
Problem
Coal Feeder
Problem
Boiler Feed
Problem - Wet
Coal
12/17/74
VI2/7 5
2 hrs.
> 24 hrs. before
boiler load back
to previous levels
12/20/74 21 hrs,
24 hrs. - rising
boiler load
followed
> 48 hrs.
before gas flow
and efficiencies
back to previous
levels
3 hrs.
0 hrs.; no
adverse effect
on unit operation
> 24 hrs.
-E4-
-------
* RANK OF TRANSIENT CONDITIONS - EMISSION INFLUENCE
Inducing Greatest
Efficiency Drop
1. Second Stage
Outage 8/26/75
2. Second Stage
Outage 12/16/74
3. Drop in boiler
load - wet coal
12/8/74
Longest Duration of
Emission Influence
1. Drop in boiler
load - wet coal
12/8/74
1. Boiler Feed
Problem - Wet Coal
12/20/74
3. Second Stage
outage 8/26/75
4. Centrifuge Repair 4,
11/15/74
5. Coal Feeder Problem 5.
12/17/74
6. First Stage Outage
12/7/74
Centrifuge Repair
11/15/74
Combined Ranking
1. Second Stage
Outage 8/26/75
1. Drop in boiler
load - wet coal
12/8/74
3. Second Stage
Outage 12/16/74
4. Centrifuge Repair
11/15/74
Second Stage Outage 5. Boiler Feed
12/16/74 Problem -Wet Coal
12/20/74
5.
First Stage Outage
12/7/74
7. Boiler Feed Problem 5. Coal Feeder Prob-
Wet Coal 12/20/74 lem 12/17/74
6. Coal Feeder
Problem 12/17/74
7. First Stage
Outage 12/7/74
Excluded from the table is the transient condition that posi-
tively affected scrubber performance - the rising boiler load,
and those that demonstrated negligible effects; The two brief
centrifuge diversions; the leak of the first stage discharge
header before its repair; the coal feeder problem on 1/12/75;
and the second stage outage of 8/26/75, when inadequate data
prohibited a proper assessment of its consequences.
-E5-
-------
BO.lLIiiR/SCRUBUER DATA jM/KlNs: IRAN'S] liNT CON'UmoNS
Date 11 November 74 Timn Span 0100-0245 n-ansient LoncUtion 31lut Duwil "
i
w
(Tv
1
Time
0100
0115
0130
0145
0200
0215
0230
0245
Boiler Scrubber A F
Load 2nd Stage
(MK) fin. I!?0)
5.1
5.1
1.0
o.o
1 Scrubber Inlet
Inlet Srrubber SO?
ACFM pll fpp.-,}
6.5 1000
1000
6.0
1175
5.6 1200
Outlet
S()2
(ppirO
220
220
250
1200
Leaks
SO? Removal
Ei'rieier.cy
"f -
78.0
78.0
78.7
o.o
-------
BOILKR/SCRUBBCR DATA DURJNC TRy\NSIENT CONDITIONS
I
W
-j
I
Date 12 November 74 Time Span 1900-2000 Transient Condition Shut down - broken belt on
Dryer
Scrubber
Inlet
ACFM
Tijne
1900
1915
1930
1945
2000
Boiler
Load
fMW)
Scrubber P
2nd Stay;e
fin. H?6)
Scrubber
Pll
Inlet
SU2
Outlet
S02
(ppr,i)
188
185
7.1
7.0
920
900
SOp Removal
Efficiency
185
150
OFF SCALE
80.2
83.3
-------
DATA Ul'K I \(; TRANS HA'T CONDITIONS
Date 15 November 71* Time Span 0940-1300 Transient- Condition C.c
Roller Scrubber A. P Scrubber Inlet
Load 2nd Stage Inlet Scrubber S02
Time (MW) fin. HI") ACFM pH (,,pm)
i
n
00
1
0930
0945
1000 180 5.8
1015
1030
1045
1100 3.0
1115
1130
1145
1200 178 3.0
1215
1230
1.245
780
6.4 1150
1450
7.3 1300
1200
7.1 1100
in so
JTtrij.ugc Rt
Outlet
Cppm)
100
250
340
340
27!)
265
210
-uair
SOp Removal
Efficiency
87
78
76
73
77
75
80
.2
.3
.6
.8
.5
.9
.0
1300
5.0
7.3
1050
-------
Bmhr.K/SCKl'BHCR DATA DTK IMC TRANS! r.\!'J' COM) ITTONS
Date 16 November 74 TiiTie Span 1930-2145 Transient Condition Shut Down- leaks
i
W
vo
I
Time
1930
1945
2000
2015
2030
2045
2100
2115
2135
2145
Boiler Scrubber /^ P Scrubber Inlet
Load 2nd Stage Inlet Scrubber S()2
(MW) fin. H?0) ACFM pi I fnpnO
1000
178 1.2 — 7.4 1000
1000
7.4 1000
0.0 — 1000
Outlet
S(>2
fppn)
230
250
210
210
1000
SOo Removal
Efficiency
• u
77.0
75.0
79.0
79.0
0.0
-------
BOILCR/SCRUniJCR DATA DUKJNC TRANSJCNT CONDITIONS
Date 24
Time
0240
0300
0315
0330
0345
0400
i 0415
« 0430
0
i
November 7 4 Time Span 0240-0430 Transient Condition Start-Up
Boiler
Load
(MW)
148
150
Scrubber A.
2nd Stage
Tin. H?0)
0.5
'£*. b
2.5
2.5
P Scrubber. Inlet
Inlet Scrubber S02
ACFM PH (ppm)
7.7 800
850
'
7.7 875
875
Outlet
S02
(ppm)
170
150
150
240
SOp Removal
Efficiency
78.8
82.4
82.9
72.6
BOILER/SCRUBBER DATA DURING TRANSIENT CONDITIONS
Date 24
Time
•MMMHM*
0730
0745
0800
0815
0830
0845
November 74
Boiler
Load
fMW)
147
Time Span 07
Scrubber ^
2nd Stage
(in. H?0)
4.9
6.8
5.5
6.4
0.0
30-0845 Transient Condition
^P Scrubber. Inlet
Inlet Scrubber 803
ACFM pH (ppm)
900
7.3 900
850
Shut-Down
Outlet
S02
(ppm)
190
190
850
SOp Removal
Efficiency
78.9
78.9
0.0
-------
BOILER/SCRUBBER DATA Dl:K!\C TRANSIENT CO\'DITIONS
Date 1 December 7 4 Time Span 1800-2200 Transient Condition Scrubber Shut
Boiler Scrubber ^ P Scrubber Inlet
Load 2nd Stage Inlet Scrubber S02
Time (MW) (in. H?0) ACFM pH (ppm)
i
w
i
1800 178 6.2
1810
1820
1830
1840
1850
1900 176
1910
1920
1930
1940
1950
2000 177 5.4
2010
2020
2030
2040
2050
7.1
900
900
900
880
850
7.1 900
850
880
Outlet
S()2
(ppm)
200
205
200
200
210
210
220
210
220
Down-_Dryer Con
: Failure
SOp Removal
Efficiency
c/
/>->
77.2
77.8
77.8
76.1
76.5
75.6
75.3
75.0
2100
183
100
> 500 Blow back from
stack gas back
pressure
-------
BOILCR/SCRliBRER DATA DUKlXt', TRANSTCNT CONIU'TIONS
1
w
K)
1
r>-4-~ 1
LJ IA •- V- '
Time
1120
1140
1200
1220
1240
1300
1400
r\ op otWK ovt "7 It
±J> X— i— -W^IWV -—A. « .
Boiler
Load
(M\v)
179
179
179
o>_._^ .-._„ ii?n-i
i J.IHV, op<-ll 1
Scrubber £> P
2nd Stage
(in. H?0)
3.0
5.0
7.5
400 T>>-.nT\o ; fin t- Cf\r>r)
Scrubber
Inlet Scrubber
ACFM pn
135,700
140,800 7.5
146,400 7.4
173,100 7.3
i t T nn Sen
Inlet
S02
(ppm)
800
750
780
875
ubber First
UO-1250)
Outlet
S02
(ppm)
200
270
220
120
Stage Outage
SO p Removal
Efficiency
o.;
75.0
64.0
71.8
86.3
THR*
83.15
*THR = Theoretical Removal Efficiency calculated from Ghemico Efficiency Equation.
-------
BOILER/SCRUBBER DATA DURING TRANSIENT CONDITIONS
Date 7 December 74 Time Span 1630-1900 Transient Condition Scrubber Start Up
i
H
I-1
U)
1
Boiler
Load
Time (MW)
Start Up
1630
1640
1650
1700 165
1710
1720
1730
1740
1750
1800 167
1810
1820
1830
1840
1850
Scrubber A. P Scrubber Inlet
2nd Stage Inlet Scrubber S02
(in. H20) ACFM pH fppm)
900
0.8 188,400 7.1 900
900
860
0.8 188,400 7.1 950
930
930
Outlet
S02
(ppm)
270
210
210
205
210
205
205
SOp Removal
Efficiency
/b
70.0%
76.7
76.7
76.1
77.9
78.0
78.0
1900
173
2.8
188,400
7.2
940
-------
BOlLllR/SCRilBRCK DATA DI'KiVO TRANS]IINT CONDITIONS
Date 8 December 74 Time Suari 0600-2400 Trwrm
Time
0600
0700
0800
0900
1000
, 1100
w
£ 120°
1 1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
Boiler
Load
(MW)
180
179
177
146
144
143
137
127
110
110
106
102
103
96
97
102
102
100
102
Scrubber A. P
2nd Stage
(in. H?0)
8.5
8.5
8.5
8.3
8.1
8.1
7.3
6.0
6.2
3.5
3.5
. 3.8
5.6
3.8
3.9
3.9
3.5
3.8
4.0
Scrubber
Inlet
ACFM
183,400
188,400
183,400
183,400
180,200
100,200
173,100
165,900
165,900
146,400
146,400
153,600
153,600
180,200
183,400
138,400
183,400
138,400
138,400
;it>nt- r i-i n Hi firm DroDoins Load
Sorubber
PH
7.0
6.9
6.8
6.7
6.9
6.9
6.9
6.9
6.9
6.9
7.2
7.0
7,0
7.0
7.1
7.1
7.2
7.2
7.0
Inlet
S02
(ppm)
1000
950
1000
1200
1100
1200
1100
1200
1100
1100
1050
1050
1020
1020
1020
1100
1000
1050
1100
Outlet
S02
(ppm)
135
140
180
200
200
200
220
240
220
240
250
250
260
260
270
280
240
280
290
Because nf WP
SO 2 Removal
Efficiency
%
86.5
85.3
82.0
83.3
81.8
83.3
80.0
80.0
80.0
78.2
76.2
76.2
74.5
74.5
81.4
74.5
76.0
73.3
73.6
-------
BOILKR/SCRUBBER DATA DUR.INC TRANSIENT CONDITIONS
I
o
M
cn
e 9 December 74 Time Span 0700-1200 Transient Condition Rising Boiler Load
Time
0700
0800
0900
1000
1100
1200
Boiler
Load
(MW)
100
99
161
185
185
185
Scrubber A P
2nd Stage
(in. H?0)
4.4
4.3
4.5
4.5
4.3
4.7
Scrubber
Inlet
ACFM
188,400
108,400
197,600
197,600
197,600
218,100
Scrubber
Pli
7.1
7.1
7.1
7.0
6.9
6.9
Inlet
S02
(ppml
1200
1050
1100
900
850
850
Outlet
S02
(ppm)
320
220
230
220
185
175
SOp Removal
Efficiency
/*w
73.3
79.0
79.1
75.5
78.2
79.4
-------
BGILCR/SCRUBnER DATA Dl'RINC TRANSIENT CONDITIONS
Date 11 December 74 Time Span 04-00-0500 Transient Condition Scrubber Shut Down- Leak in Bleed
Line
Boiler Scrubber A P Scrubber Inlet Outlet SO-, Removal
Time
0400
0425
0500
Load 2nd Stage
fMW) fin. H?0)
163 1.0
Scrubber Down
163 0.0
Inlet Scrubber S02 S(>2 Efficiency
ACFM pH fppml fppm) %
180,200 7.2 1100 240 78.2
100,200 7.1 1100 ^>1000 Back flow due to
stack gas back
pressure
i
M
-------
BOUXR/SCRWBr.R DATA DURJNil TRANSIENT CONDITIONS
Date 13 December 74Time Span 1810-2200 Transient Condition Scrubber Start Up
Time
1810
1855
1900
1910
1920
2000
2100
2200
w
Bniler
Load
(MW)
120
118
111
116
113
Scrubber ^ P
2nd Stage
fin. H?6)
1.4
3.2
2.7
2.7
5.3
Scrubber
Inlet
ACFM
223,400
228,400
242,200
228,400
242,200
Scrubber
PH
7.2
7.2
7.1
7.1
6.8
Inlet
SO 2
fPPm)
1250
1150
1180
1200
1250
Outlet
S02
fPPm)
240
285
290
275
235
SOp Removal
Efficiency
%
80.8%
77.2
75.2
75.4
77.0
81.2
-------
I
W
B()HJ':i
-------
BOILKR/SCRUBBER DATA DI'RINC TRANSICNT CONDITIONS
i
n
M
vo
I
e 16 December 74Time Span 1300-1700 Transient Condition Scrubber 2nd stage down & start
Time
1200
1300
1310
1322
1343
1352
1400
1412
1424
1439
1457
1500
1510
1515
1520
1530
1S40
1550
1555
Boiler
Load
(MW)
146
146
146
143
Scrubber
135
135
110
78
110
165
Scrubber A P Scrubber
2nd Stage Inlet Scrubber
fin. H?0) ACFM Di[
6.4 159,700
0.0 7.5
0.0 74,800 > 8
0.0 82,900 >8
Start Up (2nd Stage)
(1.0)
Assumed
1.8 7.5
up;
Inlet
SU2
(ppm)
940
890
885
890
900
900
600
450
wet coal
Outlet
S02
(ppm)
160
685
685
680
790
135
115
115
100
110
80
SOo Removal 02
Efficiency %
% In Out
83.0
23.0
23.6
20.0
85.0
87.2
87.2
10.0+
77.8 10.*
75.6 9.0
82.2 10. +
-------
I
M
BOILP.R/SCRli
BBER DATA DL'RJXC TRANSIENT CONDITIONS
Date 17 December 7 4Time Span 0900-1400 Transient Condition Experiements changing the
Boiler
Load
Time (MW)
0900 151
0950
1000 162
1035
1100 174
1130
1150
1200 182
1225
1245
1300 182
1320
1400 182
Scrubber A
2nd Stage
fin. H?0)
3.7
8.2
8.2
8.0
8.7
7.4
6.2
6.0
6.6
8.3
8.5
9.5
9.7
P Scrubber
Inlet Scrubber
ACFM pi!
130,600 7.2
7.1
159,700 7.1
7.0
159,700 7.0
7.0
7.0
180,200 7.1
7.2
7.3
197,600 7.1
180,200 7.2
liquid
f 1 ow rat*3 in the scrubber 2nd stags
Inlet Outlet SO-, Removal Liquid
S02 S02 Efficiency Flow
(ppm) (ppm) % Rate*
790
1050
1050
1020
950
900
850
960
880
810
810
805
790
165
170
170
135
135
170
195
180
180
120
135
110
110
79.1
83.8
83.8
86.8
.85.8
81.1
77.1
81.3
79.5
85.2
83.3
86.3
86.1
5900
7000
6800
5100
4000
5100
5000
5800
5800
*Liquid Flow Rate (MgO) (gpm)
-------
BOILER/SCRUBBER DATA HURINC TRANSIENT CONDITIONS
I
w
Date 19 December 74Time Span 0800-1300 Transient Condition Scrubber Second
Time
0800
0900
1000
1100
1200
1300
Boiler Scrubber A
Load 2nd Stage
(MW) (in. H?6)
157 8.5
157 8.4
157
156
-
Scrubber completely
P Scrubber
Inlet Scrubber
ACFM p]|
197,600 7.0
207,400 7.0
159,700
165,900
165,900
shut down.
repair
Inlet
SO 2
*1200
1200
1200
1200
1200
2nd stage
Outlet
(ppm)
234
230
>300
>300
>300
Stage Outage to
recycle header
S02 Removal
Efficiency
o/
/P
80.5
80.8
<75.0
< 75.0
<75.0
*Readings from DuPorit Analyzer
-------
I
w
to
to
I
BOILER/SCRUBBER DATA DURJNC TRANSIENT CONDITIONS
Ic 13 D eu'eaniJtiJf ?H '!'
Time
Start Up
1600
1700
1800
Boiler
Load
CMW)
-
150
143
ime Span J.DUU-J.OUU Trans
Scrubber £» P
2nd Stage
fin. H?0)
2.8
6.0
6.2
Scrubber
Inlet
ACFM
173,100
133,400
197,600
lent Condition Scrubber Start Up
Scrubber
pH
7.0
7.1
7.1
Inlet
SO 2
(PPn-Q
1200
1300
1200
Outlet
St>2
(ppm)
>300
220
228
SOp Removal
Efficiency
-------
BOILER/SCRUBBER DATA Dl-RJN'C TRANSIENT CONDITIONS
I
n
OJ
i
e 20 December 74 Time Span 0700-1200 Transient Condition Wet Coal-Boiler Feed Problem
Time
0700
0800
0900
1000
1100
1200
Boiler
Load
(MW)
90
99
98
94
88
90
Scrubber A P
2nd Stage
(in. H?0)
3.5
3.4
3.6
3.6
3.6
3.8
Scrubber
Inlet
ACFM
99,300
91,100
99,300
—
—
__
Scrubber
Pll
7.0
7.0
7.0
7.0
7.0
7.2
Inlet
SO 2
1180
1200
1180
1180
1020
960
Outlet
(ppm)
280
285
240
240
200
186
SOp Removal
Efficiency
76.3
76.3
79.7
79.7
80.4
80.6
-------
I
n
BOILER/SCRUBBER DATA DURIN'C TRANSIENT CONDITIONS
C C.L. Ecv; efiilitM' 74- 1'
Time
0800
0900
?. oiler
Load
(MW)
136
140
irne Span ueuu-lluu Transient Condition Scrubber Shut
Scrubber <£. P
2nd Stage
fin. H?6)
6.2
^
Scrubber.
Inlet
ACFM
135,700
—
oc- rubber
PH
7.1
_
Inlet
SO 2
fPPni)
980
Outlet
SC)2
fppm)
180
Down-Leaks Star
SO P Removal
Efficiency
?'o
81.6
Start Up
1000 166
1100 174
6.2
200
7.2
890
128
85.6
-------
BOILCR/SCRUBBER DATA DURJNO TR/\NSTCNT CONDITIONS
1
H
to
l/i
1
Date .22 December 74 Time Span 0800-1100 Transient Condition Scrubber Start Up
Boiler Scrubber A p Scrubber. Inlet Outlet SOp Removal
Load 2nd Stage Inlet Scrubber SO^ S02 Efficiency
Time (MW) (in. H20) ACFM pH fppm) (pptrO %
1020 166
1100 174 6.2 140,800 7.2 890 128 85.6
1200 173 6.2 140,000 7.2 800 140 82.5
1300 174 6.3 140,800 7.1 800 200 75.0
-------
I
M
fo
DATA DIT-iINC TRANSIENT CONDITIONS
Date 23 December 74 Time Span 0800-0900 Transient Condition Scrubber Shut Down-Leaks in first
Time
0800
0900
0930
Boiler
Load
CMW)
140
169
Scrubber ^ P
2nd Stage
fin. HpO}
8.0
6.2
Scrubber
Inlet
ACFM
173,100
146,400
Scrubber
PH
7.0
7.2
and
Inlet
S02
880
860
second stage.
Outlet SO
S02 Ef:
fppm)
160
160
P Removal
ficiency
81.8
81.4
-------
BOILCR/SCRUBBER DATA DURilNC TRANSIENT CONDITIONS
Date 29 December 7 i* Time Span 1600-1800 Transient Condition Scrubber Shut Down-Leak in elbow
of 1st stage
Time
1600
1700
Boiler
Load
fMW)
137
-
Scrubber A P
2nd Stage
fin. H?0)
3.5
0.0
Scrubber.
Inlet
ACFM
165,900
130,600
So rubber
PH
7.1
7.7
Inlet
SO 2
fPP"0
1680
200
Outlet
S()2
fPPm)
300
1600
SOp Removal
Efficiency
%
82.1
Back flow froi
stack gas
pressure
1800
130,600
-------
i
M
K>
00
I
BOILER/SCRUBBER DATA DUR.lK'i; TRANSIENT CONDITIONS
e S January ,/b
Time
1400
1500
1600
Boiler
Load
(MW)
181
DOWN
Shut Down - Leaks in 1st Stage
'ime Span 1400-1700 Transient Condition Start Up - 1st Stage only
Scrubber -4- P
2nd Stage
fin. H?0)
-
FOR REPAIRS
Scrubber.
Inlet
ACF«~
120,300
Inlet
Scrubber S02
pH fppm)
8 1380
Outlet
S02
fppm)
1290
SO 2 Removal
Efficiency
0 '
/!••
6.5%
1700
176
1.0
1300
1220
6.2%
-------
BOILER/SCRUBBER DATA DURINC TRANSIENT CONDITIONS
Date 8 January 75 Time Span 1700-2400 Transient Condition Scrubber operating with only ]
i
w
ro
vo
I
Time
1700
1800
1900
2000
2100
2200
2300
2400
Boiler
Load
fMW)
176
179
179
181
180
183
Scrubber ^ P
2nd Stage
fin. H?0)
1.0
3.4
4.0
4.0
4.0
4.0
4.0
4.0
Scrubber.
Inlet
ACFM
180,200
255,000
291,800
291,800
291,800
291,800
291,800
438,300
Inlet
Sorubber S02
pH fppm)
8 1300
1320
1300
1380
1390
1390
1430
" 1430
Outlet
S02
fppm)
1220
1290
1290
1340
1260
1280
1340
1340
Ste
S02 Removal
Efficiency
o/
6.2
2.3
0.8
3.5
9.4
7.9
6.3
6.3
AVERAGE:
5.3
-------
i
w
o
I
BOILRR/SCRURBER DATA DURJNC. TRANSIENT CONDITIONS
C ~
Time
0800
0830
-——- j , — A JL.1I
Boiler
Load
cm)
119
SHUT DOWN
I»V- «_I|J>C%AI •*-*
Scrubber A P
2nd Stage
fin. H?0)
-
wv — ** L JL all r:
Scrubber
Inlet
ACFM
266,200
>j.t:ii L cuuu.
Scrubber
PH
-
r>i — - '
Condition o*mt: Duwn-ntipairs & ^reparation istj
Stage Only
Inlet Outlet SOp Removal
S02 S02 Efficiency
CPPm) (ppm) %
900
800
11.1
-------
BOTU'.R/SCRUBBER DATA Dl'RINC TRAMS] CNT
I
n
e 18
Time
1304
1355
1410
1425
1440
1505
1520
1530
1545
1600
1615
1630
1645
1700
1730
January 75
Boiler
Load
(MW)
126
150
178
SHUT
Start
Time Span 1340-1730 Transient Condition (1315)
Up- Shut
Screw
Scrubber A P Scrubber Inlet Outlet
2nd Stage Inlet Scrubber 862
(in. H?0) ACFM pH fppm)
860
5.6 197,600 7.5 810
940
4.2 188,400 7.2
900
860
5.4 188,400 7.3 900
900
850
DOWN
S()2
(ppm)
200
140
180
170
140
120
Down (1730)
Conveyer Overloa
SOp Removal
Efficiency
•:/
76.7
82.7
80.9
81.1
84.4
86.7
-------
BOILER/SCRUBBER DATA DURlMfl TRANSIENT CONDITIONS
Dsite_ 19 Jar)uaz°y 75 Time Span 1130-1345 Transput- r-^r.^
H
CJ
to
i
Time
1130
1145
1200
1215
1230
1245
1300
1315
1330
1345
Boiler Scrubber £ P Scrubber
Load 2nd Stage Inlet Scrubber
(MW) fin. H?0) ACFM pH
177 3.4 180,200 7.5
175 4.4 173,100 7.2
SHUT DOWN
Start Up - Shut Down
:ior. (1130) (1345 1«L Stage Qve
Inlet
S02
1100
1050
1000
1000
Outlet
S02
fppm)
200
190
195
200
180
SOp Removal
Efficiency
82.7
81.4
80.0
82.0
-------
BOILER/SCRUBBER DATA DURJNC, TRANSIENT CONDITIONS
Date 23 January 75 Time Span 1445-1700 Transient Condition Start Up
i
w
OJ
OJ
Time
1445
1500
1515
1535
1550
1605
1620
1635
1650
Boiler Scrubber <£ P
Load 2nd Stage
(Mlv) fin. H?0)
START UP
181 1.8
178 2.0
Scrubber Inlet
Inlet Scrubber S02
ACFM pll fppni)
78,800 7.7 1180
- 1200
74,000 7.6 1250
1190
Outlet
SO 2
fppm)
100
280
290
270
SOp Removal
Efficiency
%
91.5
76.7
76.8
77.3
1700
176
3.2
120,300
6.9
1180
-------
BOILER/SCRUBBER DATA DURJN(i TRANSIENT CONDITIONS
Date 27 January 75
Boiler
Load
Time (MW)
0520
0530
0545
0600 115
0615
0630
0645
0700 163
0715
i 0730
2 0745
* 0800 176
0815
0830
0845
0900 162
0915 •'
0930
0945
1000 116
1015
1030
1045
1100 138
1115
1130
1145
Time Span 0600-1540 Transient Condition Start
Scrubber A P Scrubber Inlet
2nd Stage Inlet Scrubber S02
fin. H?0) ACFM pH fppm)
1100
0.7 ~ 7.4 1100
1000
1.8 -- 7.4 1000
1000
0.2 — 7.5 900
880
856
13.0 309,200 7.5
900
10.8 255,000 7.4 900
900
10.2 242,200 7.2 900
1000
Up- High
Outlet
S02
fppm)
230
240
250
250
220
170
80
63
50
75
90
110
120
Gas Flow- Shut
SOp Removal
Efficiency
%
79.1
78.2
75.0
75.0
78.0
80.7
90.6
93.0
94.4
91.7
90.0
87.8
88.0
-------
BOILER/SCRUBBER DATA Dl.IR.JNC TRANSIENT CONDITIONS
Date 27 January
75
Boiler
i
n
u>
Ul
Time
1200
1220
1235
1250
1305
1320
1345
1400
1415
1430
1445
1500
1510
1520
Load
(MW)
174
175
174
173
Time Span Continued Trarisien
Scrubber ^ P
2nd Stage
(in. H?0)
8.0
7.8
8.0
2.2
Scrubber
inlet Sc
ACFM
207,400
207,400
228,400
188,400
t Condition Start
Inlet
rubber SO 2
pll (ppni)
7.2 1000
1000
7.3 1000
1000
7.1
1000
1000
7.2
950
Up-High
Outlet
S()2
Cppm)
120
120
130
120
115
200
205
Gas Flow- Shut
SOp Removal
Efficiency
88.0
88.0
87.0
88.0
88.5
80.0
78.4
-------
BOILER/SCRUBBER DATA DURING TRANSIENT CONDITIONS
1
w
OJ
Date
Time
1435
1800
2000
2200
11 August 75 Time
Boiler
Load
(raw)
185
182
183
183
Scrubber /\ P
Second Stage
(in.HoO)
2.6
3.4
3.4
Span 1435-2200
Scrubber
Inlet
ACFM
87,000
218,100
218,100
218,100
Scrubber
pH
7.7
7.3
7.1
Transient Condition Start up
* Inlet
S02
(ppm)
900
900
900
*Outlet
so2
(ppm)
264
264
264
S02 Removal
Efficiency
70.7
70.7
70.7
Velocity
FPM
*DuPont Unit
-------
w
u»
BOILER/SCRUBBER DATA DURING TRANSIENT CONDITIONS
Date 15 August 75
_Time Span 0200-0400
Boiler Scrubber A P Scrubber
Load Second Stage Inlet Scrubber S02
Time (mw) (in.HoO) ACFM pH (ppm)
_Transient Condition Complete Shut Down/
Dryer plugged
Inlet Outlet S02 Removal
0200 178 3.8
0400 Shut Down
188,400
7.2
*1080
so2
(ppm)
*240
Efficiency
77.8
Velocity
PPM
*DuPont Unit
-------
BOILER/SCRUBBER DATA DURING TRANSIENT CONDITIONS
Date 22 August 75 Time Span 1400-1600
Transient Condition
0.1 iu
ity increase
1
n
w
00
1
Boiler Scrubber A P Scrubber
Load Second Stage Inlet
Time (mw) (in.H.,0) ACFM
1400 176
1430 Start
1438
1439
1440
1441
1442
1443
1444
1445
1446
1447
1448
1449
1450
1500 153,600
1515
1530
1600 177 2.0 165/SOO
Inlet
Scrubber S02
pH (ppm)
20
20
1000
1020
1050
1100
1100
1100
7.4 1190
Outlet
so2
(ppm)
1000
1050
1070
1070
1070
800
500
200
250
300
370
380
380
360
(1620 FPM
S02 Removal
Efficiency
%
_
70.0
69
68
68
68
to 2025 FPM)
Velocity
FPM
930
1175
1500
1500
1560
1430
1375
1375
1375
1375
1430
1500
1500
1500
1500
1560
1560
1560
1620
-------
BOILER/SCRUBBER DATA DURING TRANSIENT CONDITIONS
I
M
OJ
Date
Time
1600
1630
1645
1700
1715
1730
1745
1800
22 August 75 Time
Boiler
Load
(raw)
177
179
184
Scrubber A P
Second Stage
(in.HoO)
2.0
,
3.2
Velocity
increase
Span 1630-1800 Transient Condition (1620 FPM to 2025 FP»
Scrubber
Inlet
ACFM
165,900
173,100
207,400
Inlet
Scrubber S02
pH (ppm)
1200
1200
1190
1130
1130
1150
7.3 1170
Outlet
so2
(ppm)
370
370
330
330
310
300
300
S02 Removal
Efficiency
%
69
69
72.3
70.8
72.6
74
74.4
Velocity
FPM
1620
1560
1760
1940
2025
1940
1940
-------
BOILER/SCRUBBER DATA DURING TRANSIENT CONDITIONS
Date 23 August 75
_Tirae Span 2100
Transient Condition Centrifuge Clog/
I
w
o
I
Time
2000
2100
2115
2120
2125
2200
2300
2315
2330
2345
2400
2415
2430
0100
0200
0300
0303
0304
0305
0309
Boiler Scrubber ^ P Scrubber
Load Second Stage Inlet
(mw) (in.HoO) ACFM
174 3.2 207,400
180
178 1.5 146,400
174 146,400
158 120,300
114
107
104
Scrubber off
Inlet Outlet
Scrubber S02 S02
pH (ppm) (ppm)
7.0 *1500 *360
400
400
400
500
7.0 *1080 *480
480
480
450
470
500
550
500
480
480
420
420
420
420
1000
Complete Shut Down
S02 Removal Hastings
Efficiency Voltage/
%
76.0
73.3
73.3
73.3
66.7
55.6
55.6
55. -6
58.3
56.5
53.7
49.1
53.7
55.6
55.6
61.1
61.1
61.1
61.1
Velocity
3.3V/2025
3.3v/2025
3.3v/2025
2.4V/1375
2.4V/1375
2.5V/143Q
2 . 4V/1375
1.7v/1025
1.9v/1125
2.1v/12i5
2.1v/1225
2.3v/1325
2.0V/1175
1.9V/1125
2.0V/1175
2.0V/1175
2.0V/1175
1.6V/1025
1.2V/810
*DuPont Unit
-------
BOILER/SCRUBBER DATA DURING TRANSIENT CONDITIONS
1
w
•u
I-
1
Date
Time
1300
1330
1400
1500
1600
25 August 75 Time
Boiler Scrubber &P
Load Second Stage
(mw) (in.H->0)
184
Start Up
175 1.8
178
182 3.5
Span 1300-1600
Scrubber
Inlet Scrubber
ACFM pH
173,100 7'3
173,100
180,200 7.3
Transient Condition Start Up
Inlet
S02
(ppm)
1080*
1140*
Outlet S02 Removal
S02 Efficiency
(ppm) %
360* 66.7
300* 73.7
Velocity
FPM
*DuPont Unit
-------
BOILER/SCRUBBER DATA DURING TRANSIENT CONDITIONS
Date
Time
0400
0415
0500
0515
0600
0700
0710
0715
, 0716
w 0717
*» 0718
0719
0720
0730
0800
0815
0900
1000
1030
1045
1100
1200
1230
1245
1300
1330
1345
1400
26 August 75 Time Span 0400-1400 Transient Condition Rapid v<
Boiler
Load
(raw)
176
183
180
176
177
176
178
180
184
185
185
Scrubber A P Scrubber
Second Stage Inlet
(in.HoO) ACFM
3-2 197,600
3.4 197,600
125,400
0-9 125,400
120,300
0.8 120,300
146,400
1.6 146,400
173,100
3.6 197,600
Inlet
Scrubber S02
pH (ppm)
6.9 1300
1200
1200
1380
6.9 1320
1350
1300
1200
1150
1370
1350
1300
7.2 1340
1340
1350
7.1 1340
1290
1290
1250
7.1 1250
1250
1200
1200
1120
1100
6.8 1100
Outlet
so2
(ppm)
390
400
420
470
400
470
470
470
. 540
540
490
450
420
420
410
420
420
370
350
320
300
300
SO 2 Removal
Efficiency
%
70.0
66.7
65.0
65.9
69.7
65.2
65.2
63.9
59.7
59.7
63.7
66.4
67.4
67.4
67.2
66.4
66.4
69.2
70.8
71.4
72.7
72.7
Velocity
FPM
1840
1175
1275
1560
1940
1225
1275
1175
1275
1275
1275
1225
1275
1225
1225
1275
1175
1175
1175
1430
1375
1430
1430
1690
1690
1940
1940
1940
-------
BOILER/SCRUBBER DATA DURING TRANSIENT CONDITIONS
i
W
Date 26 August 75 Time Span 1850-1920 Transient Condition 2nd stac
Boiler Scrubber £. P Scrubber
Load Second Stage Inlet
Time (mw) (in.H00) ACFM
1800 178 3.5
1830 Shut Down
1845
1850
1855
1900 174 173,100
1905
1910
1915
1920
Inlet
Scrubber S02
pH (ppm)
7.1 1175
1175
1140
1140
1120
1120
Outlet
so2
(ppm)
350
330
320
320
400
900
1000
1000
S02 Removal
Efficiency
%
70.2
71.9
71.9
71.9
64.9
21.1
10.7
10.7
Velocity
FPM
1500
1500
1500
1500
1620
1690
1690
1620
1690
1690
-------
BOILER/SCRUBBER DATA DURING TRANSIENT CONDITIONS
I
W
Date
Time
1400
1415
1430
1445
1500
1515
1530
1535
1536
1537
1538
1539
1540
27 August 75 Timc Soan 1400-1540
Boiler Scrubber A P Scrubber
Load Second Stage Inlet Scrubber
(raw) (in.HoO) ACFM pH
175 87,000
180 87,000
Shut Down
Tv-ai-ioT •
Inlet
S02
(ppm)
1390
1350
1350
1200
1275
1275
1080
Outlet
so2
(ppm)
1200
1200
1140
1150
1150
1100
900
900
900
900
1000
1025
i4.j — let- S+*q'
S02 Removal
Efficiency
13.7
11.1
15.6
4.2
9.8
13.7
Hastings
Voltage/
Velocity^
1.3v/350
1.3v/850
1.3v/850
1.2v/810
1.3v/850
1.3V/850
1.3v/850
1.2V/810
l.lv/770
l.Ov/730
0
0
0
Average
11.4
-------
APPENDIX F
LISTS OF SCRUBBER MALFUNCTIONS AND MAINTENANCE
-Fl-
-------
-F2-
-------
LIST OP
SCRUBBER MALFUNCTIONS
-F3-
-------
Date
Oct. 8
Oct. 8
Oct. 9
Oct. 9
Oct. 9
Oct. 9
Oct. 9
Oct. 10
Oct. 10
Oct. 11
Oct. 12
Oct. 12
Oct. 14
Oct. 14
Oct. 14
Type of
Malfunction
Centrifuge hopper clogged
"A" first stage recycle
pump won ' t start
Leak in second stage
suction header
Centrifuge chute clogged
"A" MgO pump not operat-
ing properly
MgS03 weigh belt out of
order
Shut-down
Required
Yes
No
No
No
No
No
No
ID fan kicked out Yes
Centrifuge hopper clogged No
Bucket elevator ball bearings
failed No
"B" recycle pump and. line
clogged No
Leak in suction header of
"C" recycle pump No
Leak in seal of "B" MgO
pump No
Centrifuge hopper clogged No
Leak in first stage discharge
line at elbow Yes
Duration
of Outage
j nr.
1 hr.
27 hrs.
Oct. 15 Centrifuge seized
No
Remedial Action Taken
Blank installed ahead of leak
Diverted centrifuge; wash hopper and
dryer with water
Breaker repaired
Repaired, on Oct. 10
Divert centrifuge; wash chute
Pump replaced during shutdown
Bypass used
Restart fan
Divert centrifuge; wash hopper
Divert centrifuge; lower fan amps;
replace bearings
Lower fan amps; wash out pump and
line
Switch to "B" pump; leak sealed itself
on "C" pump
Repaired during Oct. 18 outage
Divert centrifuge; wash hopper i
Inspect and replace line with a blank
Bump the start switch and it broke loosi
-------
tn
I
*5 days
6% hrs.
Type of Shut-down Duration
Date Malfunction Required of Outage
Oct. 16 South pinch valve leaking No
Oct. 18 l.Leak in 6" blank at top
of scrubber
2.Leak in gasket of 14" Yes
first stage blank
3.6" pinch valve liner
leaking
4. "A" and "B" transfer
pumps leaking
Oct. 22 "A" dilution tank agitator
not working No
Oct. 23 Leak in pH meter pot No
Oct. 23 Two leaks in centrifuge
case No
Oct. 23 Leak in "B" recycle pump No
Oct. 24 Leak in discharge line from
sump pump No
Oct. 24 Centrifuge chute clogged No
Oct. 24 Discharge line on "A" MgO
pump clogged No
Oct. 25 Centrifuge hopper clogging
continuously No
Oct. 25 Boiler tube leaks Yes
Remedial Action Taken
15 days
21 hrs.
Nov. 10 pH meter not working No
Nov. 10 Leak in centrifuge cover Yes
(Nov.11)
Leak plugged
*Repairs 1 through 4 took 2 hrs. 45 mins.
At start up, leaks developed in the MgO
magnetic flow meter to the tangential
sprays
"B" tank used; oil replaced in "A"
tank gear box
Leak plugged
One leak plugged; the other couldn't
be reached
"C" pump put in service; re-wrap "B" pump
Repaired Nov. 7
Bypass centrifuge; unplug chute
Switch to "B" pump; clean "A" pump
Divert centrifuge; wash hopper, adjust
vibrator cycle time
Repaired
Readings taken on bench pH meter
Repaired during next outage
-------
Type of Shut-down Duration
Date Malfunction Required of Outage
Nov. 10 Steam control valve not
operating properly No
Nov.10 Leak in mother liquor
return line No
Nov. 11 1.Large leak in second
stage bleed line Yes 2 days
2.Leak in pH meter 18 hrs.
3.Leak in bypass around
second stage recycle
pump discharge, valve
Nov. 13 pH meter inaccurate No
Nov. 14 Leak in centrifuge cover No
Nov. 14 Centrifuge hopper clogged No
Nov. 14 "B" thickener valve opened
up causing the dilution tank
to overflow No
Nov. 14 MgO weigher motor not
operating No
Nov. IS Leak in centrifuge cover
gasket No
Nov. IS Leak in "B" thickener No
Nov. 16 "A" second, stage recycle
pump noisy and vibrating No
Nov. 16 MgS03 conveyor kicked out
twice No
Nov. 16 Centrifuge hopper clogged No
Nov. 16 MgSC>3 weigh belt broke No
Remedial Action Taken
Operate valve manually
Repaired during next outage
Repaired
Readings taken on bench pH meter.
Meter repaired on Nov. IS
Repaired Nov. IS
Divert centrifuge; wash hopper
Valve reset
Electrician called to repair
Repaired Nov. 18
"A" thickener put into service
Switched to "B" pump until "A" is
inspected
Divert centrifuge; clean out restriction
Divert centrifuge; wash hopper
Placed on bypass until repaired
-------
-vl
I
Date
Nov. 16
Nov. 16
Nov. 19
Nov. 20
Nov. 20
Nov. 20
Nov. 21
Nov. 21
Nov. 21
Nov. 21
Nov. 21
Nov. 24
Nov. 25
Nov. 25
Nov. 26
Nov. 26
Type of Shut-down
Malfunction Required
MgSC>3 bucket elevator
kicked out three times No
6" pinch valve liner in
the first stage recycle
line ruptured Yes
Leak in centrifuge cover No
Inside bearing on dryer
conveyor broke No
Centrifuge hopper clogged No
New leak in centrifuge cover No
Duration
of Outage
Bucket elevator tripped
No
Rappers on the dryer fell off No
Thermocouple and conduit on
dryer broken off No
Centrifuge hopper clogged No
Belts on dryer ID fan burnt Yes
off
Dryer screw conveyor hub
failure Yes
MgSC>3 solid equipment kick
out No
Centrifuge cover leaks No
Centrifuge hopper clogged.
twice No
Hole in 6" recycle water
line on first stage No
2 days
20 hrs.
2 days
7 hrs.
Remedial Action Taken
Divert centrifuge; dig out buckets
Repaired during shutdown
Welded on Nov. 22
Repaired Nov. 22
Divert centrifuge; wash hopper
Welded on Nov. 22
Dig out boot
Replaced Nov. 22
Repaired Nov. 22
Divert centrifuge; wash hopper
Belts replaced in 2% hours. The
dryer ID fan would not start. During
this outage the boiler burst a tube
causing Unit #3 to go off line.
hrs. Hub replaced
Dig out buckets and dryer screw conveyor
Welded during outage
Divert centrifuge; wash hopper
Temporary rubber patch applied
-------
00
I
Type of Shut-down Duration
Date Malfunction Required of Outage
Nov. 21 First stage level con-
troller and MgO level
controller not working No
Nov. 27 Centrifuge hopper clogged No
Nov. 28 Leak in first stage distrib-
ution header No
Nov. 28 Dryer clogged No
Nov. 28 Drain nippel in sump
pump leaking No
Nov. 28 pH meter out of calibration No
Nov. 29 Leak in 6" bleed line from
first stage No
Nov. 29 Dryer clogged No
Nov. 30 Centrifuge hopper clogged No
Nov. 30 Leak in 6" bleed line worse No
Dec. 1 Southwest torus spray
broke off No
Dec. 1 Leaks in 6" bleed line out 3 days
of control Yes 18 hrs.
Dec. 5 Leak in first stage discharge
header . No
Dec. 7 Leak in 6" first stage re-
cycle line at pinch valve No
Dec. 7 Centrifuge hopper clogged No
Dec. 8 MgO weigh feeder belt ran
off track No
Remedial Action Taken
Repaired
Divert centrifuge; wash hopper
Hole patched temporarily
Centrifuge diverted; dryer allowed to
clean itself
Recalibrate
Pipe clamps installed
Divert centrifuge; allow dryer to clear
Divert centrifuge; wash hopper
Pipe clamps installed
Flows cut back to torus sprays; un-
successful attempt to install blind
Temporary replacement line installed
Stop recycle; install blind
Patch leak
Divert centrifuge; wash hopper
Reset belt
-------
Type of Shut-down
Date Malfunction Required
Dec. 8 New leak in 6" first
stage recycle line No
Dec. 8 Centrifuge hopper clogged No
Dec. 8 . Dryer clogged No
Duration
of Outage
Remedial Action Taken
Patch hole
Divert centrifuge; wash hopper
Divert centrifuge; allow dryer to
clear itself
VO
i
Dec. 9 Transition pipe at screw
feeds clogged No
Dec. 10 Centrifuge hopper clogged No
Dec. 10 Centrifuge cover leak No
Dec. 11 Leaks in 6" first stage
bleed line Yes
Dec. 12 6" first stage bleed line
sleeve failure Yes
Dec. 13 Mother liquor agitator
kicked out No
Dec. 14 Hole in 6" pinch valve on
first stage recycle line No
Dec. 15 Leak on second stage dis-
charge header No
Dec. 15 Lost flow in "B" MgO pump No
Dec. 16 Lost flow in "B" MgO pump No
Dec. 16 Centrifuge hopper clogged No
Divert centrifuge; clean out
Divert centrifuge; wash hopper
32 hrs. Replace line
28 hrs. Replace line
Reset
Repaired Dec. 16
Switch to "A" pump; clean out "B" pump
Backflush pump
Divert centrifuge; wash hopper
-------
I
•n
M
o
I
Type of Shut-down Duration
Date Malfunction Required of Outage
Dec. 17 Hole in first stage of
scrubber vessel No
Dec. 17 pH meter clogged with
crystals No
Dec. 17 Leak in second stage dis-
charge header No
Dec. 18 Dryer conveyor tripped No
Dec. 18 Another leak in second
stage discharge header No
Dec. 18 Dryer clogged No
Dec. 19 Failure of second stage
discharge header pipe Yes 2% hrs.
Dec. 19 "C" MgO pump clogged No
Dec. 19 Dryer conveyor tipped No
Dec. 19 Leak in first stage scrubber
vessel No
Dec. 20 Leak in first stage reducer No
Dec. 20 Front rappers on dryer not
hitting No
Dec. 20 Leak in line to upper pond No
Dec. 21 Leaks on two of the first
stage nozzle lines No
Dec. 21 Leak in 8" pinch valve liner 1 hr.
on first stage recycle line Yes 10 man.
Dec. 22 Leak in first stage recycle
line to plumb bob No
Remedial Action Taken
Hole patched
Flush out
Repaired Dec. 19
Divert centrifuge; reset switch
Repaired Dec. 9
Cut back load and allow dryer to clear
itself
Weld leak
Unclogged Dec. 30
Reset switch
Repaired Jan. 13
Temporary patch applied; welded on Dec. 21
Band couldn't be tightened; centrifuge
diverted until dryer cleared; repaired
on Jan. 11
Replaced with hose
Leaks plugged
Scrubber shut down on Dec. 22 to repair
leak
Welded, during Dec. 23 outage
-------
Date
Dec. 23
Type of
Malfunction
Shut-down
Required
l.Leak in 8" pinch valve
on first stage recycle
line Yes
2.Leak in second stage dis-
charge line
Dec. 26 pH meter not working No
Dec. 28 Centrifuge hopper clogged. No
Dec. 28 Leak in elbow of "A" first
stage pump No
Dec. 28 Leak at pH meter electrode No
Dec. 29 Bucket elevator tripped No
Dec. 29 Leak in elbow of "A" first
stage pump Yes
Dec. 29 Leak in elbow of "A" first
stage pump Yes
Jan. H- 3" drain at bottom of scrubber
plugged No
Jan. 4 Leak in second stage drain
connection Yes
Jan. 8 Leak in elbow of "B" dis-
charge pump Yes
Jan.10 Leaks in second stage lines Yes
Jan. 11 MgO belt slipping No
Jan. 11 MgO steam sparger clogged No
Jan. 11 Leak in centrifuge cover No
Duration
of Outage
3 days
12 hrs.
40 min.
15 min.
4 days
22 3/4
hrs.
3 days
9 hrs.
2 hrs.
28 hrs.
Remedial Action Taken
1. Replaced with spool piece
2. Leak welded
Remove restriction from line
Divert centrifuge; wash hopper
Leak plugged
Leak plugged
Dug out boot; reset elevator
Leak plugged
Leak required only 15 minutes to repair,
but fan would not start. It was de-
cided to leave the scrubber off so
other repairs could be made.
Unplug during shutdown
Leak repaired
Leak repaired
Inspect, repair and replace lines
Belt tightened
Cleaned
-------
CO
I
Type of Shut-down
Date Malfunction Required
Jan. 12 "A" MgO pump failure No
Jan. 13 SOp analyzer outlet probe
clogged No
Jan. 13 MgO weigh feeder incorrect No
Jan. 13 Another leak in centrifuge
cover No
Jan. 14 Centrifuge hopper clogged No
Jan. 1U- First stage level controller
frozen No
Jan. 14- "A" thickener underflow pump
and. rotometer frozen No
Jan. 14 Run out of MgO Yes
Jan. 18 MgS03 conveyor at top of
silo kicked out Yes*
Jan. 19 Leak in liner of first
stage bleed valve No
Jan. 19 Oil leaking from mother
liquor agitator gear box No
Jan. 19 First stage overflow Yes
Jan. 23 First stage bleed lines
semi restricted No
Jan. 23 MgO weigh feeder belt
slipping No
Duration
of Outage
3 days
20% hrs.
4 days
45 min.
Remedial Action Taken
Switch to "B" pump
Stainless steel bands and tubing need
to be replaced
Recalibrate
Divert centrifuge; wash hopper; use
vibrators constantly
Manual control used until controls
unfrozen
i
Pump was cleared; rotometer to be replaced;
*Unable to inspect or fix due to icy
conditions on platforms. Conveyor
freed when conditions permitted.
Removed metal pieces from valve; no
replacement liner available.
Refilled with oil
Remove restriction from first stage
bleed line
Both thickeners put in operation to get
more flow to the dilution tank
Cut back fan amps so MgO could catch
up
-------
Date
Jan. 24
Jan. 24
Jan. 24
Jan. 24
Jan. 24
Jan. 25
Jan. 27
Jan. 27
Aug. 11
Aug. 11
Aug. 15
Aug. 24
Aug. 24
Aug. 24
Type of Shut-down
Malfunction Required
Leak in first stage
tangential spray header No
Leak in first stage
torus spray No
Centrifuge hopper clogged No
Bucket elevator tripped No
Leak in 10" header at top
of scrubber No
Leak in 10" header at top
of scrubber Yes*
Inlet damper for Mode II
would not open No
Restriction in first stage
pump "A" No*
First stage bleed valve liner
failure No
Cracked steam control valve No
Duration
of Outage
Dryer Clogging
Dryer Clogging
Bucket elevator tripped
Excessive centrifuge
vibration
Aug. 26 . Wet centrifuge cake
Yes
No
No
Yes
Yes*
38%
hrs.
7 days
10% hrs.
Remedial Action Taken
Patched during boiler outage
Patched during boiler outage
Divert centrifuge; wash hopper
V-Belts on top of elevator replaced
Patch leak
*Shut down to patch leak and to save
wear on the system as visitors are ex-
pected on Jan. 27
Damper opened with aid of a crow-bar.
*Shut down shortly after. Restriction
was a broken off tangential nozzle.
Scrubber to be kept off until after
a scheduled boiler outage.
Replaced Aug. 12
Replaced with spool piece on Aug. 14
Clean dryer manually
Remove build up manually
Reset elevator
37% hrs. Repairs made to centrifuge
*First stage only; weir height on
centrifuge lowered
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Date
Aug. 27
Sept. 19
Oct. 20
Type of
Maitunerion
Leak in first stage
recycle lines
Gear box failure in
"A" thickener
Pins sheared in centrifuge
Shut-down Duration
Required. of
Yes
No
Yes
days Replace lines
4% hrs.
Final
"B" thickener only used
None
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LIST OF
SCRUBBER MAINTENANCE
-F15-
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Oct., 9 1. "A" underflow booster pump installed
Oct. 11 1. Inboard bucket elevator bearing to be greased
once per day.
2. Outboard bucket elevator bearings to be greased
once per week.
3. Silo vibrator motors to be greased once every
three months.
4. All unused pumps and the centrifuge (when not
in use) shall be bumped at least once per day.
Oct. 15 1. Silo vibrator motor replaced.
Oct. 18
to
Oct. 21 1. Inspect MgO slurry flow meter.
Oct. 22 1. Boulders of MgO broken up in silo.
Oct. 25 1. Electricians adjust vibrator times; install
toggle switches for manual operation.
Oct. 27 1. A detailed inspection/lubrication program was
initiated by Chemico personnel to be performed
during the 4-12 shift. The program consisted
of inspecting/lubricating the following:
Thickener Area -
1. Transfer pump bearing pedestals
2. Underflow pump bearing cases.
3. Underflow booster bearing cases.
4. Dilution tank gear reducer-agitator.
5. Dilution tank agitator bearings.
6. Thickener rake drive gears.
7. Thickener rake lift gears.
8. Dry er
A. Lubricate tires
B. Lubricate trunions
C. Lubricate thrust bearings
D. Oil drive gear case
-F16-
-------
Scrubber Area -
1. ID fan motor oil levels
2. ID fan fluid drive oil levels
3. ID fan bearings oil
4. ID fan boiley controllers
5. First stage pumps-motors oil level
6. First stage pumps-bearings oil level
7. Second stage pumps-bearings oil level
8. Dryer ID fan-bearings lubricate
9. Dryer ID fan-bailey controller lubricate
10e #4 conveyor (top silo) bearings and reducer
11. Bucket elevator bearings and reducer
12. Plumb bob limitorque gear reducer
Dryer Area -
1. #1 conveyor bearings and gear reducer
2. #2 conveyor bearings and gear reducer
3. Dryer conveyor bearings and gear reducer
4. Centrifuge reservoir and bearings
5. Stack damper (dryer) lubricate
6. Premix tank agitator bearing lubricate
7. MgO mix tank agitator gear reducer
8. Mother Liquor tank agitator gear reducer
9. MgO pumps bearing oil
10. Mother Liquor pumps bearing oil
11. Bottom bucket elevator four bearings (weekly)
Oct. 27
to
Nov. 11 1. Clean out valves on "A" MgO pump dicharge line
installed.
2. The level in the MgO silo was measured.
3. The ID fan was inspected.
4-. Dryer rappers were adjusted.
5. Rappers on the centrifuge hopper were
relocated.
6. A new motor was installed on the dryer
conveyor.
7. Vibrator installed on the MgSOg silo so
sticking would not occur.
8. First stage cone was opened and inspected.
9. Bucket elevator bearings were inspected and
lubricated; one was replaced.
10. Weigh belts were zeroed and calibrated.
11. Electricians installed a larger heater in
the "B" MgO pump switch.
-F17-
-------
Nov. 11 1. Temperature monitors on fire box and steam
to control valves were serviced.
Nov. 13 2. The thermocouple on the circulation line was
repositioned for more effective control.
3. Flow rate checks on the MgO slurry lines.
Nov. 18 1. Hub on the dryer screw conveyor was inspected
to and replaced.
Nov. 19 2. The liner on the centrifuge divert valve was
inspected and replaced.
Nov. 22 1. Electrician removed the inspection plate from
the dryer. ID fan wouldn't start and discovered
the housing one-half filled with water. After
draining the housing, the pulley hub was in-
spected and found to be worn.
2. Inspected bearings on dryer screw conveyor.
Nov. 25 1. pH controller serviced.
Dec. 3 1. Removed one stellited restricting orifice plate
to from the first stage bleed line to the thickener.
Dec. 5
Dec. 6 1. Removed the three remaining stellited restrict-
ing orifice plates from the first stage bleed
line.
2. DuPont SOj analyzer serviced.
Dec. 9 1. Oilers on vibrators serviced.
Dec. 10 1. Overload heaters installed in "B" MgO pump.
Dec. 12 1. "A" thickener rakes were inspected.
Dec. 13 1. Inspected first stage bleed line for restrictions.
Dec. 11 1. Removed and inspected motor on Mother Liquor
agitator; gears need replacement.
Dec. 16 1. Larger overload heaters installed, in "B"
second stage pump.
Dec. 17 1. Blanks were installed in the tangential nozzle
lines to prevent leaks.
Dec, 23 1. Inspected screens in the MgO tank.
to 2. Pre-mix tank cleaned.
Dec. 26
-F18--
-------
Dec. 27 1. Pipe thickness measurements made.
2. Adjusted packing on first stage and
transfer pumps.
Dec. 29 1. inside of the second stage vessel inspected.
to 2. Drain valves installed on the casings of
Jan. 3 "B" and "C" MgO pumps.
3. Top mist eliminator washed.
Jan. 6 1. Second stage vessel checked for leaks.
to
Jan. 7
Jan. 10 1. During the past week, all equipment requiring
lubrication was serviced.
Jan. 15 1. Repacked both first stage recycle pumps.
to 2. Calibrate level controllers.
Jan. 18 3. New buckets installed on MgSC>3 elevator.
4. Rotometers thawed and insulated as needed.
5. Clean out MgO pre-mix tank.
6. Inspect, clean and grease steam sparger valve.
7. Cleaned guages on MgO pumps.
8. pH meter pot serviced.
9. "B" first stage pump taken apart to remove
an 18" section of tangential nozzle.
10. Inspected tangential nozzles; 6 of 10 missing.
Jan. 19 1. Removed two of the remaining four tangential
to spray nozzles from the first stage.
Jan. 23 2. All pumps fully opened to prevent freezing.
3. First stage discharge header drained to
prevent freezing.
Jan. 25 1. First stage recycle pumps jumpered so they
could be stopped without tripping the ID fan.
Jan. 26 1. New V-belts installed at the top of the MgS03
bucket elevator.
Aug. 24 1. Inspection of inside of first stage vessel.
Sept. 19 1. Inspect bucket elevator and tighten buckets if
needed.
-FID--
-------
TECHNICAL REPORT DATA
/Please read Instructions on the reverse before completing)
1. HEPOHTNO.
EPA-600/2-7'f-165
2.
3. RECIPIENT'S ACCESSION-NO.
4, "ITLE AND SUBTITLE
Magnesia FGD Process Testing on a Coal-Fired
Power Plant
8. REPORT DATE
August 1977
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Diane K. Sommerer
8. PERFORMING ORGANIZATION REPORT NO.
Y-8479
9. PERFORMING OROAMZATION NAME AND ADDRESS
York Research Corporation
One Research Drive
Si:amford, Connecticut 06906
10. PROGRAM ELEMENT NO.
1AB013; ROAP 21BAV
11. CONTRACT/GRANT NO.
68-02-1401, Tasks 1,10,24,
and 25
12 SPONSORING AGENCY NAME AND ADDRESS
D PERIOD COVERED
EPA, Office oi Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD
Task Final; 10/74-8/75
14. SPONSORING AGENCY CODE
EPA/600/13
is SUPPLEMENTARY NOTES IERL_RTP pr0ject officer for this report is C. J.Chatlynne, Mail
Erop 61, 919/541-2915.
16. ABSTRACT
repOrt gives results of a field measurement program to determine the
operability and reliability of the Chemico magnesium oxide ventuo scrubber operating
at Potomac Electric Power Company's Dickerson Generating Station, Frederick , MD.
A continuous source-monitoring station was installed at the scrubber, complemented
by a field analytical laboratory intended for the measurement and analysis of various
process streams. These facilities continuously monitored process and emission
variables between October 1974 and January 1975, and during August 1975. Scrubber
operation .was evaluated during steady-state and transient operation, the latter inclu-
ding startups, shutdowns, and malfunctions. During the tests, the scrubber was avail1-
able about 48% of the time, including all levels of operation. Approximately 80% of
system availability- was steady-state, with the system operating normally. The tests
showed that, although scrubber availability was not ideal (due to logistics problems
m supplying raw materials (MgO) , and to mechanical problems mainly attributable
to under-design in such areas as piping, slurry pumps, and other auxiliary equip-
ment), the basic scrubber concent and design should meet critical criteria once these
problems are remedied.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Group
Air Pollution
Flue Gases
Desulfurizatiori
Magnesium Gxudes
Scrubbers
Venturi Tubes
Coal
Combustion
Electric Power
Plants
Air Pollution Control
Stationary Sources
13B
21B
07A,07D
07B
14B
21D
18. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
264
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EFA Form 2220-1 (9-73)
-F20-
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