' P A U'S' Environmental Protection Agency Industrial Environmental Research EPA~600/7-78~051d
"• »» Office of Research and Development Laboratory jft-re
Research Triangle Park. North Carolina 27711 MBTCn 1978
EPA UTILITY FGD SURVEY:
December 1977 - January 1978
Interagency
Energy-Environment
Research and Development
Program Report
-------
RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories were established to facilitate further development and application of en-
vironmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7. Interagency Energy-Environment Research and Development
8. "Special" Reports
9. Miscellaneous Reports
This report has been assigned to the INTERAGENCY ENERGY-ENVIRONMENT
RESEARCH AND DEVELOPMENT series. Reports in this series result from the
effort funded under the 17-agency Federal Energy/Environment Research and
Development Program. These studies relate to EPA's mission to protect the public
health and welfare from adverse effects of pollutants associated with energy sys-
tems. The goal of the Program is to assure the rapid development of domestic
energy supplies in an environmentally-compatible manner by providing the nec-
essary environmental data and control technology. Investigations include analy-
ses of the transport of energy-related pollutants and their health and ecological
effects; assessments of, and development of, control technologies for energy
systems; and integrated assessments of a wide range of energy-related environ-
mental issues.
EPA REVIEW NOTICE
This report has been reviewed by the participating Federal Agencies, and approved
for publication. Approval does not signify that the contents necessarily reflect
the views and policies of the Government, nor does mention of trade names or
commercial products constitute endorsement or recommendation for use.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
-------
EPA-600/7-78-051a
March 1978
EPA UTILITY FGD SURVEY:
December 1977 - January 1978
by
Bernard A. Laseke, Jr.
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
Contract No. 68-01-4147
Task 3
Program Element No. EHE624
EPA Project Officers:
N. Kaplan and J. C. Herlihy
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
-------
NOTICE
This report, (prepared by PEDCo Environmental, Inc.,
Cincinnati, Ohio under EPA Contract No. 68-01-4147, Task No. 5)
is provided as an information transfer document. Data in this
report are supplied voluntarily by utility representatives; flue
gas desulfurization (FGD) system designers, vendors, and sup-
pliers; regulatory personnel; and others. Neither EPA nor the
designated contractor warrants the accuracy or completeness of
information contained in this report.
The format of this report, which represents the first in a
series of six, has been extensively revised from previous issues.
The succeeding five issues will be supplemental in nature. The
user is therefore cautioned to retain this issue for reference
throughout the year, because much of the inf_or_inat.io_n, contained in.
this_ report will not be published again untjA around March 1979.
Supplemental issues wTTl be cumulative, so that it will be
necessary only to retain the latest issue and this report to have
all available information.
Initial distribution of the report (generally, one copy per
company) is limited to organizations and individuals indicating a
specific interest in the field of FGD technology. Additional
copies of this report and succeeding issues can be purchased from
National Technical Information Service, Springfield, Virginia
22151.
ii
-------
CONTENTS
Notice ii
Tables iv
Executive Summary and Highlights v
Table 1 Summary List of FGD Systems 1
Table 2 Status of FGD Systems 4
Table 3 Performance Description for Operational FGD Systems 22
Table 4 Summary of FGD Systems by Company 146
Table 5 Summary of FGD Systems by Vendor 147
Table 6 Summary of New and Retrofit FGD Systems by Process 149
Table 7 Summary of Operating FGD Systems by Process and
Generating Units 150
Table 8 Summary of Sludge Disposal Practices for Operational
FGD Systems 151
Table 9 Summary of FGD Systems by Process and Regulatory
Class 152
Table 10 Summary of FGD Systems Under Construction 154
Table 11 Summary of Planned FGD Systems 156
Table 12 FGD System Operations That Have Been Terminated
or Shut Down Indefinitely 159
Table 13 Total of FGD Megawatt Capacity by Year 213
Appendix A FGD Systems Economics A-l
Appendix B FGD Process Flow Diagrams B-l
Appendix C Definitions C-l
iii
-------
TABLES
Number Page
I Number and Total MW of FGD Systems v
II Summary of Changes: FGD Summary Report, December
1977 - January 1978 ix
IE Performance of Operational Units During December -
January Period x
iv
-------
EXECUTIVE SUMMARY AND HIGHLIGHTS
This report is prepared every other month by PEDCo Environmental,
Inc., under a contract to the Industrial Environmental Research
Laboratory/RTF and the Division of Stationary Source Enforcement
of the U.S. Environmental Protection Agency. Table 1 summarizes
the current status of the FGD systems addressed in this two-month
period.
Table I
NUMBER AND TOTAL MW OF FGD SYSTEMS
Status
Operational
Under construction
Planning:
Contract awarded
Letter of intent
Requesting/evaluating bids
Considering only FGD systems
TOTAL
No. of
units
31
38
20
3
6
33
131
MW
10,550
15,664
10,415
865
2,660
15,525
55,679
Table II (page vii) summarizes the individual units that changed
status during the report period.
The performance of the operating systems is summarized in Table
III (page viii). Other activity highlights during the months of
December and January are summarized below:
Present total power-generating capacity in the United States is
approximately 570,000 MW. Of this total 250,000 MW are generated
by coal. As indicated in Table I, 31 FGD-equipped units, repre-
senting 10,550 MW of power capacity, are now in service. - Thus, a
little under 2 percent of the total capacity and a little over 4
-------
percent of the coal-fired capacity are controlled by FGD. By
1986 the projected total power-generating capacity in the United
States will be 800,000 MW. Of this total approximately 570,000
MW will be coal-fired. As indicated in Table I, 131 FGD-equipped
units representing 55,679 MW are projected for service. There-
fore, assuming that no unit retirements occur, about 7 percent of
the total projected generating capacity and about 16 percent of
the projected coal-fired capacity will be controlled by FGD in
1986.
Alabama Electric Cooperative reported that construction of the
Tombigbee 3 limestone FGD system commenced during the period.
Foundation work is now in progress.
Arizona Public Service reported that Cholla 1 was not in service
during the latter part of November, all of December, and the
first part of January because of a scheduled unit outage for
turbine, boiler, and FGD system overhaul. The unit resumed
operations in late January and the boiler operated 135 hours
during the remainder of the month. The A and B FGD modules
operated 131 and 123 hours in January, producing operability
index values of 97 and 91 percent, respectively.
Cincinnati Gas & Electric announced that the FGD contract for
East Bend 2 has been awarded to Babcock & Wilcox (B&W). B&W will
design and supply a lime scrubbing FGD system which will go into
operation in January 1981.
Columbus and Southern Ohio Electric reported that the A-module of
the Conesville 5 FGD system was restarted on December 3, 1977.
The A-module operated 162 hours with an availability of 93
percent. The B-module operated 199 hours in December with an
availability of 97 percent. Conesville 5 was shut down for a
scheduled 3-month turbine, boiler, and FGD system overhaul
beginning December 12, 1977.
Indianapolis Power & Light Company declared Petersburg 3 com-
mercial on November 29 with two of its four scrubber modules in
operation. All four modules were certified operable in December
prior to a scheduled outage for completion of heat tracing.
Kansas City Power & Light Company reported that La Cygne 1 had a
total system availability of 94 percent in November and 97 per-
cent in December. The unit operated only 300 hours in December
because of a turbine overhaul.
The Department of Electric and Water Utilities of the City of
Lakeland, Florida, is currently evaluating bids for a new 350-MW
coal-fired power-generating unit scheduled for installation at
their Mclntosh Station. Mclntosh 3 will fire 2.5 to 3.0 percent
sulfur coal and utilize ESP's and an FGD system for particulate
-------
and sulfur dioxide control. Mclntosh 3 is scheduled for opera-
tion in October 1981.
The PGD system on the 178-MW Cane Run 4 of Louisville Gas &
Electric (LG&E) was available 85 and 90 percent for December and
January, respectively. Although the utility encountered lime
feed freeze up problems, the FGD system itself experienced no
problems that required outage time during the period. LG&E also
reported that the Mill Creek 4 FGD system is now under construc-
tion.
Montana Power reported that the Colstrip 1 and 2 lime/alkaline
flyash FGD systems were available 96 and 98 percent, respec-
tively, in December, and 98 percent for both systems in January.
Nevada Power reported operability index values for the Reid
Gardner 3 FGD system of 92 and 99 percent for December and
January, respectively. The Reid Gardner 2 FGD system remained in
service during the period. The Reid Gardner 3 FGD system was
down throughout December for repairs to the booster fan (new wear
plates).
Northern States Power reported that the Sherburne No. 1 FGD
system was available 93 percent during the period. The No. 2 FGD
system was available 93 percent in December and 92 percent in
January. Unavailability of the No. 1 system was attributed
primarily to heavy maintenance on the 107 module. Unavailability
of the No. 2 system was attributed to strainer and wash screen
replacement in the module reaction tanks which commenced in late
December and continued throughout the period.
Otter Tail Power announced that a -contract has been awarded to
Wheelebrator-Frye and Atomics International (AI) for a sodium
carbonate FGD system for Coyote No. 1. The FGD system combines
AI's aqueous carbonate process in a fabric filter supplied by
Wheelebrator-Frye. The 400-MW system is scheduled to start-up
in May 1981.
Pacific Gas & Electric (PG&E) announced that it plans to install
a 2-unit, coal-fired power-generating station in Northern Cali-
fornia. PG&E plans to burn low sulfur coal (0.8 percent) in both
800-MW units and use ESP's and FGD systems for the control of
particulates and sulfur dioxide. Tentative operation dates are
1984 and 1985.
Potomac Electric and Power (PEPCO) reported that S02-removal
capability will not be included in the wet scrubber modules now
being installed on Dickerson 1 and 2. PEPCO plans to meet state
emission regulations by burning low or medium sulfur coal in
these units.
VI 1
-------
Public Service of Indiana (PSI) announced that the FGD systems
planned for Gibson 3 and 4 have been cancelled because of a
recent district court decision identifying the units as existing
sources. PSI also announced that an FGD system is being planned
for Gibson 5, which is a new coal-fired unit scheduled for opera-
tion in 1982.
The Tennessee Valley Authority reported that the 530-MW Widows
Creek 8 FGD system achieved an operability of 97 percent in
December and 96 percent in January. In addition, TVA also
announced that the FGD contract for the Widows Creek 7 was
awarded to Combustion Engineering (CE). CE will design and
supply a 575-MW limestone scrubbing spray tower system for this
unit.
VI 1 1
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TABLE II. SUMMARY OF CHANGES: FGD SUMMARY REPORT, DECEMBER 1977-JANUARY 1978
FGD status report
11/30/77
Alabama Electric coop.
Tomb ig bee No. 3
Cincinnati Gas b Electric
East Bend No. 2
Cofnoonwealth Edison
Will County No. 1
De Ima r va Powe r
Lakeland Dept. of Elec. b Water
Mclntoah, No . 3
Lou 13 vi 1 le Gas b Electric
Hill Creek No. 4
Ot ter Ta 1 1 Power
Coyote No. 1
Pacific Gaa b Electric
Fossil No. 1
Paci f ic Gas b Electric
Fossil No. 2
Potomac Electric b Power
Dickerson No . 1
Potomac Electric b Power
Dickerson No. 2
Gibson 3
Gibson 4
Gibson 5
Tennessee Valley Authority
Widows Creek No. 7
United Power Association
Coal Creek 1
Wisconsin Power b Light
Columbia No. 2
1/31/78
Operational
No.
32
-1
31
MW
10,717
167
10,550
Under
No.
34
tl
tl
tl
38
MW
14,219
225
495
Cont rdct
awarded
No.
20
-1
+ 1
-1
tl
545
15,664
tl
-1
tl
20
MW
9,758
225
600
495
400
575
545
527
10,415
Letter of
No .
4
-1
3
MW
1,392
527
865
Requesting/
No.
fl
-1
Cons ider my
FGD
MW NO.
4,210
600
34
MW
14,630
tl , 350
-1
-1
6
650
650
2,660
-1
400
tl 800
tl 800
-1 190
-1 190
tl
-1
33
650
575
15,525
Total
No.
132
-1
*!
tl
tl
-1
-1
-1
-1
tl
131
MW
54,926
167
350
800
800
190
190
650
650
650
55,679
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TABLE III. PERFORMANCE OF OPERATIONAL UNITS
DURING DECEMBER-JANUARY PERIOD
Plant
Cholla 1
Cone s\ 1 1 le 5
Elrama
Phil lips
Petersburg 3
Hawthorn 3
Hawthorn 4
La Cygne 1
Lawrence 4
Lawrence 5
Green River
1. 2. and 3
Cane Run 4
Paddys Run 6
M. R. Young 2
Colstrip 1
Colstrip 2
Reid Gardner 1
Reid Gardner 2
Reid Gardner 3
D.H. Mitchell 11
Sherburne 1
Sherburne 2
Bruce
Mansfield 1
Bruce
Mansfield 2
Eday stone 1A
Winyah 2
Southwest 1
Shawnee IDA
Shawnee 10B
Widow's Creek 8
Martin LaXe 1
Total (31)
capacity
115
400
510
410
530
140
100
820
125
400
64
178
65
450
360
360
125
125
125
115
710
710
825
825
120
280
200
10
10
550
793
10,550
PCD unit
period*
115
400
310
410
530
140
100
820
125
400
64
178
450
360
360
125
125
125
115
710
710
120
280
10
10
550
793
8,435
No
period
825
825
1.650
Shut down
period
200
65
200
465
FGD lyaten
Dec-
95
73
70
97
50
85
98
98
85
0
88
93
93
41"
56
Jan
47
68
94
"
90
56
67
99
92
92
18
FGD ayitem
opera-
bili ty
Dec
69
63
85
32
0
92
97
1 1) " •
Jan
32
67
68
74
99
96
FGD •yaterr
Dec
72
63
100
33
0
96
59
Jan
94
32
87
69
67
99
96
FGD ayatem
< 1 )
Dec
24
50
82
71
0
93
56
Jan
23
67
56
67
99
79
• This category include! the flue gaa capacity being handled by the FGD eyete« at l«a»t part of the tine during
the report period.
•• The percent figure* lilted are average values for all •yatem «crubbing train* during the period in question.
a Cuiwnulative (October, November, December)
-------
FGO STATUS REPORT 01/78
COMPANY NAME
TABLE 1
SUMMARY LIST OF FGO SYSTEMS
UNIT NAME
START UP DATE STATUS
REG
CLASS
ALABAMA ELECTRIC COOP
ALABAMA ELECTRIC COOP
ALLEGHENY POWER SYSTEM
ALLEGHENY POWER SYSTEM
ARIZONA ELECTRIC POWER COOP
ARIZONA ELECTRIC POWER COOP
ARIZONA PUBLIC SERVICE
ARIZONA PUBLIC SERVICE
ARIZONA PUBLIC SERVICE
ARIZONA PUBLIC SERVICE
ARIZONA PUBLIC SERVICE
ARIZONA PUBLIC SERVICE
ARIZONA PUBLIC SERVICE
ARIZONA PUBLIC SERVICE
BASIN ELECTRIC POWER COOP
BASIN ELECTRIC POWER COOP
BASIN ELECTRIC POWER COOP
BASIN ELECTRIC POWER COOP
BASIN ELECTRIC POWER COOP
BIG RIVERS ELECTRIC COOP CORP.
BIG RIVERS ELECTRIC COOP CORP.
BOARD OF MUNICIPAL UTILITIES
BRAZOS ELECTRIC POWER COOP
CENTRAL ILLINOIS LIGHT CO.
CENTRAL ILLINOIS LIGHT CO.
CENTRAL ILLINOIS PUBLIC SERV
CENTRAL MAINE POWER CO.
CINCINNATI GAS & ELECTRIC CO.
COLORADO UTE ELECTRIC ASSN.
COLORADO UTE ELECTRIC ASSN.
COLUMBUS & SOUTHERN OHIO ELEC.
COLUMBUS & SOUTHERN OHIO ELEC.
COLUMBUS & SOUTHERN OHIO ELEC.
COLUMBUS & SOUTHERN OHIO ELEC.
COMMONWEALTH EDISON
DELMARVA POWER CO.
DUQUESNE LIGHT
DUOUESNE LIGHT
EASTERN KENTUCKY POWER COOP
GENERAL PUBLIC UTILITIES
GENERAL PUBLIC UTILITIES
GULF POWER CO.
GULF POWER CO.
GULF POWER CO.
HOOSIER COOPERATIVE
HOOSIER COOPERATIVE
INDIANAPOLIS POWER » LIGHT CO.
INDIANAPOLIS POWER & LIGHT CO.
KANSAS CITY POWER & LIGHT
KANSAS CITY POWER & LIGHT
KANSAS CITY POWER & LIGHT
KANSAS POWER & LIGHT
KANSAS POWER & LIGHT
KANSAS POWER & LIGHT
KANSAS POWER & LIGHT
KENTUCKY UTILITIES
LAKELAND UTILITIES
LOUISVILLE GAS & ELECTRIC
LOUISVILLE GAS & ELECTRIC
TOMBIGBEE NO. 2 6-78
TOMBIGBEE NO. 3 6-79
PLEASANTS NO. i 3-79
PLEASANTS NO. a 3-eo
APACHE NO a 6-78
APACHE NO 3 4-79
CHOLLA NO 1 10-73
CHOLLA NO a 6-78
CHOLLA NO. 4 6-80
FOUR CORNERS NO. 1 0- 0
FOUR CORNERS NO. 2 0-0
FOUR CORNERS NO. 3 0-0
FOUR CORNERS NO. 4 0-0
FOUR CORNERS NO. 5 0-0
ANTELOPE VALLEY NO. 1 0-81
ANTELOPE VALLEY NO. 2 0-83
LARAMIE RIVER NO. 1 4-80
LARAMIE RIVER NO. a 10-80
LARAMIE RIVER NO. 3 6-83
REID NO. 3 12-79
REID NO. 3 13-80
SIKESTON POWER STATION 11-80
SAN MIGUEL NO. 1 13-79
DUCK CREEK NO. 1 8-78
DUCK CREEK NO.a 1-83
NEWTON NO.l 11-79
SEARS ISLAND NO. 1 11-86
EAST BEND NO 2 1-81
CRAIG NO. 1 3-79
CRAIG NO. 2 3-79
CONESVILLE NO 5 1-77
CONESVILLE NO 6 10-78
POSTON NO. 5 0-81
POSTON NO. 6 0-83
POWERTON NO. 51 ia-79
DELAWARE CITY NOS. 1 2 & 3 4-80
ELRAMA POWER STATION 10-75
PHILLIPS POWER STATION 7-73
SPURLOCK GENERATING PLANT NO.i. 3-80
COHO NO.l 5-87
SEWARD NO.7 5-84
CRIST NO. 4 AND NO. 5 0-76
CRIST NO. 6 AND NO. 7 0-80
LANSING SMITH NO. 1 AND NO. Z 0-80
MEROM NO. 1 0-80
MEROM NO. a o-ai
PETERSBURG NO 3 10-77
PETERSBURG NO 4 4-82
HAWTHORN NO, 3 ll-7a
HAWTHORN NO. 4 8-72
LA CYGNE NO 1 2-73
JEFFERY NO. 1 6-78
JEFFERY NO. 2 6-80
LAWRENCE NO 4 ia-68
LAWRENCE NO 5 11-71
GREEN RIVER NOS. 1 3 AND 3 9-75
MCINTOSH POWER PLANT UNIT NO.3 10-81
CANE RUN NO 4 8-76
CANE RUN NO 5 4-78
2
a
z
2
2
a
i
2
3
6
6
6
6
6
6
6
3
3
6
2
2
3
2
2
6
a
6
3
a
a
i
2
6
6
2
2
1
1
5
7
7
7
7
7
5
5
1
5
1
1
1
2
2
1
1
1
5
1
2
A
A
A
A
B
B
B
B
E
B
B
B
B
B
B
B
B
B
B
A
A
A
A
A
A
A
A
A
B
B
B
B
6
B
C
C
3
6
A
A
A
B
B
B
A
A
A
A
B
B
C
B
B
B
B
C
A
B
B
1. OPERATIONAL UNITS
2. UNITS UNDER CONSTRUCTION
3. PLANNED - CONTRACT AWARDED
4. PLANNED - LETTER OF INTENT SIGNED
5. PLANNED - REQUESTING/EVALUATING BIDS
6. CONSIDERING ONLY FGD SYSTEMS
7. CONSIDERING FGD SYSTEMS AS WELL AS ALTERNATIVE METHODS
A. BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
B. BOILER SUBJECT TO STATE STANDARD THAT IS MORE STRINGENT THAN THE FEDERAL NSPS
C. BOILER SUBJECT TO STATE STANDARD THAT IS EQUAL TO OR LESS STRINGENT THAN NSPS
D. OTHER
E. REGULATORY CLASS UNKNOWN
-------
FGO STATUS REPORT 01/78
COMPANY NAME
TABLE 1
SUMMARY LIST OF FGD SYSTEMS
UNIT NAME
START UP DATE STATUS
REG
CLASS
LOUISVILLE GAS & ELECTRIC
LOUISVILLE GAS & ELECTRIC
LOUISVILLE GAS & ELECTRIC
LOUISVILLE GAS & ELECTRIC
LOUISVILLE GAS & ELECTRIC
LOUISVILLE GAS & ELECTRIC
MINNESOTA POWER AND LIGHT CO.
MINNKOTA POWER COOPERATIVE
MONTANA POWER CO.
MONTANA POWER CO.
MONTANA POWER CO.
MONTANA POWER CO.
NEVADA POWER
NEVADA POWER
NEVADA POWER
NEVADA POWER
NEVADA POWER
NEVADA POWER
NEVADA POWER
NEVADA POWER
NEVADA POWER
NEVADA POWER
NEW ENGLAND ELEC SYSTEM
NIAGARA MOHAWK POWER COOP.
NORTHERN INDIANA PUB SERVICE
NORTHERN INDIANA PUB SERVICE
NORTHERN INDIANA PUB SERVICE
NORTHERN STATES POWER CO.
NORTHERN STATES POWER CO.
NORTHERN STATES POWER CO.
NORTHERN STATES POWER CO.
OTTER TAIL POWER COMPANY
PACIFIC GAS AND ELECTRIC
PACIFIC GAS AND ELECTRIC
PACIFIC POWER AND LIGHT CO.
PENNSYLVANIA POWER CO.
PENNSYLVANIA POWER CO.
PENNSYLVANIA POWER CO.
PHILADELPHIA ELECTRIC CO.
PHILADELPHIA ELECTRIC CO.
PHILADELPHIA ELECTRIC CO.
PHILADELPHIA ELECTRIC CO.
POTOMAC ELECTRIC & POWER
POWER AUTHORITY OF NEW YORK
PUBLIC SERVICE CO OF NEW MEX.
PUBLIC SERVICE CO OF NEW M£X.
PUBLIC SERVICE CO OF NEW HEX.
PUBLIC SERVICE CO OF NEW HEX.
PUBLIC SERVICE OF INDIANA
SALT RIVER PROJECT
SALT RIVER PROJECT
SALT RIVER PROJECT
SOUTH CAROLINA PUBLIC SERVICE
SOUTH CAROLINA PUBLIC SERVICE
SOUTHERN ILLINOIS POWER COOP
SOUTHERN INDIANA GAS&ELECTHIC
SOUTHERN MISSISSIPPI ELECTRIC
SOUTHERN MISSISSIPPI ELECTRIC
SPRINGFIELD CITY UTILITIES
1. OPERATIONAL UNITS
2. UNITS UNDER CONSTRUCTION
3. PLANNED - CONTRACT AWARDED
CANE RUN NO 6
MILL CREEK NO 1
MILL CREEK NO ^
MILL CREEK NO 3
MILL CREEK NO 4
PADDYS RUN NO 6
CLAY BOSWELL NO. 4
MILTON R. YOUNG NO. 2
COLSTRIP NO 1
COLSTHIP NO 2
COLSTRIP NO. 3
COLSTRIP NO. 4
HARRY ALLEN STATION NO. 1
HARRY ALLEN STATION NO. ^
HARRY ALLEN STATION NO. 3
HARRY ALLEN STATION NO. «
REID GARDNER NO 1
REID GARDNER NO Z
REID GARDNER NO 3
REID GARDNER NO 4
WARNER VALLEY STATION NO. 1
WARNER VALLEY STATION NO. 2
BRAYTON POINT NO.3
CHARLES R. HUNTLEY NO.6
BAILLY NO. 7
BAILLY NO. 8
D.H. MITCHELL NO.11
SHEHBURNE COUNTY STATION NO.l
SHERBURNE COUNTY STATION NO.2
SHERBURNE COUNTY STATION NO.3
SHERBURNE COUNTY STATION NO.4
COYOTE NO. 1
FOSSIL NO. 1
FOSSIL NO. 2
JIM BHIDGEH NO. 4
SRUCE MANSFIELD NO. 1
BRUCE MANSFIELD NO. 2
BRUCE MANSFIELD NO. 3
CROMBY
EDDYSTONE NO. IA
EDOYSTONE NO. IB
EDDYSTONE NO. 2
DICKERSON NO. 0
ARTHUR KILL
SAN JUAN NO. 1
SAM JUAN NO. £
SAN JUAN NO. 3
SAN JUAN NO. 4
GIBSON 5
CORONADO NO.l
CORONADO NO.2
CORONAOO NO.3
WINYAH NO. 2
WJNYAH NO. 3
MARION NO. 4
A.B. BROWN NO.l
R.D. MOHROW NO.l
R.O. MORROW NO.2
SOUTHWEST NO. 1
11-79
1-82
1-81
4-78
6-80
4-73
0-80
9-77
11-75
7-76
7-80
7-81
6-63
6-84
6-85
6-86
4-74
4-74
7-76
0- 0
6-82
6-63
0- 0
0-80
0- 0
0- 0
6-77
3-76
4-77
5-81
5-83
5-81
0-84
0-85
9-79
4-76
7-77
4-80
6-80
9-75
6-60
6-80
5-85
9-62
4-78
7-78
1-79
5-81
0-82
4-79
4-80
0-97
7-77
0-80
6-78
4-79
5-78
8-78
4-77
2
6
6
2
2
1
3
1
1
1
3
3
6
6.
6
6
1
1
1
4
6
6
6
3
6
6
1
1
1
3
3
3
6
6
2
1
1
3
b
1
4
6
7
7
2
2
4
6
b
3
3
6
1
5
2
2
2
2
1
B
B
B
B
A
C
A
B
B
8
B
B
B
B
8
B
8
a
B
B
B
B
C
C
C
C
C
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
D
B
8
B
6
B
A
B
B
B
A
A
A
A
A
A
A
4. PLANNED - LETTER OF INTENT SIGNED
5. PLANNED - REQUESTING/EVALUATING BIDS
6. CONSIDERING ONLY FGD SYSTEMS
7. CONSIDERING FGD SYSTEMS AS WELL AS ALTERNATIVE METHODS
A. BOILER CONSTRUCTED SUBJECT TO FEOtRAL NSPS
B. BOILER SUBJECT TO STATE STANDARD THAT IS MOKE STRINGENT THAN THE FEDERAL NSPS
C. BOILER SUBJECT TO STATE STANDARD THAT IS EQUAL TO OR LESS STRINGENT THAN NSPS
D. OTHER
E. REGULATORY CLASS UNKNOWN
-------
FGD STATUS REPORT 01/78
COMPANY NAME
TABLE 1
SUMMARY LIST OF FGD SYSTEMS
UNIT NAME
START UP DATE STATUS
REG
CLASS
SPRINGFIELD WATER LIGHT&POWER
TENNESSEE VALLEY AUTHORITY
TENNESSEE VALLEY AUTHORITY
TENNESSEE VALLEY AUTHORITY
TENNESSEE VALLEY AUTHORITY
TEXAS MUNICIPAL POWER AGENCY
TEXAS POWER AND LIGHT CO.
TEXAS POWER AND LIGHT CO.
TEXAS POWER AND LIGHT CO.
TEXAS UTILITIES CO.
TEXAS UTILITIES CO.
TEXAS UTILITIES CO.
TEXAS UTILITIES CO.
TEXAS UTILITIES CO.
TEXAS UTILITIES CO.
UNITED POWER ASSOCIATION
UNITED POWER ASSOCIATION
UTAH POWER & LIGHT CO.
UTAH POWER & LIGHT CO.
VIRGINIA ELECTRIC AND POWER CO
WISCONSIN POWER & LIGHT CO.
DALLMAN NO. 3
SHAWNEE N0.10A
SHAWNEE NO.108
WIDOWS CREEK NO. 7
WIDOWS CREEK NO. 8
GIBBONS CREEK UNIT NO.
SANDOW NO.4
TWIN OAKS NO. 1
TWIN OAKS NO. 2
FOREST GROVE NO. 1
MARTIN LAKE NO. 1
MARTIN LAKE NO. 2
MARTIN LAKE NO. 3
MARTIN LAKE NO.
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS AS OF
01/78
CURRENT MONTH
ALABAMA ELECTRIC COOP
TOMBIGBEE NO. 2
225 MW - NEW
COAL 0.8 - 1.5 PERCENT SULFUR
PEABODY ENGINEERING
LIMESTONE SCRUBBING
STARTUP 6/78
PEABOOY ENGINEERING HAS BEEN AWARDED THE CONTRACT FOR THE INSTALLATION
OF A LIMESTONE SCRUBBING SYSTEM ON THIS UNIT. A HIGH-EFFICIENCY ESP WILL
BE INSTALLED UPSTREAM OF THE SCRUBBING SYSTEM TO PROVIDE PRIMARY
PARTICULATE CONTROL. THE FGD SYSTEM CONTAINS TWO SCRUBBING TRAINS,
TREATING APPROXIMATELY 70 PERCENT OF THE FLUE GAS FUR REMOVAL OF SULFUR
DIOXIDE. STACK GAS REHEAT WILL NOT 8E REQUIRED. THE TOTAL INSTALLED COST
FOR BOTH TOMBIGBEE NO. 2 AND NU. 3 FGD SYSTEMS IS $40.46 MM. CURRENTLY,
ERECTION OF THE SCRUBBING EQUIPMENT IS IN PROGRESS.
ALABAMA ELECTRIC COOP
TOMBIGBEE NO. 3
225 MW - NEW
COAL 0.8 - 1.5 PERCENT SULFUR
PfcABODY ENGINEERING
LIMESTONE SCRUBBING
STARTUP 6/79
PEABODY ENGINEERING HAS BEEN AWARDED THE CONTRACT FOR THE INSTALLATION
OF A LIMESTONE SCRUBBING SYSTEM ON THIS UNIT. A HIGH-EFFICIENCY ESP WILL
BE INSTALLED UPSTREAM OF THE SCRUBBING SYSTEM TO PROVIDE PRIMARY
PARTICULATE CONTROL. THE FGD SYSTEM CONTAINS TWO SCRUBBING TRAINS,
TREATING APPROXIMATELY 70 PERCENT OF THE FLUE GAS FOR REMOVAL OF SULFUR
DIOXIDE. STACK GAS REHEAT WILL NOT BE REQUIRED. UNIT NO. 3 TURBINE AND
BOILER ARE CURRENTLY UNDER CONSTRUCTION. CURRENTLY, FOUNDATION WORK ON
THE SCRUBBER PLANT IS COMPLETE. EQUIPMENT ERECTION WILL COMMENCE SHORTLY.
ALLEGHENY POWER SYSTEM
PLEASANTS NO. i
625 MW - NEW
COAL 4.5 PERCENT SULFUR
BABCOCK & WILCOX
LIME SCRUBBING
STARTUP 3/79
THE THREE PRINCIPAL OPERATING UTILITY COMPANIES OF THE ALLEGHENY HOWF.R
SYSTEM ARE INSTALLING AN EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED
UNIT WHICH INCLUDES A HIGH EFFICIENCY ESP UPSTREAM OF FOUR TRAY TOWERS
(MAX) FOR THE CONTROL OF PARTICULATES AND SULFUR DIOXIDE. DESIGN REMOVAL
EFFICIENCIES FOR THIS EMISSION CONTROL SYSTEM ARE 99.5 AND 90 PERCENT
RESPECTIVELY. THE ORAVO CO. IS SUPPLYING THIOSORBIC LIME. THE CONSULTING
ENGINEERING FIRM IS UNITED ENGINEERS AND CONSTRUCTORS. CURRENTLY, EREC-
TION OF THE SCRUBBING EQUIPMENT IS IN PROGRESS.
ALLEGHENY POWER SYSTEM
PLEASANTS NO. 2
625 MW - NEW
COAL 1.5 PERCENT SULFUR (MAX)
BABCOCK & WILCOX
LIME SCRUBBING
STARTUP 3/80
THE THREE PRINCIPAL OPERATING UTILITY COMPANIES OF THE ALLEGHENY POWER
SYSTEM ARE INSTALLING AN EMISSION CONTROL SYSTEM FUR THIS NEW COAL-FIRtD
UNIT WHICH INCLUDES A HIGH EFFICIENCY ESP UPSTREAM OF FOUR TRAY TOWERS
FOR THE CONTROL OF PARTICULATES AND SULFUR DIOXIDE. DESIGN REMOVAL
EFFICIENCIES FOR THIS EMISSION CONTROL SYSTEM ARE 99.5 AND 90 PERCENT,
RESPECTIVELY. THE DRAVO CO. IS SUPPLYING THIOSORBIC LIME. THE CONSULTING
ENGINEERING FIRM IS UNITED ENGINEERS AND CONSTRUCTORS. CURRENTLY, FOUNDA-
TION WORK ON THE SCRUBBER PLANT IS IN PROGRESS.
ARIZONA ELECTRIC POWER COOP
APACHE NO 3
200 MW - NEW
COAL 0.5- 0.8 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 6/78
AEPC HAS AWARDED A CONTRACT TO RESEARCH COTTRELL FOR A WET LIMESTONE
SCRUBBING SYSTEM. THE UNIT WILL FIRE BITUMINOUS COAL WITH A SULFUR CON-
TENT OF 0.5-0.8X, AND ASH CONTENT OF 10.OX (HEATING VALUE - 10,000-
11,000 BTU/LB). THERE is A 22 ACRE SLUDGE POND AND A 64 ACRE ASH POND.
PONDS WILL BE UNLINED AND 10 FEET DEEP. THERE WILL BE NO REHEAT. CON-
STRUCTION OF THE SYSTEM IS NOW NEARING COMPLETION. ALL FGD EQUIPMENT IS
INSTALLED. SCRUBBER LINING IS COMPLETE. THE PLASTIC GIRDERS SUPPORTING
THE MIST ELIMINATORS WERE REPLACED WITH STEEL GIRDERS.
ARIZONA ELECTRIC POWER COOP STRUCTURAL STEELWORK FOR HOT-SIDE UOP ESP'S is COMPLETE. STRUCTURE
APACHE NO 3 ERECTION OF THE SCRUBBER-ABSORBER TOWERS IS COMPLETE. EACH SCRUBBER CAN
200 MW - NEW HANDLE 400,000 ACFM 3 270 F AND RECIRCULATE 20,000 GPM OF SLURRY. BOILER
COAL 0.5- 0.8 PERCENT SULFUR CONSTRUCTION HAS BEGUN. THERE ARE CURRENTLY 2 PONDS WITH A TOTAL OF 20-
RESEARCH COTTRELL YRS CAPACITY FOR THE DISPOSAL OF THE UNFIXATED SLUDGE. 2 ADDITIONAL PONDS
LIMESTONE SCRUBBING ARE PLANNED PROVIDING AN ADDITIONAL 20 YRS OF DISPOSAL CAPABILITY. THERE
STARTUP 4/79 WILL BE NO REHEAT AND A KELLOGG LINER IS PLANNED FOR THE WET STACK, WHICH
WILL CONSIST OF A COMMON OUTER SHELL AND A SEPARATE FLUE FOR EACH UNIT.
ARIZONA PUBLIC SERVICE
CHOLLA NO 1
115 MW - RETROFIT
COAL 0.44-1 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 10/73
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS LIMESTONE SCRUBBING SYSTEM WAS PLACED IN SERVICE IN OCTOBER 1973.
THE SCRUBBER PLANT CONSISTS Of TWO PARALLEL SCRUBBING TRAINS. PARTICU-
LATE CONTROL IS PROVIDED BY TWO FLOODED-DISC SCRUBBERS. S02 CONTROL IS
PROVIDED BY ONE PACKED (MUNTERS PACKING) TOWER (A-SIDE). FLUE GAS CLEAN-
ING WASTES ARE DISCHARGED TO AN EXISTING FLY ASH POND. NO WATER IS RE-
CYCLED BACK FROM THE DISPOSAL POND. IN-LINE STEAM HEHEATEHS RAISE THE
GAS TEMPERATURE 40 F.
ARIZONA PUBLIC SERVICE
CHOLLA NO 2
250 MW - NEW
COAL 0.14-1 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 6/78
THE CONTRACT FOR THIS WET LIMESTONE SCRUBBING SYSTEM HAS BEEN AWARDED
BY THE UTILITY TO RESEARCH-COTTRELL. THIS SYSTEM IS A LARGER-SCALE
APPLICATION OF THE CHOLLA NO.l DESIGN. ALL DESIGN AND ENGINEERING WORK
HAVE BEEN COMPLETED. CONSTRUCTION OF THE UNIT IS NOW NEARING COMPLETION.
THE UNIT COMMERCIAL START-UP DATE IS JUNE 1978. THE FGD SYSTEMANT
CONSISTS OF FOUR PARALLEL FLOOOED-DISC SCRUBBERS AND PACKED TOWER ABSORBER
TRAINS. THREE ARE REQUIRED FOR FULL LOAD CAPACITY. INITIAL BOILER START-
UP DATE IS FEBRUARY 1978.
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF F60 SYSTEMS AS OF 01/76
CURRENT MONTH
ARIZONA PUBLIC SERVICE
CHOLLA NO. 4
350 MW - NEW
COAL 0.44-1 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 6/80
UNIT NO. 4 IS CURRENTLY UNDER CONSTRUCTION. APS HAS AWARDED THE F6D CON-
TRACT TO RESEARCH COTTRELL. THE STATE REGULATORY AGENCY HAS NOT YET DE-
CIDED THE EMISSIONS REGULATIONS WHICH WILL APPLY TO THE PLANT. THE C-E
BOILER WILL FIRE THE SAME COAL AS CHOLLA NO. 1, WITH SULFUH CONTENT OF
0.44-1.0 PERCENT. THE A-E FIRM IS EBASCO. COMMERCIAL START-UP IS SLATED
FOR 06/80. THE FGD SYSTEM IS A DOUBLE LOOP LIMESTONE ABSORPTION PROCESS
AND REVENUES OF THE CONTRACT TO R-C ARE REPORTED TO BE S5 MM.
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 1
175 MW - RETROFIT
COAL 0.75 PERCENT SULFUR
CHEMICO/APS
LIME/ALKALINE FLYASH SCRUBBING
STARTUP O/ 0
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 2
175 MW - RETROFIT
COAL 0.75 PERCENT SULFUR
CHEMICO/APS
LIME/ALKALINE FLYASH SCRUBBING
STARTUP O/ 0
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 3
229 MW - RETROFIT
COAL 0.75 PERCENT SULFUR
CHEMICO/APS
LIME/ALKALINE FLYASH SCRUBBING
STARTUP O/ 0
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 4
755 MW - RETROFIT
COAL 0.7 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
APS MAY BE UPGRADING THE OPERATIONAL PARTICULATE SCRUBBERS AT THE FOUR
CORNERS UNIT NOS. 1, 2 AND 3 FOR 802 REMOVAL. EACH UNIT HAS 2 VENTURI
SCRUBBER MODULES FOR PARTICULATE CONTROL. APPROXIMATELY 30X OF THE FLUE
GAS S02 CONTENT IS REMOVED AT THE PRESENT TIME IN THE VENTURIES BECAUSE
OF THE ALKALINITY OF THE COLLECTED FLYASH. NEW MEXICO APC OFFICIALS IN-
DICATED THAT THE FOUR CORNERS STATION WILL BE REQUIRED TO REDUCE S02
EMISSIONS AT LEAST 67.5* OF THE CURRENT LEVEL. UPGRADING OF THE VENTURIES
WOULD BE AFFECTED BY SUPPLEMENTING THE ALKALINITY OF THE SCRUBBING FLUID.
APS MAY BE UPGRADING THE OPERATIONAL PARTICULATE SCRUBBERS AT THE FOUR
CORNERS UNIT NOS. 1, 2 AND 3 FOR S02 REMOVAL. EACH UNIT HAS 2 VENTURI
SCRUBBER MODULES FOR PARTICULATE CONTROL. ROUGHLY 30X OF THE FLUE GAS S02
CONTENT is REMOVED AT THE PRESENT TIME IN THE VENTURIES WITH THE HIGH
ALKALINE FLYASH. NEW MEXICO APC OFFICIALS INDICATED THAT THE 5 FOUK COR-
NERS UNITS WILL BE REQUIRED TO REMOVE AT LEAST 67.5X OF THE S02 CONSIDER-
ING ALL OF THE PLANTS TOGETHER. UPGRADING OF THE VENTURIES WOULD BE AF-
FECTED BY ADJUSTING ACID-ALKALINITY.
APS MAY BE UPGRADING THE OPERATIONAL PARTICULATE SCRUBBERS AT THE FOUR
CORNERS UNIT NOS. 1, 2 AND 3 FOR S02 REMOVAL. EACH UNIT HAS 2 VENTURI
SCRUBBER MODULES FOR PARTICULATE CONTROL. ROUGHLY 30X OF THE FLUE GAS S02
CONTENT IS REMOVED AT THE PRESENT TIME IN THE VENTURIES WITH THE HIGH
ALKALINE FLYASH. NEW MEXICO APC OFFICIALS INDICATED THAT THE 5 FOUR COR-
NERS UNITS WILL BE REQUIRED TO REMOVE AT LEAST 67.5X OF THE S02 CONSIDER-
ING ALL OF THE PLANTS TOGETHER. UPGRADING OF THE VENTURIES WOULD BE AF-
FECTED BY ADJUSTING ACID-ALKALINITY.
THE UTILITY IS CURRENTLY EVALUATING THE DATA AND INFORMATION ACCUMULATED
DURING THE HORIZONTAL PROTOTYPE SCRUBBING PROGRAM IN ORDER TO ASCERTAIN
VARIOUS POSSIBLE STRATEGIES TO CONTROL THE EMISSIONS FROM THIS COAL FIRED
755-MW UNIT. APS MAY BE REQUIRED TO REDUCE THE CURRENT LEVEL OF 802 EMIS-
SIONS FROM THE ENTIRE PLANT BY 67.5X. A DECISION ON THE USE OF FGD FOR
THIS UNIT WILL BE ANNOUNCED SHORTLY.
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 5
755 MW - RETROFIT
COAL 0.7 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
THE UTILITY IS CURRENTLY EVALUATING THE DATA AND INFORMATION
ACCUMULATED DURING THE HORIZONTAL PROTOTYPE SCRUBBING PROGRAM
IN ORDER TO ASCEHTAIN VARIOUS POSSIBLE STRATEGIES TO CONTROL
THE EMISSIONS FROM THIS COAL-FIRED 755-MW UNIT. A DECISION,
PENDING THE OUTCOME OF LOCAL REGULATORY AGENCY HEARINGS
WILL BE ANNOUNCED IN THE NEAR FUTURE.
BASIN ELECTRIC POWER COOP
ANTELOPE VALLEY NO. 1
450 MW - NEW
LIGNITE 1.0 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/81
THE UTILITY IS CURRENTLY PLANNING TO INSTALL A WET SCRUBBING SYSTEM TO
CONTROL S02 EMISSIONS FROM THIS LIGNITE-FIRED BOILER. VARIOUS PROCESSES
ARE NOW BEING EVALUATED BY THE UTILITY. THIS NEW FACILITY IS
LOCATED IN THE MERCER COUNTY AREA NEAR BEULAH, NORTH DAKOTA AND IS
KNOWN AS THE ANTELOPE VALLEY STATION. BOTH UNITS 1 AND 2 WILL BE REQUIRED
TO COMPLY WITH AIR EMISSION STANDARDS VIA BEST AVAILABLE TECHNOLOGY.
START-UP IS SCHEDULED FOR 1981. BIDS ARE EXPECTED TO GO OUT THIS SPRING.
BASIN ELECTRIC POWER COOP
ANTELOPE VALLEY NO. 2
450 MW - NEW
LIGNITE 1.0 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/83
THE UTILITY IS CURRENTLY INVESTIGATING VARIOUS FGD PROCESSES FOR THIS
SECOND LIGNITE-FIRED UNIT SCHEDULED AT THIS NEW STATION LOCATED IN MERCER
COUNTY, NEAR BEULAH, NORTH DAKOTA. THIS NEW FACILITY WILL BE KNOWN AS
THE ANTELOPE VALLEY STATION AND WILL BE REQUIRED TO COMPLY WITH AIR
EMISSION STANDARDS VIA THE BEST AVAILABLE TECHNOLOGY. START-UP IS NOW
SCHEDULED FOR 1963. BIDS ARE EXPECTED TO GO OUT THIS SPRING.
-------
COMPANY
POWER STATION
TABLE £
STATUS OF FGD SYSTEMS AS OF
01/78
CURRENT MONTH
BASIN ELECTRIC POWER COOP
LARAMIE RIVER NO. 1
550 MW - NEW
COAL 0.6 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 4/80
RESEARCH-COTTRELL IS CURRENTLY FABRICATING THE DUAL-LOOP LIMESTONE WET
SCRUBBERS. ON-SITE CONSTRUCTION IS TO BEGIN APRIL 1978. SLUDGE WILL BE
DEWATERED TO 83X SOLIDS BEFORE LANDFILL. THE SCRUBBERS WILL BE MADE OF
STAINLESS STEEL AND WILL HANDLE 2.3 MM ACFM AT 286 F. L/G RATIO WILL BE
60. THE TOTAL CAPITAL COST FOR BOTH THE SYSTEMS IS ESTIMATED TO BE 80
MM DOLLARS. THE OPERATING COST WILL BE 1.5 MILLS/KWH. B*W HAS BEEN AWARD'
ED CONTRACT FOR 2 ESP'S AT A COMBINED COST OF $28 MM. THE ESP'S ARE FOR
UNITS 1 AND 2. STACK WILL BE CONCRETE WITH ACID BRICK LINING.
BASIN ELECTRIC POWER COOP
LARAMIE RIVER NO. 2
550 MW • NEW
COAL 0.8 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 10/80
RESEARCH-COTTRELL IS CURRENTLY FABRICATING THE DUAL-LOOP LIMESTONE WET
SCRUBBERS. ON-SITE CONSTRUCTION IS TO BEGIN APRIL 1978. SLUDGE WILL BE
DEWATERED TO 63X SOLIDS BEFORE LANDFILL. THE SCRUBBERS WILL BE MADE OF
STAINLESS STEEL AND WILL HANDLE 2.3 MM ACFM AT 286 F. L/G RATIO WILL BE
60. THE TOTAL CAPITAL COST FOR BOTH THE SYSTEMS IS ESTIMATED TO BE 80
MM DOLLARS. THE OPERATING COST WILL BE 1.5 MILLS/KWH. B&W HAS BEEN AWARD-
ED CONTRACT FOR 2 ESP'S AT A COMBINED COST OF $28 MM. THE ESP'S ARE FOR
UNITS 1 AND 2. STACK WILL BE CONCRETE WITH ACID BRICK LINING.
BASIN ELECTRIC POWER COOP
LARAMIE RIVER NO. 3
550 MW - NEW
COAL 0.8 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 6/83
THE UTILITY IS STILL CONSIDERING VARIOUS FGD PROCESSES. LARAMIE RIVER
STATION WILL FIRE SUB-BITUMINOUS COAL WITH THE FOLLOWING CHARACTERIS-
TICS* 8100 BTU/LB, 0.8 PERCENT SULFUR AND 7.0 PERCENT ASH.
THE EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED UNIT IS BEING SUPP-
LIED BY AMERICAN AIR FILTER, THE SYSTEM WILL CONSIST OF A COLD-SIDE ESP
AND TWO SPRAY TOWERS CONTROLLING PARTICULATE AND 802 TO 99.6 PERCENT AND
90 PERCENT, RESPECTIVLEY. THE B&W BOILER WILL FIRE HIGH SULFUR C3.5 TO
4.5 PERCENT) WESTERN KENTUCKY COAL. FGD SYSTEM FOUNDATIONS HAVE BEEN
LAID, ONE REACTION TANK HAS BEEN ASSEMBLED AND A SECOND TANK IS BEING
CONSTRUCTED. THE FGD SYSTEM WILL INCLUDE AN INDIRECT HOT AIR REHEAT SYST.
IUCS WILL CONSTRUCT A SLUDGE DISPOSAL SYSTEM TO SERVICE BOTH REID 2 AND 3
THE EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED UNIT IS BEING SUPP-
LIED BY AMERICAN AIR FILTER. THE SYSTEM WILL CONSIST OF A COLD-SIDE ESP
AND TWO SPRAY TOWERS CONTROLLING PARTICULATE AND S02 TO 99.6 PERCENT AND
90 PERCENT, RESPECTIVELY. THE B&W BOILER WILL FIRE HIGH SULFUR (3.5 TO
a.5 PERCENT) WESTERN KENTUCKY COAL. THE FGO SYSTEM WILL INCLUDE AN
INDIRECT HOT AIR REHEAT SYSTEM. IUCS WILL CONSTRUCT A SLUDGE DISPOSAL
SYSTEM TO SERVICE BOTH REID 2 AND 3. THE BOILER IS CURRENTLY UNDER CON-
STRUCTION.
B&W WAS AWARDED A CONTRACT FOR BOILER AND AIR QUALITY CONTROL SYSTEM
INSTALLATION. 2.8 PERCENT SULFUR COAL IS TO BE BURNED. THE AOC SYSTEM
WILL CONSIST OF 2 ESP'S FOLLOWED BY 3 SCRUBBERS EACH CAPABLE OF HANDLING
SOX OF THE BOILER LOAD-ONE WILL BE ON STAND-BY AT ALL TIMES. SIKESTON
STATION WILL FEATURE A DOUBLE-LINED STACK, 2 PONDS, ONE FOR FLY ASH, THE
OTHER FOR SCRUBBER SLUDGE/BOTTOM-ASH DISPOSAL, AND 4 AXIAL FLOW FANS. NO
STACK GAS REHEAT IS PLANNED. GROUND BREAKING IS SET FOR APRIL 1978. MAX-
IMUM FLUE GAS CAPACITY IS 748,390 ACFM $ 286 F.
BIG RIVERS ELECTRIC COOP CORP.
REID NO. 2
250 MW - NEW
COAL 3.5-4.0 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 12/79
BIG RIVERS ELECTRIC COOP CORP.
REIO NO. 3
240 MW - NEW
COAL 3.5-4.0 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 12/80
BOARD OF MUNICIPAL UTILITIES
SIKESTON POWER STATION
235 MW - NEW
COAL 2.8 PERCENT SUFUR
BABCOCK & WILCOX
LIMESTONE SCRUBBING
STARTUP 11/80
BRAZOS ELECTRIC POWER COOP
SAN MIGUEL NO. 1
400 MW - NEW
LIGNITE 1.67 PERCENT SULFUR
BABCOCK & WILCOX
LIMESTONE SCRUBBING
STARTUP 12/79
THE EMISSION CONTROL EQUIPMENT FOR THE COAL-FIKED RADIANT BOILER WILL
CONSIST OF AN ESP UPSTREAM OF FOUR LIMESTONE SCRUBBING MODULES.
THE SCRUBBER FLUE GAS CAPACITY IS NOMINALLY DESIGNED AT 1.579 MILLION
ACFM (302 F). DESIGN S02 REMOVAL EFFICIENCY IS 86 PERCENT FOR 4aOO PPM
S02 INLET. L/G RATIOS ARE 10 AND 45 FOR QUENCHER AND ABSORBER, RESPEC-
TIVELY. RESEARCH COTTRELL HAS BEEN AWARDED SLUOGE DISPOSAL CONTRACT.
FGD SYSTEM FOUNDATION IS COMPLETE WITH STRUCTURAL STEEL SOON TO BE
ERECTED. BOILER CONSTRUCTION IS ABOUT 50* COMPLETE.
CENTRAL ILLINOIS LIGHT CO.
DUCK CREEK NO. 1
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS AS OF
01/78
CURRENT MONTH
CENTRAL ILLINOIS LIGHT CO.
DUCK CREEK NO.2
400 MM - NEW
COAL 2.5-3.0 PERCENT SULFUR
NOT SELECTED
LIMESTONE SCRUBBING
STARTUP 1/82
SCRUBBING UNIT IS SCHEUULEO TO COMMENCE OPERATIONS IN JANUARY 1982. THE
UTILITY HAS NOT YET SELECTED A SYSTEM SUPPLIER. A DECISION CONCERNING
THE STATUS OF THE BOILER AND CONTROL STRATEGY WILL BE ANNOUNCED IN EARLY
1976. THE UTILITY IS LOOKING AT ESP'S FOR PARTICULATE CONTROL AND
LIMESTONE OR DUAL ALKALI FOR S02 SCRUBBING. THE PLANT IS NOW IN THE
PROCESS OF PREPARING SPECS.
CENTRAL ILLINOIS PUBLIC SERV
NEWTON NO.l
575 MW - NEW
COAL 4.0 PERCENT SULFUR
BUELL/ENVIROTECH
DOUBLE ALKALI SCRUBBING
STARTUP 11/79
A CONTRACT HAS BEEN AWAROEO BY CIPSCO TO BUELL/ENVIROTECH FOR THE
INSTALLATION OF AN EMISSION CONTROL SYSTEM ON UMT NO. 1. THE KEY COM-
PONENTS OF THE EMISSION CONTROL SYSTEM INCLUDE* A HIGH-EFFICIENCY ESP,
FOUR PRECOOLERS, FOUR POLYSPHERE ABSORBERS, THKEE THICKENERS, TWO EX-
PERIMENTAL REHEAT SYSTEMS, AND THREE HORIZONTAL EXTRACTION FILTERS FOR
SLUDGE DEWATERING. APPROXIMATELY 25 PERCENT OF THE CONSTRUCTION WORK
AT THE PLANT HAS BEEN COMPLETED. THE FGD SYSTEM WILL HAVE CEILCOTE-
LINEO ABSORBER MODULES.
CENTRAL MAINE POWER CO.
SEARS ISLAND NO. 1
600 MW - NEW
COAL SOURCE UNDETERMINED
NOT SELECTED
NOT SELECTED
STARTUP 11/86
BECAUSE OF THE DISCOVERY OF A GEOLOGICAL FAULT ON SEARS ISLAND, THE
UTILITY HAS CANCELLED PLANS FOR A 1150-MW NUCLEAR POWER PLANT. A
600-MW COAL-FIRED UNIT IS NOW BEING PLANNED IN ITS PLACE. COMMERCIAL
OPERATION IS PROJECTED FOR NOVEMBER 1986. COMPLIANCE WITH 302 NSPS WILL
BE ACHIEVED BY INSTALLING AN FGD SYSTEM. LIME AND LIMESTONE SCRUBBING
PROCESSES ARE BEING GIVEN PRIMARY CONSIDERATION. CURRENTLY, CMPCO HAS
FILED AN APPLICATION WITH THE STATE PUBLIC UTILITIES COMMISSION. AN EN-
VIRONMENTAL PERMIT APPLICATION WILL BE FILED WITHIN THE NEXT TWO YEARS..
CINCINNATI GAS & ELECTRIC CO.
EAST BEND NO 2
600 MW - NEW
COAL
BABCOCK & WILCOX
LIME SCRUBBING
STARTUP 1/81
A CONTRACT HAS BEEN CONDITIONALLY AWARDED TO BABCOCK AND WILCOX FOR A
COMMERCIAL LIME SCRUBBING SYSTEM. A COAL SOURCE AND SUPPLY HAS NOT BEEN
FINALIZED, COMMERCIAL START-UP DATE HAS BEEN DELAYED ONE YEAR TO JANUARY
1981. THE A-t DESIGN FIRM IS SARGENT AND LUNOY.
COLORADO UTE ELECTRIC ASSN.
CRAIG NO. 1
450 MW - NEW
COAL 0.45 PERCENT SULFUR
PEABODY ENGINEERING
LIMESTONE SCRUBBING
STARTUP 3/79
THE CONSTRUCTION OF THE LIMESTONE SLURRY SPRAY TOWER SCRUBBING
SYSTEM FOR SULFUR DIOXIDE REMOVAL FROM LOW-SULFUR COAL-FIRED BOILER FLUE
GAS HAS BEGUN. THE FOUNDATION IS COMPLETE AND THE SILOS ARE UP. PANTI-
CULATE CONTROL WILL BE PROVIDED BY HOT-SIDE ESP'S UPSTREAM OF THE SCRUB-
BER PLANT. SLUDGE DISPOSAL IS UNDECIDED. THERE WILL BE A STEAM COIL TYPE
STACK GAS REHEAT INCLUDED. REQUIRED PARTICULATE AND SULFUR DIOXIDE RE-
MOVAL EFFICIENCIES ARE 99.8 AND 85 PERCENT, RESPECTIVELY. FGD SYSTEM
START-UP IS SCHEDULED FOR SPRING 1979.
COLORADO UTE ELECTRIC ASSN.
CRAIG NO. 2
450 MW - NEW
COAL 0.45 PERCENT SULFUR
PEABOOY ENGINEERING
LIMESTONE SCRUBBING
STARTUP 3/79
PEABODY ENGINEERED SYSTEMS HAS BEEN AWARDED A CONTRACT IN EXCESS OF
$60 MILLION TO DESIGN AND SUPPLY A LIMESTONE SLURRY SPRAY TOWER
SCRUBBING SYSTEM FOR S02 REMOVAL FROM LOW-SULFUR COAL-FIRED BOILER FLUE
GAS FOR UNITS 1 & 2. PARTICULATE CONTROL WILL bE PROVIDED BY HOT-SIDE
ESP'S UPSTREAM OF THE SCRUBBER PLANT. SLUDGE WILL BE STABILIZED AND HAUL-
ED TO A MINE^ILL. THERE WILL BE A STEAM COIL TYPE STACK GAS REHEATER IN-
CLUDED. REQUIRED PARTICULATE AND 502 REMOVAL EFFICIENCIES ARE 99.8
AND 85 PERCENT, RESPECTIVELY. FGD START-UP IS SCHEDULED FOR SPRING 1979.
COLUMBUS & SOUTHERN OHIO ELEC.
CONESVILLE NO 5
400 MW - NEW
COAL 4.5 - 4.9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
STARTUP 1/77
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE BOILER AND ESP WERE COMPLETED AND PLACED IN SERVICE IN SEPT. 1976.
THE B-SIDE MODULE BECAME AVAILABLE FOR SERVICE IN JANUARY 1977.
COMMERCIAL OPERATIONS WERE ACHIEVED ON FEBRUARY 13, 1977. THE EMISSION
CONTROL SYSTEM FOR THIS UNIT CONSISTS OF A COLD-SIDE ESP FOLLOWED BY
TWO TCA LIME SCRUBBING MODULES SUPPLIED BY UOP. ORAVO is SUPPLYING THE
THIOSORBIC LIME SCRUBBING REAGENT. IUCS IS SUPPLYING THEIR POZ-0-TEC
SLUDGE STABILAZATION FACILITY.
COLUMBUS & SOUTHERN OHIO ELEC.
CONESVILLE NO 6
400 MW - NEW
COAL 4.5 - 4.9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
STARTUP 10/78
THE UTILITY SIGNED LONG-TERM CONTRACTS WITH DRAVO FOR THE PURCHASE OF
THIOSORBIC LIME AND WITH IUCS FOK A SLUDGE FIXIATION SYSTEM. CON-
STRUCTION OF THIS UNIT COMMENCED IN 1977 AND IS SCHEDULED TO BE
COMPLETED BY JANUARY 1978. SIMILAR TO CONESVILLE NO.5, THIS MINE MOUTH
PLANT WILL BURN COAL WITH 17 PERCENT ASH CONTENT AND 4.5 TO 4.9 PERCENT
SULFUR CONTENT. AN ELECTROSTATIC PRECIPITATOR WILL BE INSTALLED UPSTREAM
THE FGD SYSTEM. THE FGD SYSTEM WILL INCLUDE TWO TCA MODULES FOR THE RE-
MOVAL OF S02. THE A-E DESIGN FIRM IS BLACK AND VEATCH.
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COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS AS OF
01/78
CURRENT MONTH
COLUMBUS & SOUTHERN OHIO ELEC. THIS UNIT WILL BURN HIGH SULFUR UHIO COAL (APPROXIMATELY 2.5 PERCENT
P03TON NO. 5 SULFUR CONTENT). THE DESIGN OF THE EMISSION CONTROL STRATEGY HAS
375 MW - NEW NOT YET BEEN FINALIZED.
COAL 2.5 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/81
COLUMBUS & SOUTHERN OHIO ELEC. THIS UNIT WILL BURN HIGH SULFUR COAL (APPROXIMATELY 2.5 PERCENT
POSTON NO. 6
375 MW - NEW
COAL 2.5 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/83
SULFUR CONTENT). THE DESIGN OF THE EMISSION CONTROL STRATEGY
FOR THIS UNIT HAS NOT YET BEEN FINALIZED.
COMMONWEALTH EDISON
POWERTON NO. 51
425 MW • RETROFIT
COAL 3.6 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
STARTUP 12/79
UOP WAS AWARDED THE CONTRACT FOR THE INSTALLATION OF A WET LIMESTONE
SCRUBBING SYSTEM THAT WILL BE BACKFITTED ONTO BOILER NO. 51, ONE OF TWO
IDENTICAL BOILERS SUPPLYING STEAM TO AN 850-MW TURBINE-GENERATOR. THE
FGD SYSTEM IS DESIGNED TO TREAT FLUE GAS RESULTING FROM THE COMBUSTION
OF HIGH SULFUR COAL (3.b PERCENT SULFUR* 8.3 PERCENT ASH* 17.3 PERCENT
MOISTURE* 10,500 BTU/LB.) AND MEET S02 EMISSION STANDARDS OF 1.8 LB.
S02/MM BTU. CURRENTLY, EXCAVATION, BACKFILL, AND STRUCTURAL STEEL
ERECTION IS IN PROGRESS.
DELMARVA POWER CO.
DELAWARE CITY NOS. 1 2 & 3
180 MW - RETROFIT
COKE 7-6 PERCENT SULFUR
DAVY POWERGAS
WELLMAN LORD
STARTUP 1/80
DELMARVA'S DELAWARE CITY PLANT HAS
-------
COMPANY
POWER STATION
TABU 2
STATUS OF FGO SYSTEMS AS OF
01/78
CURRENT MONTH
GENERAL PUBLIC UTILITIES
SEWARD NO.7
800 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 5/8a
STARTUP DATE CHANGED TO 5/84 FOR BOTH BOILER AND DESULFURIZATION SYSTEM.
LIME, LIMESTONE SCRUBBING, AND COAL DESULFURIZATION ARE THE PRIMARY STRA-
TEGIES BEING CONSIDERED FOR COMPLIANCE WITH NEW SOURCE PERFORMANCE STAN-
DARDS. NO DECISION HAS BEEN MADE YET.
GULF POWER CO.
CRIST NO. a AND NO. 5
150 MW - RETROFIT
EACH UNIT IS 75 MW. IF SCRUBBERS ARE SELECTED THEY WILL BE REQUIRED IN
1976. NO DECISION HAS YET BEEN ANNOUNCED.
NOT SELECTED
NOT SELECTED
STARTUP 0/78
GULF POWER CO.
CRIST NO. 6 AND NO.
820 MW - NEW
NOT SELECTED
NOT SELECTED
STARTUP 0/80
UNIT 6 IS 330 MW. UNIT 7 IS 500 MW.
NO DECISION HAS YET BEEN ANNOUNCED.
FGD MAY BE REQUIRED IN 1980.
GULF POWER CO.
LANSING SMITH NO. 1 AND NO. i
305 MW - RETROFIT
COAL
NOT SELECTED
NOT SELECTED
STARTUP 0/80
UNIT NO. 1 IS 125 MW. UNIT NO. 2 IS 180 MW. IF SCRUBBERS ARE SELECTED,
THEY WILL BE REQUIRED IN 1979 AND 1980 ON THE RESPECTIVE UNITS.
HOOSIER COOPERATIVE
MEROM NO. 1
490 MW » NEW
COAL 3.5 PERCENT SULFUR
NOT SELECTED
LIMESTONE SCRUBBING
STARTUP 0/60
MEROM 1 AND 2 ARE HOOSIER COUP'S NEW 190 MW COAL-FIRED UMTS PLANNED FOR
LOCATION IN SULLIVAN, INDIANA. THE FLUE GAS STREAMS WILL BE CLEANED OF
PARTICULATES WITH ESPS (99.4X) AND OF SULFUR DIOXIDE WITH LIMESTONE
SCRUBBERS C90X). SLUDGE WILL BE STABILIZED AND STOCK PILED. THE UTILITY
IS CURRENTLY REQUESTING/EVALUATING BIDS FOR THE FGD SYSTEMS. FGD STAKT-UP
DATES ARE SCHEDULED FOR LATE 1980 (NO.l) AND MID 1981 IN0.2).
HOOSIER COOPERATIVE
MEROM NO. 2
490 MW - NEW
COAL 3.5 PERCENT SULFUR
NOT SELECTED
LIMESTONE SCRUBBING
STARTUP 0/81
MEROM 1 AND 2 ARE HOOSIER COOP'S NEW 490 MW COAL-FIRED UNITS PLANNED FUR
LOCATION IN SULLIVAN, INDIANA. THE FLUE GAS STREAMS WILL BE CLEANED OF
PARTICULATES WITH ESPS (99.4X) AND OF SULFUR DIOXIDE WITH LIMESTONE
SCRUBBERS (90X). SLUDGE WILL BE STABILIZED AND STOCK PILED. THE UTILITY
IS CURRENTLY REQUESTING/EVALUATING BIDS FOR THE FGD SYSTEMS. FGD START-UP
DATES ARE SCHEDULED FOR LATE 1980 CNO.l) AND MID 1981 IN0.2).
INDIANAPOLIS POWER & LIGHT CO. INDIANAPOLIS P & L HAS AWARDED A CONTRACT TO UNIVERSAL OIL PRODUCTS FOR A
PETERSBURG NO 3
530 MW - NEW
COAL 3.0-3.5 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
STARTUP 10/77
WET LIMESTONE SCRUBBING S02 CONTROL SYSTEM. AN ESP PROVIDES PRIMARY PAR-
TICULATE CONTROL. THE UNIT FIRES BITUMINOUS COAL WITH A SULFUR CONTENT
OF 3.0-3.5X, AN ASH CONTENT OF 9-10X, AND A HEAT CONTENT OF 11,000
BTU/LB. THE FOUR MODULES OPERATED FOR 24 HOURS IN MID-DECEMBER FOR
EQUIPMENT TESTING. THE SCRUBBERS WERE TAKEN OUT OF SERVICE SO THAT SOME
FINAL ADJUSTMENTS COULD BE MADE. SCRUBBERS ARE EXPECTED TO BE BACK IN
SERVICE BY EARLY MARCH 1976.
INDIANAPOLIS POWER & LIGHT CO. INDIANAPOLIS POWER & LIGHT ANNOUNCED THAT A NEW COAL-FIRED POWER
PETERSBURG NO 4
530 MW - NEW
COAL 3,5 PERCENT SULFUR
NOT SELECTED
LIMESTONE SCRUBBING
STARTUP 4/82
GENERATING UNIT IS BEING PLANNED FOR THEIR PETERSBURG GENERATING STATIUN
LOCATED IN PETERSBURG, INDIANA. THIS NEW UNIT WILL FIRE HIGH-SULFUH
SUBBITUMINOUS COAL WITH A HEATING VALUE OF 11,000 BTU/LB AND ASH AND
SULFUR CONTENTS OF 10 PERCENT AND 3.5 PERCENT, RESPECTIVELY. THE UTILITY
IS NOW CONSIDERING VARIOUS FGD STRATEGIES FOR THE CONTROL OF SULFUR
DIOXIDE, GIVING PRIMARY CONSIDERATION TO WET LIMESTONE SCRUBBING.
BIOS FOR FGD SYSTEM ARE NOW BEING EVALUATED.
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COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS AS OF
01/78
CURRENT MONTH
KANSAS CITY POWER & LIGHT
HAWTHORN NO. 3
140 MW - RETROFIT
COAL 0.5-3.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
STARTUP 11/72
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE SCRUBBER PLANT HAS BEEN CONVERTED FROM A LIMESTONE FURNACE INJECTION
AND TAIL-END SCRUBBING SYSTEM TO A TAIL-END WET LIME SCRUBBING SYSTEM.
LIME-BASED OPERATIONS COMMENCED ON FEBRUARY 7, 1977. COMPLIANCE TESTING
FOR KANSAS CITY PARTICULATE STANDARDS INDICATED THE NO.3 UNIT WAS WELL
WITHIN THE 0.17 POUND REGULATION. THE 2-MODULE SCRUBBER PLANT CAN ONLY BE
BY-PASSEO DURING EMERGENCIES.
KANSAS CITY POWER & LIGHT
HAWTHORN NO. 4
100 MW - RETROFIT
COAL 0.5-3.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
STARTUP 8/72
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE SCRUBBER PLANT HAS BEEN CONVERTED FROM A LIMESTONE FURNACE INJECTION
AND TAIL-END SCRUBBING SYSTEM TO A TAIL-END WET LIME SCRUBBING SYSTEM.
OPERATIONS IN THE LIME SCRUBBING MODE COMMENCED ON JANUARY 1, 1977.
COMPLIANCE TESTING FOR KANSAS CITY PARTICULATE REGULATIONS INDICATED THE
UNIT IS MEETING THE 0.17 POUND REGULATION. THE 2-MODULE SCRUBBER PLANT
CAN ONLY BE BY-PASSED DURING EMERGENCIES.
KANSAS CITY POWER * LIGHT
LA CYGNE NO 1
830 MW - NEW
COAL 5.0 PERCENT SULFUR
BABCOCK & WILCOX
LIMESTONE SCRUBBING
STARTUP 3/73
KANSAS POWER & LIGHT
JEFFERY NO. 1
680 MW - NEW
COAL 0.30 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 6/78
KANSAS POWER & LIGHT
JEFFERY NO. 2
680 MW - NEW
COAL 0.30 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 6/80
KANSAS POWER & LIGHT
LAWRENCE NO 4
125 MW - RETROFIT
COAL 0.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 12/68
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE EMISSION CONTROL SYSTEM FOR THIS N£« COAL-FIRED POWER-GENERATING UNIT
CONSISTS OF EIGHT SCRUBBER MODULES FOR FLY ASH AND S02 REMOVAL. EACH
MODULE INCLUDES A VENTURI SCRUBBER IN SERIES WITH A 2-STAGE IMPINGEMENT
PLATE ABSORBER. THE SCRUBBER PLANT IS AN INTEGRAL PART OF THE POWER-
GENERATING COMPLEX, ALLOWING NO FLUE GAS BYPASS. INITIAL OPERATIONS
COMMENCED IN FEB. 1973. COMMERCIAL SERVICE WAS ATTAINED BY JUNE 1973.
TOTAL SYSTEM AVAILABILITY FOR THE MONTH OF JANUARY WAS 94 PERCENT.
KP&L HAS PURCHASED A COMBUSTION ENGINEERING AIR QUALITY CONTROL SYSTEM
FOR PARTICULATE AND S02 REMOVAL CONSISTING OF A COLD-SIDE ESP, I.D. FANS,
BY-PASS CAPABILITY, AND SPRAY TOWERS. AN OVERFIRE AIR SYSTEM AT THE TAN-
GENTIAL FIKED PULVERIZED BURNERS WILL CONTROL NOX EMISSIONS. THE CLEANED
GASES WILL BE VENTED TO A 600 FT STACK. CONSTRUCTION IS PROCEEDING ACCORD-
ING TO SCHtDULE. THE ESP'S HAVE BEEN INSTALLED. THE SLURRY HOLD TANKS AND
ABSORBERS ARE IN PLACE. SLUDGE DISPOSAL STRATEGY HAS NOT BEEN FINALIZED.
THIS UNIT WILL FIRE 0.3X SULFUR C6X ASH) WYOMING COAL.
KP&L HAS PURCHASED A COMBUSTION ENGINEERING AIR QUALITY CONTROL SYSTEM
FOR PARTICULATE AND S02 REMOVAL CONSISTING OF A COLD-SIDE ESP, I.D. FANS,
BY-PASS CAPABILITY, AND SPRAY TOwERS. AN OVERFIHE AIM SYSTEM AT THE TAN-
GENTIAL FIRED PULVERIZED BURNERS WILL CONTROL NOX EMISSIONS. THE CLEANED
GASES WILL BE VENTED TO A 600 FT STACK. CONSTRUCTION IS PROCEEDING ACCORD-
ING TO SCHEDULE. THE ESP'S ARE NOW GOING IN. THE SLURRY HOLD TANKS AND
ABSORBERS ARE IN PLACE. SLUDGE DISPOSAL STRATEGY HAS NOT BEEN FINALIZED.
THIS UNIT WILL FIRE 0.3X SULFUR (6X ASH) WYOMING COAL.
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE NEW LIMESTONE FGl) SYSTEM COMMENCED OPERATIONS IN EAHLY JANUARY 1977.
THERE HAVE BEEN NO FORCED SCRUBBER OUTAGES REPORTED SINCE START-UP.
CONTINUOUS S02 MONITORS HAVE RECORDED 302 REMOVAL EFFICIENCIES OF BETTER
THAN 85X. PARTICULATE REMOVAL IS REPORTED TO BE EXCELLENT, YIELDING NO
VISIBLE PLUME. THE PLANT IS FIRING COAL RATED AT 12,300 BTU/LB WITH A
SULFUR CONTENT OF 3.5X.
KANSAS POWER & LIGHT
LAWRENCE NO 5
400 MW - NEW
COAL 0.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 11/71
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE ORIGINAL LIMESTONE INJECTION AND TAIL-END SCRUBBING SYSTEM IS STILL
IN SERVICE WHILE A NEW ROD-SCRUBBER AND SPHAY TOWER ABSORBER SYSTEM IS
BEING ERECTED ALONG SIDE THE EXISTING SYSTEM. THE NEW SCRUBBER PLANT
INCLUDES 2 MODULES EACH CAPABLE OF HANDLING APPROXIMATELY so* OF THE TO-
TAL BOILER FLUE GAS FLOW. THE SYSTEM DESIGNER AND SUPPLIER IS COMBUSTION
ENGINEERING. THE UNIT FIRES APPROXIMATELY 140 TONS/HOUR OF LOW SULFUR
WYOMING COAL HAVING HEAT AND SULFUR CONTENTS OF 10,000 BTU/LB AND 0.5X.
KENTUCKY UTILITIES
GREEN RIVER NOS. 1 2 AND
64 MW - RETROFIT
COAL 3.8 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 9/75
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE SCRUBBER PLANT INSTALLED AT THIS STATION CONSISTS OF OME MODULE
DESIGNED TO REMOVE PARTICULATES (VARIABLE-THROAT VENTURI) AND S02 (MUBILb
-BED ABSORBER) FROM COAL-FIRED BOILER FLUE GAS. THfc SCRUBBER WAS DESIGNED
AND SUPPLIED BY AAF. INITIAL SCRUBBER PLANT STARTUP OCCURRED IN SEPTEMBER
1975. SCRUBBING OPERATIONS RESUMED IN NOVEMBER FOLLOWING A 5-MONTH SHUT-
DOWN RESULTING FROM A STRIKE BY PLANT OPERATING PERSONNEL. THE SYSTEM
HAS HAD LOW AVAILABILITY BECAUSE OF FROZEN EQUIPMENT.
10
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COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS AS OF
01/78
CURRENT MONTH
LAKELAND UTILITIES
MCINTOSH POWER PLANT UNIT NO.3
350 MW - NEW
COAL 2.6 PERCENT SULFUR
NOT SELECTED
LIMESTONE SCRUBBING
STARTUP 10/81
THE CITY OF LAKELAND DEPARTMENT OF ELECTRIC AND WATER UTILITIES IS EVALU-
ATING BIDS FOR IT NEW 350 MW POWER GENERATING UNIT, MCINTOSH NO. 3. THE
UNIT WILL UTILIZE COLD-SIDE ESP'S FOR PARTICULATE REMOVAL AND LIMESTONE
SCRUBBING FOR S02 CONTROL. A DECISION SHOULD BE MADE PUBLIC IN MARCH.
START-UP IS SCHEDULED FOR OCTOBER 1981.
LOUISVILLE GAS & ELECTRIC
CANE RUN NO 4
176 MW - RETROFIT
COAL 3.5 - 4.0 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 8/76
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE FGD SYSTEM RETROFITTED ON THIS BOILER WAS DESIGNED AND SUPPLIED BY
AMERICAN AIR FILTER AND WAS FIRST PLACED IN THE GAS PATH ON AUGUST 7,
1976. THE SYSTEM CONSISTS OF TWO PARALLEL MODULES WHICH INCLUDE MOBILE
BED CONTACTORS AND OPERATE WITH A CARBIDE LIME ADDITIVE. FOLLOWING A
NUMBER OF MAJOR SYSTEM MODIFICATIONS (CHEVRON-TYPE MIST ELIMINATOR, OIL
FIRED REHEAT, PLASITE DUCT LINER, HIGHER L/G), THE SYSTEM SUCCESSFULLY
PASSED COMPLIANCE TESTING (85X S02 REMOVAL) ON AUGUST 3 AND 4, 1977.
LOUISVILLE GAS & ELECTRIC
CANE RUN NO 5
183 MW - RETROFIT
COAL 3.5 - 4.0 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
STARTUP 4/78
LOUISVILLE GAS & ELECTRIC
CANE RUN NO 6
277 MW - RETROFIT
COAL 3.5 - 4.0 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
DOUBLE ALKALI SCRUBBING
STARTUP 11/79
LOUISVILLE GAS & ELECTRIC
MILL CREEK NO 1
330 MW - RETROFIT
COAL 3.5- 4.0 PERCENT SULFUR
NOT SELECTED
LIME SCRUBBING
STARTUP 1/82
COMBUSTION ENGINEERING HAS BEEN AWARDED A CONTRACT BY LG&E TO DESIGN AND
SUPPLY TWO SPRAY TOWER ABSORBERS FOR FULL-LOAD S02 REMOVAL SERVICE. THE
ABSORBERS WILL UTILIZE CARBIDE LIME AS THE SCRUBBING REAGENT. IN-LINE
STEAM REHEAT, A COMMON REACTION TANK, AND A THICKENER FOR SOLIDS DEWATER-
ING ARE INCLUDED IN THE FGD PLANT. AN EXISTING UPSTREAM ESP PROVIDES
PRIMARY PARTICULATE CONTROL. SYSTEM CONSTRUCTION IS NEARING COMPLETION.
THE START-UP DATE FOR THE SCRUBBER PLANT HAS BEEN DELAYED UNTIL SPRING
BECAUSE OF THE COAL STRIKE.
THE CONTRACT FOR THIS FULL-SCALE DEMONSTRATION SCRUBBING SYSTEM HAS BEEN
AWARDED TO A .0 .LI TTLE/COMBUSTION EQUIPMENT ASSOC. FOR THE INSTALLATION
OF A DOUBLE ALKALI SCRUBBER. THE FEDERAL EPA WILI, SUBSIDIZE A MAXIMUM
$4.5 MM FOR OPERATION, RESEARCH AND DEVELOPMENT, AND REPORT WRITING FOR
A ONE-YEAR PERIOD FOLLOWING THE FIRST THREE MONTHS OF OPERAT ION(NOTE*TH IS
SUBSIDY KILL NOT BE APPLIED FOR ANY CAPITAL EXPENDITURES). ENGINEERING
DESIGN WORK IS UNDERWAY. SITE PREPARATION, EXCAVATION AND FOUNDATION WORK
COMMENCED IN JULY. DUCTWORK TIE-IN IS COMPLETE.
A COMPLIANCE SCHEDULE HAS BEEN SUBMITTED TO THE JEFFERSON COUNTY AIR POL-
LUTION CONTROL DISTRICT WITH 1/82 ESTABLISHED AS THE STARTUP DATE FOR AN
FGD SYSTEM. OPERATING DATA AND INFORMATION FROM THE FULL-SCALE SCRUBBER
PLANT NOW IN SERVICE ON THE NO.4 UNIT AT CANE HUN WILL BE OBTAINED BEFORE
THE UTILITY PROCEEDS WITH ADDITIONAL SYSTEM DESIGN WORK.
LOUISVILLE GAS & ELECTRIC A COMPLIANCE SCHEDULE HAS BEEN SUBMITTED TO THE JEFFERSON COUNTY AIR POL-
MILL CREEK NO 2 LUTION CONTROL DISTRICT WITH 1/81 ESTABLISHED AS THE STARTUP DATE FOR AN
330 MW - RETROFIT FGD SYSTEM. OPERATING DATA AND INFORMATION FROM THE FULL-SCALE SCRUBBER
COAL 3.5- 4.0 PERCENT SULFUR PLANT NOW IN SERVICE ON THE NO.4 UNIT AT CANE RUN WILL BE OBTAINED BEFORE
NOT SELECTED THE UTILITY PROCEEDS WITH ADDITIONAL SYSTEM DESIGN WORK.
LIME SCRUBBING
STARTUP 1/81
LOUISVILLE GAS & ELECTRIC
BECAUSE POWER DEMAND HAS NOT COME UP AS RAPIDLY AS HAD BEEN EXPECTED,
MILL CREEK NO 3 UNIT START-UP HAS BEEN MOVED BACK TO APRIL 15, 1976. CONSTRUCTION ON
425 MW - NEW THIS NEW FACILITY'S FGD SYSTEM IS NEARING COMPLETION. THE SYSTEM IS DE-
COAL 3.5- 4.0 PERCENT SULFUR SIGNED AND SUPPLIED BY AMERICAN AIR FILTER AND WILL UTILIZE CARBIDE LIME
AS THE ABSORBENT. FOUR MOBILE-BED ABSORBERS WILL TREAT THE FLUE GAS RE-
SULTING FROM THE COMBUSTION OF HIGH SULFUR COAL. THE SYSTEM WILL OPERATE
IN A CLOSED WATER LOOP. THE SCRUBBING WASTE WILL BE STABILIZED WITH
FLYASH AND LIME.
AMERICAN AIR FILTER
LIME SCRUBBING
STARTUP 4/78
LOUISVILLE GAS & ELECTRIC BECAUSE POWER DEMAND HAS NOT COME UP AS RAPIDLY AS HAD BEEN EXPECTED,
MILL CREEK NO 4 UNIT START-UP HAS BEEN MOVED BACK TO JUNE 1980. CONSTRUCTION OF THIS NEW
495 MW - NEW 495-MW COAL-FIRED UNIT IS ON SCHEDULE. CURRENTLY, FOUNDATION WORK IS IN
COAL 3.5- 4.0 PERCENT SULFUR PROGRESS. THIS AAF SYSTEM WILL INCLUDE MOBILE-BED ABSORBERS TREATING
AMERICAN AIR FILTER HIGH SULFUR COAL FLUE GAS. THE SYSTEMS WATER LOOP WILL BE CLOSED. THE
LIME SCRUBBING SLUDGE WILL BE STABILIZED WITH LIME AND FLYASH. STEAM REHEAT WILL PRO-
STARTUP 6/80 VIDE GAS TEMPERATURE ELEVATION OF THE SCRUBBED GASES PRIOR TO DISCHARGE
TO THE MAIN STACK.
11
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COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS AS OF
01/78
CURRENT MONTH
LOUISVILLE GAS & ELECTRIC
PADDYS RUN NO 6
65 MW - RETROFIT
COAL 3.5 - 4.0 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
STARTUP 4/73
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS SCRUBBING SYSTEM WAS DESIGNED BY COMBUSTION ENGINEERING AND PLACED
IN SERVICE IN APRIL 1973. THE FGO SYSTEM CONSISTS OF TWO 2-STAGE MARBLE
BED ABSORBERS WHICH ARE DESIGNED TO USE CARBIDE LIME ADDITIVE AS THE
SCRUBBING REAGENT. PADDYS RUN NO. IS A PEAK-LOAD UNIT THAT OPERATES
ONLY DURING DEMAND PERIODS. AN EXTENSIVE EPA SCRUBBER/SLUDGE EVALUATION
STUDY WAS COMPLETED IN AUGUST 1977.
MINNESOTA P S L HAS AWARDED A CONTRACT TO PEABODY ENGINEERING FOR A LIME/
ALKALINE FLYASH S02 CONTROL SYSTEM. THE CONFIGURATION WILL BE VENTUHI
SCRUBBERS FOLLOWED BY SPRAY TOWERS. HOT SIDE ESP'S WILL BE USED FOR
PARTICULATE CONTROL. STACK GAS REHEAT WILL 6E ACCOMPLISHED BY BYPASSING
5X OF FLUE GAS AROUND THE SCRUBBER. THE UNIT WILL FIRE SUB-BITUMINOUS
LIME/ALKALINE FLYASH SCRUBBING COLSTR1P COAL WITH A SULFUR CONTENT OF 0.8X, AND AN ASH CONTENT OF 9.OX
STARTUP 0/80 CHEATING VALUE - 8300 BTU/LB). MAKE-UP WATER SOURCE WILL BE THE RIVER OR
THE CLAY-LINED POND.
MINNESOTA POWER AND LIGHT co.
CLAY BOSWELL NO. 4
500 MW - NEW
COAL 0.8 PERCENT SULFUR
PEABODY ENGINEERING
MINNKOTA POWER COOPERATIVE
MILTON R. YOUNG NO. 2
450 MW - NEW
LIGNITE 0.7 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 9/77
MONTANA POWER CO.
COLSTRIP NO 1
360 MW - NEW
COAL 0.8 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 11/75
MONTANA POWER CO.
COLSTRIP NO 2
360 MW - NEW
COAL 0.8 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 7/76
MONTANA POWER CO.
COLSTRIP NO. 3
700 MW - NEW
COAL 0.7 PERCENT SULFUR
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
STARTUP 7/80
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS LIME/ALKALINE FLYASH SCRUBBING SYSTEM WAS DESIGNED AND SUPPLIED BY
AOL/CONTRUCTION EQUIPMENT ASSOCIATEES. IT CONSISTS OF A COLD-SIDE ESP
FOLLOWED BY TWO SPRAY TOWERS. MIST ELIMINATION IS PROVIDED BY A WASH
TRAY AND CHEVRON ARRANGEMENT. 25* FLUE GAS BYPASS PROVIDES STACK GAS RE-
HEAT. THE UNIT FIRES A LOW-SULFUR NORTH DAKOTA LIGNITE WITH AN AVERAGE
ASH CONTENT OF 8 PERCENT, SULFUR CONTENT OF 0.7 PERCENT, AND HEAT CONTENT
OF 6500 BTU/LB.
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS FGD EQUIPPED UNIT WAS DECLARED COMMERCIAL IN NOVEMBER 1975. THE
SCRUBBING SYSTEM PROVIDES PARTICULATE AND S02 CONTROL WITH THREE SCRUB-
BER MODULES. EACH MODULE CONSISTS OF A OOWNFLOW VENTURI SCRUBBER CENTER-
ED WITHIN AN UPFLOW SPRAY TOWER ABSORBER. EACH MODULE CAN TREAT 40X OF
THE TOTAL BOILER FLUE GAS AND THE MODULES CANNOT BE BYPASSED. THE UN-
STABILIZED SLUDGE IS DISPOSED IN AN ON-SITE LINED DISPOSAL POND. IN-LINE
STEAM REHEAT AND CLOSED WATER LOOP CAPABILITY ARE INCLUDED IN THE SYSTEM.
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS FGD EQUIPPED UNIT WAS DECLARED COMMERCIAL IN AUGUST 1976. THE
SCRUBBING SYSTEM PROVIDES PARTICULATE AND S02 CONTROL WITH THREE SCRUB-
BER MODULES. EACH .MODULE CONSISTS OF A DOWNFLOW VENTURI SCRUBBER CENTER-
ED WITHIN AN UPFLOW SPRAY TOWER ABSORBER. EACH MODULE CAN TREAT 70X OF
THE TOTAL BOILER FLUE GAS AND THt MODULES CANNOT BE BYPASSED. THE UN-
STABILIZED SLUDGE IS DISPOSED IN AN ON-SITE LINED DISPOSAL POND. IN-LINE
STEAM REHEAT AND CLOSED WATER LOOP CAPABILITY ARE INCLUDED IN THE SYSTEM.
A CONTRACT FOR THE INSTALLATION OF TWO ADDITIONAL LIME/ALKALINE FLYASH
SCRUBBING SYSTEMS HAS BEEN AWARDED TO A.D. LITTLE/COMBUSTION EQUIPMENT
ASSOCIATES. THESE SYSTEMS WILL BE INSTALLED ON UNITS NOS. 3 AND 4 OF
THE COLSTRIP POWER STATION. COLSTRIP UNITS 1 AND 2 ARE BOTH EQUIPPED
WITH OPERATIONAL LIME/ALKALINE FLYASH SCRUBBING SYSTEMS FOR THE REMOVAL
OF PARTICULATES AND SULFUR DIOXIDE. ENGINEERING WORK FOR THE NEW SYSTEMS
IS NOW UNDERWAY. THIS CONTRACT IS EXPECTED TO EXCEED S50 MM.
MONTANA POWER CO.
COLSTRIP NO. 4
700 MW - NEW
COAL 0.7 PERCENT SULFUR
A CONTRACT FOR THE INSTALLATION OF TWO ADDITIONAL LIME/ALKALINE FLYASH
SCRUBBING SYSTEMS HAS BEEN AWARDED TO A.D. LITTLE/COMBUSTION EQUIPMENT
ASSOCIATES. THESE SYSTEMS WILL BE INSTALLED ON UNITS NOS. 3 AND 4 OF
THE COLSTRIP POWER STATION. COLSTRIP UNITS 1 AND 2 ARE BOTH EQUIPPED
ADL/COMBUSTION EQUIP ASSOCIATE WITH OPERATIONAL LIME/ALKALINE FLYASH SCRUBBING SYSTEMS FOR THE REMOVAL
LIME/ALKALINE FLYASH SCRUBBING OF PARTICULATES AND SULFUR DIOXIDE. ENGINEERING WORK FOR THE NEW SYSTEMS
STARTUP 7/81 IS NOW UNDERWAY. THIS CONTRACT IS EXPECTED TO EXCEED $50 MM.
NEVADA POWER
HARRY ALLEN STATION NO.
500 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/83
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM.
TIONS HAVE NOT YET BEEN PREPARED.
SPECIFICA-
12
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF F6D SYSTEMS AS OF
01/78
CURRENT MONTH
NEVADA POWER
HARRY ALLEN STATION NO. 2
500 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/84
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM. SPECIFICA-
TIONS HAVE NOT YET BEEN PREPARED.
NEVADA POWER
HARRY ALLEN STATION NO.
500 MW • NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/85
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM.
TIONS HAVE NOT YET BEEN PREPARED.
SPECIFICA-
NEVADA POWER
HARRY ALLEN STATION NO.
500 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/66
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGO SYSTEM.
TIONS HAVE NOT YET BEEN PREPARED.
SPECIFICA-
NEVADA POWER
REID GARDNER NO 1
125 MW - RETROFIT
COAL 0.5 - 1.0 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
STARTUP 4/74
NEVADA POWER
REID GARDNER NO 2
125 MW - RETROFIT
COAL 0,5 - 1.0 PERCENT SULFUR
ADL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
STARTUP 4/74
NEVADA POWER
REID GARDNER NO 3
125 MW - NEW
COAL 0.5 - 1.0 PERCENT SULFUR
ADL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
STARTUP 7/76
NEVADA POWER
REID GARDNER NO 4
125 MW - NEW
COAL 0-5- 1.0 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
STARTUP O/ 0
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 (JF THIS REPORT.
THIS SODIUM CARBONATE-BASED (TRONA) SCRUBBING SYSTEM CONSISTS OF ONE
MODULE CONTAINING A TWIN VARIABLE-THROAT VENTURI SCRUBBER FOLLOWED BY A
SEPARATOR IN SERIES WITH A SINGLE-STAGE PERFORATED-PLATE ABSORBER TOWER.
PRIMARY. PARTICULATE CONTROL IS PROVIDED BY UPSTREAM MECHANICAL COLLECTORS.
A STEAM INDIRECT HOT AIR REHEAT SYSTEM RAISES THE GAS TEMPERATURE 30 F
PRIOR TO DISCHARGE TO THE MAIN STACK. THE FLUE GAS CLEANING WASTES ARE
ULTIMATELY DISPOSED IN AN ON-SITE CLAY-LINED SOLAR EVAPORATION POND.
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS SODIUM CARBONATE-BASED (TRONA) SCRUBBING SYSTEM CONSISTS OF ONE
MODULE CONTAINING A TWIN VARIABLE-THROAT VENTURI SCRUBBER FOLLOWED BY A
SEPARATOR IN SERIES WITH A SINGLE-STAGE PERFORATED-PLATE A8SOR8ER TOWER.
PRIMARY PARTICULATE CONTROL IS PROVIDED BY UPSTREAM MECHANICAL COLLECTORS.
A STEAM INDIRECT HOT AIR REHEAT SYSTEM RAISES THE GAS TEMPERATURE 30 F
PRIOR TO DISCHARGE TO THE MAIN STACK. THE FLUE GAS CLEANING WASTES ARE
ULTIMATELY DISPOSED IN AN ON-SITE CLAY-LINED SOLAR EVAPORATION POND.
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS UNIT IS A NEW COAL-FIRED BOILER THAT IS EQUIPPED WITH SODIUM
CARBONATE-BASED(TRONA)SCRUBBING SYSTEM WHICH INCORPORATES A TWIN
VARIABLE-THROAT VENTURI SCRUBBER FOLLOWED BY A SEPARATOR IN SERIES WITH
A SINGLE-STAGE PERFORATED-PLATE ABSORBER TOWER. THE MODULE WAS FIRST
PLACED IN SERVICE ON BOILER FLUE GAS IN JULY 1976. MECHANICAL COLLECTORS
PROVIDE PRIMARY PARTICULATE CONTROL. REHEAT -IS PROVIDED BY A STEAM IN-
DIRECT HOT AIR RtHEAT SYSTEM. WASTE DISPOSAL IS ON-SITE CLAY-LINED POND.
NEVADA POWER COMPANY HAS SIGNED A LETTER OF INTENT WITH COMBUSTION EQUIP-
MENT ASSOCIATES FOR THE CONSTRUCTION OF AN FGO SYSTEM ON REID GARDNER NO.
1. HOWEVERf CONSTRUCTION OF THE BOILER HAS BEEN INDEFINITELY POSTPONED.
NEVADA POWER
WARNER VALLEY STATION NO.
250 MW - NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/82
SPECIFICATIONS ARE BEING PREPARED FOR A SCRUBBING SYSTEM. NEVADA POWER
HAS NOT YET ANNOUNCED PLANS FOR THIS UNIT'S EMISSION CONTROL STRATEGY.
13
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS AS OF
01/78
CURRENT MONTH
NEVADA POWER
WARNER VALLEY STATION NO. 2
250 MW • NEW
COAL
NOT SELECTED
NOT SELECTED
STARTUP 6/83
SPECIFICATIONS ARE BEING PREPARED FOR A SCRUBBING SYSTEM. NEVADA POWER
HAS NOT YET ANNOUNCED PLANS FOR THIS UNIT'S EMISSION CONTROL STRATEGY.
NEW ENGLAND ELEC SYSTEM
BRAYTON POINT NO.3
650 MW - RETROFIT
COAL 3.0 PERCENT SULFUR
NOT SELECTED
REGENERABLE NOT SELECTED
STARTUP O/ 0
THE UTILITY IS CURRENTLY INVESTIGATING VARIOUS ADVANCED REGENERABLE
FLUE GAS DESULFURIZATION SYSTEMS WHICH OFFER A BREAKTHROUGH IN
OPERATING COSTS AND PRODUCE ELEMENTAL SULFUR AS AN END
PRODUCT. THE UTILITY IS CURRENTLY INVOLVED IN BENCH AND LABORATORY
SCALE INVESTIGATIONS OF SULFUR RECOVERY. THE NO. 3 UNIT IS CURRENTLY
OPERATIONAL, FIRING LOW SULFUR FUEL OIL.
NIAGARA MOHAWK POWER COOP.
CHARLES R. HUNTLEY NO.6
100 MW - RETROFIT
COAL 2.5-4.5 PERCENT SULFUR
ATOMICS INTERNATIONAL
AOUEDUS CARBONATE SCRUBBING
STARTUP 0/80
A CONTRACT WAS AWARDED TO ATOMICS INTERNATIONAL FOR THE DESIGN AND IN-
STALLATION OF AN AQUEOUS CARBONATE FGD SYSTEM. THIS DEMONSTRATION SYSTEM
WILL PRODUCE END-PRODUCT SULFUR. FUNDS ARE BEING PROVIDED BY THE US EPA
AND THE EMPIRE STATE ELECTRIC ENERGY RESEARCH CORP. THE DESIGN S02 RE-
MOVAL EFFICIENCY WILL BE 90 PERCENT. AN INTERMEDIATE UNIT IS BEING CON-
SIDERED AS A PILOT BEFORE APPLICATION OF THE JOO MW SCALE UNIT. GROUND
BREAKING FOR CONSTRUCTION WILL BE IN JUNE 1978.
NORTHERN INDIANA PUB SERVICE
BAILLY NO. 7
190 MW - RETROFIT
COAL 3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
CONSIDERING A LIME OR LIMESTONE SCRUBBING UNIT. ALSO WAITING FOR PER-
FORMANCE OF WELLMAN LORD/ALLIED CHEMICAL UNIT IN SERVICE AT THEIR
D.H, MITCHEL NO. 11 UNIT. LOW SULFUR COAL MAY BE EMPLOYED TO COMPLY WITH
S02 EMISSION REGULATIONS. APPLICABLE INDIANA S02 REGULATIONS ARE STILL
NOT FIRMLY ESTABLISHED.
NORTHERN INDIANA PUB SERVICE
BAILLY NO. 8
400 MW - RETROFIT
COAL 3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
CONSIDERING A LIME OR LIMESTONE SCRUBBING UNIT. ALSO WAITING FOR PERFOR-
MANCE OF WELLMAN LORD/ALLIED CHEMICAL UNIT UNDER CONSTRUCTION AT THEIR
D. H. MITCHELL NO. 11 UNIT. LOW SULFUR COAL MAY BE BURNED TO COMPLY WITH
S02 EMISSION REGULATIONS. APPLICABLE INDIANA S02 REGULATIONS ARE STILL
NOT FIRMLY ESTABLISHED.
NORTHERN INDIANA PUB SERVICE
O.H. MITCHELL NO.11
115 MW - RETROFIT
COAL 3.2-3.5 PERCENT SULFUR
DAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
STARTUP 6/77
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS FGD SYSTEM IS AN INTEGRATION OF THE WELLMAN-LORD S0£ RECOVERY PROCES
OFFERED BY DAVY POWERGAS AND THE 302 TO SULFUR REDUCTION PROCESS DE-
VELOPED BY ALLIED CHEMICAL. DAVY POWERGAS IS THE DESIGN AND CONSTRUCTION
FIRM AND ALLIED CHEMICAL IS SYSTEM OPERATOR AND PRODUCT MARKETER.
PERFORMANCE TESTS WERE SUCCESSFULLY COMPLETED ON SEPTEMBER 14, 1977. A
DEMONSTRATION YEAR COMMENCED ON SEPTEMBER 16, 1977.
NORTHERN STATES POWER CO.
SHERBURNE COUNTY STATION NO.l
710 MW - NEW
COAL 0.8 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 3/76
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
FULL COMMERCIAL OPERATION OF THE SYSTEM BEGAN ON MAY i, 1976. THE SCRUB-
BING SYSTEM FOR THIS UNIT CONSISTS OF 12 MODULES. EACH SCRUBBING MODULE
INCORPORATES A VENTURI-ROO SECTION AND A MARBLE BED ABSORBER FOR PAH-
TICULATE AND SULFUR DIOXIDE REMOVAL. A FORCED OXIDATION SYSTEM CONVERTS
ALL THE CALCIUM SULFITE TO SULFATE PRIOR TO DISCHARGE TO A CLAY-LINED
SETTLING POND. STACK GAS REHEAT IS PROVIDED BY IN-LINE HOT WATER TUBES.
NORTHERN STATES POWER CO.
SHERBURNE COUNTY STATION NO.2
710 MW - NEW
COAL 0.8 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 4/77
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT,
THE SHERBURNE NO. 2 AIR QUALITY CONTROL SYSTEM IS IDENTICAL IN DESIGN TO
THE SYSTEM IN OPERATION ON THE NO. 1 UNIT AT THIS STATION. TWELVE 2-STAGE
PARTICULATE SCRUBBER (VENTURI-ROD SCRUBBER) AND SULFUR DIOXIDE ABSORBER
(MARBLE-BED ABSORBER) MODULES ARE PROVIDED FOR FLY ASH AND S02 CONTROL.
ELEVEN MODULES ARE REQUIRED FOR FULL GENERATING CAPACITY OPERATIONS.
THE CALCIUM SULFITE IS FORCIBLY OXIDIZED TO SULFATE PRIOR TO DISCHARGE TO
THE DISPOSAL POND. STACK GAS REHEAT PROVIDED BY IN-LINE HOT WATER TUBES.
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS AS OF
01/78
CURRENT MONTH
NORTHERN STATES POWER CO.
SHERBURNE COUNTY STATION NO.3
860 MW - NEW
COAL 0.8 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 5/81
NORTHERN STATES POWER CO.
SHERBURNE COUNTY STATION NO.4
860 MW - NEW
COAL 0.8 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 5/83
OTTER TAIL POWER COMPANY
COYOTE NO. 1
400 MW - NEW
LIGNITE 0.9 PERCENT SULFUR
WHEELABRATOR-FRYE/A.I.
AQUEOUS CARBONATE/FAB. FILTER
STARTUP 5/81
PACIFIC GAS AND ELECTRIC
FOSSIL NO. 1
800 MW * NEW
COAL 0.8 PERCENT SULFUR
NOT SELECTED
LIMESTONE SCRUBBING
STARTUP 0/84
TWO ADDITIONAL COAL-FIRED POWER-GENERATING UNITS ARE SCHEDULED TO BE IN-
STALLED AT NSP'S SHERBURNE COUNTY GENERATING STATION IN BECKER MINNESOTA.
COMBUSTION ENGINEERING WAS AWARDED A CONTRACT FOR LIMESTONE SLURRY SPRAY
TOWER FGO SYSTEMS ON THE 860 MW UNITS 344. THE TWO STAGE SCRUBBING
MODULES REMOVE PARTICULATE (99.5X) & 302 (60X). COMMERCIAL START-UP DATES
ARE NOW SCHEDULED FOR MAY 1981 AND MAY 1983. THE BOILER CONTRACT HAS BEEN
AWARDED TO BABCOCK AND WILCOX AND THE TURBINE WILL BE SUPPLIED BY GENERAL
ELECTRIC. CONSTRUCTION IS SCHEDULED TO COMMENCE DURING THE SUMMER OF '78.
TWO ADDITIONAL COAL-FIRED POWER-GENERATING UNITS ARE SCHEDULED TO BE IN-
STALLED AT NSP'S SHERBURNE COUNTY GENERATING STATION IN BECKER MINNESOTA.
COMBUSTION ENGINEERING WAS AWARDED A CONTRACT FOR LIMESTONE SLURRY SPRAY
TOWER FGD SYSTEMS ON THE 860 MW UNITS 3*4. THE TWO STAGE SCRUBBING MOD-
ULES REMOVE PARTICULATE C99.5X) AND 302 180X). COMMERCIAL START-UP DATES
ARE NOW SCHEDULED FOR MAY 1981 AND MAY 1983. THE BOILER CONTRACT HAS BEEN
AWARDED TO BABCOCK AND WILCOX AND THE TURBINE WILL BE SUPPLIED BY GENERAL
ELECTRIC.
THIS NEW COAL-FIRED STATION IS JOINTLY OWNED BY FIVE UTILITIES. OTTER
TAIL POWER IS THE MAJOR OWNER AND CONSTRUCTOR. MONTANA-DAKOTA UTILITIES
IS THE FACILITY OPERATOR. THIS PLANNED UNIT WILL FIRE LOW SULFUR LIGNITE
FROM THE MERCER COUNTY AREA IN ITS 8&W CYCLONE-FIRED BOILER. THE CONTRACT
FOR THIS AQUEOUS CARBONATE/FABRIC FILTER SU2 SCRUBBER WAS AWARDED TO
WHEELABRATOR-FRYE. AND ATOMICS INTERNATIONAL. THE DRY REMOVAL SYSTEM COM-
BINES THE OPEN LOOP OF AI'S AQUEOUS CARBONATE PROCESS WITH A W-F FABRIC
FILTER. ACTUAL PLANT CONSTRUCTION BEGAN SEPT. 77. START-UP SET FOR MAY 81.
THE CITY OF LAKELAND DEPARTMENT OF ELECTRIC AND WATER UTILITIES IS EVALU-
ATING BIDS FOR IT NEW 350 MW POWER GENERATING UNIT, MCINTOSH NO. 3. THE
UNIT WILL UTILIZE COLD-SIDE ESP'S FOR PARTICULATE REMOVAL AND LIMESTONE
SCRUBBING FOR S02 CONTROL. A DECISION SHOULD BE MADE-PUBLIC IN MARCH.
START-UP IS SCHEDULED FOR OCTOBER 1981.
PACIFIC GAS AND ELECTRIC
FOSSIL NO. 2
800 MW - NEW
COAL 0.8 PERCENT SULFUR
NOT SELECTED
LIMESTONE SCRUBBING
STARTUP 0/85
THE CITY OF LAKELAND DEPARTMENT OF ELECTRIC AND WATER UTILITIES IS EVALU-
ATING BIDS FOR IT NEW 350 MW POWER GENERATING UNIT, MCINTOSH NO. 3. THE
UNIT WILL UTILIZE COLD-SIDE ESP'S FOR PARTICULATE REMOVAL AND LIMESTONE
SCRUBBING FOR S02 CONTROL. A DECISION SHOULD BE MADE PUBLIC IN MARCH.
START-UP IS SCHEDULED FOR OCTOBER 1981.
PACIFIC POWER AND LIGHT CO.
JIM BRIDGER NO. 4
509 MW - NEW
COAL 0.56 PERCENT SULFURCAVG.)
UNIVERSAL OIL PRODUCTS
SODIUM CARBONATE SCRUBBING
STARTUP 9/79
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 1
825 MW - NEW
COAL 4.7 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
STARTUP 4/76
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 2
825 MM - NEW
COAL 4.7 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
STARTUP 7/77
UOP WAS AWARDED A CONTRAST FOR THE INSTALLATION OF THE FGD SYSTEM AT THE
NEW 509 MW COAL-FIRED JIM BRIDGER UNIT NO. 4. THE FGD SYSTEM WILL CONSIST
OF THREE PARALLEL ABSORBER MODULES EACH TREATING ONE-THIRD OF THE BOILER
FLUE GAS AT FULL LOAD. AN ESP WILL PROVIDE PRIMARY PARTICULATE CONTROL.
A CEILCOTE-LINEO WET/DRY STACK IS INCLUDED IN THE SYSTEM. PPL'S PILOT
STUDY INSPECTION REVEALED SCALE FORMATION PROBLEMS. TESTS ARE BEING CON-
DUCTED TO RESOLVE THIS PROBLEM. TO DATE, FOUNDATION CONSTRUCTION IS
COMPLETE AND VESSEL ERECTION HAS COMMENCED.
THIS EMISSION CONTROL SYSTEM WAS DESIGNED TO REMOVE FLYASH AND SOS FROM
3,35 MM ACFM OF FLUE GAS VIA WET LIME SCRUBBING. THE INITIAL SHAKEDOWN
AND DEBUGGING PHASE OF OPERATION BEGAN FOR PART OF THE SYSTEM IN DECEMBER
1975. PARTIAL COMMERCIAL OPERATION COMMENCED IN APRIL 1976. THE UNIT WAS
CERTIFIED FULL-LOAD COMMERCIAL IN JUNE 1976. THE FGD SYSTEM HAS EXPERI-
ENCED OPERATIONAL PROBLEMS SINCE IT HAS BEEN IN SERVICE REQUIRING A NUM-
BER OF SYSTEM REPAIRS AND DESIGN MODIFICATIONS. REFER TO BACKGROUND IN-
FORMATION SECTION IN TABLE 5 OF THIS REPORT FOR GREATER DETAIL.
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS EMISSION CONTROL SYSTEM WAS DESIGNED TO REMOVE FLYASH AND 302 FROM
3.35 MM ACFM OF FLUE GAS USING THIOSORBIC LIME AS A SCRUBBING ABSORBENT.
SIX SCRUBBING TRAINS, EACH INCLUDING TWO VENTURI SCRUBBERS IN SERIES
ARRANGEMENT, ARE PROVIDED FOR FULL-LOAD OPERATION. THE INITIAL SHAKEDOWN
AND DEBUGGING PHASE OF OPERATION BEGAN FOR THREE TRAINS IN JULY, 1977.
FULL COMMERCIAL OPERATION FOR THE ENTIRE SYSTEM COMMENCED ON OCTOBER 1,
1977.
15
-------
COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS AS OF
01/78
CURRENT MONTH
PENNSYLVANIA POWEH CO.
BRUCE MANSFIELD NO. 3
825 MM - NEW
COAL 4.7 PERCENT SULFUR
PULLMAN KELLOGG
LIME SCRUBBING
STARTUP 4/80
THE PULLMAN KELLOGG DIVISION OF PULLMAN INCORPORATED HAS BEEN AWARDED
A CONTRACT IN EXCESS OF $50 MILLION BY THE CAPCO CONSORTIUM FOR THE IN-
STALLATION OF SULFUR DIOXIDE ABSORBERS ON THIS 825 MM COAL-FIRED POWER-
GENERATING UNIT. THE EMISSION CONTROL SYSTEM FOR THIS UNIT WILL CONSIST
OF ESP'S UPSTREAM OF FIVE WEIR HORIZONTAL CROSSFLOW WET SCRUBBING MOD-
ULES. CONSTRUCTION OF THE BOILER IS CURRENTLY IN PROGRESS. DUE TO RE-
VISED CAPCO FORECASTS, UNIT START-UP HAS BEEN MOVED BACK TO APRIL 1980.
PHILADELPHIA ELECTRIC CO.
CROMBY
150 MW - RETROFIT
COAL 2-U PERCENT SULFUR
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
STARTUP 6/80
THE UTILITY PLANS TO RETROFIT ONE OF THE TWO BOILERS AT CROMBY WITH AN
FGD SYSTEM. HOWEVER, A FINAL DECISION HAS NOT BEEN MADE. THE PROCESS
BEING GIVEN PRIME CONSIDERATION IS MAGNESIUM OXIDE SCRUBBING, DESIGNED
JOINTLY BY UNITED ENGINEERS AND PHILADELPHIA ELECTRIC. ENGINEERING
DESIGN WORK IS SCHEDULED TO COMMENCE SOON. TENTATIVE FGD SYSTEM
START-UP IS SCHEDULED FOR JUNE 1980. CURRENTLY, PECO IS CONTINUING
PROCESS EVALUATION STUDIES AT THE EDDYSTONE EXPERIMENTAL UNIT.
PHILADELPHIA ELECTRIC CO.
EDDYSTONE NO. 1A
120 MW - RETROFIT
COAL 2.5 PERCENT SULFUR
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
STARTUP 9/75
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF THREE PARALLEL
SCRUBBING TRAINS FOR THE CONTROL OF PARTICULATE ANQ SULFUR DIOXIDE.
THE C-SIDE SCRUBBING TRAIN INCLUDES AN S02 ABSORBER MODULE IN SERIES
WITH A PARTICULATE SCRUBBER. APPROXIMATELY ONE-THIRD OF THE BOILER FLUE
GAS IS SCRUBBED WITH MAGNESIUM OXIDE SLURRY FOR S02 REMOVAL. THE SPENT
SLURRY IS REGENERATED AT THE ESSEX SULFURIC ACID PLANT IN NEWARK, N.J.
THE REGENERATED MAGOX IS RETURNED TO THE PLANT FOR S02 SCRUBBING SERVICE.
PHILADELPHIA ELECTRIC CO.
EDDYSTONE NO. IB
240 MW - RETROFIT
COAL 2.5 PERCENT SULFUR
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
STARTUP 6/80
THE INSTALLATION OF S02 SCRUBBERS ON THE BALANCE OF THE FLUE GAS FROM
THIS UNIT WILL FOLLOW PENDING THE OUTCOME OF THE PERFORMANCE OF THE
SCRUBBING UNIT WHICH HAS BEEN INSTALLED AND CURRENTLY OPERATIONAL
ON THE EOOYSTONE NO. 1 UNIT. CURRENTLY, 3 WET PARTICULATE SCRUBBERS ARE
TREATING THE FULL GAS LOAD FROM THIS UNIT. THE PERFORMANCE OF THE MAGOX
UNIT IS DESCRIBED IN THE EDDYSTONE NO. IA FILE CONTAINED IN THIS REPORT.
PHILADELPHIA ELECTRIC CO.
EDDYSTONE NO. 2
336 MW - RETROFIT
COAL 2.4 PERCENT SULFUR
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
STARTUP 6/80
THE UTILITY IS AWAITING PERFORMANCE RESULTS FROM THE EXISTING MGO
SCRUBBER INSTALLED ON UNIT NO. 1 AT THIS STATION BEFORE PROCEEDING
WITH THE DESIGN OF AN FGD SYSTEM FOR THIS COAL-FIRED BOILER. THE PROCESS
BEING GIVEN PRIME CONSIDERATION IS MAGNESIUM OXIDE SCRUBBING DESIGNED
JOINTLY BY UNITED ENGINEERS AND PHILADELPHIA ELECTRIC. ENGINEERING
DESIGN WORK IS SCHEDULED TO COMMENCE SOON. TENTATIVE FGD SYSTEM
START-UP IS SCHEDULED FOR JUNE 1980.
POTOMAC ELECTRIC & POWER
OICKERSON NO. 4
800 MW - NEW
COAL 2.0 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 5/85
THERE ARE NO FIRM PLANS FOR INSTALLATION OF FGD SYSTEM. STARTUP DATE OF
BOILER IS PLANNED FOR 1985. THIS UNIT WILL BURN 2 PERCENT SULFUR COAL
WITH A HEATING VALUE OF 11,000 BTU/LB.
POWER AUTHORITY OF NEW YORK
ARTHUR KILL
700 MW - NEW
COAL - 3X SULFUR - REFUSE
NOT SELECTED
NOT SELECTED
STARTUP 9/82
THE UTILITY IS CONSIDERING BOTH REGENERABLE AND LIMESTONE SCRUBBING
PROCESSES. FGD TECHNOLOGY IS BEING CONSIDERED FOR A FOSSIL FUEL BURNING
UNIT WHICH WILL EMPLOY COAL AS THE PRIMARY FUEL AND OIL AS BACKUP. REFUSE
WILL BE PROVIDED FOR SUPPLEMENTAL FUEL SUPPLIES. THE PREFERRED PLANT SITE
IS THE ARTHUR KILL FACILITY LOCATED ON STATEN ISLAND. THE PROJECT DESIGN
ENGINEERING FIRM IS SARGENT AND LUNOY. PUBLIC SERVICE COMMISSION HEARINGS
ARE IN PROGRESS. NO DECISIONS WILL BE MADE UNTIL LATE SPRING 1978.
PUBLIC SERVICE CO OF NEW MEX. CONSTRUCTION
SAN JUAN NO. 1 WELLMAN LORD
375 MW - NEW S02 REDUCTION
COAL 0.8 PERCENT SULFUR WILL PRECEDE
DAVY POWERGAS/ALLIED CHEMICAL FOR EACH UNIT
WELLMAN LORD/ALLIED CHEMICAL STORED ON THE
STARTUP 4/78 REPORTED HAS
IS 90% COMPLETE. THIS FGD SYSTEM IS AN INTEGRATION OF THE
802 RECOVERY PROCESS OF DAVY POWERGAS AND ALLIED CHEMICAL'S
TO SULFUR PROCESS. A HOT SIDE ELECTROSTATIC PRECIPITATOR
THE SCRUBBING UNIT. FOUR ABSORBER TOWERS WILL BE INSTALLED
. THREE WILL CARRY THE FULL LOAD. MOLTEN SULFUR WILL BE
PLANT SITE. THE INSTRUMENTATION CONTROL PROBLEM PREVIOUSLY
BEEN SOLVED. START-UP IS SCHEDULED FOR APRIL 1978.
16
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COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS AS OF 01/78
CURRENT MONTH
PUBLIC SERVICE CO OF NEW MEX.
SAN JUAN NO. 2
310 MM - RETROFIT
COAL 0.8 PERCENT SULFUR
OAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
STARTUP 7/78
PUBLIC SERVICE CO OF NEW MEX.
SAN JUAN NO. 3
500 MW - NEW
COAL 0.6 PERCENT SULFUR
OAVY POWERGAS
WELLMAN LORD
STARTUP 1/79
THE CONSTRUCTION OF THIS SYSTEM IS NOW UNDERWAY. CONSTRUCTION IS
NEARING COMPLETION. START-UP IS NOW SCHEDULED FOR JULY 1978. THIS FGD
SYSTEM IS AN INTEGRATION OF THE WELLMAN LORD S02 RECOVERY PROCESS OF
DAVY POWERGAS AND ALLIED CHEMICAL'S S02 REDUCTION TO SULFUR PROCESS. A
HOT SIDE ELECTROSTATIC PRECIPITATOR WILL PRECEDE THE SCRUBBING UNIT. FOUR
ABSORBER TOWERS WILL BE INSTALLED FOR THIS UNIT. THREE WILL CARRY THE
FULL LOAD. MOLTEN SULFUR WILL BE STORED ON THE PLANT SITE. START-UP DELAY
WAS CAUSED BY A BOILER EXPLOSION.
THE UTILITY HAS SIGNED A LETTER-OF-INTENT WITH DAVY POWERGAS FOR
ONE SCRUBBER MODULE WHICH WILL BE DESIGNED TO BRING THE UNIT INTO
COMPLIANCE WITH NSPS BY JAN. 1979. THE FGD SYSTEM FOR THE REMAINDER
OF THE FLUE GAS FROM THIS 500-MW UNIT HAS NOT BEEN SELECTED. PRIMARY
PARTICULATE CONTROL WILL BE EFFECTED BY AN UPSTREAM ESP.
PUBLIC SERVICE CO OF NEW MEX.
SAN JUAN NO. 4
500 MW - NEW
COAL 0.8 PERCENT SULFUR
DAVY POWERGAS
WELLMAN LORD
STARTUP 5/81
THE UTILITY HAS PLACED A HOLD ON FURTHER ENGINEERING DESIGN WORK AT THE
PRESENT TIME. THE PROJECTED START-UP DATE FOR UNIT 4 IS
MAY 1981. THE WELLMAN LORD S02 RECOVERY PROCESS WILL BE UTILIZED TO BRING
THE UNIT INTO COMPLIANCE WITH NSPS. AN ESP WILL BE PROVIDED UPSTREAM OF
THE FGD SYSTEM FOR PRIMARY PARTICULATE CONTROL.
PUBLIC SERVICE OF INDIANA
GIBSON 5
650 MW - NEW
COAL 3.3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/82
THE UTILITY IS IN THE PROCESS OF PREPARING SPECIFICATIONS. SCHEDULED
START-UP OF THIS 650 MW UNIT IS 1982.
SALT RIVER PROJECT
CORONADO NO.l
350 MW - NEW
COAL 1.0 PERCENT SULFUR (MAX)
PULLMAN KELLOGG
LIMESTONE SCRUBBING
STARTUP 4/79
THIS NEW UNIT WILL BURN LOW SULFUR WESTERN COAL. A MAXIMUM OF 80X OF THE
FLUE GAS WILL BE SCRUBBED TO MEET SULFUR DIOXIDE EMISSION REGULATIONS.
PULLMAN/KELLOGG WILL DESIGN AND FABRICATE TWO WEIR HORIZONTAL
CROSSFLOW SCRUBBER MODULES, WHICH WILL UTILIZE LIMESTONE SLURRY FOR
302 CONTROL. THE SYSTEM WILL UTILIZE RUBBER-LINED SLURRY RECYCLE PUMPS,
EACH RATED AT 9800 GPM, RIGIFLAKE-LINED SCRUBBER MODULES, VERTICAL HEIL
DEMISTERS, AND A MINIMUM OF 20 PERCENT REHEAT. THE SLUDGE WILL BE PONDED.
THE FOUNDATION IS COMPLETED AND STRUCTURAL WORK HAS COMMENCED.
SALT RIVER PROJECT
CORONADO NO.2
350 MW - NEW
COAL 1.0 PERCENT SULFUR (MAX)
PULLMAN KELLOGG
LIMESTONE SCRUBBING
STARTUP «/80
THIS NEW UNIT WILL BURN LOW SULFUR WESTERN COAL. A MAXIMUM OF SOX OF THE
FLUE GAS WILL BE SCRUBBED TO MEET SULFUR DIOXIDE EMISSION REGULATIONS.
PULLMAN/KELLOGG WILL DESIGN AND FABRICATE TWO WEIR HORIZONTAL
CRUSSFLOW SCRUBBER MODULES, WHICH WILL UTILIZE LIMESTONE SLURRY FOR
302 CONTROL. THE SYSTEM WILL UTILIZE RUBBER-LINED SLURRY RECYCLE PUMPS,
EACH RATED AT 9800 GPM, RIGIFLAKE-LINED SCRUBBER MODULES, VERTICAL HEIL
DEMISTERS AND A MINIMUM OF 20 PERCENT REHEAT. THE SLUDGE WILL BE PONDED.
FOUNDATION WORK HAS BEEN COMPLETED, STRUCTURAL STEEL WORK HAS COMMENCED.
SALT RIVER PROJECT
CORONADO NO.3
350 MW - NEW
COAL 1.0 PERCENT SULFUR (MAX)
NOT SELECTED
LIMESTONE SCRUBBING
STARTUP 0/97
THIS NEW UNIT WILL BURN LOW SULFUR WESTERN COAL. 80 PERCENT OF THE
GAS WILL BE SCRUBBED TO MEET SULFUR DIOXIDE EMISSION REGULATIONS.
THE UTILITY IS CURRENTLY CONSIDERING THE INSTALLATION OF TWO HORIZONTAL
CROSSFLOW SCRUBBING MODULES EMPLOYING A LIMESTONE SCRUBBING SOLUTION
TO REMOVE S02 FROM THE FLUE GAS. SCHEDULED COMMERCIAL OPERATION
DATE IS 1967. PLANS FOR AN EMISSION CONTROL SYSTEM HAVE NOT
BEEN FINALIZED. SLUDGE WILL PROBABLY BE PONDED.
SOUTH CAROLINA PUBLIC SERVICE
WINYAH NO. 2
260
COAL
MW - NEW
1.0 PERCENT SULFUR
BABCOCK * WILCOX
LIMESTONE SCRUBBING
STARTUP 7/77
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF A 100X CAPACITY ESP
FOLLOWED BY A SOX CAPACITY LIMESTONE FGD SYSTEM. ONE FGD MODULE, CONSIST-
ING OF A VENTURI SCRUBBER AND TRAY TOWER ABSORBER, REMOVES 70* OF THE
INLET S02. REHEAT IS SUPPLIED BY THE FLUE SAS BYPASS. THE SCRUBBING
WASTES ARE DISCHARGED TO AN ON-SITE, UNLINED DIKED POND. THE NO. 2 UNIT
COMMENCED INITIAL OPERATIONS IN JULY 1977. THE ACCEPTANCE TEST FOR COM-
MERCIAL CERTIFICATION WAS SUCCESSFULLY COMPLETED IN DECEMBER 1977.
17
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COMPANY
POWER STATION
TABLE 2
STATUS OF FGD SYSTEMS AS OF
01/78
CURRENT MONTH
SOUTH CAROLINA PUBLIC SERVICE
WINYAH NO. 3
300 MW - NEW
COAL 2.3 PERCENT SULFUR
NOT SELECTED
NOT SELECTED
STARTUP 0/80
SANTEE COOP, AND SOUTH CAROLINA PUBLIC SERVICE AWARDED RILEY STOKER
A CONTRACT TO DESIGN, FABRICATE AND ERECT A NEW STEAM GENERATING UNI
THE COAL-FIRED DRY-BOTTOM TURBO-FIRED FURNACE WILL PRODUCE STEAM FOR THE
300 MW TURBINE GENERATOR. BOX OF THE FLUE GAS WILL BE SCRUBBED FOR S02,
20X WILL BE BYPASSED FOR REHEAT. THE COAL BURNED HAS A 11,500
BTU/LB AND 2.3X SULFUR. STARTUP IS SCHEDULED FOR THE SUMMER OF 1980. THE
FGD SYSTEM CONTRACT IS UP FOR BIDS.
SOUTHERN ILLINOIS POWER COOP
MARION NO. 4
18U MW - NEW
COAL a.5-5.0 PERCENT SULFUR
BABCOCK & WILCOX
LIMESTONE SCRUBBING
STARTUP 6/78
THE EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED BOILER CONSISTS OF AN
ESP FOR PARTICULATE CONTROL FOLLOWED BY 2 SPRAY TOWERS FOR 502 CONTROL.
LIMESTONE SLURRY WILL BE USED AS THE SCRUBBING REAGENT. SIPC IS NOT PLAN-
NING TO UTILIZE FLUE GAS REHEAT AND IS CURRENTLY PLANNING ON BRICK LINING
FOR THE STACK. SIPC INTENDS TO USE A LANDFILL WITH ASH STABILIZATION OF
WASTE FOR SLUDGE DISPOSAL. CURRENTLY, CONSTRUCTION IS 75 PERCENT COMPLETE
ON THE UNIT AND FGD SYSTEM.
SOUTHERN INDIANA GAS&ELECTRIC
A.B. BROWN NO.l
250 MW - NEW
COAL 3.75 PERCENT SULFUR
FMC CORPORATION
DOUBLE ALKALI SCRUBBING
STARTUP 1/79
THE UTILITY HAS AWARDED A CONTRACT TO FMC FOR THE INSTALLATION OF A
DOUBLE ALKALI SCRUBBING SYSTEM UTILIZING SODA ASH AND LYE. THIS UNIT IS
A PART OF A NEW POWER STATION LOCATED IN WEST FRANKLIN, INDIANA. THE
SYSTEM WILL PRODUCE FILTER CAKE AS A WASTE PRODUCT WHICH WILL BE DIS-
POSED OF IN AN ON-SITE LANDFILL. THE PARTICULATE EMISSIONS WILL BE CON-
TROLLED BY A BUELL-ENVIROTECH COLD-SIDE ESP. THE CONSTRUCTION WORK AND
ENFINEERING IS 20X COMPLETE.
SOUTHERN MISSISSIPPI ELECTRIC
R.D. MORROW NO.l
180 MW - NEW
COAL 1.0 PERCENT SULFUR
RILEY STOKER / ENVIRONEERING
LIMESTONE SCRUBBING
STARTUP 5/78
CONSTRUCTION OF THE WET LIMESTONE SCRUBBING SYSTEM IS 50 PERCENT COM-
PLETE. PARTICULATES WILL BE CONTROLLED BY A HIGH-EFFICIENCY ESP UPSTREAM
OF THE SCRUBBING SYSTEM. DESIGN SULFUR DIOXIDE AND PARTICULATE REMOVAL
EFFICIENCIES ARE 85 AND 99.6 PERCENT, RESPECTIVELY. A WATER SPRAY HAS
BEEN ADDED IN THE BY-PASS DUCT TO PROTECT THE LINER FROM TEMPERATURE
EXCURSION, SCRUBBER SLUDGE WILL BE STABILIZED WITH FLYASH AND DISPOSED ON
THE PLANT SITE.
SOUTHERN MISSISSIPPI ELECTRIC
R.O. MORROW NO.2
180 MW - NEW
COAL 1.0 PERCENT SULFUR
RILEY STOKER / ENVIRONEERING
LIMESTONE SCRUBBING
STARTUP 8/78
CONSTRUCTION OF THE WET LIMESTONE SCRUBBING SYSTEM IS 50 PERCENT COM-
PLETE. PARTICULATES WILL BE CONTROLLED BY A HIGH-EFFICIENCY ESP UPSTREAM
OF THE SCRUBBING SYSTEM. DESIGN SULFUR DIOXIDE AND PARTICULATE REMOVAL
EFFICIENCIES ARE 85 AND 99.6 PERCENT, RESPECTIVELY. A WATER SPRAY HAS
BEEN ADDED IN THE BY-PASS DUCT TO PROTECT THE LINER FROM TEMPERATURE
EXCURSION. SCRUBBER SLUDGE WILL BE STABILIZED WITH FLYASH AND DISPOSED ON
THE PLANT SITE.
SPRINGFIELD CITY UTILITIES
SOUTHWEST NO. 1
200 MW - NEW
COAL 3.5 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
STARTUP 4/77
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED UNIT CONSISTS OF A
FOUR-FIELD HIGH EFFICIENCY ESP (99.6X DESIGN) AND 2 TURBULENT CONTACT AB-
SORBER MODULES (BOX DESIGN) FOR THE CONTROL OF PARTICULATES AND S02. BOTH
THE ESP AND LIMESTONE FGD SYSTEM ARE SUPPLIED BY UOP. THE SCRUBBING
WASTES ARE DEWATERED BY A ROTARY DRUM VACUUM FILTER AND THE FILTER CAKE IS
HAULED AWAY TO A LANDFILL. INITIAL OPERATION OF THE FGD SYSTEM OCCURRED IN
APRIL 77. IN SEPT. 77, THE UNIT SUCCESSFULLY COMPLETED COMPLIANCE TESTING.
SPRINGFIELD WATER LIGHT4POWER A CONTRACT HAS BEEN AWARDED TO RESEARCH COTTRELL FOR THE INSTALLATION OF
DALLMAN NO. 3
190 MW - NEW
COAL 3.0-4.3 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 7/80
A LIMESTONE SCRUBBING SYSTEM. REQUIRED SULFUR DIOXIDE REMOVAL EFFICIENCY
IS 90 PERCENT. A SLUDGE DISPOSAL STRATEGY HAS NOT BEEN FINALIZED, BUT
THE UTILITY IS CONSIDERING EITHER PONDING OR LANDFILL. SCRUBBER CONSTRUC-
TION OF THE FGD SYSTEM SHOULD COMMENCE IN LATE 1978. FGD START-UP IS
SCHEDULED FOR JULY 1980. BOILER OPERATION IS SCHEDULED TO COMMENCE IN
JUNE 1978.
TENNESSEE VALLEY AUTHORITY
SHAWNEE N0.10A
10 MW - RETROFIT
COAL 2.9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME/LIMESTONE SCRUBBING
STARTUP 4/72
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
TURBULENT CONTACT ABSORBER(TCA) LIME/LIMESTONE SCRUBBING SYSTEM HAS BEEN
OPERATIONAL SINCE APRIL 1972. THIS TEST PROGRAM IS FUNDED BY THE EPA.
TVA IS THE CONSTRUCTOR AND FACILITY OPERATOR. THE BECHTEL CORP. OF SAN
FRANCISCO IS THE MAJOR CONTRACTOR, TEST DIRECTOR, AND REPORT WRITER.
DURING THE REPORT PERIOD, OPERATIONS WERE CONDUCTED WITH LIMESTONE
SLURRY CIRCULATING THROUGH THE UNIT. FORCED OXIDATION ON FLY ASH-LADEN
FLUE GAS WAS EVALUATED.
18
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COMPANY
POWER STATION
TABLE 2
STATUS OF F60 SYSTEMS AS OF
01/78
CURRENT MONTH
TENNESSEE VALLEY AUTHORITY
SHAWNEE N0.10B
10 MM - RETROFIT
COAL 2,9 PERCENT SULFUR
CHEMICO
LIME/LIMESTONE SCRUBBING
STARTUP 4/72
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
VENTURI/SPRAY TOWER LIME/LIMESTONE SCRUBBING SYSTEM HAS BEEN OPERATIONAL
SINCE APRIL 1972. THIS TEST PROGRAM IS FUNDED BY THE EPA. TVA IS THE
CONSTRUCTOR AND FACILITY OPERATOR. THE BECHTEL CORP. OF SAN FRANCISCO IS
THE MAJOR CONTRACTOR, TEST DIRECTOR, AND REPORT WRITER. DUHING THE REPORT
PERIOD. FORCED OXIDATION WAS EVALUATED ON FLY ASH-FREE FLUE GAS WITH
LIME SLURRY AS THE SCRUBBING AGENT.
TENNESSEE VALLEY AUTHORITY
WIDOWS CREEK NO. 7
575 MW - RETROFIT
COAL 3.7 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP O/ 0
TENNESSEE VALLEY AUTHORITY ANNOUNCED DURING THE REPORT PEHIOO THAT A CON-
TRACT HAS BEEN AWARDED TO COMBUSTION ENGINEERING FOR A LIMESTONE SLURRY
SPRAY TOWER FGO SYSTEM. THE FGD SYSTEM WILL TREAT HIGH SULFUR COAL FLUE
GAS. THE SPRAY TOWER ABSORBERS WILL BE CONSTRUCTED OF 317 L STAINLESS
STEEL. THE NO. 7 UNIT FIRES COAL WITH THE SAME CHARACTERISTICS AS THE COAL
FIRED IN THE NO. 8 UNIT.
TENNESSEE VALLEY AUTHORITY
WIDOWS CREEK NO. 8
550 MW - RETROFIT
COAL 3.7 PERCENT SULFUR
TENNESSEE VALLEY AUTHORITY
LIMESTONE SCRUBBING
STARTUP 5/77
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE EMISSION CONTROL SYSTEM FOR THIS 550-MW COAL-FIRED POWER-GENERATING
UNIT CONSISTS OF EXISTING ELECTROSTATIC PRECIPITATORS FOLLOWED BY FOUR
PARALLEL SCRUBBING TRAINS, EACH CAPABLE OF HANDLING 25 PERCENT OF THE
BOILER FLUE GAS FROM UNIT NO. 8. EACH TRAIN INCLUDES A RECTANGULAR-
THROAT VENTURI SCRUBBER AND A GRIO-TOWER ABSORBER SUPPLIED BY POLYGON.
THE GRID TOWER CAN BE CONVERTED TO A MOBILE-BED TOWER IF GREATER S02 RE-
MOVAL IS REQUIRED.
TEXAS MUNICIPAL POWER AGENCY
GIBBONS CREEK UNIT NO. 1
400 MW - NEW
LIGNITE - 1.06 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 1/82
COMBUSTION ENGINEERING WAS AWARDED A CONTRACT TO DESIGN AND SUPPLY
A 400 MW LIGNITE-FIRED BOILER, ESP, AND FGD SYSTEM AT GIBBONS CREEK
STEAM ELECTRIC STATION UNIT NO. 1. THE BOILER WILL BURN l.ObZ SULFUR
LIGNITE. FLUE GAS WILL BE CLEANED OF PARTICULATES BY A COLD-SIDE ESP
199.73X EFFICIENCY). S02 WILL BE REMOVED BY 3 SPRAY TOWER MODULES UTILI-
ZING A LIMESTONE SLURRY (72.5 TO 87.5X EFFICIENCY). COMMERCIAL START-UP
HAS BEEN SET FOR JANUARY 1982.
TEXAS POWER AND LIGHT CO.
SANDOW NO.4
545 MW - NEW
LIGNITE
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
STARTUP 7/80
COMBUSTION ENGINEERING HAS BEEN CHOSEN AS THE BOILER AND FGD VENDOR FOR
THIS UNIT. BOILER CONSTRUCTION BEGAN ON SEPTEMBER 9, 1977. THE PARTI-
CULATE REMOVAL IS TO TAKE PLACE ON THE COLD-SIDE OF THE AIR HEATER.
SOME PORTION OF FLUE-GAS WILL BYPASS SCRUBBER FOR REHEAT. THE SPENT
SLURRY WILL BE PONDED AND WATER RECYCLED. FGD CONSTRUCTION IS SCHEDULED
TO BEGIN NOVEMBER 1978.
TEXAS POWER AND LIGHT CO.
TWIN OAKS NO. 1
750 MW - NEW
LIGNITE
NOT SELECTED
NOT SELECTED
STARTUP 8/83
THIS UNIT WILL BE JOINTLY OWNED BY TP&L AND ALCOA. A FIRM DECISION HAS
NOT BEEN MADE WHETHER TO INSTALL FGD FACILITIES. THIS IS PRIMARILY
DUE TO THE FACT THAT SUCH A DECISION IS NOT YET REQUIRED IN THE
UTILITIES PLANNING TIMETABLE.
TEXAS POWER AND LIGHT CO.
TWIN OAKS NO. 2
750 MW - NEW
LIGNITE
NOT SELECTED
NOT SELECTED
STARTUP 9/84
THIS UNIT WILL BE JOINTLY OWNED BY TP&L AND ALCOA. A FIRM DECISION HAS
NOT BEEN MADE WHETHER TO INSTALL FGD FACILITIES. THIS IS PRIMARILY
DUE TO THE FACT THAT SUCH A DECISION IS NOT YET REQUIRED IN THE
UTILITIES PLANNING TIMETABLE.
TEXAS UTILITIES CO.
FOREST GROVE NO. 1
750 MW - NEW
LIGNITE
NOT SELECTED
NOT SELECTED
STARTUP 0/81
TEXAS UTILITIES REPORTED THAT A NEW 750-MW LIGNITE-FIRED UNIT IS IN
THE EARLY PLANNING STAGE FOR THE FOREST GROVE STATION IN ATHENS, TEXAS.
START-UP IS SCHEDULED FOR LATE 1981. THE BOILER WILL BE SUPPLIED
BY THE BABCOCK & WILCOX COMPANY.
19
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COMPANY
POWER STATION
TABLE 2
STATUS OF FGO SYSTEMS AS OF
01/78
CURRENT MONTH
TEXAS UTILITIES CO.
MARTIN LAKE NO. 1
793 MW - NEW
COAL 1.0 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 8/77
THIS NEW 793-MW POWER
0.9X SULFUR (AVG) AND
UNIT HAS BEEN EQUIPPED
COLD-SIDE ESP'S AND A
TRELL. THE FGD SYSTEM
TREAT 75X OF THE TOTAL
FOR REHEAT. TOTAL S02
WASTES ARE STABILIZED
GENERATING UNIT FIRES TEXAS LIGNITE WHICH CONTAINS
6.OX ASH (AVG.). IN ORDER TO MEET FEDERAL NSPS THt
WITH AN EMISSION CONTROL SYSTEM WHICH INCLUDES
LIMESTONE FGO SYSTEM BOTH SUPPLIED BY RESEARCH-COT-
CONSISTS OF 6 PACKED/SPRAY TOWER ABSORBERS WHICH
BOILER FLUE GAS. THE REMAINING FLUE GAS IS BYPASSED
REMOVAL EFFICIENCY IS 70.5X. THE FLUE GAS CLEANING
AND DISPOSED IN AN ON-SITE, LINED POND.
TEXAS UTILITIES CO.
MARTIN LAKE NO. 2
793 MW - NEW
COAL 1.0 PERCENT SULFUR
RESEAHCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 2/78
TEXAS UTILITIES CO.
MARTIN LAKE NO. 3
793 MW - NEW
COAL 1.0 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 12/76
THIS NEW 793-MW POWER GENERATING UNIT WILL FIRE TEXAS LIGNITE CONTAINING
0.9X SULFUR (AVG.) AND 8X ASH (AVG.). TO MEET FEDERAL NSPS, THE UNIT WILL
BE EQUIPPED WITH AN EMISSION CONTROL SYSTEM CONSISTING OF COLO-SIDE ESP S
AND A LIMESTONE FGD SYSTEM, BOTH SUPPLIED BY RESEARCH-COTTRELL. THE FGD
SYSTEM CONSISTS OF 6 PACKED/SPRAY TOWER ABSORBERS WHICH WILL TREAT 75X OF
THE TOTAL BOILER FLUE GAS. THE REMAINING GAS WILL BE BYPASSED FOR REHEAT.
TOTAL DESIGN S02 REMOVAL EFFICIENCY IS 70.5X. THE FLUE GAS CLEANING WASTES
WILL BE STABILIZED AND DISPOSED IN AN ON-SITE, LINED POND.
THIS NEW 793-MW POWER GENERATING UNIT WILL FIRE TEXAS LIGNITE CONTAINING
0.9X SULFUR (AVG.) AND 8X ASH (AVG.). TO MEET FEDERAL NSPS, THE UNIT WILL
BE EQUIPPED WITH AN EMISSION CONTROL SYSTEM CONSISTING OF COLD-SIDE ESP'S
AND A LIMESTONE FGD SYSTEM, BOTH SUPPLIED BY RESEARCH-COTTRELL. THE FGD
SYSTEM CONSISTS OF 6 PACKED/SPRAY TOWER ABSORBERS WHICH WILL TREAT 75X OF
THE TOTAL BOILER FLUE GAS. THE REMAINING GAS WILL BE BYPASSED FOR REHEAT.
TOTAL DESIGN 302 REMOVAL EFFICIENCY IS 70.5X. THE FLUE GAS CLEANING WASTES
WILL BE STABILIZED AND DISPOSED IN AN ON-SITE, LINED POND.
TEXAS UTILITIES CO.
MARTIN LAKE NO. a
793 MW - NEW
COAL 1.0 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
STARTUP 11/82
THE CONTRACT FOR THIS FGD SYSTEM HAS BEEN AWARDED TO RESEARCH-COTTRELL.
THE BOILER IS NOW BEING ERECTED. START-UP IS SCHEDULED FOR THE FOURTH
QUARTER OF 1982.
TEXAS UTILITIES CO.
MONTICELLO NO.3
750 MW - NEW
LIGNITE 1.5 PERCENT SULFUR
CHEMICO
LIMESTONE SCRUBBING
STARTUP 2/76
THE EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF A HIGH EFFICIENCY
ESP AND A LIMESTONE FGD SYSTEM. THE ESP (POLLUTION CONTROL-WALTHER) IS
PROVIDED FOR PRIMARY PARTICULATE CONTROL (99.56X). THE FGD SYSTEM CONSISTS
OF LIMESTONE SCRUBBING SPRAY TOWERS (CHEMICO) AND WILL PROVIDE PRIMARY
S02 CONTROL (7«X). THE FGD SYSTEM IS DESIGNED TO TREAT APPROXIMATELY 3MM
SCFM OF FLUE GAS RESULTING FROM COAL WITH 1.5X SULFUR, 18.9X ASH AND
O.OaX CI. THE FLUE GAS CLEANING WASTES WILL BE STABILIZED AND DISPOSED IN
AN ON-SITE, LINED POND. CURRENTLY, INSTALLATION IS NEARING COMPLETION.
UNITED POWER ASSOCIATION
COAL CREEK NO. 1
545 MW • NEW
LIGNITE - 0.63 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
STARTUP 11/78
THE CONTRACT FOR THIS SCRUBBING SYSTEM HAS BEEN AWARDED TO COMBUSTION
ENGINEERING FOR THE INSTALLATION OF LIME FGD SYSTEMS ON UNITS NOS.l AND 2
AT THIS STATION. THE SCRUBBING SYSTEM FOR EACH BOILER WILL CONSIST OF
4 SPRAY TOWER ABSORBER MODULES FOR REMOVING 302 FROM THE FLUE GAS.
ELECTROSTATIC PHECIPITATORS WILL BE INSTALLED UPSTREAM OF EACH SCRUBBING
SYSTEM. FGD CONSTRUCTION BEGAN IN EARLY AUGUST 1977.
UNITED POWER ASSOCIATION
COAL CREEK NO. 2
545 MW - NEW
LIGNITE • 0.63 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
STARTUP 11/79
THE CONTRACT FOR THIS SCRUBBING SYSTEM HAS BEEN AWARDED TO COMBUSTION
ENGINEERING FOR THE INSTALLATION OF LIME FGD SYSTEMS ON UNITS NOS. 1 AND
2 AT THIS STATION. THE SCRUBBING SYSTEM FOR EACH BOILER WILL CONSIST OF
4 SPRAY TOWER ABSORBER MODULES FOR REMOVING S02 FROM THE FLUE GAS.
ELECTROSTATIC PRECIPITATORS WILL BE INSTALLED UPSTREAM OF EACH SCRUBBING
SYSTEM. FGD CONSTRUCTION BEGAN IN AUGUST 77. THE START-UP TARGET
DATE MAY NOT BE ACHIEVED DUE TO DELAYS IN CONSTRUCTION SCHEDULE.
UTAH POWER » LIGHT CO.
EMERY NO.I
400 MW - NEW
COAL 0.5 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
STARTUP 12/78
A CONTRACT HAS BEEN AWARDED TO THE CHEMICO AIR POLLUTION DIVISION FOR
A PEBBLE LIME WET SCRUBBING SYSTEM ON THIS NEW UNIT. THE SCRUBBING
SYSTEM IS DESIGNED TO OPERATE IN AN OPEN WATER LOOP MODE WITH AN S02
REMOVAL EFFICIENCY OF 80 PERCENT FOR LOW SULFUR UTAH COAL. PRIMARY
PARTICULATE CONTROL WILL BE PROVIDED BY AN ESP UPSTREAM OF THE SCRUBBERS.
THE SCRUBBER SLUDGE WILL BE STABILIZED WITH FLYASH AND DISPOSED ON THE
PLANT SITE. THE A-E DESIGN FIRM FOR THIS PROJECT IS STEARNS-ROGER.
CONSTRUCTION IS UNDERWAY ON THE FGD SYSTEM FOR THIS UNIT.
20
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COMPANY
POWER STATION
UTAH POWER & LIGHT CO.
HUNTIN6TON NO.l
415 MW - NEW
COAL 0.5 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
STARTUP 4/78
TABLE a
STATUS OF F60 SYSTEMS AS OF
01/78
CURRENT MONTH
A CONTRACT HAS BEEN AWARDED TO CHEMICO AIR POLLUTION DIVISION FOR
A LIME SCRUBBING SYSTEM ON THIS NEW UNIT. SITE PREPARATION AND CONSTRUC-
TION IS NEARING COMPLETION. THE STATE OF UTAH REGULATIONS REQUIRE THE
BEST AVAILABLE AND MOST COST EFFECTIVE TECHNOLOGY FOR SULFUR DIOXIDE
REMOVAL. PRIMARY PARTICULATE REMOVAL WILL BE PROVIDED BY AN ESP INSTALLED
UPSTREAM OF THE WET SCRUBBING SYSTEM. THE TURNKEY COST FOR THE TWO FGD
SYSTEMS (EMERY NO.l AND HUNTINGTON NO.l) IS S29 MM AND $26 MM RESPECTIVE-
LY.
VIRGINIA ELECTRIC AND POWER CO THE UTILITY IS PRESENTLY CONSIDERING BOTH DESULFURIZATION AND THE USE OF
MT. STORM
1147 MW • RETROFIT
COAL
NOT SELECTED
NOT SELECTED
STARTUP O/ 0
LOW SULFUR COAL. A DESULFURIZATION SYSTEM WOULD TREAT 69 PERCENT OF THE
FLUE GAS FROM THREE BOILERS. CONSTRUCTION AND STARTUP DATES ARE CON-
SIDERED INDEFINITE AT THIS TIME.
WISCONSIN POWER & LIGHT CO.
COLUMBIA NO.
-------
CONTENTS
TABLE 3
UTILITY COMPANY SIZE
POWER STATION RETROFIT
ARIZONA PUBLIC SERVICE US
CHOLLA NO 1
COLUMBUS & SOUTHERN OHIO ELEC. 400
CONESVILLE NO 5
OUQUESNE LIGHT 510
ELRAMA POWER STATION
OUQUESNE LIGHT 410
PHILLIPS POWER STATION
INDIANAPOLIS POWER & LIGHT CO. 530
PETERSBURG NO 3
KANSAS CITY POWER & LIGHT 140
HAWTHORN NO. 3
KANSAS CITY POWER & LIGHT 100
HAWTHORN NO. 4
KANSAS CITY POWER & LIGHT 620
LA CYGNE NO 1
KANSAS POWER & LIGHT 185
LAWRENCE NO 4
KANSAS POWER & LIGHT 400
LAWRENCE NO 5
KENTUCKY UTILITIES 64
GREEN RIVER NOS. 1 1 AND 3
LOUISVILLE GAS & ELECTRIC 178
CANE HUN NO 4
LOUISVILLE GAS & ELECTRIC 65
PADDYS RUN NO 6
MINNKOTA POWER COOPERATIVE 450
MILTON R. YOUNG NO. 2
MONTANA POWER CO. 360
COLSTRIP NO 1
MONTANA POWER CO. 360
COLSTRIP NO 2
NEVADA POWER 125
REID GARDNER NO 1
NEVADA POWER 125
REID GARDNER NO 2
NEVADA POWER 125
REID GARDNER NO 3
NORTHERN INDIANA PUS SERVICE 115
O.H. MITCHELL NO.11
NORTHERN STATES POWER CO. 710
SHERBURNE COUNTY STATION NO.l
NORTHERN STATES POWER CO. 710
SHERBURNE COUNTY STATION NO.2
PENNSYLVANIA POWER CO. 825
BRUCE MANSFIELD NO. 1
PENNSYLVANIA POWER CO. 625
BRUCE MANSFIELD NO. 2
PHILADELPHIA ELECTRIC CO. 120
EDDYSTONE NO. 1A
OF FGO PROCESS/VENDOR PAGE NO.
UNIT (MW)
RESEARCH COTTRELL
LIMESTONE SCRUBBING 24
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING 29
CHEMICO
LIME SCRUBBING 33
CHEMICO
LIME SCRUBBING 38
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING 43
COMBUSTION ENGINEERING
LIME SCRUBBING 45
COMBUSTION ENGINEERING
LIME SCRUBBING 50
BABCOCK & WILCOX
LIMESTONE SCRUBBING 55
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING 60
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING 64
AMERICAN AIR FILTER
LIME SCRUBBING 68
AMERICAN AIR FILTER
LIME SCRUBBING 73
COMBUSTION ENGINEERING
LIME SCRUBBING 77
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING 81
AOL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING 84
ADL/COMBUSTIUN EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING 85
ADL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING 88
ADL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING 93
ADL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING 99
DAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL 104
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING 107
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING 11 1
CHEMICO
LIME SCRUBBING 114
CHEMICO
LIME SCRUBBING 120
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING 123
22
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CONTENTS - TABLE 3
UTILITY COMPANY
POWER STATION
SOUTH CAROLINA PUBLIC SERVICE
WINYAH NO. 2
SPRINGFIELD CITY UTILITIES
SOUTHWEST NO. J
TENNESSEE VALLEY AUTHORITY
SHAWNEE N0.10A
TENNESSEE VALLEY AUTHORITY
SHAWNEE NO.106
TENNESSEE VALLEY AUTHORITY
WIDOWS CREEK NO. 6
TEXAS UTILITIES CO.
MARTIN LAKE NO. 1
SIZE OF FGD PROCESS/VENDOR
RETROFIT UNIT (Mw)
280 BABCOCK & HILCOX
LIMESTONE SCRUBBING
£00 UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
10 UNIVERSAL OIL PRODUCTS
LIME/LIMESTONE SCRUBBING
10 CHEMICO
LIME/LIMESTONE SCRUBBING
550 TENNESSEE VALLEY AUTHORITY
LIMESTONE SCRUBBING
793 RESEARCH COTTRELL
LIMESTONE SCRUBBING
PAGE NO.
127
130
133
134
141
144
23
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY,
PARTICULATES
ARIZONA PUBLIC SERVICE
CHOLLA NO 1
JOSEPH CITY ARIZONA
115 MW
COAL 0.44-1 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
RETROFIT
10/73
OPERATIONAL
99.7 PERCENT
soe
56.5 PERCENT
WATER MAKE UP
OPEN LOOP 1.04 GPM/MW
SLUDGE DISPOSAL
EXISTING FLY ASH POND
UNIT COST
SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS LIMESTONE SCRUBBING SYSTEM HAS PLACED IN SERVICE IN OCTOBER 1973.
THE SCRUBBER PLANT CONSISTS OF TWO PARALLEL SCRUBBING TRAINS. PARTICU-
LATE CONTROL IS PROVIDED BY TWO FLOODED-DISC SCRUBBERS. S02 CONTROL IS
PROVIDED BY ONE PACKED (HUNTERS PACKING) TOWER IA-SIDE). FLUE GAS CLEAN-
ING WASTES ARE DISCHARGED TO AN EXISTING FLY ASH POND. NO WATER IS RE-
CYCLED BACK FROM THE DISPOSAL POND. IN-LINE STEAM REHEATERS RAISE THE
GAS TEMPERATURE 40 F.
24
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BACKGROUND INFORMATION
ON
CHOLLA NO. 1
THE CHOLLA POWER STATION, LOCATED NEAR JOSEPH CITY, ARIZONA, HAS ONE 115-MW COAL-FIRED BOILER
IN SERVICE AND TWO 250-MW UNITS UNDER CONSTRUCTION. CHOLLA NO. 1 IS A DRY-BOTTOM PULVERIZED-COAL-
FIREO UNIT DESIGNED BY COMBUSTION ENGINEERING. THE AVERAGE CHARACTERISTICS OF THE COAL BURNED DUR-
ING THE COURSE OF 1975 ARE: HEAT CONTENT OF 10,150 BTU/LB; ASH CONTENT OF 13.45 PERCENT; SULFUR
CONTENT OF 0.52 PERCENT; CHLORIDE OF 0.04 PERCENT (MAX.); AND MOISTURE CONTENT OF la.77 PERCENT.
THE FGD SYSTEM AT THE CHOLLA PLANT WAS MANUFACTURED BY RESEARCH-COTTRELL, AND INSTALLATION WAS
COMPLETED ON DECEMBER 3, 1973. THE COMBINED SULFUR DIOXIDE DESIGN REMOVAL EFFICIENCY (FOR BOTH
MODULES A AND B) IS 58.5 PERCENT. THE SYSTEM CONSISTS OF TWO PARALLEL TRAINS (MODULES A AND B).
EACH TRAIN IS DESIGNED FOR 240,000 ACFM THROUGHOUT AT 276 F, AND HANDLES APPROXIMATELY 50 PERCENT
OF THE BOILER'S FLUE GAS LOAD. THE A-SIOE CONSISTS OF A CEILCOTE-LINED VARIABLE-THROAT FLOODED
DISC SCRUBBER (FDS) FOLLOWED BY A PACKED TOWER (MUNTER'S PACKING). THE B-SIDE IS SIMILAR IN DESIGN.
HOWEVER, THE TOWER IS NOT PACKED AND LIMESTONE SLURRY IS NOT CIRCULATED THROUGH IT. EITHER ONE OH
BOTH OF THE SCRUBBERS CAN BE BY-PASSED. GAS LEAKAGE AROUND EACH TRAIN IS ESTIMATED TO BE ABOUT 4.5
PERCENT OF THE GAS BEING TREATED. THE TOWER PACKING, WHICH IS APPROXIMATELY 2-FEET THICK, IS CON-
STRUCTED OF POLYPROPYLENE CORRUGATED SHEETS JOINED TOGETHER IN CRISS-CROSS PATTERNS SIMILAR TO
HONEYCOMBS. THE TOWER MIST ELIMINATORS ARE CONSTRUCTED OF POLYPROPYLENE, AND THE REHEATERS ARE
SHELL AND TUBE TYPE CONSISTING OF 3 STAINLESS STEEL TUBE BUNDLES PER UNIT. THE STACK IS ACID
BRICK LINED. PIPING AND RECIRCULATING PUMPS ARE RUBBER LINED.
LIMESTONE FOR THE FGO SYSTEM IS PURCHASED IN GROUND FORM SUITABLE FOR SLURRYING. THE MAIN
SOURCE OF SUPPLY IS THE SUPERIOR CO. LOCATED NEAR PHOENIX, ARIZONA. THIS GRADE OF LIMESTONE IS
GENERALLY KNOWN AS RED WALL LIMESTONE AND IS CONSIDERED A VERY HIGH QUALITY GRADE. CHEMICAL SPEC-
IFICATIONS ARE: MINIMUM CALCIUM OXIDE CONTENT, 52 PERCENT; MINIMUM CALCIUM CARBONATE CONTENT, 95
PERCENT; MAXIMUM MAGNESIUM OXIDE CONTENT, 2 PERCENT; MAXIMUM MAGNESIUM CARBONATE CONTENT, 0.5 PER-
CENT; MAXIMUM SILICA CONTENT, 1 PERCENT.
THE PLANT HAS NO SLUDGE TREATMENT OR FIXATION SYSTEMS. THE SLUDGE IS PUMPED TO THE FLY ASH POND
ON AN INTERMITTENT BASIS THROUGH A COMMON PIPING SYSTEM WITH THE FLY ASH. NO POND WATER IS RECYCLED
TO THE FGD SYSTEM (SOLAR EVAPORATION POND). A GENERAL PROCESS FLOW DIAGRAM OF THE CHOLLA FGD SYSTEM
IS PRESENTED IN APPENDIX B.
PROBLMS AND SOLUTIONS: INITIAL AND SUBSEQUENT OPERATION
DECEMBER, 1973 TO APRIL 2, 1974: BECAUSE OF A DIFFERENCE IN THE SIZE OF THE MAIN DUCT AND RE-
HEATER TRANSITION DUCT, THE GAS FLOW PRODUCED HARMONIC VIBRATIONS IN THE REHEATER. THE VIBRATIONS
WERE PARTIALLY DAMPED BY INSTALLATION OF BAFFLES. ONE OF THE REHEATER TUBE BUNDLES WAS BADLY COR-
RODED BY ACID THAT CONDENSED IN THE UNINSULATED DUCT UPSTREAM OF THE REHEATERS. THE TUBE BUNDLE WAS
REPLACED, AND A BAFFLE WAS INSTALLED TO DIVERT CONDENSED ACID FROM REHEATER TUBES. ALSO, THE DUCT
UPSTREAM OF THE REHEATEK WAS INSULATED. THE ACID CONDENSATION OCCURED ONLY IN THE 8-MOOULE WHICH
CONTAINS NO INTERNAL PACKING AND THEREFORE HAS A LOWER DEGREE OF SULFUR DIOXIDE REMOVAL
(25 PERCENT).
ANOTHER PROBLEM RESULTED BECAUSE OF SOLIDS BUILD UP IN THE FDS STUFFING GLAND BOX AND ON TOP
OF THE SPRAY DOME. ALSO, SOME LINES PLUGGED, PARTICULARLY WHEN THE SYSTEM OPERATED AT LOW FLOW
RATES. SOLIDS SETTLED OUT IN STANDBY PUMPS, AND EXCESSIVE FAN VIBRATIONS OCCURRED BECAUSE OF ACCU-
MULATION OF SCALE BUILDUP WHEN THE UNIT WAS IDLt. TO SOLVE THESE PROBLEMS, THE PACKING GLAND POSI-
TION WAS REVERSED (INSTALLED UPSIDE DOWN), THE FAN WAS SANDBLASTED, THE PIPING WAS MODIFIED TO ELIM-
INATE STAGNANT POCKETS, AND PUMPS WERE FLUSHED IMMEDIATELY AFTER REMOVAL FROM SERVICE.
OPERATION OF THE SYSTEM THROUGHOUT 1975 AND 1976 WAS ACCOMPANIED BY A NUMBER OF MINOR PROBLEM
AREAS INCLUDING: SIGNIFICANT CORROSION ATTACK IN THE VESSEL WALLS OF THE VENTURI FLOODED-OISC
PARTICULATE SCRUBBER MODULE: ACID CORROSION IN THE B-SIDE REHEATER HOUSING; SCALE BUILDUP IN THE
PIPEOUTLET AT THE SLUDGE/FLY ASH EVAPORATION POND; PLUGGING IN THE SCRUBBER TOWER PACKING AND MIST
ELIMINATOR; EROSION IN THE PUMPS; CORROSION IN THE BOILER EXHAUST ELBOW OF THE DUCTWORK LEADING FROM
THE SCRUBBERS TO THE STACK. ADDITIONAL INFORMATION AND DATA ON THE PERFORMANCE OF THE CHOLLA FGO
SYSTEM ARE PROVIDED IN THE TABLE THAT FOLLOWS.
25
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ARIZONA PUBLIC SERVICE
MONTH
JAN. 74
FEB. 74
MAR. 74
APR. 74
MAY 74
JUN. 74
JUL. 74
AUG. 74
SEP. 74
OCT. 74
NOV. 74
DEC. 74
JAN. 75
FEB. 75
MAR. 75
APR. 75
MAY 75
JUN. 75
JUL. 75
RELIABILITY (X)
MODULE A MODULE B
FSD SYSTEM RELIABILITY
CHOLLA UNIT NO. 1
CHOLLA UNIT NO. 1
COMMENTS
MAY 76
JUN. 76
JUL. 76
97
100
100
66
98
100
97
97
95
83
100
100
98
96
88
48
100
97
76
64
100
90
94
66
57
99
100
92
97
99
68
98
100
99
99
65
40
100
98
AUG.
SEP.
OCT.
NOV.
DEC.
JAN.
FEB.
MAR.
APR.
75
75
75
75
75
76
76
76
76
95
96
84
100
100
99
99
100
97
55
80
100
99
98
100
39
98
ANNUAL BOILER AND FGD SYSTEM OVERHAUL.
MODULES WERE BOTH OFF-LINE FOR MOST OF MONTH FOR SCHEDULED RE-
PAIRS AND CLEANING.
PLUGGING IN THE A-SIDE ABSORBER PACKING AND MIST ELININATORS WAS
OBSERVED. NO OTHER MAJOR PROBLEMS MERE ENCOUNTERED DURING
THE PERIOD.
MODULES WERE SHUT DOWN TO CLEAN FLOW RESTRICTIONS IN FLOODED-
DISC RECIRCULATION LINES.
THE A SIDE WAS SHUT DOWN ONCE FOR INSPECTION.
MINOR OUTAGE RESULTED FROM PLUGGED FDS RECIRCULATION LINES.
OUTAGES RESULTED FROM SCHEDULED EQUIPMENT OVERHAULS AND RECOAT-
ING OF VESSELS.
NO MAJOR OUTAGES OR PROBLEMS OCCURED DURING THE REPORT PERIOD.
MINOR PROBLEMS ENCOUNTERED INCLUDED RECYCLE PUMP REBUILDING AND
MALFUNCTIONING OF THE B-SIDE REHEATER COIL.
MODULE A OPERATED 715 HOURS DURING THE REPORT MONTH, AND MODULE
B OPERATED 654 HOURS. MODULE A EXPERIENCED SOME MINOR VALVE
AND LINE PLUGGING. MODULE B OPERATING HOURS WERE LOWER BECAUSE
OF REDUCED SYSTEM REQUIREMENTS.
THE UNIT IS CURRENTLY EXPERIENCING COATING FAILURES IN THE
ELBOW OF THE SCRUBBER EXHAUST DUCT. ALSO, THE UTILITY PERFORM-
ED SOME MINOR REPAIRS TO THE HOUSING OF THE B-SIDE REHEATER.
DURING THE MONTH THE A-SIDE EXPERIENCED SOME CORROSION AND
PLUGGING PROBLEMS IN THE REHEATER TUBES. IN ADDITION TO PLUGGED
FOS LINES, PACKING AND MIST ELIMINATORS, APS ALSO REPORTED THAT
HEAVY PUMP MAINTENANCE WAS REQUIRED.
LOW RELIABILITY FACTORS FOR THE MONTH OF JUNE RESULTED FROM A
SCHEDULED MID-YEAR SCRUBBER SHUTDOWN FOR MAINTENANCE, INSPEC-
TION AND REPAIRS. SOME SCALING AND CORROSION PROBLEMS WERE
UNCOVERED IN THE SYSTEM'S RECYCLE TANKS.
DURING THE JULY-AUGUST PERIOD THE UTILITY REPORTED THAT REPAIRS
26
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ARIZONA PUBLIC SERVICE
RELIABILITY UJ
MONTH MODULE A MODULE B
AUG. 76 100 100
FGD SYSTEM RELIABILITY
CHOLLA UNIT NO. i
CHOLLA UNIT NO. 1
SEP. 76
OCT. 76
NOV. 76
DEC. 76
100
56
96
96
100
56
98
100
COMMENTS
TO THE COATING IN THE ELBOW OF THE SCRUBBER EXHAUST OUCT WERE
COMPLETED. A MALFUNCTIONING SOLENOID VALVE IN THE MIST ELIM-
INATOR WASH SYSTEM OF THE B-SIDE, PREVENTING ADEQUATE WASHING,
RESULTED IN A MINOR SCRUBBER OUTAGE.
THE BQILER REMAINED IN SERVICE THE ENTIRE MONTH. A-SIDE SERVICE
TIME WAS 720 HOURS. B-SIDE SERVICE TIME WAS 676 HOURS. NO
SIGNIFICANT PROBLEMS WERE REPORTED.
THE BOILER WAS IN SERVICE 417 HOURS DURING THE MONTH. A-SIDE
AND B-SIDE OPERATIONAL HOURS WERE 115 AND 277 RESPECTIVELY.
DURING THE MONTH THE BOILER, A-SIDE AND B-SIDE TRAINS WERE IN
SERVICE 720, 682 AND 556 HOURS, RESPECTIVELY. TWO MINOR FORCED
SCRUBBER OUTAGES OCCURRED DURING THE PERIOD DUE TO A HEHEATER
STEAM LEAK AND INLET GAS DAMPER ADJUSTMENTS TO BOTH THE A-SIOE
AND B-SIDE SCRUBBING TRAINS.
BOILER, A-SIDE, AND B-SIDE OPERATION HOURS FOR THE MONTH WERE
744, 742 AND 498 HOURS, RESPECTIVELY. ONE OUTAGE WAS REPORTED
BECAUSE OF AN ADDITIONAL ADJUSTMENT TO THE A-SIDE GAS INLET
DAMPER.
NOTE: THE PERFORMANCE INDEX VALUES CONTAINED IN THE TEXT OF THIS TABLE ARE BASED UPON THE MODULES'
ACTUAL SERVICE TIME FOR THE PERIOD VERSUS THE NUMBER OF HOURS THE MODULES ARE CALLED UPON TO OPER-
ATE FOR THE SAME PERIOD. THE MODULES OPERATE ON A DEMAND-ONLY BASIS. FLUE GAS IS BYPASSED AROUND THE
MODULES WHEN THEY ARE NOT REQUIRED FOR SERVICE.
JAN. 77
FEB. 77
72
99
93
99
MAR. 77
APR. 77
MAY. 77
72
100
87
93
100
87
JUN. 77
JUL. 77
AUG. 77
SEP. 77
OCT. 77
100
97
97
100
100
100
99
99
100
100
SERVICE HOURS FOR JANUARY: BOILER = 744, A-SIDE = 532, B-SIDE *
684.
SERVICE HOURS FOR FEBRUARYS BOILER = 672, A-SIDE s fe4B, B-SIDt =
591. THE MUNTERS PACKING IN THE A-SIDE TOWER WAS REPLACED. IN
ADDITION SOME MINOR PROBLEMS WERE ENCOUNTERED IN THE FORM OF
SCRUBBER VESSEL PLUGGING, MINOR CORROSION AND LIQUID PIPING
PROBLEMS, AND MECHANICAL DIFFICULTIES WITH THE BY-PASS DAMPERS.
AVERAGE S02 INLET/OUTLET VALVES DURING THE PERIOD WERE 350 PPM
AND 175 PPM.
SERVICE HOURS FOR MARCH: BOILER = 744, A-SIDE = 532, B-SIDE =
684.
SERVICE HOURS FOR APRIL: BOILER = 638, A-SIDE = 635, B-SIDE =
629.
SERVICE HOURS FOR MAY: BOILER s 645, A-SIDE = 645, B-SIDE = 645.
OUTAGE TIME FOR THE BOILER AND THE FGD SYSTEM WERE A RESULT OF
THE SCHEDULED MID-YEAR SCRUBBER CLEANOUT. DURING MAY, RE-
SEARCH-COTTRELL PERSONNEL CONDUCTED FORCED OXIDATION TESTS, BY
BLOWING AIR INTO THE FLOODED DISC SCRUBBER AND CONVERTING ALL
CAS03 TO CAS04 FOR SUPERIOR SLUDGE OEWATERING, HANDLING AND
SCALE-FREE OPERATION.
SERVICE HOURS FOR JUNE: BOILER, A-SIDE AND B-SIDE = 720.
SERVICE HOURS FOR JULY: BOILER = 744, A-SIDE = 724, B-SIDE =
734. MINOR PROBLEMS INCLUDED A LEAK IN THE LIMESTONE SLURRY
TANK AND A LEAK IN THE B-SIDE RETURN LIME FROM THE FDS TO THE
FDS TANK. RESEARCH-COTTRELL PERSONNEL ARE STILL ON THE PLANT
SITE, CONTINUING FORCED OXIDATION STUDIES.
SERVICE HOURS FOR AUGUST: BOILER = 744, A-SIDE = 723.3, B-SIDE :
733.7.
FOR SEPTEMBER: BOILER = 720, A-SIDE a 717.9, B-SIDE = 717.8.
THE DOWNTIME WAS REQUIRED TO REPAIR TWO DIFFERENT LEAKS. ONE
LEAK OCCURRED AT THE SLURRY DISPOSAL TANK. THE OTHER WAS
LOCATED IN THE FDS RETURN LINE BETWEEN THE TOWER AND FDS TANK.
SERVICE HOURS FOR OCTOBER: BOILER * 744, A-SIDE AND B-SIDE
743.2. OPERATIONS WERE VERY SUCCESSFUL IN OCTOBER 1977.
27
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ARIZONA PUBLIC SERVICE FGD SYSTEM RELIABILITY CHOLLA UNIT NO. 1
CHOLLA UNIT NU. 1
RELIABILITY U)
MONTH MODULE A MODULE B COMMENTS
NOV. 77 100 98 SERVICE HOURS FOR NOVEMBER! BOILER AND A-SIDE = 166.5/ B-SIDE s
1*12. B-SIDE OUTAGE DUE TO LEAKS IN VENTURI SECTION Of SCRUBBER
AND EXPANSION JOINT IN RECYCLE PUMP. BOILER OPERATED ONLY 168.5
HOURS BECAUSE OF A SHUTDOWN FOR OVERHAUL IN LAST HALF OF NOVEM-
BER. SCHEDULED START-UP IS MID-DECEMBER.
DEC. 77 THE BOILER AND THE SCRUBBERS WERE DOWN AS THE OVERHAUL PERIOD
CONTINUED. THIS WAS A MAJOR OVERHAUL AND EXTENDED INTO JAN. 78.
JAN. 78 97 91 DURING THE OVERHAUL THE FLOODED DISC SCRUBBER TANK HEADER FOR
SLURRY LIME WAS DAMAGED REPAIRED. THE BOILER WAS OPERATED
ONLY 135 HRS. DURING JANUARY AS THE OVERHAUL HAD EXTENDED INTO
THIS MONTH.
28
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
COLUMBUS & SOUTHERN OHIO ELEC,
CONESVILLE NO 5
CONESVILLE OHIO
400 MM
COAL 4.5 - 4.9 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
NEW
1/77
OPERATIONAL
99.6 PERCENT
soe
89.5 PERCENT
WATER MAKE UP
OPEN LOOP
SLUDGE DISPOSAL
PUMPED TO A LANDFILL
UNIT COST
SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE BOILER AND ESP WERE COMPLETED AND PLACED IN SERVICE IN SEPT. 1976.
THE B-SIOE MODULE BECAME AVAILABLE FOR SERVICE IN JANUARY 1977.
COMMERCIAL OPERATIONS WERE ACHIEVED ON FEBRUARY 13, 1977. THE EMISSION
CONTROL SYSTEM FOR THIS UNIT CONSISTS OF A COLD-SIDE ESP FOLLOWED BY
TWO TCA LIME SCRUBBING MODULES SUPPLIED BY UOP. DRAVO IS SUPPLYING THE
THIOSORBIC LIME SCRUBBING REAGENT. IUCS IS SUPPLYING THEIR POZ-0-TEC
SLUDGE STABILAZATION FACILITY.
29
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BACKGROUND INFORMATION
ON
CONESVILLE NO. 5
THE CONESVILLE POWER STATION IS LOCATED ON THE MUSKINGUM RIVER, APPROXIMATELY 740 FEET ABOVE
SEA LEVELr NEAR COSHOCTON, IN NORTHEAST OHIO. THE PLANT HAS A CURRENT CAPACITY OF 1644 MW (NAME-
PLATE) WITH AN ADDITIONAL 111 MW UNDER CONSTRUCTION. UNITS 1,2, AND 3 HAVE A COMBINED CAPACITY OF
433 MW (UNITS 1 AND 2 HAVE A COMMON STACK). UNIT NO.4 IS RATED AT 800 MW AND UNIT NO.5 IS RATED AT
411 MW. UNIT NO.6, CURRENTLY UNDER CONSTRUCTION WILL ALSO BE RATED AT 411 MW. UNITS 3 AND 4 HAVE
SEPARATE STACKS. UNITS 5 AND 6 SHARE A COMMON STACK,
BOILER NO. 5 IS A DRY-BOTTOM, PULVERIZED-COAL-FIRED COMBUSTION ENGINEERING UNIT, INSTALLED IN
1976. THE BOILER IS FIRED WITH 25 PERCENT EXCESS AIR AND IS RATED AT 89 PERCENT EFFICIENCY. THE
HEAT RATE IS 8600 BTU/KWH. THE PLANT BURNS A MIXTURE OF HIGH-SULFUR OHIO COAL, WITH SULFUR CONTENTS
OF FROM 4.2 TO 5.1 PERCENT, ASH CONTENTS OF FROM 12 TO 19 PERCENT, AND HEATING VALUES OF FROM 10,300
TO 11,220 BTU/LB. FORTY PERCENT OF THE COAL FIRED COMES BY CONVEYOR FROM A NEARBY (7 MILES DISTANT)
COAL MINE COMPLEX. THE REMAINDER IS TRUCKED IN FROM SOUTHEAST OHIO.
THE AIR POLLUTION CONTROL SYSTEM AT CONESVILLE NO. 5 CONSISTS OF A RESEARCH-COTTRELL COLO-SIDE
ESP, FOLLOWED BY TWO UNIVERSAL OIL PRODUCTS (UOP) 302 ABSORBER MODULES. THE ESP IS DESIGNED FOR
99.65 PERCENT REMOVAL EFFICIENCY AND THE TURBULENT CONTACT ABSORBERS (TCA) MODULES ARE DESIGNED FOH
S02 REMOVAL EFFICIENCY OF 89.6 PERCENT. THE SYSTEM IS DESIGNED FOR AN OUTLET S02 LOADING OF 1.0
LB/MILLION BTU INPUT. BOILER I.D. FANS ARE LOCATED IMMEDIATELY DOWNSTREAM OF THE ESP.
FOLLOWING THE I.D. FANS, THE FLUE GAS IS HEADERED INTO THE TWO PARALLEL TCA SCRUBBING TRAINS,
EACH ABSORBER CAPABLE OF HANDLING 60 PERCENT OF THE FLUE GAS FLOW. A PRESATURATOR SECTION, CONSTR-
UCTED OF CARPENTER 20, QUENCHES THE HOT GAS, LOWERING THE TEMPERATURE FROM 286F TO 125F, AND PROVID-
ING INITIAL S02 REMOVAL. THE GAS THEN ENTERS THE NEOPRENE-LINED, CARBON STEEL ABSORBER MODULES,
WHERE TWO LEVELS OF 1.5 INCH BALLS PROVIDE TURBULENT BEDS FOR FINAL S02 REMOVAL. THE LOWER STAGE IS
COMPARTMENTED TO MAINTAIN UNIFORM BALL DEPTH. FOLLOWING EACH ABSORBER MODULE, THE FLUE GAS PASSES
THROUGH A FIBERGLASS TRAP-OUT TRAY AND TWO HORIZONTAL BANKS OF CHEVRON-TYPE MIST ELIMINATORS. THE
BOTTOM OF THE TRAP-OUT TRAY IS WASHED INTERMITTENTLY AND THE LOWER MIST ELIMINATOR IS WASHED CONTIN-
UALLY WITH RECYCLED POND WATER. THE FLUE GAS FROM THE PARALLEL ABSORBER TRAINS IS THEN HEAOERED
INTO THE 800-FT, CEILCOTE-LINEO STACK. FOLLOWING THE BOILER I.D. FAN THERE IS BYPASS BREECHING
AROUND THE ENTIRE SCRUBBER LOOP. THERE IS NO STACK GAS REHEAT CURRENTLY BEING EMPLOYED, ALTHOUGH
THE POSSIBILITY EXISTS OF ADD-ON REHEAT AT SOME FUTURE DATE.
DRAVO THIOSORBIC LIME FROM MAYSVILLE, KENTUCKY IS UTILIZED IN THE UOP SCRUBBER MODULES AT A
STOICHIOMETRIC RATIO OF 1.1. THE CALCINED, PELLETIZED LIME HAS A NOMINAL PARTICLE DIAMETER OF 1.75
INCH, AN MGO CONTENT OF 3 TO 8 PERCENT AND A CAO CONTENT OF 90 TO 95 PERCENT. THE LIME SLAKER DISC-
HARGED THE 20 PERCENT SOLIDS SLURRY INTO AN AGITATED LIME SLURRY SUMP WHERE IT IS RETAINED FOR A
5-MINUTE PERIOD PRIOR TO TRANSFER TO THE LIME SLURRY STORAGE TANK, WHICH HANDLES THE SURGE REQUIRE-
MENTS OF THE ABSORPTION SYSTEM. THE TRANSFER OF SLURRY FROM THE STORAGE TANK TO THE TCA RECYCLE
TANKS IS ACCOMPLISHED BY VARIABLE SPEED PUMPS WHICH RESPOND TO CHANGING S02 AND LOAD CONDITIONS VIA
A PH MONITOR. THE SCRUBBING LIQUOR CONTAINS 7 TO 12 PERCENT SOLIDS. THE ABSORBENT LIQUOR IS RECIR-
CULATED BY 4 PUMPS d STANDBY) EACH RATED AT 12,000 GPM. SCRUBBER OUTLET PH is 5.8, AND PH IN THE
RECYCLE TANK IS APPROXIMATELY 6.8.
A BLEED STREAM OF SPENT REACTION PRODUCTS IS CONTINUOUSLY WITHDRAWN FROM THE TANK PUMPED TO THE
THICKENER SYSTEM. THE THICKENER IS 100 FT IN DIAMETER AND 14 FT DEEP IN THE CENTER. HERE THE RE-
ACTION PRODUCT SLURRY IS CONCENTRATED TO AN UNDERFLOW COMPOSITION OF APPROXIMATELY 30-35 PERCENT
SOLIDS. THIS UNDERFLOW IS CYCLED TO THE IUCS FIXATION FACILITIES WHERE IT IS FURTHER THICKENED,
VACUUM FILTERED AND MIXED WITH A BLEND OF DRY FLY ASH AND LIME TO FORM A 73 PERCENT SOLIDS SUBSTANCE
(IUCS POZ-0-TEC). THE PRODUCT IS BEING CYCLED TO A DIKED POND.
THE WASTE WATER POND, WHICH WILL RECEIVE THE ASH WATER, COOLING WATER SLOWDOWN AND WATER FROM
THE SLUDGE TREATMENT PLANT, IS EXPECTED TO OVERFLOW INTO THE MUSKINGUM RIVER DURING ALL PLANT OPER-
ATING PERIODS (LOW AND HIGH LOAD OPERATIONS). THEREFORE, ALL SYSTEM OPERATIONS WILL BE CONDUCTED IN
A WATER POSITIVE MODE.
REFER TO APPENDIX B FOR A GENERAL PROCESS FLOW DIAGRAM. THE OPERATING HISTORY OF THE
CONESVILLE UNIT IS SUMMARIZED CHRONOLOGICALLY IN THE PERFORMANCE TABLE THAT FOLLOWS.
30
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COLUMBUS & SOUTHERN OHIO ELECTRIC
OPERATING HISTORY
CONESVILLE NO. 5
CONESVILLE UNIT. 5
MODULE MODULE
AVAILABILITY OPERABILITY
(PERCENT) (PERCENT)
MONTH/YR A B A 8
DEC. 76
JAN. 77
FEB. 77
43
COMMENTS
S02 REMOVAL OPERATIONS WERE SCHEDULED TO COMMENCE IN
DECEMBER. HOWEVER A MAJOR FIRE IN MODULE NO. SA DELAYED
START-UP. THE FIRE CAUSED $2.1 MILLION DAMAGE TO THE
MODULE. THE UTILITY'S INSURANCE COVERED THE DAMAGE AND
A NErt SCRUBBER MODULE WILL BE PURCHASED FROM AND IN-
STALLED BY U.O.P. THE 5A MODULE IS SCHEDULED TO COM-
MENCE OPERATIONS IN NOVEMBER 1977.
THE UTILITY IS CURRENTLY CONDUCTING AIR AND WATER TESTS
ON MODULE 56 AND SCRUBBING OPERATIONS WITH 58 ARE NOW
SCHEDULED FOR JANUARY.
INITIAL START-UP FOR DEBUGGING AND COMMISSIONING PUR-
POSES OCCURRED IN EARLY JANUARY. EARLY OPERATIONS WERE
MARKED BY COLD WEATHER RELATED PROBLEMS SUCH AS FROZEN
LINES AND GEARS, CRACKED FLANGES, A FROZEN LIME BELT
CONVEYOR, AND A FROZEN PIPELINE FROM THE THICKENER TO
THE IUCS FACILITY. COMMERCIAL AVAILABILITY FOR SERVICE
OCCURRED ON JANUARY 27. NO JANUARY OPERATING HOURS ARE
AVAILABLE.
COMMERCIAL START-UP OF MODULE 5B ACHIEVED ON FEBRUARY
13, 1977. AFTER START-UP, THE SCRUBBER LOGGED 286 HOURS
OF OPERATION. THE LONGEST PERIOD OF CONTINUOUS OPERA-
TION WAS 132 HOURS. THE BOILER LOGGED 668 HOURS DURING
FEBRUARY. PRUBLEMS INCLUDED PRESSURE SURGES IN THE
PRESATURATOR PIPING LINE, UNSATISFACTORY OPERATION OF
THE CONTINUOUS 502 ANALYZERS, POOR VELOCITY DISTRIBUTION
THROUGH THE TCA BEDS, AND CARRYOVER OF SCRUBBING LIQUID
INTO THE MIST ELIMINATOR SECTION. THE ESP IS REPORTED
TO BE OPERATING SATISFACTORILY. COMPLIANCE TESTING FOR
THIS UNIT IS SCHEDULED FOR MAY 1977.
31
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COLUMBUS & SOUTHERN OHIO ELECTRIC
CONESVILLE UNIT NO. 5
OPERATION TIME (HR)
PERIOD BOILER A-SIOE B-SIDE
APR. 77 665 361
AVAILABILITY = 40 PERCENT
OPERABILITY = 38 PERCENT
RELIABILITY = 39 PERCENT
UTILIZATION = 36 PERCENT
MAY 77 712
AVAILABILITY = SB PERCENT
OPERABILITY a 50 PERCENT
RELIABILITY = 51 PERCENT
UTILIZATION = 48 PERCENT
JUN. 77 713
AVAILABILITY » 66 PERCENT
OPERABILITY a 59 PERCENT
RELIABILITY = 60 PERCENT
UTILIZATION a 58 PERCENT
355
418
JUL. 77
744
AUG. 77 U
ALL INDEX VALUES = 0 PERCENT
SEP- 77 469
AVAILABILITY = 52.9 PERCENT
PEPRABILITY = 39.9 PERCENT
RELIABILITY » 46.9 PERCENT
UTILIZATION x 26 PERCENT
OCT. 77 559 0
AVAILABILITY (X) =
OPERABILITY (X) =
RELIABILITY (X) s
UTILIZATION (X) «
NOV. 77 715 9
AVAILABILITY (X) a 10
OPERABILITY (X) s n
RELIABILITY (X) s 4
UTILIZATION (X) a1 4
DEC. 77 162
AVAILABILITY (X) a 93
OPERABILITY (X) a 64
RELIABILITY (X) a 62
UTILIZATION CX) = 22
187
135
32
24
25
16
234
33
33
33
33
199
97
79
76
27
COMMENTS
THE UTILITY REPORTED A NUMBER OF PROBLEM AREAS REGARDING
SCRUBBER OPERATIONS DURING THE REPORT PERIOD. SPECIF-
ICALLY, SOME CORROSION HAS BEEN REPORTED IN THE PRESAT-
URATOR AREA (316 SS CONSTRUCTION), THE RUBBER LINER IN
THE RECYCLE TANK IS PEELING OFF (PROBABLY AN APPLICATION
PROBLEM), SOME PLUGGING IN THE TUBE THICKENERS HAS OC-
CURRED, AND THE QUALITY OF THE LIME SLURRY HAS BEEN A
REAL PROBLEM AREA (ROCKS UP TO FIVE INCHES IN DIAMETER
HAVE BEEN DETECTED). THE LATTER ITEM HAS PROMPTED
DRAVO TO INSTALL MECHANICAL SEPARATORS AND METAL DETEC-
TORS AT THE LIME SHIPMENT FACILITY, A STACK OUTLET
TEMPERATURE OF 200 F IS BEING MAINTAINED IN ORDER TO
MINIMIZE ACID RAINOUT AND STACK CORROSION PROBLEMS.
THE B-SIDE MODULE DID NOT OPERATE THE ENTIRE MONTH
PENDING COMPLETION OF A NUMBER OF NECESSARY MODIFICA-
TIONS AND REPAIRS. THE MAJOR ITEMS ADDRESSED DURING
THE PERIOD INCLUDED:
*M MODIFICATIONS TO THE UNIT PROCESS CONTROL SYSTEM
AND INSTRUMENTATION LOOPS.
*REPAIRS TO THE RECLAIM WATER PIPING NETWORK.
•REPAIRS TO THE ABSORBER LINER.
•REPAIRS TO THE PIPING BETWEEN THE THICKENER AND
IUCS BUILDING.
THE UTILITY IS CURRENTLY PLANNING TO CONDUCT A PARTICU-
LATE DROP TEST DURING THE MONTH OF SEPTEMBER.
THE REPLACEMENT A-SIOE TCA MODULE REPLACING THE ORIGINAL
MODULE DESTROYED BY FIRE DECEMBER OF 1976 IS EXPECTED
TO BE AVAILABLE FOR COMMERCIAL SERVICE IN JANUARY 1978.
THE SCRUBBER WAS NOT OPERATING THE ENTIRE MONTH. RE-
PAIRS AND MODIFICATIONS CONTINUED UNTIL SEPTEMBER 13.
THERE WERE SOME WEATHER-RELATED DELAYS.
THERE HAD BEEN NO PROBLEMS RECORDED SINCE THE SCRUBBER
OPERATION BEGAN AGAIN ON SEPTEMBER 13.
THE UTILITY IS PREPARING FOR AN S02 AND PARTICULATE DROP
TEST PUSHED BACK FROM SEPTEMBER, AS PREVIOUSLY REPORTED,
TO THE WEEK OF OCTOBER 24.
B-MODULE HAD TO BE RELINED IN SOME AREAS WITH NEOPRENE
RUBBER. SCRUBBER WAS DOWN FROM OCT. 10 TO NOV. 10.
MODULE A WENT BACK ON LINE NOV. 21. DURING LOW LOAD
PERIODS SOLIDS BUILD UP TENDED TO CAUSE PLUGGING BECAUSE
OF LOW FLOW RATES. DURING LOW LOAD PERIODS ALL GAS WAS
DUCTED THROUGH ONE SCRUBBER WHILE THE OTHER WAS SHUT-
DOWN.
DURING THE DECEMBER 1977 TO MARCH 1978 SHUTDOWN, THE
CARBON STEEL FLUE WILL BE REPLACED BY ACID-bRICK LINED
STACK.
CONESVILLE NO. 5 WENT DOWN DECEMBER 12 FOR A 3-MONTH
SCHEDULED OUTAGE. MODULE A WAS STARTED DECEMBER 3 AND
OPERATED AS MUCH AS POSSIBLE THROUGH DECEMBER 12. MOD-
ULE B OPERATED DECEMBER 1 THROUGH 12. THE UNIT WENT
DOWN FOR A COMPLETE OVERHAUL TO CHECK HOW WELL VENDOR
SPECS WERE ACHIEVED ON THE BOILER AND TURBINES. THE
UNIT IS SCHEDULED TO BE BACK ON LINE IN MID-MARCH BUT
THIS MAY BE PUSHED BACK TO APRIL 1ST. RELINING OF THE
STACK IS STILL CONTINUING
JAN. 78 00
ALL INDEX VALUES = 0 PERCENT
32
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
DUOUESNE LIGHT
ELRAMA POWER STATION
ELRAMA PENNSYLVANIA
510 MM
FUEL CHARACTERISTICS COAL 1.0 - 2.8 PERCENT SULFUR
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCYr
PARTICULATES
CHEMICO
LIME SCRUBBING
RETROFIT
10/75
OPERATIONAL
99 PERCENT
802
83 PERCENT DESIGN - 2X S COAL
WATER MAKE UP
OPEN LOOP
SLUDGE DISPOSAL
HAULAWAY TO OFF SITE LANDFILL
UNIT COST
SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
OPERATIONS ARE CONTINUING WITH THREE BOILERS COUPLED INTO THE FIVE-MODULE
SCRUBBING SYSTEM. THE PLANT IS FIRING 1.0 - 2.8 PERCENT SULFUR COAL.
SCRUBBING WASTES ARE CHEMICALLY FIXATED BY THE IUCS SYSTEM AND LANDFILL-
ED.
33
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BACKGROUND INFORMATION
ON
EIRAMA POWER STATION
DUOUENSE LIGHT COMPANY, AN INVESTOR-OWNED ELECTRIC UTILITY, SERVES ABOUT ONE-HALF CUSTOMERS IN
SOUTHWESTERN PENNSYLVANIA AND HAS A NET GENERATING CAPABILITY OF APPROXIMATELY 2500 MW. THIS CAP-
ABILITY IS GENERATED BY COMBUSTION TURBINES IN SIMPLE AND COMBINED-CYCLE MOOES, BY NUCLEAR PLANTS,
AND BY COAL-FIRED POWER STATIONS. THE COMPANY IS SOLE OWNER AND OPERATOR OF THREE COAL-FIRED
STATIONS, TWO OF WHICH HAVE BEEN RETROFITTED WITH WET SCRUBBERS USING LIME AS THE ABSORBING
REAGENT.
THE SCRUBBER FACILITY AT THE 494-MW ELRAMA STATION IS ALMOST IDENTICAL TO THE SYSTEM AT THE
PHILLIPS STATION. GIBB & HILL WAS THE A-E FIRM AND CHEMICO SCRUBBERS HAVE BEEN INSTALLED WITHIN
THE SAME DESIGNATED BATTERY LIMITS AS PHILLIPS. MECHANICAL AND ELECTRICAL DUST-REMOVAL EQUIPMENT
REMOVES MOST PARTICULATES FROM THE BOILER EMISSIONS, AND THE GAS TO AND FROM THE SCRUBBERS IS
HEADERED IN THE SAME WAY. UNLIKE THE PHILLIPS SYSTEM, HOWEVER, THERE ARE FOUR BOILERS, EACH WITH
ITS OWN TURBINE GENERATOR. FIVE SINGLE-STAGE SCRUBBERS WERE INSTALLED, WITH THE INTENTION THAT
KNOWLEDGE GAINED FROM THE TEST PROGRAM AT PHILLIPS WOULD BE APPLIED TO ELRAMA TO ENABLE COMPLIANCE
WITH EMISSION REGULATIONS (0.6 LB. S02/MILLION BTU).
THE FIRST ELRAMA SCRUBBER WAS PLACED IN SERVICE ON OCTOBER 26, 1975. IT HAD BEEN SCHEDULED FOR
AN EARLIER STARTUP DATE, BUT BECAUSE OF THE SEVERITY AND NUMBER OF PROBLEMS ENCOUNTERED AT PHILLIPS,
STARTUP WAS DELAYED UNTIL MANY OF THE PROBLEMS AT PHILLIPS WERE RESOLVED AND THE MODIFICATIONS COULD
BE INCORPORATED AT BOTH STATIONS.
THE SCRUBBERS ARE 30 FT DIA X 60 FT HIGH AND LINED WITH CEILCOTE. THE GAS FLOW RATE IS 550,000
ACFM AT 325 F. THE OUTLET GAS TEMPERATURE IS 120 F. THE LIQUID RECIRCULATION RATE IS 16,000 GPM
AND THE SLURRY CONTAINS 3-5X SOLIDS. A PH OF 6 IS MAINTAINED IN THE SCRUBBER. THE I.D. FANS ARE
RUBBER LINED AND HAVE ssoo HP. THE OVERALL PRESSURE DROP is ABOUT 30 IN WG. THE RECIRCULATING
PUMPS ARE 317 L SS, WHEREAS THE INTERCONNECTING PIPING IS RUBBER LINED.
BOILER NO. 2 WAS INITIALLY CONNECTED TO THE FGD SYSTEM ON OCTOBER 26, 1975. THIS BOILER HAS AN
EQUIVALENT CAPACITY OF APPROXIMATELY 100 MW, AND THE EMISSIONS ARE HANDLED BY ONE SCRUBBER. TO
ENSURE RELIABILITY IN THE CASE OF A SCRUBBER MALFUNCTION, TWO SCRUBBERS ARE OPERATED AT PARTIAL LOAD
TO PROTECT THE BOILER AND TURBINE GENERATOR AGAINST A TRIP-OFF.
THE BOILER OPERATED CONTINUOUSLY ON THE SCRUBBER SYSTEM THROUGH JANUARY 1976. TWO MINOR
OUTAGES OCCURRED DURING THIS PERIOD, ONE CAUSED BY INOPERATIVE THROAT DAMPERS AND THE OTHER
INVOLVING FAILURE OF A LIME FEEDER BELT. ON FEB. n, 197&, A SECOND BOILER WAS COUPLED INTO THE
SCRUBBER COMPLEX. PRESENTLY, 2 UNITS ARE THE MAXIMUM THAT CAN BE TIED INTO THE SCRUBBER PLANT. TO
DATE, THE UTILITY HAS ENCOUNTERED THE USUAL MINOR STARTUP PROBLEMS AND SOME MAJOR PROBLEMS AS WELL.
THE MAJOR PROBLEMS HAVE BEEN FROZEN PIPES AND THICKENERS, THE LATTER INVOLVING HARDWARE AND DESIGN
ASSOCIATED WITH RECIRCULATION OF THE SLUDGE WITHIN THE THICKENERS TO ATTAIN 30 TO 40 PERCENT SOLIDS
CONCENTRATION.
THE SLUDGE BEING GENERATED AT THIS STATION IS TREATED BY THE IUCS METHOD, WHICH EMPLOYS A
VACUUM FILTER THAT INCREASES THE SOLIDS IN THE UNDERFLOW TO 50 TO 60 PERCENT, SO THAT LESSER AMOUNTS
OF DRY FLY ASH ARE REQUIRED FOR MIXING WITH THE SLUDGE.
34
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OUOUESNE LIGHT
ELRAMA POWER STATION
PERIOD
OCT. 75
TO
JAN. 76
FEB. 76
MAR. 76
APR. 76
MAY 76
JUN. 76
OPERATING HOURS
BOILER SCRUBBER VESSELS
101 201 301 401
1169
1506 976
501
636
JUL. 76
AUG. 76
SEP. 76
OCT. 76
NOV. 76
DEC. 76
ONE BOILER WAS CONNECTED TO THE SCRUBBER SYSTEM ON
OCTOBER 26, 1975. A SECOND BOILER WAS CONNECTED
ON FEBRUARY 4, 1976. FOUR OF THE SCRUBBER VESSELS
HAVE BEEN IN SERVICE IN VARIOUS COMBINATIONS. THE
SERVICE HOURS TO JANUARY Sli 1974 ARE POSTED IN
THE ACCOMPANYING TABLE. THE FIFTH VESSEL HAS NOT
BEEN IN SERVICE BECAUSE IT IS BEING REVISED FOR
TRIAL INSTALLATION OF RUBBER-LINED RECYCLE PUMPS.
THE SYSTEM OPERATED DURING THE REPORT PERIOD WITH
a BOILERS COUPLED INTO THE SCRUBBING SYSTEM. RE-
VISIONS TO THE FIFTH SCRUBBING VESSEL HAVE BEEN
COMPLETED AND OPERATIONS ARE PROCEEDING WITH TWO
RUBBER-LINED RECYCLE PUMPS.
THE SYSTEM IS STILL OPERATING WITH TWO BOILERS
COUPLED INTO THE SCRUBBING SYSTEM. THE FIFTH
SCRUBBING VESSEL WAS TAKEN OUT OF SERVICE FOR RE-
PAIRS AND MODIFICATIONS REQUIRED FOR THE RUBBER-
LINED RECYCLE PUMPS. THE UTILITY IS CURRENTLY
CONDUCTING A PERFORMANCE TEST ON THE SCRUBBING
SYSTEM IN THE TWO BOILER OPERATION MODE. THE IUCS
SLUDGE FIXATION SYSTEM IS STILL OPERATING AT THIS
STATION.
THE FIFTH SCRUBBING VESSEL EMPLOYING TWO RUBBER-
LINED RECYCLE PUMPS WAS OPERATIONAL FOR A SHORT
PERIOD OF TIME DURING THE REPORTING MONTHS. TWO
BOILERS REMAIN COUPLED INTO THE SCRUBBING SYSTEM.
THE CONSTRUCTION OF ADDITIONAL EQUIPMENT AT THIS
FACILITY IS CONTINUING. ADDITIONAL LIME STORAGE
SILOS AND A THICKENER WILL BE REQUIRED FOR FULL
SCALE OPERATION. THE UTILITY HAS SIGNED A LETTER
OF INTENT WITH lues FOR A LONG-TERM SLUDGE FIX-
ATION SYSTEM. HIGH CALCIUM LIME IS STILL BEING
EMPLOYED IN THE SCRUBBING SYSTEM.
OPERATIONS AT THIS STATION DURING THE REPORT
PERIOD PROCEEDED WITH TWO BOILERS COUPLED INTO
THE 5-MODULE SCRUBBING SYSTEM. THE 5TH SCRUBBING
VESSEL WAS OPERATIONAL DURING THE REPORT PERIOD
WITH THE RUBBER-LINED RECYCLE PUMPS IN SERVICE.
TESTS WERE CONDUCTED DURING THE PERIOD TO DETER-
MINE PARTICULATE AND S02 REMOVAL EFFICIENCIES.
S02 REMOVAL EFFICIENCY WAS 50 PERCENT. PARTICU-
LATE EMISSIONS WERE BEING REDUCED WELL BELOW
0.1 LB/MM BTU STANDARD (ACTUAL RESULTS : 0.01
LB/MM BTU). THESE RESULTS WERE BASED ON 2 BOILERS
COUPLED INTO THE 5 SCRUBBING MODULES WHILE BURNING
MEDIUM-SULFUR (1.0 TO 2.8 PERCENT) COAL. THE
MECHANICAL COLLECTORS AND ESP'S WERE IN SERVICE
DURING THE TESTS. OPERATIONS ARE STILL PROCEEDING
ON AN OPEN WATER-LOOP BASIS. PART OF THE THICKEN-
ER OVERFLOW IS STILL BEING DIVERTED TO THE ASH
POND AND NOT RECYCLED BACK TO THE PROCESS. BE-
CAUSE BOTH THE BEAVER VALLEY AND BRUCE MANSFIELD
STATIONS ARE FULLY OPERATIONAL, THIS STATION HAS
BEEN RELEGATED TO PEAK LOAD OPERATIONS. GENERAL
LOAD OPERATIONS ARE FULL LOAD CAPACITY IN THE
DAYTIME AND 50 TO 60 PERCENT LOAD REDUCTION AT
NIGHT.
THE SCRUBBER REMAINED IN SERVICE THROUGHOUT THE
REPORT PERIOD WITH TWO BOILERS COUPLED INTO THE
SCRUBBING SYSTEM. RECYCLE PUMP EVALUATION IS
BEING CONDUCTED BY THE UTILITY AT BOTH THE PHIL-
LIPS AND ELRAMA STATIONS. OBSERVATIONS OF THE
RUBBER-LINED RECYCLE PUMPS INDICATE SOME SEVERE
ABRASION AND GOUGING HAVE OCCURRED AFTER 1000
HOURS OF SERVICE TIME.
35
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DUQUESNE LIGHT ELRAMA POWER STATION
OPERATING HOURS
PERIOD BOILER SCRUBBER VESSELS
101 201 301 401 501
77 THE SCRUBBER PLANT CONTINUED OPERATIONS DURING THE
77 REPORT PERIOD WITH TWO BOILERS COUPLED INTO THE
MAR. 77 SYSTEM. TESTING ON THIOSORBIC LIME WAS CONDUCTED
DURING THE PERIOD. INSTALLATION OF THE ADDITIONAL
THICKENER, LIME FEEDERS AND SILOS IS STILL IN
PROGRESS, FULL COMPLIANCE OPERATION FOR THIS
STATION IS SCHEDULED FOR EARLY 1978. THE FULL
COMPLIANCE STRATEGY WILL CONSIST OF THE FOLLOWING:
83X 803 REMOVAL FOR ax SULFUR COAL UTILIZING
THIOSORBIC LIME C6-13X MG), FIXATING THE SCRUBBER
SLUDGE WITH THE IUCS POZ-0-TEC STABILIZATION
METHOD AND HAULING THIS MATERIAL TO AN OFF-SITE
DISPOSAL/LANDFILL AREA. CURRENT 303 AND PARTICU-
LATE REMOVAL EFFICIENCIES ARE 50 AND 99 + X, RE-
SPECTIVELY. THE INTERIM IUCS UNIT NOW IN SERVICE
CONSISTS OF THE OLD MOHAVE PROTOTYPE PLUS A
VACUUM FILTER. THE STABILIZED MATERIAL HAS BEEN
UTILIZED IN A PARKING LOT CONSTRUCTION PROJECT.
IUCS HAS BEEN AWARDED A 10-YEAR CONTRACT FOR THE
CONTINUED USE OF THIS SYSTEM FOR FUTURE PLANT
OPERATIONS.
APR. 77 CONSTRUCTION OF TWO 120-FOOT DIAMETER THICKENERS
MAY 77 IS CONTINUING. DUE TO THE GOUGING OF THE RUBBER-
LINED RECYCLE PUMPS DURING THEIR TESTINGf THEY
HAVE BEEN REMOVED. THE UTILITY IS CONSIDERING
TRYING ANOTHER SET OF RUBBER-LINED PUMPS.
DUOUESNE LIGHT ALSO IS CONTINUING EFFORTS TO
OBTAIN ALTERNATE LANDFILL AREAS FOR SLUDGE DIS-
POSAL.
JUN. 77 DUQUESNE LIGHT REPORTED THE FOLLOWING ITEMS FOR
JUL. 77 THE ELRAMA SCRUBBER PLANT DURING THE REPORT PERIOD
* TWO BOILERS (300 MW) WERE COUPLED INTO THE
SCRUBBER PLANT.
* THE INTERIM IUCS STABILIZATION UNIT (MOHAVE
PROTOTYPE) CONTINUED TO FIXATE SCRUBBER
WASTES.
* CONSTRUCTION OF THE TWO ADDITIONAL THICKENERS
CONTINUED (CONSTRUCTION IS ON SCHEDULE).
* FULL PLANT COMPLIANCE IS PROJECTED FOR FEB-
RUARY 1978.
* S02 REMOVAL EFFICIENCY IS APPROXIMATELY 50*.
* ELRAMA IS OPERATING IN A BASE/INTERMEDIATE
LOAD MODE (FULL LOAD DAYTIME/HALF LOAD NIGHT-
TIME). 1976 CAPACITY FACTOR WAS 69.5X.
AUG. 77 DURING THE REPORT PERIOD:
SEP. 77 * THE TWO ADDITIONAL THICKENERS WERE COMPLETELY
INSTALLED.
* THE IUCS SYSTEM WAS UPGRADED.
* END OF CONSTRUCTION IS PROJECTED FOR FEBRUARY
1978.
* FULL PLANT COMPLIANCE IS PROJECTED FOR APRIL
1978.
OCT. 77 MODULE 101 rtAS UNAVAILABLE OCTOBER 4 DUE TO
A BLEED VALVE LEAK AND WAS TAKEN OUT OF SER-
VICE AT THE END OF THE MONTH FOR CLEANUP.
MODULE aoi WAS AVAILABLE FOR THE COMPLETE
MONTH. MODULE 301 AND 401 HAD OUTAGES IN
OCTOBER DUE TO RUBBER LINING FAILURE ON I.D.
FAN. MODULE 501 HAD RECYCLE PUMP OUTAGES IN
LATE NOVEMBER.
* NEW RUBBER LINED WORMEN RECYCLE PUMPS WERE
INSTALLED.
* LIME HANDLING SYSTEM INSTALLATION CONTINUES.
* TUBE LEAKS FORCED BOILER OUTAGE IN NOVEMBER.
* LAST TWO BOILERS EXPECTED TO TIE INTO FGD
36
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DUOUESNE LIGHT ELRAMA POWER STATION
101 201 301 401 501 SYSTEMS IN JANUARY 1978.
OPERATING HOURS
PERIOD BOILER SCRUBBER VESSELS
101 201 301 401 501
NOV. 77 0 64 672 162 426 MODULE 101, 201 AND 401 HAVE LOW OPERATIONAL HOURS
BECAUSE ONLY 2 BOILERS ARE TIED INTO F6D SYSTEM TO
DATE. THE SLUDGE HANDLING SYSTEM IS WORKING WELL.
DEC. 77
JAN. 78
SCRUBBER HOURS WERE NOT REPORTED BY THE UTILITY FOR THIS PERIOD. HOWEVERi THEY WILL BE AVAIL-
ABLE FOR THE NEXT UPDATE.
DURING THE PERIOD A NEW WORMER RECYCLE PUMP INSTALLED IN NOVEMBER EXPERIENCED JACK SHAFT
BEARING PROBLEMS RESULTING IN THE REMOVAL OF SCRUBBER TRAIN 501 FROM SERVICE. BOILER NO. 4
WAS CONNECTED ADDING AN ADDITIONAL 176 MW TO THE FGD SYSTEM. THE IUCS SLUDGE DISPOSAL
FACILITY IS IN SERVICE PRODUCING GOOD PRODUCT. LOW LOAD AND COAL STRIKE HAVE HAMPERED GOOD
SCRUBBER OPERATIONS. THERE IS SOME OUTAGE TIME SCHEDULED FOR MARCH.
37
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
DUOUESNE LIGHT
PHILLIPS POWER STATION
SOUTH HEIGHT PENNSYLVANIA
410 MW
COAL 1.0- S.8 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
RETROFIT
7/73
OPERATIONAL
99 PERCENT
S02
MATER MAKE UP
83 PERCENT DESIGN - 2X S COAL
OPEN LOOP
SLUDGE DISPOSAL
HAULAWAY TO OFF SITE LANDFILL
UNIT COST
OPERATIONAL
EXPERIENCE
SEE APPENDIX A, FGD SYSTEM ECONOMICS
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS SCRUBBING SYSTEM HAS BEEN IN SERVICE SINCE JULY 1973. ALL 6 BOILERS
ARE COUPLED INTO THE SCRUBBING SYSTEM. THE PLANT FIRES COAL WITH A HEAT-
ING VALUE Of HiOOO BTU/LB AND ASH AND SULFUR CONTENTS OF 31 PERCENT AND
1.0 - 2.8 PERCENT, RESPECTIVELY. DEWATERED SLUDGE FROM THE IUCS INTERIM
PROCESSING PLANT IS BEING HAULED TO AN OFF-SITE LANDFILL. THE SLUDGE
CONTAINS NO FIXATIVE.
38
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BACKGROUND INFORMATION
ON
PHILLIPS POWER STATION
THE PHILLIPS POWER STATION IS LOCATED ON THE OHIO RIVER ABOUT £0 MILES NORTHWEST OF PITTSBURGH.
THE POWER STATION CONSISTS OF SIX COAL-FIRED BOILERS HAVING A NET GENERATING CAPABILITY OF 387 MW.
THE RESULTANT FLUE GASES ARE DISCHARGED TO A COMMON HEADER, TO WHICH THE FGD MODULES ARE CONNECTED
THROUGH ISOLATION VALVES. THE BOILERS ARE CURRENTLY BUKNING COAL WITH A HEATING VALUE OF 11,350 BTU
PER POUND AND SULFUR AND ASH CONTENTS OF Z.Z AND 18.2 PERCENT, RESPECTIVELY.
THE FGD SYSTEM, WHICH SUPPLEMENTS THE EXISTING MECHANICAL AND ELECTROSTATIC OUST COLLECTORS,
CONSISTS OF FOUR TRAINS OF WET VENTUR1-TYPE SCRUBBERS, INSTALLED AT A COST OF APPROXIMATELY S103/KW.
GIBBS & HILL., WAS ENGAGED AS THE A-E FIRM FOR THE ENTIRE PROJECT. BATTERY LIMITS OF THE CHEMICO
CORPORATION ARE CONFINED TO THE SCRUBBERS AND ASSOCIATED PUMPS AND CONTROLS BETWEEN THE INLET HOT
GAS DUCT MANIFOLD AND THE EXIT WET GAS HEADER (INCLUDING THE REHEATER, EXCLUDING THE NEW ID FANS).
THE FOUR TRAINS ARE LOCATED DOWNSTREAM OF EXISTING MECHANICAL COLLECTORS AND ESP'S INSTALLED IN
SERIES ON EACH OF THE SIX PULVERIZED-COAL-FIRED BOILERS. THREE OF THE TRAINS ARE SINGLE-STAGE
VENTURI SCRUBBERS ORIGINALLY INTENDED FOR PARTICULATE REMOVAL. THE FOURTH TRAIN IS A DUAL-STAGE
VENTURI SCRUBBER-ABSORBER AND IS THE PROTOTYPE FOR DETERMINING THE FEASIBILITY OF TWO-STAGE SCRUB-
BING FOR COMPLIANCE WITH SULFUR DIOXIDE EMISSION LIMITS. A DIAGRAM OF THE SCRUBBER-ABSORBER TRAIN
INSTALLED AT THE PHILLIPS STATION IS PRESENTED IN APPENDIX B.
EACH TRAIN IS EQUIPPED WITH A NEW WEI-TYPE ID FAN. A NEW COMMON DUCT DIRECTS GAS STREAMS FROM
AIR BOILERS TO THE SCRUBBER SYSTEM, WHERE THEY CAN BE SENT TO ANY OR ALL OF THE TRAINS. THE SCRUB-
BED GAS IS EXHAUSTED THROUGH A COMMON DUCT AND AN OIL-FIRED REHEATER TO A NEW GROUND-SUPPORTED
STACK WHICH CONTAINS AN ACID-RESISTANT BRICK LINER.
SLAKED QUICKLIME IS ADDED TO THE LOWER CONE OF EACH OF THE SCRUBBER VESSELS TO NEUTRALIZE THE
RECIRCULATING LIQUOR, WHICH, IN SINGLE-STAGE SCRUBBING WITH HIGH-CALCIUM LIME, REACTS WITH APPROX-
IMATELY 50 PERCENT OF THE SULFUR DIOXIDE IN THE FLUE GAS. A LIQUOR BLEED FLOW OF APPROXIMATELY 4
PERCENT IS SENT TO ONE OR BOTH OF THE THICKENERS FOR REMOVAL OF SOLIDS. THE OVERFLOW IS RETURNED TO
THE SYSTEM AND THE UNDERFLOW IS DISCHARGED TO THE IUCS SLUDGE FIXATION SYSTEM. THIS INTERIM SLUDGE
FIXATION SYSTEM COMMENCED OPERATIONS IN DECEMBER 1976. THE FACILITY INCLUDES DEWATERING .EQUIPMENT
AND FLY ASH ADDITION EQUIPMENT (COLLECTED FROM THE ESP). THE FIXATED MATERIAL IS THEN HAULED AWAY
TO AN OFF-SITE LANDFILL AREA.
FLUE GASES FROM THE BOILERS ARE ACCELERATED TO A HIGH VELOCITY IN THE SCRUBBER. AT THE THROAT,
THE GASES COLLIDE WITH THE SCRUBBING LIQUID, ATOMIZING IT INTO SMALL DROPLETS. THE FLY ASH AND THE
SULFUR DIOXIDE IN THE GAS ARE REMOVED BY THE SLURRY DROPLETS AND EXIT AT THE BASE OF THE TOWER. THE
GAS THEN REVERSES DIRECTION AND FLOWS UP THROUGH THE MIST ELIMINATOR, WHERE FINE DROPLETS ARE REMOV-
ED BEFORE THE GAS LEAVES THE SCRUBBER.
STARTUP OF A PORTION OF THE PHILLIPS SCRUBBER SYSTEM BEGAN JULY 1973. SEVERAL PROBLEMS THEN
DEVELOPED IN THE FORM OF EROSION OF FANS AND THE LIME FEED SYSTEM, CAUSING OUTAGES OF THE SCRUBBER
SYSTEM. AFTER AN EXTENDED OUTAGE, THE SCRUBBER SYSTEM WAS RETURNED TO SERVICE IN MARCH 1974. THE
SYSTEM HAS BEEN OPERATING CONTINUOUSLY SINCE THAT TIME WITH VARIOUS NUMBERS OF BOILERS CONNECTED TO
THE SCRUBBER SYSTEM AND SCRUBBER TRAINS IN SERVICE.
DETERMINATION OF THE AVAILABILITY OF THE PHILLIPS SYSTEM HAS BEEN DIFFICULT. UNTIL ALL BOILERS
WERE CONNECTED TO THE SCRUBBERS, THERE WAS AT LEAST ONE SPARE TRAIN AND AS MUCH AS 100 PERCENT SPARE
SCRUBBER CAPACITY. THEREFORE, HAVING A TRAIN OUT OF SERVICE FOR MAINTENANCE DID NOT REDUCE THE CAP-
ABILITY OF THE SCRUBBER SYSTEM. UNTIL ALL SIX BOILERS WERE CONNECTED, MEANINGFUL AVAILABILITY
FACTORS COULD NOT BE COMPUTED. ON MARCH 17, 1975, THE SIXTH BOILER WAS CONNECTED, AND ALL FOUR
SCRUBBER TRAINS WERE REQUIRED TO BE IN SERVICE. OPERATION IN THAT MODE CONTINUED UNTIL AUGUST 4,
1975, WHEN THE NO. 6 BOILER WAS REMOVED FROM THE SCRUBBER SYSTEM BECAUSE THE PH LEVEL COULD NOT 8E
MAINTAINED AND DEPOSITS BECAME UNMANAGEABLE TO THE POINT THAT SCRUBBER OUTAGES WERE REDUCING GENERA-
TING CAPABILITY OF THE STATION. ADDITIONAL INFORMATION AND DATA ON SUBSEQUENT BOILER AND SCRUBBER
PLANT OPERATIONS ARE PROVIDED IN A CHRONOLOGICAL FASHION IN THE TABLE THAT FOLLOWS.
39
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DUQUESNE LIGHT PHILLIPS POWER STATION
OPERATING HOURS
BOILER SCRUBBER-ABSORBER
MONTH 2 2 3 a 5 6 101 201 301 401
JUL. 75 83 644 703 319 605 643 400 180 531 723
FOURTH FGD TRAIN AND SIXTH BOILER WERE TIED IN ON MARCH 17, 1975. PARTICIPATE TESTS IN MAY
SHOWED OUTLET LOADINGS OF 0.04 LB/MILLION BTU. THE TWO-STAGE TRAIN HAS BEEN OUT OF SERVICE
FROM JUNE 19 FOR GENERAL CLEANING AND REPAIR OF A LEAK IN THE FIRST-STAGE SCRUBBER.
AUG. 75 354 701 454 457 517 445 478 682 323 319
SCRUBBER UNAVAILABILITY FORCED RETURNING BOILER NO. 6 TO THE SCRUBBER BYPASS GAS PATH TO
PREVENT LOSS OF BOILER CAPACITY. PLUGGING AND MAINTENANCE PROBLEMS HAVE BEEN ENCOUNTERED.
EVALUATION OF VARIOUS RECYCLE PUMPS IS CONTINUING.
SEP. 75 463 287 669 503 672 525 57 561 685 536
OCT. 75 547 575 620 604 681 687 607 207 505 487
IN OCTOBER 1975, PHILLIPS INITIATED THIOSORBIC LIME SCRUBBING IN THEIR SINGLE-STAGE MODULES
ON AN EXPERIMENTAL BASIS. THE PURPOSE IS TO STUDY COMPLIANCE FEASIBILITY, S02 REMOVAL
EFFICIENCY, AND OUALITY OF THE SLUDGE GENERATED BY THE SINGLE-STAGE MODULES.
NOV. 75 16 720 688 70 720 593 626 720 0 75
DEC. 75 172 660 709 0 689 547 360 661 182 386
THE UTILITY CONCLUDED THE THIOSORBIC LIME TESTING PROGRAM IN MID-DECEMBER. FOUR BOILERS WERE
COUPLED TO THE SCRUBBING SYSTEM DURING THE RUN. THE UTILITY IS NOW ANALYZING THE DATA
GENERATED DURING THE TEST PROGRAM. THE SCRUBBERS HAVE BEEN PUT BACK ON REGULAR LIME. NO
UNUSUAL PROBLEMS WERE ENCOUNTERED DURING THE TEST RUN.
JAN. 76 222 722 639 0 662 661 277 536 101 707
THE 2.5-MONTH TEST PROGRAM WITH THIOSORBIC LIME INCLUDED 1612 HOURS ON ONE TRAIN AND 1309
HOURS ON ANOTHER TRAIN. RESULTS INDICATE THAT THE REQUIRED DEGREE OF S02 REMOVALC83 PERCENT)
CAN BE OBTAINED WITH AN MGO CONTENT OF 6-10 PERCENT IN THE LIME WITH SINGLE-STAGE SCRUBBING.
FEB. 76 445 588 672 0 633 571 657 662 166 406
MAR. 76 695 353 659 461
APR. 76
PLANT OPERATION IS PROCEEDING WITH A TOTAL OF 4 BOILERS COUPLED INTO THE SCRUBBING SYSTEM
(EQUALING 336 MW, WHICH IS 87 PERCENT OF THE TOTAL PLANT CAPACITY). THE FGD SYSTEM OPERATED
ON HIGH CALCIUM LIME DURING THE REPORT PERIOD. THE GENERAL OPERATION MODE AT THIS FACILITY
HAS ONE OF THE FOUR SCRUBBING TRAINS OUT CONTINUALLY FOR REPAIRS, CLEANING, AND PREVENTIVE
MAINTENANCE. THE UTILITY IS STILL EXPERIENCING PROBLEMS WITH SOLIDS DEPOSITION IN THE
VENTURI THROAT OF THE SCRUBBING MODULE, CAUSING MOVEMENT INHIBITION AND GREATER PRESSURE
DROPS. THE FGD SYSTEM AVAILABILITY FOR THE FIRST QUARTER OF 1976 WAS 72 PERCENT. THE SLUDGE
STABILIZATION PRACTICES ARE STILL CONTINUING AT THIS FACILITY.
MAY 76
JUN. 76
REDUCED LOAD OPERATIONS WERE REPORTED BY THE UTILITY FOR THE MAY-JUNE PERIOD BECAUSE OF A
SCHEDULED TURBINE OVERHAUL TO UNIT NO.6. THE SCRUBBING SYSTEM WAS SHUT DOWN ON JUNE 27 FOR A
SCHEDULED FOUR WEEK REPAIR PERIOD. THE MAJORITY OF THE WORK WILL BE CONCENTRATED ON THE
STACK, ASSOCIATED DUCTWORK AND BOILER DAMPERS. ALSO, THE UTILITY IS PROCEEDING WITH THE
INSTALLATION OF 3 ADDITIONAL LIME STORAGE SILOS AND A THIRD THICKENER.
JUL. 76
AUG. 76
THE 4-WEEK SYSTEM OVERHAUL WAS COMPLETED JULY 25. DURING THIS PERIOD, THE FOLLOWING REPAIRS
AND MODIFICATIONS WERE MADE!
•REPAIR OF THE TURNING VANES TO THE SCRUBBER DEMISTER.
•REPAIR OF THE EXPANSION JOINT SEAL WHERE THE DUCTWORK TIES INTO THE MAIN STACK.
•REPAIR OF STEEL BANDS AROUND INNER STACK STRUCTURE.
•OVERHAUL OF I.D. FANS.
•REPAIR OF BOILER EXIT DAMPERS.
•REPAIR LEAKAGE OF THE ACID-BRICK LINING IN THE MAIN STACK.
THE THREE ADDITIONAL LIME STORAGE SILOS AND THE FOUNDATION FOR THE ADDITIONAL 75-FOOT
DIAMETER THICKENER HAVE BEEN INSTALLED. THE UTILITY HAS SIGNED A LETTER-OF-INTENT WITH IUC3.
FOR A LONG-TERM SLUDGE TREATMENT SYSTEM.
40
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OUQUENSE LIGHT
PHILLIPS POWER STATION
OPERATING HOURS
MONTH
SEP. 76
BOILER
a 3
SCRUBBER-ABSORBER
101 201 301 401
OCT. 76
BOILER NOS. 2-6 WERE COUPLED INTO THE SCRUBBING SYSTEM. BOILER NO. 1 IS DOWN FOR OVERHAUL
AND REPAIRS. THE IUCS INTERIM SLUDGE PROCESSING PLANT IS UNDER CONSTRUCTION AND WILL BE IN
SERVICE BY DECEMBER 1976. THE TEMPORARY FACILITIES WILL PROCESS THE THICKENER UNDER FLOW AND
PONDED SLUDGE UNTIL THE POND IS DEPLETED OF SLUDGE AND THE PERMANENT FACILITY HAS BEEN
INSTALLED. SCRUBBING OPERATIONS ARE STILL PROCEEDING IN AN OPEN-WATER-LOOP MODE WITH PART OF
THE THICKER OVERFLOW BEING DIVERTED TO THE ASH POND. BECAUSE BOTH THE BEAVER VALLEY AND
BRUCE MANSFIELD STATIONS ARE FULLY OPERATIONAL, THIS STATION HAS BEEN RELEGATED TO PEAK LOAD
OPERATIONS. GENERAL LOAD OPERATIONS ARE FULL LOAD CAPACITY IN THE DAYTIME AND 50 TO 67
PERCENT LOAD REDUCTION AT NIGHT.
TOTAL SCRUBBER HOURS; 23,274
TOTAL BOILER HOURS; 83,642
TOTAL SCRUBBER OUTAGE TIME; 5,500
TOTAL SCRUBBER AVAILABILITY HOURS;
23,274
AVERAGE MW LOAD/ SCRUBBER OPERATION
HOUR; 243
TOTAL OPERABILITY INDEX; 28 PERCENT
TOTAL RELIABILITY INDEX; ei PERCENT
THE FIGURES IN THE LEFT-HAND COLUMNS HAVE BEEN
COMPILED BY THE UTILITY FOR SYSTEM OPERATIONS FOR
THE PERIOD FOLLOWING START-UP IN JULY 1973
INCLUSIVE TO OCTOBER 1976. THE TOTAL SCRUBBER
HOURS VALUE INCLUDE OPERATION TIME WHEN ONE OR
MORE OF THE MODULES WERE IN SERVICE. TOTAL BOILER
AND UNAVAILABILITY VALUES APPLY FOR ALL THE COR-
RESPONDING UNITS. THE TOTAL SCRUBBER AVAILABILITY
INDEX INCLUDES THE TIME WHEN ONE OR MORE MODULES
WERE AVAILABLE FOR SERVICE.
NOV. 76
DEC. 76
THE UTILITY REPORTS THAT BOILERS 2-b REMAINED COUPLED INTO THE SCRUBBING SYSTEM DURING THE
REPORT PERIOD. THE INTERIM IUCS FIXATION FACILITY WAS INSTALLED AND COMMENCED OPERATIONS
IN DECEMBER. THE UTILITY REPORTS THAT THE VENTURI SCRUBBERS AHE STILL DEVELOPING LARGE
AMOUNTS OF SCALE ON THE INTERNALS, RESULTING IN TWICE NORMAL PRESSURE DROPS. THE RECYCLE
PUMP EVALUATION HAS BEEN IN PROGRESS. APPROXIMATELY 2500 TO 2800 HOURS OF OPERATION TIME
HAVE BEEN ACCUMULATED ON THE VARIOUS UNITS WITH NO FAILURES OH APPRECIABLE WEAR OBSERVED.
THE ADDITIONAL OEWATERING AND REAGENT PREPARATION EQUIPMENT IS NOW BEING INSTALLED. THE
CONTRACT HAS BEEN AWARDED TO DRAVO TO PROVIDE THIOSORBIC LIME FOR THIS SCRUBBING SYSTEM. ALL
BOILERS HAVE BEEN HEADERED INTO THE SCRUBBER PLANT. A NUMBER OF THE UNITS WERE DOWN FOR
OVERHAUL AND REPAIR THE INTERIM IUCS POZ-0-TEC UNIT REMAINED IN SERVICE, FILTERING OUT WATER
ONLY. THE RECYCLE PUMP EVALUATION IS CONTINUING. AFTER 4000 HRS. OF OPERATION. THE CARBOR-
UNDUM IMPELLERS AND WEAR RINGS STILL LOOK GOOD. S02 AND PARTICULATE REMOVAL EFFICIENCIES
ARE 50 & 99 + X RESPECTIVELY. INSTALLATION OF THE ADDITIONAL SILOS, THICKENERS, AND LIME
FEEDERS IS STILL IN PROGRESS. FULL COMPLIANCE PLANT OPERATIONS ARE SCHEDULED FOR DEC.
JAN. 77
FEB. 77
MAR. 77
1977 FULL COMPLIANCE OPERATIONS WILL INCLUDE 83X S02 REMOVAL FOR 2X SULFUR COAL UTILIZING
THIOSORBIC LIME (6-12XMG) & FIXATING THE SCRUBBER WASTES WITH THE IUCS POZ-0-TEC METHOD.
THE FIXATED MATTER WILL BE HAULED AWAY TO AN OFF-SITE DISPOSAL AND LANDFILL. IUCS HAS BEEN
AWARDED A 10 YEAR CONTRACT FOR THE USE OF THIS METHOD. THE CARBORUNDUM IMPELLORS AND WEAR
RINGS CONTINUE TO LOOK GOOD AFTER MORE THAN 5000 HOURS OF OPERATION.
APR. 77
MAY. 77
THIOSORBIC LIME TESTS BEGAN IN LATE MAY BUT LASTED ONLY ABOUT ONE WEEK. THE SCRUBBER SYSTEM
WAS SHUT DOWN FOR 3 TO 4 DAYS IN MAY DUE TO LEAKING IN THE WET DUCT HEADER THAT LEADS TO THE
STACK. WHILE FIXING THE LEAK, INSPECTION OF OTHER COMPONENTS REVEALED THAT THE BOILER EXIT
DAMPERS WERE ERODING. ONE 201 EXTERNAL MIST ELIMINATOR ALSO WAS SEVERLY ERODED AND PLUGGED
ONCE THE LEAK TO THE HEADER WAS REPAIRED, FLUE GAS FROM FOUR BOILERS BEGAN TO BE SCRUBBED.
TWO OF THE SIX BOILERS ARE DOWN FOR MAINTENANCE. THE DAMPERS AND MIST ELIMINATOR REPAIRS
WILL BE CORRECTED AT A SCHEDULED OUTAGE TIME. OVERALL SCRUBBER AVAILABILITY IS ABOUT 75 PER-
CENT. THE INTERIM SLUDGE DISPOSAL SYSTEM STILL IS OPERATIONAL. THE PERMANENT SLUDGE DISPOSAL
FACILITY IS ON SCHEDULE FOR THE DECEMBER 1977 COMPLETION DATE.
JUN. 77
JUL. 77
ALL 6 BOILERS ARE COUPLED INTO THE SCRUBBER PLANT. FLUE GAS FROM 5 OF THESE UNITS IS BEING
TREATED BY THE SCRUBBERS. UNIT NO. 6 HAS BEEN DOWN FOR AN EXTENDED TURBINE REPAIR OUTAGE.
-------
DUQUENSE LIGHT
PHILLIPS POWER STATION
MONTH
1
BOILER
3
OPERATING HOURS
SCRUBBER-ABSORBER
101 201 301 401
DEC.
JAN.
OPERATIONS ARE PROCEEDING WITH ONE SCRUBBING TRAIN BEING SPARED AT ALL TIMES (MAINTENANCE
AND CLEANOUT). S02 REMOVAL EFFICIENCY IS APPROXIMATELY SOX. THE RECYCLE PUMP EVALUATION
STUDY CONTINUED DURING THE PERIOD. COMPONENTS BEING EVALUATED INCLUDE* CARBORUNDUM IMPELLERS,
CARBORUNDUM WEAR RINGS, TITANIUM IMPELLERS, 31733 WEAR RINGS STELLITE TIPPED. A THIOSORBIC
LIME TEST WAS PREMATURELY TERMINATED BECAUSE OF SOME MINOR SLAKER/FEEDER PROBLEMS. HIGH
CALCIUM VIRGIN LIME WAS UTILIZED DURING THE MAJORITY OF OPERATIONS THROUGHOUT THE PERIOD.
ONLY 4 OF THE 6 BOILERS ARE OPERATING AS THE TURBINE REPAIR OUTAGE CONTINUES.
AUG. 77
SEP. 77
OCT. 77
NOV. 77
LIME HANDLING AND SOLID WASTE DISPOSAL FACILITIES WERE BEING SCALED UP TO HANDLE FULL
CAPACITY AND A THIRD THICKENER WAS INSTALLED AND BROUGHT INTO SERVICE DURING THIS REPORT
PERIOD. THE IUCS SYSTEM IS IN THE INTERIM PHASE. WASTE WATER IS BEING MIXED WITH FLYASH AND
DISPOSED OF. CURRENT CONSTRUCTION WORK IS EXPECTED TO BE COMPLETED 6Y THE END OF JANUARY
WHEN ALL b BOILERS WILL BE BACK ON LINE FOR A TWO MONTH TEST PERIOD. THIOSORBIC LIME IS
STILL BEING TESTED. RESULTS ARE NOT YET AVAILABLE. THE FGD SYSTEM WILL BE DOWN FOR THE
FIRST WEEKEND OF NOVEMBER. THE SYSTEM WILL ALSO BE CHECKED FOR MAIN DUCT LEAKS AT THIS TIME.
ALSO THE SCRUBBER AND STACK LININGS AND RECYCLE PUMPS WILL BE THOROUGHLY CHECKED. NECESSARY
REPLACEMENTS AND REPAIRS WILL BE CARRIED OUT. CURRENT S02 REMOVAL EFFICIENCY IS 50 PERCENT.
BY EARLY APRIL THE SYSTEM IS EXPECTED TO REACH COMPLIANCE WITH AN S02 EFFICIENCY OF 83
PERCENT.
r
MODULE 101 WAS DOWN A TOTAL OF 113 HOURS IN OCTOBER. MODULE 201 WAS PUT IN SERVICE ON
OCTOBER 26 AFTER EXTENSIVE CLEAN UP AND REPAIRS TO RUBBER LINING AND I.D. FAN. MODULE 301
WAS DOWN A TOTAL OF 57 HOURS IN OCTOBER. MODULE aoi WAS DOWN A TOTAL OF 36 HOURS IN OCTOBER
FOR REPAIRING HOLES IN FAN LINING AND TYING IN THICKENER BLEED LINE.
1
DURING SHUTDOWN OUTLET DUCT LEAKS WERE REPAIRED. BOILER EXIT DAMPERS WERE REPLACED DUE TO
EROSION BY FLYASH. CORROSION OF STEEL BANDS IN STACK WAS ALSO NOTICED. DEWATERING OPERATIONS
ARE NOT WORKING PROPERLY, CAUSING PROBLEMS IN SLUDGE HANDLING. THE RESULTS FROM THIOSORBIC
LIME USE CAN NOT YET BE QUANTIFIED DUE TO LIME FEED SYSTEM PROBLEMS.
22391 20996
AN OVERHAUL FROM NOV.
22229 22259
17 TO MONDAY 2-6-78 WHEN IT RETURNED TO
77
77 (CUMULATIVE HRS. THRU 1-8-78)
SCRUBBER TRAIN 301 WAS DOWN FOR
SERVICE.
SCRUBBER TRAIN 401 WAS REMOVED FROM SERVICE ON THE 6TH OF FEBRUARY.
THE IUCS INTERIM SLUDGE TREATMENT SYSTEM HAS HAD SOME DEWATERING PROBLEMS. DURING DECEMBER
PHILLIPS EXPERIENCED POOR SLUDGE REMOVAL. THE IUCS PLANT IS WORKING ON A PART TIME BASIS.
FULL OPERATIONS ARE EXPECTED LATE THIS SPRING.
THE POOR QUALITY SLUDGE IS SENT TO AN EMERGENCY POND AND THEN RECIRCULATED BACK TO THE THICK-
ENER BUT THIS CAUSES A WATER UNBALANCE IN THE SYSTEM.
TESTING WITH THIOSORBIC LIME i> 5» MGO HAS SHOWN THAT THE MGO CONCENTRATION IS NOT GREAT
ENOUGH TO EFFECT ADEQUATE 802 REMOVAL ON A SINGLE STAGE SCRUBBER. THEY ARE GOING TO TEST AT
A GREATER MGO CONCENTRATION BY STARTING AT 10X AND THEN DROPPING BACK UNTIL THE CONCENTRATION
IS SATISFACTORY. THIS TESTING, AS WELL AS SCRUBBER OPERATIONS, HAVE, HOWEVER, BEEN HAMPERED
BY LOW LOADS AS A RESULT OF THE COAL STRIKE.
THERE WILL BE AN OUTAGE AT PHILLIPS TO REPLACE THE CARBON STEEL BANDS WITH STAINLESS STEEL
BANDS.
42
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
INDIANAPOLIS POWER & LIGHT CO.
PETERSBURG NO 3
PETERSBURG INDIANA
530 MW
COAL 3.0-3.5 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
NEW
10/77
OPERATIONAL
99.3 PERCENT
S02
60 PERCENT (DESIGN)
WATER MAKE UP
SLUDGE DISPOSAL
IUCS SLUDGE STABILIZATION
UNIT COST
SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
INDIANAPOLIS P & L HAS AWARDED A CONTRACT TO UNIVERSAL OIL PRODUCTS FOR A
WET LIMESTONE SCRUBBING S02 CONTROL SYSTEM. AN ESP PROVIDES PRIMARY PAK-
TICULATE CONTROL. THE UNIT FIRES BITUMINOUS COAL WITH A SULFUR CONTENT
OF 3.0-3.5X, AN ASH CONTENT OF 9-10X, AND A HEAT CONTENT OF UrOOO
BTU/LB. THE FOUR MODULES OPERATED FOR 2« HOURS IN MID-DECEMBER FOR
EQUIPMENT TESTING. THE SCRUBBERS WERE TAKEN OUT OF SERVICE SO THAT SOME
FINAL ADJUSTMENTS COULD BE MADE. SCRUBBERS ARE EXPECTED TO BE BACK IN
SERVICE BY EARLY MARCH 1978.
43
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BACKROUND INFORMATION ON
PETERSBURG NO. 3
THE PETERSBURG POWER STATION, OWNED AND OPERATED BY THE INDIANAPOLIS POWER AND LIGHT COMPANY
(IPALCO), IS LOCATED NEAR PETERSBURG, INDIANA, APPROXIMATELY 100 MILES SOUTHWEST OF INDIANAPOLIS.
THE STATION CONSISTS OF THREE COAL-FIRED, STEAM-TURBINE, GENERATING UNITS, WHICH HAVE A COMBINtU
POWER GENERATING CAPACITY OF 1180 MN. UNIT 1 IS RATED AT 320 MW, UNIT 2 AT 430 MW, AND UNIT 1 Al
530 MW. THE UTILITY IS PLANNING THE INSTALLATION OF ANOTHER 530-MW UNIT, WHICH IS SCHEDULED TO Bt
IN SERVICE BY APRIL 1982. UNIT 4 WILL BRING THE STATION'S COMBINED POWER GENERATING CAPACITY TO
1710 MW. OF THE THREE OPERATIONAL UNITS, ONLY UNIT 3 IS REQUIRED TO MEET CURRENT FEDERAL NErtiUUKCE
PERFORMANCE STANDARDS FOR SULFUR DIOXIDE (S02) EMISSIONS (1.2 LB/MM BTU) . THIS UNIT IS FITTED WITH
A FLUE GAS DESULFURIZATION (FGD) SYSTEM.
THE BOILER ON UNIT 3 IS A COMBUSTION ENGINEERING UNIT DESIGNED TO FIRE HIGH-SULFUR INDIANA
BITUMINOUS COAL WITH THE FOLLOWING CHARACTERISTICS: HEAT CONTENT, 10,750 BTU/LB; SULFUR CONTENT,
U.50 PERCENT? ASH CONTENT, 8 TO 15 PERCENT; MOISTURE CONTENT, 10.5 TO 16.5 PERCENT. THE EMISSION
CONTROL SYSTEM ON THIS UNIT CONSISTS OF TWO ELECTROSTATIC PRECIPITATORS (ESP'S) FOR THE CONTROL OF
PARTICULATE MATTER AND AN FGD SYSTEM WITH FOUR WET LIMESTONE SCRUBBER MODULES FOR CONTROL OF S02.
BOILER FLUE GAS, WHICH IS GENERATED AT A RATE OF 1.9 MILLION ACFM AT 279 F, CONTAINS 3.55
GRAINS OF PARTICULATES PER ACTUAL CUBIC FOOT AND 2567 PPM OF S02. THE GAS FIRST ENTERS ONE OF THE
TWO RESEARCH COTTRELL COLO-SIDE ESP'S FOR PRIMARY PARTICULATE CONTROL. THE ESP'S REMOVE 99.3 PER-
CENT OF THE INLET PARTICULATE MATTER, WHICH RESULTS IN AN OUTLET LOADING OF 0.025 GR/ACF (0.1 LB/MM
BTU). FOUR FORCED-DRAFT BOOSTER FANS (ONE PER MODULE), EACH WITH AN 18 IN. W.G., THEN BOOST THE GAS
THROUGH THE FGD SYSTEM. THE FOUR TURBULENT CONTACT ABSORBERS (TCA'S) THAT COMPRISE THE FSO SYSTEM
WERE SUPPLIED BY UNIVERSAL OIL PRODUCTS (UOP) . THE TOTAL CAPACITY OF THE SYSTEM IS DIVIDED EVENLY
AMONG THE MODULES, EACH OF WHICH IS 30 FT. BY 30 FT. BY 100 FT. HIGH AND CAPABLE OF TREATING
475,000 ACFM OF FLUE GAS. LIMESTONE SLURRY IS CONTACTED WITH THE GAS STREAM IN EACH OF THREE LEVELS
OF MOBILE BED PACKING (1,5-INCH-DIAMETER SPHERES) IN EACH MODULE. MODULE PRESSURE DROP IS 8.5 IN.
W.G., SUPERFICIAL GAS VELOCITY IS 14.5 FT/S, AND LIGIUID-TO-GAS (L/G) RATIO IS 60. TWO 9300-GPM
PUMPS PROVIDE LIMESTONE SLURRY FOR EACH MODULE (ONE SPARE PUMP PER TWO MODULES). THE SCRUBBED FLUE
GAS (375,000 ACFM AT 118 F), WHICH CONTAINS 385 PPM 802, THEN PASSES THROUGH THE MIST ELIMINATORS
AND IS REHEATED FROM 118 TO 148 F BEFORE IT IS DISCHARGED THROUGH THE 616-FT MAIN STACK. REHEAT IS
PROVIDED BY HEATING AMBIENT AIR WITH STEAM TUBE BUNDLES LOCATED OUTSIDE THE GAS DUCTS.
THE SPENT SCRUBBING SOLUTION IS DISCHARGED FROM THE TCA MODULES TO AN EXTERNAL RECYCLE TANK,
WHERE CHEMICAL REACTIONS ARE COMPLETED. FLUE GAS CLEANING WASTES (CALCIUM SULFITE, CALCIUM SULFATE,
CALCIUM CARBONATE, FLY ASH) ARE DISCHARGED FROM THE LIQUID RECIRCULATION LOOP TO A THICKENER (165 FT
IN DIAMETER), WHERE THE WASTE SOLIDS SETTLE OUT. THICKENER OVERFLOW IS SENT TO A THICKENER OVERFLOW
RECLAIM WATER TANK FOR RETURN TO THE PROCESS; 150 TONS/HOUR OF THICKENER UNDERFLOW, WHICH IS 35
PERCENT SOLIDS, IS DISCHARGED TO AN IUCS SLUDGE STABILIZATION SYSTEM FOR CHEMICAL FIXATION BEFORE
BEING PIPED TO FINAL DISPOSAL IN AN ON-SITE, UNLINED, DISPOSAL POND LOCATED APPROXIMATELY 4000 FT
FROM THE GENERATING UNIT. CLARIFIED WATER IS RETURNED TO THE PROCESS FOR FURTHER USE.
A BALL MILL WITH A CAPACITY OF 50 TONS/HR PROVIDES ON SITE LIMESTONE PREPARATION. THE MILL IS
FED DIRECTLY FROM A 400-TON LIMESTONE STORAGE SILO. THE CRUSHED LIMESTONE IS SLURRIED TO A 38 PER-
CENT SOLIDS SOLUTION AND STORED IN 320,000-GAL MIX/HOLD TANKS. TWO PUMPS TRANSFER FRESH SLURRY FROM
THE STORAGE TANKS TO THE RECIRCULATION TANKS. THE MODULES, TANKS, AND PUMPS IN THE FGD SYSTEM ARE
RUBBER-LINED. EXHAUST GAS DUCTWORK IS LINED WITH A CEILCOTE LINER.
"INITIAL OPERATING EXPERIENCE*
BY DECEMBER 12, 1977, IPALCO HAD PUT THE FIRST TWO TCA MODULES INTO OPERATION. THE OTHER TWO
MODULES WERE PLACED ON LINE THE LATTER PART OF THE SAME MONTH. SEVERE COLD WEATHER CONDITIONS HAVE
NECESSITATED THE ERECTION OF TEMPORARY ENCLOSURES AROUND SEGMENTS OF THE FGD SYSTEM UNTIL THE
INSTALLATION OF HEAT TRACING IN THE LIQUID CIRCUIT IS COMPLETED.
44
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
KANSAS CITY POWER & LIGHT
HAWTHORN NO. 3
KANSAS CITY MISSOURI
140 MW
COAL 0.5-3.b PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
RETROFIT
11/72
OPERATIONAL
99 PERCENT
soe
70 PERCENT
WATER MAKE UP
OPEN LOOP 7.0 GPM/MW
SLUDGE DISPOSAL
PLANT SITE DISPOSAL POND
UNIT COST
SEE APPENDIX A, FSD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE SCRUBBER PLANT HAS BEEN CONVERTED FROM A LIMESTONE FURNACE INJECTION
AND TAIL-END SCRUBBING SYSTEM TO A TAIL-END WET LIME SCRUBBING SYSTEM.
LIME-BASED OPERATIONS COMMENCED ON FEBRUARY 7, 1977. COMPLIANCE TESTING
FOR KANSAS CITY PARTICULATE STANDARDS INDICATED THE NO.3 UNIT WAS WELL
WITHIN THE 0.17 POUND REGULATION. THE 3-MOOULE SCRUBBER PLANT CAN ONLY BE
BY-PASSED DURING EMERGENCIES.
45
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BACKGROUND INFORMATION
ON
HAWTHORN NOS. 3 AND 4
THE HAWTHORN POWER STATION IS OWNED AND OPERATED BY THE KANSAS CITY POWER AND LIGHT COMPANY AND
SITUATED IN A HEAVILY INDUSTRIALIZED AREA ON THE NORTH BANK OF THE MISSOURI RIVER IN EAST KANSAS
CITY, MISSOURI. THE PLANT CONTAINS FIVE COAL-FIRED BOILERS. UNITS 1 AND 2 ARE CONSIDERED PEAK
BOILERS, EACH RATED AT 80 MW. UNITS 3 AND 4 ARE CYCLIC-LOAD BOILERS. EACH RATED AT 100 MW. UNIT 5
IS A BASE-LOAD BOILER RATED AT 500 MW. UNITS 1 TO 4 WERE PURCHASED AND PLACED IN SERVICE BETWEEN
1950 AND 1955. UNIT NO. 5 WAS PLACED IN SERVICE IN EARLY 1970. ALL THE HAWTHORN BOILERS ARE DRY-
BOTTOM PULVERIZEO-COAL-FIRED UNITS DESIGNED AND MANUFACTURED BY COMBUSTION ENGINEERING. TWO GRADES
OF COAL ARE BURNED AT THE STATION; A LOW SULFUR COAL FROM THE WYOMING AREA THAT TYPICALLY CONTAINS
0.5X SULFUR AND 11 PERCENT ASH WITH A HEATING VALUE OF 9800 8TU/LB AND A HIGH SULFUR COAL FROM
OKLAHOMA THAT TYPICALLY CONTAINS 3.5X SULFUR AND la PERCENT ASH WITH A HEATING VALUE OF 11,500
BTU/LB. OF THE FIVE COAL-FIRED BOILERS INSTALLED AT THE STATION, TWO UNITS 3 AND 4 HAVE BEEN RETRO-
FITTED WITH PARTICULATE AND SULFUR DIOXIDE SCRUBBER PLANTS.
THE ORIGINAL SCRUBBER PLANTS INSTALLED ON UNITS 3 AND 4 CONSISTED OF LIMESTONE INJECTION AND
TAIL-END WET SCRUBBER MODULES SUPPLIED BY COMBUSTION ENGINEERING AND PLACED IN SERVICE NOVEMBER
1973 AND AUGUST 1972, RESPECTIVELY. A GENERAL DESCRIPTION OF THE PROCESS FOLLOWS; DRY
LIMESTONE WAS INJECTED DIRECTLY INTO THE FURNACE BOX AND CALCINED TO LIME. THE FURNACE-CALCINED
LIMESTONE AND BOILER FLUE GAS WERE THEN DISCHARGED TO A TAIL-END WET SCRUBBING SYSTEM CONSISTING OF
TWO MARBLE-BED ABSORBERS WHERE PARTICULATES AND SULFUR DIOXIDE WERE REMOVED FROM THE GAS STREAM.
THE SPENT LIME AND OTHER SCRUBBING WASTES WERE THEN DISCHARGED INTO A COMMON CLARIFIER TANK AND THE
UNDERFLOW WAS PUMPED, UNTREATED AND UNSTABILIZED, TO AN UNLINED DISPOSAL POND USED FOR THE DISPOSAL
OF FLY ASH FROM THE OTHER BOILERS. THE SCRUBBER PLANT INSTALLED ON EACH BOILER CONTAINED TWO
IDENTICAL MARBLE-BED ABSORBERS, EACH CAPABLE OF TREATING 500,000 ACFM OF FLUE GAS AT 300 F. A
CHEVRON-TYPE MIST ELIMINATOR AND A FINNED-TUBE STEAM REHEATER WERE ALSO INCORPORATED IN EACH MODULE
IN ADDITION TO A MIST ELIMINATOR WASH SYSTEM CONSISTING OF EIGHT AUTOMATICALLY-OPERATED WATER
LANCES. BY-PASSING OF THE MODULES WAS POSSIBLE THROUGH A SERIES OF DAMPERS AND DUCTWORK AROUND EACH
MODULE.
THE ORIGINAL SCRUBBER DESIGN OF THE SYSTEM INSTALLED ON THE NO. 4 BOILER HAD TO BE MODIFIED
SHORTLY AFTER START-UP BECAUSE OF BOILER TUBE PLUGGING ATTRIBUTED TO THE LIMESTONE INJECTION. THE
MODE OF OPERATION OF THIS SYSTEM WAS MODIFIED TO LIMESTONE INJECTION INTO THE FLUE GAS DUCT NEAR THE
INLET TO THE MARBLE-BED ABSORBER. THE SIMPLIFIED PROCESS FLOW DIAGRAMS OF THESE ORIGINAL SCRUBBEK
PLANTS ARE PRESENTED IN APPENDIX B.
46
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KANSAS CITY POWER & LIGHT HAWTHORN UNIT NO. 3
OPERATING HOURS F6D OPEkABlLITY (X)
MONTH BOILER MODULE 3A MODULE 38 MODULE A MODULE B
JUL. 75 584 o 247 o 42
PROBLEMS WITH MODULE 3A INCLUDED A LEAK IN CITY WATER LINE, A PLUGGED DUCT TO THE 1.0. FAN,
A MALFUNCTIONING OUTLET DAMPER FROM THE SCRUBBER. IN MODULE B MARBLES HERE LOST FROM THE
BED AND A SPRAY HEADER WAS BROKEN.
AUG. 75 0 0 00 0
LOST I.D. FAN FOR HALF OF THE BOILER. CARRYOVER OF JULY PROBLEMS.
SEP. 75 358 247 81 69 23
OUTAGE DUE TO CLEANING AND MECHANICAL REPAIRS. POTS, COVERS, AND MARBLES IN THE MARBLE BED
OF MODULE 38 WERE REPLACED.
OCT. 75 180 117 145 65 81
MODULE 3A OUTAGE WAS DUE LARGELY TO REPLACEMENT OF A RECYCLE PUMP MOTOK. A SCHEDULED BOILER
OVERHAUL REDUCED BOILER OPERATION HOURS.
NOV. 75 0 0 00 0
DEC. 75 0 0 00 0
JAN. 76 0 0 00 0
BOILERS AND SCRUBBERS WERE SHUTDOWN FOR A SCHEDULED TURBINE OVERHAUL. THE SYSTEM IS SCHEDUL-
ED TO GO BACK ON-LINE IN JANUARY 1976. SYSTEM WAS DOWN ALL MONTH BECAUSE OF FROZEN EQUIP-
MENT AND LINES AND A MANPOWER SHORTAGE DUE TO A BOILER AND TURBINE OVERHAUL UN ANOTHER UNIT
AT THIS STATION.
FEB. 76 503 148 7 37 1
SCRUBBER OUTAGES RESULTED FROM PLUGGING IN THE SCRUBBER BED, CAUSED BY CONVERSION FROM AN
UNDER-BED TO OVER-BED SPRAY SYSTEM.
MAR. 76 0 0 00 0
APR. 76 0 0 00 0
RECONVERSION OF MODULE 36'S SPRAY SYSTEM ARRANGEMENT HAS BEEN COMPLETED. ALSO THE BYPASS
SYSTEM HAS BEEN MODIFIED AND CHANGED TO A SLIDE-GATE DAMPER ARRANGEMENT.
MAY. 76 0 0 00 0
THE SYSTEM WAS SHUT DOWN DURING THE MONTH DUE TO THE CONTINUATION OF MANPOWER SHORTAGE
PROBLEMS. THE UTILITY DID PERFORM SOME CLEANING AND REPAIRS DURING THE MONTH.
JUN. 76 505 198 230 39 44
THE UTILITY IS IN THE PROCESS OF MODIFYING THE DEMISTER WASH SYSTEM BOTH UNITS NOS. 3 AND 4.
THE WATER LANCES, FORMERLY CONSTRUCTED OF FRP, ARE BEING CHANGED TO CARBON STEEL COMPONENTS
IN ORDER TO RECTIFY LOSS OF SPRAY NOZZLES AND SUBSEQUENT SHATTERING OF THE LANCES.
JUL. 76
AUG. 76
THE UTILITY IS NOW IN THE PROCESS OF CONVERTING THIS SYSTEM FROM LIMESTONE INJECTION AND
TAIL END SCRUBBING TO A LIME SLURRY BASED SCRUBBING SYSTEM.
SEP. 76
OCT. 76
THE SYSTEM WAS VIRTUALLY OUT OF SERVICE THE ENTIRE REPORT PERIOD. MANPOWER COMMITMENTS WERE
SERIOUSLY HAMPERED BY A MAJOR EXPLOSION WHICH OCCURRED IN THE COAL MILL PULVERIZING AREA OF
HAWTHORN NO. 5.
NOV. 76 0 0 00 0
DEC. 76 0 0 00 0
THE UNIT DID NOT OPERATE DURING THE PERIOD BECAUSE OF THE ONGOING MAJOR MODIFICATIONS BEING
IMPLEMENTED TO THE SCRUBBING SYSTEM. THE SYSTEM SHOULD BE READY FOR OPERATION FEB. 1. THE
UNIT MUST UNDERGO A SERIES OF TESTS TO INSURE COMPLIANCE WITH CITY AND FEDERAL REGULATIONS.
JAN. 77 0 0 00 0
FEB. 77 383 337 264 88 69
MAR. 77 482 476 411 99 85
THE NO. 3 UNIT WAS DOWN THE ENTIRE MONTH OF JANUARY FOR COMPLETION UF MODIFICATIONS AND
REPAIRS TO THE SCRUBBERS AND BOILER. THE UNIT BECAME AVAILABLE FOR SERVICE AND TESTING ON
47
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KANSAS CITY POWER & LIGHT HAWTHORN UNIT NO. 3
OPERATING HOURS F6D OPEKABILITY CX)
MONTH BOILER MODULE 3A MODULE 3B MODULE A MODULE B
FEB. 7. THE UNIT'S MEASURED PARTICULATE EMISSIONS AT THE SCRUBBER OUTLET WAS 0.12 LH/MM
BTU (WELL BELOW THE 0.17 LB REGS). A BLEND OF APPROXIMATELY 2.0 X SULFUK COAL IS BEING FIKEO
IN THE BOILER. THE CONVERSION FROM LIMESTONE TO LIME HAS BEEN GOOD. SOME INITIAL PROBLEMS
WITH PROCESS CHEMISTRY CONTROL HAVE BEEN CORRECTED. IN ADDITION, SOME MINOR MECHANICAL
PROBLEMS IN THE FORM OF PUMP MALFUNCTIONS AND LOSS OF SLAKING WATER PRESSURE HAVE BEEN
ENCOUNTERED. SYSTEM OPERATIONS ARE STILL CONTINUING AT OX SOLIDS AND 100X SLOWDOWN. FRESH
WATER MAKE-UP REQUIREMENT IS APPROXIMATELY 7.0 GPM/MW.
APR. 77 720
-------
KANSAS CITY POWER & LIGHT HAWTHORN UNIT NO. 3
FGD SYSTEM
MONTH PERIOD MRS. BOILER MRS. FGD SYSTEM MRS. AVAILABILITY CX)
OCT. 77 744 00 0
NOV. 77 730 411 411 57
THE UNIT WAS SHUT DOWN BECAUSE OF A LACK OF NATURAL GAS. DURING THIS PERIOD THE FGD SYSTEM
WAS OVERHAULED. THE ORIGINAL REACTION TANKS AND SPRAY HEADERS WERE REPLACED BY STAINLESS
STEEL COMPONENTS. THE INTERCONNECTING PIPING IS RUBBER LINED. THE UNIT BEGAN FIRING COAL
NOVEMBER 3.
NOTES THE BOILER AND FGD SYSTEM MUST RUN SIMULTANEOUSLY BECAUSE NO BY-PASS IS ALLOWED EXCEPT DUR-
ING EMERGENCIES. WHENEVER THE BOILER IS DOWN THE SCRUBBER IS EFFECTIVELY UNAVAILABLE BECAUSE
THE DOWN TIME IS UTILIZED FOR SCRUBBER MAINTENANCE AND REPAIR. THEREFORE, AVAILABILITY AND
UTILIZATION FACTORS ARE IDENTICAL FOR THIS SYSTEM.
DEC. 77 744 541 541 73
JAN. 78 744 346 346 47
OUTAGES SOME LEAKS IN THE FGD PIPING WERE REPLACED AND MODULES WERE CLEANED. THERE WERE
NO FGO RELATED OUTAGES.
49
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
KANSAS CITY POWER & LIGHT
HAWTHORN NO. 4
KANSAS CITY MISSOURI
100 MH
COAL 0.5-3.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
RETROFIT
8/73
OPERA-TIONAL
99 PERCENT
S02
70 PERCENT
WATER MAKE UP
OPEN LOOP 7.0 GPM/MW
SLUDGE DISPOSAL
PLANT SITE DISPOSAL POND
UNIT COST
SEE APPENDIX A, FGU SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE SCRUBBER PLANT HAS BEEN CONVERTED FROM A LIMESTONE FURNACE INJECTION
AND TAIL-END SCRUBBING SYSTEM TO A TAIL-END WET LIME SCRUBBING SYSTEM.
OPERATIONS IN THE LIME SCRUBBING MODE COMMENCED ON JANUARY 1, 1977.
COMPLIANCE TESTING FOR KANSAS CITY PARTICULATE REGULATIONS INDICATED THE
UNIT IS MEETING THE 0.17 POUND REGULATION. THE 2-MODULE SCRUBBER PLANT
CAN ONLY BE BY-PASSED DURING EMERGENCIES.
50
-------
BACKGROUND INFORMATION
ON
HAWTHORN NOS. 3 AND a
THE HAWTHORN POWER STATION IS OWNED AND OPERATED BY THE KANSAS CITY POWER AND LIGHT COMPANY AND
SITUATED IN A HEAVILY INDUSTRIALIZED AREA ON THE NORTH BANK OF THE MISSOURI RIVER IN EAST KANSAS
CITY, MISSOURI. THE PLANT CONTAINS FIVE COAL-FIRED BOILERS. UNITS 1 AND 2 ARE CONSIDERED PEAK
BOILERS, EACH RATED AT «0 MW. UNITS 3 AND 4 ARE CYCLIC-LOAD BOILERS. EACH RATED AT 100 MW. UNIT 5
IS A BASE-LOAD BOILER RATED AT 500 MW. UNITS 1 TO 4 WERE PURCHASED AND PLACED IN SERVICE BETWEEN
1950 AND 1955. UNIT NO. 5 WAS PLACED IN SERVICE IN EARLY 1970. ALL THE HAWTHORN BOILERS ARE DRY-
BOTTOM PULVERIZED-COAL-FIRED UNITS DESIGNED AND MANUFACTURED BY COMBUSTION ENGINEERING. TWO GRADES
OF COAL ARE BURNED AT THE STATION: A LOW SULFUR COAL FROM THE WYOMING AREA THAT TYPICALLY CONTAINS
0.5X SULFUR AND 11 PERCENT ASH WITH A HEATING VALUE OF 9800 BTU/LB AND A HIGH SULFUR COAL FROM
OKLAHOMA THAT TYPICALLY CONTAINS 3.5X SULFUR AND 14 PERCENT ASH WITH A HEATING VALUE OF 11,500
BTU/LB. OF THE FIVE COAL-FIRED BOILERS INSTALLED AT THE STATION, UNITS 3 AND 4 HAVE BEEN RETRO-
FITTED WITH PARTICULATE AND SULFUR DIOXIDE SCRUB8ER PLANTS.
THE ORIGINAL SCRUBBER PLANTS INSTALLED ON UNITS 3 AND 4 CONSISTED OF LIMESTONE INJECTION AND
TAIL-END WET SCRUBBER MODULES SUPPLIED BY COMBUSTION ENGINEERING AND PLACED IN SERVICE NOVEMBER
1972 AND AUGUST 1972, RESPECTIVELY. A GENERAL PROCESS DESCRIPTION OF THE PROCESS FOLLOWS: DRY
LIMESTONE WAS INJECTED DIRECTLY INTO THE FURNACE BOX AND CALCINED TO LIME. THE FURNACE-CALCINED
LIMESTONE AND BOILER FLUE GAS WERE THEN DISCHARGED TO A TAIL-END WET SCRUBBING SYSTEM CONSISTING OF
TWO MARBLE-BED ABSORBERS WHERE PARTICULATES AND SULFUR DIOXIDE WERE REMOVED FROM THE GAS STREAM.
THE SPENT LIME AND OTHER SCRUBBING WASTES WERE THEN DISCHARGED INTO A COMMON CLARIFIER TANK AND THE
UNDERFLOW WAS PUMPED, UNTREATED AND UNSTABILIZED, TO AN UNLINED DISPOSAL POND USED FOR THE DISPOSAL
OF FLY ASH FROM THE OTHER BOILERS. THE SCRUBBER PLANT INSTALLED ON EACH BOILER CONTAINED TWO
IDENTICAL MARBLE-BED ABSORBERS, EACH CAPABLE OF TREATING 500,000 ACFM OF FLUE GAS AT 300 F. A
CHEVRON-TYPE MIST ELIMINATOR AND A FINNED-TUBE STEAM REHEATER WERE ALSO INCORPORATED IN EACH MODULE
IN ADDITION TO A MIST ELIMINATOR WASH SYSTEM CONSISTING OF EIGHT AUTOMATICALLY-OPERATED WATER
LANCES. BY-PASSING OF THE MODULES WAS POSSIBLE THROUGH A SERIES OF DAMPERS AND DUCTWORK AROUND EACH
MODULE.
THE ORIGINAL SCRUBBER DESIGN OF THE SYSTEM INSTALLED ON THE NO. 4 BOILER HAD TO BE MODIFIED
SHORTLY AFTER START-UP BECAUSE OF BOILER TUBE PLUGGING ATTRIBUTED TO THE LIMESTONE INJECTION. THE
MODE OF OPERATION OF THIS SYSTEM WAS MODIFIED TO LIMESTONE INJECTION INTO THE FLUE GAS DUCT NEAR THE
INLET TO THE MARBLE-BED ABSORBER. THE SIMPLIFIED PROCESS FLOW DIAGRAMS OF THESE ORIGINAL SCRUBBER
PLANTS ARE PRESENTED IN APPENDIX B.
51
-------
KANSAS CITY POWER & LIGHT
HAWTHORN UNIT NO. 4
MONTH
OPERATING HOURS
BOILER MODULE 4A
MODULE 4B
FGD OPERABILITY (X)
MODULE A MODULE B
JUL. 75 518 41 128 8 25
MARBLE BED PLUGGING AND STRAINER PROBLEMS ON BOTH MODULES.
AUG. 75 168 212
LOST HALF OF BOILER DUE TO NO. 4B I.D. FAN OUTAGE. BOTH FGD MODULES WERE SHUT DOWN TO ENSURE
AGAINST THE LOSS OF THE ENTIRE UNIT. NEW CHEMISTRY- ATTEMPTING TO RUN AT IOOX SLOWDOWN AND
NEAR ZERO PERCENT SOLIDS. EMPHASIS ON PARTICULATE CONTROL. MAINTAINING PH AT 5 WITHOUT
LIMESTONE INJECTION.
SEP. 75 395 206 210 52 53
SCRUBBER MODULES WERE RETURNED TO SERVICE ON SEP. 21 AFTER REPLACEMENT OF THE ORIGINAL I.D.
FAN ON MODULE 48 SIDE.
NEW PROCESS DESIGN - MARBLES REMOVED FROM SCRUBBER BED OF MODULE A AND REPLACED WITH A STAIN-
LESS STEEL PERFORATED BED. THE MARBLES WERE REMOVED BECAUSE OF CONTINUING OPERATIONAL
DIFFICULTIES. VERY GOOD PERFORMANCE RESULTED IN INCREASED AVAILABILITY AND CONTINUATION OF
HIGH PARTICULATE REMOVAL EFFICIENCY C97 PERCENT).
OCT. 75 721 429 656 60 91
MINOR BOILER RESTRICTION ON THE MODULE 4A SIDE BETWEEN THE ECONOMIZER AND THE INLET DRAFT
DUCT-CHEMISTRY PROCESS MODIFICATION OF RUNNING AT 100 PERCENT BLOWDOWN AND ZERO PERCENT
SOLIDS IS STILL IN PROGRESS. S02 REMOVAL EFFICIENCY IN THE 50 TO 60 PERCENT RANGE. KCP&L
IS CONCENTRATING HEAVILY ON PARTICULATE EMISSION CONTROL.
NOV. 75 720 0 713 0 99
MODULE 4A WAS SHUT DOWN DURING THE REPORT PERIOD BECAUSE OF LOSS OF DRAFT THROUGH THE DUCT-
WORK FROM THE ECONOMIZER TO THE AIR PREHEATER. THE REHEATER PLUGGED FREQUENTLY UNTIL THE
SYSTEM WAS SHUT DOWN.
DEC. 75
640
103
16
BOILER OUTAGE OF 5 DAYS WAS DUE TO A SCHEDULED OVERHAUL.
JAN. 76 0 0 0 0 0
THE SYSTEM WAS DOWN ALL MONTH BECAUSE OF FROZEN EQUIPMENT AND LINES; MANPOWER WAS ASSIGNED
TO A BOILER AND TURBINE OVERHAUL ON ANOTHER UNIT.
FEB. 76 579 0 450 0 78
MODULE 4A WAS SHUT DOWN THE ENTIRE MONTH BECAUSE OF CONTINUING LOSS OF DRAFT THROUGH THE
DUCTWORK FROM THE ECONOMIZER TO THE AIR PREHEATER. MARBLE BED PLUGGING AND LOSS OF A RECYCLE
PUMP OCCUREO ON MODULE 4B.
MAR. 76
APR. 76
706
550
0
231
24
220
0
42
3
40
DURING THE REPORT PERIOD THE UNIT'S BYPASS SEALS WERE REPLACED WITH SLIDE-GATE DAMPERS.
MAY 76 365 99 99 27 27
JUN. 76 460 294 23 65 5
EXPERIENCING PLUGGING PROBLEMS. ONE SECTION OF THE REHEAT TUBE BUNDLES HAS BEEN REMOVED IN
ORDER TO FACILITATE CLEANING AND MAINTENANCE. CURRENTLY, THE UTILITY IS IN THE PROCESS OF
MODIFYING THE SCRUBBING SYSTEM FHOM A LIMESTONE INJECTION AND TAIL-END BASED SYSTEM TO A
LIME SLURRY-BASED SYSTEM.
SEP. 76
OCT. 76
THE SYSTEM WAS OUT OF SERVICE VIRTUALLY THE ENTIRE REPORT PERIOD. OPERATIONS AND MANPOWER
COMMITMENTS WERE SERIOUSLY HAMPERED BY A MAJOR EXPLOSION WHICH OCCURRED IN THE COAL MILL PUL-
VERIZING AREA OF HAWTHORN NO. 5.
NOV. 76
DEC. 76
786
0
442
0
91
0
THE UTILITY IS IN THE PROCESS OF CONVERTING THE SYSTEM TO A WET-LIME SCRUBBING SYSTEM.
START-UP IN THE LIME SCRUBBING MODE WILL COMMENCE THE FIRST PART OF JANUARY.
JAN. 77
FEB. 77
MAR. 77
572
591
539
486
168
440
424
292
525
85
80
97
74
50
82
THE UNIT BECAME AVAILABLE FOR SERVICE IN THE LIME SCRUBBING MODE ON JAN. 1, 1977. TESTING
FOR COMPLIANCE WITH PARTICULATE CODES OCCURRED DURING THE MONTH. THE 0.17 LB/MM BTU EMISSION
REGULATION IS BEING MET BY THE NO. 4 UNIT. A BLEND OF APPROXIMATELY 2.OX SULFUR COAL IS
BEING BURNED IN THE UNIT TO REMEDY THIS. SOME REHEAT PROBLEMS AND PLUGGING IN THE SUCTION
OF THE RECYCLE TANK BY A RAINCOAT WERE ALSO REPORTED. SYSTEM OPERATIONS ARE STILL CONTINUING
AT OX SOLIDS AND 100X BLOWDOWN. THE FRESH WATER MAKE-UP REQUIREMENT IS 7.0 GPM/MW.
-------
KANSAS CITY POWER & LIGHT HAWTHORN UNIT NO. 4
OPERATING HOURS F60 OPERABILITY (Z)
MONTH BOILER MODULE 4A MODULE 48 MODULE A MODULE B
APR. 77 720 311 311 43 43
MAY 77 740 180 180 54 54
THE SYSTEM IS NOW OPERATING WELL AT ABOUT 15-25X SLOWDOWN. THE PH CONTROL SYSTEM OPERATIONS
HAVE BEEN EXCELLENT. DURING MAY THE BOILER BURNED GAS FOR 408 HOURS. THE OPERABILITY VALUES
00 NOT INCLUDE THESE HOURS. THE OPERABILITY VALUES DO NOT INCLUDE THESE HOURS. S02 REMOVAL
EFFICIENCY IS ESTIMATED AT 50-60* FOR BOTH A AND B SCRUBBING MODULES, ALTHOUGH ACTUAL TESTS
HAVE NOT BEEN RUN FOR ABOUT ONI-ANO-A-HALF YEARS. CURRENTLY BOTH MODULES ARE BEING OPERATED
SIMULTANEOUSLY.
JUN. 77 720 FGD NOT REQUIRED-NATURAL GAS
UNIT NO. 4 FIRED GAS THROUGHOUT THE MONTH. THE SCRUBBER PLANT WAS SHUT DOWN FOR MODIFICA-
TIONS DURING THE PERIOD. SPECIFICALLY, ALL THE INTERNAL SCRUBBER COMPONENTS WERE REPLACED
WITH 316 LSS (UNDER-BED SPRAY HEADERS), A NEW REACTION TANK LINER WAS INSTALLED, AND RUBBER-
LINED PIPING REPLACED THE ORIGINAL CARBON STEEL RECYCLE PIPING (FROM THE RECYCLE PUMPS TO
THE SPRAY MAIIFOLD).
JUL. 77 696 120 120
THE STAINLESS STEEL MODIFICATIONS WERE COMPLETED BY JULY 25 AND THE UNIT RESUMED COAL FIRING.
THE SCRUBBER MODULES WERE IN SERVICE APPROXIMATELY ISO HOURS FOR THE REMAINDER OF THE MONTH.
THE SYSTEM SUCCESSFULLY COMPLETED FEDERAL PARTICULATE REMOVAL TESTS (0.15 LB/MM BTU MEASURED)
DURING THIS TIME. THE UNIT FIRED THE HIGH SULFUR, HIGH ASH (PEABODY-OKLAHOMA) COAL DURING
THE TEST. OPACITY TESTS FOR BOTH UNITS 3 AND 4 WILL BE CONDUCTED IN SEPTEMBER.
AUG. 77 550 550 550 74 74
SEP. 77 589 520 520 73 73
DURING THE LATTER PART OF SEPTEMBER THE CLARIFIER BECAME PLUGGED. THE UNIT FIRED NATURAL
GAS WHILE THE CLARIFIER WAS CLEANED.
53
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KANSAS CITY POWER & LIGHT HAWTHORN UNIT NO. t
FGD SYSTEM
MONTH PERIOD HRS. BOILER HRS. FGD SYSTEM HRS. AVAILABILITY (*J
OCT. 77 744 550 550 7a
NOV. 77 780 496 496 *><*
A GENERATOR EXCITER PROBLEM CAUSED A BOILER OUTAGE DURING OCTOBER. THERE WERE TWO OTHER
OUTAGES DURING OCTOBER THAT WERE SCRUBBER RELATED. THE FIRST WAS CAUSED BY A PLUGGED HEADER
AND THE SECOND OCCURRED WHEN THE LIQUID LEVEL IN INTERNAL REACTION TANK EXCEEDED CONTROL
LEVEL RESULTING IN PROBLEMS TO THE INLET GAS DUCT OG THE SCRUBBER. DURING NOVEMBER THERE
WERE TWO INSTANCES OF PLUGGED UNDER BED NOZZLES ON THE 4A MODULE. THE SCRUBBER WAS DOWN
U7.33 HOURS FOR FGD RELATED MAINTENANCE.
ON NOVEMBER 10 AN EPA OPACITY TEST WAS RUN ON MODULES 3 AND 4. AVERAGE OPACITY WAS 16.76X
RUNNING AT OR NEAR FULL LOAD. THE UNITS ARE NOW CERTIFIED FOR PARTICULATE AND OPACITY.
NOTE: THE BOILER AND FGD SYSTEM MUST RUN SIMULTANEOUSLY BECAUSE NO BY-PASS IS ALLOWED EXCEPT DURING
EMERGENCIES. WHENEVER THE BOILER IS DOWN THE SCRUBBER IS EFFECTIVELY UNAVAILABLE BECAUSE
THE DOWN TIME IS UTILIZED FOR SCRUBBER MAINTENANCE AND REPAIR. THREEFOREi AVAILABILITY AND
UTILIZATION FACTORS ARE IDENTICAL FOR THIS SYSTEM.
DEC. 77 744 530 520 70
JAN. 78 744 508 508 68
MODULE 4A HAD SEVERAL PROBLEMS INCLUDING SPRAY NOZZLE PLUGGING. THE SCRUBBER ON THE RECYCLE
PUMP MALFUNCTIONED. SOME NEW SPRAY NOZZLES WERE INSTALLED. THERE WERE SEVERAL BOILER
RELATED OUTAGES.
54
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
KANSAS CITY POWER & LIGHT
LA CYGNE NO 1
LA CYGNE KANSAS
820 MW
COAL 5.0 PERCENT SULFUR
BABCOCK & WILCOX
LIMESTONE SCRUBBING
NEW
2/73
OPERATIONAL
98 PERCENT
S02
76 PERCENT
WATER MAKE UP
OPEN LOOP 1.4 SPM/MW
SLUDGE DISPOSAL
PLANT SITE DISPOSAL POND
UNIT COST
SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED POWER-GENERATING UNIT
CONSISTS OF EIGHT SCRUBBER MODULES FOH FLY ASH AND 302 REMOVAL. EACH
MODULE INCLUDES A VENTURI SCRUBBER IN SERIES WITH A 2-STAGE IMPINGEMENT
PLATE ABSORBER. THE SCRUBBER PLANT is AN INTEGRAL PART OF THE POWER-
GENERATING COMPLEX, ALLOWING NO FLUE GAS BYPASS. INITIAL OPERATIONS
COMMENCED IN FEB. 1973. COMMERCIAL SERVICE WAS ATTAINED BY JUNE 1973.
TOTAL SYSTEM AVAILABILITY FOR THE MONTH OF JANUARY WAS 9« PERCENT.
55
-------
BACKGROUND INFORMATION
ON
LA CYGNt UNIT NO. 1
THE LA CYGNE POWER STATION OF KANSAS CITY POWER AND LIGHT COMPANY BEGAN COMMERCIAL OPERATION ON
JUNE 1, 1973, AS A JOINT PROJECT OF KANSAS GAS AND ELECTRIC COMPANY AND KANSAS CITY POWER * LIGHT
COMPANY. THE STATION IS LOCATED ABOUT 55 MILES SOUTH OF KANSAS CITY, IN LINN COUNTY, KANSAS.
ELECTRIC POWER GENERATING FACILITY CONSISTS OF TWO COAL-FIRED BASE-LOAD BOILERS WITH ASSOCIATED
STEAM TURBINES AND ELECTRIC GENERATORS. THE PLANT HAS THREE OIL-FIRED BOILERS, USED PRIMARILY FOR
STARTUP OF THE LARGE UNIT. THE COMBINED IvET GENERATING CAPACITY OF THE PLANT IS APPROXIMATELY 1450
MW (UNIT NO. 1 - 620 MW, UNIT NO. 2 - 630 MvO.
BOILER NO. 1 AT LA CYGNE, DESIGNED BY BABCOCK AND WILCOX, IS A DRY-BOTTOM, PULVERIZED-COAL-
FIRED CYCLONE UNIT. THE COAL BURNED IS LOW-GRADE, SUBBITUMINOUS, WITH AN AS-FIRED HEATING VALUE OF
9000 TO 9700 BTU/LB AND ASH SULFUR CONTENTS OF £5 PERCENT AND 5 PERCENT, RESPECTIVELY. POLLUTION
CONTROL EQUIPMENT ON THIS BOILER CONSISTS OF EIGHT SCRUBBING MODULES FOR THE CONTROL OF PARTICULATE
AND SULFUR DIOXIDE EMISSIONS. THIS SCRUBBING SYSTEM WAS DESIGNED AND CONSTRUCTED BY BABCOCK AND
WILCOX AS AN INTEGRAL PART OF THE POWER GENERATING FACILITIES. BYPASSING OF THE BOILER'S FLUE 6AS
AROUNU THE FGD SYSTEM IS NOT POSSIBLE. A PROCESS FLOW DIAGRAM OF THE LA CYGNE AIR QUALITY CONTROL
SYSTEM AND RELATED MAJOR EQUIPMENT IS PRESENTED IN APPENDIX B.
PROBLEMS AND SOLUTUIONS
THE FGD INSTALLATION HAS BEEN PLAGUED WITH NUMEROUS PROBLEMS SINCE THE FIRST TRIAL OPERATION ON
DECEMBER 26, 1972. SOME OF THESE PROBLEMS, SUCH AS VIBRATIONS OF THE INDUCED-DRAFT FANS AND THEIR
SENSITIVITY TO IMBALANCE, OCCURRED EVEN BEFORE THE BOILER WAS FIRED. AS THESE FABRICATION PROBLEMS
WERE CORRECTED AND THE FGO SYSTEM WENT INTO OPERATION, TWO OTHER TYPES OF PROBLEMS APPEARED. THE
FIRST TYPE, ASSOCIATED WITH THE WET LIMESTONE PROCESS, INCLUDED PLUGGING OF THE DEMISTER AND STRAIN-
ERS. THE CORROSION ASSOCIATED WITH CONDENSATION OF ACID VAPORS FROM THE GAS ON THE REHEATER TUBE
BUNDLES WAS CONTROLLED BY INJECTION OF SLIP STREAMS OF HOT AIR FROM THE BOILER'S COMBUSTION AIR
HEATER INTO THE SCRUBBED FLUE GASES AT THE INLET TO THE REHEATER UNITS. THIS PRACTICE, WHICH RE-
DUCED THE MAXIMUM GENERATING CAPACITY OF THE BOILER BY LIMITING THE AIR AVAILABLE FOR COAL COM-
BUSTION, IS NO LONGER NECESSARY BECAUSE OF RECENT SYSTEM DESIGN MODIFICATIONS.
BECAUSE THE FGD SYSTEM INCLUDES NO SPARE MODULES AND IT CANNOT BE BYPASSED, OUTPUT OF THE
BOILER IS TOTALLY CONTROLLED BY PERFORMANCE AND AVAILABILITY OF THE FGO MODULES. PRESENT PROCEDURES
CALL FOR CLEANING ONE MODULE EACH NIGHT ON A ROTATIONAL SCHEDULE AND KEEPING ALL MODULES AVAILABLE
DURING THE DAYTIME PEAK PERIODS. CLEANUUTS REQUIRE THREE MEN FOR A PERIOD OF 10 TO 12 HOURS.
RECENT MODIFICATIONS BY THE UTILITY ON THE SCRUBBER INSTALLATION HAVE RESULTED IN PLANS FOR PROLONG-
ED OPERATIONAL PERIODS, WITH MODULES STAYING ON-LINE CONTINUOUSLY FOR PERIODS UP TO 3 WEEKS. THIS
PREVENTIVE MAINTENANCE AND CLEANOUT SCHEDULE HAS, TO DATE, NOT YET BEEN ADOPTED.
THE UTILITY HAS RECENTLY COMPLETED ADDITIONAL SYSTEM MODIFICATIONS, INCLUDING THE INSTALLATION
OF AN EIGHTH SCRUBBING MODULE (PLACED IN COMMERCIAL SERVICE JULY 1977). THE COST OF THE ADDITIONAL
MODULE WAS APPROXIMATELY $5.2 MILLION AND ENABLES THE PLANT TO INCREASE ITS MAXIMUM CQNTINOUS GENER-
ATING CAPACITY FROM THE PREVIOUS 700-MW LEVEL TO 800 MW. THE ORIGINAL AIR QUALITY CONTROL SYSTEM
DESIGN ALLOTTED ADDITIONAL SPACE FOR SUCH A SYSTEM EXPANSION. UTHER SYSTEM MODIFICATIONS
INCLUDE: CHANGING THE i.o. FANS IN ORDER TO MINIMIZE OR ELIMINATE A FAN PARALLELING PROBLEM,
INSTALLATION OF ADDITIONAL BANKS OF STEAM TUBE REHEATERS, CHANGING THE MIST ELIMINATOR WASH SYSTEM,
INSTALLATION OF AN ADDITIONAL SLUDGE POND, AND IMPROVEMENT OF THE SYSTEM'S INSTRUMENTATION/CONTROL
LOOPS FOR AUTOMATIC OPERATION.
TABLE THAT FOLLOWS.
56
-------
KANSAS CITY POWER t LIGHT OPERATING HISTORY LA CYGNE UNIT NO. 1
MONTH
JAN.
FEB.
MAR.
APR.
MAY
JUN.
JUL.
AUG.
SEP.
OCT.
NOV.
DEC.
74
74
74
74
74
74
74
74
74
74
74
74
BOILER HOURS
A
49
66
67
69
93
75
90
69
90
90
B
32
66
70
83
84
80
90
88
71
71
"T"*fc.r^w/i
C
44
59
BOILER
75
78
83
80
73
73
60
60
BOILER
u A i • a i rt\j
0
87
76
SHUTDOWN
88
85
90
81
81
76
61
61
SHUTDOWN
NOTE: THE 1971 FIGURES ARE BASED UPON ACTUAL SYSTEM
BOILER HOURS.
JAN.
FEB.
MAR.
APR.
MAY
JUN.
JUL.
AUG.
SEP.
OCT.
NOV.
DEC.
JAN.
FEB.
MAR.
75
75
75
75
75
75
75
75
75
75
75
75
76
76
76
694
82
5
DURING REDUCED LOAD CONDITIONS
ALTHOUGH THEY WERE AVAILABLE.
FIGURES INDICATE. 1975 FIGURES
IN THE PERIOD.
683
667
590
630
MODULES A AND D ARE
CLEANING.
610
SYSTEM SHUTDOWN OCT.
REMAINED INOPERATIVE
231
346
95
88
78
96
BOILER
BOILER
90
SHUTDOWN
SHUTDOWN
76
t/Ukt
E
23
52
74
78
82
65
81
83
84
84
OPERATION
93
F
37
100
100
84
83
79
78
69
85
85
HOURS
92
DAYS OF OPERATION
SOME OF THE MODULES WERE NOT REQUIRED
AVAILABILITY WAS THEREFORE HIGHER THAN
ARE BASED UPON SYSTEM AVAILABLE HOURS
85
85
90
94
64
90
75 88 87
USED FOR RESEARCH TESTS
78 84
16, 1975 OWING
THROUGHOUT THE
66
93
77
90
90
65
84
90
84
85
89
86
87
78 92 85
. ONE MODULE IS SHUT DOWN
84 85
TO PROBLEMS WITH
MONTH.
46
60
74
93
79
GENERATOR
72
96
78
AND I.
73
89
G AVERAGE
81
65
88
80
87
77
99
86
84
84
AS A FUNCTION
96
50
69
80
80
86
80
85
81
76
76
OF ACTUAL
90
AND THEREFORE SHUT DOWN,
SOME OF THE POSTED
AS A FUNCTION OF HOURS
83
89
85
83
EACH EVENING
74
D. AIR FAN.
65
94
89
86
66
84
FOR
60
SYSTEM
66
91
597 91 87 81 85 87 89 84 86
AVAILABILITY FIGURES FOR OCTOBER AND NOVEMBER DO NOT INCLUDE THE OUTAGE TIME FROM OCTOBER 16
TO NOVEMBER 13. BOILER OUTAGES OF 80, 50, AND 11 HOURS, TOTALING 141 HOURS, OCCURRED DURING
DECEMBER.
618
594
643
86
94
92
85
90
90
91
66
88
72
91
93
64
92
94
52
93
91
84
95
91
03
92
91
57
-------
KANSAS CITY POWER & LIGHT
OPERATING HISTORY
LA CYGNE UNIT NO. 1
MONTH
BOILER HOURS
PERCENT AVAILABILITY-8Y MODULE
B C D E
AVERAGE
APR. 76 BOILER OVERHAUL
THE SYSTEM WAS SHUT DOWN ON APRIL 6 FOR A SCHEDULED BOILER, AIR PREHEATER, AND STACK BREECH-
ING OVERHAUL. DURING THIS OUTAGE SOME MAINTENANCE WAS PERFORMED ON THE SCRUBBER DUCTWORK,
PRIMARILY BECAUSE OF CORROSION PROBLEMS.
MAY 76 436 96 92 93 96 89 95 96 9"
THE SCHEDULED UNIT OUTAGE ENDED MAY 10 WHEN THE SYSTEM WAS RESTARTED. DURING THE REMAINDER
OF THE MONTH FOUR UNIT OUTAGES WERE ENCOUNTERED, TOTALING OVER 70 HOURS.
JUN. 76
93
91 94 95 93 93 91 93
FOUR FORCED MINOR SCRUBBER OUTAGES OCCURRED DURING THE MONTH, RESULTING IN A TOTAL AVERAGE
SYSTEM AVAILABILITY OF 93.33 PERCENT.
JUL.
76 96 95 92 93 93 94 94 94
THE UNIT RECORDED ITS LARGEST MW-HOUR MONTH SINCE INITIATION OF COMMERCIAL OPERATION.
MINOR SCRUBBER OUTAGES OCCURRED DURING THE MONTH.
TWO
AUG. 76
SEP. 76
OCT. 76
NOV. 76
DEC. 76
C
(
(
JAN. 77
FEB. 77
MAR. 77
94 93 92 94 92 90 88 92
THE SYSTEM WAS TAKEN OUT OF SERVICE AUGUST 24 FOR REPAIR OF A TURBINE BLADE. THE UTILITY
TOOK ADVANTAGE OF THIS OUTAGE PERIOD TO PROCEED WITH COATING THE STACK INNER STRUCTURE WITH
PLASTITE 4005. THE AUGUST AVAILABILITY FIGURES DO NOT INCLUDE THIS OUTAGE TIME.
TURBINE REPAIR
TURBINE REPAIR
UNIT NO. i REMAINED OUT OF SERVICE ALL OF SEPTEMBER AND THE FIRST THREE WEEKS OF OCTOBER
BECAUSE OF COMPLETION TO TURBINE BLADE REPAIRS WHICH COMMENCED ON AUGUST 24. THE SYSTEM WAS
RETURNED TO SERVICE ON OCTOBER 20. OPERATION WAS INTERMITTENT PENDING TURBINE BLADE RE-
BALANCING AND REESTABLISHMENT OF NORMAL OPERATING CONDITIONS.
627
706
95
87
93
89
94
95
94
94
94
93
95
94
91
94
90
DURING THE MONTH OF DECEMBER THE UTILITY CONDUCTED SOME MINOR REPAIR AND MODIFICATION WORK
ON THE AOCS. SPECIFICALLY A-MOOULE EXPERIENCED SOME VENTURI RECYCLE PUMP PROBLEMS AND THE
c-MoouLE's REHEAT STEAM TUBE BUNDLES WERE INCREASED IN NUMBER FROM FOUR TO EIGHT.
714
634
94
93
90
93
95
93
95
94
95
93
92
94
90
88
93
93
94 92 86 94 91 94 90 92
KCP&L REPORTS THAT THE 8TH MODULE HAS BEtN INSTALLED AND WILL BE PLACED IN SERVICE SOMETIME
DURING THE MONTH OF APRIL. THE SYSTEM MODIFICATIONS PROGRAM IS STILL IN PROGRESS. TWO
CRUCIAL MODIFICATION AREAS ARE REHEAT AND MIST ELIMINATION. ADDITIONAL BANKS OF STEAM TUBE
BUNDLES HAVE BEEN INSTALLED IN SOME MODULES. THE MIST ELIMINATORS IN TWO MODULES HAVE BEEN
MODIFIED TO THE POINT WHERE THEY HAVE BEEN OPERATING CONTINUOUSLY CLEAN. THE AUCS'S WATER
LOOP IS NOW 95X CLOSED. ALSO, A NEW SETTLING POND IS BEING INSTALLED AT THE PLANT. THE
PLANT IS STILL GENERATING 700-720 MW DURING THE DAY AND 500-570 MW AT NIGHT. 50F OF REHEAT
HAS BEEN DETERMINED AS THE NECESSARY AMOUNT FOR THE LA CYNGE NO. 1 UNIT.
APR. 77
96
94
94
96
95
TURBINE PROBLEMS.
WHEN IT IS EXPECTED
THE BOILER
THE
THE
AND
THAT 800 MW WILL
MAY 77 TURBINE REPAIR
DURING APRIL, THE AVERAGE AVAILABILITY INDEX FOR THE SEVEN MODULES WAS 95.2 PERCENT.
EIGHTH MODULE IS READY FOR OPERATION AND IN FACT HAS BEEN RUN FOR TWO DAYS. HOWEVER,
BOILER AND SCRUBBER SYSTEM WERE SHUT DOWN IN MAY DUE TO
EIGHT MODULES ARE EXPECTED TO START UP ABOUT JUNE 27,
GO ON LINE. THE MIST ELIMINATOR WASHING CONFIGURATION IS BEING CHANGED TO WORK COUNTER-
CURRENT TO THE GAS FLOW. ADDITIONAL TUBE BUNDLES ARE BEING ADDED TO INCREASE THE REHEAT
AREA. THESE CHANGES SHOULD BE TAKEN CARt OF BY THE END OF JUNE. THE NEW SETTLING POND IS
STILL BEING DRAWN UP. EXCAVATION HAS NOT BEGUN.
JUN. 77 TURBINE REPAIR
THE UNIT REMAINED SHUT DOWN DURING THE PERIOD AS THE TUR8HME REPAIR AND OVERHAUL CONTINUED
MINOR CLEANOUT AND REPAIR WORK WAS DONE ON THE SCRUBBER PLANT DURING THE TURBINE OUTAGE
58
-------
KANSAS CITY POWER & LIGHT
MONTH
JUL. 77
BOILER HOURS
OPERATING HISTORY
PERCENT AVAILABILITY-BY MODULE
B C D E F
LA CYGNE UNIT NO. 1
AVERAGE
528 95 93 94 95 95 95 95 95 95
FOLLOWING THE TURBINE OUTAGE, THE UNIT WAS PLACED BACK IN COMMERCIAL SERVICE ON JULY 5.
RESUMPTION OF OPERATIONS WAS CONDUCTED WITH EIGHT SCRUBBER MODULES IN THE FLUE GAS PATH,
ENABLING THE UNIT TO OPERATE AT A MAXIMUM CONTINUOUS LOAD CAPACITY OF 800 TO 820 Mw. PARTI-
CULATE REMOVAL TESTS DETERMINING COMPLIANCE WITH KANSAS REGULATIONS (0.13 LB/MM BTU) IS
SCHEDULED TO BE CONDUCTED IN LATE AUGUST.
AUG. 77
SEP. 77
507
89
93
94
89
93
90
90
93
93
95
93
92
94
87
THE PARTICULATE REMOVAL TESTS WERE CONDUCTED IN LATE AUGUST AND UNIT NO. 1 HAS PASSED THE
COMPLIANCE REQUIREMENTS. MODULE B HAD LOW AVAILABILITY DUE TO THE BURNING OF THE MOTOR ON
THE RECIRCULATING PUMP. IT WAS REMOVED AND STARTED AGAIN AFTER 12 DAYS.
OCT. 77
456
91
96
89
94
93
94
89
93
92
THE SYSTEM RAN SMOOTHLY THROUGH OCTOBER, HOWEVER, A 12-DAY BOILER OUTAGE WAS REQUIRED TO DE-
SLAG THE BOILER.
NOV. 77
234
93
96
93
94
92
93
96
95
94
THE BOILER HAS BEEN DOWN SINCE NOV. 15 BECAUSE OF A NECESSARY TURBINE OVERHAUL AND IS EX-
PECTED TO GO BACK ON-LINE DEC. 19.
DEC. 77
300
98
98
96
96
THE TURBINE OVEHHAUL CONTINUED UP TO DECEMBER 25.
OUTAGES IN DECEMBER.
96 97
THERE WERE A
98 99 97
FEW SMALL BOILER RELATED
JAN. 78
300
90
95
95
95
93
94
94
94
THERE WERE SOME BOILER RELATED OUTAGES IN JANUARY, TOTALLING ABOUT 50 HOURS.
CONTINUED TO OPERATE WITHOUT ANY PROBLEMS.
94
THE FGO SYSTEM
59
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT HATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
KANSAS POWER & LIGHT
LAWRENCE NO 4
LAWRENCE KANSAS
125 MW
COAL U.5 PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
RETROFIT
ia/66
OPERATIONAL
99 PERCENT
S02
75 PERCENT
WATER MAKE UP
OPEN LOAD
SLUDGE DISPOSAL
PLANT SITE DISPOSAL POND
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTIUN IN TABLE 3 OF THIS REPORT.
THE NEW LIMESTONE FGD SYSTEM COMMENCED OPERATIONS IN EARLY JANUARY 1977.
THERE HAVE BEEN NO FORCED SCRUBBER OUTAGES REPORTED SINCE STAKT-UP.
CONTINUOUS S02 MONITORS HAVE RECORDED S02 REMOVAL EFFICIENCIES OF BETTER
THAN B5X. PARTICULATE REMOVAL IS REPORTED TO BE EXCELLENT, YIELDING NO
VISIBLE PLUME. THE PLANT IS FIRING COAL RATED AT 12,300 BTU/LB WITH A
SULFUR CONTENT OF 3.5X.
60
-------
BACKGROUND INFORMATION
ON
LAWRENCE NO. 4
KANSAS POWER AND LIGHT'S LAWRENCE NO. 4 UNIT, AT LAWRENCE, KANSAS, IS A CYCLIC-LOAD BOILER
EQUIPPED TO BURN COAL, NATURAL GAS SUPPLEMENTED WITH FUEL OIL, OR A COMBINATION OF THESE THREE
FUELS. THIS 125-MW COMBUSTION ENGINEERING UNIT BEGAN GENERATING OPERATIONS IN 1959. THE COAL FIRED
IS FROM A LOW-SULFUR SOUTHEAST WYOMING SEAM, AND HAS AN AVERAGE HEATING VALUE OF 10,000 8TU/LB, A
SULFUR CONTENT OF 0.5 PERCENT, AND AN ASH CONTENT OF 11 PERCENT,
LAWRENCE NO. 4 IS NOW OPERATING WITH A RETROFITTED COMBUSTION ENGINEERING WET LIMESTONE FGD
SYSTEM WHICH BEGAN COMMERCIAL OPERATION IN EARLY JANUARY 1977. THE WET LIMESTONE SCRUBBING MODE RE-
PLACES THE ORIGINAL FGD APPROACH WHICH WAS LIMESTONE INJECTION INTO THE BOILER BOX FOLLOWED BY
SINGLE-STAGE MARBLE BED SCRUBBERS. A SIMILAR CONVERSION PROCESS IS PRESENTLY UNDERWAY AT THE 400-MW
LAWRENCE NO. 5 UNIT, CURRENTLY SCHEDULED FOR START-UP IN THE FIHST HALF OF 1978. THE FGO SYSTEMS ON
THESE TWO UNITS WILL SHARE THE NEW WET LIMESTONE MILLING FACILITIES AND RECIRCULATION TANKS IN BOTH
THE PARTICULATE REMOVAL AND S02 ABSORPTION LOOPS.
THE AIR QUALITY CONTROL SYSTEM AT THE LAWRENCE NO. a UNIT CONSISTS OF TWO-STAGE SCRUBBING FOLL-
OWED BY AN I.D. FAN LEADING INTO THE STACK. THE FIRST SCRUBBING STAGE UTILIZES THE ROD SCRUBBING
APPROACH FOR PARTICULATE REMOVAL. THE SECOND STAGE IS A SPRAY TOWER S02 ABSORPTION LOOP. OVERFLOW
FROM THE SPRAY TOWER RECIRCULATION TANK FEEDS INTO THE PARTICULATE LOOP AND A SIGNIFICANT PORTION OF
THE so2 is THEREFORE REMOVED IN THE PARTICULATE SCRUBBER.
THE FGD SYSTEMS ON LAWRENCE NO. 4 AND NO. 5 FEATURE FULLY-AUTOMATED CONTROLS. LIMESTONE FEED
RATE IS CURRENTLY GOVERNED PRIMARILY BY A PH MONITORING SYSTEM, AND THE CAPABILITY EXISTS TO TIE IN
THE INLET AND OUTLET SOS MONITOR READINGS TO THE CONTROL SYSTEM. THERE ARE ALSO AUTOMATIC DENSITY
METERS IN THE LIMESTONE SLURRY TANKS.
FOR A SIMPLIFIED FLOW DIAGRAM OF THE LIMESTONE SCRUBBING SYSTEM, REFER TO APPENDIX 8. THE
ORIGINAL LIMESTONE INJECTION SYSTEM, NOW REPLACED, IS ALSO REPRESENTED IN APPENDIX B.
*A HISTORY OF PROBLEMS WITH THE INJECTION SYSTEM AT LAWRENCE NO. a*
PROBLEMS WITH THE FGD SYSTEM ON BOILER NO. 4 INCLUDED BUILDUP AND PLUGGING OF THE INLET DUCT
WHERE HOT GASES ENTER THE SCRUBBERS, EROSION OF SCRUBBERS WALLS, CORROSION OF SCRUBBERS INTERNALS,
BUILDUP ON ID FAN ROTORS, AND PLUGGING OF DRAIN LINES, MARBLE BEDS, AND DEMISTERS. LOW S02 REMOVAL
WAS CAUSED BY OVERBURNING OF THE LIMESTONE AND DROPOUT OF THE LIME WITH THE ASH IN THE BOTTOM OF THE
SCRUBBER.
THE SCRUBBERS WERE MODIFIED IN 1969 BY RAISING THE DEMISTER AND ADDING SOOT BLOWERS IN THE
INLET DUCT AND REHEATfcR TO REDUCE PLUGGING. NEh SPRAY NOZZLES WERE ALSO INSTALLED. REHEATER PLUGG-
ING WAS ELIMINATED BY REPLACING COPPER REHEAT COILS WITH A CARBON STEEL UNIT HAVING WIDELY SPACED
FINS.
MAJOR MODIFICATIONS IN 1970 WERE SANDBLASTING AND COATING OF THE INTERIOR OF THE SCRUBBERS, RE-
PLACEMENT OF ALL INTERNAL STEEL PIPES WITH PLASTIC AND FIBERGLASS, AND REPLACEMENT OF STAINLESS
STEEL DEMISTERS WITH FIBERGLASS. SINCE DEMISTER PLUGGING WAS NOT COMPLETELY ELIMINATED, THE UNIT
WAS WASHED MANUALLY EVERY NIGHT TO MAINTAIN THE REQUIRED OUTPUT.
THE MODIFICATIONS IN THE SUMMER OF 1972 ON THE TWO FGD MODULES INCLUDED ENLARGEMENT OF THE CRY-
STALLIZATION TANK, AND INSTALLATION OF NEW PLASTIC SPRAY NOZZLES, NEW SLURRY PUMPS AND STRAINERS,
AND NEW MULTIPLE MIXERS IN THE TANK.
PROBLEMS THAT REMAINED INCLUDED CORROSION, INEFFICIENT DAMPERS, EXPANSION JOINT FAILURE,
DEMISTER FOULING, RAPID EROSION OF THE SLURRY PUMP, AND VALVE FAILURE. OPERATION OF THE FGD SYSTEM
SINCE THE FALL OF 1973 HAS BEEN THE MOST SUCCESSFUL TO DATE.
OPERATION OF THE SCRUBBER SYSTEM ON THE WYOMING COAL HAS PROVED TO BE MOKE EFFICIENT AND ECON-
OMICAL THAN EARLIER OPERATIONS BECAUSE A LESSER DEGREE OF S02 REMOVAL IS REQUIRED FOR COMPLIANCE.
THE SCRUBBER SYSTEM IS STILL OPERATING IN THE HIGH-SOLIDS MODE AS AN S02 AND PARTICULATE REMOVAL
SYSTEM, NORMAL MANUAL CLEANING REQUIREMENTS HAVE BEEN REDUCED TO TWO 4-HOUR SHIFTS PER SCRUBBER
PER WEEK.
IN 1974 THIS UNIT WAS AVAILABLE FOR OPERATION 343 DAYS. FIFTY PERCENT OF THE FUEL CONSUMED WAS
COAL, 2 PERCENT FUEL OIL, AND 48 PERCENT NATURAL GAS. DURING 1975 THIS UNIT WAS AVAILABLE FOR OPER-
ATING 333 DAYS. SIXTY-FOUR PERCENT OF THE FUEL CONSUMED WAS COAL, 3 PERCENT FUEL OIL, AND 33
PERCENT NATURAL GAS.
BY LATE 1976, THE ORIGINAL EMISSION CONTROL SYSTEM HAS REPLACED WITH A ROD AND SPRAY TOWER
SCRUBBER FOR PARTICULATE AND 302 REMOVAL. INFORMATION ON THE ORIGINAL AND REPLACEMENT SYSTEM IS
GIVEN IN THE FOLLOWING TABLE.
61
-------
KANSAS PUwER & LIGHT LAWRENCE UNIT NO. «
OPERATING HISTORY - NOW TERMINATED LIMESTONE INJECTION SYSTEM - LAWRENCE NO. «
OPERATING HOURS AVAILABILITY
MONTH BOILER MODULE A MODULE B MODULE A MODULE B
THE FGD SYSTEM HAS OPERATED SATISFACTORILY FOR OVER A YEAR. AVAILABILITY IS REPORTED TO BE
ADEQUATE FOR THE OPERATION OF THIS STATION. STATION LOAD IS REDUCED TO 50 PERCENT EVERY
NIGHT. THEREFORE, ONE OF THE MODULES CAN BE TAKEN OFF-LINE NIGHTLY FOR CLEANING OR REPAIR.
rtYUMING COAL (0.5 PERCENT SULFUR) IS BEING BURNED IN THE BOILER. SOME NATURAL GAS HAS BEEN
BURNED SINCE JUNE 20.
JUL. 7b NOT LOGGED
AUG. 75
EACH MODULE SHUT DOWN ONCE PER WEEK FOR INSPECTION AND CLEAN-UP. NO BOILER OUTAGES OCCURRED
DURING THE JULY-AUGUST PERIOD.
SEP. 75 N01 LOGGED
OCT. 75
NUV. 75 NOT LOGGED
DEC. 75
JAN. 76 NOT LOGGED
FEB. 76
PRESENT PROJECTIONS 8Y THE UTILITY CALL FOR THIS UNIT TO BE AVAILABLE 330 DAYS DURING 1976.
THE FUEL CONSUMPTION WILL BE 80 PERCENT COAL, 12 PERCENT NATURAL GAS, AND fl PERCENT FUEL OIL.
THE UTILITY IS REPLACING THIS SCRUBBER SYSTEM WITH A VENTRI-ROD FOLLOWED BY A SPRAY TOWER.
MAR. 76
APR. 76
MAY. 76 NO INFORMATION WAS REPORTED BY THE UTILITY FOR THE PERIOD.
JUN. 76
JUL. 76 NO INFORMATION WAS REPORTED BY THE UTILITY FOR THE PERIOD.
AUG. 76
SEP. 76
OCT. 76
NOV. 76 TURBINE OVERHAUL AND REPAIR
DEC. 76
THE UTILITY REPORTS THAT THE UNIT REMAINED OUT OF SERVICE THROUGHOUT THE REPORT PERIOD AS A
SCHEDULED TURBINE OVERHAUL, WHICH COMMENCED IN MID-SEPTEMBER, CONTINUED. THE NEW EMISSION
CONTROL SYSTEM, CONSISTING OF A ROD SECTION AND SPRAY TOWER SCRUBBING SYSTEM, HAS BEEN
INSTALLED ON THIS UNIT. INITIAL OPERATION OF THE SYSTEM WILL COMMENCE FOLLOWING COMPLETION
OF THE TURBINE OVERHAUL. THE UNIT WILL CONTINUE TO FIRE LOW SULFUR WYOMING COAL (0.5X SULFUR
10,000 8TU/LB).
62
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KANSAS POWER & LIGHT LAWRENCE UNIT NO. 4
OPERATING HISTORY - WET LIMESTONE SCRUBBING SYSTEM - LAWRENCE NO. 1
JAN. 77 THE NEW LIMESTONE FGO SYSTEM BECAME COMMERCIALLY OPERABLE IN EARLY JANUARY 1977.
FEB. 77 THERE HAVE BEEN NO FORCED OUTAGES AND NO DOWNTIME SINCE START-UP. THE UTILITY REPORTS
MAR. 77 THAT BOTH PARTICULATE AND soa REMOVALS ARE QUITE SATISFACTORY. MINOR PROBLEMS HAVE BEEN
RELATED TO MAINTAINING DESIRED SOLIDS LEVEL IN THE MAKE-UP TANK. MODIFICATION PLANS
INCLUDE CESSATION OF SLURRY DILUTION, WHICH CURRENTLY PRECEDES THE INTRODUCTION OF THE
FRESH LIMESTONE SLURRY INTO THE RECIRCULAT ION LOOP. THE UTILITY PLANS TO PUMP THE 35-
PERCENT SOLIDS SLURRY DIRECTLY FROM THE SLURRY TANK INTO THE REC IRCULATION LOOP. CURRENT-
LY SEVERAL DIFFERENT MAKES OF SLURRY PUMPS ARE BEING USED. ALL ARE FUNCTIONING WELL SO
FAR. THE PUMPS HAVE NOT BEEN IN SERVICE LONG ENOUGH FOR COMPARISONS TO BE DRAWN.
APR. 77 THE SCRUBBER WAS NOT REQUIRED FOR SERVICE DURING THE REPORT PERIOD BECAUSE NATURAL
MAY 77 GAS WAS FIRED IN THE BOILER. KP&L ANTICIPATES THAT THE NATURAL GAS AVAILABILITY SHOULD
LAST THROUGHOUT THE MAJORITY OF THE SUMMER/ REQUIRING NO SCRUBBER PLANT OPERATIONS DURING
THE PERIOD.
JUN. 77 THE NO. 4 BOILER HAS BEEN FIRING 100X NATURAL GAS FOR ALL BUT APPROXIMATELY 8 TO 10
JUL. 77 DAYS SINCE THE BEGINNING OF APRIL 1977. DURING THE DAYS WHEN COAL WAS FIRED. 1HE TnO-
STAGE WET PARTICULATE AND SG2 REMOVAL SYSTEM HAS BEEN UTILIZED AND OPERATIONS HAVE BEEN
SATISFACTORY WITH THE EXCEPTION OF MINOR PROBLEMS RELATED TO THE MINIMAL USAGE OF THE
SYSTEM. PROBLEMS IN THE SCRUBBING TRAIN HAVE INCLUDED SOME MIST ELIMINATOR CKACKSf
PROBLEMS WITH THE RECYCLE TANK STRAINER SCREEN WASH, A COMPRESSOR BREAKDOWN IN THE RECYCLE
TANK AIR AGITATION SYSTEM, AND SOME SOOT BLOWER PROBLEMS. IN ADDITION, THE DENVER SLURRY
PUMPS ARE EXPERIENCING SOME ON-GOING PROBLEMS, WHILE THE ALLEN-SHERMAN-HOFF PUMPS ARE
OPERATING SATISFACTORILY.
THE UTILITY IS PLANNING FOR AN INTERRUPTION OF GAS SUPPLY IN THE FOURTH QUARTER OF
THIS YEAR, AND THE RESTART OF CONTINUOUS COAL-FIRING POWER GENERATION.
AUG. 77 THE BOILERS BURNED NATURAL GAS THROUGHOUT AUGUST. THE MIST ELIMINATOR CRACKS HAVE
SEP. 77 BEEN REPAIRED, BUT THE RECYCLE TANK STRAINER PROBLEMS PERSISTED. THE AIR AGITATION SYSTEM
COMPRESSOR WAS MALFUNCTIONING. THE DENVER SLURRY PUMPS ARE FUNCTIONING ADEQUATELY AT
PRESENT. THE PUMP GLAND PACKINGS ARE BEING REDESIGNED. AS OF 9/15/77 THE UNIT BURNED
OCT. 77 COAL. THE SYSTEM CAPACITY WAS CUT BACK TO 50 PERCENT 150-55 MW) IN OCTOBER BECAUSE A NEW
NOV. 77 COOLING TOWER IS BEING CONSTRUCTED. ON NOV. 15 A MAJOR FGD SYSTEM OVERHAUL TOOK PLACE
WHILE THE TURBINE WAS DOWN FOR INSPECTION AND THE NEW COOLING TOWER WAS BEING CONNECTED.
UNIT IS DUE BACK ON-LINE IN MID-DECEMBER.
DEC. 77 THE UNIT CAME ON-LINE DECEMBER 208 WITH FULL CAPACITY. THE CONSTRUCTION OF THE NEW
COOLING TOWER IS COMPLETE. THE TURBINES WERE BALANCED.
JAN. 78 THE FGD SYSTEM OPERATED WITHOUT ANY PROBLEMS OTHER THAN SOME FREEZING OF THE PIPE-
LINES. THE FREEZER IN THE DISCHARGE LINE CAUSED CLARIFIER PLUGGING.
63
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/78
UTILITY NAME KANSAS POWER & LIGHT
UNIT NAME LAWRENCE NO 5
UNIT LOCATION LAWRENCE KANSAS
UNIT RATING tOO MW
FUEL CHARACTERISTICS COAL 0.5 PERCENT SULFUR
FGD VENDOR COMBUSTION ENGINEERING
PROCESS LIMESTONE SCRUBBING
NEW OR RETROFIT NEW
START UP DATE 11/71
FGD STATUS OPERATIONAL
EFFICIENCY,
PARTICULATES 99 PERCENT
S0£ 65 PERCENT
WATER MAKE UP OPEN LOOP
SLUUGE DISPOSAL PLANT SITE DISPOSAL POND
UNIT COST
OPERATIONAL REFER TU THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
EXPERIENCE THE ORIGINAL LIMESTONE INJECTION AND TAIL-END SCRUBBING SYSTEM IS STILL
IN SERVICE WHILE A NEW ROD-SCRUBBER AND SPRAY TOWER ABSORBER SYSTEM IS
BEING ERECTED ALONG SIDE THE EXISTING SYSTEM. THE NEW SCRUBBER PLANT
INCLUDES a MODULES EACH CAPABLE OF HANDLING APPROXIMATELY sox OF THE TO-
TAL BOILER FLUE GAS FLOW. THE SYSTEM DESIGNER AND SUPPLIER IS COMBUSTION
ENGINEERING. THE UNIT FIRES APPROXIMATELY UO TONS/HOUR OF LOW SULFUR
WYOMING COAL HAVING HEAT AND SULFUR CONTENTS OF 10,000 BTU/LB AND 0.5X.
64
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BACKGROUND INFORMATION
ON
LAWRENCE NO. 5
UNIT NO. 5 AT LAWRENCE POWER STATION IS A CYCLIC-LOAD STEAM BOILER EQUIPPED TO BURN COAL,
NATURAL GAS SUPPLEMENTED WITH OIL, OR COMBINATIONS OF THESE FUELS. THE BOILER, PLACED IN SERVICE IN
1971, HAS A RATED CAPACITY OF 400 MW WHEN BURNING COAL AND NATURAL GAS.
THE COAL NOW BURNED AT THE LAWRENCE POWER PLANT IS A LOW-SULFUR SOUTHEAST COAL, HAVING AN AVE-
RAGE HEATING VALUE OF 10,000 BTU/LB AND SULFUR AND ASH CONTENTS OF 0.5 AND 11 PERCENT RESPECTIVELY.
THE BOILER'S ORIGINAL FGD SYSTEM WAS SUPPLIED BY COMBUSTION ENGINEERING AND PLACED IN SERVICE
IN 1971. ORIGINAL EQUIPMENT INCLUDED 8 IDENTICAL MODULES WITH A CAPACITY OF 150,000 SCFM/MODULE.
EACH MODULE CONSISTS OF A SINGLE-STAGE MARBLE BED SCRUBBER FOLLOWED BY A CHEVRON-TYPE DEMISTEft AND
INDIRECT STEAM REHEATER. ALL THE MODULES ARE FITTED WITH BY-PASS DUCTS AND HYDRAULIC SEAL DAMPERS.
THE PLANT INCLUDES FACILITIES FOR STORING AND MILLING LIMESTONE (COMPOSITION: 93 PERCENT CALCIUM
CARBONATE, 6 PERCENT SILICA, AND 1 PERCENT MAGNESIUM CARBONATE).
SPENT SLURRY FROM THE UNIT ALONG WITH THE SLURRY FROM UNIT NO. 4 IS SENT TO THREE INTER-
CONNECTED UNLINED SLUDGE DISPOSAL PONDS OF 16, 28, AND 4 ACRES. COOLING TOWER SLOWDOWN SUPPLIES
MAKE-UP WATER TO THE POND SYSTEM. CLARIFIED POND WATER IS RECYCLED. THE SLUDGE IS NOT TREATED
FURTHER AND IS REPORTED TO SET AND SOLIDIFY IN THE PONDS.
PROBLEMS AND SOLUTIONS
PROBLEMS WITH THE FGO SYSTEM ON BOILER NO. 5 WERE SIMILAR PROBLEMS TO THOSE OF THE SYSTEM ON
BOILER NO. 4: LOCALIZED CORROSION IN SOME EQUIPMENT, UNSATISFACTORY DAMPER OPERATION, DEMISTER
FOULING, EXPANSION JOINT FAILURE, AND RAPID WEAR OF SLURRY-RECIRCULATING PUMPS. IN ADDITION TO
THESE PROBLEMS, BOILER NO. 5 IS PLAGUED WITH POOR FLUE GAS DISTRIBUTION TO THE EIGHT FGD MODULES
WHICH, UNLIKE THE MODULES ON BOILER NO. 4 ARE ALL INTERCONNECTED TO A COMMON STACK.
FGD SYSTEM AVAILABILITY IS ADEQUATE FOR THE OPERATION OF THIS STATION. BECAUSE THE STATION
LOAD IS REDUCED TO FIFTY PERCENT, AS MANY AS FOUR MODULES ARE SHUT DOWN FOR CLEANING AND REPAIR EACH
EVENING.
OPERATION OF THE SCRUBBER SYSTEM ON WYOMING COAL HAS PROVED TO BE MORE EFFICIENT AND ECONOMICAL
BECAUSE OF THE LESSER DEGREE OF SOa REMOVAL REQUIRED.
IN 1974 THE UNIT WAS AVAILABLE FOR OPERATION 338 DAYS* 66 PERCENT OF THE FUEL CONSUMED WAS
NATURAL GAS, 27 PERCENT COAL, AND 6 PERCENT FUEL OIL. DURING 1975 THE UNIT WAS AVAILABLE FOR OPER-
ATION 352 DAYS, FUEL CONSUMPTION WAS 45 PERCENT NATURAL GAS, 42 PERCENT COAL, AND 13 PERCENT FUEL
OIL.
KP&L, IN ORDER TO MAINTAIN SCRUBBING OPERATIONS FOR THIS UNIT, IS NOW FOLLOWING A COURSE SIM-
ULAR TO THE ONE EMPLOYED FOR THE NO. 4 UNIT AT THIS STATION. SPECIFICALLY, A TWO-TRAIN VENTURI-ROD
SCRUBBER AND SPRAY TOWER ABSORBER ASSEMBLY IS BEING INSTALLED ALONGSIDE THE EXISTING MARBLE-BED
SYSTEM. THE MARBLE-BED UNITS WILL REMAIN IN SERVICE UNTIL THE NEW SPRAY TOWER SYSTEM HAS BEEN COMP-
LETED AND DUCTED INTO THE BOILER FLUE GAS STREAM. THIS WILL OCCUR SOMETIME DURING THE COURSE OF
1978. ADDITIONAL DATA AND INFORMATION IS PROVIDED IN THE TABLE THAT FOLLOWS. A FLOW DIAGRAM OF THE
INJECTION SYSTEM IS PROVIDED IN APPENDIX B.
65
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KANSAS POWER & LIGHT
LAWRENCE UNIT NO. 5
OPERATING HOURS
MONTHS BOILER FGD MODULES
WYOMING COAL IS BEING BURNED IN THIS UNIT. FGD SYSTEM AVAILABILITY IS REPORTED T0_f^ *DE"
QUATE FOR OPERATION OF THIS STATION. SINCE STATION LOAD IS REDUCED'TO 50 PERCENT EVERY
NIGHT, AS MANY AS FOUR MODULES CAN BE SHUT DOWN FOR CLEANING AND REPAIR EACH EVENING.
FGD UNITS WERE OFF-LINE MOST OF JUNE FOR MAJOR REBUILDING OF THE SPRAY SYSTEMS IN ALL
MODULES. SOME OIL WAS BURNED TO ALLOW BYPASSING OF THE REPAIR.
NOT LOGGED
OIL AND GAS WERE BURNED IN JULY AND AUGUST. NO FGD OPERATION.
NOT LOGGED
GAS AND OIL BURNED ON A PART-TIME BASIS DURING SEPTEMBER AND OCTOBER. BOILER OUTAGE WAS DUE
TO INSPECTION, TURBINE REPAIR, AND REPLACEMENT OF THE SLURRY TANK SCREEN.
NOT LOGGED
JUL. 75
AUG. 75
SEP. 75
OCT. 75
NOV. 75
DEC. 75
JAN
76 NOT LUGGED
PROJECTIONS BY THE UTILITY FOR THIS UNIT CALL FOR 330 DAYS OF OPERATION IN 1976 WITH FUEL
CONSUMPTION BEING 60 PERCENT COAL, 25 PESCENT FUEL OIL, AND 15 PERCENT NATURAL GAS. LIKE
UNIT 0, THIS UNIT MAY BE CONVERTED TO A VENTRI-ROD AND SPRAY TOWER SCRUBBING SYSTEM.
FEB. 76
MAR. 76
NO INFORMATION WAS REPORTED BY THE UTILITY FOR THE PERIOD.
APR. 76
MAY. 76
NO INFORMATION WAS REPORTED BY THE UTILITY FOR THE PERIOD.
JUN. 76
JUL. 76
AUG. 76
SEP. 76
NO INFORMATION WAS REPORTED BY THE UTILITY FOR THE PERIOD.
NO INFORMATION WAS REPORTED BY THE UTILITY FOR THE PERIOD.
OCT. 76
NOV. 76
DEC. 76
THE UTILITY REPORTS THAT THE INSTALLATION OF THE NEW ROD AND SPRAY TOWER SCRUBBING SYSTEM IS
NOW IN PROGRESS. THE SYSTEM WILL INCLUDE TWO SCRUBBING TRAINS, EACH HANDLING 50 PERCENT OF
THE FLUE GAS CAPACITY. FOUNDATION AND STRUCTURAL STEEL ERECTION HAS BEEN COMPLETED. SOME
OF THE BREECHING HAS BEEN INSTALLED. THE FGD SYSTEM WILL OPERATE ON A FULLY AUTOMATED BASIS.
KP&L REPORTS THAT C-E HAS ENCOUNTERED SOME PROBLEMS WORKING OUT AND FINE-TUNING SOME OF THE
LOGIC CIRCUITS. THE BOILER FIRES NO.a FUEL OIL IN ADDITION TO LOW SULFUR WYOMING COAL WHILE
THE NEW SCRUBBING FACILITIES ARE BEING INSTALLED. THE ORIGINAL INJECTION AND TAIL-END SCRUB-
BING SYSTEM IS STILL AVAILABLE FOR SERVICE AND OPERATED WHEN THE UNIT FIRES COAL. THE SYSTEM
WILL TREAT FLUE GAS RESULTING FROM THE BURNING OF LOW SULFUR CO.5 PERCENT) WYOMING COAL.
JAN. 77
FEB. 77
MAR. 77
APR. 77
MAY 77
JUN.
JUL.
KP&L REPORTED THAT CONSTRUCTION OF THE NEW SCRUBBING SYSTEM IS STILL IN PROGRESS. ALL
FOUNDATION WORK HAS BEEN COMPLETED. ERECTION OF THE STRUCTURAL STEEL AND BREECHING IS CON-
TINUING. THE ORIGINAL SCRUBBING SYSTEM IS STILL AVAILABLE FOR SERVICE. THE INJECTION AND
TAIL-END SCRUBBER PLANT WAS IN SERVICE AND OPERATED WHEN THE BOILER FIRED COAL. ERECTION OF
THE NEW SCRUBBER PLANT IS CONTINUING. THE MODULES ARE NOW BEING ERECTED AT THE PLANT SITE,
PARALLEL TO THE EXISTING MARBLE-BED SYSTEM.
77
77
OPERATION OF THE EXISTING MARBLE BED SCRUBBERS HAS BEEN QUITE SATISFACTORY AND NEARLY PROBLEM
FREE. CONSTRUCTION ON THE NEW SCRUBBER PLANT IS CONTINUING. THE TWO PARALLEL SCRUBBING
MODULES, EACH DESIGNED To HANDLE FLUE GAS FROM 200 MW OF GENERATING CAPACITY, ARE INSTALLED,
AS ARE THE REHEATER TUBE BUNDLES. THE CUNNECTINU DUCTWORK IS CURRENTLY GOING IN. THE EXIST-
ING MARBLE BED SCRUBBERS WILL BE REMOVED WHEN THE NEW SCRUBBING SYSTEM IS HEADY FOR S02 RE-
MOVAL OPERATIONS.
AUG.
SEP.
77
77
THE CONSTRUCTION ON THE NEW SCRUBBER PLANT IS CONTINUING ACCORDING TO SCHEDULE AND IS EXPECT-
ED TO BE COMPLETE BY APRIL 1978. KP&L INDICATED THAT MOKE DETAILED INFORMATION WILL BE
AVAILABLE FOR THE NEXT REPORT.
66
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KANSAS POWER & LIGHT
LAWRENCE UNIT NO. 5
MONTHS
OCT. 77
NOV. 77
1
DEC. 77
JAN. 78
OPERATING HOURS
BOILER FGD MODULES
THE SYSTEM OPERATED UNDER NORMAL CONDITIONS THROUGHOUT OCTOBER AND NOVEMBER WITH NO PROBLEMS.
THE CONSTRUCTION OF TWO NEK VENTURI SCRUBBERS IS OVER. INLET DUCTWORK IS BEING INSTALLED.
THE OUTLET DUCTWORK WILL BE INSTALLED ALONG WITH ADDITIONAL CONTROLS DURING THE SCHEDULED
OUTAGE IN APRIL 78. PRESENT FGO SYSTEM OPERATED WITHOUT ANY PROBLEMS.
67
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
KENTUCKY UTILITIES
GREEN RIVER NUS. 1 2 AND 3
CENTRAL CITY KENTUCKY
6U MW
COAL 3.8 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
RETROFIT
9/75
OPERATIONAL
99.7 PERCENT
S02
80 PERCENT GUARANTEE
WATER MAKE UP
OPEN LOOP 1.20 GPM/MW
SLUDGE DISPOSAL
PLANT SITE DISPOSAL POND
UNIT COST
SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE SCRUBBER PLANT INSTALLED AT THIS STATION CONSISTS OF ONE MODULE
DESIGNED TO REMOVE PARTICULATES (VARIABLE-THROAT VENTURI) AND S02 (MOBILE
-BED ABSORBER) FROM COAL-FIRED BOILER FLUE GAS. THE SCRUBBER WAS DESIGNED
AND SUPPLIED BY AAF. INITIAL SCRUBBER PLANT STARTUP OCCURRED IN SEPTEMBER
1975. SCRUBBING OPERATIONS RESUMED IN NOVEMBER FOLLOWING A 5-MONTH SHUT-
DOWN RESULTING FROM A STRIKE BY PLANT OPERATING PERSONNEL. THE SYSTEM
HAS HAD LOW AVAILABILITY BECAUSE OF FROZEN EQUIPMENT.
63
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BACKGROUND INFORMATION
ON
GREEN RIVER POWER STATION
THE GREEN RIVER POWER STATION IS WHOLLY OWNED AND OPERATED BY THE KENTUCKY UTILITIES COMPANY
AND SITUATED ON THE GREEN RIVER, NEAR CENTRAL CITY IN MUHLENBERG COUNTY, KENTUCKY. THE STATION CON-
SISTS OF FOUR TURBINE GENERATORS AND FIVE COAL-FIRED BOILERS. TOTAL PLANT POWER-GENERATING CAPACITY
IS APPROXIMATELY 242 MW.
AS THE RESULT OF A CONTRACT AWARDED BY KENTUCKY UTILITIES (KU) TO AMERICAN AIR FILTER (AAF), A
TAIL-END WET LIME SCRUBBING SYSTEM WAS DESIGNED AND INSTALLED ON BOILERS 1, 2, AND 3 AT THE GREEN
RIVER STATION.
THE FLUE GAS DESULFURIZATION CFGD) AND PARTICULATE REMOVAL SYSTEM CONSISTS OF ONE SCRUBBER
MODULE DESIGNED TO HANDLE A MAXIMUM OF 360,000 ACFM OF FLUE GAS AT 300 F. THE BLOW-THROUGH SCRUBBER
MODULE CONTAINS A VARIABLE-THROAT FLOODED-ELBOW VENTURI FOR FLY ASH REMOVAL AND A MOBILE BED CON-
TACTOR FOR SULFUR DIOXIDE REMOVAL. ENTRAINED WATER DROPLETS ARE REMOVED VIA A CENTRIFUGAL DEMISTER
BEFORE DISCHARGE TO A LOCAL STACK. THE SLURRY RECYCLE/DISCHARGE SYSTEM CONSISTS OF ONE COMMON ACID
RESISTANT TANK WITH TWO PARTITIONS MAKING A TOTAL OF THREE COMPARTMENTS. COMPLETION OF CHEMICAL
REACTIONS, RECIRCULATION OF SOLUTION AND WASTES DISCHARGE ARE CONTROLLED AND MONITORED HERE. MECH-
ANICAL COLLECTORS ARE PROVIDED UPSTREAM OF THE WET SCRUBBING SYSTEM FOR PRIMARY PAftTICULATE MATTER
REMOVAL.
THE SCRUBBER LINING WAS INITIALLY "CARBOLINE" WHICH HAD TO BE REPLACED DUE TO EXCESSIVE
FLAKING. IN JANUARY 77, THE SCRUBBER AND STACK WERE RELINED BY PRECRETE. THE L/G RATIO MAINTAINED
IS 39.5 AND A PH OF 7.8-8 IS MAINTAINED AT THE INLET OF THE SCRUBBER. THE GAS TEMPERATURE AT THE
OUTLET IS 115 F WHEREAS THE SLURRY HAS AN OUTLET PH VALUE OF 5.6-6. THE SOLIDS CONTENT OF THE
RECIRCULATING SLURRY IS 20X. THE SCRUBBER INTERNALS ARE POLYURETHANE PING-PONG BALLS (1 1/2 IN.
DIA.). THE RECIRCULATING PUMPS WERE RUBBER LINED. THEY WERE REPLACED BY HIGH NI ALLOY MATERIAL.
BOILERS 1, 2, AND 3 ARE PULVERIZED COAL-FIRED UNITS SERVICING TWO TURBINES, EACH RATED AT 32 MW
(GROSS). THE FUEL BURNED IN THESE UNITS IS PRIMARILY A HIGH SULFUR WESTERN KENTUCKY COAL (10,797
BTU/LB., 3.8 TO 4.0 PERCENT SULFUR, 13 TO 14 PERCENT ASH). THE FGD SYSTEM CAN BE BYPASSED THROUGH A
SERIES OF DUCTWORK AND GUILLOTINE DAMPERS.
A TURNKEY CONTRACT FOR THIS PROJECT WAS AWARDED TO AAF IN JUNE 1973. CONSTRUCTION AND INSTAL-
LATION OF THE SYSTEM WAS COMPLETED BY MID-SEPTEMBER 1975. FOLLOWING GENERAL ELECTRICAL AND MECH-
ANICAL DEBUGGING, WHICH INCLUDED OPERATION OF THE AGITATORS AND PUMPS, THE UNIT WAS PUT IN SERVICE
ON AIR AND WATER ONLY IN AUGUST 1975. DURING THIS OPERATION PERIOD, THE FLOW OF GAS AND LIQUID,
OPERATION OF DAMPERS, AND SPRAY PATTERNS WERE MONITORED AND CALIBRATED. NEXT, THE SYSTEM WAS
OPERATED ON AIR AND WATER UNDER NORMAL PROCESS CONDITIONS. THE PURPOSE OF THIS PHASE OF OPERATION
WAS TO DETECT ANY EARLY FAILURES OF A MECHANICAL NATURE PRIOR TO THE INITIAL FLUE GAS RUN.
THE FLUE GAS RUN COMMENCED THE MORNING OF SEPTEMBER 13, 1975. INITIAL OPERATION PROCEEDED ON A
HALF-LOAD BASIS BECAUSE ONE OF THE TURBINE GENERATORS WAS OUT OF SERVICE FOR OVERHAUL AND REPAIRS.
IN ADDITION, OPERATION OF THE SCRUBBING SYSTEM WAS CONDUCTED ON AN OPEN-WATER-LOOP BASIS. THIS MODE
OF OPERATION (HALFLOAD, OPEN LOOP) CONTINUED INTO THE FIRST QUARTER OF 1976. IN MARCH, THE SYSTEM
BEGAN OPERATION AT FULL LOAD CAPACITY IN A CLOSED-WATER-LOOP MODE. GUARANTEED SULFUR DIOXIDE
REMOVAL EFFICIENCY IS 80 PERCENT FOK 3.8 PERCENT SULFUR COAL HAVING A HEATING VALUE EQUAL TO OR
GREATER THAN 11,000 BTU/LB.
ADDITIONAL INFORMATION ON THE OPERATION OF THIS SYSTEM IS PRESENTED IN THE PERFORMANCE TABLE
THAT FOLLOWS. A GENERAL PROCESS FLOW DIAGRAM IS PRESENTED IN APPENDIX B.
69
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KENTUCKY UTILITIES GREEN RIVER UNIT NOS. 1, 2, AND 3
TOTAL BOILER MODULE MODULE CALLED HR. MODULE
PERIOD PERIOD (HR) OPERATION (HR) AVAILABILITY (HR) TO OPERATE (HR) OPERATED
DEC. 75 744 398 550 331 257
AVAILABILITY = 74X
RELIABILITY a 78X
OPERABILITY a 65X
UTILIZATION s 35X
SYSTEM BECAME OPERATIONAL SEPTEMBER 13, 1975 ON A HALF-LOAD BASIS BECAUSE OF TURBINE OVER-
HAUL. THE HALF-LOAD MODE CONTINUED THROUGHOUT THE REPORT PERIOD. LOGGING OF OPERATING DATA
BEGAN DECEMBER 1975.
JAN. 76 744 572 312 456 6"
AVAILABILITY = 42X
RELIABILITY a 14X
OPERABILITY a 11X
UTILIZATION a 9X
SYSTEM WAS DOWN A TOTAL OF 432 HOURS IN JANUARY. MAJOR PROBLEMS WERE FAILURE OF THE RECYCLE
PUMPS AND FEED TANK AGITATOR. THAWING AND REPAIR OF NUMEROUS FROZEN LINES, AND SHUTDOWN OF
SUMP PUMPS WAS NECESSARY.
FEB. 76 696 499 486 499 211
AVAILABILITY = 70X
RELIABILITY = 42X
OPERABILITY * 42X
UTILIZATION * 30X
THE SYSTEM WAS INOPERATIVE A TOTAL OF 210 HOURS IN FEBRUARY. OUTAGE WAS DUE TO REPAIRS OF
TANK AGITATORS, RECYCLE PUMPS, AND REACTANT PUMPS AND TO CLEANOUT OF REACTANT PUMPS, SLURRY
PUMPS, SLAKE TANKS, AND MIX-HOLD TANK.
MAR. 76 744 450 722 409 386
AVAILABILITY = 97x
RELIABILITY = 95X
OPERABILITY s 85X
UTILIZATION = 52X
DURING THE REPORT PERIOD ALL THE RUBBER-LINED IMPELLERS WERE REPLACED IN THE PUMPS.
APR. 76 720 522 648 522 522
AVAILABILITY = 90X
RELIABILITY * 100X
OPERABILITY = 100X
UTILIZATION s 77X
THE UTILITY MADE A PRIOR COMMITMENT TO RUN AT 100 PERCENT OPERABILITY DURING THE MONTH OF
APRIL.
MAY 76 744 456 606 456 456
AVAILABILITY = SIX
RELIABILITY = 100X
OPERABILITY = 100X
UTILIZATION = 61X
JUN. 76 720 597 720 596 589
AVAILABILITY = 100X
RELIABILITY = 99X
OPERA8ILITY a 99X
UTILIZATION = 82X
JUL. 76 744 584 666 581 574
AVAILABILITY = 90X
RELIABILITY = 99X
OPERABILITY = 98X
UTILIZATION s 72X
AUG. 76 744 744 722 744 72g
AVAILABILITY = 97X
RELIABILITY = 97X
OPERA6ILITY = 97X
UTILIZATION « 97X
THE MAJORITY OF THE TOTAL FORCED SCRUBBER OUTAGE TIME OCCURRED BECAUSE OF VIBRATION IN THF
SCRUBBER BOOSTER I.D. FAN NECESSITATING SYSTEM SHUTDOWN AND REPAIR
70
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KENTUCKY UTILITIES GREEN RIVEk UNIT NOS. 1, 2, AND 3
TOTAL BOILER MODULE MODULE CALLED HR. MODULE
PERIOD PERIOD (HR) OPERATION (HR) AVAILABILITY (HR) TO OPERATE (HR) OPERATED
SEP. 76 720 571 617 571 571
AVAILABILITY = 86X
RELIABILITY a IOOX
OPERABILITY a 100X
UTILIZATION = 79X
HALF-LOAD OPERATIONS WERE CONDUCTED THROUGHOUT THE PERIOD BECAUSE OF BEARING PROBLEMS TO ONE
OF THE TWO TURBINE GENERATING UNITS. MINOR FAN PROBLEMS OCCURRED BUT NO FURCED OUTAGE TIME
WAS REQUIRED.
OCT. 76 744 699 744 699 699
AVAILABILITY - IOOX
RELIABILITY s IOOX
OPERABILITY s IOOX
UTILIZATION a 94X
NOV. 76 720 704 720 704 704
AVAILABILITY = IOOX
OPERABILITY = IOOX
RELIABILITY a 98X
UTILIZATION * 98X
DURING NOVEMBER AND DECEMBER SOME FLUE GAS WAS BY-PASSED AROUND THE SYSTEM WHILE THE UTILITY
CONDUCTED A CHECKOUT OF THE SCRUBBER INTERNALS AND REPLACED SOME OF THE PACKING SPHERES IN
THE MOBILE BED.
DEC. 76 744 536 539 591 517
AVAILABILITY - 73X
OPERABILITY = 97X
RELIABILITY a 87X
UTILIZATION a 70X
JAN. 77 744 744 698 744 698
AVAILABILITY a 94X
OPERABILITY a 94X
RELIABILITY f 94X
UTILIZATION a 94X
NO PROBLEMS OCCURRED DURING THE MONTH OF JANUARY.
FEB. 77 672 266 243 266 243
AVAILABILITY a 36X
OPERABILITY = 91X
OPERABILITY a 91X
UTILIZATION a 36X
DURING THE MONTH OF FEBRUARY IT WAS FOUND THAT THE CARBOLINE STACK LINER WAS BADLY DETERIOR-
ATED. SCRUBBER AND BOILER OPERATIONS WERE TERMINATED UNTIL THE STACK LINING IS REPAIRED.
THE BOILER IS NOT OPERATED WITHOUT THE SCRUBBER BECAUSE THERE IS NO ESP FOR PARTICULATE
CONTROL. A MAY FIRST RE-START IS CURRENTLY PLANNED.
MAR. 77 744 0 0 00
ALL INDEX VALUES a OX
APR. 77 720 167 268 167 164
AVAILABILITY a 40X
RELIABILITY = 98X
OPERABILITY a 96X
UTILIZATION a 23X
CURRENT PLANT LOAD REQUIREMENTS DICTATE THAT OF THE THREE AVAILABLE BOILERS, ONE OR TWO ARE
ON-LINE AT A GIVEN TIME AND THE THIRD IS UNDERGOING MAINTENANCE OPERATIONS.
MAY 77 744 527 736 527 513
AVAILABILITY = 99X
RELIABILITY = 98X
OPERABILITY a 96X
UTILIZATION a 69X
THE STACK WAS REPAIRED FIRST BY WELDING A BACKUP METAL PLATE TO THE PORTIONS OF THE STACK
WHERE PITTING OCCURRED. THE ENTIRE STACK WAS THEN LINED WITH REFRACTORY COATING CALLED PRE-
CRETE G-8 BY AAF. STACK REPAIRS WERE COMPLETED MARCH 7.
JUN. 77 720 34 720 34 34
AVAILABILITY a IOOX
RELIABILITY a IOOX
OPERABILITY » 100X
UTILIZATION a 5X
WORK ON THE SCRUBBER MODULE DURING THE MONTH CONCERNED REPAIRS TO THE UNDERBED DAMPER SYSTEM.
LEAKING IN THE VENTURI AND LIME SLAKING OPERATIONS WAS ALSO REPAIRED.
71
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KENTUCKY UTILITIES
GREEN RIVER UNIT NOS. It
AND
PERIOD
JUL. 77
TOTAL
PERIOD (HR)
744
BOILER
OPERATION (HR)
MODULE
AVAILABILITY (HR)
744
MODULE CALLED
TO OPERATE (HR)
0
HR. MODULE
OPERATED
AVAILABILITY = icox
ALL OTHER INDEX VALUES = OX
A STRIKE BY PLANT OPERATING PERSONNEL RESULTED IN NO OPERATIONS FOR BOILERS 1, 2« *ND 3 OR
THE SCRUBBER MODULE THROUGHOUT THE MONTH. KU IS CONSIDERING INCLUDING A STACK GAS REHEAT
SYSTEM AND MODIFYING THE MIST ELIMINATOR (HADIAL VANE TO A CHEVRON-TYPE UNIT).
AUG. 77 744 0 744 0
AVAILABILITY = 100X
ALL OTHER INDEX VALUES - OX
THE STRIKE CONTINUED THROUGH THE MONTHS OF AUGUST AND SEPTEMBER.
HAVE STARTED ON OCTOBER 10.
(I 744 0
THE PLANT WAS KEPORTED TO
SEP. 77 720 0
AVAILABILITY = 10UX
ALL OTHER INDEX VALUES = OX
UNITS 1, 2, AND 3 AND SCRUBBER REMAINED OUT OF SERVICE BECAUSE OF THE CONTINUING PLANT
STRIKE.
0 744 0 0
OCT. 77 744 0
AVAILABILITY * icox
ALL OTHER INDEX VALUES = OX
FGO SYSTEM WAS DOWN THIS MONTH DUE TO A STRIKE, HOWEVER, THE SYSTEM WAS AVAILABLE.
AND SCRUBBER WERE BACK IN SERVICE IN NOVEMBER.
THE UNITS
332
634
332
301
NOV. 77 720
AVAILABILITY = 86X
RELIABILITY =
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
LOUISVILLE GAS & ELECTRIC
CANE RUN NO 4
LOUISVILLE KENTUCKY
176 MM
COAL 3.5 - 4.0 PERCENT SULFUR
AMERICAN AIR FILTER
LIME SCRUBBING
RETROFIT
8/76
OPERATIONAL
99 PERCENT
soa
65 PERCENT
MATER MAKE UP
OPEN LOOP
SLUDGE DISPOSAL
PLANT-SITE DISPOSAL POND
UNIT COST
SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE FGD SYSTEM RETROFITTED ON THIS BOILER WAS DESIGNED AND SUPPLIED BY
AMERICAN AIR FILTER AND WAS FIRST PLACED IN THE GAS PATH ON AUGUST 7,
1976. THE SYSTEM CONSISTS OF TWO PARALLEL MODULES WHICH INCLUDE MOBILE
BED CONTACTORS AND OPERATE WITH A CARBIDE LIME ADDITIVE. FOLLOWING A
NUMBER OF MAJOR SYSTEM MODIFICATIONS (CHEVRON-TYPE MIST ELIMINATOR, OIL
FIRED REHEAT, PLASITE DUCT LINER, HIGHER L/G), THE SYSTEM SUCCESSFULLY
PASSED COMPLIANCE TESTING (85X 502 REMOVAL) ON AUGUST 3 AND 4, 1977.
73
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BACKGROUND INFORMATION
ON
CANE RUN NO. 4
THE CANE RUN POWER STATION IS OPERATED BY THE LOUISVILLE GAS AND ELECTRIC COMPANY AND LOCATED
IN LOUISVILLE, KENTUCKY. THE PLANT CONSISTS Of SIX ELECTRIC POWER STEAM GENERATING UNITS HAVING A
TOTAL STEAM TURBINE NET GENERATING CAPACITY OF 992-MW.
UNIT NO. 4 IS A COAL-FIRED STEAM GENERATING BOILER WITH A CONTINUOUS NET GENERATING CAPACITY OF
176-MW. THE UNIT HAS A MAXIMUM POWER GENERATION CAPACITY OF 190-MW. THE UNIT HEAT RATE IS JO,030
BTU/KWH. THE BOILER IS CURRENTLY BURNING COAL WITH A GROSS HEATING VALUE OF 11,500 BTU/LB AND AVE-
RAGE SULFUR AND ASH CONTENTS OF 3.5-4.0 PERCENT AND 11.0-12.0 PERCENT, RESPECTIVELY.
THE EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF AN ELECTROSTATIC PRECIPITATION (ESP) UP-
STREAM OF A WET SCRUBBING SYSTEM. THE ESP PROVIDES PRIMARY PARTICULATE CONTROL WHILE THE WET SCRUB-
BING SYSTEM PROVIDES ADDITIONAL PARTICULATE REMOVAL AND PRIMARY SULFUR DIOXIDE CONTROL.
THE FLUE GAS DESULFURIZATION (FGD) SYSTEM CONSISTS OF TWO IDENTICAL PARALLEL SCRUBBING TRAINS
DESIGNED AND SUPPLIED BY THE AMERICAN AIR FILTER CAAF) COMPANY. THE WET SCRUBBING SYSTEM UTILIZES A
SLURRY OF CARBIDE LIME FOR SULFUR DIOXIDE REMOVAL FROM THE FLUE GAS. THE CARBIDE LIME IS A WASTE 8Y
-PRODUCT OBTAINED FROM A NEARBY ACETYLENE MANUFACTURING PLANT. THE HYDRATED LIME CONTAINS 90.9 TO
92.0 PERCENT CALCIUM HYDROXIDE, 2.0 TO 2.5 PERCENT SILICA, 3.0 TO 8.0 PERCENT CALCIUM CARBONATE, AND
0.1 PERCENT MAGNESIUM OXIDE.
EACH SCRUBBING TRAIN IS EQUIPPED WITH A GUILLOTINE-TYPE BY-PASS DAMPER ALLOWING BY-PASSING OF
THE GAS AROUND THE SCRUBBERS. EASH 5CRUBBBING TRAIN CONTAINS THE FOLLOWING MAJOR PIECES OF EQUIP-
MENT: I.D. BOOSTER FAN, UUENCH SECTION, FLOODED ELBOW, MOBILE BED CONTACTOR, CENTRIFUGAL DEMISTER,
AND A 3-SECTION REACTANT TANK SYSTEM. THE WASTE DISPOSAL SYSTEM CONSISTS OF A 75-FOOT DIAMETER
THICKENER FOR LIQUID-SOLIDS SEPARATION AND A FLY ASH POND FOR ULTIMATE DISPOSAL OF THE THICKENER
UNDERFLOW. THE SCRUBBING WASTES ARE STABILIZED WITH FLY ASH AND WATER IS RECYCLED BACK TO THE PROC-
CESS. THE ORIGINAL SYSTEM DESIGN DOES NOT INCLUDE STACK GAS REHEAT CAPABILITY. THE SCRUBBED GASES
ARE DISCHARGED TO AN EXISTING 250-FOOT, ACID BRICK-LINED STACK.
THE GAS FLOW RATE IS 370.000 ACFM ol 320 F. THE OUTLET GAS TEMPERATURE IS 130 F. A PH OF 9-9.2
IS MAINTAINED IN THE SCRUBBER WHICH IS LINED WITH PRECRETE AND PLACITE 4005 AND PACKED WITH 1 1/4
IN. DIA. POLYURETHANE BALLS. THE L/G RATIO VARIES FROM 55 FOW ABOVE 140 MW TO 65 FOR UNDER 100 MW.
THE I.D. FANS ARE SITUATED BEFORE THE SCRUBBER AND CONSUME 1100 HP.
THE PERFORMANCE TABLE THAT FOLLOWS SUMMARIZES THE OPERATING HISTORY, PROBLEMS/SOLUTIONS AND
MODIFICATIONS SINCE STARTUP. A SIMPLIFIED PROCESS FLOW DIAGRAM IS PROVIDED IN APPENDIX B OF THIS
REPORT.
74
-------
LOUISVILLE GAS AND ELECTRIC
F6D SYSTEM PERFORMANCE
CANE RUN UNIT NU.
PERFORMANCE FACTORS (X)
PERIOD HOURS BOILER (HR) SCRUBBERS (HR) OPERABILITY UTILIZATION
AUG. 76 744 740 666 90 90
OUTAGE TIME DURING THE MONTH WAS DUE PRIMARILY TO EQUIPMENT INSPECTIONS, REPAIR/ REPLACEMENT
OF AUXILIARY MOTOR PARTS, AND DEPLETION OF ABSORBENT SUPPLY BECAUSE OF A LATE BAKGE DELIVERY.
THE SCRUBBING SYSTEM HAS BEEN GENERALLY OPERATING AT APPROXIMATELY 50 TO 80 PERCENT FLUE GAS
CAPACITY. SOME MINOR PROBLEMS HAVE BEEN ENCOUNTERED WITH AUXILIARY EQUIPMENT MOTORS AND
SPRAY NOZZLES IN THE MOBILE BED CONTACTOR. THE SPRAY NOZZLES ARE SPINNEK-VANE COMPONENTS
ORIGINALLY CONSTRUCTED OF PLASTIC. OPERATING TEMPERATURES AND PRESSURES HAVE CAUSED THE
PLASTIC HOUSING TO EXPAND RESULTING IN THE VANES EXTRUDING OUT THE FRONT END, SUBSEQUENTLY
CAUSING A BLOCKAGE OF THE SLURRY FEED. THE NOZZLES HAVE BEEN REPLACED WITH CERAMIC CON-
STRUCTED COMPONENTS.
SEP. 7b
720
720
650
90
90
OCT. 76 744 600 540 90 73
THE SYSTEM WAS IN SERVICE THROUGHOUT THE MONTH, BEING AVAILABLE TO THE BOILER ON A 90 PERCENT
BASIS. THE UNIT WAS TAKEN OUT OF SERVICE ON OCTOBER 25 TO IMPLEMENT ADDITIONAL MODIFICATIONS
TO THE SCRUBBING SYSTEM. MAJOR SYSTEM MODIFICATIONS INCLUDE INCREASING PUMP CAPACITY AND DE-
CREASING PRESSURE DROP. THESE TWO PROBLEMS HAVE HINDERED OPERATION OF THE UNIT AT FULL LOAD
CAPACITY. TO DATE, THE MECHANICAL RELIABILITY OF THE SYSTEM, AS A FUNCTION OF SERVICE TIME
VERSUS OUTAGE TIME, HAS BEEN VERY GOOD.
NOV. 76 720
95
DEC. 76 744 90
THE SYSTEM INCURRED NO MAJOR PROBLEMS OR UPSETS DURING THE REPORT PERIOD.
SLURRY IS EMPLOYED AS THE SULFUR DIOXIDE ABSORBENT.
CARBIDE LIME
JAN. 77 744 00 00
DURING JAN.l - JAN.11, THE SCRUBBER WAS UTILIZED 95 PERCENT OF THE TIME. THEN THE OHIO RIVER
BECAME IMPASSABLE DUE TO ICE FORMATION AND THIS CAUSED THE CESSATION OF BARGE DELIVERIES OF
LIME.
FEB. 77 672 00 00
DURING FEBRUARY, THE SCRUBBER WAS ONLY OPERATED FOR TWO 4-HOUR PERIODS TO PREVENT TOTAL
FREEZE-UP.
MAR. 77
744
432
(AFTER
RESTART)
358
(AFTER
RESTART)
«3X
(AFTER
RESTART)
63%
(AFTER
RESTART)
IN MARCH, THE SCRUBBER CAME BACK ON-LINE AT 10 AM, ON MARCH 14TH, AND HAS RUN CONTINUOUSLY
THROUGH THE END OF THE PERIOD. FROM THE 14TH THROUGH THE END OF THE MONTH, THERE WAS ONE
PERIOD OF SCRUBBER BY-PASS, WHEN DC SUPPLY TO THE BY-PASS HAD TO BE REPAIRED.
APR. 77
MAY 77
THE SCRUBBER SYSTEM RAN FOR THE FIRST 18 DAYS IN APRIL, WITH A RELIABILITY OF 95X. FROM THAT
TIME (APRIL 18) THROUGH AN EXPECTED DATE OF JULY Id, THE SCRUBBER SYSTEM WILL BE DOWN FOR THE
FOLLOWING MODIFICATIONS:
1. TO REMOVE DEMISTER AND REPLACE WITH A CHEVRON TYPE.
2. TO INCREASE L/G BY ADDING A NEW SPRAY HEADER.
3. TO ADD DIRECT, OIL-FIRED REHEAT, AND
4. TO REPLACE THE LINING IN THE SYSTEM FROM THE DEMISTER THROUGH THE STACK WITH PLASTITE
4005 TO BE INSTALLED BY GENERAL COATINGS (THE ORIGINAL LINING WAS BUBBLING, BUT HAD NOT
YET FAILED; FAILURE SEEMED IMMINENT WITHIN 4-5 MONTHS).
SYSTEM REMAINED OUT OF SERVICE PENDING COMPLETION OF SYSTEM MODIFICATIONS.
JUN. 77
JUL. 77
744 360 324 90 90
(AFTER (AFTER (AFTER (AFTER
RESTART) RESTART) RESTART) RESTART)
SYSTEM MODIFICATIONS WERE COMPLETED AND THE SCRUBBER PLANT WAS PLACED BACK IN SERVICE ON JULY
17. ON AUGUST 4 THE SYSTEM UNDERWENT AND SUCCESSFULLY COMPLETED TESTING FOR COMPLIANCE WITH
LOCAL (JEFFERSON COUNTY) AND FEDERAL S02 AIR EMISSION REGULATIONS. THE ABOVE-MENTIONED MOD-
IFICATIONS ENABLED THE SYSTEM TO EXCEED THE 85X S02 REQUIREMENT (JEFFERSON COUNTY) AND FED-
ERAL STANDARD (1.2 LB/MM BTU). ACTUAL TEST RESULTS INDICATED AN 86 TO 89X S02 REMOVAL EF-
FICIENCY FOR 3.3 TO 3.4X SULFUR COAL, WHICH IS EQUIVALENT TO AN OUTLET EMISSION VALUE OF
0.8 LB/MM BTU HEAD INPUT. ALL TESTING WAS PERFORMED BY EPA PERSONNEL.
AUG. 77
744
657
588
94
93
SEP. 77 720 529 524 99 99
THE FGD SYSTEM WAS FURTHER TESTED USING METHOD 6 BY FEDERAL EPA AND WAS OFFICIALLY APPROVED
TO HAVE ACHIEVED COMPLIANCE. THE SYSTEM PERFORMED VERY WELL DURING THIS PERIOD.
75
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LOUISVILLE GAS AND ELECTRIC CANE RUN UNIT MO. 4
PERFORMANCE FACTORS cx>
PERIOD HOURS BOILER (MR) SCRUBBERS (HR) OPERABILITY UTILIZATION
OCT. 77 744 677 662 9ft 69
EPA MAY CONTINUE TO TEST THROUGHOUT JANUARY. NO REAL PROBLEMS ENCOUNTERED IN MAINTAINING
COMPLIANCE.
NOV. 77 720 483 454 94 63
DEC. 77 744 715 608 85 82
JAN. 78 67 67
NO PROBLEMS OCCURRED DURING THIS PERIOD TO CREATE ANY FGD DOWNTIME. DURING DECEMBERf
"AIKCO", THE LIME SUPPLIER, HAD 1200 FT OF THEIR FEED LINE FREEZE UP. LIME BECAME UNAVAIL-
ABLE FOR A TIME BUT THERE WERE NO SCRUBBER BREAKDOWNS,
76
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F60 SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY,
PARTICULATES
LOUISVILLE GAS & ELECTRIC
PADDYS RUN NO fc
LOUISVILLE KENTUCKY
65 MW
COAL 3.5 - «.0 PERCENT SULFUR
COMBUSTION ENGINEERING
LIME SCRUBBING
RETROFIT
a/73
OPERATIONAL
99 PERCENT
soe
60 PERCENT
WATER MAKE UP
OPEN LOOP 0.7 GPM/MW
SLUDGE DISPOSAL
HAULAWAY TO BORROW PIT
UNIT COST
OPERATIONAL
EXPERIENCE
SEE APPENDIX A, FGD SYSTEM ECONOMICS
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT,
THIS SCRUBBING SYSTEM WAS DESIGNED BY COMBUSTION ENGINEERING AND PLACED
IN SERVICE IN APRIL 1973. THE FGD SYSTEM CONSISTS OF TWO 2-STAGE MARBLE
BED ABSORBERS WHICH ARE DESIGNED TO USE CARBIDE LIME ADDITIVE AS THE
SCRUBBING REAGENT. PADDYS RUN NO. is A PEAK-LOAD UNIT THAT OPERATES
ONLY DURING DEMAND PERIODS. AN EXTENSIVE EPA SCRUBBER/SLUDGE EVALUATION
STUDY WAS COMPLETED IN AUGUST 1977.
77
-------
BACKGROUND INFORMATION
ON
PADDY'S RUN NO. 6
PADDY'S RUN POWER STATION IS LOCATED IN LOUISVILLE, KENTUCKY. THE PLANT HAS SIX ELECTRIC POWER
GENERATING UNITS WITH A TOTAL RATED CAPACITY OF 320 MW. UNIT NO. 6 IS RETROFITTED WITH A CARBIDE
LIME-BASED FSD SYSTEM.
UNIT NO. 6 IS A PEAK LOAD COAL-FIRED BOILER. MANUFACTURED BY FOSTER WHEELER AND INSTALLED IN
1950. THIS UNIT FIRES COAL WITH A GROSS HEATING VALUE OF 11,500 BTU/LB AND AVERAGE SULFUR AND ASH
CONTENTS OF 3.7 PERCENT AND 13 PERCENT, RESPECTIVELY.
THE FGD SYSTEM CONSISTS OF TWO MODULES. EACH HANDLES 175,000 ACFM OF 350 F FLUE GAS. EACH
MODULE IS MADE UP OF TWO STAGES OF 3-INCH MARBLE BEDS, FOLLOWED BY A TWO-STAGE CHEVRON-TYPE DEMISTER
THE GAS IS REHEATED BY DIRECT COMBUSTION OF NATURAL GAS. AN EXISTING ELECTROSTATIC PRECIPATATOR
CESP, RESEARCH-COTTRELL) IS INSTALLED UPSTREAM OF THE SCRUBBING SYSTEM PROVIDING PRIMARY CONTROL OF
PARTICULATE EMISSIONS. THIS UNIT OPERATES WITH A 99.1 PERCENT PARTICULATE REMOVAL EFFICIENCY.
PARTICULATE LOADING AT THE ESP OUTLET IS 0.05 GR/SCF.
THE SYSTEM UTILIZES A SLURRY OF CARBIDE LIME AS THE SULFUR DIOXIDE ABSORBENT. THE CARBIDE
LIME, A WASTE BY-PRODUCT OBTAINED FROM A NEARBY ACETYLENE MANUFACTURING PLANT CONTAINS 90 TO 92
PERCENT CALCIUM HYDROXIDE, 2.0 TO 2.5 PERCENT SILICA, 3.0 TO 8.0 PERCENT CALCIUM CARBONATE, AND 0.1
PERCENT MAGNESIUM OXIDE.
THE UNIT OPERATES IN A CLOSED-LOOP MODE. THE SULFUR DIOXIDE IS ABSORBED IN THE MARBLE BED BY A
SLURRY OF CALCIUM SULFITE TO FORM A MIXTURE OF CALCIUM SULFITE/BISULFITE. EFFLUENT FROM THE MARBLE-
BED TOWER IS CONVERTED IN THE REACTION TANK TO CALCIUM SULFITE BY THE ADDITION OF CALCIUM HYDROXIDE.
HALF OF THE REACTION TANK EFFLUENT IS RETURNED TO THE ABSORBER TOWERS WHILE THE OTHER HALF IS FED TO
A CLARIFIER TANK. THE CALCIUM SULFITE CRYSTALS PRECIPITATE WITH THE AID OF A FLOCCULANT, WHICH is
ADDED AT THE RATE OF 4 TO 7 PPM. THE OVERFLOW IS RETURNED TO THE REACTION TANK. THE UNDERFLOW,
CONTAINING 22 TO 21 PERCENT SOLIDS, IS STABILIZED BY MIXING IT WITH LIME. APPROXIMATELY 60 TO 100
POUNDS OF LIME ARE USED PER TON OF DRY SOLIDS OF SLUDGE. THE FIXED SLUDGE IS TRANSPORTED BY TRUCKS
TO A 10-ACRE OFF-SITE LANDFILL AREA.
ON-SITE CONSTRUCTION OF THE FGO SYSTEM COMMENCED IN JUNE 1972 AND WAS COMPLETED BY APRIL 1973.
INITIAL STARTUP OCCURRED ON APRIL 5, 1973. SYSTEM SHAKEDOWN WAS COMPLETED BY JULY 1973. A SUMMARY
OF THE SYSTEM'S PERFORMANCE HISTORY IS PROVIDED IN THE TABLE THAT FOLLOWS. A SIMPLIFIED PROCESS
FLOW DIAGRAM IS PROVIDED IN APPENDIX B OF THIS REPORT.
78
-------
LOUISVILLE GAS & tLECTRIC
FGD SYSTEM OPERABILITY
PADDY'S RUN UNIT NO. fa
OPERABILITY (X)
MONTH MODULE A MODULE B
APR. 73 18 56
MAY 73 11
JUN. 73 1
JUL. 73
AUG. 73 53
SEP. 73
OCT. 73
NOV. 73
DEC. 73
AUG. 74
SEP. 75
OCT. 75
MAR. 76
APR. 76
65
85
49
35
44
JAN. 74 0
THROUGH
JUL. 74 0
50
SEP. 74 0
OCT. 74 100
NOV. 74
THROUGH
AUG. 75
12
94
100
78
0
0
77
0
100
100
100
NOV. 75 100
DEC. 75 90
100
100
100
90
JAN. 76 100 100
FEB. 76 NO DEMAND
NO DEMAND
NO DEMAND
MODULES WERE OPEHATED ONE AT A TIME, WITH FREQUENT SHUTDOWNS FOR IN-
SPECTION OF EQUIPMENT AND MINOR REPAIRS.
SINGLE-MODULE OPERATION CONTINUED THROUGH MAY 19, WHEN THE UNIT WAS
SHUT DOWN FOR MODIFICATIONS. THt MOST SIGNIFICANT MUDIFICATION WAS
INSTALLATION OF EQUIPMENT FOR INJECTION OF A FLOCCULATING AGENT INTO
THE CLARIFIER TANK.
OPERATION WAS INTERMITTENT FHOM JUNE 19 TO JULY 11 BECAUSE OF MECHAN-
ICAL PRObLEMS WITH THE SLURRY HUMPS.
DURING A SCHEDULED OUTAGE FRUM JULY 12 THHUUGH AUGUST 1, SEVERAL
REPAIRS WERE MADE TO THE LIME SLURRY MAKE-UP SYSTEM. A DISINTEGRATOR
UNIT WAS INSTALLED TU REDUCE PLUGGING OF STRAINERS AND SLURRY CONTROL
VALVES.
THE OPERATION WAS CONTINUOUS FROM AUGUST 2 TO AUGUST IB EXCEPT FOR A
BRIEF SHUTDOWN DUE TO A BOILER-RELATED PROBLEM. FRUM AUGUST 19 TO
SEPTEMBER 5, THE SYSTEM WAS SHUT DOWN TO REPLACE THE CLARIFIER'S
UNDERFLOW LINE WITH ONt UF LARGER DIAMETER AND TO INSTALL ADDITIONAL
PUMP CAPACITY IN THE CLARIFIER'S OVERFLOW SYSTEM.
THE UNIT OPERATED CONTINUOUSLY BETWEEN SEPTEMBER 6 AND SEPTEMBER 20
EXCEPT FOR A 7-HOUR SHUTDOWN TO REPAIR A MARBLE BED SUPPORT PLATE.
THE UNIT WAS SHUT UOWN THE REMAINDER OF THE MONTH. THE FGO SYSTEM
REMAINED IN SERVICE TO DEC. 20 AFTER WHICH THE BOILER AND THE SCRUB-
BER MODULES WERE SHUT DOWN BECAUSE OF NO DEMAND (THIS IS A PEAKING-
LOAD BOILER) .
BOILER SHUT DOWN BECAUSE OF NO DEMAND.
UNIT HAS BEEN UN AND OFF FREQUENTLY DUE TO FLUCTUATION IN POWER DE-
MAND.
BOILER DOWN BECAUSE OF NO DEMAND.
BOILER TURNED ON SPECIFICALLY TO PERFORM LIMESTONE TESTS ON FGD
SYSTEM.
NO DEMAND
BOILER AND FGD SYSTEM OPERATIONAL ALL OF SEPTEMBER AND FIRST TWO
WEEKS IN OCTOBER. SYSTEM OUTAGE DURING THE LAST TWU WEEKS OF OCTOBER
WAS DUE PRIMARILY TO BREECHING IN THE BOILER SECTION. OPERABILITY
FOR BOTH MODULES DURING THE OPERATIONAL PERIOD WAS 100 PERCENT
(BASED UPON LG&E'S PEAK LOAD DETERMINATION). 302 REMOVAL WAS RE-
PORTED TO BE OVER 98 PERCENT.
BOILER AND SCRUBBER SYSTEM RAN MOST OF THE REPORT PERIOD ON A MONDAY-
THROUGH-FRIDAY BASIS. TWO MINOR OUTAGES IN DECEMBER WERE DUE TO
MALFUNCTION AND REPAIR OF THE DUAL STRAINER SWITCH SHAFT IN THE BOT-
TOM OF THE SCRUBBER MODULE.
S02 REMOVAL EFFICIENCY WAS REPORTED TO BE 99 PERCENT DURING JANUARY.
THE SYSTEM WAS SHUT DOWN IN EARLY FEBRUARY IN PREPARATION FOR AN EPA
SCRUBBER/SLUDGE STUDY SCHEDULED FOR JUNE OR JULY. THE SCRUBBER WILL
NOT BE OPERATED UNTIL THE START OF THE STUDY PROGRAM UNLESS THE
BOILER IS REQUIRED FOR PEAKING POWER DEMANDS. HIGHLIGHTS OF THE
SCRUBBER/SLUDGE STUDY PROGRAM ARE AS FOLLOWS:
6 MONTHS DURATION.
ONE SCHEDULED SHUTDOWN FOR TEST MODIFICATIONS.
DELIBERATE HIGH CHLORIDE CONCENTRATION OPERATION.
MGO INNOCULATION.
EXTENSIVE SLUDGE STUDY: FIXATION, LEACHATES, SEASONAL VARIA-
TIONS.
THE UNIT DID NOT OPRATE DURING THE REPORT PERIOD IN ANTICIPATION OF
THE EPA SCRUBBER/SLUDGE STUDY. THE UTILITY IS NOW COMPLETING SYSTEM
MODIFICATIONS FOR THE OPERATION OF THE TEST PROGRAM.
79
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LOUISVILLE GAS AND ELECTRIC
FGD SYSTEM OPERABILITY
PADDY'S RUN UNIT NO. 6
OPERABILITY U)
MONTH MODULE A MODULE B
MAY 76 100 100
JUN. 76
JUL. 76 100
AUG. 76 100
SEP. 76
OCT. 76
NOV. 76
DEC. 76
JAN.
FEB.
MAR.
APR.
MAY
77
77
77
77
77
JUN. 77
JUL. 77
AUG. 77
100
100
NO DEMAND
99
99
99
99
SEP. 77 NOT OPERATIONAL
OCT. 77 NOT OPERATIONAL
NOV. 77 NOT OPERATIONAL
THIS PEAK LOAD UNIT WAS OPERATED PART OF THE TIME DURING THE REPORT
PERIOD (APPROXIMATELY 2 WEEKS IN MAY AND 2 WEEKS IN JUNE). THE
SCRUBBER WAS AVAILABLE TO THE BOILER 100 PERCENT OF THE TIME. S02
REMOVAL EFFICIENCY WAS 96 TO 99 1 DURING THIS OPERATING SEGMENT.
THE UNIT WAS OPERATIONAL PART OF THE TIME DURING THE JULY-AUGUST
PEUIOD. THE SCRUBBING SYSTEM WAS AVAILABLE TO THE BOILER ON A 100
PERCENT BASIS. NO MAJOR SCRUBBER-RELATED PROBLEMS WERE ENCOUNTERED.
THE UNIT DID NOT OPERATE THROUGHOUT SEPTEMBER AND THE FIRST 3 WEEKS
OF OCTOBER. THE EPA-FUNDED SCRUBBER/SLUDGE STUDY PROGRAM COMMENCED
OCTOBER 25. THE INITIAL PHASE OF THE PROGRAM CALLS FOR OPERATIONS
TO PROCEED FOR A 20 TO 30-DAY PERIOD WITH CARBIDE LIME SCRUBBING
ABSORBENT. FOLLOWING COMPLETION OF THIS RUN, THE UNIT WILL BE SHUT
DOWN AND MODIFICATIONS WILL BE INCORPORATED INTO THE SYSTEM FOR
OPERATION WITH COMMERCIAL GRADE (HIGH CALCIUM) LIME.
THE UNIT WAS IN SERVICE DURING THE REPORT PERIOD. THE SCRUBBING
SYSTEM OPERATED 99.5 PERCENT OF THE TIME THE BOILER WAS IN SERVICE.
CARBIDE LIME WAS EMPLOYED AS THE SOa ABSORBENT. THE HIGH CALCIUM
(VIRGIN) LIME RUN, SCHEDULED AS PART OF THE SCRUBBER/SLUDGE STUDY,
WILL COMMENCE ON MARCH 1, 1977.
BECAUSE OF SEVERE WEATHER CONDITIONS, THERE WERE NO BOILER OPERA-
TIONS AND NO SCRUBBER OPERATIONS UNTIL MARCH 15, 1977.
IN MID MARCH, LG&E BEGAN TESTS FOR EPA WITH REGULAR LIME, ONE OF
THE OBJECTIVES OF THE TEST WAS TO DETERMINE WHETHER THERE WERE
APPRECIABLE DIFFERENCES BETWEEN REGULAR LIME AND CARBIDE LIME AT
THIS FACILITY. DURING OPERATION WITH REGULAR LIME, SCALING PROB-
LEMS OCCURRED WHICH INDICATES THAT THE SCALING RESULTED FROM
INCREASED OXIDATION LEVELS. AVAILABLE OPTIONS FOR CONTROLLING
SCALING WERE LIMITED BY THE FIXED DESIGN FEATURES OF THE SCRUBBER
HARDWARE. THE OPTION SELECTED WAS ADDITION OF MGO TO THE SCRUBBING
MEDIUM. WHEN MGO WAS ADDED, THE SCALING PROBLEM WAS ELIMINATED,
ALLOWING COMPLETION OF THE TEST PROGRAM.
THE SCRUBBER/SLUDGE EVALUATION STUDY CONTINUED DURING THE PERIOD.
THE SCRUBBER PLANT (ONE MODULE IS BEING UTILIZED FOR THIS EXPERI-
MENTAL PROGRAM) WAS IN SERVICE ON A VIRTUALLY CONTINUOUS BASIS FROM
JUNE 18 TO AUGUST 8, OPERATING ON MAGNESIUM INNOCULATED COMMERCIAL
LIME. SYSTEM OPERABILITY DURING THIS PERIOD WAS APPROXIMATELY 9&x.
S02 REMOVAL EFFICIENCY WAS MEASURED IN EXCESS OF 99.5X. THE SYSTEM
WAS SHUTDOWN AT THIS POINT TO PERFORM A NUMBER SCHEDULED MODIFICA-
TIONS TO THE SYSTEM FOR TEST PURPOSES. SPECIFICALLY, MODIFICATIONS
ARE BEING IMPLEMENTED TO THE SYSTEM IN ORDER TO BYPASS THE REACTION
TANK IN ORDER TO CONDUCT A SHORT TERM RETENTION TIME TEST. THE TEST-
ING WAS COMPLETED IN AUGUST 77 AFTER THE MODIFICATIONS WERE MADE.
THE UNIT IS CURRENTLY NOT OPERATING DUE TO LACK OF POWER REQUIREMENT.
THE UNIT IS CURRENTLY NOT OPERATING DUE TO LACK OF POWER REQUIREMENT.
THE UNIT IS CURRENTLY NOT OPERATING DUE TO LACK OF POWER REQUIREMENT.
DEC. 77 NOT OPERATIONAL
THE UNIT IS CURRENTLY NOT OPERATING DUE TO LACK OF POWER REQUIREMENT.
JAN. 78 NOT OPERATIONAL
THE UNITS IS CURRENTLY NOT OPERATING DUE TO LACK OF POWER REQUIREMENT.
80
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
MINNKOTA POWER COOPERATIVE
MILTON R. YOUNG NO. 2
CENTER NORTH DAKOTA
450 MM
LIGNITE 0.7 PERCENT SULFUR
ADL/COM6USTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
NEW
9/77
OPERATIONAL
99,6 PERCENT
SO?
MATER MAKE UP
75 PERCENT
CLOSED LOOP
SLUDGE DISPOSAL
PLANT SITE/MINE FILL
UNIT COST
OPERATIONAL
EXPERIENCE
SEE APPENDIX A, F6D SYSTEM ECONOMICS
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 1 OF THIS REPORT.
THIS LIME/ALKALINE FLYASH SCRUBBING SYSTEM WAS DESIGNED AND SUPPLIED BY
ADL/CONTRUCTION EQUIPMENT ASSOCIATEES. IT CONSISTS OF A COLD-SIDE ESP
FOLLOWER BY TWO SPRAY TOWERS. MIST ELIMINATION IS PROVIDED BY A WASH
TRAY ANO CHEVRON ARRANGEMENT. 25X FLUE GAS BYPASS PROVIDES STACK GAS RE-
HEAT. THE UNIT FIRES A LOW-SULFUR NORTH DAKOTA LIGNITE WITH AN AVERAGE
ASH CONTENT OF 8 PERCENT, SULFUR CONTENT OF 0.7 PERCENT, AND HEAT CONTENT
OF 6500 BTU/LB.
81
-------
BACKROUND INFORMATION ON
MILTON R. YOUNG NO. 2
THE MILTON R. YOUNG POWER STATION, OWNED AND OPERATED BY MINNKOTA POWER COOPERATIVE AND
BUTTE ELECTRIC COOPERATIVE, IS LOCATED NEAR CENTER, NORTH DAKOTA, APPROXIMATELY 30 MILES
OF BISMARCK. THIS MINE-MOUTH PLANT, WHICH HAS A TOTAL OPERATING POWER-GENERATING CAPACITY Of 690
MW, CONSISTS OF TWO SEPARATE COAL-FIRED, STEAM-TURBINE, GENERATING UNITS. UNIT 1 IS RATED 235 MW.
UNIT 2 IS RATED 440 MW. THE BOILERS ON BOTH UNITS FIRE NORTH DAKOTA LIGNITE FROM
NEARBY MINES. AVERAGE CHARACTERISTICS OF THIS COAL ARE 6500 BTU/L8, 0.7 PERCENT SULFUR, AND 7.5
PERCENT ASH. BOTH UNITS ARE FITTED WITH ELECTROSTATIC PRECIPITATORS (ESP'S) FOR PARTICULATE CON-
TROL. UNIT 2 IS ALSO EQUIPPED WITH A FLUE GAS DESULFURIZATION (FGD) SYSTEM FOR SULFUR DIOXIDE (802)
CONTROL.
BOILER 2 IS A CYCLONE-FIRED, STEAM-GENERATING UNIT SUPPLIED BY 8ABCOCK AND WILCOX. THE ESP, A
COLD-SIDE UNIT SUPPLIED BY WHEELABRATOR-FRYE, PROVIDES PRIMARY PARTICULATE CONTROL. TWO SPRAY
TOWERS, WHICH UTILIZE FLY ASH ALKALI AND LIME SUPPLEMENT AS SCRUBBING REAGENTS, PROVIDE PRIMARY 802
CONTROL. THIS FGD PROCESS HAS DESIGNED ANO SUPPLIED BY COMBUSTION EQUIPMENT ASSOCIATES AND ARTHUR
D. LITTLE (CEA/ADL). DESIGN CRITERIA ANO OPERATING PARAMETERS FOR THIS FULL-SCALE FGD SYSTEM WERE
DETERMINED DURING AN EXTENSIVE PILOT PLANT (5000 ACFM) TEST PROGRAM CONDUCTED BY THE OWNING/OPER-
ATING UTILITY COMPANIES AND THE SYSTEM SUPPLIER IN CONJUNCTION WITH THE MINNESOTA POWER ANO LIGHT
CO. AND GRAND FORKS ENERGY RESEARCH CENTER. THE EMISSION CONTROL SYSTEMS, COMPLETE WITH DISPOSAL
SYSTEMS FOR WASTE SOLIDS AND WASTEWATER, ARE DESCRIBED BRIEFLY IN THE FOLLOWING PARAGRAPHS.
BOILER FLUE GAS (1.8 MILLION ACFM AT 340 F) FIRST PASSES THROUGH THE ESP, WHERE PRIMARY PAKTIC-
ULATE REMOVAL TAKES PLACE. PARTICULATE LOADING IN THE FLUE GAS AT THE INLET TO THE ESP RANGES FROM
0.70 TO 1.50 GR/SCF ANO AVERAGES APPROXIMATELY 1.15 GR/SCF. THE ESP IS DESIGNED TO REMOVE 99.5 PER-
CENT OF THE INLET PARTICULATE MATTER, WHICH MEANS THE OUTLET LOADING WILL AVERAGE 0.005 GR/SCF.
AFTER IT PASSES THROUGH THE ESP, 85 PERCENT OF THE FLUE GAS IS ROUTED TO THE FGO SYSTEM. BASED ON A
MAXIMUM SULFUR CONTENT OF 1.3 PERCENT IN THE COAL, APPROXIMATELY 1900 PPM (DRY) 302 ENTERS THE FGD
SYSTEM. THE FLUE GAS CONTACTS THE SCRUBBING SOLUTION THROUGH A SERIES OF SPRAY ZONES ARRANGED VER-
TICALLY IN THE SPRAY TOWERS. THE SCRUBBING MEDIUM IS A SOLUTION OF SOLUBILIZEO ALKALI (CAO, MGO,
NA20) OBTAINED FROM THE FLY ASH COLLECTED IN THE ESP'S, SUPPLEMENTED BY A LIME REAGENT, WHICH IS
ADDED TO THE SOLUTION FOR S02 REMOVAL AND PH CONTROL PURPOSES. BASED ON THE MAXIMUM 302 INLET CON-
CENTRATION AND THE REQUIRED NEW SOURCE EMISSION STANDARD OF 1.2 LB/MM BTU, THE ABSORBERS REMOVE
APPROXIMATELY 85 PERCENT OF THE INLET S02. BECAUSE 85 PERCENT OF THE FLUE GAS STREAM IS TREATED,
THIS PRODUCES A TOTAL REMOVAL EFFICIENCY OF APPROXIMATELY 70 PERCENT AND RESULTS IN AN OUTLET 302
CONCENTRATION OF 535 PPM (DRY). WHEN THE BOILER FIRES COAL WITH MAXIMUM SULFUR CONTENT (1.3X), THE
FGD SYSTEM OPERATES AT A LIQUID TO GAS (L/G) RATIO OF 80 IN THE SPRAY TOWERS; THE PH AND SUSPENDED
SOLIDS LEVELS IN THE RECYCLE SOLUTION AWE 6.4 TO 6.5 AND 12 PERCENT, RESPECTIVELY; AND SUPPLEMENTAL
LIME IS ADDED TO THE SYSTEM AT A RATE OF 4 TONS/HR.
AFTER THE SCRUBBED GASES PASS THROUGH THE SPRAY ZONE OF THE ABSORBERS, THEY ENTER A CHEVRON-
TYPE MIST ELIMINATOR (ME). A WASH TRAY, LOCATED BENEATH THE ME, DILUTES ANY ENTRAINMENT CARRIED
INTO THE ME TO PREVENT PLUGGING, SCALING, AND EVENTUAL RESTRICTION OF GAS FLOW. THE WASH TRAY OPER-
ATES OFF A SEPARATE REC1RCULATION LOOP AND TANK TO INSURE A HIGH-QUALITY WASH WATER LOW IN SUSPEND-
ED SOLIDS AND DISSOLVED SALTS. TO PREVENT PLUGGING, SPRAYS IRRIGATE THE ME'S WITH A MIXTURE OF
MAKEUP WATER AND CLARIFIED LIQUOR FROM THE TRAY LOOP. ALSO, SPRAYS UNDER THE WASH TRAY FLOOD THE
UNDERSIDE OF THE TRAY AND THE AREA FROM THE TRAY DOWN TO THE TOP RECYCLE SPRAYS.
THE SCRUBBED GAS STREAM IS REHEATED BY MIXING IT WITH THE 340 F 15 PERCENT BYPASS FLUE GAS
STREAM. THIS RAISES THE TEMPERATURE OF THE SATURATED SCRUBBED GAS STREAM FROM 13b TO 165 F. THE
GASES ARE THEN DISCHARGED TO THE ATMOSPHERE THROUGH THE STACK. THE SPENT SCRUBBING SOLUTION IS DIS-
CHARGED TO A RECYCLE TANK AT THE BOTTOM OF THE SPRAY TOWERS, WHERE THE CHEMICAL
REACTIONS ARE COMPLETED. FLUE GAS CLEANING WASTES (ALKALI SULFITE/SULFATE SALTS, FLY ASH) ARE DIS-
CHARGED FROM THE RECIRCULATION LOOP TO A THICKENER, WHERE THE WASTE SOLIDS SETTLE OUT. THE CLARI-
FIED OVERFLOW FROM THE THICKENER IS RETURNED TO THE PROCESS AND USED FOR FLY ASH SLURRY PREPARATION.
THE THICKENER UNDERFLOW (MAXIMUM 40 PERCENT SOLIDS CONTENT) IS DISCHARGED TO A VACUUM THICKENER
BUILDING, WHICH HOUSES TWO ROTARY-DRUM VACUUM FILTERS FOR ADDITIONAL SOLIDS DEWATERING. THE FILTER
CAKE, WHICH is PRODUCED AT A RATE OF 50 TONS/HR AND CONTAINS &o PERCENT SOLIDS, is TRANSPORTED BY
CONVEYOR TO THREE 35 TON, OFF-THE-ROAD TRUCKS FOR CONTINUOS HAULING TO A MINE LANDFILL RECLAMATION
AREA FOR FINAL DISPOSAL. ADDITIONAL WATER RECOVERED IN THE VACUUM FILTER PROCESS IS ALSO USED FOR
FLY ASH SLURRY PREPARATION. DURING EMERGENCY CONDITIONS (MECHANICAL MALFUNCTION, HIGH FLOW RATES),
THE SLUDGE FROM THE VACUUM FILTER SYSTEM CAN BE PILED OUTSIDE THE VACUUM FILTER BUILDING FOR HANDL-
ING BY FRONT END LOADERS AND OFF THE ROAD TRUCKS.
82
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MINNKOTA POWER COOPERATIVE MILTON R. YOUNG NO. 2
•INITIAL OPERATING EXPERIENCE*
THE OPERATING UTILITY COMPANY HAS REPORTED INTERMITTENT OPERATION SINCE INITIAL START-UP IN
SEPTEMBER 1977. MAJOR OPERATIONAL PROBLEMS HAVE OCCURRED AS A RESULT OF SEVERE WINTER WEATHER
CONDITIONS. PARTICULARLY NUMEROUS INSTANCES OF FROZEN AND RUPTURED LINES. THE SYSTEM HAS SHUT DOWN
DURING THE FIRST PART OF THE MONTH OF DECEMBER TO INSTALL HEAT TRACING IN THE LIQUID CIRCUIT. IN
ADDITION, SOME MINOR PROBLEMS HAVE BEEN REPORTED WITH THE SYSTEM'S GUILLOTINE GAS DAMPERS AND FLOW
METERS (ROTAMETERS).
OCTOBER-NOVEMBER 1977 - THE OPERATING UTILITY COMPANY WAS REPORTED INTERMITTENT OPERATION SINCE
INITIAL START-UP IN SEPTEMBER. SEVERE WINTER WEATHER PROBLEMS HAVE CAUSED FROZEN AND RUP-
TURED LINES. THESE CONDTIONS HAVE MADE SHUTDOWNS NECESSARY FOR THE INSTALLATION OF ELECTRICAL HEAT
TRACING ON SLURRY LINES AND WATER PIPING.
DECEMBER-JANUARY 1978 - THERE WAS AN EMER6ENCY SHUTDOWN ON DECEMBER 5 AS A RESULT OF BEARING DAMAGE
WITHIN THE TURBINES. AS A CONSEQUENCE, THE COMPLIANCE TEST ORIGINALLY SCHEDULED TO dE WITHIN THIS
PERIOD HAS BEEN TENTATIVELY RESCHEDULED WITH THE EPA FOR THE END OF MARCH. THE UNIT IS EXPECTED TO
BE BACK ON LINE FEB. 20 AT WHICH TIME THE UTILITY EXPECTS TO HAVE THE SYSTEMS IN EQUILIBRIUM (WATER
BALANCE) .
83
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH
01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
MONTANA POWER CO.
COLSTRIP NO 1
COLSTRIP MONTANA
360 MW
COAL 0.6 PERCENT SULFUR
ADL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
NEW
11/75
OPERATIONAL
99.5 PERCENT ACTUAL
S0£
WATER MAKE UP
70-75 PERCENT (ACTUAL)
CLOSED LOOP
SLUDGE DISPOSAL
CLAY-LINED DIKED POND
UNIT COST
SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS FGD EQUIPPED UNIT WAS DECLARED COMMERCIAL IN NOVEMBER 1975. THE
SCRUBBING SYSTEM PROVIDES PARTICULATE AND S03 CONTROL WITH THREE SCRUB-
BER MODULES. EACH MODULE CONSISTS OF A DOWNFLOW VENTURI SCRUBBER CENTER-
ED WITHIN AN UPFLOW SPRAY TOWER ABSORBER. EACH MODULE CAN TREAT 10X OF
THE TOTAL BOILER FLUE GAS AND THE MODULES CANNOT BE BYPASSED. THE UN-
STABILIZED SLUDGE IS DISPOSED IN AN ON-SITE LINED DISPOSAL POND. IN-LINE
STEAM REHEAT AND CLOSED WATER LOOP CAPABILITY ARE INCLUDED IN THE SYSTEM.
84
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS THROUGH
01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY,
PARTICULATES
MONTANA POWER CO.
COLSTRIP NO 2
COLSTRIP MONTANA
360 MW
COAL 0.8 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
LIME/ALKALINE FLYASH SCRUBBING
NEW
7/76
OPERATIONAL
99.5 PERCENT ACTUAL
soa
70-75 PERCENT (ACTUAL)
WATER MAKE UP
CLOSED LOOP
SLUDGE DISPOSAL
UNIT COST
SEE APPENDIX A, FGO SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS FGD EQUIPPED UNIT WAS DECLARED COMMERCIAL IN AUGUST 1976. THE
SCRUBBING SYSTEM PROVIDES PARTICULATE AND S02 CONTROL WITH THREE SCRUB-
BER MODULES. EACH MODULE CONSISTS OF A DOWNFLOW VENTURI SCRUBBER CENTER-
ED WITHIN AN UPFLOW SPRAY TOWER ABSORBER. EACH MODULE CAN TREAT 70X OF
THE TOTAL BOILER FLUE GAS AND THE MODULES CANNOT BE BYPASSED. THE UN-
STABILIZEO SLUDGE IS DISPOSED IN AN ON-SITE LINED DISPOSAL POND. IN-LINE
STEAM REHEAT AND CLOSED WATER LOOP CAPABILITY ARE INCLUDED IN THE SYSTEM.
85
-------
BACKGROUND INFORMATION
UN
COLSTRIP UNITS 1 AND 2
THE COLSTRIP POWER STATION OF THE MONTANA POWER COMPANY 13 LOCATED NEAR COLSTRIP. MONTANA,
APPROXIMATELY 100 MILES EAST OF BILLINGS, MONTANA. THE STATION CONTAINS TWO NEW 360-MW COAL-FIRED
POWER-GENERATING UNITS. AT THE PRESENT TIME, THE UTILITY IS PLANNING THE ADDITION OF TWO MORE
700-MW COAL-FIRED POWER-GENERATING UNITS AT THE STATION. THIS MINE MOUTH PLANT FIRES LOW-SULFUR,
LOW HEAT CONTENT COLSTRIP COAL, PRODUCING A FLUE GAS CONTAINING UP TO 6 GR/SCFD PARTICULATE AND UP
TO 1000 PPM SULFUR DIOXIDE. THE GENERAL CHARACTERISTICS OF THIS COAL ARE; HEATING VALUE (AS FIRED)
68«3 BTU/LB. (MIN. 6162 BTU/LB); SULFUR CONTENT, 0.77 PERCENT (12 MAX); ASH CONTENT, 8.59 PERCENT;
MOISTURE CONTENT, 23.87 PERCENT.
IN ORDER TO MEET AIR POLLUTION EMISSION STANDARDS OF 400 PPM FOR SULFUR DIOXIDE (1.0 LB/MM BTU)
AND 0.03 GR/SCFD FOR PARTICULATES, THE BOILERS ARE EQUIPPED WITH SCRUBBER PLANTS FOR THE CONTROL OF
PARTICULATES AND SULFUR DIOXIDE. THE SYSTEMS INSTALLED ON UNITS 1 AND 2 WERE DESIGNED AND SUPPLIED
BY COMBUSTION EQUIPMENT ASSOCIATES (CEA) AND AUTHUR D. LITTLE (ADD. THE PROCESS INSTALLED UTILIZES
THE HIGH ALKALINITY OF THE FLY ASH (APPROXIMATELY 20 PERCENT CALCIUM OXIDE) FOR THE REMOVAL OF
SULFUR DIOXIDE AND SUPPLEMENTAL LIME SLURRY FOR PH AND SCALE CONTROL. DESIGN PARTICULATE AND SULFUR
DIOXIDE REMOVAL EFFICIENCIES ARE 99.5 AND 60 PERCENT, RESPECTIVELY.
EACH BOILER IS EQUIPPED WITH THREE SCRUBBER MODULES, EACH MODULE CAPABLE OF HANDLING HO PERCENT
OF THE BOILER FLUE GAS CAPACITY (1,430,000 ACFM AT 291F). EACH SCRUBBER INCORPORATES A VARIABLE-
THROAT VENTURI (DESIGN SUPERFICIAL GAS VELOCITY; 200 FT/SEC), A SPRAY ABSORPTION SECTION (DESIGN
SUPERFICIAL GAS VELOCITY; 11.5 FT/SEC), AN INTERNAL RECYCLE TANK, A WASH TRAY, AND A CHEVRON-TYPE
MIST ELIMINATOR. THE VENTURI AND SPRAY SECTIONS OPERATE ON A RECIRCULATING SLURRY LOOP CONTAINING
12 PERCENT SOLIDS (CONSISTING PRIMARILY OF CALCIUM SALTS AND FLY ASH). TOTAL MODULE PRESSURE DROP
IS APPROXIMATELY 23.5 INCHES H20. TOTAL MODULE LIQUID-TO-GAS RATIO IS APPROXIMATELY 33 GAL/1000 ACF.
A WASH TRAY IS SITUATED BENEATH THE MIST ELIMINATOR IN ORDER TO DILUTE ANY ENTRAINMENT REACHING THE
COMPONENT, THUS REDUCING THE POTENTIAL FOR PLUGGING AND SCALING. THE TRAY OPERATES OFF A SEPARATE
RECYCLE TANK AND RECIRCULATION LOOP. REHEAT IS SUPPLIED BY IN-THE-FLUE-GAS-STREAM STEAM TUBE BUND-
LES (MINIMUM DELTA T: 50F). THE REHEATERS ARE ALSO EQUIPPED WITH SOOT BLOWERS FOR CLEANING. THE
SCRUBBER BOOSTER FANS (INCLUDED DRAFT, 43.5 INCHES H20) ARE LOCATED DOWNSTREAM OF THE SCRUBBERS AND
OPERATE ON DRY, REHEATED FLUE GAS. THE FANS WERE LOCATED DOWNSTREAM IN THIS SCRUBBER DESIGN BECAUSE
OF THE HIGH PARTICULATE LOADING OF THE INLET FLUE GAS. THE SCRUBBING WASTES (UNREACTED FLY ASH,
9 PARTS CALCIUM SULFATE/1 PART CALCIUM SULFITE) ARE DISCHARGED TO AN INITAL HOLDING BASIN (520 ACRE-
FEET) ADJACENT TO THE SCRUBBER PLANT AND THEN PUMPED (50.8 DRY TPH/2 UNITS) THREE MILES TO A PERMAN-
ENT SLUDGE DISPOSAL POND (2218 ACRE-FEET, CLAY-LINED WHERE NECESSARY). CLEAN LIQUOR IS RETURNED
FROM PONDS FOR ADDITIONAL SCRUBBING SERVICE. FRESH MAKE-UP WATER TO THE SYSTEM IS LIMITED TO AP-
PROXIMATELY THE AMOUNT OF WATER LOST IN THE SCRUB BER PLANT VIA EVAPORATION AND SLUDGE.
PERFORMANCE HISTORY:
UNIT NO. 1 BECAME AVAILABLE FOR SERVICE DURING THE LATTER PART OF 1975. UNIT NO. 2 WAS PLACED IN
SERVICE DURING THE SUMMER OF 1976. THE OVERALL PERFORMANCE OF THE SCRUBBER SYSTEM HAS BEEN EXCELL-
ENT, HOWEVER, THE OPERATIONAL EXPERIENCE OF THESE FULL SCALE UNITS HAS SHOWN SEVERAL PROBLEM AREAS.
INSTRUMENTATION IN SLURRY AND FLUE GAS SERVICE HAS NOT BEEN TROUBLE FREE. THE STACK OPACITY, S02
AND N03 MONITORS ALONG WITH 302 MONITORS ON THE INLET AND THE OUTLET OF THE SCRUBBER MODULES HAVE
EXHIBITED UNSTABLE AND ERRATIC BEHAVIOR. IN-LINE PH PROBES HAVE EITHER ERODED AWAY OR LOST SENSI-
TIVITY DUE TO DEPOSITS FORMING ON THE ELEMENTS. MANUAL SAMPLING IS REQUIRED FOR CHEMICAL CONTROL OF
THE PH AS WELL AS THE SLURRY DENSITY. WET-DRY DEPOSITS HAVE FORMED AT THE INLET TO THE SCRUBBER
VESSEL WHERE THE HOT, DUST-LADEN GAS IS COOLED AND HUMIDIFIED. THESE DEPOSITS, NOT TO BE CONFUSED
WITH CALCIUM SULFATE SCALE, REQUIRE MANUAL REMOVAL FROM EACH SCRUBBER MODULE EVERY TWO WEEKS. LAB-
ORATORY MODEL TESTS ON GAS FLOW AND LIQUID DISTRIBUTION PLUS FULL SCALE TESTS IN ONE SCRUBBER MODULE
WHICH INVOLVE BOTH LIQUID AND GAS FLOW TURNING VANES SHOW PROMISE IN EXTENDING THE TIME BETWEEN
CLEANINGS. IN VIEW OF THE PROMISING RESULTS, THESE MODIFICATIONS ARE BEING INSTALLED ON ALL THREE
MODULES OF UNIT NO. i.
THE SUPPLEMENTARY ALKALI FEED PROVIDED BY THE LIME SYSTEM IS REQUIRED FOR EFFECTIVE CHEMICAL CONTROL
OF THE SCRUBBER SYSTEM. PLUGGING OF LINES AND EQUIPMENT FAILURE HAVE MADE THE LIME SYSTEM DIFFICULT
TO USE, THE ALKALI FOUND IN THE ASH WHICH IS CAPTURED BY THE SCRUBBER HAS BEEN GENERALLY ADEQUATE
TO KEEP THE PH WITHIN THE CONTROL RANGE. BETTER CONTROL OF THE LIME SYSTEM WOULD KEEP THE PH MORE
CONSTANT AND ALLOW THE S02 REMOVAL TO BE OPTIMIZED. FAILURES OF THE PROTECTIVE GLASS-FLAKE LINING
OVER THE CARBON STEEL VESSEL WALLS AND DUCTS HAS OCCURRED IN SEVERAL AREAS. THESE FAILURES WERE
EVIDENT PRIOR TO A MAJOR TEMPERATURt EXCURSION THAT OCCURRED ON UNIT NO. 1 IN OCTOBER 1976. THE
TEMPERATURE EXCURSION FOLLOWED A STATION BLACKOUT AND THE FAILURE OF THE EMERGENCY SCRUBBER QUENCH
WATER SUPPLY SYSTEM TO OPERATE. GLASS-FLAKE LINING AND PLASTIC CHEVRON MIST ELIMINATORS WERE DAM-
AGED AT THAT TIME AND ACCOUNT FOR THE LOW SCRUBBER AVAILABILITY DURING NOVEMBER AND DECEMBER
A FAILURE OF AN ID FAN MOTOR DURING THE SAME TIME PERIOD INDEPENDENT OF THE TEMPERATURE EXCURSION
ALSO CONTRIBUTED TO THE LOWER AVAILABILITY FIGURE. QUICK CLEAN BASKET STRAINERS WERE ADDED TO THE
SUCTION PIPING OF THE TwO MAIN RECYCLE PUMPS OF EACH VESSEL TO REMOVE FOREIGN MATERTAIS ANn HFPnSTTS
BEFORE THE* CLOG SPRAY NOZZLES. ucruoi
A PROGRAM IS UNDER WAY TO EVALUATE ABRASION RESISTANT PROTECTIVE LINING MATERIALS THAT fOULD BE
USED WHERE THE FLUE GAS MAKES ITS 180 DEGREE TURN FOLLOWING THE VENTURI DOWN-COMER ANn PASSFS HYTHF
ABSORPTION SPRAYS. r.oota 01
ADDITIONAL INFORMATION CONCERNING THE PERFORMANCE OF THE COLSTRIP FGD SYSTEM MOOULFS IS TNr-
LUDEO IN THE FOLLOWING TABLE. A GENERAL PROCESS FLOW DIAGRAM OF THE SCRUBBING SYSTFM IS
IN APPENDIX B.
86
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MONTANA POWER CO.
COLSTKIP UNIT NOS. 1 AND 2
NOTE: SCRUBBER AVAILABILITY IS DEFINED BY MONTANA POWER AS THE TOTAL MODULE HOURS AVAILABLE
DIVIDED BY THREE TIMES THE HOURS IN THE MONTH (BECAUSE THERE ARE THREE SCRUBBER MODULES
PER GENERATING UNIT) AND EXPRESSED AS A PERCENTAGE. WHENEVER WORK IS DONE ON A MODULE
THAT TAKES IT OUT OF SERVICE OR WOULD PREVENT ITS USE (rtHETHER THE BOILER IS OPERATING
OR NOT), THE RESPECTED MODULE IS TERMED UNAVAILABLE.
MONTHLY CAPACITY
FACTOR X
UNIT
SEP. 75
OCT. 75
NOV. 75
DEC. 75
JAN. 76
FEB. 76
MAR. 76
APR. 76
MAY 76
JUN. 76
JUL. 76
AUG. 76
SEP. 76
OCT. 76
NOV. 76
DEC. 76
JAN. 77
FEB. 77
MAR. 77
APR. 77
MAY 77
JUN. 77
JUL. 77
AUG. 77
SEP. 77
OCT. 77
NOV. 77
DEC. 77
1
1
19
42
60
64
65
57
50
26
0
28
38
65
73
56
67
73
3
0
50
64
69
72
2
1
23
20
13
65
77
80
82
68
75
71
68
£3
61
58
*UNIT NO. 2 AVAIL
OUTAGE. SCR
IS THE AVAIL
UBBE
ABIL
NO.
ON
1
3
19
24
30
26
24
28
14
0
20
23
30
30
30
31
31
2
0
25
26
28
29
DAYS
LINE
2
3
16
13
10
30
31
30
31
30
27
28
29
13
28
28
AVG
1
50
139
203
239
265
273
277
219
210
0
167
194
239
281
225
249
270
161
23fa
286
284
284
ON
FOR DAYS
LINE
2
66
171
180
162
232
298
303
297
258
285
293
264
209
249
238
SCRUBBER
AVAILABILITY X
90
98
98
74
97
0
93
95
89
80
63
74
93
95
1ILITY OF 77X FOR OCTOBtH 1977 INCLUDES NO
MAINTENANCE WAS PERFORMED THROUGH PART OF
n NOT INCLUDING THE BOILER OUTAGE TIME.
AVAILABLE HOURS
THE OUTAGE TIME
100
100
99
96
98
90
94
93
83
94
97
83 85
85 63
87 88
85 91
93 81
93 90
96 77*
98*
96 98
98 98
DURING A BOILER
, THE 98X FIGURE
87
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
NEVADA
REID GARDNER UO 1
MOAPA NEVADA
125 MW
FUEL CHARACTERISTICS COAL O.b - 1.0 PERCENT SULFUR
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
AOL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
RETROFIT
H/T*
OPERATIONAL
99 PERCENT
S02
85 PERCEfJT
MATER MAKE UP
OPEN LOOP 0.4U GPM/MW
SLUDGE DISPOSAL
SOLAR EVAPORATION POND
UNIT COST
SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND I NFORrtA T ION SECTION IN TABLE 3 OF THIS REPORT.
THIS SODIUM CAR60i\iATE-6ASED (TRONA) SCRUBBING SYS1EM CONSISTS OF ONE
MODULE CONTAINING A TuIN VARIABLE-THROAT VENTURI SCRUBBER FOLLOWED BY A
SEPARATOR IN StKlES rtlTH A SINGLE-STAGE PERFORATED-PLATE A8SOHBEH TOWER.
PRIMARY PAHTICULATt CONTROL IS PROVIDED BY UPSTREAM MECHANICAL COLLECTORS.
A STEAM INDIRECT HOT AlK REHEAT SYSTEM RAISES THE GAS TEMPERATURE 30 F
PRIOR TO DISCHARGE TO TrlE MAIN STACK. THE FLUE GAS CLEANING WASTES ARE
ULTIMATELY DISPOSED IN AN ON-SITE CLAY-LINED SOLAR EVAPORATION POND.
88
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BACKGROUND INFORMATION
ON
REID GARDNER UNITS 1, 2, AND 3
THE REID GARDNER POWER STATION IS LOCATED NEAR MOAPA, NEVADA, ABOUT 50 MILES NORTH OF LAS VEGAS
THE STATION HAS THREE ELECTRIC POWER GENERATING UNITS, (REIO GARDNER 1, 2, AND 3) EACH RATED AT
125 MW. UNITS 1 AND 2 ARE RETROFITTED WITH SODIUM CAR86NATE-BASEO FGO SYSTEMS. UNIT NO. 3 IS A NEW
INSTALLATION, ALSO EQUIPPED WITH A SODIUM CARBONATE-BASED FGD SYSTEM. THE COAL BURNED AT THE PLANT
HAS AN AVERAGE GROSS HEATING VALUE OF 12,450 BTU/L8. AND ASH AND SULFUR CONTENTS OF 8 AND 0.5
PERCENT RESPECTIVELY.
THE FGD SYSTEMS INSTALLED ON REID GARDNER UNITS 1,2,&3 WERE DESIGNED AND INSTALLED BY COM-
BUSTION EQUIPMENT ASSOCIATES IN ASSOCIATION WITH A. D. LITTLE. THE SYSTEMS FOR UNITS 1 AND 2 WERE
PLACED IN SERVICE IN APRIL 1971. THE SYSTEM FOR UNIT 3 WAS PLACED IN OPERATION ON JULY 12, 1976.
THE SCRUBBING SYSTEM DESIGN WAS BASED ON INFORMATION AND DATA OBTAINED FROM AN 8000-ACFM PILOT PLANT
PROGRAM CONDUCTED AT THIS STATION IN 1971 AND 1972.
THE FGD SYSTEM CONSISTS OF A SINGLE MODULE, DESIGNED TO HANDLE 473,000 ACFM OF GAS AT 350 F.
THE MODULE IS MADE UP OF A TWIN VARIABLE-THROAT VENTURI SCRUBBER, FOLLOWED BY A SINGLE-STAGE TRAY
TOWER ABSORBER. GAS BYPASS IS ACHIEVED BY A GUILLOTINE-TYPE DAMPER. A COMMON FACILITY FOR TRONA
(SODIUM CARBONATE ORE) STORAGE AND SAND REMOVAL SERVES ALL THE FGO MODULES AT THE REID GARDNER
PLANT. SULFUR DIOXIDE REMOVAL EFFICIENCY is REPORTED TU BE as PERCENT. PRIMARY PARTICULATE REMOVAL
IS ACCOMPLISHED BY 75 PERCENT EFFICIENT MECHANICAL COLLECTORS INSTALLED UPSTREAM OF THE WET SCRUB-
BERS. THE TOTAL PARTICULATE REMOVAL EFFICIENCY OF THE MECHANICAL COLLECTION AND WET SCRUBBING
SYSTEM EXCEEDS THE 99 PERCENT LEVEL.
IN THIS SODIUM CARBONATE PROCESS, HOT FLUE GAS FROM THE BOILER PASSES FIRST THROUGH THE MECHAN-
ICAL COLLECTORS WHERE PRIMARY PARTICULATE REMOVAL TAKES PLACE. PRESSURE IS THEN BOOSTED BY AN IND-
UCED DRAFT FAN BEFORE THE GAS STREAM SPLITS AS IT ENTERS THE TWIN-THROAT VENTURI SCRUBBER. THE HOT
FLUE GAS IS QUENCHED BY A SHOWER OF CIRCULATED SODIUM-BASE LIQUOR. THE GAS THEN tNTERS THE TRAY
TOWER AND BUBBLES THROUGH THE RADIAL-VANE MIST ELIMINATOR, WHERE THE REMAINING LIQUID DROPLETS CAR-
RIED OVER WITH THE GAS ARE TRAPPED AND REMOVED.
EFFLUENT FROM THE FGD SYSTEM IS FROM TWO SOURCES: THE SLIP STREAM OF SPENT LIQUOR DISCHARGED
FROM THE RECIRCULATION TANK, AND THE ALKALINE CLAHIFIER UNDERFLOW, WHICH SERVES TO NEUTRALIZE THE PH
OF THE COMBINED LIQUOR BEFORE IT IS DISCHARGED TO THE SLUDGE SETTLING PONDS. THE SPENT LIQUOR IS
PUMPED INTO ONE OF TWO SETTLING PONDS. THE OVEKFLOW FROM THIS POND IS PUMPED TO A LARGER 45-ACRE
POND, WHERE THE BRINE IS EVAPORATED. THE FGD SYSTEM OPERATES ON AN OPEN WATER LOOP WITH NO LIQUOR
RECYCLED TO THE MODULES FROM THE PONDS.
ADDITIONAL INFORMATION CONCERNING THE PEHFORMANCt OF THE SCRUBBERS INSTALLED AT THE REID
GARDNER STATION, INCLUDING PROBLEMS, SOLUTIONS, AND MODIFICATIONS, ARE PRESENTED IN THE FOLLOWING
TABLES. IN ADDITION, A GENERAL PROCESS FLOW DIAGRAM OF THE SODIUM CARBONATE SCRUBBING SYSTEM IS
PRESENTED IN APPENDIX 8.
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NEVADA POWER REID GARDNER UNIT NO. 1
HR.
BORER MODULE CALLtO
TOTAL OPERATION AVAILABLE UPON TO OPERATION
PERIOD (HR.) (HR.) IHR.) OPERATE (HR.)
MAR. 75
APR. 75
MAY 75
JUN. 75
DURING FEBRUARY THE FGD SYSTEM OPERATED KITH 95 PERCENT AVAILABILITY ON TRONA SUPPLEMENTED
WITH SODA ASH. AVAILABILITY IN JANUARY HAS ONLY ABOUT 65 PERCENT BECAUSE OF FROZEN SODIUM
CARBONATE FEED LINES. PROBLEMS IN FEBRUARY INCLUDED A 2-DAY LACK OF CHEMICALS. NO SIGNIFI-
CANT PROBLEMS OCCURRED IN MARCH. THE UNIT RAN APRIL 1 THROUGH APRIL 12 WITH 100 PERCENT
AVAILABILITY. THE BOILER WAS THEN SHUT DOWN FUR ROUTINE MAINTENANCE. THE SYSTEM WAS PLACED
BACK ON LINE MAY 12. SECOND PERFORMANCE TEST WAS PASSED. PROBLEMS INCLUDED ABRASION OF
RUBBER-LINED PIPES AND ROUTINE MECHANICAL AND INSTRUMENTAL PROBLEMS. HIGH ASH CONTENT, UP TO
20 PERCENT, HAD NO EFFECT ON EMISSIONS. OPERABILITY FOR THE MONTH OF JULY WAS 85 PERCENT.
JUL. 75
AUG. 75
SEP. 75 720 716 559
OPERABILITY s 78X
UTILIZATION = 7ttX
OF THE 4 OUTAGES REPORTED, 3 WERE CAUSED BY SCRUBBER MALFUNCTIONS.
OCT. 75 744 303 106
OPERABILITY = 60X
UTILIZATION = 141
LOW OPERATING TIME WAS DUE TO SCHEDULED BOILER MAINTENANCE. ONE OUTAGE WAS DUE TO THE MAL-
FUNCTION OF A SODA ASH BLOWER.
NOV. 75 720 654 394
OPERABILITY s 60X
UTILIZATION = 55X
THE UTILITY REPORTS SYSTtM PERFORMANCE IN TERMS OF THE OPERABILITY INDEX. UNIT NO. 1 OPER-
ABILITY WAS LOW FOR 1HE MONTH OF NOVEMBER BECAUSE OF DELAYS IN DELIVERY OF REPAIR MATERIALS.
THREE FORCED OUTAGES DURING THE MONTH WERE DUE TO REHEATER STEAM LEAKS, COLLAPSE OF A VENTURI
STRAINER, AND A FROZEN CARBONATE LINE. THE SYSTEM WAS SHUT DOWN FOR 16 DAYS FOR COMPLETION
OF PIPING CONVERSION: THIS OUTAGE WAS NOT DUE TO SCRUBBER MALFUNCTION.
DEC. 75
JAN. 76 744 647 604 327 186
AVAILABILITY = 81X
OPERA8ILITY = 29X
RELIABILITY = 57X
UTILIZATION = 25X
FEB. 76 6*6 664 631 585 520
AVAILABILITY = 91X
OPERABILITY = 78X
RELIABILITY = 89X
UTILIZATION = 75X
THE UTILITY REPORTED FIVE SCRUBBER INOPERATIVE PERIODS DURING THE MONTH OF FEBRUARY, TWO OF
WHICH WERE SCRUBBER RELATED OUTAGES. THE FORCED SCRUBBER OUTAGES OCCURRED BECAUSE OF A
DEPLETION OF CHEMICAL, CHEMICAL LINE PLUGGING AND SEAL WATER PROBLEMS.
MAR. 76 744 398 743 288 287
AVAILABILITY = 99X
OPERABILITY = 72X
RELIABILITY = 99X
UTILIZATION = 39X
ONLY ONE FORCED SCRUBBER OUTAGE OCCURRED DURING THE MONTH BECAUSE OF A VENTURI LEAK.
APR. 76 720 106 106 97 97
AVAILABILITY = 15X
OPERAblLITY = 91X
RELIABILITY = 100X
UTILIZATION = 13*
THE BOILER WAS TAKEN OUT OF SERVICE APRIL 5 FOR INSPECTION OF VALVES AND CUAL CONDUITS.
MAY 76
JUN. 76
ALL INDEX VALUES = OX
THE NO. 1 UNIT WAS SHUT DOWN THE ENTIRE MONTH fOX A SCHEDULED TURBINE OVERHAUL AMD BURNER
LINE CONDUIT REPLACEMENT. t"n«uL »wu BUKNtK
90
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NEVADA POWER
REID GARDNER UNIT NO. i
PERIOD
BOILER
TOTAL OPERATION
(MR.) (MR.)
MODULE
AVAILABLE
(HR.)
HR.
CALLED
UPON TO
OPERATE
OPERATION
(HK.)
JUL. 76
ALL INDEX VALUES = OX
THE NO. 1 UNIT REMAINED OUT OF SERVICE THROUGHOUT THE MONTH FOR COMPLETION OF THE TURBINE AND
BOILER OVERHAUL WHICH COMMENCED THE PRfcCEEOING MONTH.
479
719
366
360
AUG. 76 744
AVAILABILITY = 971
OPERABILITY = 7SX
RELIABILITY = 94X
UTILIZATION = 49X
TWO FORCED SCRUBBER OUTAGES OCCURRED DURING THE MONTH ATTRIBUTED TO PLUGGING IN THE TRAY RE-
CYCLE TANK AND THICKENER TANK. TOTAL BOILER OUTAGE TIME FUR THE MONTH EXCEEDED 265 HOURS.
SEP. 76 720 656 683 676 639
AVAILABILITY = 95X
OPERABILITY as 97X
RELIABILITY e 95X
UTILIZATION = 89X
TWO FORCED SCRUBBER OUTAGES WERE REPORTED BY THE UTILITY FOR THE MONTH. THESE MINOR OUTAGES
WERE CAUSED BY PLUGGING IN THE VENTURI SPRAY HEADERS AND AN i.e. FAN MALFUNCTION. TOTAL
FORCED OUTAGE TIME AMOUNTED TO 36.8« HOURS.
OCT. 76 744 678 728 664 648
AVAILABILITY = 98X
OPERABILITY = 96X
RELIABILITY » 98X
UTILIZATION = 87X
SCRUBBER OUTAGE TIME WAS REQUIRED FOR INSTALLATION OF A NEW CARBONATE FEED LINE. IN
ADDITION, A MINOR SCRUBBER TRIP WAS CAUSED BY PLUGGING IN THE SCRUBBER EFFLUENT SUCTION LINE,
631
623
605
508
NOV. 76 720
AVAILABILITY = 87x
RELIABILITY f 84X
OPERABILITY = SIX
UTILIZATION = 71X
ONE FORCED SCRUBBER OUTAGE OCCURRED DURING THE REPORT PERIOD BECAUSE OF A SCREW CONVEYOR
FAILURE, RESULTING IN AN INABILITY TO MIX THE CHEMICAL ABSORBENT.
690
652
599
DEC. 76 744 677
AVAILABILITY = 93X
RELIABILITY = 92X
OPERABILITY = 88X
UTILIZATION = SOX
TWO FORCED SCRUBBER OUTAGES OCCURRED DURING DECEMBER BECAUSE OF CHEMICAL DEPLETION AND A
PLUGGED SENSING LINE.
533
501
437
JAN. 77 744 645
AVAILABILITY a 72X
RELIABILITY = 87X
OPERABILITY s 67X
UTILIZATION = 59X
THE SCRUBBER OPERATED WITH NO DOWNTIME UNTIL JANUARY 22, WHEN RUBBER LINING REPAIRS WERE
INITIATED IN THE SEPARATOR SECTION IN THE SCRUBBING MODULE. THE SCRUBBER WAS DOWN THROUGHOUT
THE REST OF THE REPORT PERIOD.
0
599
FEB. 77 672 599
ALL INDEX VALUES = OX
SYSTEM SHUT DOWN FOR CONTINUATION OF RUBBER LINING REPAIRS.
0
669
0
MAR. 77 744 669
ALL INDEX VALUES = OX
SYSTEM SHUT DOWN FOR CONTINUATION OF RUBBER LINING REPAIRS.
APR. 77
ALL INOEX VALUES = OX
THE MODULE WAS UNAVAILABLE FOR SERVICE DURING THE REPORT MONTHS BECAUSE OF REPAIRS TO THE
SCRUBBER LINING DAMAGED FROM A HIGH TEMPERATURE EXCURSION RESULTING FROM A MALFUNCTION IN THE
UNIT'S AIR PREHEATER
MAY 77
ALL INDEX VALUES = OX
91
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NEVADA POWER KEIO GARDNER UNIT NO. 1
HR.
BOILER MODULE CALLED
TOTAL OPERATION AVAILABLE UPON TO OPERATION
PERIOD (HR.) (HR.) (HR.) OPERATE (HR.)
JUN. 77 720 701 339 720 315
AVAILABILITY = 4?x
RELIABILITY = It*
OPERABILITY = 45X
UTILIZATION = 44X
REPAIRS ON THE DAMAGED RUBBER LINING WEKt COMPLETED BY MID-JUNE AND THE SYSTEM REMAINED IN
SERVICE THROUGHOUT THE MONTH WITH THE EXCEPTION OF ONE MINOR FORCED OUTAGE (7.5 MRS. FOR A
HIGH-LOW PRESSURE TRIP CAUSED bY A PLUGGED SENSING LINE).
JUL. 77 744 744 740 744 744
AVAILABILITY = 99%
StLIABILITY s 99X
OPERABILITY = S9X
UTILIZATION = 99X
THE SYSTEM WAS TAKEN OUT OF 1 HE GAS PATH ONLY ONCE DURING THE MONTH BECAUSE OF A SCHEDULED
INSPECTION OF THE NEWLY REPLACED RUBBER LINER IN THE SEPARATOR SECTION.
AUG. 77 744 662 138 744 138
AVAILABILITY = 19X
RELIABILITY = 19X
OPERABILITY = 21X
UTILIZATION = 19X
I.D. FAN RELAYS WERE INSTALLED BECAUSE OF HIGH FAN VIBRATIONS.
SEP. 77 720 343 720 720 252
AVAILABILITY = 64%
RtLIABILITY * 69*
OPERABILITY r 73X
UTILIZATION s 35X
BOILER WAS OUT OF SERVICE FOR MOST Of THE MONTH. BOILER RETURNED TO SERVICE ON THE 2«TH.
THE SCRUBBER STILL HAD LIMIT SWITCH PROBLEM WITH 14 A & B GUILLOTINE DAMPERS.
OCT. 77 744 635 630 744 630
AVAILABILITY = 99X
RELIABILITY s 99X
OPERABILITY = 99X
UTILIZATION = 84.7X
THE UNIT WAS SHUT DOWN FOR 5 HOURS DURING OCTOBER TO REPAIR AN ID FAN LEAK. THE BALANCE Of
THE OUTAGE TIME WAS BOILER RELATED. (TOTAL OUTAGE TIME WAS 113.92 HOURS).
NOV. 77 720 690 693 589 562
AVAILABILITY s 78.7X
RtLIABILITY s 76.6X
OPERABILITY = 81.5X
UTILIZATION s 78.IX
THE SCRUBBER WAS DOWN APPROXIMATELY 153.57 HRS. DURING NOVEMBER. PROBLEMS ENCOUNTERED IN-
CLUDED SCREEN PLUGGING IN THE RECYCLE TANK AND A SCRUBBER INSTRUMENTATION DIFFICULTY. THE
SYSTEM WAS ALSO DOWN FOR THE INSTALLATION OF AN OUTLET NOZZLE IN THE BOOSTER TANK.
DEC. 77 744 631 522 744 522
AVAILABILITY = 65X
RELIABILITY = 83X
OPEHABILITY = 82X
UTILIZATION = 7U
THE SCRUBBER WAS OFF-LINE FOR APPROXIMATELY 109 HOURS DUE TO HIGH TRAY DIFFERENTIAL PRESSURE
AND SOME PLUGGING IN THE I.D. FAN SENSING LINE. THE BOILER WAS DOWN ABOUT 113 HRS. IN DEC.
JAN. 78 744 616 416 744 416
AVAILABILITY = 5&x
RELIABILITY = 69X
OPERABILITY = 68X
UTILIZATION = 56X
THE MODULE WAS UNAVAILABLE APPROXIMATELY 328.15 HOURS DURING JANUARY. TWO OUTAGES WERE CAUS-
ED BY HIGH TRAY DIFFERENTIAL PRESSURE. AN ELECTRICAL PROBLEM BECAUSE 1A FORCED DRAFT FAN WAS
OUT AND LOST AIR TO THE I.D. FAN DAMPER CAUSED SOME OUTAGE TIME. THE BOILER WAS OUT OF
SERVICE APPROXIMATELY 96 HRS.
92
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY,
PARTICULATE3
NEVADA POWER
REIO GARDNER NO £
MOAPA NEVADA
125 MW
COAL 0.5 - 1.0 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
RETROFIT
4/74
OPERATIONAL
99 PERCENT
S02
85 PERCENT
WATER MAKE UP
OPEN LOOP 0.40 GPM/MW
SLUDGE DISPOSAL
SOLAR EVAPORATION POND
UNIT COST
SEE APPENDIX A, KGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS SODIUM CARBONATE-BASED (TRONA) SCRUBBING SYSTEM CONSISTS OF ONE
MODULE CONTAINING A TWIN VARIABLE-THROAT VENTURI SCRUBBER FOLLOWED BY A
SEPARATOR IN SERIES WITH A SINGLE-STAGE PERFORATED-PLATE ABSORBER TUWEK.
PRIMARY PARTICULATE CONTROL IS PROVIDED BY UPSTREAM MECHANICAL COLLECTORS.
A STEAM INDIRECT HOT AIR REHEAT SYSTEM RAISES THE GAS TEMPERATURE 30 F
PRIOR TO DISCHARGE TO THE MAIN STACK. THE FLUE GAS CLEANING WASTES ARE
ULTIMATELY DISPOSED IN AN ON-SITE CLAY-LINEO SOLAR EVAPORATION POND.
93
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BACKGROUND INFORMATION
ON
REID GARDNER UNITS 1, 2, AND 3
THE REID GARDNER POKER STATION IS LOCATED NEAR MOAPA, NEVADA, ABOUT 50 MILES NORTH OF LAS VEGAS
THE STATION HAS THREE ELECTRIC POWER GENERATING UNITS, (REIO GARDNER 1, 2, AND 3) EACH RATED AT
125 MM. UNITS 1 AND 2 ARE RETROFITTED WITH SODIUM CARBONATE-BASED FGD SYSTEMS. UNIT NO. 3 IS A NEW
INSTALLATION, ALSO EQUIPPED WITH A SODIUM CARBONATE-BASED FGD SYSTEM. THE COAL BURNED AT THE PLANT
HAS AN AVERAGE GROSS HEATING VALUE OF 12,a50 BTU/LB. AND ASH AND SULFUR CONTENTS OF d AND 0.5
PERCENT RESPECTIVELY.
THE FGD SYSTEMS INSTALLED ON REID GARDNER UNITS 1,2,43 WERE DESIGNED AND INSTALLED BY COM-
BUSTION EQUIPMENT ASSOCIATES IN ASSOCIATION WITH A. D. LITTLE. THE SYSTEMS FOR UNITS 1 AND 2 MERE
PLACED IN SERVICE IN APRIL 1974. THE SYSTEM FOR UNIT 3 WAS PLACED IN OPERATION ON JULY 12, 1976.
THE SCRUBBING SYSTEM DESIGN WAS BASED ON INFORMATION AND DATA OBTAINED FROM AN 8000-ACFM PILOT PLANT
PROGRAM CONDUCTED AT THIS STATION IN 1971 AND 1972.
THE FGD SYSTEM CONSISTS OF A SINGLE MODULE, DESIGNED TO HANDLE «73,000 ACFM OF GAS AT 350 F.
THE MOOULt IS MADE UP OF A TWIN VARIABLE-THROAT VENTUHI SCRUBBER, FOLLOWED BY A SINGLE-STAGE TRAY
TOWER ABSORBER. GAS BYPASS IS ACHIEVED BY A GUILLOTINE-TYPE DAMPER. A COMMON FACILITY FOR TRONA
(SODIUM CARBONATE ORE) STORAGE AND SAND REMOVAL SERVES ALL THE FGO MODULES AT THE REID GARDNER
PLANT. SULFUR DIOXIDE REMOVAL EFFICIENCY IS REPORTED TO BE 8b PERCENT. PRIMARY PARTICULATE REMOVAL
IS ACCOMPLISHED BY 75 PERCENT EFFICIENT MECHANICAL COLLECTORS INSTALLED UPSTREAM OF THE WET SCRU-
BBERS. THE TOTAL PARTICULATE REMOVAL EFFICIENCY OF THE MECHANICAL COLLECTION AND WET SCRUBBING
SYSTEM EXCEEDS THE 99 PERCENT LEVEL.
IN THIS SODIUM CARBONATE PROCESS, HOT FLUE GAS FROM THE BOILER PASSES FIRST THROUGH THE MECHAN-
ICAL COLLECTORS WHERE PRIMARY PARTICULATE REMOVAL TAKES PLACE. PRESSURE IS THEN BOOSTED BY AN IND-
UCED DRAFT FAN BEFORE THE GAS STREAM SPLITS AS IT ENTERS THE TWIN-THROAT VENTURI SCRUBBER. THE HOT
FLUE GAS IS QUENCHED BY A SHOWER OF CIRCULATED SODIUM-BASE LIQUOR. THE GAS THEN ENTERS THE TRAY
TOWER AND BUBBLES THROUGH THE RADIAL-VAiME MIST tLIMINATOR, WHERE THE REMAINING LIQUID DROPLETS CARR-
IED OVER WITH THE GAS ARE TRAPPED AND REMOVED.
EFFLUENT FROM THE FGD SYSTEM IS FROM TwO SOURCES* THE SLIP STREAM OF SPENT LIUUOR DISCHARGED
FROM THE RECIRCULATION TANK, AND THt ALKALINE CLARIFIER UNDERFLOW, WHICH SERVtS TO NEUTRALIZE THE PH
OF THE COMBINED LIQUOR BEFORE IT IS DISCHARGED TO THE SLUDGE SETTLING PONDS. THE SPENT LIQUOR IS
PUMPED INTO ONE OF TWO SETTLING PONDS. THE OVERFLOW FROM THIS POND is PUMPED TO A LARGER IS-ACRE
POND, WHERE THE BRINE IS EVAPORATED. THE FGD SYSTEM OPERATES ON AN OPEN WATER LOOP WITH NO LIQUOR
RECYCLED TO THE MODULES FHOM THE PONDS.
ADDITIONAL INFORMATION CONCERNING THE PERFORMANCE OF THt SCRUBBERS INSTALLED AT THE REID
GARDNER STATIUN, INCLUDING PROBLEMS, SOLUTIONS, AND MODIFICATIONS, ARE PRESENTED IN THE FOLLOWING
TABLES. IN ADDITION, A GENERAL PROCESS FLOW DIAGRAM OF THE SODIUM CARBONATE SCRUBBING SYSTEM IS
PRESENTED IN APPENDIX B.
94
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NEVADA POWER REIQ 6ARONEH UNIT N0> £
HR.
BOILER MODULE CALLED
TOTAL OPERATION AVAILABLE UPON TO OPERATION
PERIOD CHR.) (HR.) (HR.) OPERATE INK.)
FEB. 75
MAR. 75
APR. 75
MAY 75
JUN. 75
DURING FEBRUARY THE FGD SYSTEM OPERATED WITH 90 PERCENT OPERABILITY ON TKONA SUPPLEMENTED
WITH SODA ASH. PROBLEMS INCLUDED A PLUGGED RECYCLE LINfc STRAINER, SEAL KATtR FILTERS, AND
BOILER CONTROLS. UNIT WAS RESTARTED AFTER SHUTDOWN FOR 5-YEAK TURBINE OVERHAUL. SECOND
PERt-ORMANCE TEST WAS PASSED. PROBLEMS INCLUDED ABRASION UF RUBBER-LINED PIPES AND ROUTINE
MECHANICAL AND INSTRUMENTAL PROBLEMS. HIGH ASH CONTENT, UP TO dO PERCENT, HAD NO EFFECT ON
EMISSIONS.
JUL. 75
THE FGD SYSTEM OPERABILITY FOR THE MONTH OF JULY WAS 85 PERCENT.
AUG. 75
SEP. 75 720 645 49fa
OPERABILITY = 77%
UTILIZATION = 69%
THREE FORCED SCRUBBER OUTAGES OCCURRED BECAUSE OF STRAINER PLUGGING, BROKEN BUCKET ELEVATOR,
WORN RECIRCULATION PIPING, AND RUBBER LINER LEAKAGE.
OCT. 75 744 531 464
OPERABILITY = 87%
UTILIZATION = 62X
THREE FORCED SCRUBBER OUTAGES WERE REPORTED FOR THE MONTH OF OCTOBER BECAUSE OF PUMP REPAIR,
INSTRUMEN] PLUGGING, AND REPAIR OF SYSTEM PIPING LEAKAGE.
NOV. 75 720 603 596
OPERABILITY = 99%
UTILIZATION = 63%
THE UTILITY PREFERS Tu REPORT SYSTEM PERFORMANCE IN TERMS OF THE OPERABILITY INDEX BECAUSE UF
EASE OF CALCULATION, REQUIRES NU JUDGEMENT, AND REFLECTS THE ACTUAL PERFORMANCE OF 1 HE FGD
SYSTEM ACCURATELY IF THE REASONS FOR DOWNTIME ARE KNOWN.
DEC. 75
JAN. 76 744 691 b35 691 458
AVAILABILITY = 72%
RELIABILITY = 66%
OPERABILITY = 66%
UTILIZATION = 62%
BOILER WAS OUT OF SERVICE A TOTAL UF 3 DAYS DURING THE MONTH. SCRUBBER OUTAGES WERE CAUSED
BY FROZEN CARBONATE LINES, PLUGGED PRESSURE -SENSING LINES, DUCT PRESSURE TRIPS, AND OVERHAUL
OF A TRAY RECYCLE PUMP.
FEB. 76 696 675 582 675 578
AVAILABILITY = 84%
RELIABILITY = 86X
OPERAblLITY = 86%
UTILIZATION = 83%
THE UTILITY REPORTED FOUR SCRUBBER INACTIVE PERIODS DURING THE MONTH, THREE OF WHICH WERE
SCRUBBER-RELATED OUTAGES. THE FORCED SCRUBBER OUTAGES OCCURRED BECAUSE UF PLUGGING IN A
VENTURI PUMP, DEPLETION OF CHEMICAL, CHEMICAL LINE PLUGGING AND SEAL HATER PROBLEMS.
MAR. 76 744 660 495 633 395
AVAILIBILITY = 67X
RELIABILITY = 62X
OPERABILITY = 60X
UTILIZATION a 53%
TWO FORCED SCRUBBER OUTAGES WERE REPORTED FOR THE MUNTH BECAUSE UF AN ELECTRICAL FAILURE AND
PLUGGING IN THE TRAY SYSTEM RESULTING IN A SUBSEQUENT OVERHAUL DF THE TRAY CYCLE PUMPS.
APR. 76 720 629 622 584 488
AVAILABILITY = 85X
RELIABILITY = 83%
OPERABILITY s 77X
UTILIZATION = 68%
FOUR FORCED SCRUBBER OUTAGES WERE REPORTED BY THE UTILITY FOR APRIL. PROBLEMS ENCOUNTERED
WERE; PLUGGED SENSING LINES, A REHEATER LEAK, VENTURI SPOOL RECYCLE REPLACEMENT, AND TANK
PATCHING.
95
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NEVADA POWER REI° GARDNER UNIT NO. 2
HR.
BOILER MODULE CALLED
TOTAL OPERATION AVAILABLE UPON TO OPERATION
PERIOD (HR.) (Hk.) (HR.J (HR.)
MAr 76
AVAILABILITY = 99%
RELIABILITY = 98%
OPERABlLlTY = 83%
UTILIZATION 3 79%
PROBLEMS ENCOUNTERED DURING THE MONTH INCLUDED PLUGGED VEMTURI LINES AND A PLUGGED SENSING
LINE. TOTAL SCRUBBER OPERATION TIME TO DATE IS 9,488 HOURS.
JUL. 76 744 518 676 43 421
AVAILABILITY = 9ix
RELIABILITY = 96%
OPERAblLITY = 81*
UTILIZATION = b7X
TWO FORCED SCRUBBER OUTAGES WERE REPORTED DURING THE MONTH. A PROBLEM WITH A HIGH SOLIDS
CONCENTRATION IN IHE VENTURI SCRUBBING CYCLE AND THE REPLACEMENT OF A RUBBER-LINED PIPE IN
THE VENTURI SCRUBBER RESULTED IN AN OUTAGE TIME OF APPROXIMATELY 19 HOURS.
AUG. 76 744 709 710 564 530
AVAILABILITY = 95%
RELIABILITY = 94X
OPERABlLlTY = 7b%
UTILIZATION = 71%
FORCED SCRUBBER OUTAGE TIME TOTALED 34.5 HOURS. TWO TRIPS OCCURRED DURING THE MONTH BECAUSE
OF LEAKAGE IN THE VENTURI RECYCLE LINt AND PLUGGING IN THE THICKENER TANK. THE REMAINING
SCRUBBER OUTAGE TIME DURING THE MONTH RESULTED FROM DEPLETION OF CHEMICAL ABSORBENT (TRONA)
AND BOILER TRIPS.
SEP. 76 720 681 677 697 653
AVAILABILITY = 94%
RELIABILITY = 94X
OPEKABILITY = 96X
UTILIZATION = 91%
TWO FORCED SCRUBBER OUTAGES, TOTALING 43.5 HOURS OF OUTAGE TIME, WERE REPORTED BY THE
UTILITY DURING THE MONTH. MINOR TRIPS WERE CAUSED BY PLUGGING IN THE I.D. FAN REFERENCE LINES
AND A FALSE HIGH TEMPERATURE HEADING IN THE VENTURI CAUSED BY WATER IN THE INSTRUMENT.
OCT. 76 744 694 708 692 656
AVAILABILITY = 95%
RELIABILITY = 95%
OPERABlLlTY = 95%
UTILIZATION = 88%
TOTAL FORCED OUTAGE TIME FOR THE MONTH AMOUNTED TO APPROXIMATELY 36 HOURS. SCRUBBER TRIPS
WERE CAUSED BY VENTURI GAS DAMPER PROBLEMS, PLUGGING IN THE SCRUBBER EFFLUENT LINE, AND RE-
PLACEMENT OF THE CARBONATE FEEO LINE, SCRUBBER OUTAGE TIME DUE TO BOILER TRIPS AMOUNTED TO
APPROXIMATELY 65 HOURS.
NOV. 76 730 621 374 709 363
AVAILABILITY = 52X
RELIABILITY = 51%
OPERABlLlTY = 58%
UTILIZATION = 50%
DURING A BOILER OUTAGE TO REPAIR A CONDENSER TUBE LEAK AND BOTTOM ASH NOZZLE, THE SCRUBBER'S
GUILLOTINE DAMPERS WERE BADLY DAMAGED, AND THE SCRUBBER REMAINED OUT OF SERVICE DURING THE
MONTH OF DECEMBER.
DEC. 76 744 275 0 00
ALL INDEX VALUES = OX
JAN. 77 744 00 00
ALL INDEX VALUES = OX
THE BOILER WAS OFF-LINE DURING JANUARY FOR MAINTENANCE.
FEB. 77 672 516 623 431 387
AVAILABILITY = 93%
RELIABILITY = 88%
OPERABlLlTY = 75%
UTILIZATION = 56%
TWO MINOR SCRUBBER OUTAGES RESULTED FROM A VENTURI PIPING LEAK WASH TRAY RECYCLF TANK
CLEANING. AT THE END OF THE MONTH, THERE WERE SOME ELECTRICAL PROBLEMS
96
-------
NEVADA POWER
REID GARDNER UNIT NO. 2
HR.
BOILER MODULE CALLED
TOTAL OPERATION AVAILABLE UPON TO OPERATION
PERIOD (HR.) (HR.) (HR.) OPERATE (HR.)
MAR. 77 744 659 688 535 s&7
AVAILABILITY a 92X
RELIABILITY a 97X
OPERABILITY a 8&X
UTILIZATION a 76X
PROBLEMS, A PLUGGED SPRAY TRAY, DUCT
APR. 77 720 720 685 685 685
AVAILABILITY a 95X
RELIABILITY a 95X
OPERABILITY = 95X
UTILIZATION a 95X
THE SCRUBBER MODULE REMAINED IN SERVICE ON A CONTINUOUS BASIS THROUGHOUT THE MONTH. THE
SYSTEM WAS FORCED OUT OF THE GAS PATH ON JUNE 39 BECAUSE OF A LEAK IN THE VENTURI DISCHARGE
LINE (FORCED OUTAGE TIME a 34.67 HOURS).
MAY 77 744 524 734 455 445
AVAILABILITY = 99X
RELIABILITY = 98X
OPERABILITY = 85X
UTILIZATION = 60X
THE SCRUBBER MODULE WAS TAKEN OUT OF THE SAS PATH TWICE DURING MONTH. BOILER OUTAGE (256
HOURS) AND ONE FORCED SCRUBBER OUTAGE (NO EMERGENCY SPRAY BECAUSE THE ASH SERVICE PUMPS HERE
OUT FOR APPROXIMATELY 10 HOURS).
JUN. 77 720 634 679 636 596
AVAILABILITY = 94%
RELIABILITY = 94X
OPERABILITY = 93X
UTILIZATION = 83X
FOUR OUTAGES WERE REPORTED. THREE WERE FORCED SCRUBBER OUTAGES DUE TO PLUGGING OF THE ID
FAN SENSING LINE, A BREAKER TRIP RESULTING IN LOSS OF CONTROL POWER AND PLUGGED SPRAY NOZZLES
IN THE VENTURI. TOTAL FORCED SCRUBBER OUTAGE TIME WAS APPROXIMATELY 41 HOURS FOR THE MONTH.
JUL. 77 744 733 298 744 298
AVAILABILITY a 40X
RELIABILITY = 40X
OPERABILITY = 41X
UTILIZATION a 40X
EIGHT FORCED SCRUBBER OUTAGES WERE REPORTED, SEVEN OF WHICH WERE DUE TO A HIGH/LOW TRIP IN
SCRUBBER DUCT. ONE TWO HOUR OUTAGE WAS REQUIRED TO CORRECT A PLUGGING PROBLEM IN THE
VENTURI SPRAY NOZZLES.
AUG. 77 744 629 590 744 590
AVAILABILITY a 87X
RELIABILITY a 87X
OPERABILITY = 91X
UTILIZATION = 79X
A LEAK IN THE VENTURI RECYCLE HEADER AND A SCRUBBER DUCT HI-LO BOILER TRIP PROBLEM WERE THE
SCRUBBER RELATED OUTAGES DURING THE MONTH OF AUGUST. THERE ALSO WAS A BOILER OUTAGE.
SEP. 77 720 716 488 693 462
AVAILABILITY a 74X
RELIABILITY = 71X
OPERABILITY a 67X
UTILIZATION a 64X
OUTAGES DURING SEPTEMBER RESULTED FROM A LEAK IN THE VENTURI RECYCLE LINES, TRAY RECYCLE
PUMP REPAIR AND DUCT PRESSURE HI-LO SENSING LINE PLUGGING. OUTAGES ALSO OCCURRED WHEN THE
ASH SLUICE SYSTEM WENT OUT OF SERVICE (NO EMtRBENCY SPRAYS), WHEN A TRAY PLUGGED AND ONE
OCCURRED TO ALLOW CLEANING OF A SUCTION SCREEN IN THE TRAY RECYCLE TANK.
OCT. 77 744 704 564 742 562
AVAILABILITY = 76X
RELIABILITY a 76X
OPERABILITY a 80X
UTILIZATION s BOX
THE SCRUBBER WAS DOWN FOR 157 HOURS IN OCTOBER. THE SCRUBBER-RELATED OUTAGE TIME WAS NEEDED
TO CLEAN A PLUGGED TRAY RECYCLE TANK SCRtEN AND A SEPARATOR TO THE VENTURI TANK. ALSO, A
HIGH SOLIDS PROBLEM IN THE VENTURI RECYCLE SYSTEM HAD TO BE CORRECTED, A SCRUBBER DUCT HI-LO
PRESSURE BOILER TRIP WAS REPAIRED AND ID FAN LEAKS WERE PATCHED.
97
-------
NEVADA POWER
REID GARDNER UNIT NO. 2
BOILER MODULE
TOTAL OPERATION AVAILABLE
PERIOD (HR.) (HR.) (HR.)
96 622
HR.
CALLED
UPON TO
OPERATE
98
OPERATION
(HR.)
NOV. 77 720
AVAILABILITY ' 86X
RELIABILITY = OX
OPERABILITY « OX
UTILIZATION « OX
THE BOILER WAS OUT OF SERVICE FROM OCTOBER 31 UNTIL NOVEMBER 26.
SERVICE FOR AN 10 FAN ROTOR REPAIR.
0 7
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PART1CULATES
NEVADA POWER
REID GARDNER NO 3
MOAPA NEVADA
125 MM
COAL 0.5 - 1.0 PERCENT SULFUR
AOL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE SCRUBBING
NEW
7/76
OPERATIONAL
99 PERCENT
S02
65 PERCENT
MATER MAKE UP
OPEN LOOP 0.40 GPM/MW
SLUDGE DISPOSAL
SOLAR EVAPORATION POND
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION StCTION IN TABLE 3 OF THIS REPORT.
THIS UNIT IS A NEW COAL-FIHED BOILER THAT IS EQUIPPED WITH SODIUM
CARBONATE-BASED(TKONA)SCRUB8ING SYSTEM WHICH INCORPORATES A T«IN
VARIABLE-THROAT VENTURI SCRUBBER FOLLOWED BY A SEPARATOR IN SERIES WITH
A SINGLE-STAGE PERFORATED-PLATE ABSORBER TOWER. THE MODULE WAS FIRST
PLACED IN SERVICE ON BOILER FLUE GAS IN JULY 1976. MECHANICAL COLLECTORS
PROVIDE PRIMARY PARTICULATE CONTROL. REHEAT IS PROVIDED BY A STEAM IN-
DIRECT HOT AIH REHEAT SYSTEM. WASTE DISPOSAL IS ON-S1TE CLAY-LINED POND.
99
-------
BACKGROUND INFORMATION
ON
REID GARDNER UNITS If 2, AN[) 3
THE REID GARDNER POWER STATION IS LOCATED NEAR MOAPA, NEVADA, ABOUT 50 MILES NORTH OF LAS VEGAS
THE STATION HAS THREE ELECTRIC POWER GENERATING UNITS, (REID GARDNER 1, 2, AND 3) EACH RATED AT
125 Mw. UNITS I ANO 2 ARE KETRUFITTED wITH SODIUM CARBONATE-BASED FGD SYSTEMS. UNIT NO. 3 IS A NEW
INSTALLATION, ALSO EQUIPPED WITH A SODIUM CARBONATE-BASED FGD SYSTEM. THE COAL BURNED AT THE PLANT
HAS AN AVERAGE GROSS HEATING VALUE OF 12.15U BTU/LB. AND ASH AND SULFUR CONTENTS OF 8 AND 0.5
PERCENT RESPECTIVELY.
THE FGD SYSTEMS INSTALLED ON REID GARDNER UNITS 1,2,8.3 WERE DESIGNED AND INSTALLED BY COM-
BUSTION EQUIPMENT ASSOCIATES IN ASSOCIATION WITH A. D. LITTLE. THE SYSTEMS FOR UNITS I AND 2 WERE
PLACED IN SERVICE IN APRIL 197*4. THE SYSTEM FOR UNIT 3 WAS PLACED IN OPERATION ON JULY 12, 1976.
THE SCRUBBING SYSTEM DESIGN WAS BAStD ON INFORMATION AND DATA OBTAINED FROM AN 8000-ACFM PILOT PLANT
PROGRAM CONDUCTED AT THIS STATION IN 1971 AND 1972.
THE FGD SYSTEM CONSISTS OF A SINGLE MODULE, DESIGNED TO HANDLE 173,000 ACFM OF GAS AT 350 F.
THE MODULE IS MADE UP OF A TWIN VARIABLE-THROAT VENTURI SCRUBBER, FOLLOWED BY A SINGLE-STAGE TRAY
TOWER ABSORBER. GAS BYPASS IS ACHIEVED BY A GUILLOTINE-TYPE DAMPER. A COMMON FACILITY FOR TRONA
(SODIUM CARBONATE ORE) STORAGE AND SAND REMOVAL SERVES ALL THE FGD MODULES AT THE REID GARDNER
PLANT. SULFUR DIOXIDE REMOVAL EFFICIENCY is REPORTED TO BE as PERCENT. PRIMARY PARTICULATE REMOVAL
IS ACCOMPLISHED BY 75 PERCENT EFFICIENT MECHANICAL COLLECTORS INSTALLED UPSTREAM OF THE WET SCRUB-
BERS. THE TOTAL PARTICULATE REMOVAL EFFICIENCY OF THE MECHANICAL COLLECTION AND wET SCRUBBING
SYSTEM EXCEEDS THE 99 PERCENT LEVEL.
IN THIS SODIUM CARBONATE PROCESS, HOT FLUE GAS FROM THE BOILER PASSES FIRST THROUGH THE MECHAN-
ICAL COLLECTORS WHERE PRIMARY PARTICULATE REMOVAL TAKES PLACE. PRESSURE IS THEN BOOSTED BY AN IN-
DUCED DRAFT FAN BEFORE THE GAS STREAM SPLITS AS IT ENTERS THE TWIN-THROAT VENTURI SCRUBBER. THE HOT
FLUE GAS IS QUENCHED BY A SHOWER OF CIRCULATED SODIUM-BASE LIQUOR. THE GAS THEN ENTERS THE TRAY
TOW£R AND BUBBLES THROUGH THE RADIAL-VANE MIST ELIMINATOR, WHERE THE REMAINING LIQUID DROPLETS CARR-
IED OVER WITH THE GAS ARE TRAPPED AND REMOVED.
EFFLUENT FROM THE FGO SYSTEM IS FROM TWO SOURCES* THE SLIP STREAM OF SPENT LIQUOR DISCHARGED
FROM THE RECIRCULATION TANK, ANO THE ALKALINE CLARIFIER UNDERFLOW, WHICH SERVES TO NEUTRALIZE THE PH
OF THE COMBINED LIQUOR BEFORE IT IS DISCHARGED TO THE SLUDGE SETTLING PONDS. THE SPENT LIQUOR IS
PUMPED INTO ONE OF TWO SETTLING PONDS. THE OVERFLOW FROM THIS POND IS PUMPED TO A LARGER 45-ACRE
POND, WHERE THE BRINE IS EVAPORATED. THE FGD SYSTEM OPERATES ON AN OPEN rtATER LOOP WITH NO LIQUOR
RECYCLEO TO THE MODULES FROM THE PONDS.
ADDITIONAL INFORMATION CONCERNING THE PERFORMANCE OF THE SCRUBBERS INSTALLED AT THE REID
GARDNER STATION, INCLUDING PROBLEMS, SOLUTIONS, AND MODIFICATIONS, ARE PRESENTED IN THE FOLLOWING
TABLES. IN ADDITION, A GENERAL PROCESS FLOW DIAGRAM OF THE SODIUM CARBONATE SCRUBBING SYSTEM IS
PRESENTED IN APPENDIX 8.
100
-------
NEVADA POWER Reio 6ARUNER UNIT N0. 3
HR.
BOILER MODULE CALLED
TOTAL OPERATION AVAILABLE UPON TO OPERATION
PERIOD (HR.) (HR.) IHR.) OPERATE (HR.)
JUL. 76 744 692 355 449 316
AVAILABILITY = 45X
RELIABILITY « 70X
OPERABILITY * 46X
UTILIZATION s 42X
COMMERCIAL OPERATION COMMENCED ON JULY 12, 1976. FOUR OUTAGES WERE REPORTED FOR THE MONTH,
THREE OF WHICH WERE FORCED SCRUBBER OUTAGES. PROBLEMS WERE ENCOUNTERED WITH A BUCKET ELE-
VATOR MALFUNCTION AND A HIGH SOLIDS CONCENTRATION IN THE VENTURI SCRUBBING SOLUTION CYCLE.
AUG. 76 744 744 420 647 323
AVAILABILITY = 56X
RELIABILITY * SOX
OPERABILITY * 43X
UTILIZATION = 43X
FORCED SCRUBBER OUTAGES RESULTED FROM AN 1.0. FAN ELECTRICAL MALFUNCTION, 1.0. FAN INSULA-
TION, THICKENER TANK PLUGGING, REHEATER MOTOR BURNOUT ANO DESTRUCTION OF THE VENTURI FLOOR.
SEP- 76 720 679 352 682 314
AVAILABILITY = 49X
RELIABILITY = 46X
OPERABILITY « 46X
UTILIZATION s 44X
THE SYSTEM WAS PLACED BACK IN SERVICE ON SEPTEMBER 14 FOLLOWING EXTENSIVE REPAIRS AND MOD-
IFICATIONS FROM THE PRECEDING MONTH. THREE MINOR SCRUBBER TRIPS WERE ENCOUNTERED THROUGHOUT
THE DURATION OF THE MONTH. PROBLEMS REPORTED AT THE UTILITY WERE tWO REHEATER FAN TRIPS AND
A VENTURI VIBRATION TRIP.
OCT. 76 744 548 160 743 159
AVAILABILITY = 22X
RELIABILITY = 21X
DPERABILITY = 29X
JTILIZATION s 21X
THREE FORCED SCRUBBER OUTAGES WERE REPORTED FOR THE MONTH. TRIPS OCCURRED BECAUSE OF HIGH
SOLIDS CONTENT IN THE VENTURI RECYCLE SOLUTION, A SCRUBBER GAS DAMPEK MALFUNCTION, AND
VENTURI BOX.
10V. 76 720 264 205 727 212
WAILA8ILITY = 28%
IELIABILITY s 29X
IPERABILITY a 80X
ITILIZATION = 29X
THE SCRUBBER SYSTEM WAS NOT IN OPERATION THE FIRST HALF OF NOVEMBER DUE TO REPAIRS OF LEAKS
IN THE VENTURI SCRUBBER BOX. THE SYSTEM WAS RESTARTED NOV. 19, AND EXPERIENCED ONE FORCED
OUTAGE, BECAUSE OF A SCREW CONVEYOR MALFUNCTION, PREVENTING CHEMICAL MIXING.
EC. 76 744 744 737 728 721
VARABILITY = 99X
ELIABILITY = 99X
PERA8ILITY = 97X
TILIZATION = 97X
DURING THE MONTH, ONE MINOR SCRUBBER OUTAGE OCCURRED BECAUSE OF REPAIRS TO THE I.D. FAN EX-
PANSION JOINT.
AN. 77 744 690 731 689 676
VAILABILITY » 98X
ELIABILITY a 98X
PEHABILITY = 98X
ULIZATION « 9ix
TWO MINOR FORCED OUTAGES WERE THE RESULTS OF A PLUGGED TRAY ANO A REHEATER STEAM LEAK.
:B. 77 672 575 543 594 422
/AILABILITY = BIX
PLIABILITY = 72X
'ERA8ILITY = 74X
TILIZATION = 63X
A TOTAL OF 117 HRS. OF DOWNTIME WAS THE RESULT OF THREE FORCED SCRUBBER OUTAGES CAUSED BY
PROBLEMS WITH THE UPPER TRAY. A FOURTH OUTAGE RESULTED FROM DOWNTIME FOR CLEANING OUT THE
SODIUM CARBONATE LINE.
101
-------
NEVADA POWER
REID GARDNER UNIT NO. 3
PERIOD
MAR. 77
BOILER
TOTAL OPERATION
(HR.) (HR.)
744
639
MODULE
AVAILABLE
(MR.)
324
HR.
CALLtD
UPON TO
OPERATE
637
OPERATION
(HR.)
334
AVAILABILITY * 44X
RELIABILITY * 52X
OPERABILITY = SIX
UTILIZATION = 442
THE NO. 3 MODULE EXPERIENCED TWO MAJOR FORCED OUTAGES DURING MARCH.
SEPARATOR REQUIRED DOWNTIME FOR CURING AND
THE RUBBER LINING IN THE
THE'SCRUBBER FAN EXPANSION JOINT BLEW OUT. THREE
MINOR OUTAGES WERE CAUSED BY A PLUGGED TRAY AND THE 035 LIMIT SWITCH TRIPPING.
709
618
702
600
APR. 77 720
AVAILABILITY = 86X
RELIABILITY = 85X
OPERABILITY * 65X
UTILIZATION = 83X
THREE SCRUBBER OUTAGES WERE REPORTED, TWO WERE FORCED OUTAGES. A HIGH TRAY DIFFERENTIAL AND
A PLUGGED STRAINER IN THE TRAY RECYCLE TANK RESULTED IN A FORCED OUTAGE TIME OF APPROXIMATELY
102 HOURS.
470
467
594
124
MAY 77 744
AVAILABILITY = 63X
RELIABILITY = 21X
OPERABILITY = 2bX
UTILIZATION * 16X
THE MODULE WAS UNAVAILABLE DURING THE FIRST THREE WEEKS OF THE MONTH BECAUSE OF A FORCED OUT-
AGE REQUIRED FOR THE REPLACEMENT OF THE FRP LINER IN THE MODULE'S SEPARATOR SECTION. NO
OPERATING DATA WAS MADE AVAILABLE BY THE UTILITY FOR THE MONTH. IN ADDITION THE REHEA1ER FAN
BREAKER WAS RECEIVED AND THE VENTURI DAMPER.
70b
475
666
443
JUN. 77 720
AVAILABILITY = 98X
RELIABILITY = 64X
OPERABILITY = 63X
UTILIZATION = 62X
FOUR SCRUBBER OUTAGES WERE REPORTED, THREE OF WHICH WERE FORCED. PROBLEMS ENCOUNTERED INCLUDED
A HIGH TRAY DIFFERENTIAL PRESSURE READING AND A VENTURI RECYCLE LINE THROTTLE VALUE.
744
542
744
542
JUL. 77 744
AVAILABILITY = 73x
RELIABILITY = 73X
OPERABILITY = 73%
UTILIZATION = 73X
FIVE FORCED SCRUBBER OUTAGES WERE CAUSED BY A HIGH TKAY DIFFERENTIAL PRESSURE READING, SCRUB-
BER FAN VIBRATION PROBLEMS, AND REPAIRS TO THE VENTUKI DISCHARGE VALVE.
629
375
744
375
AUG. 77 744
AVAILABILITY = 70X
RELIABILITY = 63X
OPERABILITY = 63X
UTILIZATION = 50X
DUE TO A LEAK IN VENTURI RECYCLE LINE THfc. UNIT WAS OFF THE LINE PART OF THE MONTH. A FALSE
ALARM DUE TO SCRUBBER OUTLET TEMPERATURE CAUSED SHUTDOWN FOR ABOUT A DAY. BOILER WAS OUT OF
SERVICE FOR ABOUT A WEEK DURING THIS REPORT PERIOD.
SEP. 77 720 720 736 654 646
AVAILABILITY = 90X
RELIABILITY = 99%
OPERAblLITY = 90X
UTILIZATION = 90X
HIGH SOLIDS IN THE VENTURI RECYCLE SYSTEM CAUSED SOME TIME OFF IN SEPTEMBER.
AND POST NEUTRALIZATION LINES WERE INSTALLED.
NEW EFFLUENT
OCT. 77 744 506 171 460 455
AVAILABILITY = 99X
RELIABILITY = 99X
OPERABILITY = 90X
UTILIZATION = 61X
THE SCRUBBER WAS DOWN 284.42 HOURS DURING OCTOBER FOR A SCHEDULED BOILER OUTAGE. 4 45 HOURS
ADDITIONAL OUTAGE TIME OCCURRED AS A RESULT OF HIGH VIBRATION PROBLEMS ON A SCRUBBER FAN.
102
-------
IEVADA POWER KEIO 6AROf
-------
TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UMIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PAKTICULATES
NORTHERN INDIANA PUS SERVICE
D.H. MITCHELL NO.11
GARY INDIANA
115 MW
COAL i.2-3.5 PERCENT SULFUR
DAVY POHERGAS/ALL1ED CHEMICAL
HELLMAN LORD/ALLIED CHEMICAL
RETROFIT
b/77
OPERATIONAL
99.5 PERCENT
SOI
90 PERCENT GUARANTEE
WATER MAKE UP
CLOSED LOOP
SLUDGE DISPOSAL
ELEMENTAL SULFUR PRODUCT
UNIT COST
SEE APPENDIX A, FGO SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS FGD SYSTEM IS AN INTEGRATION OF THE WELLMAN-LORD SOi RECOVERY PROCES
OFFERED BY DAVY POWERGAS AND THE SOS TO SULFUR REDUCTION PROCESS DE-
VELOPED BY ALLIED CHEMICAL. DAVY POWERGAS IS THE DESIGN AND CONSTRUCTION
FIRM AND ALLIED CHEMICAL IS SYSTEM OPERATOR AND PRODUCT MARKETER.
PERFORMANCE TESTS WERE SUCCESSFULLY CUMPLETEO ON SEPTEMBER 1«, 1977. A
DEMONSTRATION YEAR COMMENCED ON SEPTEMBER 16, 1977.
104
-------
BACKGROUND INFORMATION
ON
O.H. MITCHELL NO. 11
IN JUNE OF 1972 THE NORTHERN INDIANA PUBLIC SERVICE CO. (NIPSCO) AND THE U.S. ENVIRONMENTAL
PROTECTION AGENCY ENTERED INTO A COST-SHARED CONTRACT FOR THE CONSTRUCTION AND OPERATION OF A
WELLMAN-LORD/ALLIED CHEMICAL FGO DEMONSTRATION PLANT. THE SYSTEM WAS INSTALLED
ON GENERATING UNIT NO. 11 AT NIPSCO'S D.H. MITCHELL POWER STATION IN GARY, INDIANA, ON THE SOUTHERN
TIP OF LAKE MICHIGAN. UNIT NO. 11 IS RATED AT 115 MW AND FIRES MIDWEST COAL WITH A HEAT VALUE OF
11,000 BTU/LB. AND SULFUR AND ASH CONTENTS OF 3.5 AND 10.OX RESPECTIVELY.
THIS UNIT WILL BE THE FIRST REGENERABLE FGD SYSTEM TO CONTROL THE TOTAL FLUE GAS EMISSION FROM
A FULL SCALE COAL-FIRED GENERATING UNIT. IT IS ALSO THE FIHST SYSTEM TO RECOVER ELEMENTAL SULFUR
OF A MARKETABLE QUALITY FROM THE FLUE GAS OF AN ELECTRIC UTILITY. THE PRIMARY ENGINEERING AND CONS-
TRUCTION FIRM IS DAVY POWER6AS. ALLIED CHEMICAL, UNDER CONTRACT TO NIPSCO, OPERATES THE FGD FAC-
ILITY AND MARKETS THE USEFUL PRODUCTS.
THE FGD SYSTEM CONSISTS OF THREE MAJOR PROCESS UNITS: A rtELLMAN-LORO SOS RECOVERY UNIT, A DAVY
POWERGAS PURGE TREATMENT UNIT, AND AN ALLIED CHEMICAL S02 REDUCTION UNIT.
THE S02 RECOVERY SYSTEM INCLUDES A FLUE GAS BOOSTER BLOWER, A PRESCMU8BER (OKIFICE CONTACTOR),
A THREE-STAGE TRAY TOWER ABSORBER, AND AN EVAPOKATOR/CRYSTALLIZER. THE PRESCKUBBER is A VARIABLE-
THROAT VENTURI USED TO SATURATE THE FLUE GAS AND REMOVE ANY FLYASH NOT COLLECTED IN THE ESP UNIT.
THE FLYASH SLURRY is SPENT CONTINUOUSLY TO THE ASH PONDS. THE ABSORBER is A THREE-STAGE KOCH VALUE
TRAY ABSORPTION TOWER FOLLOWED BY A MIST ELIMAINTOR AND A STACK GAS REHEAtER. THE SPENT SCRUBBING
(SODIUM SULFITE-BISULFITE) SOLUTION IS REGENERATED IN AN EVAPORATOR/CKYSTALLIZEW. HEUE THE SOLUTION
IS HEATED UNTIL THE BISULFITE DECOMPOSES, EMITTING S02 GAS AND PRECIPITATING SOlHUM SULFITE
CRYSTALS. THESE ARE REMOVED AND REDISSOLVED IN THE CONDENSATE FROM THE EVAPORATOR FOR RECYCLE TO
THE ABSORBER.
A SMALL SIDESTREAM IS REMOVED FROM THE SCRUBBING LIQUOR LEAVING THE ABSORBER AND SENT TO THE
PURGE TREATMENT UNIT TO REMOVE SODIUM SULFATE. THIS SYSTEM CONSISTS OF FOUR CHILLED-WALL CRYSTALL-
IZERS WHERE SODIUM SULFATE CRYSTALS FORM, FOLLOWED BY A CENTRIFUGE AND CRYSTAL UHYER.
THE SULFUR DIOXIDE FROM THE EVAPORATOR/Ch Y5TALLUER IS COMPRESSED AND SENT TO THE ALLIED CHEM-
ICAL 802 REDUCTION PLANTr WHERE IT IS REACTED WITH NATURAL GAS. THE RESULTING ELEMENTAL SULFUR IS
CONDENSED AND STORED IN MOLTEN FORM, WHILE THE OFF-GASES ARE BURNED IN A TAIL GAS INCINERATOR AND
RETURNED TO THE AbSORBER INLET. THE ALLIED PLANT IS DESIGNED TO GENERATE 25 TON/DAY OF SULFUR.
A SUMMARY OF THE PERFORMANCE OF THE WELLMAN-LORD FGD DEMONSTRATION UNIT, PROBLEMS/SOLUTIONS
AND MODIFICATIONS IS PROVIDED IN THE PERFORMANCE HISTORY TABLE THAT FOLLOWS. A SIMPLIFIED PROCESS
FLOW DIAGRAM IS PROVIDED IN APPENDIX B OF THIS REPORT.
105
-------
NORTHERN INDIANA PUBLIC SERVICE
0. H. MITCHELL UNIT NO. 11
NIPSCO WELLMAN-LORD S02 KECOVERY SYSTEM
OPERATING HISTORY
•INITIAL OPERATING EXPERIENCE*
FOLLOWING COMPLETION OF CONSTRUCTION IN MID-1976, START-UP OF THE VARIOUS SUBSYSTEMS AND COM-
PONENT PARTS WAS INITIATED. DURING THE PERIOD JULY THROUGH NOVEMBER, THREE SUSTAINED HUNS OF THE S02
ABSORBER AND REGENERATION SYSTEM UNDER NORMAL OPERATING CONDITIONS WERE ACHIEVED. 302 REMOVAL
EFFICIENCY WAS EQUAL TO OR GREATER THAN THE SOX PERFORMANCE CRITERIA. UNIT 11 BOILER OPERATED 121
FULL DAYS AND 10 PARTIAL DAYS. THE WELLMAN-LORD S02 RECOVERY UNIT OPERATED 71 FULL DAYS AND 23
PARTIAL DAYS. DURING THIS PERIOD, NUMEROUS MODIFICATIONS AND CORRECTIONS TO THE SYSTEM WERE COM-
PLETED. THESE INCLUDED MODIFYING THE ABSORBER KOCH VALVE THAYS TO IMPROVE TURN-DOWN, RUBBER LINING
THE BOTTOM ABSORBER COLLECTOR TRAY, RELOCATING ANO IMPROVING TEMPERATURE CONTROL OF THE LOW
PRESSURE STEAM SUPPLY, INSTALLING IMPROVED S02 SAMPLE PROBES ANU SEVERAL REPLACEMENTS ANO MODIFI-
CATIONS TO THE PURGE SALT RECOVERY AREA. FULLY INTEGRATED OPERATIONS INCLUDING S02 REDUCTION AND
SULFUR RECOVERY OCCURRED IN NOVEMBER, 1976. JANUARY THROUGH MAY 1977 - UNIT 11 BUILEK WAS OUT-OF-
SERVICE FUR ABOUT FIVE MONTHS FOLLOWING A BOILER RELATED MISHAP WHICH OCCURRED ON JANUARY 15, 1977,
DURING START-UP AFTER A SCHEDULED MAINTENANCE TURN AROUND.
ON JUNE 13, 1977 FGD OPERATIONS RESUMED FOLLOWING RETURN TO FULL SERVICE OF UNIT 11 BOILER. BY
JUNE 15 FULLY INTEGRATED OPERATION OF THE ENTIRE FGD PLANT WAS ACHIEVED. THROUGH JUNE AND JULY,
SEVERAL HUNDRED HOURS OF TOTAL SYSTEM OPERATION AT BOTH PARTIAL AND FULL LOAD WERE ACCRUED.
PERFORMANCE TESTS
AUGUST-SEPTEMBER 1977 - PERFORMANCE TESTS COMMENCED ON AUGUST 29, 1977 ANO WERE SUCCESSFULLY
COMPLETED ON SEPTEMBER 14, 1977. THE TEST PERIOD INCLUDED 12 DAYS AT 92 MW FLUE GAS EQUIVALENT AND
3-1/2 DAYS AT 110 MW FLUE GAS EUUIVALENT. DURING THIS PERIOD, 91 PERCENT OF THE S02 WAS REMOVED
WHILE BURNING COAL CONTAINING 3 PERCENT SULFUR AND 204 TONS OF ELEMENTAL SULFUR WERE RECOVERED. ALL
PERFORMANCE CRITERIA WERE MET INCLUDING 802 REMOVAL, PARTICULATE EMMISSION, RAW MATERIAL AND UTILITY
CONSUMPTIONS AND RECOVERED SULFUR QUALITY. THE FGD UNIT SHUT DOWN SEPTEMBER 19 AND REMAINED IDLE
THROUGH MONTH END DUE TO COAL FEED PROBLEMS RESULTING FROM WET COAL ON THE UNIT 11 BOILER.
DEMONSTRATION PERIOD
OCTOBER 1977 - A DEMONSTRATION PERIOD OF ONE YEAR BEGAN SEPTEMBER 16. DURING OCTOBER, THE FGD
UNIT OPERATED 132 HRS. OPERATIONS WERE INTERRUPTED WHILE HEAT BALANCE TESTS WERE CONDUCTED ON THE
UNIT 11 BOILER BY NIPSCO ANO TRW AND WERE INTERRUPTED FURTHER TO MAKE REPAIRS TO THE 802 REDUCTION
SECTION, THE EVAPORATOR, ANO THE UNIT 11 BOILER.
OPERATING SUMMARY (HOURS ANO VIABILITY PARAMETER DATA WILL BE INCLUDED IN THE NEXT REPORT.
106
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/76
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
NORTHERN STATES POWER CO.
SHER8URNE COUNTY STATION NQ.l
BECKEK MINNESOTA
710 MW
COAL O.a PERCENT SULFUR
COMBUSTION ENGINEERING
LIMESTONE SCRUBBING
NEW
OPERATIONAL
99 PERCENT
502
PERCENT
WATER MAKE UP
OPEN LOOP 1.13 GPM/MW
SLUDGE DISPOSAL
CLAY-LINED DISPOSAL POND
UNIT COST
SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE ^ OF THIS REPORT.
FULL COMMERCIAL OPEKA1ION OF THE SYSTEM BEGAN ON MAY 1, 1976. THE SCRUB-
BING SYSTEM FOR THIS UNIT CONSISTS OF 12 MODULES. EACH SCRUBBING MODULE
INCORPORATES A VENTURI-ROD SECTION AND A MARBLE BED ABSOR8EK FOR PAR-
TICULATE AND SULFUR DIOXIDE REMOVAL. A FORCED OXIDATION SYSTEM CONVERTS
ALL THE CALCIUM SULFITE TO SULFATE PRIOR TO DISCHARGE TO A CLAY-LINED
SETTLING POND. STACK GAS REHEAT IS PROVIDED BY IN-LINE HOT rtATER TUBES.
107
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BACKGROUND INFORMATION
UN
SHERBURNE CUUNTY GENERATING PLANT
THE SHERBURNE COUNTY GENERATING PLANT OF THE NORTHERN STATES POWER COMPANY IS LOCATED ON THE
MISSISSIPPI RIVER IN SHfcReuRNE COUNTY NEAR BECKER, MINNESOTA. THIS NEW POWfcH GENERATING PLANT CUR-
RENTLY HAS TWO COAL-FIRED UNITS IN SERVICE AND 1 WO IN THE EARLY PLANNING STAGES. UNIT NO. 1 IS
RATED AT 710 MH AND FIRES MONTANA COLSTRIP COAL WITH A HEATING VALUE OF 8300 8TU/LB, AND SULFUR,
ASH, AND MOISTURE CONTENTS OF 0.8, 9.0 ANO 25.0 PERCENT, RESPECTIVELY. IN OROER TO MEET MINNESOTA
POLLUTION CONTROL AGENCY PARTICULATt AND S02 EMISSION STANDARDS OF 0.96 LBS. S02 ANO 0.087 LSS. PAR-
TICULATE PER MILLION BTU HEAT INPUT TO THE BOILER, THE UNIT WAS FITTED WITH A LIMESTONE-BASED WET
SCRUBBING SYSTEM FOR SIMULTANEOUS PARTICULATE AND S02 REMOVAL.
THE NORTHERN STATES POWER CO., SHERBURNE NO. 1 SCRUBBER DESIGN IS BASED UPON THE RESULTS OF A
PILOT PLAN! TEST PROGRAM CONDUCTED AT COMBUSTION ENGINEERING'S (CE) KRE1SINGER DEVELOPMENT LABOR-
ATORY AND A PROTOTYPE SCRUBBER PROGRAM CONDUCTED JOINTLY BY COMBUSTION ENGINEERING AND NORTHERN
STATES POWER AT THE UTILITY'S BLACK DOG STATION. THE SCRUBBING SYSTEM IS COMPRISED OF A FIRST STAGE
FIXED-ROD VENTURI SCRUBBER FOR PARTICULATE REMOVAL AND A MARBLE BED ABSORBER TO COMPLETE PARTICULATE
REMOVAL AND ACHIEVE THE NECESSARY SULFUR DIOXIDE REMOVAL. THE SCRUBBING HAS BEEN GUARANTEED TO
REMOVE 99 PERCENT OF THE PARTICULATE MATTER ENTERING THE SCRUBBING SYSTEM, OR MAINTAIN AN EMISSION
0.0<* GR/OSCF, WHICHEVER OUTLET VALUE IS GREATER. THE SULFUR OIUXIDE DESIGN REMOVAL EFFICIENCY IS
BASED UPON THE REMOVAL OF 50 PERCENT OF THE SULFUR IN THE FUEL (MAXIMUM FUEL SULFUR CONTENT OF 1.2
PERCENT) OR MAINTAIN AN EMISSION UF 200 PPM, WHICHEVER OUTLET VALUE IS GREATER.
THE GENERAL SCENARIO OF THE SHERBURNE NO. 1 SCRUBBING SYSTEM CONSISTS OF 12 SCRUBBING MODULES,
11 OF WHICH ARE REQUIRED FOR FULL LOAD CAPACITY. EACH MODULE HAS A RATED FLUE GAS CAPACITY OF
200,000 TO 220,000 ACFM AT 13b F. AN AGITATED REACTION TANK IS LOCATED AT THE BOTTOM OF EACH SCRUB-
BER MODULE. THE PURPOSE OF THE REACTION TANK IS TO ALLOW COMPLETION OF SULFUR DIOXIDE FORMATION TO
SULFITE, PROVIDE FORCED OXIDATION OF SULFITE TO SULFATE, AND FACILITATE PRECIPITATION OF CALCIUM
SULFATE SOLIDS. IN FORCED OXIDATION, AIR IS BUBBLED INTO THE REACTION TANK, OXIDIZING SULFITE TO
SULFATE. THE SULFATE FORMED is PRECIPITATED IN THE REACTION TANK BY ADDITION OF GYPSUM SEED
CRYSTALS. A BLEED LINE PROVIDES THE NECESSARY SOLIDS REMOVAL TO A 160-FOOT DIAMETER CLARIFIER.
HERE THE WASTE SOLIDS (FLY ASH, CALCIUM CARBONATE, AND CALCIUM SULFATE) SETTLE OUT AND THE CLARIFIED
WATER IS RETURNED TO THE PROCESS.
THE SCRUBBER MODULES ARE 2b FT X 18 FT X 60 FT HIGH AND HAVE « IN. DEEP, 13/16 IN. OIA. GLASS
MARBLE PACKING IN THE MARBLE BED SECTION. THE LIQUID FLOW RATE IN 5600 GPM PER MODULE AND OF WHICH
ABOUT 3500 6PM IS RECYCLED. THE SOLIDS CONTENT OF THE SLURRY IS 8-10X BY WEIGHT ANO THE PH MAIN-
TAINED IS 5-5.5. THE I.D. FANS HAVE A POWER RATING OF 6000 HP AND THE PRESSURE DROP ACROSS EACH
MODULE IS 20 IN. WG.
THE CLEANED FLUE GAS THEN PASSES THROUGH A DOUBLE ROW, TWO-PASS CHEVRON MIST ELIMINATOR. RE-
HEAT OF tO F IS ADDED TO THE GAS STREAM TO PROVIDE PROTECTION TO THE DOWNSTREAM DUCTWORK, I.D. FAN,
AND PLUME CONTROL BEFORE FINAL DISCHARGE TO THE ATMOSPHERE. THE CLARIFIER UNDERFLOW IS PUMPED TO A
SETTLING POND WHICH IS 45-FEET DEEP AND 62 ACRES IN AREA, WITH AN 18-INCH CLAY LINING. THE WATER IS
RECYCLED FROM THE POND BACK TO THE PROCESS. A GENERAL FLOW DIAGRAM OF THE SHERBUHNE SCRU88ER
ARRANGEMENT IS PROVIDED IN APPENDIX B.
INITIAL OPERATION OF THE SYSTEM COMMENCED MARCH 16, 1976. FULL COMMERCIAL OPERATION COMMENCED
MAY 1, 1976. PROBLEMS ENCOUNTERED DURING INITIAL STARTUP OPERATIONS HAVE INCLUDED THE USUAL MECH-
ANICAL PROBLEMS ASSOCIATED WITH A NEW SYSTEM AND SOME PLUGGING IN THE SCRUBBER INTERVALS. SPECIF-
ICALLY, PROBLEMS HAVE BEEN ENCOUNTERED IN THE SPRAY SYSTEM, REQUIRING THE DESIGN OF THE NOZZLES TO
BE CHANGED FROM PLASTIC ANO RUBBER COMPONENTS TO CERAMIC SPINNER-VANE COMPONENTS. ALSO, SOME PLUG-
GING PROBLEMS HAVE BEEN ENCOUNTERED IN THE SPRAY HEADERS, PRIMARY CONTACTOR, AND MARBLE BED. THIS
HAS STEMMED LARGELY FROM THE MALFUNCTION OF THE STRAINER SYSTEM BECAUSE OF POOR NOZZLE CONFIGUR-
ATIONS. NSP IS CURRENTLY MAKING MODIFICATIONS IN THIS AREA.
108
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NORTHERN STATES POWER CO.
BOILER OPERATION TIME AND MODULE OPERABILITY U)
101 102 103 104 105 106 107 106 109 110 111 112
SHERBURNE COUNTY STATION UNIT NO. 1
BOILER
PERIOD HR.
MAR. 76
APR. 76
A PRELIMINARY SYSTEM CHECKOUT WAS SUCCtSFULLY COMPLETED BY PASSING AIR AND WATER THROUGH
THE SYSTEM. FIRST COMMERCIAL OPERATION COMMENCED MAY 1, 1976. THIS IS AN INTERMIOIATE LOAD
UNIT, OPERATING NEAR FULL CAPACITY DURING THE DAY AND 35 PERCENT CAPACITY AT NIGHT.
MAY 76 657 62 83 81 59
TOTAL SYSTEM AVAILABILITY = 86X
MEGAWATT-HOURS GENERATED = SIB,050
72
SO
69
60
75
67
JUN. 76 688
TOTAL SYSTEM AVAILABILITY = 84*
MEGAWATT-HOURS GENERATED = 372,450
MODIFICATIONS ARE CONTINUING ON THE SPKAY SYSTEM, SPRAY NOZZLES AND STRAINER SYSTEM.
80
= 269,700
51 84 83
76
81
71
75
84
63 91
81
76
87
69
91
JUL. 76 512 80 62 71 81
TOTAL SYSTEM AVAILABILITY = 84X
MEGAWATT-HOURS GENERATED
AUG. lt> 705 46 93
TOTAL SYSTEM AVAILABILITY = 94X
MEGAWATT-HOURS GENERATED = 421,110
SINCE JULY 1, THE NO. 1 UNIT HAS BEEN GENERATING 95-98 PERCENT OF REQUIRED MW-HOURS. THE
SLURRY NOZZLES AKE FREQUENTLY PLUGGED BY PARTICLES ABOVE QUARTER INCH SIZE. NSP IS NOW
PLANNING TO MODIFY THE DUPLEX STRAINER SYSTEM TO ALLEVIATE THIS PROBLEM. IN ADDITION, THE
DEPOSITION OF SOFT SOLIOS IS STILL CONTINUING IN THE DEMISTERS AND REHEATERS. HARD SCALE
GYPSUM FURMATION ON THE VESSEL WALLS HAS LEVELED OFF. A CREW OF 70 PEOPLE is REQUIRED TO
MAINTAIN SCRUBBER OPERATIONS. THE CLEANING PROCEDURE CALLS FOR 3-4 MODULES TO BE TAKEN OUT
OF SERVICE EACH NIGHl. THUS, EACH MODULE IS CLEANED ONCE EVERY THkEE DAYS.
SEP- 76 566 87 90 93 76 76
TOTAL SYSTEM AVAILABILITY = 95 PERCENT
MEGAWATT-HOURS GENERATED => 349,470
79
85
79
85
80
96
OCT. 76 606 97 84 96 96 95 30 74 76 91 81 100 67
TOTAL SYSTEM OPERABILITY HAS TO BE 100 PERCENT SINCE THE SCRUBBERS CANNOT BE BYPASSED TO
OPERATE THE BOILER. NSP IS NOW IN THE PROCESS OF MODIFYING THE S1RAINEH DESIGN. THE DUPLEX
UNITS ARE TO BE REPLACED BY IN-TANK SCREENS AND SOOT BLOwEHS, BOTH LOCATED AT THE SUCTION
SIDE OF THE SPRAY WATER PUMP. CARBON STEEL FIN TUBE REHEAT BUNDLES ARE ALSO AN AREA OF
CONCERN. MULTIPLE FAILURES IN FOUR UNITS HAVE BEEN EXPERIENCED.
NOV. 76 720 83 80 87 79 92 60
TOTAL SYSTEM AVAILABILITY = 93 PERCENT
MEGAWATT-HOURS GENERATED = 470,820
97
91
89
95
69 78
94
88
73
73
93
DEC. 76 722 88 84 87 80 71
TOTAL SYSTEM AVAILABILITY = 95 PERCENT
MEGAWATT-HOURS GENERATED - 460,920
THE MODIFICATIONS OF THE DUPLEX STRAINER SYSTEM IS ONGOING, CURRENTLY APPROXIMATELY ONE-
THIRD COMPLETED ON THE UNIT MO. 1. THE UTILITY IS NOW CONDUCTING A FULL-LOAD EVALUATION
STUDY, ANALYZING SYSTEM OPERATION ON 10 MODULES vs. THE DESIGNED n MODULES. THE UNIT is
CURRENTLY HAVING DIFFICULTY COMPLYING WITH THE 20 PERCENT OPACITY REGULATION, DUE TO THE
EXTREMLY FINE FLY ASH BEING £MITTED(70 PERCENT LESS THAN 1 MICRON.)
JAN. 77 607 94 75 99 76 9fa
TOTAL SYSTEM AVAILABILITY = 90 PERCENT
MEGAWATT-HOURS GENERATED = 366,060
FEB. 77 609 89 99 64 96 64
TOTAL SYSTEM AVAILABILITY = 91 PERCENT
MEGAWATT-HOURS GENERATED = 395,210
77
99
95
92 81
81 62
98
86
93 95
40
93
83
75 95
98
78
61
MAR. 77 743 47 92 95 93 93
TOTAL SYSTEM AVAILABILITY s 95 PERCENT
MEGAWATT-HOURS GENERATED = 510,650
LOW OPERABILITIES ARE DUE PRIMARILY TO THE COMPLETION OF STRAINER MODIFICATIONS. THESE
WERE PERFORMED ON ONE MODULE AT A TIME. MODULE 101 WAS THE LAST TO UNDERGO MODIFICATIONS
ANO WORK WAS COMPLETED KM THE THIRD nEEK OF MARCH. Al THE PRESENT TIME, ALL MODULES ARE
FITTED WITH IN-TANK STRAINERS. THE 10 MODULES VS. 11 MODULES EVALUATION WILL BE RESUMED IN
THE NEAR FUTURE.
109
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NORTHERN STATES POWER CO.
SHERBUWNE COUNTY STATION UNIT NO. 1
BOILER OPERATION TIME AND MODULE OPERABILITY (X)
BOILER
PERIOD HR. 101 102 103 104 105 106 107 108 109 110 111
APR. 77 718 84 65 92 95 96
TOTAL SYSTEM AVAILABILITY s 95 PERCENT
MEGAWATT-HOURS GENERATED = 160,100
62
96
73
81
91
58
98 96
93
78
90
35
88
87
MAY 77 312 96 18 92 87 95
TOTAL SYSTEM AVAILABILITY = 92 PERCENT
MEGAWATT-HOURS GENERATED = 195,790
DURING THE REPORT PERIOD, THE UNIT WAS IN SERVICE ONLY 13 DAYS DURING THE MONTH OF MAY
BECAUSE OF A SCHEDULED TURBINE OVERHAUL EXTENDING FROM MAY 14 TO MID-JUNEC JUNE 18 PROJ.)
JUN. 77 248 76 77 75 75 30
TOTAL SYSTEM AVAILABILITY = 92 PERCENT
MEGAWATT-HOURS GENERATED » 127,290
87
94
58
91
61
17
80
83
78
83
83
JUL. 77 736 93 66 92 90 92
TOTAL SYSTEM AVAILABILITY a 97 PERCENT
MEGAWATT-HOURS GENERATED = 476,490
THE UNIT CAME BACK ON LINE 6/18/77 AFTER COMPLETION OF THE FIRST YEAR INSPECTION. ONE OF
THE HIGHEST AVAILABILITIES EVER DEMONSTRATED ON THIS UNIT WAS RECORDED DURING JULY AS A
RESULT OF THE COMPLETED CLEANOUT OVER THE OUTAGE. A SCRUBBER CLEANOUT AND STAINLESS STEEL
MODIFICATIONS TOOK PLACE.
AUG. 77 640 85 89 66 55 81
TOTAL SYSTEM AVAILABILITY = 95 PERCENT
MEGAWATT-HOURS GENERATED a 357,380
90
62
83
83
79
90
72
86
85
77
90
77
66
SEP. 77 686 86 85 88 92 88
TOTAL SYSTEM AVAILABILITY = 95 PERCENT
MEGAWATT-HOURS GENERATED * 416,430
DURING AUGUST ONLY NORMAL MAINTENANCE WAS REQUIRED. IN SEPT., MODULE 106 SPRAY WATER PUMP
WAS OVERHAULED. SOME ANGLES WERE INSTALLED ON THE PRIMARY CONTACTOR RODS TO RESIST EROSION.
OCT. 77 609 70 81 95 97 63
TOTAL SYSTEM AVAILABILITY = 88 PERCENT
MEGAWATT-HOURS GENERATED = 360,850
35
82
87
99
91
96
39 58
96
89 89
92 52
NOV. 77 705 77 91 42 86 79
TOTAL SYSTEM AVAILABILITY = 92 PERCENT
MEGAWATT-HOURS GENERATED = 412,360
OPERABILITES BELOW 50 PERCENT ARE DUE TO SPRAY WATER PUMP OVERHAULS. TWENTY-FOUR PUMPS ARE
BEING COMPLETELY OVERHAULED. STRAINER/WASHER SCREEN EROSION HAS BEEN A PROBLEM. REPAIR AND
REPLACEMENT HAS BEEN CONTINUALLY NECESSARY. 316 SS MATERIAL KILL BE USED IN FUTURE. THE
REPLACEMENT MATERIAL IS EXPECTED TO ARRIVE DEC. 12, 1977 AND WORK IS EXPECTED TO TAKE
THREE MONTHS.
DEC, 77 557 97 90 95 94 71
TOTAL SYSTEM AVAILABILITY = 93 PERCENT
MEGAWATT-HOURS 6ENERATED = 325,050
92
84
26 67
92
64
96
91
98
80
95
88
90
82
JAN. 78 648 83 63 88 73 84
TOTAL SYSTEM AVAILABILITY = 92 PERCENT
MEGAWATT-HOURS GENERATED = 374,290
THE REPLACEMENT PROGRAM HAS BEGUN ON DtC.21. IT TAKES 4/6 DAYS FOR WORK ON EACH MODULE.
MODULE 107 HAD HIGH MAINTENANCE ALONG WITH fHfc STRAINERS REPLACEMENT.
110
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH
01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
NORTHERN STATES POWER CO.
SHERBURNE COUNTY STATION NO.
BECKER MINNESOTA
710 MW
COAL 0.8 PERCENT SULFUR
COMdUSTION ENGINEERING
LIMESTONE SCRUBBING
NEW
a/77
OPERATIONAL
99 PERCENT
5 PERCENT
WATER MAKE UP
OPEN LOOP 1.13 GPM/MW
SLUDGE DISPOSAL
CLAY-LINEO DISPOSAL POND
UNIT COST
SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THfc BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE SHERBURNE NO. 2 AIR QUALITY CONTROL SYSTEM is IDENTICAL IN DESIGN TO
THE SYSTEM IN OPERATION ON THE NO. 1 UNIT AT THIS STATION. TWELVE cJ-STAGE
PARTICULATE SCRUBBER (VENTURI-ROD SCRUBBER) AND SULFUR DIOXIDE ABSORBER
(MARBLE-BED ABSORBER) MODULES ARE PROVIDED FOR FLY ASH AND S02 CONTROL.
ELEVEN MODULES ARE REQUIRED FOR FULL GENERATING CAPACITY OPERATIONS.
THE CALCIUM SULFITE is FORCIBLY OXIDIZED TO SULFATE PRIOR TO DISCHARGE TO
TM£ DISPOSAL POND. STACK GAS REHEAT PROVIDED bY IN-LINE HOT WATER TUBES.
Ill
-------
BACKGROUND INFORMATION
ON
SHERBURNE COUNTY GENERATING PLANT
THE SHERBURNE COUNTY GENERATING PLANT (SHERCO) OF THE NORTHERN STATES POWER COMPANY (NSP) IS
LOCATED ON THE MISSISSIPPI RIVER IN SHERBURNE COUNTY, BECKER, MINNESOTA, APPROXIMATELY «5 MILES
NORTHWEST OF MINNEAPOLIS. THIS NEW POWER-GENERATING PLANT CURRENTLY HAS TWO COAL-FIRED UNITS IN
SERVICE AND TWO IN THE tARLY DESIGN STAGES. UNIT NO. 2 IS RATED AT 710 MW AND FIRES LOW SULFUR COL-
STRIP MONTANA COAL THAT HAS A HEATING VALUE OF 830 BTU/LB, SULFUR CONTENT OF 0.8 PERCENT, ASH
CONTENT OF 9.0 PERCENT, AND A MOISTURE CONTENT OF 25.0 PERCENT. IN ORDER TO MEET MINNESOTA
POLLUTION CONTROL AGENCY EMISSION CODES OF o.96 LB SULFUR DIOXIDE AND 0.097 LB ^ARTICULATES PER
MILLION BTU HEAT-INPUT TO THE BOILER, THE UNIT WAS FITTED WITH A NON-REGENERABLE LIMESTuNE-BASEO WET
SCRUBBING SYSTEM.
THE DESIGN OF THE SCRUBBER PLANT FOR SHERCO NO. 2 IS IDENTICAL TO THAT EMPLOYED FOR THE NO. 1
UNIT NOW IN SERVICE AT THIS STATION (SEE THE PRECEDING FILE IN THIS REPORT FOR ADDITIONAL INFOR-
MATION). THE SCRUBBER DESIGN IS BASED UPON PILOT PLANT AND PROTOTYPE PLANT RESEARCH PROGRAMS CON-
DUCTED AT CUMBUSTION-ENGINEERING'S (c-E) KREISINGER LABORATORY AND NSP'S SLACK oo& STATION. THE
BLACK DOG PROTOTYPE UNII WAS OPERATED FOR FOURTEEN MONTHS FROM MARCH 1973 TO MAY 1974. NSP, C-E,
ANU BLACK & VEATCH WERE RESPONSIBLE FOT THE OPERATION OF THE isooo ACFM PROTOTYPE SCRUBBER. IHE
RESULTS OF THIS PROGRAM INDICATED THAT C-E FIXED-ROD SCRUBBER AND SINGLE-STAGE MARbLE-BED ABSORBER
MODULES WOULD PROVIDE SUFFICIENT POLLUTANT REMOVAL CAPABILITY WITH MINIMAL SCALING AND PLUGGING
PROBLEMS. THE SCRUBBING SYSTEM HAS BEEN GUARANTEED TO REMOVE 99 PERCENT OF THE INLET PARTICULATE
MATTER ENTERING THE SCRUBBING PLANT OR MAINTAIN AN EMISSION OUTLET OF O.OH GR/SCF, WHICHEVER VALUE
IS GREATER, AND REMOVE 50 PERCENT OF THE SULFUR IN THE FUEL (MAXIMUM FUEL SULFUR CONTENT OF 1.2
PERCENT) OR MAINTAIN AN EMISSION UUTLET OF 200 PP M 302, WHICHEVER VALUE IS CREATE*.
THE SCRUBBER PLANT DESIGN FOR SHERCO NO. 2 CONSISTS OF 12 C-E VENTKI-ROO SCRUBBER AND MARBLE
BED ABSORBER MODULES, 11 UF WHICH ARE REQUIRED FOR UNIT FULL-LOAD CAPACITY. EACH MODULE HAS A
MAXIMUM FLUE GAS CAPACITY OF 220,000 ACFM AT 135 F. INCLUDED IN EACH MODULE IS A VENTUKI SECTION
WITH TWO PARALLEL ROWS OF HORIZONTALLY ORIENTED RODS (PRIMARY CONTACTOR), A SINGLE STAGE MARBLE-BED
(3.5 TO «.0-INCH DEEP BED OF 13/lb-INCH DIAMETER GLASS SPHERES), LADDER VANES FOR GAS-FLOW DISTRI-
BUTION, TWO-STAGE CHEVRON-TYPE DEMISTER, FINNED-TUBE HOT WATER HEAT EXCHANGER, AND AN INTERNAL
REACTION TANK. THE REACTION TANK IS LOCATED AT THE BOTTOM OF EACH MODULE AND FACILITATES THE
COMPLETION OF THE CHEMICAL ABSORPTION OF S02 TO CALCIUM SULFITE. IN ADDITION, THE SULFITE SPECIES
FORMED IS FORCIBLY OXIDIZED TO SULFATE IN THE REACTION TANK VIA AIR BUBBLING AND AGITATION. THE
SULFA1E SPECIES FORMED IS PRECIPITATED OUT bY THE ADDITION OF A GYPSUM SEED Tu THE REACTION TANK
LIQUOR, OEWATERED IN A 160-FOOT DIAMETER CLARIFIER, AND DISPOSED OF WITH IHE COLLECTED PARTICULATE
MATTER IN AN ON-SITE 18-INCH CLAY-LINED SLUDGE FOND (2790 ACRE-FEET CAPACITY). WATER IS RECYCLED
BACK TO THE SCRUBBER PLANT FROM THE DISPOSAL POND FOR FURTHEK SERVICE.
THE ABSORPTION OF SULFUR DIOXIDE FKOM THE FLUE GAS STREAM RESULTS FROM THE PRESENCE OF TwO
ALKALINE MATERIALS. THE CALCIUM UXIDE IN THE FLY ASH (APPROXIMATELY 17 PERCENT UY WEIGHT) AND THE
CALCIUM CARBONATE IN THE TAIL-END LIMESTONE ADDITIVE.
ADDITIONAL INFORMATION OF THE OPERATION OF THIS UNIT IS PROVIDED IN THE PERFORMANCE HISTORY
TABLE THAT FOLLOWS. A SIMPLIFIED PROCESS FLOW DIAGRAM OF THE SHERCO SCRUBBER SYSTEM IS PROVIDED IN
APPENDIX B OF THIS REPORT.
112
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NORTHERN STATES POWER CO.
BOILER OPERATION TIME AND MODULE UPERABILITY (X)
BOILER
PERIOD HR. 201 £02 203 204 205 206 207 206 209 210 211 212
SHERBURNE COUNTY STATION UNIT NO.
APR. 77 697 0 95 93 87 83
TOTAL SYSTEM AVAILABILITY = 92 PERCENT
MEGAWATT-HOURS GENERATED = 142,170
UNIT CAPACITY FACTOR = 78 PERCENT
100
94
76
74
98
91
94
87
92
85
91
86
98
HAY 77 644 33 100 44 95 94
TOTAL SYSTEM AVAILABILITY = 91 PERCENT
MEGAWATT-HOURS GENERATED = 421,020
UNIT CAPACITY FACTOR = 75 PERCENT
FROM FULL SCALE STARTUP ON APRIL 1, THE SYSTEM HAS BEEN OPERATING VERY WELL WITH NO MAJOR
PROBLEMS ENCOUNTERED. THE UTILITY IS MAINTAINING A SCHEDULE OF NIGHTLY CLEANING ON THE
SCRUBBERS. THE CURRENT SCHtMt IS SUCH THAT EACH MOOULE IS CLEANED AFTER 7-8 DAYS.
JUN. 77 720 92 76
TOTAL SYSTEM AVAILABILITY
MEGAWATT-HOURS GENERATED
78 79 89
= 96 PERCENT
= 423,680
74
67
88
88
78
45
85
JUL. 77 602 96 87 86 97 96 88 68 95 57 93 94 87
TOTAL SYSTEM AVAILABILITY = 97 PERCENT
MEGAWATT-HOURS GENERATED = 382,890
MODULE 101 HAS BEEN IN THE SPRAY TOWER MODE SINCE SEPT. 5, 1976. THIS DESIGN PAVED THE WAY
FOR THE DESIGN ON SHERCO NOS. 3 AND 4. THE CEILCOAT LINING FAILURE IS OBSERVED ABOVE THE
LIQUID LEVEL OF INTERNAL RECYCLE TANK. BUBBLING AND CRACKING CAN BE SEEN HERE. THE LINER
EXTENDS UP THROUGH THE MODULE TO THE REHEATEK.
AUG. 77 67b 86 ?5 67 82 84
TOTAL SYSTEM AVAILABILITY = 93 PERCENT
MEGAWATT-HOURS GENERATED = 366,500
35
82
80
86
56
56
79
67
71
73
33
66
SEP. 77 717 89 61 82 90 81
TOTAL SYSTEM AVAILABILITY = 94 PERCENT
MEGAWATT-HOURS GENERATED = 423,280
MOOULE 206 AND 209 SPRAY PUMPS WERE OVERHAULED. THE NOZZLES REQUIRED EXTENSIVE CLEANING.
THE STRAINERS IN MODULE 207 AND 209 REACTION TANKS HAVE STARTED ERODING. NSP ANTICIPATES
REPLACING THEM VERY SOON.
OCT. 77 b64 96 89 67 66 62
TOTAL SYSTEM AVAILABILITY = 95 PERCENT
MEGAWATT-HOURS GENERATED = 449,140
99 98
73 75
93
66
96
94
96
77
70
81
91 65
NOV. 77 715 85 93 68 80 93
TOTAL SYSTEM AVAILABILITY = 91 PERCENT
MEGAWATT-HOURS GENERATED = 435,360
LOW OPERABILITIES ARE DUE TO SPRAY WATER PUMP OVERHAULS. 24 PUMPS ARE BEING OVERHAULED.
STRAINER/WASHER SCREEN EROSION HAS BEEN A PROBLEM. 316 S3 MATERIAL WILL BE USED IN FUTURE.
REPLACEMENT MATERIAL IS EXPECTED TO ARRIVE DECEMBER 12, 1977 AND WORK IS EXPECTED TO LONG
FOR THREE MONTHS.
DEC. 77 733 53 93 94 81 89
TOTAL SYSTEM AVAILABILITY = 93 PERCENT
MEGAWATT-HOURS GENERATED = 443,500
95 93
67
91
83
88
62 62
77
72
90
73
92
84
JAN. 78 682 91 75 64 72 74
TOTAL SYSTEM AVAILABILITY = 92 PERCENT
MEGAWATT-HOURS GENERATED = 387,190
THE REPLACEMENT OF STRAINER SCREENS HAS BEGUN ON DEC. 21. IT TAKES 4-6 DAYS FOR WORK ON
EACH MOOULE.
113
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THKOUGH
01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
PENNSYLVANIA POWER CO.
BKUCE MANSFIELD NO. 1
SHIPPINGPORT PENNSYLVANIA
aas MW
COAL 4.7 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
NEW
fl/76
OPERATIONAL
99.B PERCENT DESIGN
302
92 PERCENT (DESIGN)
WATER MAKE UP
OPEN LOOP
SLUDGE DISPOSAL
RESERVOIR LANDFILL
UNIT COST
SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
THIS EMISSION CONTROL SYSTEM WAS DESIGNED TO REMOVE FLYASH ANO S02 FROM
J5.3b MM ACFM OF FLUE GAS VIA WET LIME SCRUBBING. THE INITIAL SHAKEDOWN
AND DEBUGGING PHASE OF OPERATION BEGAN FOR PART OF THE SYSTEM IN DECEMBER
1975. PARTIAL COMMERCIAL OPERATION COMMENCED IN APRIL 1976. THE UNIT WAS
CERTIFIED FULL-LOAD CUMMERCIAL IN JUNE 1976. THE FGO SYSTEM HAS EXPERI-
ENCED OPERATIONAL PROBLEMS SINCE IT HAS BEEN IN SERVICE REQUIRING A NUM-
BER OF SYSTEM REPAIRS AND DESIGN MODIFICATIONS. REFER TO BACKGROUND IN-
FORMATION SECTION IN TABLE 5 OF THIS REPORT FOR GREATER DETAIL.
114
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BACKGROUND INFORMATION
ON
BRUCE MANSFIELD UNIT NO. 1
THE BRUCE MANSFIELD PLANT IS A 2475 NET MW, THREE-UNIT, COAL FIRED FACILITY LOCATED ON THE OHIO
RIVER IN THE BOROUGH OF SHIPPINGPORT, PENNSYLVANIA. THIS NEW FACILTTY IS BEING BUILT BY PENN-
SYLVANIA POWER COMPANY, ACTING ON ITS OWN BEHALF AND AS AGENT FOR THE OTHER PARTICIPATING CENTRAL
AREA POWER COORDINATION (CAPCO) GROUP OF INVESTOR-OWNED ELECTRIC UTILITIES, INCLUDING THE CLEVELAND
ELECTRIC ILLUMINATING COMPANY, OUUUESNE LIGHT COMPANY, OHIO EDISON COMPANY, AND TOLEDO tOlSON
COMPANY.
BRUCE MANSFIELD NO. 1 IS A COAL-FIRED, ONCE-THROUGH, SUPERCRITICAL STEAM GENERATOR WHICH FIRES
333 TONS/HR OF COAL GENERATING APPROXIMATELY b.b MM LB/HR OF STEAM AT 3,765 PSIG, 1005 F/1005 f.
THE EMISSION CONTROL EQUIPMENT REQUIRED FOR THIS UNIT IS DESIGNED TO MEET STATE EMISSION REGULATIONS
OF O.t> LBS SULFUR DIOXIuE/MM 6TU OF HEAT INPUT AND 0.0175 GR/bCF OF PARTICULATE WHEN BURNING 11,900
BrU/LB COAL HAVING AVERAGE ASH AND SULFUR CONTENTS UF 12.5 AND 1.7 PERCENT, RESPECTIVELY.
IN LATE 1970, AN INTENSIVE INVESTIGATION Of MOKE THAN 30 POTENTIAL OESULFURIZATION SYSTEMS WAS
INITIATED. THE SYSTEM ULTIMATELY CHOSEN FOR THE REMOVAL OF FLY ASH AND SULFUR OIuXIDE WAS THE
VENTURI wET-SCRUBblNG SYSTEM, PROVIDED BY CHEMICO AIR POLLUTION CONTROL CO., UTILIZING THE DRAVO
CORPORATION'S THIOSORBIC LIME AS THE SCRUBBING ABSORBENT.
THE DESIGN FEATURES OF THE SCRUBBING SYSTEM DICTATE THAT EACH SCRUBBING TRAIN CONSIST OF A
SCRUBBING VESSEL (VARIABLE-THROAT VENTURI), A 9000 HP I.D. FAN, AND AN ABSORBER VESSEL IF IXEO-THROAT
VENTURI). THERE ARE SIX SCRUbBER TRAINS PER UNIT TO HANDLE THE FLUE GAS FLOW FROM EACH BOILER AT
FULL LOAD (JS.iS MM ACFM AT 285 F). THE SCRUBBER/ABSORBER TRAINS ARE ARRANGED IN TWO GROUPS OF
THREE. THE TREATED FLUE GAS, WHICH HAS PASSED THROUGH tACH GROUP OF THE SCRUBBING SYSTEM TRAINS IS
DUCTED THROUGH UNE OF THE TWO HEAT CHAMBERS AND THEN DISCHARGED FRUM ONE OF TWO CHIMNEY FLUES. THE
950 FOOT CHIMNEY CONTAINS FOUR CARBON STEEL FLUfcS. THE INNER SURFACES OF flHICH ARE COATED rtlTH
POLYESTER FLAKEGLASS LINING AND ARE CAPABLE OF ACCOMODATING TWO UNITS AT FULL LOAD.
THE ADJUSTABLE VENTURI THROAT SCRUBBING MODULES REMOVE MOST OF THE FL*ASH CONTAINED IN THE FLUE
GAS. THE ABSORBER MODULE, WHICH IS A FIXED-THROAT VENTURI, REMOVES SOME OF ThE REMAINING FLYASH.
SULFUR DIOXIDE IS ABSORBED IN BOTH THE SCRUBBER AND ABSORBER BY DROPLETS OF LIME SLURRY, CONTAINING
2 TO b PEKCENT MAGNESIUM OXIDE.
THE SCRUBBER-RECYCLE BLEED IS COMBINED WITH A FLYASH SLURRY FROM THE BOILER AND DISCHARGED TO A
200-FOOT DIAMETER THICKENER. SLUDGE FRUM THE THICKENER IS THEN PUMPED TO A WASTE DISPOSAL SYSTEM
WHERE IT IS MIXED WITH A STABILIZING AGENT CCALCILOX) AND THEN PUMPED APPRUXIMATELY 7 MILES TO THE
LITTLE BLUE RUN DISPOSAL AREA. THE DISPOSAL AREA IS LOCATED IN A RAVINE UPSTREAM OF A 000 FT HIGH
HYDRAULIC DAM DESIGNED TO CONTAIN THICKENER SLUDGE AND WATER.
A SIMPLIFIED PROCESS FLOW DIAGRAM IS PRESENTED IN APPENDIX B.
SINCE THE UNIT COMMENCED COMMERCIAL OPERATION IN APRIL 1976, A NUMBER OF PROBLEM AREAS HAVE BEEN
ENCOUNTERED. MAJOR AREAS OF CONCERN ARE SPECIFIED bELOw:
1. EXCESSIVE MAINTENANCE PROBLEMS WITH THE WET I.D. FAN HOUSINGS.
2. EXCESSIVE WATER ENTRAINMENT AND CARRY OVER OUT UF THE STACK CAUSING A STACK
RAIN PROBLEM.
3. REHEAT BURNER PROBLEMS.
*t. STACK FLUE LINER FAILURES.
ADDITIONAL INFORMATION CONCERNING THE PERFORMANCES OF THIS SYSTEM, INCLUDING REMOVAL EFFIC-
IENCY, PROBLEMS AND SOLUTIONS ARE PROVIDED IN THE PERFORMANCE TABLE THAT FOLLOWS.
115
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PENNSYLVANIA POWER CO.
BRUCE MANSFIELD UNIT NO. 1
MONTH BOILER
DEC. 75
JAN. 76
FEB. 76
APR. 76 506
OPERATING HOURS
FSD MODULES COMMENTS
A B C D E F
INITIAL OPERATION (SHAKEDOWN AND DEBUGGING) FOR PART OF
THt SYSTEM COMMENCED IN DECEMBER 1975.
UNIT SHUT DOWN FOR ONE WEEK BECAUSE OF PLUGGED MIST
ELIMINATORS AND I.D. FAN HOUSING VIBRATION PROBLEMS.
FIRST ATTEMPTS AT STARTING UP THE REHEAT BURNERS WERE
MADE THIS MONTH. SO MANY PROBLEMS ENCOUNTERED THAT THE
VENDOR IS GOING TO REDESIGN NEW REHEAT BUHNERS.
0* 210* 984* 2147* 2808*2427*THt INSTALLATION BEGAN PARTIAL COMMERCIAL OPERATION
APRIL 5. THE SCRUBBING SYSTEM IS CURRENTLY HANDLING
*NOTE - THESE FIGURES REPRESENT FLUE GAS AT A TOTAL EQUIVALENT CAPACITY OF APPROXIMATE-
LY 640 MW (GROSS). TOTAL MOOULE BY MODULE UPERATION
HOURS LOGGED TO-UATE ARE POSTED IN THE ACCOMPANYING
TABLE.
TOTAL OPERATING HOURS
ACCUMULATED TO DATE.
MAY 76 595 209 605 592 492 622 493 THE LAST SCRUBBER TRAIN WAS PLACED IN SERVICE DURING
TOTAL SYSTEM AVAILABILITY = sox
TUTAL SYSTEM OPERABILITY = IOOX
TUTAL SYSTEM RELIABILITY = IOOX
TOTAL SYSTEM UTILIZATION = 60%
JUN. 76 720 714 660 701 674
TOTAL SYSTEM AVAILABILITY = ioox
TOTAL SYSTEM OPERABILITY = IOOX
TOTAL SYSTEM RELIABILITY = ioox
TOTAL SYSTEM UTILIZATION * 10UX
JUL. 76 673 537 590 606 637
TOTAL SYSTEM AVAILABILITY = 901
TOTAL SYSTEM OPERABILITY = 100%
TOTAL SYSTEM RELIABILITY = IOOX
TOTAL SYSTEM UTILIZATION = 90X
705 573
662 661
AUG. 76 705
TOTAL SYSTEM
TOTAL SYSTEM
TUTAL SYSTEM
TOTAL SYSTEM
SEP. 76 720
TOTAL SYSTEM
TOTAL SYSTEM
TOTAL SYSTEM
TOTAL SYSTEM
OCT. 76 720
TOTAL SYSTEM
TOTAL SYSTEM
TOTAL SYSTEM
TOTAL SYSTEM
NOV. 76 277
TUT»L SYSTEM
TOTAL SYSTEM
TOTAL SYSTEM
TOTAL SYSTEM
672 620 653 535
AVAILABILITY s 95X
OHERABILITY = IOOX
RELIABILITY = IOOX
UTILIZATION = 95X
708 617 693 695
AVAILABILITY = IOOX
OPERABILITY = IOOX
RELIABILITY x IOOX
UTILIZATION = IOOX
708 617 693 695
AVAILABILITY = 99X
OPERABILITY = IOOX
RELIABILITY = IOOX
UTILIZATION = 99X
270 278 262 113
AVAILABILITY = 38X
OPERABILITY = IOOX
RELIABILITY r IOOX
UTILIZATION 3 38X
500 668
596 464
596 464
159 246
THE MONTH. SERVICE TIME TOTALS FOR ALL 6 SCRUBBER-AB-
SORBER TRAINS THROUGH MAY ARE POSTED IN THE ACCOMPANY-
ING TABLE ALONG WITH THE PERFORMANCE INDEX VALUES.
DURING OFF-PEAK HOURS ON THE WEEKENDS WHEN THE UNIT IS
OPERATING AT REDUCED LOADS MAINTENANCE IS PERFORMED ON
THE SHUT DOWN FGO MODULES SO THAT THEY WILL BE IN OPER-
ATING CONDITION FOR FULL LOAD OPERATION DURING THE HIGH
DEMAND HOURS.
THE UNIT WAS DECLARED COMMERCIALLY AVAILABLE FOR FULL
LOAD OPERATION AT 825 MW (NET) ON JUNE 1, 1976. IN-
STALLED THE REVISED SCRUBBER BAFFLE SYSTEM IN AN EFFORT
TO CORRECT THE SCRUBBER RECYCLE PUMP CAVITATION PRO-
BLEMS. THE VALUES DISPLAYED IN THE ACCOMPANYING TABLE
INCLUDE THE ACTUAL BOILER HOURS AND THE MODULAR OPER-
ATING HOURS. THE PERFORMANCE INDEX VALUES CALCULATED
ARE BASED UPON TOTAL SCRUBBING SYSTEM OPERATION.
TESTS CONDUCTED THIS MONTH SHOWED THAT THE FGD SYSTEM
MIST ELIMINATORS ARE NOT PERFORMING TO DESIGN AND THAT
THERE IS EXCESSIVE WATER ENTRAINED IN THE CLEANED FLUE
GA5SES CAUSING A STACK RAIN PROBLEM. CHEMICO IS WORK-
ING ON THE DESIGN OF ADDITIONAL MIST ELIMINATORS THAT
WILL REMOVE THIS EXCESS WATER. THE VENDOR is STILL
TRYING TO SOLVE THE REHEAT BURNER PROBLEMS.
SECONDARY VERTICAL MIST ELIMINATORS WERE INSTALLED IN
THE ABSORBER DISCHARGE DUCT IN AN ATTEMPT TO REDUCE THE
EXCESSIVE ENTRA1NEU WATER. THEY DID NOT WORK BECAUSE
THE FLUE GAS BLEW THEM APART IN A FEW MINUTES OF OP-
ERATION.
DURING A THREE WEEK OUTAGE (DUE TO A FURNACE IMPLOSION)
THE UNIT NO. 1 CHIMNEY FLUES WERE INSPECTED. THE 'A'
FLUE POLYESTER LINING MATERIAL WAS FLAKING UFF AND ACID
ATTACK WAS STARTING TO CORRODE THE CARBON STEEL FLUE.
THE LINING VENDOR IS INVESTIGATING THE PROBLEM, DURING
THE OUTAGE THE PLUGGED MIST ELIMINATORS WERE CLEANED
AND THE SCALE THROUGHOUT THE FtO SYSTEM WAS REMOVED.
116
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PENNSYLVANIA POWER CO.
MONTH BOILER
OPERATING HOURS
FGD MODULES
B C 0 E
BRUCE MANSFIELD UNIT NO. 1
COMMENTS
DEC. 76 732 584 726 664 433
TOTAL SYSTEM AVAILABILITY = 100X
TOTAL SYSTEM OPERABILITY = 100X
TOTAL SYSTEM RELIABILITY = 100*
TOTAL SYSTEM UTILIZATION = 971
626
1 17
-------
PENNSYLVANIA POWER CO. BRUCE MANSFIELD UNIT NO. 1
MONTH BOILER F6D MODULE
A 8 C 0 E F
JAN. 77
OPERATING HOURS 675 660 613 502 661 627 614
FGO SYSTEM AVAILABILITY X 95 92 77 95 92 91
FGD SYSTEM OPERABILITY X 98 91 74 98 93 91
F6D SYSTEM UTILIZATION X 69 82 68 89 84 83
TOTAL FGD SYSTEM LOST GENERATION FACTOR* = 11X
DURING THE FIRST PART OF THE MONTH, THE THICKENER RAKE MECHANISM JAMMED AND COULD NOT BE RE-
PAIRED. THE THICKENER WAS OPERATED FOR APPROXIMATELY THREE WEEKS WITH THE RAKE STOPPED UNTIL
THE UNIT NO. 2 THICKENER COULD BE PUT INTO EMERGENCY SERVICE. SEVERE WINTER WEATHER MADE
OPERATION OF THE OUTDOOR FGD SYSTEM VERY DIFFICULT AND AFFECTED THE RELIABILITY OF THE UNIT.
FEB. 77
OPERATING HOURS 540 437 376 439 516 544 451
FGD SYSTEM AVAILABILITY X 77 69 77 86 92 81
FGD SYSTEM UPERABILITY X 81 70 81 96 100 84
FGO SYSTEM UTILIZATION X 65 56 65 77 81 67
TOTAL FGO SYSTEM LOST GENERATION FACTOR = 24.3X
A SECOND SET OF VERTICAL SECONDARY M1S1 ELIMINATORS WAS INSTALLED IN THE ABSORBER DISCHARGE
DUCT BUT THE FLUE GAS BLEW THEM OUT BEFORE THEIR EFFICIENCY FOR REMOVING ENTRAINED WATER IN
THE FLUE GAS COULD BE TESTED.
MAR. 1 THRU 12, 77
OPERATING HOURS 264 259 264 152 252 257 202
FGD SYSTEM AVAILABILITY X 99 100 58 95 97 80
FGD SYSTEM UPERABILITY X 98 100 58 95 97 77
FGD SYSTEM UTILIZATION X 98 100 58 95 97 77
TOTAL FGD SYSTEM LOST GENERATION FACTOR = 12X
AT 0000 MARCH 12TH THE UNIT WAS SHUT DOWN FOR A 10-WEEK TURBINE OVERHAUL OUTAGE. DURING THE
UUTA&E, REPAIRS WERE STARTED ON "A" CHIMNEY FLUE WHICH WILL NOT BE COMPLETED UNTIL THE END OF
AUGUST. AN INSPECTION OK "B" CHIMNEY FLUE SHOWED THE SAME TYPE OF REPAIRS WOULD BE NEEDED,
BUT WORK WILL NOT START ON "6" UNTIL THE "A" FLUE HAS BEEN REPAIRED. BECAUSE OF THESE RE-
PAIRS, THE UNIT WILL BE OPERATING AT APPROXIMATELY HALF LOAD FUR ROUGHLY ONE YEAR.
MAR. 13 THRU MAY 22, 77
OPERATING HOURS 000 000
TOTAL FGO SYSTEM LOST GENERATION FACTOR IS DEFINED AS THE TOTAL MONTHLY LOST GENERATION DUE TO FGD
TRAIN OUTAGES DIVIDED BY THE T01AL MONTHLY EXPECTED GENERATION IF THE FGD TRAINS WOULD HAVE BEEN
AVAILABLE FOR OPERATION, EXPRESSED AS A PERCENTAGE.
BECAUSE OF THE EXCESSIVE MAINTENANCE REQUIRED ON THE RUBBER LINED CARBON STEEL I.D. FAN HOUS-
INGS, FROM PIECES OF SCRUBBER SCALE DAMAGING THE LINING AND CORROSION OF THE CARBON STEEL,
INCONEL PLATE WILL BE INSTALLED ON THE SCROLL AREA OF EACH OF THE SIX FANS DURING THE OUTAGE.
A NEWLY DESIGNED SECONDARY VERTICAL MIST ELIMINATOR WILL BE INSTALLED IN THE ABSORBER DIS-
CHARGE DUCT OF ONE OF THE SCRUBBER MODULES DURING THE OUTAGE.
DURING,THE OUTAGE, ALL SCRUBBING VESSELS, DUCTS, PIPING AND MIST ELIMINATORS WILL BE CLEANED
AND ALL THE SCALE REMOVED.
DURING OPERATION OF THE FGU SYSTEM, THE PH CONTROL CUULD NOT BE AUTOMATED BECAUSE OF POOR DE-
SIGN AND OPERATIONAL PROBLEMS WITH THE PROVIDED CONTROL SYSTEM. PH CONTROL WAS MANUALLY
SAMPLED AND CONTROLLED OVEK APPROXIMATELY UNE YEAR OF OPERATION. THE PH CONIRQL AND MONITOR-
ING SYSTEMS ARE BEING REVISED BY OPERATING PERSONNEL DURING THE OUTAGE IN AN EFFORT TO IM-
PROVE THE PH CONTROL SYSTEM.
THE LIME ADDITION PIPING IS BEING REVISED IN EACH OF THE SCRUBBER VESSELS DUE TU THE SEVERE
SCALING OCCURRING WITH THE CURRENT LIME ADDITION SYSTEM. ALSO THE VENDOR IS REDESIGNING THE
EXISTING MIST ELIMINATOR SPRAY PIPING IN AN EFFORT TO CORRECT THE EXCESSIVE SCALING AND PLUG-
GING OF THE MIST ELIMINATORS.
CHANGES IN FLUSH WATER AND SEAL WATER PIPING ARE BEING MADE IN AN EFFORT TO CLOSE THE WATER
LOOP.
NEWLY MODIFIED REHEAT BURNERS WILL BE INSTALLED DURING THE OUTAGE AND TESTED ON "B" REHEATEK
WHEN THE UNIT STARTS UP IN MAY.
THE UNIT NO. 1 THICKENER WAS CLEANED OUT AND THE JAMMED RAKE DRIVE MECHANISM WAS REPAIRED
DURING THE OUTAGE.
MAY 23 THRU 31, 77
OPERATING HOURS 121 0 00 102 103 50
FGD SYSTEM AVAILABILITY X 100 100 47
FGO SYSTEM UPERABILITY X 84 85 41
FGO SYSTEM UTILIZATION X 47 48 23
TOTAL SYSTEM LOST GENERATION FACTOR = 87.2%
UNIT WAS STARTED UP ON MAY 23RD, USING D, E, AND F MODULES, DUE TO REPAIRS BEING MADE TO "A"
CHIMNEY FLUE. HAD PROBLEMS SLAKING LIME A.MO GETTING MAGNESIUM LEVELS BUILT UP IN THE SCRUB-
BER RECYCLE LOOPS AFTER STARTUP.
118
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PENNSYLVANIA POWER CO.
MONTH BOILER
FGD MODULE
C 0
BRUCE MANSFIELD UNI I
JUN. 77
OPERATING HOURS 669
F60 SYSTEM AVAILABILITY X
FGD SYSTEM OPERABILITY X
FGD SYSTEM UTILIZATION X
676
94
100
94
685
95
100
95
646
90
97
90
TOTAL FGD SYSTEM LOST GENERATION FACTOR = 53.7X
HORIZONTAL MIST ELIMINATOR PRESSURE DROPS INCREASED TO THE POINT THAT NEW MIST ELIMINATOR
MODULES WERE INSTALLED ON 0,E AND F SCRUBBERS AND D AND E ABSORBERS. THE ONLY OUTAGES EXPER-
IENCED BY THE UNIT THIS MONTH WERE DUE TO THE FGD SYSTEM.
JUL. 77
OPERATING HOURS 473
FGD SYSTEM AVAILABILITY X
FGD SYSTEM OPERABILITY X
FGO SYSTEM UTILIZATION X
190
99
100
66
193
99
100
66
471
100
100
63
TOTAL FGD SYSTEM LOST GENERATION FACTOR = 50.5X
UNIT NO. 1 WAS DUWN FROM JULY 1ST THRU JULY 12 TO MAKE SOME MODIFICATIONS TO THE GENERATOR
COOLING SYSTEM. ON JULY 19TH AND 20TH, PENNSYLVANIA'S DEPARTMENT OF ENV1RUNMENTAL RESOURCES
TESTED THE S02 AND PARTICULATE EMISSIONS FROM UNIT NO. 1'S FGD SYSTEM. S02 EMISSIONS WERE
FGD so2 REMUVAL
0.44 LB S02/MM BTU AND 1.26 LB S02/MM 8TU FOR THE TWO TESTS RESPECTIVELY.
EFFICIENCY VARIED FROM 78X TO 89X FOK THE MONTH.
AUG. 77 692 3S3 373 210 692 689 635
FGO AVAILABILITY FACTOR X 56 54 31 96 95 86
FGO OPEHABILITY FACTOR X 57 56 31 100 99 95
FGO UTILIZATION FACTOR X 52 50 28 93 93 85
TOTAL FGD LOST GENERATION FACTOR = 32.5X
UNIT NO. 1 WAS DOWN FROM AUGUST 13 TO 15 BECAUSE OF BOILER TUBE LEAKS. ON AUGUST 16, 1A
CHIMNEY FLUE LINER REPAIRS WERE COMPLETED AND A, B AND C TRAINS WERE STARTED UP. SEVERAL
REPAIRS WERE MADE TO THE ID FAN HOUSINGS THIS MONTH. THE AVERAGE S02 REMOVAL EFFICIENCY FOR
THE MONTH WAS 86.7X GASED ON THREE GRAB SAMPLES. YORK RESEARCH BEGAN SETTING UP TO CONTIN-
UOUSLY MONITOR THE S02 REMOVAL EFFICIENCIES AS PART OF AN EPA RESEARCH PROJECT TO DETERMINE
FEASIBLE NSPS FOR FGO. EXTENSIVE MODIFICATIONS ARE BEING MADE IN THE PH CONTROL SYSTEMS
IN AN EFFORT TO DEVISE A WORKABLE PH CONTROL SYSTEM.
SEP. 77 558 543 528 545 334 314 245
FGO AVAILABILITY FACTOR X 87 82 81 53 50 43
F6D OPERABILITY FACTOR X 97 95 98 60 56 44
FGO UTILIZATION FACTOR X 75 73 76 46 44 34
TOTAL FGD LOST GENERATION FACTOR = 44.5X
A BOILER TUBE LEAK CAUSED THE UNIT TO BE DOWN SEPTEMBER 10 TO 12.
FROM SEPTEMBER 17 TO 22
THE UNIT WAS DOWN TO INSTALL RIGGING IN 18 CHIMNEY FLUE 10 BEGIN FLUE LINER REPAIRS. Or E
AND F TRAINS WERE OFF THE REMAINDER OF THE MONTH. THE AVERAGE S02 REMOVAL EFFICIENCIES FOR
THE MONTH WERE 93.2X BASED ON FOUR GRAB SAMPLE TESTS.
OCT. 77 720 690 729 649 000
FGD AVAILABILITY FACTOR x 93 98 67 o o o
FGO OPERABILITY FACTOR X 96 100 90 0 0 0
FGO UTILIZATION FACTOR X 93 98 67 0 0 0
TOTAL FGO LOST GENERATION FACTOR = 55.4X
CLEANED MIST ELIMINATOR NOZZLES AND MIST ELIMINATOR ON "C". ABS STACK REPAIRS ON UNIT 2
NECESSITATED TAKING UNIT 1 DOWN FOR 2 DAYS. (A PROTECTIVE CAP HAD TO BE PUT OVER 28 FLUE BY
HELICOPTER. PREVAILING WINDS NECESSITATED TAKING UNIT 1 OFF IN URDER TO DO THIS.)
119
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL F6D SYSTEMS THROUGH
01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
PENNSYLVANIA POWER co.
BRUCE MANSFIELD NO. a
SHlPPINGPORT PENNSYLVANIA
825 MW
COAL «.7 PERCENT SULFUR
CHEMICO
LIME SCRUBBING
NEW
7/77
OPERATIONAL
99,8 PERCENT (DESIGN)
SO?
92 PERCENT (DESIGN)
WATER MAKE UP
OPEN LOOP
SLUDGE DISPOSAL
RESERVOIR LANDFILL
UNIT COST
SEE APPENDIX A, FGO SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THIS EMISSION CONTROL SYSTEM WAS DESIGNED TO REMOVE FLYASH AND SOa FROM
3.35 MM ACFM OF FLUE GAS USING THIOSOKBIC LIME AS A SCRUBBING ABSORBENT.
SIX SCRUBBING TRAINS, EACH INCLUDING TWO VENTURI SCRUBBERS IN SERIES
ARRANGEMENT, ARE PROVIDED FOR FULL-LOAD OPERA110N. THE INITIAL SHAKEDOWN
AND DEBUGGING PHASE OF OPERATION BEGAN FOR THREE TRAINS IN JULY, 1977.
FULL COMMERCIAL OPERATION FOH THE ENTIRE SYSTEM COMMENCED ON OCTOBER 1,
1S77.
120
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BACKGROUND INFORMATION
ON
BRUCE MANSFIELD UNIT NO. 2
THE BRUCE MANSFIELD PLANT IS A 2475 NET MW, THREE-UNIT, COAL-FIRED FACILITY LOCATED ON THE OHIO
RIVER IN THE BOROUGH OF SHIPPINGPORT, PENNSYLVANIA. THIS NEW FACILITY IS BEING BUILT BY PENNS-
LVANIA POWER COMPANY, ACTING ON ITS OWN BEHALF AND AS AGENT FOR THE OTHER PARTICIPATING CENTRAL AKEA
POWER COORDINATION (CAPCO) GROUP OF INVESTOR-OWNED ELECTRIC UTILITIES, INCLUDING THE CLEVELAND ELEC-
RIC ILLUMINATING COMPANY, DUOUESNE LIGHT COMPANY, OHIO EDISON COMPANY, AMD TOLEDO EDISON COMPANY
BRUCE MANSFIELD NO. 2, WHICH IS IDENTICAL TO THE NO. 1 UNIT, IS A COAL-FIRED, ONCE-IHKOUGH, SUPER-
CRITICAL STEAM GENERATOR WHICH FIRES 333 TONS/HR OF COAL GENERATING APPROXIMATELY 6.5 MM LB/HR STEAM
AT 3,785 PSIG, 1005 F/1005 F. THE EMISSION CONTROL EQUIPMENT REQUIRED FOR THIS UNIT IS DESIGNED TO
MEET STATE EMISSION REGULATIONS OF 0.6 LBS SULFUR DIOXIDE/MM BTU OF HEAT INPUT AND 0.0175 GR/SCF OF
PARTICULATE WHEN BURNING 11,900 8TU/LB COAL HAVING AVERAGE ASH AND SULFUR CONTENTS OF 12.5 AND
a.7 PERCENT, RESPECTIVELY.
IN LATE 1970, AN INTENSIVE INVESTIGATION OF MORE THAN 30 POTENTIAL DESULFURIZATIOM SYSTEMS WAS
INITIATED. THE SYSTEM ULTIMATELY CHOSEN FOR THE REMOVAL OF FLY ASH AND SULFUR DIOXIDE WAS THE
VENTURI WET-SCRUBBING SYSTEM, PROVIDED BY CHEMICO AIR POLLUTION CONTROL CO., UTILIZING THE ORAVO
CORPORATION'S THIOSORBIC LIME AS THE SCRUBBING ABSORBENT.
THE DESIGN FEATURES OF THE SCRUBBING SYSTEM DICTATE THAT EACH SCRUBBING TRAIN CONSIST OF A
SCRUBBING VESSEL (VARIABLE-THROAT VENTURI), A 9000HP I.D. FAN, AND AN ABSORBER VESSEL (FIXED-THROAT
VENTURI). THERE ARE SIX SCRUBBER TRAINS PER UNIT TO HANDLE THE FLUE GAS FLOW FROM EACH BOILER AT
FULL LOAD (3.35 MM ACFM AT 285 F). THE SCRUBBER/ABSORBER TRAINS ARE ARRANGED IN GROUPS OF THREE.
THE TREATED FLUE GAS, WHICH HAS PASSED THROUGH EACH GROUP OF THE SCRUBBING SYSTEM TRAINS IS DUCTED
THROUGH ONE OF THE TWO MEAT CHAMBERS AND THEN DISCHARGED FROM ONE OF iwo CHIMNEY FLUES. THE 950
FOOT CHIMNEY CONTAINS FOUR CARBON STEEL FLUES, THE INNER SURFACES OF WHICH ARE COATED WITH POLYESTER
FLAKEGLASS LINING AND ARE CAPABLE OF ACCOMMODATINGTWO UNITS AT FULL LOAD.
THE ADJUSTABLE VENTURI THROAT SCRUBBING MODULES REMOVE MOST OF THE FLYASH CONTAINED IN THE FLUE
GAS. THE ABSORBER MODULE, WHICH IS A FIXED-THROAT VENTURI, REMOVES SOME OF THE REMAINING FLYASH.
SULFUR DIOXIDE IS ABSORBED IN BOTH THE SCRUBBER AND ABSORBER BY DROPLETS OF LIME SLURRY, CONTAINING
Z TO 6 PERCENT MAGNESIUM OXIDE.
THE SCRUBBER-RECYCLE BLEED IS COMBINED WITH A FLYASH SLURRY FROM THE BOILER AND DISCHARGED TU A
200-FOOT DIAMETER THICKENER. SLUDGE FROM THE THICKENER IS THEN PUMPED TO A WASTE DISPOSAL SYSTEM
WHERE IT IS MIXED WITH A STABILIZING AGENT (CALCILOX) AND THEN PUMPED APPROXIMATELY 7 MILES TO THE
LITTLE BLUE RUN DISPOSAL AREA. THE DISPOSAL AREA IS LOCATED IN A RAVINE UPSTREAM OF A 400 FT HIGH
HYDRAULIC DAM DESIGNED TO CONTAIN THICKENER SLUDGE AND WATER.
A SIMPLIFIED PROCESS FLOW DIAGRAM IS PRESENTED IN APPENDIX 8.
INFORMATION CONCERNING THE PERFORMANCE OF THE UNIT SINCE COMMERCIAL OPERATIONS COMMENCED IN OCTOBER
1977 ARE SUMMARIZED AND PROVIDED IN THE TABLE THAT FOLLOWS.
121
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PENNSYLVANIA POWER CO.
BRUCE MANSFIELD UNIT NO. 2
OPERATING HOURS
F6D MODULES
MONTH BOILER
A 6 CD E F
OCT. 77 595 621 652 645 361 3«9 305
F6D AVAILABILITY FACTORX 9M 97 98 63 66 61
FGO OPERABILITY FACTORX 100 100 100 61 59 51
FGD UTILIZATION FACTORX 83 88 87 48 47 41
TOTAL FGD LOST GENERATION FACTOR 25.7X .,,-.»
UNIT 2 WAS DECLARED AVAILABLE FOR COMMERCIAL OPERATION AT 825 MK ON OCTOBER Ir 1977. CLEANED
SPRAYS IN 2F FAN. REPAIRS BEING MADE TO 2B FLUE STACK LINING DUE TO PREMATURE FAILURE OF
SEVERAL TEST PATCHES. UNIT TRIPPED DUE TO FAULTY GENERATOR CONTROL TRANSFORMERS.
122
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/76
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCYr
PARTICIPATES
PHILADELPHIA ELECTRIC CO.
EODYSTONE NO. 1A
EDOYSTONE PENNSYLVANIA
12U MM
CUAL 2.b PERCENT SULFUR
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
RETROFIT
9/75
OPERATIONAL
99.9 PERCENT
S0£
90 PERCENT
WATER MAKE UP
OPEN LOOP 1.1 GPM/MW
SLUDGE DISPOSAL
ACID PLANT REGENERATION
UNIT COST
SEE APPENDIX A, FGO SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF THREE PARALLEL
SCRUBBING TRAINS FOR THE CONTROL OF PARTICULATE AND SULFUR DIOXIDE.
THE C-SIDE SCRUBBING TRAIN INCLUDES AN S02 ABSORBER MODULE IN SERIES
WITH A PARTICULATE SCRUBBER. APPROXIMATELY ONE-THIRD OF THE BOILER FLUE
GAS IS SCRUBBED WITH MAGNESIUM OXIDE SLURRY FOR S02 REMOVAL. THE SPENT
SLURRY is REGENERATED AT THE ESSEX SULFURIC ACID PLANT IN NEWARK, N.J.
THE REGENERATED MAGOX IS RETURNED TO THE PLANT FOR SOt! SCRUBBING SERVICE.
123
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BACKGROUND INFORMATION
UN
EDDYSTONE MO. 1
THE EDDYSTONE STATION OF THE PHILADELPHIA ELECTIRC CO. (PECO) IS LOCATED ON THE DELAWARE RIVER
IN EDUYSTONE, PENNSYLVANIA, ABOUT 11 MILES SOUTHWEST OF THE CENTER OF PHILADELPHIA. THE PLANT IS
APPROXIMATELY FIVE MILES WEST OF ONE OF THE MAIN RUNWAYS OF THE PHILADELPHIA INTERNATIONAL AIRPORT.
THE STATION HAS FOUR GENERATORS WITH A TOTAL NET GENERATING CAPACITY OF 1370 MW. UNITS 1 AND 2
BURN COAL WITH AN AVERAGE GROSS HEATING VALUE OF 18,100 BTU/LB AND ASH AND SULFUR CONTENTS OF
12 PERCENT AND 2.3 PERCENT, RESPECTIVELY. STEAM CONDITIONS ARE 5,000 PSI AND 1150 f. THESE ARE THE
HIGHEST UTILITY PLANT OPERATING PRESSURE AND TEMPATURE CONDITIONS IN THE UNITED STATES.
UNITS 1 AND 2 ARE BASE-LOAD UNITS. UNITS 3 AND It ARE PEAK-LOAD GENERATORS WHICH BURN NO. 6 OIL.
THERE ARE TWO FURNACES ON THE UNIT 1 BOILER. EACH FURNACE WAS INSTALLED WITH PARTICULATE CONT-
ROLS CONSISTING OF MECHANICAL COLLECTORS AND AN ELECTROSTATIC PREC1PITATOR.
THE MAGNESIUM OXIDE-BASED FLUE GAS DESULFURIZATION (FGD) SYSTEM ON BOILER NO. 1 AT THE EDDY-
STONE STATION OF PHILADELPHIA ELECTRIC COMPANY IPECO) WAS DESIGNED AND INSTALLED BY UNITED ENG-
INEERS AND CONSTRUCTORS, INC., IN CO-OPERATION WITH PHILADELPHIA ELECTRIC. THE SYSTEM CONSISTS OF
THREE FIRST-STAGE SCRUBBER MODULES IN PARALLEL FOR PARTICULATE CONTROL (TWO ENVIRONEERING VENTURI
ROD UNITS AND ONE PEABOOY-LURGI VENTURI UNIT) AND A SECOND-STAGE ENVIRONEERING ABSORBER MODULE WITH
TWO VENTURI-ROD bEDS FOR SULFUR DIOXIDE REMOVAL.
THfc THREE FIRST-STAGE SCRUBBERS TOGETHER ARE SIZED TO HANDLE ALL THE EXHAUST GAS FROM UNIT
1 WHICH HAS A NET ELECTRIC GENERATING CAPACITY OF 316 MW. THE SECOND-STAGE ABSORBER IS SIZED TO
HANDLE ONE-THIRD OF THE GAS FLOW, EQUIVALENT TO APROXIMATELY 105 MW (NET). THE SYSTEM IS DESIGNED
TO REMOVE 90 PERCENT OF THE SULFUR DIOXIDE FROM BOILER STACK GAS. A GENERAL PROCESS FLOW DIAGRAM
OF THE WET SCRUBBING SYSTEM IS PRESENTED IN APPENDIX B.
SCRUBBER OPERATING HISTORY
THERE WAS A BRIEF OPERATING PERIOD ON THE PARTICULATE SCRUBBERS FROM MID-NOVEMBER, 1974 TO
MARCH, 1975, THAT UNCOVERED A NUMBER OF PROBLEM AKEAS. DUE TO A NUMBER OF EXTENUATING CIRCUM-
STANCES, PARTICULATE SCRUBBING WAS NOT RESTARTED UNTIL JULY 23, 1975, WITH ONE PARTICULATE SCRUBBING
TRAIN FOLLOWED BY THE OTHER TWO TRAINS, ON AUGUST 15 AND OCTOBER 2, RESPECTIVELY. THE SULFUR
DIOXIDE ABSORBER WAS STARTED FOR THE FIRST TIME ON OCTOBER 2, 1975, AND THE MAGNESIUM OXIDE REGEN-
ERATION FACILITY FIRST PROCESSED MAGNESIUM SULFITE FROM THE EODYSTONE SCRUBBER ON OCTOBER 28, 1975.
THE MAGNESIUM OXIDE REGENERATION FACILITY HAS BEEN OPERATED TO PROCESS ALL MAGNESIUM 8ULFITE
DOWNS AT THE E&OYSTONE SCRUBBER.
THE SULFUR DIOXIDE SCRUBBING SYSTEM WAS TEMPORARILY SHUT DOWN DECEMBER 31, 1975, BECAUSE THE
ACID PLANT REGENERATION FACILITY AT THE OLIN CHEMICAL SULFURIC ACID PLANT IN PAULSBORO, NEW JERSEY
PERMANENTLY CEASED OPERATIONS. THE ACID PLANT REGENERATION FACILITY WAS RELOCATED TO THE ESSEX
CHEMICAL PLANT IN NEWARK, NEW JERSEY.
THE PARTICULATE AND SULFUR DIOXIDE REMOVAL SYSTEM INSTALLED ON THE EDOYSTONE NO. 1 UNIT IS THE
FIRST PHASE OF A TWO-PHASE PROJECT. FOLLOWING SUCCESSFUL DEVELOPMENT OF THIS SYSTEM WITH MORE CONT-
INUOUS OPERATION, IT WILL BE INCORPORATED INTO THE DESIGN FOR THE COMPLETE SULFUR DIOXIDE REMOVAL ON
EDDYSTONE NO. 2 AND ONE OF THE TWO EXISTING UNITS AT THE CROMBY STATION.
ADDITIONAL INFORMATION AND DATA CONCERNING THE OPERATION OF THE PAHTICULATE AND SULFUR DIOXIDE
SCRUBBERS INSTALLED AT THIS PLANT ARE PROVIDED IN THE PERFORMANCE TABLE THAT FOLLOWS.
124
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PHILADELPHIA ELECTRIC CO. FGD SYSTEM PERFORMANCE EDDYSTONE UNIT NO. 1
PERIOD COMMENTS
NOV. 7tt THE SCRUBBING SYSTEM AT THIS PLANT CONSISTS OF THREE PARALLEL SCRUBBING TRAINS INCOR-
DEC. 74 PORATING 3 KET PARTICULATE SCRUBBERS AND ONE 302 ABSORBER MODULE. THERE WAS A BRIEF
JAN. 75 OPERATING PERIOD ON THE PARTICULATE SCRUBBERS FROM MIO-NOVEMBER 1974 TO MARCH 1975
FEB. 75 PROBLEMS ENCOUNTERED CENTERED AROUND THE SCRUBBER BOOSTER FANS AND THt FLUE SAb AMU LlUUin
MAR. 75 CONDITIONS. THE B-SIDE BOOSTER FAN DEVELOPED HIGH SHAFT VIBRATION WHEN STARTtD FOR THE
APR. 75 FIRST TIME. THIS PROBLEM WAS DESIGN-RELATED, INVOLVING AN EXCESSIVE CLEARANCE AREA
MAY 75 BETWEEN THE SHAFT AND THE WHEEL HUB. ALSO, EXTENSIVE CORROSION DEVELOPED IN THE C-SIDE
JUN. 75 PARTICULATE SCRUBBER INTERNALS. THIS WAS CAUSED BY LOW SCRUBBING SOLUTION PH LEVELS AND
CHLORIDE LEVELS AS HIGH AS 2000 PPM. THESE CONDITIONS COUPLED WITH THE THERMAL SHOCK OF A
HOT START PROCEDURE CAUSED THE CORROSION. THIS PROBLEM WAS AMELIORATED BY CAUSTIC AD-
DITION, HIGHER 6LOWDOWN AND EMPLOYING A COLD START PROCEDURE. AT APPROXIMATELY THIS TIME,
A CHECKOUT OF S02 SYSTEM WAS CONDUCTED. BLISTERING AND PEELING OF THE POLYURETHANE
COATINGS WERE DETECTED AND CORRECTED BY RECOATING WITH FLAKE GLASS.
JUL. 75 THE C-SIDE PARTICULATE SCRUBBER RESTARTED ON JULY 23, 1975. THE TWO REMAINING TRAINS, B-
AU6. 75 SIDE AND A-SIOE, WERE PUT INTO OPERATION ON AUGUST 15 AND OCTOBER 2, RESPECTIVELY. THE
SEP. 75 SU2 ABSORBER MODULE IN THE C-SIDE SCRUBBING TRAIN WAS INITIALLY PLACED IN SERVICE OCTOBER
OCT. 75 2, 1975. THE OLIN CHEMICAL MGO REGENERATION FACILITY FIRST PROCESSED MAGNESIUM SULFITE
NOV. 75 FROM THE EDOYSTONE SCRUBBER ON OCTOBER 28, 1975. THE C-SIDE PARTICULATE SCRUbBER OPERATED
DEC. 75 A TOTAL OF 2831 HOURS THROUGH JANUARY 31, 1976, FOR AN AVAILABILITY OF 70 PERCENT. THE
JAN. 76 B-SIDE TRAIN HAS OPERATED A TOTAL OF 1933 HOURS THROUGH JANUARY 31, 197b FOR AN AVAIL-
ABILITY OF 55 PERCENT. THE A-SIDE TRAIN OPERATED A TOTAL OF 626 HOURS THROUGH JANUARY
31, 1976, FOR AN AVAILABILITY OF 24 PERCENT. THE C-SIDE S02 ABSORBER WAS IN SERVICE A
TOTAL Of 556 HOURS THROUGH DECEMBER 31, 1975, WITH AN AVAILABILITY OF 33 PERCENT SINCE
STARTUP. PROBLEMS ENCOUNTERED IN THE OPERATION OF THE THREE SCRUBBING TRAINS INCLUDED:
UNDER-DESIGNED RECIRCULATION PUMPS, MALFUNCTION OF THE FLUE GAS BY-PASS DAMPER DRIVE UNITS
AND FAILURE OF THE OOUBLE-BRlCK REFRACTORY LINING IN THE REHEAT COMBUSTION CHAMBER.
FEB. 76 OPERATION OF THE S02 SCRUBBING SYSTEM AT EODYSTONE WAS TEMPORARILY HALTED BECAUSE THE ACID
MAR. 76 PLANT REGENERATION FACILITY AT THE OLIN CHEMICAL SULFURIC ACID PLANT IN PAULSBORO, NEW
APR. 76 JERSEY PERMANENTLY CEASED OPERATIONS. THE UTILITY IS NOW INVESTIGATING ALTERNATIVE
MAY 76 REGENERATION SITES. A MINUMUM PERIOD OF SIX MONTHS WILL BE REQUIRED FOR RELOCATION ONCE A
CHOICE IS MADE. THE UTILITY ANNOUNCED PLANS FOR RELOCATION OF THE REGENERATION FACILITY
AT THE ESSEX CHEMICAL PLANT IN NEWARK, NEW JERSEY.
JUN. 76 RESUMPTION OF S02 SCRUBBING OPERATIONS IS PRESENTLY SCHEDULED FOR DECEMBER 1976. THE
JUL. 76 RELOCATION OF THE REGENERATION FACILITY IS NOW IN PROGRESS. THE PARTICULATE SCRUBBERS ARE
AUG. 76 OPERATIONAL. THE C-SIDE BOOSTER FAN HAS DEVELOPED A MATERIALS FAILURE BETWEEN THE HUB AND
SHAFT (IDENTICAL TO THE B-SIDE UNIT MENTIONED ABOVE).
SEP. 76 ALL THREE BOOSTER FANS HAVE NOW DEVELOPED THE MATERIALS FAILURE BETWEEN THE HUB AND SHAFT
OCT. 76 (AS IDENTIFIED IN THE ABOVE FOR THE B-SIDE UNIT). THESE UNITS HAVE BEEN RETURNED TO THE
MANUFACTURER FOR MODIFICATIONS AND REPAIRS. CURRENTLY, ONE OF THE PARTICULATE SCRUBBERS
IS IN THE FLUt GAS STREAM. TO DATE, ALL THREE OF THE WET PARTICULATE SCRUBBERS HAVE N01
SEEN ANY APPRECIABLE SIMULTANEOUS SERVICE TIME.
NOV. 76 MGO SCRUBBING OPERATIONS ARt NOW SCHEDULED TO RESTART IN MAY 1977. REGENERATION FACILITY
DE. 76 RELOCATION IS BEING COMPLETED, AND MODIFICATIONS TO THE ID BOOSTER FANS CURRENTLY BEING
EFFECTED CONSIST OF CONVERSION FROM A SHRINK FIT TO A SLIP FIT. THESE MODIFICATIONS ARE
EXPECTED TO ELIMINATE RECURRING VIBRATION PROBLEMS.
JAN. 77 THE MAGNESIUM OXIDE SCRUBBING SYSTEM AT EDDYSTUNE NO. 1A IS STILL SCHEDULED FOR RESTART IN
FEB. 77 MAY 1977. THE START-UP OF THE NEW MAGNESIUM SULFITE REGENERATION FACILITY AT THE ESSEX
MAR. 77 CHEMICAL PLANT AT NEWARK, N.J. IS ALSO SCHEDULED FOR MAY 1977. THE THREE PARALLEL VEN1URI
SCRUBBERS CONTROLLING PARTICULATE EMISSIONS ON EDOYSTONE NO. 1 WENT BACK INTO SERVICE IN
MARCH 1977.
APR. 77 RESUMPTION OF MAGNESIUM OXIDE SCRUBBING OPERATIONS OCCURED DURING THE REPORT PERIOD. THE
MAY 77 UTILITY REPORTED THAT S02 SCRUBBING OPERATIONS WERE NOT CONTINUOUS THROUGHOUT THE PERIOD.
THE ABSORBER WAS IN SERVICE APPROXIMATELY 206 HOURS DURING MAY. REGENERATION OPERATIONS
AT THE ESSEX FACILITY WERE NOT CONDUCTED DURING THE PERIOD. PECO INTENDS TO INITIATE S02
RECOVERY AND MAGOX REGENERATION OPERATIONS OUKING THE MONTH OF JUNE. THE S02 MODULE CON-
TAINS TWO ABSORBER SECTIONS IN SERIES (EACH SECTION CONSISTING OF AN ADJUSTABLE ROD DECK
WITH UNDERSPRAYS). ONLY ONE OF THE ABSORBER SECTIONS IS BEING USED FOR 502 REMOVAL. S02
REMOVAL EFFICIENCY HAS NOT BEEN MEASURED. MAGNESIUM UXIDE LOSSES IN THE SYSTEM (ABSOR-
TION AND REGENERATION) ARE ESTIMATED AT 10 PERCENT.
JUN. 77 FAILURE OF MINOR ANCILLARY EQUIPMENT CAUSED SOME SHUTDOWNS. LATER, THE BOILER ITSELF WENT
JUL. 77 DOWN. OVER THIS PERIOD THE ROTARY VALVE ON THE MAG. SULFITE DRYER DISCHARGE PLUGGED
REPEATEDLY ALSO THE BELTS ON THE AGITATOR ON THE MAG-OX. PRESLAKER FAILED.
125
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PHILADELPHIA ELECTRIC CO. FGD SYSTEM PERFORMANCE EDDYSTONE UNIT NO. 1
p£RIOO COMMENTS
AUG. 77 THE ROTARY VALVE PROBLEM APPEARS TO BE SOLVED. CUMULATIVE AVAILABILITY SINCE MAY IS
SEP. 77 ESTIMATED TO BE ROUGHLY 33X. PECO REPORTED 131 HOURS OF CONTINUOUS OPERATION FOR THE
SCRUBBER AND THICKENER CENTRIFUGE DRYER LOOP. DURING THE REPORT PERIOD THERE HAVE BEEN
CONTINUAL PROBLEMS WITH THE GLAND PACKING ON THE FGD SYSTEM CIRCULATION PUMPS (STUFFING
BOX). PECO HAS SINCE CHANGED THE GLANO CONFIGURATION. THEME ALSO WAS A PROBLEM rtlTH HIGH
OCT. 77 SOLIDS FORMATION IN THE THICKENER. DURING THE OCTOBER-NOVEMBER PERIOD THERE WAS ONE RUN
WHICH LASTED APPROXIMATELY 5 DAYS.
NOV. 77 GLAND PACKING PROBLEMS PERSISTED AND MECHANICAL SEALS ARE BEING CONSIDERED AS POSSIBLE
ALTERNATIVES. EVEN WITH HEAT TRACING THE SEAL WATER FROZE-UP CAUSING ROTAMETERS TO BURST.
HIGH SOLIDS PROBLEM IN THICKENER IS STILL A PROBLEM AREA.
DEC. 77 THE UNIT WENT DOWN DECEMBER 22 FOR A TURBINE OVERHAUL. DURING THE OUTAGE MAINTENANCE AND
JAN. 78 MINOR MODIFICATIONS WILL BE MADE ON THE SCRUBBERS. THE UNIT IS EXPECTED BACK ON LINE THE
FIRST WEEK IN MARCH. THE AVAILABILITY FACTOR FOR THE OCT, NOV, AND DEC QUARTER WAS 4U.
DURING THIS PERIOD SOME OF THE HEAT TRACING FAILED AND OTHER PROBLEMS OCCUHED WHEN LINES
FROZE AT THE ACID PLANT CAUSING THE FACILITY TO BE RUN INTERMITTENTLY. THE GLAND PACKING
PROBLEMS HAVE NOT YET BEEN SOLVED AND MECHANICAL SEALS ARE STILL BEING CONSIDERED.
126
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGU SYSTEMS THROUGH
01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F60 VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY,
PAHTICULATES
SOUTH CAROLINA PUBLIC SERVICE
W1NYAH NO. 2
GEORGETOWN SOUTH CAROLINA
260 MM
COAL 1.0 PERCENT SULFUR
BABCOCK & WILCUX
LIMESTONE SCRUBBING
NEW
7/77
OPERATIONAL
99.4 PERCENT
35 PERCENT (TOTAL)
WATER MAKE UP
OPEN LOOP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
SEE APPENDIX A, FGD SYSTEM ECONOMICS
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
THE EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF A IOOX CAPACITY ESP
FOLLOWED BY A SOX CAPACITY LIMESTONE FGO SYSTEM. ONE FGD MODULE, CONSIST-
ING OF A VENTURI SCHUbBER AND TRAY TOrtER ABSORBER, REMOVES 70* OF THE
INLET S02. REHEAT IS SUPPLIED BY THE FLUE GAS BYPASS. THE SCRUBBING
WASTES ARE DISCHARGED TO AN ON-SITE, UNLINED DIKED POND. THE NO. i. UNIT
COMMENCED INITIAL OPERATIONS IN JULY 1977. THE ACCEPTANCE TEST FOR COM-
MERCIAL CERTIFICATION WAS SUCCESSFULLY COMPLETED IN DECEMBER 1977.
127
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BACKGROUND INFORMATION
ON
WINYAH NO. 2
THE SOUTH CAROLINA PUBLIC SERVICE AUTHORITY OWNS AND OPERATES THE WINYAH STEAM PLANT WHICH IS
LOCATED IN GEORGETOWN, SOUTH CAROLINA, THIS NEW COAL-FIRED POWER-GENERATING STATION CONSISTS OF TWO
OPERATIONAL UNITS AND ONE IN THE EARLY PLANNING STAGES. UNITS NO. 1 AND NO. 2 ARE RATED AT 315 MW
AND 280 MW, RESPECTIVELY, AND FIRE A MEDIUM SULFUR VIRGINIA COAL WITH THE FOLLOWING GENERAL CHARAC-
TERISTICS: 11,200 BTU/LB, 1.9 PERCENT SULFUR (MAXIMUM), 19 PERCENT ASH (MAXIMUM) AND 10 PERCENT
MOISTURE (MAXIMUM). IN ORDER TO MEET FEDERAL NEW SOURCE PERFORMANCE STANDARDS FOR PARTICULATE AND
SULFUR DIOXIDE EMISSIONS, UNIT NO. 2 IS FITTED WITH AN EMISSION CONTROL SYSTEM WHICH INCLUDES Ah
ELECTROSTATIC PRECIPITATOR (ESP) AND A WET SCRUBBING SYSTEM. THE ESP, INSTALLED UPSTREAM OF THE
SCRUBBER-ABSORBER PLANT, IS SUPPLIED bY RESEARCH-COTTRELL AND DESIGNED TO REMOVE APPROXIMATELY 99
PERCENT OF THE INLET FLY ASH. THE WEI SCRUBBING SYSTEM CONSISTS OF A LIMESTONE BASED FGD DESIGNED
AND SUPPLIED BY BABCUCK AND WILCOX TU REMOVE ADDITIONAL FLY ASH AND REMOVE 69 PERCENT Of THE SULFUR
DIOXIDE FROM 50 PERCENT OF THE FLUE GAS. THE REMAAINING HALF OF THE BOILER FLUE GAS IS BYPASSED
AROUND THE FGD SYSTEM AND RECOMBINED WITH THE SCRUBBED PORTION FOR REHEAT PURPOSES PRIOR TO DIS-
CHARGE TO THE STACK.
THE FGD SYSTEM CONSISTS OF ONE SCRUBBER-ABSORBER TRAIN, INCLUDING A VENTURI SCRUBBER AND TRAY
TOWER ABSORBER. FOLLOWING PASSAGE UF THE FLUE tAS THROUGH THE ESP (0.1 LB/MM BTU DESIGN OUTLET
LOADING), 50 PERCENT OF THE FLUE GAS (<407,015 ALFM, 270 F) IS BOOSTED THROUGH THE SCRUBBER AND ABSO-
RBER BY A DRY, FORCED-DRAFT BOOSTER FAN (DESIGN PRESSURE DROP OF 13.5 INCHES). THE VENTURI SCRUBBER
PROVIDES ADDITIONAL FLY ASH AND INITIAL SULFUR DIOXIDE REMOVAL. THE DESIGN FEATUKES OF THE VENTURI
INCLUDE A 3 INCH PRESSURE DROP, A SUPERFICIAL GAS VELOCITY OF 90 FT/SEC., AND L/G OF 1«.«. THE SAT-
URATED FLUE GAS (338,000 ACFM, 126 F) THEN PASSES THROUGH THE TRAY TOWER WHERE SULFUR DIOXIDE
REMOVAL IS COMPLETED. THE DESIGN FEATURES OF ThE ABSORBER INCLUDE A 4.5 INCH PRESSURE DROP, A
SUPERFICIAL GAS VELOCITY OF 10.5 FT./SEC., AND A L/G OF 07.5. THE SCRUBBING SOLUTION is A 20 PER-
CENT SOLIOS LIMESTONE SLURRY FED TO THE FGD SYSTEM AT A 130 PERCENT STOICHIOMETRIC LEVEL. THE OVER-
ALL EMISSION CONTROL SYSTEM REMOVAL EFFICIENCY IS 99.55 PERCENT FOR PAftTICULATE AND 35 PERCENT FOR
SULFUR DIOXIDE (935 PPM INLET AND 290 PPM OUTLET FOR THE FGD SYSTEM). THE SCRUBBING WASTES (6.45
TONS PER HOUR, 35 PERCENT SOLIDS) ARE DISCHARGED VIA PUMP TO AN ON-SITE, UNLINED DIKED POND WITH A
20-YEAR CAPACITY. THE CLEANED GASES ARE RECOMB1NED WITH THE BYPASSED PORTION AND DISCHARGED TO AN
FRP-LINED STACK.
128
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SOUTH CAROLINA PUBLIC SERVICE
FGD SYSTEM PERFORMANCE
COMMENTS
WINYAH NO. 2
PERIOD
OCT. 77
NOV. 77
OEC. 77
JAN. 78
DURING UPDATE PERIOD THE SCRUBBER SYSTEM WAS OPERATIONAL AND AVAILABLE 1001 Of THE TIME.
DURING THE UPDATE PERIOD, THERE WERE NO FORCED OUTAGES EXCEPT IN EARLY JANUARY WHEN THE
SYSTEM WAS DOWN FOR TWO DAYS TO CHECK THE INSTRUMENTATION. THE S02 MONITORS ARE NOT
FUNCTIONING PROPERLY. ALL THE SAMPLE LINES HAVE BEEN REPLACED SEVERAL TIMES. NEn HEAT
TRACINGS ARE INSTALLED AROUND THEM. THE ACCEPTANCE TESTS ARE EXPECTED TO BE OVER BY THE
END OF FEB.
129
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/78
UTILITY NAME SPRINGFIELD CITY UTILITIES
UNIT NAME SOUTHWEST NO. 1
UNIT LOCATION SPRINGFIELD MISSOURI
UNIT RATING 200 MW
FUEL CHARACTERISTICS COAL 3.b PERCENT SULFUR
FGD VENDOR UNIVERSAL OIL PRODUCTS
PROCESS LIMESTONE SCRUBBING
NEW OR RETROFIT NEW
START UP DATE 4/77
FGD STATUS OPERATIONAL
EFFICIENCY,
PARTICULATES 99.8 PERCENT (ACTUAL)
S02 92 PERCENT (ACTUAL)
WATER MAKE UP
SLUDGE DISPOSAL FILTER CAKE LANDFILL
UNIT COST SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL REFER TO THE bACKGROUNO INFORMATION SECTION IN TABLE 3 OF THIS REPORT.
EXPERIENCE THE EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED UNIT CONSISTS OF A
FOUR-FIELD HIGH EFFICIENCY ESP (99.6X DESIGN) AND 2 TURBULENT CONTACT AB-
SORBER MODULES (SOX DESIGN) FOR THE CONTROL OF PARTICULATES AND SOS. BOTH
THE ESP AND LIMESTONE FGD SYSTEM ARE SUPPLIED BY UOP. THE SCRUBBING
WASTES ARE OEWATERED BY A ROTARY DRUM VACUUM FILTER AND THE FILTER CAKE IS
HAULED AWAY TO A LANDFILL. INITIAL OPERATION OF THE FGD SYSTEM OCCURRED IN
APRIL 77. IN SEPT. 77, THE UNIT SUCCESSFULLY COMPLETED COMPLIANCE TESTING.
130
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BACKGROUND INFORMATION
ON
SOUTHWEST NO. i
THE SOUTHWEST POWER STATION OF THE CITY UTILITIES OF SPRINGFIELD IS LOCATED APPROXIMATELY FIVE
MILES SOUTHWEST OF SPRINGFIELD, MISSOURI. THE STATION NOW OPERATES ONE CUAL-FIREO STEAM TURBINF
GENERATOR, WHICH HAS A TOTAL GENERATING CAPACITY OF 200 MW. PLANS CALL FUR A SECOND COAL-FIRED
GENERATOR OF LIKE CAPACITY TO BEGIN OPERATING IN 1981, WHICH WILL BRING THE STATION'S CAPACITY UP TO
UOOMW.
THE NO. 1 BOILER IS A RILEY STOKER PULVERIZED COAL-FIRED UNIT. THE FUEL IS A HIGH-SULFUR BITU-
MINOUS KANSAS COAL WITH THE FOLLOWING AVERAGE CHARACTERISTICT5: 10 PERCENT ASH, 3.5 PERCENT SULFUk,
AND 12,500 BTU/LB HEATING VALUE. PRIMARY PARTICULATE CONTROL IS PROVIDED BY A COLD-SIDE ELECTROS1A-
TIC PRECIPITATOR (ESP) WITH AN EFFICIENCY OF 99.7 PERCENT, AND PRIMARY SULFUR DIOXIDE (SU2) EMISSION
CONTROL BY A LIMESTONE SLURRY FLUE GAS DESULFUR1ZAT ION (FGD) SYSTEM WITH A DESIGN EFFICIENCY OF BO
PERCENT. THESE UNIVERSAL OIL PRODUCTS CONTROL SYSTEMS ARE DESIGNED To MEET NEW SOURCE PERFORMANCE
STANDARDS OF 0.1 LB/MM BTU F02 PARTICULATES AND 1.2 LB/MM BTU FU2.S02 EMISSIONS.
THE FGD SYSTEM INCLUDES TWO bO PERCENT CAPACITY TUR60LENT CONTACT ABSORBER (TCA) MODULES AND
FACILITIES FOR LIMESTONE CRUSHING AND PREPARATION AND SLUDGE STABILIZATION. THE BOILER FLUE GAS
FIRST PASSES THROUGH THE ESP FOR PARTICULATE REMOVAL AND IS THEN BOOSTED THROUGH THE TWO TCA MODULES
BY FORCED-DRAFT BOOSTER FANS. EACH TCA MODULE CONTAINS A PRESATURATOR SECTION AND TWO LEVELS OF
TURdELENT PACKING (1.25-INCH DIAMETER MODULE SPHERES) WHERE THE 302 IN THE SATURATED GAS STREAM IS
REMOVED WHEN IT CONTACTS WITH THE LIMESTONE SLURRY. EACH MODULE IS EQUIPPED WITH A SEPARATE REClK-
CULATION TANK, WHERE REACTIONS ARE COMPLETED, FxESH SCRUBBING SLURRY IS ADDED, AND FLOE GAS CLEANING
WASTES ARE DISCHARGED. THE CLEANED, SATURATED FLUE GAS THEN PASSES THROUGH A SET OF MISjT ELIMINAT-
ORS BEFORE IT IS DISCHARGED TO THE ATMOSPHERE THROUGH THE MAIN STACK. THE FLUE GAS CLEANING BASTES
ARE DISCHARGED FROM THE RtCIRCULATION TANKS TO A THICKENER, WHERE SOLIDS ARE SEPARATED UUT AND THE
CLARIFIED LIQUOR is RETURNED TO THE PROCESS. THE SLUDGE is FIXATED TO A CEMENTITIOUS MATERIAL (7o
TO 75 PERCENT SOLIDS), THEN HAULED AWAY BY FRONT-END LOADERS TO A 10-ACRE VALLEY LANDFILL AREA ON
SITE. MAKEUP WATER FOR THE FGD SYSTEM IS SUPPLIED BY COOLING TOWER BLOWOOWN WATER. ONE UR BOTH FGD
MODULES CAN BE BYPASSED DURING EMERGENCY OF MALFUNCTION PERIODS BY THE USE OF SEAL-AIR GAS CLAMPERS.
MNITIAL OPERATING EXPERIENCE*
INSTALLATION OF THE LIMESTONE FGO SYSTEM WAS COMPLETED DURING THE FIRST UUARTER OF 1977 (BEHIND
SCHEDULE, PRIMARILY BECAUSE OF DELAYS IN ELECTRICAL WORK). FOLLOWING AIR/KATER TESTS AND CHECKOUT
OF LIMETSONE PREPARATION FACILITIES, THE FGD PLANT WAS STARTED UP IN EARLY APRIL 1977 FOR MECHANICAL
SHAKEDOWN AND DEBUGGING, WHICH CONTINUED THROUGHOUT THE SUMMER. COMPLIANCE TESTING AND CERTIFICA-
TION OF COMMERCIAL AVAILABILITY WERE SUCCESSFULLY COMPLETED IN SEPTEMBER, JUST BEFORE A SCHEDULED 3-
MONTH FALL SHUTDOWN. TO DATE, OPERATION OF THE SYSTEM HAS BEEN HAMPERED BY A NOMSER OF PROBLEMS!
MIST ELIMINATOR PLUGGING (PIPING TO MIST ELIMINATOR SPRAY SYSTEM HAS BEEN MODIFICATION), CORROSION
IN THE PRESATURATOR (WAS RELINEO WITH PRECRETE), CORROSION OF THE INLET/OUTLET GAS DAMPERS (REPLAC-
ED WITH 316 SS DAMPERS), AND FAILURE OF PRECRETE LINING IN THE SCRUBBER AND CEILCOTE IN THE STACK
(BOTH FAILURES IDENTIFIED AS APPLICATION PROBLEMS). IN ADDITION TO THESE PROBLEMS, THE UTILITY ALSO
FOUND IT NECESSARY TO CHANGE THt SYSTEM'S PH CONTROL POINT FROM 5.9 TO 5.b TO INCREASE LIMESTONE
UTILIZATION AND DECREASE PLUGGING WITHIN THE SYSTEM. AT PRESENT THE UTILITY IS KEEPING ONE TCA IN
SERVICE AND IMPLEMENTING MODIFICATIONS ON IT, WHICH, IF SUCCESSFUL, WILL THEN BE INCORPORATED INTO
THE SECOND MODULE.
131
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SPRINGFIELD CITY UTILITIES SOUTHWEST UNIT NO. 1
FGD SYSTEM PERFORMANCE HISTORY
PERIOD COMMENTS
AUG. 77
SEP. 77
DURING THE REPORT PERIOD THE FGD SYSTEM WAS OPERATING ROUGHLY 60 PERCENT OF THE TIME. A NEW
SOURCE PERFORMANCE TEST WAS RUN DURING THE SECOND WEEK OF SEPTEMBER. LATER. THE UNIT WAS
SHUT DOWN FOR THE FIRST TURBINE INSPECTION.
OCT. 77
DURING THE OCTOBER OUTAGE THE SCRUBBER OUTLET DAMPER HAS MODIFIED, SCRUBBER PACKING AND
SCRUBBER OUTLET DUCTWORK LINING WERE REPLACED, AND INSULATION WAS INSTALLED AROUND THE SEAL-
AIR FAN BETWEEN THE INLET DAMPERS. THE UNIT WAS EXPECTED TO BE BACK IN SERVICE IN DECEMBER.
NOV. 77
PLANT WAS SHUT DOWN DURING OCTOBER AND NOVEMBER AND SCHEDULED 10 START UP AGAIN IN JANUARY
1978. THE FOLLOWING MODIFICATIONS WERE MADE DURING THIS PERIOD:
* OUTLET DAMPERS WERE REPLACED BY 316 L SS DAMPERS.
* PRESATURATOR WAS RtLINEO WITH HI-MO STEEL.
* OUTLET DUCT WAS RELINEO WITH CEILCOTE.
* HOLLOW PACKING BALLS WERE REPLACED BY SOLID 1.25-IN. DIAMETER BALLS.
* LEAKING AROUND OUTLET DAMPERS WAS MINIMIZED BY SEAL-AIR FANS.
DEC. 77
JAN. 78
THE PLANT SHUT DOWN CONTINUED UNTIL JANUARY 28 WHEN THE BOILER RESTARTED. THE FGD SYSTEM
WILL BE PUT ON LINE IN FEBRUARY 1976. DURING THE OUTAGE ALL REMAINING MODIFICATIONS TO THE
FGO SYSTEM WERE COMPLETED.
NOTE:
THE HOLLOW PACKING BALLS WERE REPLACED WITH HEAVIER-WALL BALLS RATHER THAN THE SOLID
1.25 INCH DIAMETER BALLS REPORTED EARLIER.
132
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/78
UTILITY NAME TENNESSEE VALLEY AUTHORITY
UNIT NAME SHAWNEE N0.10A
UNIT LOCATION PADUCAH KENTUCKY
UNIT RATING 10 MW
FUEL CHARACTERISTICS COAL ^,<) PERCENT SULFUR
FGO VENDOR UNIVERSAL OIL PRODUCTS
PROCESS LIME/LIMESTONE SCRUBBING
NEK OR RETROFIT RETROFIT
START UP DATE 4/72
FGD STATUS OPERATIONAL
EFFICIENCY,
PARTICULATES EXPERIMENTALLY CONTROLLED
302 EXPERIMENTALLY CONTROLLED
WATER MAKE UP EXPERIMENTALLY CONTROLLED
SLUDGE DISPOSAL EXPERIMENTALLY CONTROLLED
UNIT COST
OPERATIONAL REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
EXPERIENCE TURBULENT CONTACT ABSORBER(TCA) LIME/LIMESTONE SCRUBBING SYSTEM HAS BEEN
OPERATIONAL SINCE APRIL 1972. THIS TEST PROGRAM IS FUNDED BY THE EPA.
TVA IS THE CONSTRUCTOR AND FACILITY OPERATOR. THE BECHTEL CORP. OF SAN
FRANCISCO IS THE MAJOR CONTRACTOR, TEST DIRECTOR, AND REPORT WRITER.
DURING THE REPORT PERIOD, OPERATIONS WERE CONDUCTED WITH LIMESTONE
SLURRY CIRCULATING THROUGH THE UNIT. FORCED OXIDATION ON FLY ASH-LADEN
FLUE GAS WAS EVALUATED.
133
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS THROUGH 01/78
UTILITY NAME TENNESSEE VALLEY AUTHORITY
UNIT NAME SHAWNEE N0.10B
UNIT LOCATION PAOUCAH KENTUCKY
UNIT RATING 10 MW
FUEL CHARACTERISTICS COAL 2.9 PERCENT SULFUR
FGO VENDOR CHEMICO
PROCESS LIME/LIMESTONE SCRUBBING
NEW OR RETROFIT RETROFIT
START UP DATE «/72
FGD STATUS OPERATIONAL
EFFICIENCY,
PARTICULATES EXPERIMENTALLY CONTROLLED
302 EXPERIMENTALLY CONTROLLED
WATER MAKE UP EXPERIMENTALLY CONTROLLED
SLUDGE DISPOSAL EXPERIMENTALLY CONTROLLED
UNIT COST
OPERATIONAL REFER TO BACKGROUND INFORMATION SECTION IN TABLE 3 OF THIS REPORT. THIS
EXPERIENCE VENTURI/SPRAY TOWER LIME/LIMESTONE SCRUBBING SYSTEM HAS BEEN OPERATIONAL
SINCE APRIL 1972. THIS TEST PROGRAM IS FUNDED BY THE EPA. TVA IS THE
CONSTRUCTOR AND FACILITY OPERATOR. THE BECHTEL CORP. OF SAN FRANCISCO IS
THE MAJOR CONTRACTOR, TEST DIRECTOR, AND REPORT WRITER. DURING THE REPORT
PERIOD, FORCED OXIDATION WAS EVALUATED ON FLY ASH-FREE FLUE GAS WITH
LIME SLURRY AS THE SCRUBBING AGENT.
134
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BACKGROUND INFORMATION
ON
SHAWNEE NOS. 10A AND 108
IN JUNE 1968, THE EPA INITIATED A PROGRAM TO TEST PROTOTYPE LIME AND LIMESTONE SYSTEMS FOR
REMOVAL OF SULFUR DIOXIDE AND PARTICULATE FROM COAL-FIRED BOILER FLUE EASES THE PROGRAM WAS
CARRIED OUT IN A TEST FACILITY INCORPORATED INTO THE FLUE GAS DUCTWORK OF UNIT NO. 10, A COAL-FIRED
BOILER AT THE TVA SHAWNEE POWER STATION, PAOUCAM, KENTUCKY. TVA IS THE CONSTRUCTOR AND FACILITY
OPERATOR AND BECHTEL CORP. IS THE MAJOR CONTRACTOR, TEST DIRECTOR, AND REPORT WRITER.
THE TEST FACILITY CONSISTS OF THREE PARALLEL SCRUBBER SYSTEMS OF PROTOTYPE SIZE, TREATING PART
OF THE FLUE GAS FROM THE BOILER. EACH SCRUBBER TRAIN IS CAPABLE OF TREATING APPROXIMATELY JO,000
ACFM OR THE EQUIVALENT OF APPROXIMATELY 10 MW OF POWER PLANT GENERATING CAPACITY.
THREE PARALLEL WET SCRUBBER SYSTEMS WERE SELECTED FOR THE TEST PROJECT: 1) A VENTURI WITH A
SPRAY TOWER AFTER ABSORBER, 2) A TURBULENT CONTACT ABSORBER (TCA), AND 3) A MARBLE-BEO ABSORBER.
THE VENTURI SYSTEM, MANUFACTURED BY CHEMICAL CONSTRUCTION CO., CONTAINS AN ADJUSTABLE THROA1 IHAT
PERMITS CONTROL AND VARIATION UF PRESSURE DROP UNDER A WIDE RANGE OF FLOW CONDITIONS. THE TCA UNIT,
MANUFACTURED BY UNIVERSAL OIL PRODUCTS, INCORPORATES A FLUIDIZED BED OF LOW DENSITY PLASTIC SPHERES
THAT ARE FREE TO MOVE BETWEEN RETAINING GRIDS. THE MARBLE-BED ABSORBER, SUPPLIED BY COMBUSTION
ENGINEERING CO., USES A PACKING OF 3/4-INCH GLASS MARBLE SPHERES AND A TURBULENT LAYER UF LIQUID AND
GAS ABOVE THE MARBLE LAYER TO ENHANCE MASS TRANSFER.
IN JUNE 1974, THE EPA BEGAN A 3-YEAR ADVANCED TEST PROGRAM AT THE SHAWNEE FACILITY WITH THESE
MAJOR GOALS: ti) CONTINUATION OF LONG-TERM TESTING, WITH EMPHASIS PLACED UPON THE RELIABLE OPERAT-
ION OF MIST ELIMINATION SYSTEMS AT INCREASED GAS VELOCITY, (2) INVESTIGATION OF ADVANCED PROCESS AND
EQUIPMENT DESIGN VARIATIONS FOR IMPROVING SYSTEM RELIABILITY AND PROCESS ECONOMICS, AND C3) LONG-
TERM RELIABILITY TESTING ON PROMISING PROCESS AND EQUIPMENT DESIGN VARIATIONS.
THE TWO PARALLEL SCRUBBING SYSTEMS OPERATING DURING THE ADVANCED PROGRAM ARE THE VENTURI/SPRAY
TOWER SYSTEM AND THE TCA UNIT. GENERAL PROCESS FLOW DIAGRAMS OF THE TWO PROTOTYPE UNITS ARE PROVID-
ED IN APPENDIX B. OPERATION UF THE MARBLE-BED ABSORBER UNIT HAS BEEN PERMANENTLY DISCONTINUED.
EACH OF THE SCRUBBING SYSTEMS CONTAINS ITS OWN SLURRY HANDLING FACILITIES AND CAN TREAT APPROX-
IMATELY 30,000 ACFM OF GAS AT 300 F CONTAINING 1800 TO 1000 PPM OF SULFUR DIOXIDE AND 2 TO <4
GRAINS/SCF OF PARTICULATE. BOILER NO. 1 NORMALLY BURNS A HIGH-SULFUR BITUMINOUS CUAL.
FROM JUNE 1974 TO JANUARY 1976, MIST ELIMINATION AND LIMESTONE UTILIZATION TESTS WERE CONDUCTED
AT THE SHAWNEE FACILITY. DURING THIS TEST PERIOD THE VENTURI/SPRAY TOWER SYSTEM WAS OPERATED ON
BOTH LIME AND LIMESTONE AND THE TCA SYSTEM WITH LIMESTONE. TESTING WAS PERFORMED UNDER A CLOSED-
WATER OPERATION MODE. DURING THIS PERIOD THE SLURRY SOLIDS CONTAINED APPROXIMATELY 40 TO 50
PERCENT-BY-WEIGHT FLY ASH BECAUSE OF RELATIVELY HIGH GAS INLET PARTICULATE LOADING. THIS TESTING
PROGRAM IS SCHEDULED TO RUN THROUGH TO FEB. 1978.
ADDITIONAL INFORMATION AND DATA CONCERNING THE DETAILS OF THE ADVANCED TEST PROGRAM ARE PRESEN-
TED IN THE PERFORMANCE TABLE THAT FOLLOWS.
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TENNESSEE VALLEY AUTHORITY SHAWNEE UNIT NOS. 10A AND 10B
SEP. 75 THIS EXPERIMENTAL EPA-FUNDED OPERATION IS PROCEEDING WITH THE TEST PROGRAM. TWO
OCT. 75 AbSORBER MODULES ARE CURRENTLY OPERATIONAL (10 MW EACH). THE MAKBLE-BED ABSORBER IS
STILL INOPERATIVE (SINCE JULY 1973). CURRENT EXPERIMENTS ARE RELATED TO MIST ELlMINATQK
SECTION.
NOV. 75 RECENT TESTING AT SHAWNEE HAS SHOWN THAT THE CHEVRON MIST ELIMINATORS IN BOTH THE SPRAY
DEC. 75 TOWER AND THE TCA CAN HE KEPT FREE OF SOLIDS BUILDUP AT HIGH ALKALI UTILIZATION (GREATER
THAN 90 PERCENT), USING ONLY INTERMITTENT WASHING WITH AVAILABLE RAW WATER. THIS HIGH
UTILIZATION IS NORMALLY ACHIEVED WITH LIME. IT HAS BEEN ACHIEVED WITH LIMESTONE AT RED-
UCED SCRUBBER INLET SLURRY PH (ABOUT 5.2) AND WITH THREE EFFLUENT TANKS IN SERIES TO
SIMULATE A PLUG-FLOW REATOR. TESTING IS CONTINUING TO DETERMINE THE EFFECTS OF PROCESS
VARIABLES UN MIST ELIMINATOR PERFORMANCE AND ON LIMESTONE UTILISATION. FUTURE PLANS
INCLUDE: (1) FACTORIAL TESTING WITH LIME AND LIMESTONE TO DETERMINE THE EFFECTS OF
PROCESS VARIABLES ON S02 REMOVAL AND (2) TESTING THE OXIDATION UF SLUDGE TO GYPSUM IN
THE VENTURI/SPRAY TOWER SYSTEM USING AIR SPARGING OF AN ACIDIFIED SLURRY BLEED STREAM.
JAN. 76 THE ADVANCED TEST PROGRAM IS CONTINUING. HIGHLIGHTS OF THE PROGRAM ARE AS FOLLOWS:
FEB. 76 EVALUATE SCRUBBER OPERAblLITY DURING VARIABLE LOAD OPERATION.
CONTINUE LONG-TERM RELIABILITY TESTING.
INVESTIGATE METHODS FOR IMPROVING WASTE SOLIDS SEPERATION.
CONTINUE SLUDGE OXIDATION AND SLUDGE FIXATION STUDY PROGRAMS.
EVALUATE SYSTEM PERFORMANCE AT REDUCED FLY ASH LOADINGS.
DETERMINE THE PRACTICAL UPPER LIMITS OF S02 REMOVAL EFFICIENCY.
EVALUATE ADDITION OF MAGNESIUM ION TO THE SCRUBBING SLURRY.
CHARACTERIZE ALL STACK GAS EMISSION COMPONENTS.
EVALUATE MATERIALS OF CONSTRUCTION OF ALL SCRUBBER AND PLANT-RELATED COMPONENTS.
DEVELOP A COMPUTER PROGRAM FOR DESIGN AND COST ANALYSIS OF FULL-SCALE LIME/LIMESTONE
SYSTEM.
MAR. 76 BECHTEL REPORTED THAT THE FACTORIAL TEST PROGRAM, EVALUATING THE PERFORMANCE OF THE
LIME/LIMESTONE SCRUBBING
APR. 76 SYSTEMS WITH AND WITHOUT MAGNESIUM ADDITION HAS BEEN COMPLETED. CURRENTLY TESTING IS
PROCEEDING ON THE EVALUATION OF SYSTEM PERFORMANCE AS A FUNCTION OF LOW RESIDENCE TIMES
(1.5 TO 5.0 MINUTES) IN THE RECYCLE TANKS. IN ADDITION, A FLY-ASH-FREE DUCT IS BEING
INSTALLED AT THE TEST FACILITY, THUS ENABLING EVALUATION OF SYSTEM PERFORMANCE IN THE
ABSENCE OF FLY ASH.
MAY 7fa THE TEST DIRECTOR, BECHTEL, PROVIDED THE FOLLOWING INPUT CONCERNING THE OPERATION OF
THE EXPERIMENTAL SCRUBBING SYSTEMS DURING THE REPORT PERIOD.
JUN. 76 THE EFFECT OF MGO ADDITION WAS EXPLORED IN BOTH SCRUBBER SYSTEMS. RESULTS INDICATE MAG-
NESIUM ION IN THE SCRUBBER SLURRY LIQUOR ENHANCES 303 REMOVAL AND CAN DEPRESS SULFATE
SUPERSATURATION. IT WAS FOUND THAT THE MAGNESIUM ION CONCENTRATION HAD TO EXCEED THE
EQUIVALENT CHLORIDE ION CONCENTRATION TO HAVE AN EFFECT ON S02 REMOVAL.
IN THE TCA UNIT, WITH LIMESTONE SLUkRY, S02 REMOVAL WAS INCREASED FROM 75 TO 95 PERCENT
BY INCREASING THE MAGNESIUM ION CONCENTRATION TO 9,000 PPM IN EXCESS OF EQUIVALENT
EQUAL TO 6 PERCENT BY WEIGHT OF THE LIMESTONE ADDITION RATE. IN THE VENTURI/SPRAY
TOWER SYSTEM, WITH LIME SLURRY, 302 REMOVAL WAS INCREASED FROM 75 TO 90 PERCENT BY IN-
CREASING MAGNESIUM ION CONCENTRATION TO 2,000 PPM IN EXCESS OF EQUIVALENT CHLORIDE ION.
THE MAGNESIUM OXIDE ADDITION RATE WAS 2 PERCENT BY WEIGHT OF THE LIME ADDITION RATE.
BOTH SCRUBBING SYSTEMS OPERATED IN THE SUBSATURATED SULFATE MODE WHEN MAGNESIUM OXIDE
WAS ADDED. INLET so2 CONCENTRATIONS DURING THE TESTS AVERAGE APPROXIMATELY 3,000 PPM
DURING THESE TESTS.
FOLLOWING THE TEST BLOCKS MENTIONED ABOVE, BOTH SCRUBBERS ARE OPERATING WITH LIME SLURRY
SCRUBBING SOLUTIONS, THE TCA SYSTEM ON FLUE GAS CONTAINING FLY ASH AND THE VENTURI/SPRAY
TOWER SYSTEM ON FLY ASH-FREE FLUE GAS.
JUL. 76 EXPERIMENTAL OPERATION OF THE EPA/TVA ALKALI SCRUBBING TEST FACILITY CONTINUED DURING
THE REPORT PERIOD. BECHTEL,THE TEST DIRECTOR, PROVIDED THE FOLLOWING INPUT CONCERNING
AUG. 76 THE OPERATION OF THE PROTOTYPE TEST UNITS.
VENTUHI/SPRAY TOWER SYSTEM: THIS SYSTEM RAN ON FLY ASH-FREE FLUE GAS USING A LIME
SLURRY SCRUBBING SOLUTION. NO SIGNIFICANT DIFFERENCES IN soa REMOVAL, GYPSUM SATURATION
AND SULFITE OXIDATION WERE DETECTED (VERSUS FLY ASH-LADEN FLUE GAS). ONE DIFFERENCE
NOTED WAS THE FILTER CAKE SOLIDS CONTENT WHICH WAS APPROXIMATELY 10 PERCENT LOWER FOR
THE FLY ASH-FREE SLUDGE (40 TO 50 PERCENT SOLIDS) VERSUS THE FLY ASH-LADEN SLUDGE (50 TO
60 PERCENT SOLIDS). IN ADDITION, OPERATION IN A LOW RESIDENCE TIME MODE (3 MINUTES) WAS
EXPLORED. SCALE-FREE OPERATION WAS ACHIEVED IN THIS MODE UNDER THE FOLLOWING CONDITIONS:
» PERCENT SOLIDS (NO FLY ASH) IN THE RECIRCULATED SLURRY, Pri UF THE SCRUBBER LIQUID
INLET WAS 6.0, SUPERFICIAL GAS VELOCITY OF 9.« FT./SEC., AND A TOTAL LIUUID-TO-GAS RATIO
(L-G) OF 71 GAL./MCF. SOME SCALE FORMATION OCCURED WHEN THE SOLIDS CONTENT IN THE RE-
CIRCULATED SLURRY DROPPED BELOW THE a PERCENT LEVEL.
TCA SYSTEM: THIS SYSTEM OPERATED ON FLY ASH-LADEN FLUE GAS USING A LIME SLURRY SCRUBB-
ING SOLUTION INNOCULATED WITH MAGNESIUM OXIOE. GYPSUM SU8SATURATION OPERATION WAS ACHI-
EVED UNDER THE FOLLOWING CONDITIONS: MAGNESIUM ION CONCENTRATION EXCEEDED THE
CHLORIDE ION CONCENTRATION BY 2000 PPM, SUPERFICIAL GAS VELOCITY WAS 12.5 FT./SEC.r L/G
136
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TENNESSEE VALLEY AUTHORITY SHArtNEE UNJT ^ m ^ ^
WAS 50. THE SCRUBBING SOLUTION INLET PH WAS 7.0, AND RESIDENCE TIME WAS 4-MINUTFs THC
802 REMOVAL EFFICIENCY WAS APPROXIMATELY 90 PERCENT. WHEN L/G WAS REDUCED ?o « IMI.P
ALL OTHER CONDITIONS HEMAINED CONSTANT, SEVERE GYPSUM SCALE FORMATION RESULTED rT
CREASING THE EFFECTIVE MAGNESIUM ION CONCENTRATION TO «000 PPM AND THE IcftUB^R . SMTP
INLET PH TO 8.0 DID NOT AMELIORATE THE SCALE PROBLEM. PRESENTLY, THE VEN?UKSR
'
THE
"*
SEP. 76 IN SEPTEMBER AND OCTOBER 1976, THE VENTURI/SPRAY SYSTEM WAS OPERATED WITH FLY ASH-FREE
OCT. 76 FLUE GAS USING LIME SLURRY WITH ADDED MAGNESIUM OXIDE. TYPICAL TEST CONDITIONS WERE 9 a
FT/SEC SPRAY TOWER GAS VELOCITY, 21 GAL/MCF VENTURI L/G, 50 GAL/MCF SPRAY TOWER L/G, 8
PERCENT SLURRY SOLIDS (FLY ASH-FREE), 3 MINUTES RESIDENCE TIME, 7.0 SCRUBBER INLET PH,
AND £000 PPM EFFECTIVE MG ION CONCENTRATION (I.E., EXCESS OVER EQUIVALENT CHLORIDE ION)
RESULTS WERE NOT CONSISTENT AT THESE CONDITIONS. DURING ONE PERIOD, SCRUBBING INLET
LIQUOR GYPSUM SATURATION AVERAGED 65 PERCENT WITH 80 PERCENT S02 REMOVAL AND WITH SOME
GYPSUM SCALE FORMATION. IN A LATER PERIOD, AT SEEMINGLY IDENTICAL TEST CONDITIONS, GYP-
SUM SATURATIONS DROPPED TO 10 PERCENT WITH 98 PERCENT 302 REMOVAL AND THE SCRUBBER DE-
SCALED. A SEVEN-WEEK PROGRAM OF INTENSIVE FLUE GAS CHARACTERIZATION TESTING wAS STARTED
IN MID-OCTOBER ON THE VENTURI/SPRAY TOWER SYSTEM. THESE TESTS ARE BEING MADE TO MEASURE
SIMULTANEOUS INLET AND OUTLET FLUE GAS PARTICULATE MASS LOADING, PARTICULATE SIZE DIS-
TRIBUTION, AND GASEOUS S03 CONCENTRATION. THE TCA SYSTEM CONTINUED TO OPERATE DURING
THIS PERIOD ON FLY ASH-LADEN FLUE GAS USING LIME SLURRY WITH ADDED MAGNESIUM OXIDE. THE
TEST RESULTS SOFAR INDICATED THAT THE DEGREE OF SULFATE (GYPSUM) SUBSATURAT ION IS A SEN-
SITIVE FUNCTION OF THE EFFLUENT RESIDENCE TIME CONDITIONS: GAS VELOCITY 12.5 FT/SEC, L/G
OF 50, PH OF 7.0, 8000 PPM OF MG ION, AND 8 PERCENT SULIDS. AT THESE CONDITIONS GYPSUM
SATURATIONS WERE 95, 50, AND 92 PERCENT, AT RESIDENCE TIMES OF 3, H, AND 12 MINUTES,
RESPECTIVELY. FURTHER TESTS WERE RUN AT 37 GAL/MCF L/G, AND 8.0 SCRUBBER INLET PH WITH
OTHER CONDITIONS THE SAME. DURING THESE TESTS GYPSUM SATURATIONS WERE 95, 95, 50, AND
90 PERCENT AT 3, 4, 5.4, AND 16 MINUTES RESIDENCE TIMES, RESPECTIVELY.
NOV. 76 FROM MID-OCTOBER THROUGH EARLY DECEMBER AN INTENSIVE FLUE GAS CHARACTERIZATION TESTING
DEC. 76 PROGRAM WAS CONDUCTED ON THE VENTURI/SPRAY TOWER SYSTEM WITH LIME SLURRY.
OVER THE RANGE TESTED, OUTLET PARTICULATE MASS LOADING WAS FOUND TO BE INDEPENDENT OF
SLURRY COMPOSITION (8 TO 15 PERCENT SUSPENDED SOLIDS, 3,000 TO 16,000 PPM DISSOLVED
SOLIDS), GAS FLOW RATE (20,000 TO 35,000 ACFM) , SPRAY TOWER LIQUID RATE (0 TO 1,400 GPM)
AND VENTURI PRESSURE DROP (3 TO 9 INCHES H20) . WITH 4 TO 6 GR/DSCF PARTICULATE IN THE
INLET, TYPICAL OUTLET LOADINGS WERE 0.02 TO 0.04 GR/DSCF. WHEN OPERATING WITH FLUE GAS
FROM THE ELECTROSTATIC PRECIPITATOR (0.1 TO 0.4 GR/DSCF TO THE SCRUBBER), THE SCRUBBER
OUTLET LOADING AVERAGED 0.005 GR/OSCF. THUS, ENTRAINED SLURRY FROM THE MIST ELIMINATOR
MUST HAVE BEEN LESS THAN 0.005 GR/DSCF. SIZE DISTRIBUTION DATA ARE STILL BEING ANALYZ-
ED. SULFURIC ACID MIST VALUES WERE APPROXIMATELY 2 TO 25 PPM AT THE SCRUBBER INLET AND
REMOVALS HAVE BEEN ABOUT 50 TO 75 PERCENT.
FOR THE REMAINDER OF DECEMBER THE VENTURI/SPRAY TOWER SYSTEM WAS DOWN FOR MODIFICATIONS
FOR TWO-STAGE OXIDATION TESTING. SEE APPENDIX B FOR A PROCESS FLOW DIAGRAM.
DURING NOVEMBER THE TCA WAS OPERATED WITH FLY-ASH CONTAINING FLUE GAS USING LIME SLURRY
WITHOUT ADDED MAGNESIUM OXIDE. OPERATING CONDITIONS WERE 12.5 FT/SEC GAS VELOCITY, 50
GAL/MCF L/G, 6.0 SCRUBBER INLET PH, AND & TO 15 PERCENT SLURRY SOLIUS. AT THESE CONDIT-
IONS THE S02 REMOVAL WAS ABOUT 80 PERCENT.
FLY-ASH FREE LIMESTONE TESTS WITHUUT MAGNESIUM OXIDE ADDITION BEGAN ON THE TCA SYSTEM IN
LATE NOVEMBER. TYPICAL OPERATING CONDITIONS WERE 12.5 FT/SEC GAS VELOCITY, 50 GAL/MCF
L/G, AND 1.1 TO 1.2 STOICHIOMETRIC RATIO. AT THE SAME STOICHIOME1 R Y , THE PH OF THE FLY-
ASH FREE SLURRY WAS 0.2 TO 0.3 UNITS HIGHER THAN OBSERVED IN PREVIOUS RUNS WITH FLY ASH.
JAN. 77 THE VENTURI/SPRAY TOWER SYSTEM HAS BEEN OPERATED IN A TwO-SER IES-SCRUBBER MODE WITH FORCED
FEB. 77 OXIDATION SINCE EARLY JANUARY 1977 AF1ER SYSTEM MODIFICATIONS TO ALLOW OPERATION OF THE
VENTURI AND SPRAY TOWER WITH INDEPENDENT SLURRY RECIRCULA T ION LOOPS. SULFITE OXIDATION
WAS CARRIED OUT IN AN 8 FT. DIAMETER VENTURI (PRE-SCRU6BER) EFFLUENT HOLD TANK WHICH HAD A
130 - 1/8 INCH HOLE AIR SPARGER IMMERSED IN 18 FT. UF SLURRY. THt SPRAY TOWER (AFTER
SCRUBBER) FUNCTIONED AS A PRIMARY S02 ABSORBER.
TYPICAL OPERATING CONDITIONS, USING LIMESTONE SLURRY, WERE 6.7 FT/SEC SPRAY TOWER GAS
VELOCITY, 20-30 GAL/MCF VENTURI L/G, 70 GAL/MCF SPRAY TOWER L/G, 15 PERCENT SOLIDS (WITH
FLY ASH) IN VENTURI RECIRCULATED SLURKY, 4.5-5.0 VENTURI INLET (OXIDATION TANK) PH, AND
11.3 MINUTES OXIDATION TANK RESIDENCE TIME (BASED ON 600 GPM SLURRY FLOW TO VENTURI).
DURING THESE TESTS, AVERAGE OVERALL SULFITE OXIDATION RANGED FROM 93 TO 99 PERCENT AT AIR
STOICHIOMETRIC RATIO OF 1.0 TO 4.7 LB-ATOMS OXYGEN/LB-MULE S02 ABSORBED. CORRESPONDING
AVERAGE OXIDATION IN THE SPRAY TOWER RANGED FROM 10 TO 16 PERCENT. AVERAGE OVERALL LIME-
STONE UTILIZATION RANGED FROM 83 TO 96 PERCENT. NO SCALING WAS EXPERIENCED IN EITHER
SCRUBBER. AVERAGE FILTER CAKE SOLIDS WERE 79 TO 86 PERCENT BY WEIGHT COMPARED WITH 55-65
PERCENT WITHOUT FORCED OXIDATION. SLURRY SOLIDS SETTLING RATE RANGED 0.5 TO 1.4 CM/MIN, 5
TO 10 TIMES FASTER THAN THAT FOR UNOXIOIZED SLURRY. FINAL SETTLED DENSITY RANGED 65-80
PERCENT SOLIDS COMPARED WITH 45-60 PERCENT FOR SLURRY WITHOUT FORCED OXIDATION.
FLY ASH-FREE LIMESTONE TESTING ON THE TCA SYSTEM WAS COMPLETED IN EARLY FEBRUARY. THE PH
OF THE FLY ASH-FREE SLURRY WAS 0.2 TO 0.3 UNITS HIGHER THAN OBSERVED IN PREVIOUS RUNS WITH
FLY ASH. IN ADDITION, THE FLY ASH-FREE SLURRY APPRtARED TO HAVE INFERIOR SOLIDS DE-
WATERING CHARACTERISTICS. FOR EXAMPLE, THE CENTRIFUGE CAKE SOLIDS AVERAGED ABOUT 50
PERCENT COMPARED WITH ABOUT 60 PERCENT FOR SLUDGE CONTAINING FLY ASH.
137
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TENNESSEE VALLEY AUTHORITY SHAWNEE UNIT NOS. 10A AND JOB
INTENSIVE FLUE SAS CHARACTERIZATION TESTING WITH LIMESTONE SLURRY ON THE TCA SYSTEM BEGAN
IN EARLY FEBRUARY AND ENDED IN EARLY MARCH 1977. PRELIMINARY ANALYSIS OF THE DATA SHOWED
AN OUTLET MASS LOADING OF 0.04-0.08 GRAIN/DSCF FOR FLUE GAS CONTAINING FLY ASH AND 0.02-
0.03 GRAINS/DSCF FOR FLUE GAS WITHDRAWN DOWNSTREAM OF THE ESP. IT WAS ESTIMATED THAT
THESE OUTLET MASS LOADINGS CONTAINED ABOUT 0.03 GRAIN/DSCF FLY ASH, 0.02 GRAIN/DSCF RE-
ENTRAINEO SLURRY SOLIDS, AND 0.015 ENTRAINED DISSOLVED SOLIDS (WHEN A CONTINUOUS MIST
ELIMINATOR UNDER WASH WAS USED). THESE VALUES VARY DEPENDING ON THE MIST ELIMINATOR WASH
SCHEME AND GAS FLOW RATE.
MAR. 77 DURING MARCH, THE VENTURI/SPRAY TOWER WAS TESTED WITH LIME SLURRY AND FLY ASH LADEN FLUE
GAS IN A TWO-STAGE SCRUBBER MODE WITH FORCED OXIDATION. OPERATION WITH LIME WAS SIMILAR
TO THE PREVIOUSLY REPORTED LIMESTONE OPERATION WITH GREATER THAN 95 PERCENT OXIDATION AT
AN AIR STOICHIOMETRIC RATIO OF 1.5 LB-ATOMS OXYGEN/LB-MOLE S02 ABSORBED WITH A SIMPLE AIR
SPARGER IN A VENTURI HOLD TANK. SLURRY SOLIDS SETTLING RATE VARIED FROM 0.6 TO 1/9 CM/MIN
(A 5 TO 10 FOLD ENHANCEMENT OVER UNOX10IZED SLURRY) AND FILTER CAKE SOLIDS RANGED FROM 74
TO 68 PERCENT (COMPARED WITH 45 TO 60 PERCENT WITH UNOXIDIZED SLURRY).
TWO MAJOR DIFFERENCES BETWEEN LIME AND LIMESTONE WERE OBSERVED IN A TWO-STAGE FORCED
OXIDATION. TO MAINTAIN PH CONTROL, IT WAS NECESSARY TO FEED LIME TO BOTH STAGES. WITH
LIMESTONE, FEED ONLY TO THE SECOND STAGE WAS ADEQUATE. TO MAINTAIN 80 PERCENT 802
REMOVAL, IT WAS NECESSARY TO OPERATE WITH HIGHER SLURRY SOLIDS CONCENTRATION IN THE SPRAY
TOWER LOOP WITH LIMESTONE (15 PERCENT) THAN WITH LIME (6 PERCENT), RESULTING IN A TIGHTER
WATER BALANCE WITH LIMESTONE AND INADEQUATE WATER TO FLUSH THE MIST ELIMINATOR.
PRELIMINARY LIMESTONE TYPE AND GRIND TESTS MADE ON THE TCA SYSTEM DURING MARCH INDICATED
THAT 802 REMOVAL IS IMPROVED BY THE USE OF FINER GROUND LIMESTONE. S02 REMOVAL WITH
EQUIVALENT GROUND FREDONIA WHITE AND LONGVIEW, ALABAMA LINESTONES WAS THE SAME.
BLEEDSTREAM FORCED OXIDATION TESTS ARE BEING CONDUCTED WITH A PENBERTHY ELL-S EJECTOR IN A
CLOSED LOOP AROUND A BLEED STREAM HOLD TANK. INITIAL TESTS WERE UNSUCCESSFUL DUE TO HIGH
PH OF 7 TO 8 IN THE HOLD TANK. BY LOWERING THE HOLD TANK PH TO 5 TO 6, SULFITE OXIDATION
UP TO 98 PERCENT WAS ACHIEVED.
APR. 77 UNIT 10 BOILER WAS SHUT DOWN FOR A SCHEDULED TWO-MONTH MAINTAINANCE OUTAGE. bECAUSE OF
MAY 77 THE BOILER OUTAGE, THE SHAWNEE SCRUBBERS WILL NOT OPERATE OURRING APRIL AND MAY.
JUN. 77 SCRUBBER OPERATION RESUMED ON JUNE 15 AFTER A 10-WEEK SCHEDULED MAINTENANCE OUTAGE ON THE
BOILER.
JUL. 77 THE VENTURI/SPRAY TOWER SYSTEM CONTINUED TO OPERATE WITH TWO SCRUBBER STAGES AND FORCED
OXIDATION BY MEANS OF AN AIR SPARGING RING IN THE VENTURI HOLD TANK. IN JUNE AND JULY,
OPERATION WAS WITH LIME SLURRY AND FLY ASH-FREE FLUE GAS. THE SYSTEM PERFORMED WELL WITH
LITTLE DIFFERENCE FROM THE PREVIOUS LIME SLURRY TEST BLOCK WHEN THERE WAS FLY ASH IN THE
FLUE GAS. TYPICAL RESULTS WERE ABOUT 97 PERCENT SULFITE OXIDATION AT AN AIR STOICHIOMETRY
OF 1.6 LB-ATOMS OXYGEN/LB-MOLE S02 ABSORBED AND AN OXIDATION TANK PH OF 5.5. TYPICAL
SOLIDS SETTLING RATE WAS ABOUT 2 CM/MIN (AN ORDER OF MAGNITUDE BETTER THAN WITH UNOXIDIZED
SLURRY) AND FILTER CAKE SOLIDS CONCENTRATION AVERAGED ABOUT so PERCENT (COMPARED WITH 45
TO 60 PERCENT WITH UNOXIDIZEO SLURRY).
THE TCA SYSTEM OPERATED WITH FORCED OXIDATION IN THE HOLD TANK ACHIEVED BY CIRCULATING
SLURRY THROUGH AN AIR EOUCTOR. IN JUNE AND JULY, OPERATION WAS WITH LIMESTONE SLURRY AND
FLY ASH IN THE FLUE GAS. SULFITE OXIDATION WAS POOR IN INITIAL TEST (LESS THAN 90 PER-
CENT) MAINLY BECAUSE OF INADEQUATE AIR/SLURRY CONTACT IN THE HOLD TANK. BY INCREASING
AGITATOR SPEED (TO 68 RPM), HOLD TANK SLURRY LEVEL (TO 12FT) AND DECREASING PH (TO LESS
THAN 5.5) IN THE SLURRY TO THE EDUCTOR, SULFITE OXIDATION ABOVE 90 PERCENT HAS CONSIS-
TANTLY ACHIEVED AT AN AIR STOICHIOMETRY OF ABOUT 4.5 LB/ATOMS OXYGEN/LB-MOLE 802 ABSORBED.
WASTE SOLIDS PROPERTIES WERE ENHANCED WITH OXIDATION TO ABOUT THE SAME EXTENT AS OBSERVED
IN THE VENTURI/SPRAY TOWER SYSTEM. ADDITIONAL TESTING WILL BE DIRECTED TOWARD ACHIEVING
90 PERCENT OR BETTER SULFITE OXIDATION AT A REDUCED AIR STOICHIOMETHY.
AUG. 77 THE VENTURI/SPRAY TOWER SYSTEM CONTINUED TO OPERATE WITH TWO SCRUBBER STAGES AND FORCED
SEP. 77 OXIDATION USING AN AIR SPARGER IN THE VENTURI HOLD TANK. OPERATION DURING AUGUST AND
SEPTEMBER WAS WITH LIMESTONE SLURRY AND FLUE GAS WITH LOW FLY ASH LOADING (FLUE GAS FROM
DOWNSTREAM OF THE ESP). THE SYSTEM PERFORMED WELL AT 4.5 TO 5.0 OXIDATION PH, WITH LITTLE
DIFFERENCE FROM THE PREVIOUS LIMESTONE TESTS WHEN THE FLUE GAS HAD HIGH FLY ASH LOADING.
(THE PREVIOUS TESTS WERE MADE ONLY AT OXIDATION PH OF 4,5 AND 5.0).
FOR THE AUGUST AND SEPTEMBER TESTS, THE OXIDATION PH WAS FURTHER INCREASED TO 5.5, AP-
PROACHING THE PH IN THE SPRAY TOWER. THIS CAUSED SOME DIFFICULTIES IN THE OXIDATION PH
CONTROL AND WIDER FLUCTUATIONS IN VENTURI AND SPRAY TOWER LIMESTONE STOICHIOMETRIC RATIUS.
HOWEVER, NEAR COMPLETE OXIDATION WAS STILL ACHIEVED AT THE HIGHER PH. TYPICAL RESULTS
WERE BETTER THAN 97 PERCENT SULFITE OXIDATION AT AN AIR STOICHIOMETKY OF 1.7 ATOMS OXYGEN/
MOLE S02 ABSORBED AND AN OXIDATION PH OF 5.5. THE FILTER CAKE SOLIDS CONTENT AVERAGED
BETTER THAN 85 PERCENT. TESTS WERE ALSO CONDUCTED WITHOUT THE DESUPERSATUHATION TANK IN
THE VENTURI SLURRY LOOP AND WITH THE OXIDATION TANK LEVEL DROPPED FHOM 18 TO 14 FT rtlTHOUT
ADVERSE EFFECTS.
DURING AUGUST AND SEPTEMBER, THE TCA SYSTEM WAS OPERATED MOSTLY IN A TWO-TANK FORCED
OXIDATION MODE USING AN AIR EDUCTOR. THE TCA EFFLUENT (LIMESTONE SLURRY WITH HIGH FLY ASH
LOADING) WAS COLLECTED IN A SMALL LOW-PH SLURRY HOLD TANK AND THEN PUMPED THROUGH THE AIR
EOUCTOR TO THE REGULAR HOLD TANK WHERE LIMESTONE WAS ADDED, THUS TAKING THE ADVANTAGE OF
THE LOW PH SLURRY THROUGH THE AIR EOUCTOR FOR IMPROVED SULFITE OXIDATION AND HIGH PH
SLURRY TO TCA FOR BETTER S02 REMOVAL.
133
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TENNESSEE VALLEY AUTHORITY CLJ,,ir,
SHAWNEfc UNIT NUS. 10A AND lllb
TESTS WERE MADE BOTH WITH THE AIR EDUCTOR MOUNTED ON TOP OF THE FFFlilFNT urn n T K
DOWNWARD SLURRY DISCHARGE, AND WITH THE EDUCTUR MOUNTED oS'sol OF T"HF TANK w, i / "
DISCHARGE TO THE BOTTOM OF THE TANK. AVERAGE SULFITE OXIDATION RANGED J£nM » in*^'*'
PERCENT AT ABOUT 2.5 AIR STOICHiOMETRY AND 5.2 EOUCTOR NLE °H KNG ?"u OF ?HF hllNS
MADE IN AUGUST WHEN THE ROTARY DRUM FILTER WAS USED, THE FILTER CAKE SOLlis CONTFM
AVERAGED 85 AND 86 PERCENT. riuitu LAKt SOLIDS CONTENT
A TEN-DAY RUN WAS MADE IN SEPTEMBER ON THE TCA SYSTEM WITH AUTOMATIC LIMESTONE FEFt) CON
TROL BASED ON STOICHIOMETRY . THE LIMESTONE SLURRY FEED RATE WAS C "
" C°NCENTRAT ION« THE «"«OL SYSTEM
OCT. 77 THE VENTURI/SPRAY TOWER SYSTEM CONTINUED TO OPERATED WITH TWO SCRUBBER STAGES AND FuRCED
NUV. 77 OXIDATION IN THE VENTURI HOLD TANK. IN OCTOBER, THE FOLLOWING IMPRUVtMENTS WERE MADE WITH
NO SIGNIFICANT DROP IN OXIDATION EFFICIENCY AND WITH SATISFACTORY S02 REMOVAL EFFICIENCY
• THE SPRAY TOWER GAS VELOCITY WAS INCREASED FROM 6.7 TO 9.4 FT/SEC. cr r int MI. T .
•THE OXIDATION TANK LEVEL WAS DROPPED FRUM 18 FT TO la FT.
*TME AIR SPARGER RING, CONTAINING no IM-INCH DIAMETER HOLES, WAS REPLACED WITH A
SINGLE 3-INCH DIAMETER PIPE DISCHARGING DOWNWARD AT THE CENTER OF THE OXIDATION TANK
3 INCHES FROM THE BOTTOM.
WITH AIR DISCHARGED FROM AN OPEN-ENDED PIPE IT WAS APPARENT THAT AIR DISPERSION IN THE
OXIDATION TANK WAS ACCOMPLISHED MAINLY BY THE TURBINE AGITATOR RATHER THAN THE SPARGER.
IN NOVEMBER, A ONE-MONTH RELIABILITY TEST WAS STARTED ON THE VENTUFU/SPRA Y TOWER SYSTEM
USING FORCED OXIDATION WITH TWO SCRUBBER STAGES AND LIMESTONE SLURRY WITH HIGH FLY ASH
LOADING. THE FLUE GAS RATE TO THE SCRUBBER SYSTEM WAS VARIED ACCORDING TO THE bOILER LUAD
WHICH RANGED BETWEEN 100 AND 155 MW. TEST CONDITIONS WERE SELECTED TO MEET THE EPA NEW
SOURCE PERFORMANCE STANDARDS OF 1.2 LBS S02 AND 0.1 LB PAKTICULATE PER MILLION BTU. THIS
RUN WAS STILL IN PROGRESS AT THE END OF NOVEMBER. ON THE TCA SYSTEM, FORCED OXIDATION
WITH A SINGLE SCRUBBER STAGE USING AN AIR EDUCTOR WAS DISCONTINUED IN EAhLV OCTOBER AFTtR
A HOLE ERODED THROUGH THE EDUCTOR BODY. FORCED OXIDATION TESTING WILL BE RESUMED IN EARLY
DECEMBER AFTER AN AIR SPARGER IS INSTALLED.
IN OCTOBER-NOVEMBER, A ONE-MONTH RELIABILITY TEST WITHOUT FORCED OXIDATION WAS CONDUCTED
ON THE TCA SYSTEM WITH LIMESTONE SLURRY, FLUE GAS WITH HIGH FLY ASH LOADING, THREE HOLD
TANKS IN SERIES, AND 7.5 INCHES STATIC HEIGHT OF NITRILt FOAM SPHERES IN EACH UF 3 BEOS IN
THE TCA. GAS RATE TO THE SCRUBBER WAS VARIED WITH BOILER LOAD AND STOICHIOMETRIC RATIU
WAS CONTROLLED BY AN AUTOMATIC LIMESTONE FEED SYSTEM. CONDITIONS WERE SELECTED TO MEET
THE EPA NEW SOURCE PERFORMANCE STANDARDS AT A LOW STOICHIOMETRIC RATIO OF 1 .2 MOLES CA/
MOLE 302 ABSORBED. THE AVERAGE SU2 REMOVAL FOR THE ENTIRE RUN WAS 86 PERCENT AT 2800 PPM
WHICH WAS BETTER THAN THE 83 PERCENT REQUIRED TO MEET TEHE EMISSIONS STANDARD. HOWEVER,
THE STANDARD WAS FREQUENTLY EXCEEDED FOR PERIODS GREATER IHAN THE 3 HOURS ALLOWED BY THE
EPA REGULATIONS. AVERAGE OUTLET PARTICULATE MASS LOADING WAS 0.043 GRAIN/SCF DRY WHICH
WAS BETTER THAN THE 0.052 GRAIN/SCF DRY CAT 30 PERCENT EXCESS AIR) REQUIRED TO MEET THE
STANDARD. THE RANGE OF THE OUTLET MASS LOADING WAS 0.026 TO 0.069 GRAIN/SCF DRY.
DEC. 77 A LIMESTONE RELIABILITY TEST ON THE VENTURI/SPRAY TOWER SYSTEM WAS COMPLETED IN MID-
JAN. 78 DECEMBER, 1977 AFTER 965 OPERATING HOURS. THE TEST WAS CONDUCTED WITH TWO SCRUBBER
LOOPS WITH FORCED OXIDATION IN THE FIRST (VENTURIS LOOP. THE FLUE GAS FLOW RATE WAS
VARIED ACCORDING TO THE BOILER LOAD WHICH RANGED BETWEEN 100 AND 155 MW.
TEST CONDITIONS WERE SELECTED TO MEET THE EPA NEW SOURCE PERFORMANCE STANDARDS OF
1.2 LB S02 AND 0.1 LB PARUCULATE PER MILLION BTU. THE OPERATING RELIABILITY OF THE
SYSTEM WAS DEMONSTRATED. HOWEVER, DUE TO WIDE VARIATION IN THE INLET 302 CONCENTRA-
TION C2500-3aOO PPM) AND THE SLOW SYSTEM RESPONSE TIME, THE 302 EMISSION STANDARD WAS
FREQUENTLY EXCEEDED FOR PERIODS GREATER THAN THE THREE HOURS ALLOWED BY EPA REGULA-
TIONS. AVERAGE S02 REMOVAL FOR THE ENTIRE RUN WAS 86 PERCENT AT 2950 PPM AVERAGE
INLET S02, WHICH WAS HIGHER THAN THE 8« PERCENT REQUIRED TO MEET THE STANDARD FOR
2800 PPM INLET S02. THE OUTLET PARTICULATE LOADING RANGED FROM 0.021 TO 0.063
GRAIN/DRY SCF, WITH A RUN AVERAGE OF 0.042 GRAIN/DRY SCF. THESE VALUES COMPARE WITH
A LOADING OF 0.052 GRAIN/DRY SCF OR LESS REQUIRED TO MEET THE EPA PARTICOLATE STAN-
DARD, ASSUMING 30 PERCENT TOTAL BOILER EXCESS AIR.
ANOTHER RELIABILITY RUN ON THE VENTURI/SPRAY TOWER SYSTEM WAS STARTED IN MID DECEMBER
USING LIME SCRUBBING. THE RUN WAS COMPLETED IN JANUARY 1978. WITH THE EXCEPTION OF
HIGHER SPRAY TOWER INLET PH AND HIGHER ALKALI UTILIZATION INHERENT WITH THE LIME
SYSTEM, THE OPERATING CONDITIONS AND THE TEST RESULTS WERE SIMILIAR TO THOSE UF THE
LIMESTONE RELIABILITY RUN.
ON THE TCA SYSTEM, TWO RUNS WERE MADE WITH THE NITRILE FOAM SPHERES REPLACED BY A 46
INCH HEIGHTH 123 LAYERS) OF CEILC01E PACKING SUPPORT PLATES. AT FULL GAS FLOW RATE
OF 30,000 ACFM, THE S02 REMOVAL FOR THE CEILCOTt PLATES WAS SLIGHTLY LESS THAN THAT
OF A 3-BED, 4-GRID TCA WITH FIVE INCHES OF STATIC SPHERE HEIGHT "H BED. HO«£VER,
AT 18,000 ACFM, THE SU2 REMOVAL FOR THE CEILCOTE PLATES WAS A FEW PERCENTAGE POINTS
HIGHER THAN EXPERIENCED WITH THE TCA BEDS.
FORCED OXIDATION TESTS WERE CONDUCTED ON THE TCA SYSTEM WITH AN *«
LIMESTONE SLURRY WITH HIGH FLY ASH LOADING. BOTH ONE-TANK CAIR SPARGING AND LIME-
139
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TENNESSEE VALLEY AUTHORITY SHAWNEE UNIT NOS. 10A AND 1UB
STONE ADDITION IN THE SAME TANK) AND TWO-TANK (AIR SPARGING IN THE F IRST !*£[* .
LIMESTONE AUDITION IN THE SECOND) CONHGURAT IONS WERE USED. NEAR COMPLfc ]*
OXIDATION WAS ACHIEVED IN BOTH CONFIGURATION AT AN AIH STUICHIOMETRT OF i.o
OXYGEN/MOLE S02 ABSORBED AND OXIDATION TANK PH OF 5.1-5.7. THE OXIDATION TANK LtVtL
WAS 18 FT.
140
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TABLE 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
TENNESSEE VALLEY AUTHORITY
WIDOWS CREEK NO. 6
BRIDGEPORT ALABAMA
550 MW
COAL 3.7 PERCENT SULFUR
TENNESSEE VALLEY AUTHORITY
LIMESTONE SCRUBBING
RETROFIT
b/77
OPERATIONAL
99.5 PERCENT
SOS
80 PERCENT
MATER MAKE UP
SLUDGE DISPOSAL
100-ACRE DIKED POND
UNIT COST
SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 5 OF THIS REPORT.
THE EMISSION CONTROL SYSTEM FOR THIS 550-MW COAL-FIRED POnER-GENERATING
UNIT CONSISTS OF EXISTING ELECTROSTATIC PKECIPITATOKS FOLLOWED bY FOUR
PARALLEL SCRUBBING TRAINS, EACH CAPABLE OF HANDLING 25 PERCENT OF THE
BOILER FLUE GAS FROM UNIT NO. 6. EACH TRAIN INCLUDES A RECTANGULAR-
THROAT VENTURI SCRUBBER AND A GRID-TOWER ABSORBER SUPPLIED BY POLYGON.
THE GRID TOWER CAN BE CONVERTED TO A MOblLE-BED TOWER IF GREATER S0£ RE-
MOVAL IS REQUIRED.
141
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BACKGROUND INFORMATION
ON
WIDOWS CKEEK NO. &
IN MID-1970, TENNESSEE VALLEY AUTHORITY DECIDED TO INSTALL A FULL-SCALE DEMONSTRATION LIMESTONE
SCRUBBING S02 REMOVAL SYSTEM ON GENERATING UNIT NO. 8 AT THE WIDOWS CHEEK PLANT. THE PRIMARY
OBJECTIVE WAS TO WORK OUT DESIGN AND OPERATING PROBLEMS IN S02 REMOVAL OPERATIONS AS A PREPARATION
FOR THE POSSIBILITY OF FUTURE TVA F6D OPERATIONS.
THE WIDOW CREEK POWER STATION IS LOCATED IN NORTHEAST ALABAMA, NEAR CHATTANOOGA, TENNESSEE.
UNIT NO. 8 IS A COAL-FIRED BOILER WITH A MAXIMUM GENERATING CAPACITY OF 550 MW, AND A MAXIMUM STACK
GAS RATE OF 1,600,000 CFM AT £80 DEGREES F. THE BOILER AND ESP UNITS WERE COMMISSIONED BY TVA IN
1963.
THE WET LIMESTONE FGD SYSTEM AT WIDOWS CREEK WAS PLACED IN SERVICE ON MAY 16, 19/7. THE SYSTEM
CONSISTS OF FOUR IDENTICAL SCRUBBING MODULES (IDENTIFIED AS A, B, C, AND D) EACH HANDLING 25 PERCENT
OF THE FLUE GAS FROM UNIT NO. 8. LIMESTONE STORAGE AND MILLING FACILITIES AND A SLUDGE DISPOSAL
POND ARE ALSO LOCATED ON SITE.
FLUE GAS ENTERING THE SCRUBBING MODULE FROM THE EXISTING ELECTROSTATIC PRECIPITATORS PASSES
THROUGH A «00,000 ACFM CAPACITY F.D. FAN AND INTO THE VENTURI. THE VENTURI SCRUBBER IS A REC-
TANGULAR THROAT DESIGN USED TO SATURATE, AND REMOVE FLYASH FROM THE GAS. DUE TO THE INEFFICIENCY OF
THE OLD ESP UNITS, LARGE VENTURI SCRUBBERS WERE REQUIRED IN ALL MODULES TO REMOVE PARTICULATES. 302
REMOVAL EFFICIENCY IN THE VENTURI IS ABOUT 10 PERCENT. THE ABSORBER IS A GRID TYPE ABSORPTION TOWEK
WHICH WAS SUPPLIED BY POLYGON. THE GRID TOWER WILL BE USED INITIALLY AS A SPRAY TOWER AND WILL
OPERATE AT A LIQUID-TO-GAS RATIO OF 50. THE S02 REMOVAL EFFICIENCY FOR THE ABSORBER IS ABOUT 70X,
GIVING A COMBINED SCRUBBER DESIGN EFFICIENCY OF ABOUT 80 PERCENT FOR THE ABSORBER AND VENTURI
TOGETHER. THE ENTRAINMENT SEPARATOR IS A CHEVRON VANE TYPE U PASS) LOCATED VERTICALLY IN A HORI-
ZONTAL SHELL. THE REHEAT SYSTEM CONSISTS OF A STEAM/HOT AIR INJECTION SYSTEM RAISING THE FLUE GAS
TO AN OUTLET TEMPERATURE OF 175 F.
LIMESTONE HANDLING AND MILLING EQUIPMENT INCLUDES A SHAKER FOR TRUCK AND RAIL UNLOADING, A LIVE
STORAGE SILO, A WET BALL MILL, AND A CYCLONE CLASSIFIER. THE GRINDING SYSTEM IS DESIGNED TO PRODUCE
A GROUND PARTICLE SIZE OF 90 PERCNET MINUS £00 MESH AT THE DESIGN RATE OF 50 TONS PER HOUR DRY
LIMESTONE. THE UNLOADING AND STORAGE FACILITIES UP TO AND INCLUDING THE LIVE STORAGE SILO ARE DE-
SIGNED TO ACCOMODATE A FUTURE LIMESTONE SCRUBBING FACILITY ON WIDOWS CREEK UNIT NO. 7.
WASTE BY-PRODUCT SOLIDS FROM THE SCRUBBING FACILITY WILL BE DISPOSED OF IN A DIKED POND 100
ACRES IN AREA BY 30 FEET IN HEIGHT. AN ADDITIONAL 10 FEET IN HEIGHT MAY BE ADDED TO YIELD A TOTAL
SLUDGE STORAGE CAPACITY OF 5.a MM. CUBIC YARDS, OR 10 YEARS OF SCRUBBER EFFLUENT STORAGE. THE
SLUDGE, CONSISTING OF FLYASH, REACTION PRODUCTS (HYDRATES OF CALCIUM SULFITE AND SULFATE) AND UN-
REACTED LIMESTONE IS PUMPED TO THE POND AS A 15-16 PERCENT SOLIDS SOLUTION.
THE WIDOWS CREEK NO. 8 SCRUBBING UNIT IS DESIGNED TO BE AS FLEXIBLE AS POSSIBLE. A LARGE
RESERVOIR OF QUENCH WATER IS LOCATED ABOVE THE ABSORBER TO GRAVITY FEED WATER TO THE TOWER IN CASE
OF POWER FAILURE, THEREBY SAVING THE ABSORBER AND RUBBER LINING. THE ABSORBER CAN BE OPERATED AS A
MULTI-GRID, TURBULENT CONTACT, OR SPRAY TOWER ABSORBER. PROVISIONS HAVE BEEN MADE IN THE ABSORBER
DESIGN SO THAT IT CAN READILY BE CONVERTED TO A MOBILE BED TYPE ABSORBER SHOULD IT PROVE DESIRABLE
IN THE FUTURE TO OBTAIN IMPROVED S02 REMOVAL.
ADDITIONAL INFORMATION AND DATA ARE PROVIDED IN THE PERFORMANCE HISTORY TABLE THAT FOLLOWS.
A SCHEMATIC DIAGRAM OF THE WIDOWS CREEK SCRUBBER PLANT IS PROVIDED IN APPENDIX B OF THIS REPORT.
•INITIAL OPERATING EXPERIENCE*
VIRTUALLY ALL MAJOR CONSTRUCTION ON THE SCRUBBER PLANT WAS COMPLETED DURING THE FIRST QUARTER OF
1977. STARTUP AND SHAKEDOWN PROCEDURES COMMENCED OFFICIALLY ON APRIL 30, 1977. OPERATIONS DURING
THIS INITIAL MECHANICAL SHAKEDOWN AND DEBUGGING PHASE OF OPERATIONS FOR THIS FOUR TRAIN WET LIME-
STONE SCRUBBING SYSTEM CONTINUED THROUGHOUT THE SUMMER. COMMERCIAL SCRUBBER PLANT OPERATION COM-
MENCED SOMETIME IN LATE SEPTEMBER. THE UTILITY REPORTED A NUMBER OF PROBLEMS WITH BOTH THE BOILER
SIDE AND THE SCRUBBER SIDE. ALL FOUR SCRUBBER MODULES HAD NOT BEEN IN SERVICE SIMULTANEOUSLY.
142
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TENNESSEE VALLEY AUTHORITY
-------
TABLE 3
PERFORMANCE DESCRIPTION FOk OPERATIONAL FGD SYSTEMS THROUGH 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCYr
PARTICULATES
TEXAS UTILITIES CO.
MARTIN LAKE NU. 1
TATUM TEXAS
793 MW
COAL 1.0 PERCENT SULFUR
RESEARCH COTTRELL
LIMESTONE SCRUBBING
NEW
6/77
OPERATIONAL
99.
-------
BACKGROUND INFORMATION
ON
MARTIN LAKE NO, 1
INITIAL OPERATING EXPERIENCE
THE INSTALLATION OF THE LIMESTONE SCRUBBING SYSTEM AND THE ESP HAS OVER IN OCTDBFR 77 4s srncnm Pn
THE UTILITY HAS EXPERIENCED SOME DIFFICULTIES !N THt SLUHHY HANDLING SYSTEM? ?HE IN TUL OPIATING
PHASE IS EXPECTED TO CONTINUE THROUGH FIRST UUANTER OF 77. COMPLIANCE TEST NG WAS CONDUCTED IN
LATE 77, AND CERTIFICATION OF COMMERCIAL AVAILABILITY IS AWAITED '"'^6 rtAS CONDUCTED IN
145
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TABLE «
SUMMARY OF FGO SYSTEMS BY COMPANY
•STATUS-
UTILITY
ALABAMA ELECTRIC COOP
ALLEGHENY POWER SYSTEM
ARIZONA ELECTRIC POWER COOP
ARIZONA PUBLIC SERVICE
BASIN ELECTRIC POWER COOP
BIG RIVERS ELECTRIC COOP CORP.
BOARD OF MUNICIPAL UTILITIES
BRAZOS ELECTRIC POWER COOP
CENTRAL ILLINOIS LIGHT CO.
CENTRAL ILLINOIS PUBLIC SERV
CENTRAL MAINE POWER CO.
CINCINNATI GAS & ELECTRIC CO.
COLORADO UTE ELECTRIC ASSN.
COLUMBUS & SOUTHERN OHIO ELEC.
COMMONWEALTH EDISON
DELMARVA POWER CO.
DUQUESNE LIGHT
EASTERN KENTUCKY POWER COOP
HOOSIER COOPERATIVE
INDIANAPOLIS POWER & LIGHT CO.
KANSAS CITY POWER & LIGHT
KANSAS POWER & LIGHT
KENTUCKY UTILITIES
LAKELAND UTILITIES
LOUISVILLE GAS & ELECTRIC
MINNESOTA POWER AND LIGHT CO.
MINNKOTA POWER COOPERATIVE
MONTANA POWER CO.
NEVADA POWER
NEW ENGLAND ELEC SYSTEM
NIAGARA MOHAWK POWER COOP.
NORTHERN INDIANA PUB SERVICE
NORTHERN STATES POWER CO.
OTTER TAIL POWER COMPANY
PACIFIC GAS AND ELECTRIC
PACIFIC POWER AND LIGHT CO.
PENNSYLVANIA POWER CO.
PHILADELPHIA ELECTRIC CO.
PUBLIC SERVICE CO OF NEW MEX.
PUBLIC SERVICE OF INDIANA
SALT RIVER PROJECT
SOUTH CAROLINA PUBLIC SERVICE
SOUTHERN ILLINOIS POWER COOP
SOUTHERN INDIANA GAS&ELECTRIC
SOUTHERN MISSISSIPPI ELECTRIC
SPRINGFIELD CITY UTILITIES
SPRINGFIELD WATER LIGHTSPOWER
TENNESSEE VALLEY AUTHORITY
TEXAS MUNICIPAL POWER AGENCY
TEXAS POftEK AND LIGHT CO.
TEXAS UTILITIES CO.
UNITED POWER ASSOCIATION
UTAH POWER & LIGHT CO.
WISCONSIN POWER & LIGHT CO.
TOTAL
OPERATIONAL CONSTRUCTION
CONTRACT PLANNE
AWARDED
NO
2
2
2
8
5
2
1
1
2
1
I
1
2
4
1
1
2
1
2
2
3
4
1
1
6
1
1
4
10
1
1
3
4
1
2
1
3
4
It
1
3
2
1
1
2
1
1
4
1
3
b
2
2
1
MW
450.
1250.
400.
2804.
2550.
490.
235.
400.
800.
575.
600,
600.
900.
1550.
425.
180.
920.
500.
980.
1060.
1060.
1885.
64.
350.
2283.
500.
450.
2120.
3000.
650.
100.
705.
3140.
400.
1600.
509.
2475.
646.
1715.
650.
1050.
580.
184.
250.
360.
200.
190.
1115.
400.
2045.
4672.
1090.
815.
527.
NO
0
0
0
1
0
0
0
0
0
0
0
0
0
1
0
0
2
0
0
1
3
2
1
0
2
0
1
2
3
0
0
1
2
0
0
0
2
1
0
0
0
1
0
0
0
1
0
3
0
0
1
0
0
(1
MW
0.
0.
0.
115.
0.
0.
0.
0.
0.
0.
0.
0.
0.
400.
0.
0.
920.
0.
0.
530.
1060.
525.
64.
0.
243.
0.
450.
720.
375.
0.
0.
115.
1420.
0.
0.
0.
1650.
120.
0.
0.
0.
280.
0.
0.
0.
200.
0.
570.
0.
0.
793.
0.
0.
0.
NO
2
2
2
1
0
2
0
1
1
1
0
0
2
1
1
1
0
0
0
0
0
2
0
0
4
0
0
0
0
0
0
0
0
0
0
1
0
0
2
0
0
0
1
1
2
0
0
0
0
1
1
2
2
0
MW
450.
1250.
400.
250.
0.
490.
0.
400.
400.
575.
0.
0.
900.
400.
425.
180.
0.
0.
0.
0.
0.
1360.
0.
0.
1380.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
509.
0.
0.
715.
0.
0.
0.
184.
250.
360.
0.
0.
0.
0.
545.
2336.
1090.
815.
0.
NO
0
0
0
1
2
0
1
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
2
0
0
1
0
2
1
0
0
1
0
0
0
2
0
0
0
0
0
1
1
1
0
1
0
0
1
MW
0.
0.
0.
350.
1100.
0.
235.
0.
0.
0.
0.
600.
0.
0.
0.
0.
0.
0.
u.
0.
0.
0.
0.
0.
0.
500.
0.
1400.
0.
0.
100.
0.
1720.
400.
0.
0.
825.
0.
0.
0.
700.
0.
0.
0.
0.
0.
190.
575.
400.
0.
793.
0.
0.
527.
NO
0
0
0
5
3
0
0
0
1
0
1
0
0
2
0
0
0
1
2
1
0
0
0
1
2
0
0
0
7
1
0
2
0
0
2
0
0
3
2
1
1
1
0
0
0
0
0
0
0
2
1
0
0
0
MW
0.
0.
0.
2089.
1450.
0.
0.
0.
40U.
0.
600.
0.
0.
750.
0.
0.
0.
500.
960.
530.
0.
0.
0.
350.
660.
0.
0.
0.
2625.
6bO.
0.
590.
0.
0.
1600.
0.
0.
726.
1000.
650.
350.
300.
0.
0.
0.
0.
0.
0.
0.
1500.
750.
0.
0.
0.
TOTALS
131 55679. 31 10550. 38 15661. 20 10115. 42 19050.
NOTE - PLANNED STATUS INCLUDES LETTER OF IlMTENT SIGNED, REQUESTING/EVALUTING BIDS,
AND CONSIDERING ONLY FGU SYSTEMS
146
-------
TABLE 5
SUMMARY OF FGO SYSTEMS BY VENOUR
TOTAL
MANUFACTURER/PROCESS
AOL/COMBUSTION EQUIP ASSOCIATE
DOUBLE ALKALI SCRUBBING
LIME/ALKALINE FLYASH SCRUBBING
SODIUM CARBONATE SCRUBBING
TOTAL -
AMERICAN AIR FILTER
LIME SCRUBBING
TOTAL -
ATOMICS INTERNATIONAL
AQUEOUS CARBONATE SCRUBBING
TUTAL -
BA6COCK & WILCOX
LIME SCRUBBING
LIMESTONE SCRUBBING
TOTAL -
BUELL/ENVIROTECH
DOUBLE ALKALI SCRUBBING
TOTAL -
CHEMICO
LIME SCRUBBING
LIME/ALKALINE FLYASH SCRUBBING
LIME/LIMESTONE SCRUBBING
LIMESTONE SCRUBBING
TOTAL -
COMBUSTION ENGINEERING
LIME SCRUBBING
LIMESTONE SCRUBBING
TOTAL -
DAVY POWERGAS
WELLMAN LORD
TOTAL -
DAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
TOTAL -
FMC CORPORATION
DOUBLE ALKALI SCRUBBING
TOTAL -
PEABOOY ENGINEERING
LIME/ALKALINE FLYASH SCRUBBING
LIMESTONE SCRUBBING
TOTAL -
PULLMAN KELLOGG
LIME SCRUBBING
LIMESTONE SCRUBBING
TOTAL -
RESEARCH COTTRELL
LIMESTONE SCRUBBING
TOTAL -
"ILEY STOKER / ENVIRONEERING
LIMESTONE SCRUBBING
TOTAL -
NO.
1
5
3
9
b
6
1
1
3
5
8
1
1
b
1
1
1
9
b
11
17
1
1
3
3
1
1
1
4
5
1
2
3
12
12
3
3
M\N
£77.
2570.
375.
3222.
1652.
1652.
100.
100.
1B50.
1919.
37b9.
575.
575.
3385.
527.
10.
750.
1672.
1570.
6545.
8123.
180.
180.
830.
830.
250.
250.
500.
1350.
1850.
825.
700.
1525.
5577.
5577.
760.
760.
OPERATIONAL
NO.
0
3
3
6
2
2
0
0
0
2
2
0
0
4
0
1
0
5
3
4
7
0
0
1
1
0
0
0
0
0
0
0
0
2
2
0
0
MW
0.
1170.
375.
1515.
242.
242.
0.
0.
0.
1100.
1100.
0.
0.
2570.
0.
10.
0.
2580.
305.
1945.
2250.
0.
0.
115.
115.
0.
0.
0.
0.
0.
0.
0.
0.
908.
908.
0.
0.
CufxSTkUCTIUN
WO.
1
0
0
1
4
4
0
0
2
2
4
1
1
2
U
u
1
3
3
3
b
1
1
2
2
1
1
0
4
4
0
0
0
5
5
3
3
MA
277.
0.
0.
277 .
1410.
1410.
0.
0.
1250.
584.
1834.
575.
575.
815.
0.
0.
750.
1565.
1273.
1905.
3178.
180.
180.
715.
715.
250.
250.
0.
1350.
1350.
0.
0.
0.
2236.
2236.
760.
760.
CONTKACf
AhA&DED
NO.
0
2
0
2
0
0
1
1
1
1
2
0
0
0
1
0
0
1
0
4
4
0
0
0
0
0
0
1
0
1
1
2
3
5
5
0
0
Mn
0.
1400.
0.
1400.
0.
0.
100.
100.
600.
235.
835.
0.
0.
0.
527.
0.
0.
527.
0.
2695.
2t>95.
0.
0.
0.
0.
0.
0.
500.
0 .
500.
825.
700.
1525.
2433.
2433.
0.
0.
TENNESSEE VALLEY AUTHORITY
LIMESTONE SCRUBBING
550.
1 550.
0.
147
-------
TABLE 5
SUMMARY OF FGD SYSTEMS BY VENDOR
. STATUS--- —
TOTAL OPERATIONAL CONSTRUCTION CONTRACT
AWARDED
MANUFACTURER/PROCESS
NO.
NO.
MW
NO.
MO.
TOTAL - 1 550. 1 550. 0 0. 0 0.
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING 1 120. 1 120. 0 0. 0 0.
TOTAL - i 120. i I2u. o o. o u.
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING 2 800. 1 400. 1 400. 0 0.
LIME/LIMtSlONE SCRUBBING I 10. 1 10. 0 0. 0 0.
LIMESTONE SCRUBBING 3 1155. 2 730. 1 425. 0 0.
SODIUM CARBONATE SCRUBBING i bos. o o. i 509. o o.
TOTAL - / 2474. « 1140. 3 1331. 0 0.
WHEELABRATOR-FRYE/A.I.
AQUEOUS CARBONATE/FAB. FILTER 1 400. 0 0. 0 0. 1 400.
TOTAL - 1 400. 0 0. 0 0. I 400.
89 36629.
31 10550.
3S 15664.
£0 10415.
148
-------
TABLE fa
SUMMARY OF NEW AND RETROFIT FGO SYSTEMS bY
NEW OR OPERATIONAL CONSTRUCTION CONTRACT
PROCESS RETROFIT AWARDED
LIME SCRUBBING
LIME/ALKALINE FLYASH SCRUBBING
LIME/LIMESTONE SCRUBBING
LIMESTONE SCRUBBING
SUBTOTAL - LIME/LIMESTONE
AQUEOUS CARBONATE SCRUBBING
AQUEOUS CARBONATE/FAB. FILTER
DOUBLE ALKALI SCRUBBING
MAGNESIUM OXIDE SCRUBBING
NOT SELECTED
REGENERABLE NOT SELECTED
SODIUM CARBONATE SCRUBBING
WELLMAN LORD
WELLMAN LORD/ALLIED CHEMICAL
TOTALS
LIME/LIMESTONE % Of TOTAL MW
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
N
R
NU,
3
7
3
0
0
£
e
3
14.
12.
0
0
0
0
o
0
0
1
0
0
0
0
1
2
U
0
0
1
15.
16.
, MW
£050
1467
1170
0
0
20
14<43
790
7663.
2277.
0
0
0
0
0
0
0
120
0
0
0
0
125
250
0
0
0
115
77B8.
2762.
98
82
NU
11
1
0
0
0
0
18
1
29.
2.
0
0
0
0
2
1
0
0
0
0
0
0
I
0
0
1
1
1
33.
5.
. MM
4965
183
0
U
0
0
7585
425
12550.
boa.
0
0
0
0
825
277
0
0
0
0
0
0
509
0
0
160
375
340
14259.
1405.
86
43
NO
2
0
4
0
0
0
11
1
17.
1.
0
1
1
0
0
U
U
0
0
0
0
0
0
0
0
0
0
0
18.
2.
. MA
1425
U
2427
0
0
0
5488
575
9340.
575.
0
100
400
0
0
0
0
0
0
0
0
0
0
0
U
0
0
0
9740.
675.
96
85
PROCESS
PLANNED
NO
0
2
0
3
0
0
8
0
8.
5.
0
0
0
0
0
0
0
3
18
4
0
1
1
0
2
0
0
0
29.
13.
MM
0
fabu
U
579
0
0
4210
0
4210.
1239.
U
0
0
U
U
0
0
726
9000
2100
U
650
125
0
1000
0
a
0
14335.
4715.
29
26
TOTAL NO.
OF PLANTS
NO
16
10
7
3
0
2
45
5
66.
20.
0
1
1
U
2
1
0
U
IB
4
0
1
3
2
2
1
1
2
95.
36.
. Mrt
8440
2310
3597
579
0
2U
21726
1740
337b3.
4699.
U
100
4UO
0
825
2/7
U
8<46
9000
2100
0
650
759
250
1000
180
3/5
455
46122.
9557.
73
49
149
-------
TABLE 7
SUMMARY OF OPERATING FGD SYSTEMS BY
PROCESS AND GENERATING UNITS AS OF 01/78
PROCESS/GENERATING UNITS
FGD/MW STARTUP EXPERIENCE(MO.)
LIME SCRUBBING
BRUCE MANSFIELD NO. 1
BRUCE MANSFIELD NO. 2
CANE RUN NO 4
CONESVILLE NO 5
ELRAMA POWER STATION
GREEN RIVER NOS. 1 2 AND 3
HAWTHORN NO. 3
HAWTHORN NO.
-------
TABLE 8
SUMMARY OF SLUDGt DISPOSAL PRACTICES FOR OPERATIONAL FGD SYSTEMS AS OF Ol/7a
PROCESS/GENERATING UNIT "SLUDGE- "SLUDGE PQNQ PuNO —
STABILIZED UNSTA61LIZEO LINED U^LIHtD
LIME SCRUBBING
BRUCE MANSFIELD NO. 1 825
BRUCE MANSFIELD NO. 2 8£5
CANE RUN NO 4 178 1?6
CONESV1LLE NO 5 400 uun
ELRAMA POWER STATION 510 5Ul
GREEN RIVER NOS. 1 2 AND 3 64 b4
HAWTHORN NO. 3 iao lafl
HAWTHORN NO. 4 100 luU
PADDYS RUN NO 6 65 b5
PHILLIPS POWER STATION 410 410
TOTAL 3213. 304. 0. 1867.
LIME/ALKALINE FLYASH SCRUBBING
COLSTRIP NO 1 360 360
.COLSTRIP NO 2 360 360
MILTON R. YOUNG NO. 2 450
TOTAL 0. 1170. 360. 360.
LIMESTONE SCRUBBING
CHOLLA NO 1 115 115
LA CYGNE NO i 820 »20
LAWRENCE NO 4 125 125
LAWRENCE NO 5 400 400
MARTIN LAKE NO. 1 793 793
PETERSBURG NO 3 530 530
SHERBURNE COUNTY STATION NO.l 710 710
SHERBURNE COUNTY STATION NO.2 7io 7io
WIDOWS CREEK NO. 8 550 550
WINYAH NO. 2 280 280
TOTAL 1323. 3710. 2213. 262U,
SODIUM CARBONATE SCRUBBING
REID GARDNER NO 1 l25
REID GARDNER NO ^ 1£5
REID GARDNER NO 3 125
TOTAL 0- 375« °' °'
151
-------
fABLt S
SUMMARY OF FGD SYSTEMS til PROCESS ANU REGULATORY CLASS
REGULATORY OPERATIONAL
PROCESS CLA5S
LIME SCRUBBING
LIME/ALKALINE FLYASH SCRUBBING
LIME/LIMESTONE SCRUBBING
LIMESTONE SCRUBBING
SUBTOTAL - LIME/LIMESTONE
AQUEOUS CARBONATE SCRUBBING
AQUEOUS CARBONATE/FAB. FILTER
DOUBLE ALKALI SCRUBBING
MAGNESIUM OXIDE SCRUBBING
A
B
C
0
6
A
B
C
D
£
A
ti
C
D
E
A
B
C
0
E
A
B
C
U
E
A
B
C
0
E
A
B
C
0
E
A
B
C
D
E
A
B
C
U
E
NO.
0
8
2
0
0
0
3
0
0
0
0
0
2
0
0
4
5
2
0
0
4.
16.
6.
0.
0.
0
0
0
0
C
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
hrt
0
338b
129
0
o
(i
1170
0
0
0
0
0
20
0
0
iBOi
2060
1470
0
0
1603.
6618.
1519.
0.
0.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
120
0
0
0
CONSTRUCTION
NU.
9
3
0
0
0
0
0
0
0
U
U
U
0
0
0
11
7
1
U
U
20.
10.
1.
0.
0.
0
0
0
0
0
0
0
0
0
0
2
1
0
0
0
0
0
0
0
0
MW
4140
100H
0
0
0
0
0
0
0
0
0
0
0
0
0
4675
2910
425
0
0
8815.
391B.
425.
0.
0.
0
0
0
0
0
0
0
0
0
0
825
277
0
0
0
0
0
0
U
0
CUNTKACT
AwAROtO
NO.
1
1
0
0
0
2
2
0
0
0
0
0
0
0
0
4
6
1
0
1
7.
9.
1.
0.
1.
0
0
1
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
M«v
600
825
0
0
0
1027
1400
0
0
0
0
0
0
0
0
1618
3520
575
0
350
3245.
5745.
575.
0.
350.
0
0
100
0
0
0
400
0
0
0
0
0
0
0
0
0
0
0
0
0
PLANNED
140.
0
2
0
0
0
0
3
0
0
0
0
0
0
0
0
5
3
0
(I
0
5.
8.
U.
0.
0.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
0
0
0
My.
0
660
0
0
0
0
57S
0
0
0
0
0
0
0
0
2260
1950
0
0
0
2260.
3189.
u .
0.
U.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
726
0
0
0
TOTAL NO.
PLAIMIS
NO
10
14
2
0
0
2
8
0
0
0
0
0
2
0
0
24
21
4
0
1
36.
43.
8.
0.
1.
0
0
1
0
0
a
i
0
0
0
i.
\
0
0
0
0
4
0
0
0
MW
4740
5881
129
0
0
1027
3149
0
0
u
u
0
2u
0
0
10356
10440
237U
0
350
16123.
19470.
2519.
0.
350.
0
0
100
0
0
0
400
0
0
0
B25
277
0
0
0
0
846
0
0
0
A. BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
B. BOILER SUBJECT TO STATE STANDARD THAT IS MORE STRINGENT THAN THE FEDERAL NSPS
C. BOILER SUBJECT TO STATE STANDARD THAT IS EQUAL TO OK LESS STRINGENT THAN NSHS
D. OTHER
E. REGULATORY CLASS UNKNUWN
152
-------
TABLE 9
SUMMARY OF FGO SYSTEMS BY PROCESS AND REGULATORY CLASS
REGULATOR
PROCESS CLASS
NOT SELECTED
RE6ENERABLE NOT SELECTED
SODIUM CARBONATE SCRUBBING
WELLMAN LORD
WELLMAN LORD/ALLIED CHEMICAL
TOTALS
LIME/STONE X OF TOTAL MW
A
b
c
0
E.
A
B
C
0
E
A
B
C
0
E
A
B
C
0
E
A
B
C
0
£
A
B
C
0
E
A
b
c
0
E
Y OPERA'
NO.
0
0
0
0
0
0
0
0
0
0
0
3
0
0
0
0
0
0
0
0
0
0
1
0
0
a.
20.
7.
0.
0.
100
93
93
0
0
TIONAL
MW
0
0
0
0
0
0
0
0
0
0
(J
375
U
0
0
0
0
U
b
0
0
0
115
0
U
1803.
7113.
1634.
0.
0.
CONSTRUCTION
NO.
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
1
0
0
0
2
0
0
0
22.
14.
2.
0.
0.
MW
0
0
0
0
0
0
0
0
0
0
U
509
0
0
0
0
0
160
0
0
0
71b
0
0
0
9640.
5419.
605.
0.
u .
91
72
70
0
0
CONTRACT
AWARDED
NO.
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
7.
10.
2.
0.
1.
MW
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
3245.
6145.
675.
0.
350.
100
93
85
0
100
PLANNED
NO.
7
13
2
0
0
0
0
1
0
0
U
1
0
0
0
0
2
0
0
0
0
0
0
0
0
12.
27.
3.
U.
0.
MW
4300
6210
59U
0
0
0
V
650
U
0
U
125
0
0
0
0
1000
U
U
0
0
0
0
0
U
6560.
1125U.
1240.
0.
0.
34
28
0
0
0
TOTAL NO.
PLANTS
NO
7
13
2
0
0
0
U
1
0
0
0
5
0
0
0
0
2
1
0
0
0
2
1
0
U
45.
71.
14
0
1
. MM
4300
621U
590
0
0
U
u
650
0
(1
(j
1009
0
0
U
0
1000
l«u
0
0
U
715
115
0
U
21248,
29927.
. 4154
0
350
76
65
61
0
100
A.
El
D.
E.
BOILER CONSTRUCTED SUBJEC1TO FEDERAL NSPS
BOILER SU^ECT IS BUTE SIS
OTHER
REGULATORY CLASS UNKNOWN
smNGENT THAN THE FEDERAL NSPS
"UAL TO OR LESS STRINGENT THAN NSPS
153
-------
TABLE 10
SUMMARY OF FGD SYSTEMS UNDER
CONSTRUCTION AS OF 01/78
UTILITY COMPANY
POWER STATION
ALABAMA ELECTRIC COOP
TOM8I6BEE NO. 2
ALABAMA ELECTRIC COOP
TOM8IGBEE NO. 3
ALLEGHENY POWER SYSTEM
PLEASANTS NO. 1
ALLEGHENY POWER SYSTEM
PLEASANTS NO. 2
ARIZONA ELECTRIC POWER COOP
APACHE NO i.
ARIZONA ELECTRIC POWER COOP
APACHE NO 3
ARIZONA PUBLIC SERVICE
CHOLLA NO 2
BIG RIVERS ELECTRIC COOP CORP.
REID NO. 2
BIG RIVERS ELECTRIC COOP CORP.
RE10 NO. 3
BRAZOS ELECTRIC POWER COOP
SAN MIGUEL NO. 1
CENTRAL ILLINOIS LIGHT CO.
UUCK CREEK NO. 1
CENTRAL ILLINOIS PUBLIC SERV
NEWTON NO.l
COLORADO UTE ELECTRIC ASSN.
CRAIG NO. 1
COLORADO UTE ELECTRIC ASSN.
CRAIG NO. 2
COLUMBUS & SOUTHERN OHIO ELEC.
CONESVILLE NO 6
COMMONWEALTH EDISON
POWERTON NO. 51
DELMARVA PUWER CO.
DELAWARE CITY NOS. 1 2 & 3
KANSAS POWER & LIGHT
JEFFERY NO. 1
KANSAS POWER & LIGHT
JEFFERY NO. 2
LOUISVILLE GAS & ELECTRIC
CANE RUN NO 5
LOUISVILLE GAS & ELECTRIC
CANE RUN NO 6
LOUISVILLE GAS 8, ELECTRIC
MILL CREEK NU 3
LOUISVILLE GAS & ELECTRIC
MILL CREEK NO 4
PACIFIC POWER AND LIGHT CO.
JIM BRIOGER NO. 4
NEW OR
RETROFIT
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
R
R
N
N
R
R
N
N
SIZE OF FGD
UNIT (MW)
225
225
625
625
200
200
250
250
240
400
400
575
450
150
100
125
180
680
680
183
277
125
495
PROCESS/VENDOR
PEABODY ENGINEERING
LIMESTONE SCRUBBING
PEABODY ENGINEERING
LIMESTONE SCRUBBING
BABCOCK & WILCOX
LIME SCRUBBING
BABCOCK 8, WILCOX
LIME SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
RESEARCH COTTRELL
LIMESTONE SCRUBBING
AMERICAN AIR FILTER
LIME SCRUBBING
AMERICAN AIR FILTER
LIME SCRUBBING
BABCOCK & WILCOX
LIMESTONE SCRUBBING
RILEY STOKER / ENV IRONEER ING
LIMESTONt SCRUBBING
6UELL/ENVIROTECH
DOUBLE ALKALI SCRUBBING
PEABODY ENGINEERING
LIMESTONE SCRUBBING
PEABUDY tNGINtERING
LIMESTUNE SCRUBBING
UNIVERSAL OIL PRODUCTS
LIME SCRUBBING
UNIVERSAL OIL PRODUCTS
LIMESTONt SCRUBBING
DAVY PUWtRGAS
WELLMAN LORD
COMBUSTION ENGINEERING
LIMESTUNE SCRUBBING
COMBUST1UN ENGINEERING
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING
LIME SCRUBBING
AOL/COMBUSTION EQUIP ASSUCIATE
DOUBLE ALKALI SCRUBBING
AMERICAN AIR FILTER
LIME SCRUBBING
AMERICAN AIR FILTER
START-UP
DATE
6/78
6/79
3/79
3/80
6/78
4/79
6/78
12/79
12/80
12/79
8/76
11/79
3/79
3/79
10/78
12/79
1/80
6/78
6/8U
4/78
11/79
1/78
b/80
LIME SCRUBBING
509 UNIVERSAL OIL PRODUCTS
SODIUM CARBONATE SCRUBBING
9/79
154
-------
TABLE 10
SUMMARY OF FGO SYSTEMS UNDER
UTILITY COMPANY
POWER STATION
PUBLIC SERVICE CD UF NEW MEX.
SAN JUAN NO. 1
PUBLIC SERVICE CO OF NEW MEX.
SAN JUAN NO. i.
SOUTHERN ILLINOIS POWER COUP
MARION NO. 4
SOUTHERN INDIANA GAS&ELECTR1C
A.B. BROWN NO.l
SOUTHERN MISSISSIPPI ELECTRIC
R.D. MORROW NO.l
SOUTHERN MISSISSIPPI ELECTRIC
R.D. MORROW NU.e
TEXAS POWER AND LIGHT CO.
SANDOW NO.4
TEXAS UTILITIES CO.
MARTIN LAKE NO. £
TEXAS UTILITIES CO.
MARTIN LAKE NO. 5
TEXAS UTILITIES CO.
MONTICELLO NO.3
UNITED POWtR ASSOCIATION
COAL CREEK NO. 1
UNITED POWER ASSOCIATION
COAL CREEK NO. i.
UTAH POWER & LIGHT CO.
EMERY NO.l
UTAH POWER & LIGHT CO.
HUNTINGTON NO.l
CONSTRUCTION AS OF 01/78
PROCESS/VENDOR
NEW OK
RETROFIT
N
R
N
N
N
N
N
N
N
N
N
N
N
N
SIZE OF FGD
UNIT (Mrt)
375
340
184
2bO
160
180
545
7S3
793
' 750
545
545
400
415
DAVY POWERGAS/ALLIED CHEMICAL
WELLMAN LORD/ALLIED CHEMICAL
DAVY PUKtRbAS/ALLIED CHEMICAL
vJELLMAN LORD/ALLIED CHEMICAL
BABCOCK & WILCOX
LIMESTUNt SCKUdBING
FMC COHPURATION
DOUBLE ALKALI SCRUBBING
RILEY STOKER / ENV IRUNEEKING
LIMESTUNE SCRUBBING
WILEY STOKER / ENV I RONLtK ING
LIMESTUNt SCRUBBING
COMBUSTION ENGINEEKIiMG
LIMESTONc SCRUBBING
RESEARCH CUTTRELL
LIMESTONE SCRUBBING
RESEARCH CUTTHELL
LIMESTUNE SCRUBBING
CHEMICO
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING
LIME SCRUBBING
COMBUSTION ENGINEERING
LIME SCRUBBING
CHEMICO
LIME SCRUBBING
CHEMICU
LIME SCRUBBING
START-OP
DATE
-J/78
7/78
fa/78
t/79
5/7B
8/78
7/80
12/78
u/78
11/79
12/78
"/78
155
-------
TABLE 11
SUMMARY UK PLANNED FGD SYSTEMS AS UF 01/78
UTILITY COMPANY
POWER STATION
CONTRACTS AWARDED
ARIZONA PUBLIC SERVICE
CHOLLA NO. 4
BASIN ELECTRIC POWER COOP
LARAMIE RIVER NO. 1
BASIN ELECTRIC POWER COOP
LARAMIE RIVER NO. 2
80ARO OF MUNICIPAL UTILITIES
SIKESTON POWER STATION
CINCINNATI GAS 5, ELECTRIC CO.
EAST BEND NO 2
MINNESOTA POWER AND LIGHT CO.
CLAY BOSWELL NO. 4
MONTANA POWER CO.
COLSTRIP NO. 3
MONTANA POWER CO.
COLSTRIP NO. 4
NIAGARA MOHAWK POWER COOP.
CHARLtS R. HUNTLEY NO.6
NORTHERN STATES POWER CO.
SHERBURNE COUNTY STATION NO.3
NORTHERN STATES POWER CO.
SHERBURNE COUNTY STATION NO.4
OTTER TAIL POWER COMPANY
COYOTE NO. I
PENNSYLVANIA POWER CO.
BRUCE MANSFIELD NO. 3
SALT RIVER PROJECT
CORONAUO NO.l
SALT RIVfcR PROJECT
CORONADO NO.2
SPRINGFIELD WATER LIGHT&POWER
DALLMAN NO. 3
TENNESSEE VALLEY AUTHORITY
WIDOWS CREEK NO. 7
TEXAS MUNICIPAL POWER AGENCY
GIBBUNS CREEK UNIT NO. 1
TEXAS UTILITIES CO.
MARTIN LAKE NO. 4
WISCONSIN POWER & LIGHT CO.
COLUMBIA NO. 2
NEW OR
RETROFIT
N
N
N
N
N
N
N
H
N
N
N
N
N
N
N
R
N
N
N
SUE OF FGD
UNIT (MM)
350
550
550
235
600
500
700
700
100
860
860
400
825
350
350
190
575
400
793
527
VENDOR/PROCESS START-UP
UATE
RESEARCH COTTRELL 6/80
LIMESTONE SCRUBBING
RESEARCH COTTRELL 1/80
LIMESTONE SCRUBBING
RESEARCH COTTRELL 10/80
LIMESTONE SCRUBBING
BA8COCK & WILCOX 11/80
LIMESTONE SCRUBBING
BABCOCK & WILCOX 1/81
LIME SCRUBbING
PEABODY ENGINEERING 0/80
LIME/ALKALINE FLYASH SCRUBBING
AOL/COMBUSTION EQUIP ASSOCIATE 7/80
LIME/ALKALINE FLYASH SCRUBBING
ADL/COMBUSTIUN EQUIP ASSOCIATE 7/dl
LIME/ALKALINE FLYASH SCRUBBING
ATOMICS INTERNATIONAL 0/80
AQUEOUS CARBONATE SCRUBBING
COMBUSTION ENGINEERING 5/81
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING 5/83
LIMESTONE SCRUBBING
WHEELABRATOR-FRYE/A.I. 5/81
AQUEOUS CARBONATE/FAB. FILTER
PULLMAN KELLOGG 4/80
LIME SCRUBBING
PULLMAN KELLOGG 4/79
LIMESTONE SCRUBBING
PULLMAN KELLOGG 4/80
LIMESTONE SCRUBBING
RESEARCH COTTRELL 7/80
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING O/ 0
LIMESTONE SCRUBBING
COMBUSTION ENGINEERING 1/82
LIMESTONE SCRUBBING
RESEARCH COTTRELL 11/82
LIMESTONE SCRUBBING
CHEMICO 1/80
LIME/ALKALINE FLYASH SCRUBBING
LETTER OF INTENT SIGNED
NEVADA POWER
RCIO GARDNER NO 4
PHILADELPHIA ELECTRIC CO.
EDDYSTONE NO. IB
PUBLIC SERVICE CO OF NEW MEX.
SAN JUAN NO. 3
125 ADL/COMBUSTION EQUIP ASSOCIATE O/ 0
SODIUM CARBONATE SCRUBBING
240 UNITED ENGINEERS / PECO 6/80
MAGNESIUM OXIDE SCRUBBING
500 DAVY POWERGAS 1/79
WELLMAN LORD
156
-------
TABLE 11
SUMMARY OF PLANNED FGD SYSTEMS AS UF 01/78
UTILITY COMPANY Nth OH
POWER STATION RETROFIT
REQUESTING/EVALUATING blOS
EASTERN KENTUCKY POWER COOP N
SPURLOCK GENERATING PLANT NO. 2
HOOSIER COOPERATIVE N
MEROM NO. 1
HOOSIER COOPERATIVE N
MEROM NO. 2
INDIANAPOLIS POWER & LIGHT CO. N
PETERSBURG NO 4
LAKELAND UTILITIES N
MCINTOSH POWER PLANT UNIT NO. 3
SOUTH CAROLINA PUBLIC SERVICE N
HINYAH NO. i
CONSIDERING FGD SYSTtM
ARIZONA PUBLIC SERVICE R
FOUR CORNERS NO. 1
ARIZONA PUBLIC SERVICE R
FOUR CORNERS NO. 2
ARIZONA PUBLIC SERVICE R
FOUR CORNERS NO. 3
ARIZONA PUBLIC SERVICE R
=OUR CORNERS NO. 4
ARIZONA PUBLIC SERVICE R
•OUR CORNERS NO. 5
JASIN ELECTRIC POWER COOP N
kNTELOPE VALLEY NO. 1
IASIN ELECTRIC POWER COOP N
INTELOPE VALLEY NO. 2
IASIN ELECTRIC POWER COOP N
.ARAMIE RIVER NO. 3
ENTHAL ILLINOIS LIGHT CO. N
UCK CREEK NO. 2
ENTRAL MAINE POWER CO. N
EARS ISLAND NO. 1
OLUMBUS & SOUTHERN OHIO ELEC. N
OSTON NO. 5
OLUMBUS & SOUTHERN OHIO ELEC. N
OSTON NO. 6
OUISV1LLE GAS & ELECTRIC R
ILL CREEK NO 1
3UISVILLE GAS & ELECTRIC H
ILL CREEK NO 2
•VAOA POWER N
»RRY ALLEN STATION NO. 1
:VAOA POWER N
>RRY ALLEN STATION NO. 2
VADA POWER N
SHE OF FGD
UNIT (MM)
500
490
490
530
350
300
175
175
229
755
755
150
450
550
100
600
375
375
330
330
500
500
500
VENDOK/PRUCESS
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIMESTONE SCRUBBING
NOT SELECTED
LIMESTONE SCRUBBING
NOT SELECTED
LIMESTONE SCRUBBING
NOT SELECTED
LIMESTONE SCRUBBING
NOT SELECTED
NOT SELECTtD
CHEMICO/APS
LIME/ALKALINE FLYASH
CHEMICO/APS
LIME/ALKALINE FLYASH
CHEMICO/APS
LIME/ALKALINE FLYASH
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIMESTONE SCRUBBING
NOT SELECTED
(MOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIME SCRUBBING
NOT SELECTED
LIME SCRUBBING
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
STAHT-UP
DATE
3/60
0/80
0/81
4/82
10/81
0/60
O/ 0
SCRUBBING
O/ 0
SCRUBBING
O/ 0
SCRUBBING
O/ 0
0/0
0/B1
0/83
6/8J
1/82
11/86
0/81
0/83
1/82
1/61
6/63
b/H4
6/85
157
-------
TABLE 11
SUMMARY OF PLANNED
UTILITY COMPANY
POWER STATION
NEVADA POWER
HARRY ALLEN STATION NO. 4
NEVADA POWER
WARNER VALLEY STATION NO. 1
NEVADA POWER
WARNER VALLEY STATION NO. 2
NEW ENGLAND ELEC SYSTEM
6RAYTON POINT NO.3
NORTHERN INDIANA PUB SERVICE
SAILLY NO. 7
NORTHERN INDIANA PUB SERVICE
BAILLY NO. 8
PACIFIC GAS AND ELECTRIC
FOSSIL NO. 1
PACIFIC GAS AND ELECTRIC
FOSSIL NO. 2
PHILADELPHIA ELECTRIC CO.
CROMBY
PHILADELPHIA ELECTRIC CO.
EOOYSTONE NO. 2
PUBLIC SERVICE CO OF NEW MEX.
SAN JUAN NO. «
PUBLIC SERVICE OF INDIANA
GIBSON 5
SALT RIVER PROJECT
CORONAUO NO.3
TEXAS POWER AND LIGHT CO.
TWIN OAKS NO. 1
TEXAS POWER AND LIGHT CO.
TWIN OAKS NO. 3
TEXAS UTILITIES CO.
FOREST GROVE NO. 1
FGD SYSTEMS AS OF 01/78
NEW OR
RETROFIT
N
N
N
R
R
H
N
N
R
R
N
N
N
N
N
N
SIZE OF FGD
UNIT (MW)
500
250
250
650
190
UOO
600
800
150
336
500
6bO
3SO
750
750
750
VENDOR/PROCESS
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
REGENEkABLE NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIMESTONE SCRUBBING
NOT SELECTED
LIMESTONE SCRUBBING
UNITED ENGINEERS / PECO
MAGNESIUM UXIDt SCRUBBING
UNITED ENGINEERS / PECO
MAGNESIUM OXIDE SCRUBBING
DAVY POWtRGAS
WELLMAN LORD
NOT SELECTED
NOT SELECTED
NOT SELECTED
LIMESTONE SCRUBBING
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTtD
NOT SELECTED
NOT SELECTED
3TART-UP
DATE
6/86
6/85
6/83
O/ 0
O/ 0
O/ 0
0/8
-------
CONTENTS
TABLE 12
UTILITY COMPANY
POWER STATION
ARIZONA PUBLIC SERVICE
FOUR CORNERS NO. 5A
BOSTON EDISON
MYSTIC NO 6
CENTRAL ILLINOIS LIGHT CO.
DUCK CREEK NO. 1A
COMMONWEALTH EDISON
WILL COUNTY NO 1
OAIRYLANO POWER COOP
ALMA STATION
DETROIT EDISON
ST. CLAIR NO 6
GULF POWER CO.
SCHOLZ NO. 1A
GULF POWER CO.
SCHOLZ NO. 3A
GULF POWER CO.
SCHOLZ NOS. 18 & 2B
ILLINOIS POWER
WOOD RIVER NO «
KEY WEST UTILITY BOARD
STOCK ISLAND PLANT
POTOMAC ELECTRIC S POWER
OICKERSON NO. 3
PUBLIC SERVICE CO OF COLORADO
VALMONT NO. 5
SOUTHERN CALIFORNIA tDISON
MOHAVE NO 1A
SOUTHERN CALIFORNIA EDISON
MOHAVE NO. 2A
TENNESSEE VALLEY AUTHORITY
SHAWNEE NO. IOC
UNION ELECTRIC CO.
MEREMAC NO. £
SIZE OF FED PROCESS/VENDOR
RETROFIT UNIT (MW)
lb° SO. CALIFORNIA EDISON
LIME SCRUBBING
ISO CHEM1CO
MAGNESIUM OXIDE SCRUBBING
100 KILEY STOKER / ENV1RONEERING
LIMESTONE SCRUBBING
167 6ABCOCK & IVILCOX
LIMESTONE SCRUBBING
60 FOSTER WHEELER
LIME INJECTION
163 HEABODY ENGINEERING
LIMESTONE SCRUBBING
£0 ADL/COMBUSTION EUUIP ASSOCIATE
DOUBLE ALKALI SCRUBBING
20 FOSTER WHEELER
ACTIVATED CAK80N
23 CHIYODA INTERNATIONAL
THOROUGHBRED 101
110 MONSANTO ENVIRO CHEM SYSTEMS
CATALYTIC OXIDATION
37 ZURN AIR SYSTEMS
LIMESTONE SCRUBBING
95 CHEMICO
MAGNESIUM OXIDE SCRUBBING
50 UOP/PUB SERVICE OF COLORADO
LIMESTUNE SCRUBBING
170 UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
160 SCE/STEAKNS ROGER
LIME SCRUBBING
10 TENNESSEE VALLEY AUTHORITY
LIME/LIMESTONE SCRUBBING
IHO COMBUSTION ENGINEERING
LIMESTONE INJECTION/WET SCRUB
PAGE NO.
192
195
198
201
212
213
217
220
223
227
230
233
236
239
2*40
24«
246
159
-------
TABLE 12
DESCRIPTION OF TERMINATED FGU SYSTEMS 01/76
UTILITY NAME ARIZONA PUBLIC SERVICE
UNIT NAME FOUR CORNERS NO. 5A
UNIT LOCATION FARMINGTON NEW MEXICO
UNIT RATING 160 MW
FUEL CHARACTERISTICS CUAL 0.7 PERCENT SULFUR
FGO VENDOR SO. CALIFORNIA EDISON
PROCESS LIME SCRUBBING
NEW OR RETROFIT RETROFIT
START UP DATE 2/76
FGD STATUS TERMINATED
EFFICIENCY,
PART1CULATES
soa
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL REFER TO THE BACKGROUND INFORMATION SECTION IN TAbLE 12 OF THE REPORT.
EXPERIENCE THIS MOUULE WAS ORIGINALLY INSTALLED AT THE MQHAVE GENERATING STATION
AND OPERATED DURING THE TEST MODULES EVALUATION PROGRAM. THE UNIT
WAS THEN SHUTDOWN, MOVED FROM THE MOHAVE TEST SITE, AND REASSEMBLED
AT THE FOUR CORNERS STATION OF APS. THE MODULE WAS IN SERVICE DURING
SEGMENTS FROM FEB. 1976 TO DEC. 6, 1976, TREATING APPROXIMATELY 20 PER-
CENT OF THE FLUE GAS FLOW FROM THE 75b-MW RATEO UNIT. THE PROGRAM HAS
BEEN TERMINATED AND THE MODULE DISASSEMBLED.
160
-------
BACKGROUND INFORMATION
ON
FOUR CORNERS NO. 5* - EXPERIMENTAL HORIZONTAL SCRUBBER
THE FOUR CORNERS POWER STATION, LOCATED NEAR FARMINGTON, NEW MEXICO, IS JOINTLY OWNED 8Y THE
ARIZONA PUBLIC SERVICE COMPANY AND THE SOUTHERN CALIFORNIA EDISON COMPANY. THIS STATION CON A NS
FIVE COAL-FIRED 801LEKS WITH AN EQUIVALENT ELECTRIC POWER GENERATING CAPACITY OF 2233-M*. ONLY UNIT
NO. 5 IS RETROFITTED WITH AN F60 SYSTEM. U L U *
UNIT NO. 5 IS A COAL-FIRED BOILER CAPABLE OF GENERATING S,1<4,000 LBS. OF STEAM, WHICH IS EQUI-
VALENT TO 800-MW OF NET ELECTRICAL POWER. THIS UNIT WAS FIRST PLACED IN COMMERCIAL OPERAIION JULY
1970. APPROXIMATELY SO PERCENT OF THE FLUE GAS GENERATED BY THIS BUILER IS BEING SCRUBBED INITIALLY
IN ORDER TO ESTABLISH WHAT SULFUR DIOXIDE AMD PARTICULATE REMOVAL EFFICIENCIES CAN BE ObTAIiMED.
THE FGO SYSTEM WHICH HAS BEEN RETROFITTED ON UNIT NO. b IS THE WEIR HORIZONTAL CKOSSFLOW SPRAY
SCRUBBER WHICH WAS FORMERLY INSTALLED AND OPERATED IN A TEST PROGRAM AT THE MOHAVE GENERATING STA-
TION OF THE SOUTHERN CALIFORNIA EDISON COMPANY (SEE MOHAVE NO. 2A IN TABLE 16 OF THIS REPORT).
DURING THE MOHAVE TEST PROGRAM THE HORIZONTAL MODULE WAS OPERATIONAL FROM NOVEMBER 1, 1973, TO
JANUARY 16,1974, FOR SHAKEDOWN PURPOSES. OVER THE COURSE OF THE ACTUAL TEST PROGRAM, WHICH EXTENDED
FROM JANUARY 16, 1974, TO FEBRUARY 9, 1975, THE PROTOTYPE UNIT OPERATED A TOTAL OF 5,927 HOURS IN
VARIOUS TEST MODES. FOLLOWING COMPLETION OF TESTS, THE MODULE WAS SHUT DOWN, DISMANTLED, TRANSPORT-
ED, AND REASSEMBLED AT THE FOUR CURNERS GENERATING STATION OF ARIZONA PUBLIC SERVICE FOR FURTHER
TESTING.
THE HORIZONTAL MODULE IS A FOUR-STAGE SCRUBBING CHAMBER WITH FOLLOWING DIMENSIONS! LENGTH - 48
FEET, WIDTH • 28 FEET, HEIGHT - Ib FEET. THE MODULE ITSELF IS A HOLLO* CHAMBER CONSISTING OF FOUR
STAGES OF CROSSFLOW SPRAY NOZZLES. EACH STAGE CONTAINS A ROW OF it> EXTERNALLY-MOUNTED NOZZLES. THE
SLURRY IS CYCLED THROUGH THE SCRUBBER IN A COUNTEKCURHENT MANNER AT A RATE OF 3b,000 GPM/STAGE,
FRESH LIME SLURRY IS SPRAYED ACROSS THE FLUE GAS AT THE FOURTH STAGE, WHICH IS IHE DISCHARGE END OF
THE SCRUBBING CHAMBER. THE SCRUBBING SOLUTION IS THEN COLLECTED AND RECYCLED SUCCESSIVtLY TO THE
THIRD, SECOND, AND FIRST STAGES OF THE SCRUBBING MODULE. THIS ALLOWS FOR COMPLETE DEPLETION OF ANY
EXCESS ALKALINITY AND INSURES THAT FRESH SLURRY is CONTACTING GAS HAVING THE LOWEST SULFUR DIOXIDE
CONCENTRATION. THE LIQUID RECIRCULAT ION RATE CAN BE ADJUSTED OVER A WIDE RANGE. THE MODULE IS DE-
SIGNED TO TREAT A MAXIMUM FLUE GAS CAPACITY OF 450,000 SCFM. THE DESIGN GAS VELOCITY THKOUfcH THE
MODULE IS 21.6 FT/SEC. THE CLEANED GASES THEN PASS THROUGH A DEMISTER AND ARE REHEATED BEFORE BE-
ING DISCHARGED TO THE STACK. THE SPENT SLURRY IS DISCHARGED FROM THE SCRUBBING SYSTEM TO A THICK-
ENER AND THE UNDERFLOW IS PUMPED TO AN ON-SITE SETTLING POND. WATER IS RETURNED TO THE PROCESS FOR
FURTHER USE.
A CUTAWAY VIEW OF THE WEIR SCRUBBING CHAMBER IS PRESENTED IN APPENDIX B.
161
-------
PERIOD
MONTH/YEAR
FEB. 76
MAR. 76
APR. 76
MAY 76
JUN. 76
JUU. 76
AUG. 76
SEP. 76
OCT. 76
NOV. 76
DEC. 76
ARIZONA PUBLIC SERVICE
OPERATING HOURS
BOILER FGD SYSTEM
FOUH CORNERS UNIT NO. 5A
COMMENTS
INSTALLATION OF THE MODULE AT THE FOUR CORNERS GENERATING
STATION WAS COMPLETED AND THE MODULE hAS PLACED IN-SERVICE
FEBRUARY 17, 1976, FOR INITIAL OPERATION.
THE SYSTEM WAS TAKEN DOWN IN MID-APRIL FOR A SCHEDULED BOILER
OVERHAUL.
SYSTEM RESTART IS SCHEDULED FOR JULY 1976.
THE SYSTEM HAS REMAINED OUT OF SERVICE SINCE MID-APRIL 1976
BECAUSE OF AN EXTENSIVE OVERHAUL TO THE NO. 5 BOILER PLUS THE
DEVELOPMENT OF PROBLEMS WITH THE SCRUBBER MODULE'S REHEATER
UNIT.
THfc PROTOTYPE WAS IN SERVICE THROUGHOUT THE MONTH OF NOVEMBER.
ON DEC. fa THE TEST PROGRAM WAS CONCLUDED AND THE UNIT HAS
SINCE BEEN DISMANTLED. APS IS NOrt IN THE PROCESS OF ANALYZING
THE OPERATING DATA ACCUMULATED DURING THE TEST PERIOD. A RE-
PORT ADDRESSING THE RESULTS OF THE PROGRAM WILL BE PUBLISHED
IN FEBRUARY 1977.
162
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TABLE 12
DESCRIPTION OF TERMINATED FGD SYSTEMS 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT HATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
BOSTON EDISUN
MYSTIC NO 6
EVERETT MASSACHUSETTS
150 MH
OIL 2.5 PERCENT SULFUR
CHEMICO
MAGNESIUM OXIDE SCRUBbING
RETROFIT
4/72
TERMINATED
50 PERCENT
S02
90 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
ACID PLANT REGENERATION
UNIT COST
SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 12 OF THIS REPORT.
THIS DEMONSTRATION MAGNESIUM OXIDE SCRUBBER PLANT CONSISTED OF UNE SINGLE-
STAGE VENTURI MODULE DESIGNED BY CHEMICO. THE UNIT WAS ORIGINALLY PLACED
IN SERVICE IN APRIL 1972. TERMINATION OF THE DEMONSTRATION PROGRAM OCCUR-
RED IN JUNE 1974. FUNDING FOR THE DEMONSTRATION PROGRAM WAS PROVIDED
PRIMARILY BY THE UTILITY AND EPA. THE BOILER FIRED NO.6 HIGH SULFUR RESID-
UAL FUEL OIL DUK1NG THE COURSE OF THE PROGRAM. SYSTEM OPERA8ILITY INDEX
VALUES ARE PROVIDED IN THE FOLLOWING TABLE
163
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BACKGROUND INFORMATION
ON
MYSTIC NO. b MAGNESIUM OXIDE SCRUBBER
THE MAGNESIUM OXIDE-BASED FGU SYSTEM INSTALLED AT THE MYSTIC POWER STATION OF THE BOSTON EDISON
COMPANY CONSISTS OF A CHEMICO-DES1GNED SINGLE-STAGE VENTUKI SCRUBBER MODULE- THE MODULE IS CON-
STRUCTED OF CARBON STEEL LlriEO WITH A SPRAY-APPLIED POLYESTER MATERIAL. TOTAL FLUE GAS CAPACITY OF
THE SYSTEM IS «
-------
BOSTON EDISON
BOILER
OPERATION
MONTH/YR (HR)
APR. 72
TO
MAT 73
SCRUBBER
OPfcRATION
(HR)
FGO SYSTEM AVAILABILITY
MYSTIC UNIT NO. 6
OPERABILITY
17
JUN. 73
JUL. 73
AUG. 73
SEP. 73
OCT. 73
NOV. 73
DEC. 73
JAN. 74
FEB. 74
MAR. 74
APR. 74
MAY 74
JUN. 74
592 402
575 351
BOILER SHUTDOWN
637 243
627 377
629
658
555
541
408
585
486
559
162
86
152
138
353
471
280
288
68
61
38
60
26
li
28
25
87
81
57
80
THE MODULE OPERATED INTERMITTENTLY BECAUSE UF
MECHANICAL DIFFICULTIES. A I-AJUR PROBLEM COMCEWN-
ED THE OPERATION OF THE MAGNESIUM SULFITE CRYSTALS
U K T t K 9
THE LONGEST PERIOD OF CONTINUOUS OPERATION, 7.5
DAYS, OCCURRED DURING JUNE AND JULY.
THE BOILER WAS DOWN FOR THE ANNUAL OVERHAUL.
SYSTEM AVAILABILITY DECREASED DURING THE LAST
QUARTER OF THE YEAR BECAUSE OF HEAVY EROSION/
CORROSION IN THE LIQUOR RECIRCULATION PUMPS AND
CENTRIFUGE.
SYSTEM AVAILABILITY HAS LIMITED BY BOILER-RELATED
PROBLEMS THAT CAUSED FREQUENT SHUTDOWNS IN JAN-
VARY AND FEBRUARY.
TWO 7-DAY CONTINUOUS OPERATION PERIODS OCCURRED
DURING THE MONTH.
THE 57 PEKCENT OPERABILITY INDEX VALUE FOR THE
MONTH WAS DUE TO A 2-WEEKS OUTAGE OF THE ACID
PLANT RATHER THAN TO FGD SYSTEM FAILURE. DEMON-
STRATION PROGRAM WAS COMPLETED AND FGO SYSTEM WAS
SHUT DOWN. EPA FUNDING OF MGS03 CALCINATION HAS
EXPIRED. THERE ARE NO DEFINITE PLANS FOR RESTART-
ING OF THIS UNIT. MAJOR PROBLEM AREAS ENCOUNTERED
DURING THE OPERATION OF THIS PROTOTYPE UNIT IN-
CLUDED TRIHYORATE INSTEAD UF HEXAHYDRATE 3ULFITE
CRYSTAL FORMATION, DUST PROBLEMS IN THE DRYER,
LACK OF STACK GAS REHEAT CAUSING CONDENSATION IN
THE STACK, LOUVER DAMPER PROBLEMS, EROSION OF
PUMPS, PIPING, AND CENTRIFUGE, AND MINOR ANCILLARY
EQUIPMENT FAILURES.
165
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TABLE 13
DESCRIPTION OF TERMINATED FGD SYSTEMS 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NfcW OR RETROFIT
START UP DATE
FSD STATUS
EFFICIENCY,
PARTICULATES
CENTRAL ILLINOIS LIGHT CO.
DUCK CREEK NO. 1A
CANTON ILLINOIS
100 MA
COAL 2.5 - 3.0 PERCENT SULFUR
RILEY STOKER / ENVIRONEERING
LIMESTONE SCRUBBING
NEW
9/76
TERMINATED
99.8 PERCENT
S02
85 PERCENT
WATER MAKE UP
CLOSED LOOP
SLUDGE DISPOSAL
UNIT COST
SEE APPENDIX A, FGO SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
THE INSTALLATION OF ONE OF A TOTAL OF FOUR SCRUBBER MODULES WAS
COMPLETED IN JULY 1976 AND START-OP OPERATIONS COMMENCED. SHAKEDOWN
AND DEBUGGING OPERATIONS PROCEEDED ON AN INTERMITTENT BASIS
bECAUSE OF NUMEROUS CHEMICAL AND MECHANICAL-RELATED PROBLEMS.
THE SINGLt COMPLETED SCRUBBER MODULE HAS BEEN SHUTDOWN UNTIL THE OTHER
THREE MODULES, hfcpntstNTiNG 300 M« OF SCRUBBING CAPACITY, AHE READY IN
AUGUST 19/8. UNTIL THAT TIME THE 400-MW UNIT WILL BE UTILIZING COLORADO
LOW-SULFUR COAL FOR POWER GENERATION OPERATIONS.
166
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BACKGROUND INFORMATION
ON
DUCK CREtK PLANT NO 1A
THE DUCK CREEK PLANT OF THE CENTRAL ILLINOIS LIGHT COMPANY (rnrin ie . c
GENERATING STATION LOCATED IN AN ONRECLAIMEO ST 1P-MIN NG AREA NE*J ANT N ILL?M,1 ^''I
PRESENT TIME, ONE 400-MW COAL-FIRED UNIT IS IN SERVICE AND ?HREfc MORE IOENHCAL UNHS ARE BM
PLANNED, BRINGING THE TOTAL PLANNED PLANT CAPACITY TO 20OU Mw. IDENTICAL UNITS ARt BU
THE NO. 1 POWER-GENERATING UNIT INCLUDES A 3-MILLION L6S./HR. STEAM-GENERA T IMG BQIiE
PSIG, 1005F/1005F, SINGLE REHEAT, PULVERUED-CUAL-FIREO, BALANCED DRAFT? SUPPL ED 8Y ?HE
STOKER CORPORATION TO PROVIDE STEAM TO 400-MW TURblNE. THE BOILER IS DESIGNED TO F RE hlGH-SULFUR
ILLINOIS COAL, AVAILABLE FROM NEARBY MINES, HAVING THt FOLLOWING AVERAGE CHARACTEKISTICS: HEAT
CONTENT, 10,500 HTU/Lb; SULFUR CONTENT 2.4 TO 4.0 PERCENT; ASH CONTENT, 6.0 TO 18.U PERCENT
CONSTRUCTION Of THE NO. 1 UNIT BEGAN IN THE EARLY PART OF 1972. COMMERCIAL SERVICE COMMENCED IN
JUNE 1976.
THE DESIGN OF THE EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF TWO 99.8 PERCENT-EFFICIENT
ELECTROSTATIC PRECIPITATORS SUPPLIED BY POLLUTION CONTKOL-WALTHtK (PCw) FOR THE COiMTKOL UF
PARTICULATES AND FOUR WET-LIMESTONE SCRUBBER MODULES SUPPLIED BY RILEY STOKEH/ENVIRQNEERlNG FOK THE
REMOVAL OF 75 PERCENT OF THE SULFUR DIOXIDE. THE EMISSION CONTROL SYSTEM IS DESIGNED TO FUNCTION IN
THE FOLLOWING MANNER: THE BOILER FLUE GAS, AFTER PASSING THROUGH TWO AIR PREHEATER UNIIS, tNTEHS
THE PCW ESP'S WHERE PRIMARY PARTICULATE REMOVAL OCCURS. THt PART ICULAlE-CLEAwEi) GAS IS lriEi<. DIS-
CHARGED TO A MANIFOLD SUPPLYING FOUR CENTRIFUGAL INDUCED DRAFT FANS (RADICAL TIP, INLET-DAHPER
CONTROL, 900 RPM, 4000 HP EACH). THE FLUE GAS IS BOOSTED THROUGH A COMMON HEADER INTO THE
-------
CENTRAL ILLINOIS LIGHT CO.
PERFORMANCE HISTORY
DUCK CREEK UNIT NO. U
MODULE
PERIOD OPERATION HRS.
JOL. 7b 8 HRS.
AUG. 76 18 HKS.
SEP. 7b 360 HRS.
OCT. 7fa
NOV. 76
38i HRS.
HRS.
DEC. 76
JAN. 77
FEB. 77
MAR. 77
350 HRS.
APR. 77
MAY 77
COMMENTS
INITIAL OPERATION OF THE FIRST SCRUBBER MODULE FOR SHAKEDOWN AND DE-
BUGGING PURPOSE OCCUREU DURING THE MONTH. LIMITED SEKVICE TIME RESULT-
ED FROM PROBLEMS WITH BAD WELDS, FAULTY PIPE HANGES, AND ABSORBER
LEAKS.
LIMITED OPERATIONS CONTINUED THROUGHOUT AUGUST BECAUSE OF THE START-UP
AND CONSTRUCTION PROBLEMS MENTIONED ABOVE. THE MODULE WAS TAKEN OUT
OF THE GAS PATH AT THIS POINT TO CONCENTRATE ON RESOLVING THESE PROBLEM
AREAS.
MODULE RESTART OCCURRED ON SEPT. 9. OPERATION CONTINUED THROUGHOUT
THE REMAINDER OF THE MONTH ON AN INTERMITTANT BASIS. MAJOR PROBLEMS
INCLUDED PIPE BREAKING, PUMP LINER FAILURES, PLUGGING AMD SEALING OF
MIST ELIMINATORS, AND SOME BOILER-RELATED PROBLEMS. THE MODULE RE-
MAlNtD IN SERVICE FOR APPROXIMATELY 15 DAYS OF NON-CONTINUOUS
OPERATION. THE PCW ESP MODULES HAVE REMAINED IN SEKVICE WITHOUT THE
OCCURRENCE OF ANY MAJOR PROBLEMS.
TOTAL OPERATION TIME DURING THE MONTH WAS APPROXIMATELY 16 DAYS
INON-CONTINUOUS). MAJOR PROBLEM AkEA WAS THE CONTINUATION OF MASSIVE
SCALE DEVELOPMENT UN THE MIST ELIMINATORS, RESULTING IN PLUGGING OF
THE PIPING AND NOZZLES TO THE COMPONENTS SPRAY SYSTEM.
SPORADIC OPERATION RESULTED FROM CONTINUED SCALING PROBLEMS IN THE
MIST ELIMINATOR SECTION. RILEY AND CILCO INITIATED MODIFICATIONS TO
THE DESIGN OF THE MODULE. SPECIFICALLY, A ROD DECK WAS CHANGED IN THE
ABSORBER, PRESSURE DROP ACROSS THE ABSORBER WAS INCREASED, PIPING AND
PUMP LINER MATERIALS WERE MODIFIED/REPLACED, AND A FRESH WATER WASH
SYSTEM WAS INSTALLED FOR THE MIST ELIMINATOR.
THE MODULE REMAINED OUT OF SERVICE THE ENTIRE MONTH. DURING THIS
TIME, THE BUILtR FIRED LOW SULFUR (0.6X) KENTUCKY COAL.
THE NO. 1 UNIT WAS DOWN THROUGHOUT THE ENTIRE PERIOD FOR TURBINE/BOILER
OVERHAUL. DURING THE UNIT OUTAGE, A NUMBER OF MODIFICATIONS WERE MADE
TO THE SCRUBBER.
THE NO. 1 UNIT WAS RETURNED TO SERVICE IN MID-MARCH. THE SCRUBBER
WAS PLACED IN SERVICE TO TEST THE MODIFICATIONS MADE DURING THE PRE-
CEDING OUTAGE. THESE MODIFICATIONS INCLUDED:
* THE MIST ELIMINATOR SPRAY WASH SYSTEM PIPING WAS CHANGED FROM PVC
TO FHP MATERIALS. ALSO, AN ADDITIONAL SPRAY HEADER WAS ADDED.
THE SLURRY CIRCULATION SYSTEM WAS REVAMPED.
NEUPRENE PUMP FILTERS HAVE REPLACED THE ORIGINAL ROBBER LINES.
FLUSH/DRAIN SYSTEMS HAVE BEEN INCLUDED TO MINIMIZE SOLIDS BUILD UP.
PIPING VALVES MOVED CLOSER TO THE RECYCLE TANK.
SLURRY STORAGE TANKS EQUIPPED WI1H FLUSH/DRAIN SYSTEMS.
ADDITIONAL MIXERS ADDED FOR GREATER AGITATION TO PROMOTE PROCESS
CHEMISTRY.
DURING THE LAST PART OF MARCH THE MODULE REMAINED IN SERVICE ON A
CONTINUAL BASIS WITH THE EXCEPTION OF A FEW MINOR BOILER OUTAGES.
CILCO INTENDS 10 CONTINUE EXPERIMENTAL OPERATIONS THROUGHOUT THE APRIL-
MAY PERIOD, TESTING THE MECHANICAL MODIFICATIONS AND THE AUTOMATIC
CONTROL LOOPS (SYSTEM CHEMISTRY WILL BE CONTROLLED 8Y INLET/OUTLET S0£
LOADING, SOLUTION PH, SOLUTION SOLIDS. OPERATION UP TO THIS POINT
HAS PROCEEDED IN A MANUAL CONTROL MODE). CONTINUED OPERATION BEYOND
THIS TIME FRAME WILL DEPEND UPON ThE SUCCESS OF EXPERIMENTAL
OPERATIONS. CILCO HAS THE OPTION OF FIRING LOW SULFUR COAL UNTIL THE
ENTIRE 1-MODULE SCRUBBER PLANT IS READY FOR SERVICE IN AUGUST 1978.
THE UNIT CONTINUED TO HkE LOW-SULFUR COLORADO CUAL DURING THE REPORT
PERIOD. THE RESTART OF SCRUBBER OPERATIONS CONTINUES TO BE SCHEDULED
FOK AUGUST 1978.
163
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TABLE 12
DESCRIPTION OF TERMINATED FGD SYSTEMS
01/76
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F6D VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
COMMONWEALTH EDISON
WILL COUNTY NO 1
ROMEOVILLE ILLINOIS
167 MW
COAL 0.3 PERCENT SULFUR
BA8COCK & WILCOX
LIMESTONE SCRUBBING
RETROFIT
TERMINATED
98 PERCtNT
S02
82 PERCENT
WATER MAKE UP
OPEN LOOP l.bb GPM/MW
SLUDGE DISPOSAL
HAULAWAY TO LANDFILL
UNIT COST
SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TU THE BACKGROUND INFORMATION SECTION IN TABLE 12 OF THIS REPORT.
THIS FULL SCALE DEMONS THAT ION SCRUBBING SYSTEM HAS SEEN IN SERVICE SINCE
FEBRUARY 1972. THE SYSTEM INCLUDES TWO SCRUBBING 1RAINS FOR THE
CONTROL OF PARTICULATES AND SULFUR DIUXIDE. MODULE AVAILABILITY,
UPERA8ILITY, RELIABILITY, AND UTILIZATIUN INDEX VALUES FOR THt REPORT
PERIOD ARE PROVIDED IN THE BACKGROUND INFORMATION SECTION. EXPERIMENTAL
su2 REMOVAL OPERATIONS WERE CONCLUDED IN JULY i<*77, HOWEVER, PAKTICULATE
SCRUBBING OPERATIONS ARE CONTINUING ON LOH-S WESTERN COAL FLUE GAS.
169
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BACKGROUND INFORMATION
ON
WILL COUNTY NO. 1
IN 1970, COMMONWEALTH EDISON CONTRACTED WITH THE BECHTEL CORPORATION TO INVESTIGATE THE SULFUR
REMOVAL SYSTEMS THEN AVAILABLE HAVING A SUFFICIENT DEGREE OF DEVELOPMENT TO WARRANT LARGE-SCALE IN-
STALLATION ON WILL COUNTY STATION'S UNIT NO. I. AFTER DECIDING ON A WET SCRUBBER SYSTEM USING LIME
OR LIMESTONE, BECHTEL PREPARED A SPECIFICATION AND RELEASED IT FOR BID. FROM NINE BIDDERS THAT WERE
SOLICITED, SEVEN PROPOSALS WERE RECEIVED. AFTER DETAILED STUDY AND BID EVALUATION WITH SPECIAL CON«
SIDERATION OF THE PROJECT SCHEDULE, BA8COCK AND WILCOX WAS AUTHORIZED IN SEPTEMBER 1970 TO BEGIN
DETAILED ENGINEERING FOR A LIMESTONE SLURRY SYSTEM. COMPLETION DEADLINE FOR THE PROJECT WAS
OECEMbER 31, 1971. A DEADLINE ESTABLISHED BY THE ILLINOIS COMMERCE COMMISSION AS PART OF A RATE
CASE.
THE BABCOCK AND WILCOX PROCESS WAS GUARANTEED TO REMOVE 98 PERCENT OF THE FLY ASH AND 76
PERCENT OF THE SULFUR DIOXIDE. THESE EFFICIENCIES WERE BASED ON A DUST INLET LOADING Of 1.355
GRAINS PER STANDARD CUBIC FOOT AT 70 f AND ON BURNING OF ILLINOIS COAL CONTAINING 4 PERCENT SULFUR.
THE WILL COUNTY POWER STATION IS LOCATED NEAR ROMEOVILLE, ILLINOIS. THE PLANT HAS FOUR ELEC-
TRIC POWER GENERATING UNITS WITH A TOTAL RATED CAPACITY OF 1117 MW. ONLY UNIT NO. 1 IS RETROFITTED
WITH AN FGD SYSTEM.
UNIT NO. 1 IS A WET-BOTTOM COAL-FIRED BOILER PRODUCING 167 Mrt OF ELECTRICITY. THE BOILER WAS
MANUFACTURED BY BABCOCK AND WILCOX AND WAS INSTALLED IN 1S55. THE PLANT NOW BURNS A LOW-SULFUR 10.H
PERCENT) WESTERN COAL AND A HIGH-SULFUR (4.0 PERCENT) ILLINOIS COAL.
THE WET LIMESTONE FGO SYSTEM AT WILL COUNTY WAS PLACED IN SERVICE ON FEBRUARY 23, 1972. THE
SYSTEM CONSISTS OF TWO FGD MODULES (IDENTIFIED AS A AND B), LIMESTONE HANDLING AND MILLING FACIL-
ITIES, AND A SLUDGE TREATMENT AND STABILIZATION UNIT. A PROCESS FLOW DIAGRAM OF THE FGD SYSTEM IS
GIVEN IN APPENDIX B. SULFUR DIOXIDE REMOVAL EFFICIENCY HAS BEEN MEASURED AT 82 PERCENT. SHORTLY
AFTER STARTUP AND DURING INITIAL SHAKEDOWN, NUMEROUS PROBLEMS WERE ENCOUNTERED. COMMONWEALTH EDISON
SHUTDOWN MODULE B IN MAY 1973 TO CONCENTRATE ON SOLVING THE PROBLEMS OF MODULE A. MODULE B WAS NOT
RESTARTED UNTIL MAY 1975.
THE LIMESTONE GRINDING FACILITIES CONSIST OF TWO WET BALL MILLS, EACH RATED AT 12 TONS PER HOUR
OF LIMESTONE. THE LIMESTONE IS 97.5 PERCENT CALCIUM CARBONATE, AND CONTAINS 0.99 PERCENT MAGNESIUM
CARBONATE AND 0.48 PERCENT SILICA. IT IS RECEIVED IN COARSE-GROUND FORM (ABOUT 1/2 INCH OR LESS)
AND FINELY GROUND TO 95 PERCENT THROUGH 320 MESH.
SLUDGE FROM THE SYSTEM IS SENT TO A CLARIFIER. THE OVERFLOW IS RETURNED TO THE PROCESS AND THE
UNDERFLOW IS STABILIZED BY MIXING IT WITH LIME AND FLY ASH. APPROXIMATELY 200 POUNDS OF LIME AND
400 POUNDS OF FLY ASH ARE USED PER TON OF DRY SuLIDS OF SLUDGE. THE STABILIZED MATERIAL IS THEN
TRANSPORTED BY CONCRETE MIXING TRUCKS FOR ULTIMATE DISPOSAL IN AN OFF-SITE LANDFILL AREA.
PROBLEMS AND SOLUTIONS
1972 - OEMISTER PLUGGING WAS A CONSTANT PROBLEM, MAINLY BECAUSE OF HEAVY LIMESTONE ACCUMULATION ON
THE BOTTOM OF THE DEMISTER AND ALSO BECAUSE OF LOW WASH-WATER PRESSURE CAUSED BY LEAKS IN THE POND
RETURN BYPASS. BECAUSE OF THESE PROBLEMS, MODULES A AND B WERE OUT OF SERVICE FOR SEVERAL DAYS EACH
MONTH DURING MARCH, APRIL, JUNE, AND JULY 1972. THE MODULES WERE ALSO OUT OF SERVICE FROM SEPTEMBER
26 TO NOVEMBER 21, 1972, BECAUSE THE BOILER WAS DOWN.
IN ORDER TO SOLVE THE DEMISTER PROBLEM, THE SLURRY NOZZLES WERE LOWERED AND THE SLURRY CIRCULA-
TION SYSTEM WAS LEFT OUT OF SERVICE TO KEEP THE DEMISTER CLEAN. SINCE THE SITUATION DID NOT IM-
PROVE, THE OEMISTER ELEMENTS WERE HAND-WASHED. THIS SOLVED THE PROBLEM PARTIALLY, BUT CAUSED DIFFI-
CULTY WITH THE VENTUR1 NOZZLES BECAUSE BROKEN ELEMENTS FRUM THE DEMISTER GOT INTO THE SLURRY SYSTEM.
AT HIGH GAS FLOW RATES, THE KEHEATER OF MODULE B VIBRATED EXCESSIVELY. THEREFORE, MuOULE B WAS
TAKEN OUT OF SERVICE IN APRIL TU ALLOW REHEATER MODIFICATIONS, WHICH INCLUDED RE8RACING OF THE RE-
HEATER TUBES AND INSTALLATION OF A BAFFLE PLATE TO REDUCE THE VIBRATIONS.
OTHER REASONS FOR OUTAGES WERE EROSION AND PLUGGING OF SPRAY NOZZLES, INTERNAL AND EXTERNAL
BUILDUP OF DEPOSITS ON VENTuRl NOZZLES, CORROSION, SULF1TE BLINDING PROBLEMS, AND FAN VIBRATIONS.
1973 - OEMISTER PLUGGING CONTINUED. FURTHERMORE, THE UEMISTfcS ON MODULE B BROKE LOOSE FSOM ITS
MOUNTINGS AND THE RESULTANT CARRYOVER OF WASHWATER PLUGGED THE REHEATER. THIS REHEATER ALSO LEAKED
BECAUSE OF CHLORIDE PITTING CORROSION. MODULE A WAS DOWN FROM APRIL 24 TU MAY 24, 1973, AND MODULE
B REMAINED OUT OF SERVICE FROM MAY 1973 TO MAY dO, 1975. THERE WAS NO SCRUBBER OPERATION FROM
AUGUST 27 TO SEPTEMBER 26, 1973.
IN EFFORTS TO SOLVE THE DEMISTER AND REHEATER PROBLEMS, A CONSTANT UNOERSPRAY AND INTERMITTENT
OVERSPRAY WERE USED TO WASH ALL THE DEMISTER COMPARTMENTS UF MODULE A. EXTRA NOZZLES WERE ADDED AND
A CLEAN WATER SUPPLY WAS MAINTAINED. THE REHEATER UNIT WAS ALSU RETUBED.
1974 - ONLY MODULE A OPERATED DURING 1974. TH£ MAIN PROBLEMS WERE FKEEZIMb UF THE VENTURI
THROAT DRIVE MECHANISM, TANK SCREEN BLINDING, DUCT CORROSION, AND VIBRATIONS. LOSS OF BUILDING HEAT
CAUSED EXTENSIVE DAMAGE AND KEPT THE SYSTEM DUWN FOR THE ENTIRE MONTH OF JANUARY 1974.
1975 - ENTERING 1975 MODULE A WAS OPERATIONAL AND MODULE B WAS STILL UNDERGOING MOO IFICATION.
170
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IN THE FIRST QUARTER OF 1975 THERt WERE 8 A-MOOULE UUTA&ES, ONE OF WHICH rtAS A FORCED OUTAGE, DUE TU
THE SPLITTING OF A SLURRY HOSE. MODULE B WAS RETURNED TO SERVICE ON MAT id, l<)7b. THt UTILITY
BECTOED TO OPERATE THE SCRUBBER ON ILLINOIS HIGH-SULFUR COAL. WHEN THIS OPERATION BEGAN, A MULTI-
TUDE OF PROBLEMS OCCURRED? LOWER PARTICULAU REMOVAL EFF1CIENCItS, HIGH SLURRf CARRtUvEnS, OEKlSTER
PLUGGING. REHEATER COIL FOULING AND LEAKS. MODULE A WAS TAKEN OUT OF SERVICE IN MID-JUNE F0« T*E
BFMAINDER OF 1975. BY MID-SEPTEMBER 19f5 MODULE B WAS TAKEN OUT OF SERVICE OnING TO MASSIVE SCALING
IN THE ABSORBER SYSTEM. FINALLY, UNIT NO. 1 WAS SHUT DOWN FOR OVERHAUL OF THE BOILER, TUHSINE, AND
SCRUBBER IN MID-OCTOBER? THIS OUTAGE LASTED MORE THAN H MONTHS.
PERFORMANCE FACTORS FOR EACH MODULE AND CORRESPONDING COMMENTS FOR THE REPORT PERIOD ARE P-.E-
SENTED IN THE FOLLOWING TABLE.
171
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COMMONWEALTH EDISON
FGD SYSTEM OPERABILITY WILL COUNTY UNIT NO. 1
PERIOD OPERA8ILITY (X)
MONTH/YEAR MODULE A MODULE B
MAR. 72 0 35
APR. 72
MAY 72
JUN.
JUL. 72
AUG. 72
SEP. 72
OCT. 72
NOV. 72
DEC. 72
JAN. 73
FEB. 73
MAR. 73
APR. 73
MAY 73
JUN. 73
JUL. 73
AUG. 73
SEP. 73
71)
79
32
31
21
3U
22
0
22
65
0
16
51
IS
30
0
24
11
13
(I
0
0
0
COMMENTS
MODULE A DOWN FOR REPAIR AND MODIFICATION OF DEMISTEK WASH PIPING
ASSEMBLY. MODULE B WAS REMOVED FROM SERVICE EVERY 2 OR 3 DAYS TO
HAND-WASH THE OEMI5TER. OTHER PROBLEMS WERE VIBRATION OF REHEAT-
ER TUBE BUNDLE, RAPID EROSION OF SCRUBBER SPRAY (MUZZLES, ItPLUGGlNb
OF VENTURI NOZZLES.
MODULE A OUT OF SERVICE FOH 6 DAYS BECAUSE OF NEAR-RUPTURE OF A
VENTURI PIPE EXPANSION JOINT AND HEAVY BUILDUP OF SULlDS ON DE-
MISTER. MODULE 6 OUT OF SERVICE MOST OF THE TIME FOR SIMILAR RE-
PAIR OK VENTURI PIPE EXPANSION JOINT, AND FUR MODIFICATION OF RE-
HEATER UNIT ANO OEMISTER WASH SYSTEM.
A TWO-WEEK OUTAGE OF MODULE B WAS INCURRED TO REBRACE THE REHEAT-
ER UNIT, INSTALL UNDERSPRAY NOZZLES ON DEMISTER, AMD INSTALL HEA-
VIER SCREENS IN THE SUMP. RtHEATEH PLUGGING CAUSED ADDITIONAL
OUTAGES.
BOTH MODULES WERE OUT OF SERVICE OWING TO HIGH DIFFERENTIAL PRES-
SURE ACROSS THE DEMISTERS. LEAKAGE OF A POND RETURN BYPASS VALVE
CAUSED DtMISIER PLUGGING. ALSO DURING THIS PERIOD, THE RUBBER
LINING IN MODULE A WAS REPLACED
PLUGGING OF VENTURI NOZZLES AND DEMISTER CAUSED SHUTDOWN OF MOD-
ULE A FOR 2 DAYS FOR REPAIRS. MODULE B WAS OUT OF SERVICE FOR 22
DAYS FOR CLEANING OF THE DEMISTER ANO REHEATER UNIT, INSTALLA-
TION OF OVERHEAD SPRAY NOZZLES AND REPLACEMENT OF SECTIONS OF THE
OEMISTER. THE UNIT WAS SHUT DOWN FOR TWO DAYS FOR TURBINE-GENER-
ATOR REPAIR.
BOILER DOWN SEPT. 1-b BECAUSE OF NO DEMAND. 1.0. FAN PROBLEM
CAUSED UNSIABLE OPERATION OF THE BOILER MOST OF THE MONTH.
MODULE A WAS DOWN FOR MODIFICATION OF REHEATER UNIT AND REPAIR OF
RECIRCULAT10N TANK SCREENS.
BOILER AND SCRUBBERS WERE DOWN. PRINCIPAL MODIFICATIONS INCLUD-
ED INSTALLATION OF REHEATEH BAFFLE PLATES TO DAMPEN VIBRATIONS
AND INSTALLATION OF AN EXPERIMENTAL OEMISTER WASH SYSTEM.
BOILER PROBLEMS CAOS1NG UNSTABLE OPERATION KEPT BOTH MODULES DOWN
DURING THIS MONTH.
MODULES OPERATED INTERMITTENTLY BECAUSE OF ELECTROSTATIC PRECIP-
ITATOR TESTING AND MISCELLANEOUS INSTRUMENT PROBLEMS.
BOTH MODULES WERE DOWN FUR REPAIRS AND MODIFICATIONS.
MODULES WERE OUT OF SERVICE BECAUSE OF CRACKS IN THE INLET DUCT-
WORK OF THE BOOSTER FAN. IMPROPER INSTALLATION OF THE DEMISTER
IN THE B-SIDE CAUSED KEHEATER PLUGGING.
MODULE A WAS OUT OF SERVICE FOR 5 DAYS BECAUSE OF DEMISTER PLUG-
GING. BDILER WAS DOWN FOR 4 DAYS OF INSPECTION. MODULE B WAS
OOwN BECAUSE OF LEAKS FROM REHEATER TUBES.
PERSISTING PROBLEMS WITH DEMISTER AND DEPOSITS OF CALCIUM SULFATE
SCALE ON REHEATER TUBES OF MODULE A WERE ENCOUNTERED DURING Trit
MONTH.
BOTH MODULES WERE OUT OF SERVICE DURING THIS MONTH.
MODULE B WAS KEPT DOWN TO ALLOW CONCENTRATION ON THE PROBLEMS
WITH MODULE A. BOILER-RELATED PROBLEMS WERE RESPONSIBLE FOR MOST
OF THE OUTAGES OF MODULE A.
MODULE A PROBLEMS: REHEATER TUBE LEAKS AND HIGH FAN VIBRATIONS.
MORE REHEATER TUBE LEAKS ON MODULE A ATTRIBUTED TO CHLORIDE CON-
ROSION ATTACK.
MODULES WERE DOWN. DURING THIS MONTH CHICAGO FLY ASH CO. FINISH-
ED CLEANING AND TREATING THE NORTHEAST HALF OF THE SLUDGE POND.
172
-------
COMMONWEALTH EDISON
PERIOD DURABILITY (X)
MONTH/YEAR MODULE A MODULE B
OCT. 73 id 0
FGD SYSTEM OPEKA8ILITY *ILL COUNTY UNIT NO. 1
COMMENTS
NOV. 73
DEC. 73
JAN. 7tt
FEB. 74
MAR. 71
APR. 7a
MAY 71
JUN. IH
JUL. 74
AUG. 74
SEP. 74
OCT. 74
NOV. 74
DEC. 74
JAN. 75
FEB. 75
51
21
72
93
55
91
94
97
99
99
99
°F HODUU * R"EAUD SOME PLUGGING. MODULE
Ri,Tin » ° CLEANING AND SOME MOO IF 1C A T ION . POUR GAS DIST-
RIBUTION IN MODULE SUSPECTED To CONTRIBUTE TO OEMISTER PROBLEMS.
MODULES WERE DOWN. THE MONTH WAS DEVOTED TO MODIFICATION AND
ISOLATION"! PARTICULARLr "MISTER, VENTURI THROATS, PUMPS, ANO
MODULES WERE DOWN OWING TO FREEZING IN THE 1 U-INCH-0 1 AME TErt , 4400
FT. LINE BETWEEN MODULES AND POND. SOME DAMAGE TO SUMP PUMPS OC-
CURRED. FREEZING ALSO DAMAGED SOME INSTRUMENTS.
THE FROZEN PIPELINE WAS THAWED, REANCHURED, AND WETUKNED TO SER-
VICE. THE INSTRUMENTS DAMAGED BY FREEZING WERE KEPA1RED. MODULE
A WAS KEPT DOWN UNTIL ARRIVAL OF SECOND-STAGE DEMlSTER.
MODULE A HAS READY FOR SERVICE MARCH 20 BUT HAS NOT RETURNED TO
SERVICE TILL MARCH 27 BECAUSE THE BOILER WAS DOWN.
MODULE A CONTINUED TO OPERATE UNTIL APRIL 19 (EXCEPT FOR TWO
SHORT INSPECTION OUTAGES) FOR 23 CONSECUTIVE DAYS. OPERATION WAS
ON LOW-SULFUR COAL. SUMP SCREEN FROM MODULE B WAS SUBSTITUTED
FOR DAMAGED SCREEN IN MODULE A.
MODULE A OPERATED FUR ENTIRE MONTH EXCEPT FOH SHORT OUTAGES FOH
INSPECTION. MUCH OF THIS OPERATION WAS ON HIGH-SULFUR COAL.
MODULE A OPERATED FOH ABOUT iOO HOURS. THE SYSTEM WAS OFF FOR 2
WEEKS FOR REPAIR OF VENTURI THROAT DRIVE.
MODULE A OPERATED FOH THE ENT IKE MUNTH EXCEPT FOR AN INSPECTION
OUTAGE AND TwO BOILER SHUTDOWNS. MODULE 8 WILL REMAIN DOWN UN-
TIL SATISFACTORY OPERATION OF MODULE A is ACHIEVED.
MODULE A WAS DOWN SIX TIMES THIS MONTH; 1HKEE TIMES BECAUSE OF NU
BOILER DEMAND, TWICE FOR REPAIK OF LEAKS IN STEAM PIPING, AND
ONCE FOR BALANCING OF A FAN.
MODULE A WAS OFF THREE TIMES; ONCE FOR CLEANING UF DEPOSITS FKUM
THE VENTURI 1HKOAT, ONCE FOR REPAIR OF A DESUPERHEA TER LEAK, AND
ONCE BECAUSE BOILER WAS DOWN.
MODULE A WAS DOWN FOUR TIMES; ONCE BECAUSE OF BOILER OUTAGES,
ONCE FOR INSPECTION, AND TwICE FOR HEPAIR UF HEHEATEK LEAKS.
MODULE A WAS OUT OF SERVICE THREE TIMES; TwICE BECAUSE OF llO DE-
MAND AND ONCE FOR INSPECTION.
MODULE A WAS DOWN TWICE; ONCb FOR INSPECTION AND ONCE FOK REPA1H
OF VALVE IN SPENT LIQUOR LINE TO POND.
MODULE A WAS DOWN TWICE; ONCE FOR INSPECTION AND ONCt FOR NO DE-
MAND. MODIFICATION OF MODULE B IS CONTINUING.
MODULE A WAS OUT OF SERVICE TWICE; ONCE FUR INSPECTION AND ONCt
FOR NO DEMAND. ONE SMALL REHEATER LEAK IN A STAINLESS STEEL BUN-
DLE WAS BLANKEO-OFF UN-LINE. DURING THE INSPECTION DEMISTEH UN-
DFRWASH NOZZLES WERE CLEANED AND A SMALL SECTION OF OtMISTER WAS
HFPLACED INSPECTION SHOWED THAT CONDITIONS INSIDE THE SCRUBBER
WERE ABOUT THE SAME AS BEFORE. COAL BURNED THIS MONTH AVERAGED
TeSS THAN IX SULFUR. MODIFICATION OF MODULE B IS CONTINUING.
CHICAGO FLYASH IS TREATING MATERIAL FRUM THE SCROBdER WITH PORT-
LAND CEMENT AND FLYASH AND DUMPING THE TXEAUD MATERIAL INTU THE
NORTH HALF OF THE HOLDING 8ASIN.
173
-------
COMMONWEALTH EDISON WILL COUNTY UNIT NO. 1
SYSTEM PERFORMANCE FACTORS (X)
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
MONTH/YEAR
MAR. 75 A 94 99 93 81
MODULE A WAS DOWN FOUR TIMES; TWICE FOR NO DEMAND, ONCE FOR A VENTURI HOSE LEAK, ONCE FOR AN
ACCIDENTAL 50-MINUTE TRIP. THE SYSTEM OPERATED ON LOW SULFUR COAL DURING THE MONTH. MODULE
6 MODIFICATIONS ARE CONTINUING.
APR. 75
A 37 40 36 35
SLUDGE POND WAS OVERBURDENED BY NEAR-CONTINUOUS OPERATION OF MODULE A. THE FSD SYSTEM WAS
SHUT DOWN TO ALLOW EVAPORATION OF WATER FROM THE PONO. DURING SHUT-DOWN THE FOLLOWING MODI-
FICATIONS WERE MADE: PUMP GLAND WATER FLOWS WERE REDUCED FROM 10 TO 5 GPM (FILTER BACKWASH
WAS ROUTED OUT OF SYSTEM), CONTINUOUS DEMISTER UNDERSPRAY WAS CHANGEO TO INTERMITTENT. RE-
CLAIM COAL WAS BURNED IN THE BOILER DURING THE MONTH.
MAY 75 A 64 84 84 64
B 37 37 37 37
MODULE A REMAINED OUT OF SERVICE UNTIL MAY 5 WHEN IT WAS DETERMINED THAT THERE WAS ENOUGH
FREEBOARD IN THE POND TO START OPERATING. THERE WERE TWO MORE OUTAGES; ONE FOR 45 MINUTES,
THE RESULT OF A DAMPER TRIP, THE OTHER FOR CLEANING OF UNDERSPRAY NOZZLES. MODULE B WAS
PLACED IN SERVICE AT TEN A.M. MAY SO FOR THE FIRST TIME SINCE NOON ON APRIL 13, 1973. AFTER
bRIEF START UP, WHICH WAS ROUTINE, OPERATION WAS DELAYED UNTIL THE 20TH BECAUSE OF TwO BRO-
KEN OIL PUMPS UN THE RECIRCULATION TANK MIXERS. SINCE THE STARTUP MODULE 8 HAS BEEN OUT OF
SERVICE IWICE; ONCE FUK A VENTURI PUMP TRIP AND ONCE FOR A RECIRCULATION TANK LEVEL TRIP.
THE TOTAL OUTAGE TIME WAS ONLY 1 HOUR, 40 MINUTES. RECLAIM COAL OF VARYING SULFUR CONTENT
WAS AGAIN BURNED IN THE BOILER. THE SCRUBBER SLUDGE WAS STABILIZED WITH LIME AND FLYASH AND
STORED IN THE HOLDING BASIN.
JUN. 75 A 64 61 60 54
B 85 85 84 75
MODULE A SUSTAINED FIVE OUTAGES DURING THE MONTH. THE MODULE IS PRESENTLY OUT OF SERVICE TO
ALLOW INSTALLATION OF NEW DEMISTERS AND REHEATERS. MODULE 3 WAS OUT OF SERVICE EIGHT TIMES.
LONGEST OUTAGE WAS 95 HOURS FOR CLEANING OF BOOSTER FAN AND DEMISTER. BOOSTER FAN VIBRATIONS
CAUSED A SHUTDOWN ON JUNE 30. A HIGH SULFUR COAL TEST BURN WAS CONDUCTED FOR APPROXIMATELY I
WEEKS. LOW SULFUR WESTERN COAL WAS BURNED IN THE UNIT FOR THE REMAINDER OF THE MONTH.
JUL. 75 B 79 79 77 74
MODULE A CANNOT BE RETURNED TO SERVICE UNTIL THE NEW REHEATER ORDERED IN APRIL IS RECIEVED
AND INSTALLED. MODULE 8 SUSTAINED FOUR OUTAGES, ONE FOR NO DEMAND. REHEATER FAILURES AT
1000 HOURS SEEM TO BE CAUSED BY VIBRATION FATIGUE. ONE MINOR STEAM HEADER LEAK ALSO OCCUR-
RED. LOW SULFUR COAL WAS bURNED DURING THE FIRST 3 WEEKS AND HIGH SULFUR ILLINOIS COAL WAS
BURNED DURING THE LAST WEEK OF THE MONTH.
AUG. 75 B 94 100 92 76
MODULE A REMAINED OUT OF SERVICE ALL MONTH. MODULE B WAS SHUT DOWN SEVEN TIMES DURING THE
MONTH, FOUR OF WHICH WERE DUE 10 "NO DEMAND." HIGH SULFUR PILE COAL WAS BURNED IN TnE UNIT
DURING THE MONTH, RESULTING IN A SUBSTANTIAL INCREASE IN SLUDGE PRODUCTION AND FORCING A
6-DAY, 10 HR/DAY, SLUDGE DISPOSAL OPERATION. SLUDGE STABILIZATION IS CONTINUING.
SEP. 75 B 63 63 63 63
MODULE A REMAINED OUT OF SERVICE ALL MONTH BECAUSE OF DELAY ON THE NEW REHEATER ORDER.
MODULE 8 WAS DOWN 8 TIMES BECAUSE OF MASSIVE ABSORBER SCALE, OEMISTEH AND 1.0. BOOSTER FAN
CLEANING, BALANCING 1,0. BOOSTER FAN, AND PLUGGING OF ABSORBER PUMP SCREEN. TOTAL OUTAGE
TIME WAS 236 HOURS, 40 MINUTES FOR CLEANOUT AND FAN BALANCING. HIGH SULFUR COAL WAS BURNED
IN THE BOILER WHEN THE SCRUBBER WAS IN THE GAS PATH.
OCT. 75 B 32 100 2b 26
ON OCTOBER 11, OVERHAUL BEGAN ON THE WILL COUNTY UNIT NO. 1 BOILER, TURBINE, AND SCRUBBER.
MODULE 6 EXPERIENCED TWO MINOR OUTAGES DURING THE 11-DAY PERIOD PRIOR TO THE OVERHAUL.
MODULE A REMAINED OUT OF SERVICE PENDING DELIVERY OF THE NEW REHEATER.
NOV. 75 TURBINE, BOILER, AND SCRUBBER OVERHAUL
THE SCHEDULED OVERHAUL OF THE BOILER, TURBINE, AND SCRUBBER MODULES CONTINUED. MAJOR
MAINTENANCE AREAS INCLUDED MODULE REHEATERS, PONO RETURN PUMP, VENTURI SPRAY NOZZLES, VENTURI
AND ABSORBER MODULES, PUMP VALVES, AND SUMPS.
DEC. 75 TURBINE, BOILER, AND SCRUBBER OVERHAUL
MODULE B REHEATER WAS RETURNED FROM MANUFACTURER AFTER REPAIRS AND REVISIONS. SCRUBBER
REHEATERS COULD BE INSTALLED AND OPERATING BY THE END OF JANUARY.
JAN. 76 TURBINE, BOILER, AND SCRUBBER OVERHAUL
174
-------
COMMONWEALTH EDISON
WILL COUNTY UNIT NO. 1
SYSTEM PERFORMANCE FACTORS fil
UPERABILm RELIABILITY* ' UT ILIZ A , ION
FEB. 76 TURBINE, BOILER, ANU SCRUBBER OVERHAUL
THE UNIT REMAINED UUT OF SERVICE FOR COMPLETION OF THF
THAT BEGAN ON OCTOBER U. 1975. SYSTEM KE»!1S? IS
MAR. 76
30
45
21
8
iq
REMAINED AVAILABLE FOR SERVICE T«E REST OF TH
T E
' TU""NE "°
49
OF
APR. 76 A £3 gy
fc> 51 49
A & ri* 2u
DURING THE MONTH OF APRIL THt A-SIDE INCURRED PUMP LINER FAILURES WHEN AN ISOLATION
BROKfc AND FELL INTO IHt VENTUR1 KtCYCLE PUMP. fl-StOE OUTAGES DURING APRIL HtSoLTEU FKOM
REHEATER TUBE BUNDLE LEAKS, PLUGGED ABSUkBtR TANK SCREEN, AND VENTURI PUMP LINE FAILURE
HIGH SULFER COAL (3.5 PERCENT SULFUR) HAS BURNED IN THE UOILER THROUGHOUT THt MONTH IN
ADDITION, THE UTILITY INITIATED A TESTING AND EVALUATION PROGRAM OORING THE MONTH. THIS
PROGRAM IS DESIGNED TO PROVIDE DATA AND INFORMATION CONCERNING CHEMISTRY AND RELATED
OPERATING CHARACTERISTICS.
MAY 76 B B7 bb 8b 76
THE A-SIDE WAS DOWN THE ENTIRE MONTH AWAITING A PARTS SHIPMENT (VENTURI PUMP LINERS). MUDOLE
B ENCOUNTERED FOOR FURCED SCRUBBER OUTAGES. THREE OF THESE OUTAGES WERE MECHANICAL PROBLEMS,
DUE TO A VENTURI HOSE LEAK, PLUGGED ABSORBER TANK SCREEN, AND A FOOLED I.D. BOOSTER FAN.
HIGH SULFER ILLINOIS COAL WAS BURNED IN \ HE BOILER DURING THE MONTH. THE SLUDGE HAS
STABILIZED WITH LIME AND FLY ASH AND HAULED TO AN OFF-SITE DISPOSAL AREA.
JUN. 76 A bO 44 42 3b
B 63 6b 81 70
A & B* 37 31
SIDE-A WAS RETURNED TO SERVICE JUNE 9 FOLLOWING THE INSTALLATION OF A NErt VENTURI PUMP LINE«.
FOUR FORCED SCRUBBER OUTAGES WERE REPORTED TWO BECAUSE OF NO DEMAND, ONE FUR A BYPASS DAMPER
FAILURE AND ONE FOR 1.0. BOOSTER FAN FOULING. THE B-SIDE ENCOUNTERED SEVERAL FORCED SCRUBbER
OUTAGES, TWO DUE TO NO DEMAND AND SEVERAL SHORT TRIPS BECAUSE UF SCALING AND PLUGGING IN THt
VENTURI TANK SCREEN. HIGH SULFUR ILLINOIS COAL WAS BURNED IN THE SUILER DURING IHt MONTH.
SLUDGE FIXATION AND HAULAWAY TO A DISPOSAL SITE CONTINUED.
JUL. 76 A ^0 0 0 0
B 86 "JO 84 72
THE A-SIDE REMAINED UUT OF SERVICE THE ENTIRE MONTH BECAUSE OF REPAIRS TO A DAMAGED ABSORBER
PUMP AND POND THICKENER SLUDGE OVERLOADING. THE B-SIDE ENCOUNTERED FOUR FORCED SCRUBBER
OUTAGES, TWICE FUR NO DEMAND, ONCE TD BALANCE THE I.D. BOOSTER FANS, AND ONCE TO WASH THE
I.D. BOOSTER FANS.
AUG. 76 A 98 57 96 38
B 65 61 54 41
A & B* 17 11
THE A-SIDE REMAINED UUT UF SERVICE 50 PERCENT OF THE TIME DURING THE MONTH TO AVOID POND
THICKENER OVERLOADING. FOUR SCRUBBER OUTAGES WERE REPORTED, ONE BECAUSE OF NO DEMAND AND
THREE BECAUSE OF MINOR PROBLEMS. THE 8-SIDE ENCOUNTERED THREE NO-DEMAND OUTAGES, Two BECAUSE
OF LOSS OF CHEMICAL CONTROL, ONCE FOR FOULING AND ONCE FOR SPENT SLURRY VALVE REPAIRS.
EXPERIMENTATION WITH THE SYSTEM'S PROCESS CHEMISTRY, BY LOwEKlNG THE PH SET POINT FROM 5.4 TU
b.l, WAS CONDUCTED BY THE UTILITY DURING THIS PERIOD. THIb VARIATION IN OPERATION WAS
BELIEVED TO HAVE CAUSED THE MASSIVE GYPSUM SCALING IN B01H MODULES WHICH OCCURRED DURING THE
PER 100. THE PH SET POINT WAS RETURNED BACK TO THE 5.4 VALVE. HIGH SULFtR ILLINOIS COAL WAS
BURNED IN THE BOILER DURING THE MONTH. SLUDGE STABILISATION PRACTICES CONTINUED.
SEP. 76
42
79
29
76
28
74
60
sr;
•
1 75
-------
COMMONWEALTH EDISON
PERIOD MODULE
MONTH/YEAR
OCT. 76
NOV. 7fa
SYSTEM PERFORMANCE FACTORS (X)
AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
WILL COUNTY UNIT NO. 1
30
76
0
29
56
0
26
70
0
28
55
0
A 20 26 20 20
6 72 70 66 55
A & b* 8 1
PROBLEMS RELATED TO THE A-SIDE SCRUBBER WERE DUE PRIMARILY TO REPAIRS NECESSARY TO THE 1A1
RECYCLE PUMP, AND DELAYS IN KEPLACEMtNT PARTS SHIPMENTS. THE A-SIDE MODULE WAS IN SERVICE
WHEN THE 8-SIOt WAS DOWN, HOWEVER SCRUBBING LIJUOR FLOW WAS REDUCED BECAUSE ONLY ONE RECYCLE
PUMP WAS IN USE. AT THE END OF NOVEMBER, THE REMAINING A-SIDE PUMP WAS TAKEN OUT OF SERVICE
FOR UVERHAUL ANU REPAIRS. FOLLOWING THIS THE A-SIDE WILL RESUME OPERATIONS ON ONE PUMP. ON
THE B-SIDE, 3 FORCED SCRUBBER OU1AGES OCCURRED DURING OCTOBER. ONE WAS BECAUSE OF REPAIRS
OF A REHEATER HEADER LEAK AND THE TIE-IN OF A VACUUM FILTER AT THE THICKENER. THE OTHER TWO
RESULTED FROM A VENlORI NOZZLE CLEAN-OUT AND A VENTORI LOW-FLOW TRIP. DURING NOVEMBER, 4
SCRUBBER TRIPS OCCURRED BECAUSE OF A MILLING SYSTEM FAILURE, VENTURI HEADER LEAK REPAIR AND
VENTURI NOZZLE CLEANING, REPLACEMENT OF SPENT SLURRY VALVE, AND CHEMICAL SYS1EM UP3ET. TWU
OUTAGES WERE ALSO LOGGED BECAUSE OF NO DEMAND.
*NOTE- A&B DESIGNATION AND THE CORRESPONDING PERFORMANCE VALUES REFER TO THE SIMULTANEOUS
OPERATION OF BOTH SCRUBBING TRAINS DURING THE REPORT PERIOD IN UUEST10N.
DEC. 76 A 45 46 45 45
B 53 52 51 48
THE A-SIDE WAS PLACED IN SERVICE DURING THE LATTER PART OF THE MONTH AND OPERATED CONTINUOSLY
WITH THE EXCEPTION OF ONE MINOR OUTAGE FOR SLURRY VALVE REPAIRS. A SPENT SLURRY VALVE
FAILURE FORCED THE 8-SIDE OUT OF SERVICE THE REMAINDER OF THE MONTH. SIMULTANEOUS MODULE
OPERATION TIME WAS 0 HOURS. THE SCRUBBER MODULES ARE SEEING SERVICE ON A ROTATIONAL BASIS,
I.E., ONE MODULE UP. ONE MODULE DOWN. SLODGE STABILIZATION PRACTICES AND OPERATION ON LOW
SULFUR COAL CONTINUED DURING THE MONTH.
JAN. 77 A 98 99 9H 96
B 14 111
ROTATIONAL MODULE OPERATIONS CONTINUED. A-SIDE OUTAGES WERE SPENT SLURRY VALVE FAILURE
AND PLUGGED DEMISTER UNDERSPRAYS. THE DECEMBER SPENT SLURRY VALVE FAILURE KEPT THE B-SIDE
OUT OF SERVICE UNTIL JAN. 27. ACTOAL B-SIOE SERVICE TIME WAS ONE DAY. SLUDGE STABILIZATION
AND DISPOSAL PRACTICES CONTINUED. LOW SULFUR WESTERN COAL WAS BURNED IN THE BUILER. SIM-
ULTANEOUS MODULE OPERATION WAS 0 HOURS.
FEB. 77 A 39 42 39 39
B 72 45 60 41
A&B* 13 12
DURING THE ENTIRE MONTH OF FEB. 1977, LOw-SULFUR COAL WAb BURNED IN THE BOILER. THERE WAS
VERY LITTLE DIGGING IN THE REC IRCUL AT I ON PONDS. CHICAGO FLYASH SPENT MOST OF THEIR TIME ON
CLEANING AND MAINTENANCE. MODULE A WAS OFF THE FIRST PART OF THE MONTH FOR CLEANING OF ON-
DERSPRAYS, OVERSPRAYS AND ABSORBER SPRAY NUZZELS. PLUGGING WAS CAUSED BY A FAILED CLASSIFIER
LINER, WHICH ALLOWED OVERSIZED PARTICLES TO ENTER THE SYSTEM. THE CLASSIFIER LINER WAS RE-
PLACED. MODULE B WAS FORCED OUT OF THE GAS PATH THREE TIMES THIS MONTH. THE REASONS HERE:
HIGH VIBRATION OF I.D. BOOSTER FAN, REPACKING OF 1B1 AND 182 ABSORBER PUMPS, AND BEARING
FAILURES IN A AND 8 SLURRY TRANSFER PUMPS.
MAR. 77 A 97 66 95 b4
B HI 75 79 73
A&B* 52 51
IN MARCH AN ERT S02 ANALYZER WAS INSTALLED ON THE DISCHARGE SIDE OF B MODULE I.D. BOOSTER
FAN. THIS IS AN "IN SITU" NON-DISPERSIVE ANALYZER THAT CONTINUALLY MEASURES AND MEADS OUT
CONCENTRATIONS OF S02, CU2, CO AND NO. HIGH-SULFUR COAL WAS BURNED FOR SEVEN DAYS DURING
MARCH TO PROVIDE HIGH SOLFUR SLUDGE FOR THE U.O.P. SLUDGE TEST IA U.O.P. TEST CREW WAS
EXPERIMENTING WITH POWERTON FLYASH AND HIGH-SULFUR SLUDGE). CHICAGO FLYASH SPENT ABOUT 75%
OF THEIR TIME DIGGING IN THE RECIRCUL A T ION PONO. THE REST WAS SPENT ON THE THICKENER AND
VACUUM FILTER OPERATIONS. THE SCRUBBER WASTE MATERIAL WAS TREATED WITH LIME AND FLYASH AND
HAULED TO AN OFF-SITE DISPOSAL AREA. MODULE FORCED OUT OF THE SAS PATH ONCE THIS MONTH TO
ALLOW FOR REPAIR TO A VENTURI FLOW DIFFERENTIAL LINE. MODULE FORCED OUT OF THE GAS PATH FOUR
TIMES. THE REASONS WERE: REPTUftED DIAPHRAM ON REHEATEK STEAM VALVE, ABSORBER SUCTION LEAK,
SPENT SLURRY VALVE GASKET LEAK AND PLUGGED FEED SLURRY KEC IHCULAT ION LINE.
176
-------
COMMONWEALTH EDISON
PERIOD MODULE
MONTH/YEAR
WILL COUNTY UNIT NO. 1
AVA1I4RI,in PERFORM*NCE FACTORS U)
AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
APR. T7
A
B
& B*
86
45
RPKN
68 61 61
30 33 21
« THE A'8IOE DUR1NG APRIL- ONE FOR°A 8oii-ER TU8E LEA* REPAIR« AND
InROAT LEAK> B'SIOE OUTAGES OCCURRED TWICE FOR ABSORBER SUCTION
!°.r*8H THE I
-------
COMMONWEALTH WILL COUNTY UNIT NO. 1
SYSTEM PERFORMANCE FACTORS (X)
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
MONTH/YEAR
OCT. 77 TURBINE/ BOILER AND SCRUBBER OVERHAUL
NOV. 77 A 0 0 0 0
B 9 50 9 9
UNIT 1 CAME ON LINE FOLLOWING A SIXTY-THREE DAY UNIT OUTAGE ON 11/25/77. A MODULE, HOWEVER,
WAS STILL UNDERGOING SUMP REPAIRS WITH AN EXPECTED SERVICE DATE OF LATE DECEMBER. B MODULE
IS IN GAS PATH AFTER EXPERIENCING SOME DIFFICULTY IN BALANCING ITS BOOSTER FAN.
DEC. 77 A 43 48 43 42
B 84 94 84 84
THE MONTH OF DECEMBER SAW TROUBLESOME REHEAT PLUGGING ON B MODULE. BECAUSE OF NO SPARE
REHEAT-COILS WE TRIED TAKING SOME COILS FROM A MODULE TO USE IN B MODULE; HOWEVER, B MODULE
SEEMS TO BE PLUGGED MORE SEVERELY THAN ORIGINALLY BELIEVED. A MODULE WAS DOWN HALF THE
MONTH BECAUSE OF A MAIN STEAM LEAK WHICH COULD NOT BE ISOLATED AND FINISHING THE DAMAGED
SUMP FLOOR.
CHICAGO ADMIXTURES SPENT MOST OF THEIR TIME OPERATING OUT OF THE THICKENER. THE WASTE MATER-
IAL WAS TREATED WITH LIME AND FLYASH AND HAULED TO A DISPOSAL AREA.
178
-------
TABLE 12
DESCRIPTION OF TERMINATED F6D SYSTEMS 01/76
UTILITY NAME DAIRYLAND POWER COOP
UNIT NAME ALMA STATION
UNIT LOCATION ALMA WISCONSIN
UNIT RATING 60 MM
FUEL CHARACTERISTICS COAL 3.0-3.5 PERCENT SULFUR
FGO VENDOR FOSTER WHEELER
PROCESS LIME INJECTION
NEW OR RETROFIT RETROFIT
START UP DATE 6/71
F60 STATUS TERMINATED
EFFICIENCY.
PARTICULATES
S02 25 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL THIS EXPERIMENTAL WET LIME FURNACE SYSTEM BEGAN OPERATIONS IN '71 AND WAS
EXPERIENCE OPERATIONAL FOR PERIODS UP TO 30 DAYS. IN AUGUST 1974 THE UNIT WAS TESTED
FOR TWO DAYS USING WESTERN LOW-SULFUR COAL. THE TEST SHOWED ABOUT 50%
sos REMOVAL EFFICIENCY! BUT PRECIPITATOR PERFORMANCE WAS ADVERSELY
AFFECTED. THE FGD PROJECT HAS BEEN SHUT DOWN INDEFINITELY SINCE
AUGUST 1974, AND THERE ARE NO PLANS FOR FUTURE OPERATION.
179
-------
TABLE \Z
DESCRIPTION OF TERMINATED FGD SYSTEMS 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
DETROIT EDISON
ST. CLAIR NO 6
BELLE RIVER MICHIGAN
163 MW
COAL 0.3 PERCENT SULFUR
PEABODY ENGINEERING
LIMESTONE SCRUBBING
RETROFIT
5/76
TERMINATED
99.7 PERCENT
502
90 PERCENT
MATER MAKE UP
OPEN LOOP 1.07 GPM/MW
SLUDGE DISPOSAL
10-ACRE SETTLING POND
UNIT COST
SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 12 OF THIS REPORT.
FOLLOWING THE COMPLETION OF A TWO MONTH INTERNAL S02 SCRUBBING DEMONSTRA-
TION PROGRAM THE SCRUBBER PLANT WAS BYPASSED. MODIFICATIONS WERE
IMPLEMENTED TO OPERATE IN THE PARTICULATE MODE ONLY. VENTURI SCRUBBERS
FOR PARTICULATE REMOVAL WERE PUT BACK IN OPERATION IN OCTOBER 1977. SPRAY
TOWERS ARE NOT COUPLED INTO THE SCRUBBING SYSTEM. THE BOILER IS NOW FIN-
ING LOW-SULFUR (0.3 PERCENT) WESTERN CDECKER) COAL. COMPLIANCE WITH S02
REGULATIONS IS BEING ACHIEVED WITHOUT THE NECESSITY OF SCRUBBING.
180
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BACKGROUND INFORMATION
ON
ST. CLAIR NO. 6
THE ST. CLAIR POWER PLANT OF THE DETROIT EDISON COMPANY IS LOCATED ON THE ST. CLAIR RIVER IN
BELLE RIVER, MICHIGAN, APPROXIMATELY 45 MILES NORTHEAST OF DOWNTOWN DETROIT. THIS PLANT CONTAINS 7
FOSSIL-FUEL-FIRED GENERATING UNITS WHICH HAVE A TOTAL NET GENERATING CAPACITY OF 1775-Mw. UNIT NO.
6 IS A COAL-FIREO TWO-STAGE SUPERHEATER UNIT, CONTAINING TWO SEPERATE BOILER BOXES KNOWN AS THE
SOUTH BOILER AND THE NORTH BOILER. THE TOTAL NET GENERATING CAPACITY OF THE NO. 6 UNIT IS 325 MW.
THE SUPERHEATER WAS MANUFACTURED BY COMBUSTION ENGINEERING AND PLACED IN SERVICE IN 1961. BOTH THE
NORTH BOILER AND THE SOUTH BOILER ARE EQUIPPED WITH EMISSION CONTROL SYSTEMS. THE UNIT CURRENTLY
OPERATES AT EXCESS AIR RATES OF 115 TO 120 PERCENT.
THE ST. CLAIR NO. b BOILER FIRES EXCLUSIVELY A LOW SULFUR WESTERN SUBBITUMINOUS COAL ORIGINAT-
ING FROM DECKER COMPANY'S DIETZ MINE LOCATED IN SOUTHERN MONTANA. THE AVERAGE CHARACTERISTICS OF
THIS COAL ARE: HEAT CONTENT 9500 TO 9600 BTU/LB; SULFUR CONTENT OF 0.3 TO 0.4 PERCENT; ASH CUNTENT
OF 4.0 PERCENT! AND A TOTAL MOISTURE CONTENT OF 22.0 TO 24.0 PERCENT.
THE EMISSION CONTROL SYSTEM INSTALLED ON THE NORTH BOILER CONSISTS OF MECHANICAL COLLECTORS AND
AN ELECTROSTATIC PRECIPITATOR (ESP) INSTALLED UPSTREAM OF A WET SCRUBBING SYSTEM. THE MECHANICAL
COLLECTORS AND ESP ARE PROVIDED FOR PRIMARY PARTICULATE CONTROL THE WET SCRUBBING SYSTEM PROVIDES
ADDITIONAL PARTICULATE REMOVAL AND PRIMARY DIOXIDE CONTROL.
THE FLUE GAS DESULFURIZATION (FGD) CONSISTS OF TWO PEAdOOY-LURGI VENTURI SCRUBBER AND SPRAY
TOWER ABSORBER MODULES WITH A TOTAL FLUE GAS CAPACITY OF 493,500 ACFM AT 270 F. THIS VOLUME IS
EUUIVALENT TO APPROXIMATELY so PERCENT OF THE TOTAL FLUE GAS FROM THE NO. & UNIT. THE DESIGN FLOW
RATE PER SCRUBBING TRAIN IS 246,700 ACFM AT 270 F. FLUE GAS CAN BE BYPASSED AROUND THE SCRUBBING
SYSTEM. 6.6 MW OF ELECTRICAL POWER ARE CONSUMED BY THE SCRUBBING OPERATIONS. THIS FGO SYSTEM IS AN
EXPERIMENTAL DEMONSTRATION UNIT DESIGNED AND INSTALLED BY PEABODY ENGINEERED SYSTEMS IN COOPERATION
WITH THE DETROIT EDISON COMPANY. EACH SCRUBBING TRAIN INCLUDES A CLEAR WATER TRAY ANO
RADIAL VANE MIST ELIMINATOR, A COMMON RECYCLE TANK, INDUCED DRAFT FAN, OIL-FIRED HOT-AIR-INJECT ION
REHEAT SYSTEM AND A 10.6-ACRE CLAY-LINED SETTLING POND. DESIGN REMOVAL EFFICIENCY OF THIS EMISSION
CONTROL SYSTEM IS 99.7 PERCENT FOR PARTICULATES AND 90 PERCENT FOR SULFUR DIOXIDE BASED UPON HI&H
SULFUR EASTERN COAL. A DIAGRAM OF ONE OF THE TWO PARALLEL SCRUBBING TRAINS 13 PRESENTED IN
APPENDIX B.
181
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DETROIT EDISON FGD SYSTEM PERFORMANCE ST. CLAlR UNIT NO. 6
PERIOD COMMENTS
MOV. 71 INSTALLATION OF THE FGD SYSTEM WAS ESSENTIALLY COMPLETED BY THIS TIME. A CAULIT
DEC. 74 INSTRUMENT PANEL WHICH WAS INCORRECTLY WIRED HAS BEEN RETURNED TO THE MANUFACTURER
JAN. 75 FOR REPAIR. TO DATE, THE UTILITY HAS WATER TESTED ALL THE AUXILIARY EQUIPMENT. THE
I.D. FAN HAS BEEN TESTED AND AIR BALANCE HAS BEEN CHECKED.
FEB. 75
MAR. 75 A COLD FLUE GAS RUN WAS SUCCESSFULLY CONDUCTED MAK. 32-23. DURING THIS PERIOD. THE
APR. 75 RUBBER-LINED PUMPS WERE REPAIRED AND THE LIMESTONE PREPARATION SYSTEM WAS CALIBRATED.
MAY 75
JUN. 75 THE FIRST HOT FLUE GAS RUN WAS CONDUCTED ON JUNE 22, 1975. THE RUN LASTED FOR A
JUL. 75 PERIOD OF 22 HOURS. DURING THIS RUN, THE SCRUBBER WAS PURPOSELY TRIPPED OFF AT LOADS
OF 40 AND 80 PERCENT. THIS WAS PERFORMED TO OBSERVE IF ANY DETRIMENTAL EFFECTS TO
THE STEAM GENERATION OPERATIONS RESULTED. NONE WERE DETECTED. THE SYSTEM WAS TAKEN
OUT OF SERVICE FOLLOWING THIS GAS RUN TO CORRECT THE FOLLOWING MAJOR OPERATION AREAS:
*GAS CIRCUIT: LURGI THROAT POSITIONAL FAILURE; DETERIORATION OF THE DAMPEK SEALS;
SEVERE DUCT VIBRATIONS; S02 ANALYZERS INOPERATIVE.
•LIQUID CIRCUIT: FAILURE OF PH CONTROL SYSTEM; TARGET FLOW METER TARGETS HAVE
BEEN BROKEN OFF; PUMP SEAL WATER LOW FLOW ALARM TRIPS.
AUG. 75 A SECOND HOT FLUE GAS RUN WAS INITIATED ON AUGUST 6 AND LASTED 27 HOURS. THE RUN HAS
TERMINATED BECAUSE OF A REHEA1ER THERMOCOUPLE FAILURE. A SUBSEQUENT INSPECTION OF
THE SCRUBBING SYSTEM REVEALED NO APPARENT ABNORMALITIES OR MALFUNCTIONS.
SEP. 75
A THIRD HOT FLUE GAS RUN OF 41 HOURS DURATION WAS COMPLETED OCTOBER 9. THE MAIN
OBJECTIVE OF THIS RUN WAS TO EVALUATE VARIOUS COMPONENTS OF THE FRESH WATER SPRAY
SYSTEM AND EFFECTS ON SYSTEM OPERATION. THE TEST RUN WAS PREMATURELY TERMINATED BE-
CAUSE OF A BOILER FEED PUMP MALFUNCTION, RESULTING IN A REDUCED BOILER LOAD CAUSING
SUBSEQUENT WEEPING OF THE WASH TRAY.
NOV. 75
DEC. 75 A FOURTH FLUE GAS RUN OF 23 DAYS DURATION WAS TERMINATED DUE TO EXCESSIVE VIBRATION
IN THE I.D. BOOSTER FAN. ONE OTHER SCRUBBER-RELATED OUTAGE OCCURRED WHEN THE PACKING
OF ONE OF THE SCRUBBER RECIRCULATION PUMPS NEEDED MAINTENANCE. SOS REMOVAL DURING
THIS PERIOD WAS 9U PERCENT AND PAKTICULATE OUTLET LOADING WAS 0.1 L6/1UOO L8S OF FLUE
GAS FOR 1-3 PERCENT SULFUR CUAL.
JAN. 76
FEB. 76
MAR. 76
APR. 76 THE 30-DAY VENDOR QUALIFICATION RUN AND FINAL ACCEPTANCE TEST WERE COMPLETED BY MAY
29. THE QUALIFICATION RUN WAS CONDUCTED ON A "HANDS OFF" BASIS USING PLANT PERSONNEL
EXCLUSIVELY. THE SYSTEM WAS IN SERVICE 100 PERCENT OF THE TIME THE BOILER WAS
OPERATIONAL. THE FINAL ACCEPTANCE IEST CONSISTED OF SIX 4-HR. TEST RUNS CONDUCTED IN
THE SPACE OF ONE WEEK. THE S02 REMOVAL EFFICIENCY FOR HIGH SULFUR COAL WAS 90.9
PERCENT. PARTICULATE REMOVAL ALSO EXCEEDED DESIGN LEVELS. NO MAJOR MECHANICAL OR
CHEMICAL-RELATED PROBLEMS WERE ENCOUNTERED.
JUN. 76
JUL. 76
AUG. 7fa THE UTILITY IS NOW PREPARING TU CONDUCT A 2 MONTH MINIMUM INTERNAL SCRUBBER DEMONSTRA-
TION PROGRAM TO ACQUIRE OPERATING DATA AND INFORMATION. FOLLOWING THE COMPLETION OF
THIS PROGRAM THE BOILERS WILL FIRE LOW SULFUR DECKER COAL (0.3 TO 0.4 PERCENT) TO MEET
so2 EMISSION REGULATIUNS. THE SCRUBBERS WILL CONTINUE TO OPERATE IN THE PARTICULATE
REMOVAL MODE
SEP. 7fa THE INTERNAL S02 SCRUBBING DEMONSTRATION PROGRAM COMMENCED ON OCTOBER 14. THE SCRUB-
OCT. 76 BERS OPERATED CONTINUOUSLY FOR 10 DAYS. OPERATION WAS INTERRUPTED BY A FORCED SCRUB-
BER OUTAGE RESULTING FROM SCALE AND SOLIDS CARRYOVER FROM THE WASH TRAY AND MIST
ELIMINATOR TO THE SCRUBBER I.D. BOOSTER FAN ASSEMBLY, CAUSING VIBRATION AND BALANCE
PROBLEMS. IT WAS DECIDED TO SANDBLAST THE FAN TO REMOVE SOLIDS BUILDUP ON IHE FAN
ASSEMBLY. THE UTILITY PLANS TO MODIFY THE COMPONENT'S WASH SYSTEM FOR GREATER FLOW
CAPABILITY AFTER COMPLETION OF THE S02 SCRUBBING PROGRAM. DECO ALSO PLANS TO CON-
TINUE PARTICULATE SCRUBBING FOLLOWING THE TERMINATION OF THE S0e> PROGRAM BY UNCOUPLING
THE SPRAY TOWERS AND MAINTAINING THE PEABUDY-LURGI VENTURI SCRUBBERS IN THE FLUE GAS
STREAM. SOME LIMESTONE MAY HAVE TO BE ADDED TO THE PARTICULATE SCRUBBING SOLUTION
IN ORDER TO PREVENT LOW PH SWINGS AND MINIMIZE THE POSSIBILITY UF ACID CORROSION
DAMAGE TO THE INTERNAL COMPONENTS.
182
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DETROIT EDISON ST. CLAIR UNIT NO. 6
PERIOD COMMENTS
MOV. 76 FOLLOWING THE COMPLETION OF SAND BLASTING OPERATIONS TO SCRUBBER'S I.D. BOOSTER FAN
FOR REMOVAL OF SOLIOS 8U1LD (if, OPERATIONS RESUMED ON NOVEMBER 7 AND CONTINUED
THROUGHOUT THE MONTH. THE SYSTEM'S AVAILABILITY INDEX FUR THE MONTH WAS 80 PERCENT
THE MAJORITY UF THE OUTAGE TIME WAS CONSUMED PROCURING SAND BLASTING SERVICES. THE
OPERATION ITSELF REUUIREO ONLY tt HOURS.
DEC. 76 THE S02 DEMONSTRATION PROGRAM CONTINUED THROUGHOUT DECEMBER. THE SYSTEM'S AVAILABIL-
ITY INDEX FOR THE PERIOD WAS 51 PERCENT. SCRUBBER OUTAGES RESULTED FROM MALFUNCTIONS
OF THE LIMESTONt FEEDER, THE DENSE SLURRY TRAVERSE PUMP, THE DENSE SLURRY TANK
AGITATORS, AND PLUGGING OF THE PH SAMPLE LINE.
JAN, 77 THE 503 DEMONSTRATION PROGRAM WAS OFFICIALLY TERMINATED ON DEC. 31, 1976. THE SCRUB-
FEB. 77 BER PLANT WAS SHUT DOWN AT THIS POINT AND FLUE GAS WAS BY-PASSED AROUND THE SYSTEM.
MAR. 77 THE BOILER REMAINS IN SERVICE, FIRING LOW SULFUR (0.3%) WESTERN COAL. CURRENT PLANS
CALL FOR IHE SCRUBBER PLANT TO REMAIN 001 OF SERVICE UNTIL MID-JUNE FOR DESIGN AND
OPERATIONS MODIFICATIONS. RESUMPTION OF SCRUBBER OPERATIONS WILL OCCUR IN TtiE PRI-
MARY PARTICULATE-REMOVAL MODE. THE PEABOOY-LURGI VENTURI SCRUBbERS AND SpRAY TOhER
ABSORBERS WILL REMAIN IN THE GAS STREAM. SOLUTION WILL BE CIRCULATED THROUGH THE
VENTURI'S, WASH TRAYS, AND MIST ELIMINATORS. NO SOLUTION WILL BE CIRCULATED THROUGH
THE SPRAY ZONE OF THE ABSORBER TOWERS. LIMESTONE REAGENT WILL BE ADDED TO THE
SCRUBBING SOLUTION IN ORDER TO PREVENT LOW PH SWINGS AND SUBSEQUENT MATERIALS DAMAGE
TO THE SCRUBBER'S INTERNALS, S02 REMOVAL SHOULD RESIDE IN THE 35 TO 50* RANGE IN
THIS MODE OF OPERATION BECAUSE OF THE SOLUTION'S ALKALINITY DUE TO THE FLY ASH AND
LIMESTONE. ALSO DECO PLANS TO MAINTAIN A HIGHER L/G RATIO IN THE SCRUBBER MODULES.
THIS MODE OF OPERATION IS PROJECTED TO CONTINUE FOR A ONE TO THREE-YEAR PtRIOO FOLLOW-
ING THE MID-JONE RESTART.
1S3
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TABLE 12
DESCRIPTION OF TERMINATED FGD SYSTEMS 01/76
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FED STATUS
EFFICIENCY,
PARTICULATES
GULF POWER CO.
SCHOLi! NO. 1A
CHATTAHOOCHtE FLORIDA
20 MW
COAL 3.0 PERCENT SULFUR
ADL/COMbUST ION EQUIP ASSOCIATE
OOUbLE ALKALI SCRUBBING
RETROFIT
2/7b
TERMINATED
99.7 PERCENT
302
95 PERCENT
WATER MAKE UP
CLOSED LOOP
SLUDGE DISPOSAL
ON-SITE LINED DISPOSAL POND
UNIT COST
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 12 OF THIS REPORT.
THIS PROTOTYPE SCRUBBING SYSTEM WAS INITIALLY PLACED IN SERVICE FEBRUARY
1975 AND WAS OPERATIONAL A TOTAL OF 4744 HOURS IHRUUGHOUT THE YEAH. THE
SYSTEM REMAINED IN SERVICE DURING THE FOLLOWING b MONTHS IN 1976.
SUCCESSFUL COMPLETION OF THIS PROGRAM OCCURRED ON JULY a, is/b. PRESENT
PLANS CALL FOR A FULL SCALE EPA-SPONSORED DEMONSTRATION PROGRAM WITH
THE INSTALLATION SITE BEING LOUISVILLE GAS & ELECTRIC'S CANt HUN STATION,
UNIT NO. 6.
184
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BACKGROUND INFORMATION
ON
SCHOLZ CEA/ADL DUAL ALKALI PHOTOTYPE
THE SCHOLZ STEAM POWER PLANT OF GULF POWER COMPANY IS LOCATED IN CHATTAHUOCHEE, FLOKIDA. UNIT
NO. 1 IS A COLA-FIRED STEAM BOILEK DESIGNED AND INSTALLED BY BABCOCK AND wILCUX IN 1953. THIS UNIT
IS NORMALLY RATED AT
-------
GULF POWER CO.
SCHOLZ 1A - DOUBLE ALKALI
SCHOLZ UNIT NO. U
PERIOD
TOTAL
HOURS
UNIT OPERATING HOURS
BOILERS FGD SYSTEM
FGD SYSTEM
OPERABIL1TY
PERFORMANCE CX)
UTILIZATION
FEB.
MAR.
APR.
MAY
JUN.
JUL.
AUG.
SEP.
OCT.
NOV.
DEC,
672
744
720
744
720
744
459
507
604
598
720
663
454
485
336
375
720
221
UNIT WAS PLACED IN OPERATION FtB. e,
FOR 2 MONTHS MODIFICATIONS, REPAIRS,
99 68
9fo 665
56 47
63 50
100 100
32 30
1975 AND OPERATED UNTIL JULY 18 WHEN IT WAS SHUT DOWN
AND REPLACEMENT OF PARTS. THE SYSTEM WAS UNAVAILABLE
TO THE BOILER FOR A 491-HR PERIOD BECAUSE OF ADJUSTMENTS AND MODIFICATIONS REQUIRED FOR THE
FORMAL EPA TEST PROGRAM IN MID-MAY.
75 744 744 000
75 720 577 254 44 35
75 744 559 559 100 75
THE SYSTEM WAS SHUT DOWN FROM MID-JULY TO MID-SEPTEMBER FOR MECHANICAL OVERHAUL INVOLVING
REPLACEMENT PARTS FOR VALVES THAT HAD FAILED. THE SYSTEM WAS PUT BACK IN OPERATION ON SEP
16, 1975. FROM MIO-SEP. TO MID-OCT. THE AIR PREHEATER WAS REPAIRED AND BOILER OPERATION
ADJUSTED TO REDUCE OXYGEN LEVELS IN THE FLUE GAS TO THE 5 TO 6 PERCENT RANGE. THE SYSTEM
OPERATED APPROXIMATELY 800 HRS. DURING THI3PERIOD.
75 720 620 560 90 78
75 744 732 732 100 98
THE SYSTEM RAN CONTINUOUSLY FOR THE REMAINDER OF THE TEST PERIOD THROUGH JANUARY ^, 1976.
S02 LEVELS DURING THIS PERIOD RANGED FROM 800 TO 1700 PPM. THE SYSTEM OPERATED IN THE
CONCENTRATED MODE THROUGHOUT THE REMAINDER OF THE TEST PERIOD. IN THE PERIOD FROM MID-SEP.
TO JAN. 2, 1976, THE SYSTEM OPERATED ABOUT 2100 HRS., WITH AN UPERA8ILITY FACTOR OF 97
PERCENT.
76 744
76 696
THE FGO SYSTEM AND BOILER UNDERWENT A SCHEDULED OVERHAUL DURING THE REPORT PERIOD. SYSTEM
RESTART IS SCHEDULED FOR MID-MARCH 1976, TO CONTINUE UNTIL JUNE. DURING THIS OPERATING
PERIOD HIGH-SULFUR COAL [3.5-4.ox) WILL BE BURNED TO ALLOW EVALUATION OF SYSTEM PERFORMANCE
ON HIGH SULFUR COAL.
76 744 742 445 60 60
THE SYSTEM WAS PUT BACK IN SERVICE ON MAR. 12, 1976. THE TOTAL NUMBER OF OPERATING HRS. FOR
THE MONTH OF MAR. WAS 445 HRS. THIS TRANSLATES INTO A 94X OPERABILITY FACTOR SINCE THE
MAR. 12 RESTART.
APR. 76 720 642 616 96 86
MAY. 76 744 735 651 89 68
SOME MINOR MECHANICAL PROBLEMS IN THE FORM OF AGITATOR SHAFT AND CONTROL VALUE FAILURES WERE
ENCOUNTERED DURING THE REPORT PERIOD. SINCE THE SYSTEM RESTART ON MARCH. 12, HIGH-SULFUR
COAL HAS BEEN BURNED IN THE BOILER 13.5 TO 4.5X SULFUR), RESULTING IN THE S02 INLET
CONCENTRATION LEVELS IN THE 2000 TO 2500 PPM RANGE.
JUN. 76 720 656 641 93 89
DURING THE LAST PHASE OF OPERATION, THE SYSTEM WAS TREATING FLUE GAS OF VARYING PARTICULATE
LOADS. THE UPSTREAM ESP WAS SELECTIVELY DE-ENERUIZED, BOTH PARTIALLY AND TOTALLY, NO MAJOR
UPSETS IN THE PROCESS CHEMISTRY OCCURRED. BOILER LOAD VARIATION RANGED FROM 30 TO 100X. THE
PROTOTYPE PROGRAM AT THE PLANT WAS SUCCESSFULLY CONDUCTED ON JULY 2. ADL IS CURRENTLY
COMPLETING DATA ACQUISTION AND ANALYSIS.
JUL. 76 744 54 54 100
THE PROTOTYPE TEST PROGRAM WAS SUCCESSFULLY CONCLUDED ON JULY 3, 1976.
NOTE: THE BOILER HRS., SYSTEM OP HRS., AND THE CORRESPONDING PERFORMANCE VALUE CALCULATED
INCLUDES SYSTEM OP UP TO THE SCHEDULED SHUTDOWN, ON JULY 3, 6 O'CLOCK A.M., 1976.
JAN.
FEB.
MAR.
186
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TABLE 13
DESCRIPTION OF TERMINATED FGO SYSTEMS 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F6D VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCY,
PARTICULATES
GULF POWER CO.
SCHULZ NO. 2A
CHATTAHOOCHfcE FLORIDA
20 MM
COAL 3.0 PERCENT SULFUR
FOSTER WHEELER
ACTIVATED CARBON
RETROFIT
2/76
TERMINATED
99.7 PERCENT
S02
74.5 PERCENT [DESIGN)
MATER MAKE UP
N/A DRY ADSORPTION SYSTEM
SLUDGE DISPOSAL
MOLTEN ELEMENTAL SULFUR
UNIT COST
SEE APPENDIX A, FGO SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE RED IN AUGUST 1975,
REPORT. THIS IS A PROTOTYPE DRY ADSORPTION REGENERABLE SYSTEM
DESIGNED BY FOSTER WHEELER AND BERGBAU FORSCHUNG. OPERATION OF
THE PROTOTYPE UNIT DURING THE SCHOLZ DEMONSTRATION PROGRAM PROCEEDED
ON AN INTERMITTtNT BASIS. OPERATIONAL SEGMENTS OCCUKEO IN AUGUST 1975,
OCTOBER 1975, AND MARCH, APRIL AND MAY 1976. SYSTEM OPERATIONS WERE
PREMATURELY TERMINATED AT THIS POINT AND THE PROTOTYPE UNIT WAS SHUT
DOWN. THE SYSTEM IS CURRENTLY INACTIVE.
187
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BACKGROUND INFORMATION
UN
SCHOLZ FWBF DRY ADSORPTION PROTOTYPE
IN JANUARY 1973, THE SOUTHERN SERVICES COMPANY OF GULF POWER AWARDED A CONTRACT TO THE FOSTER
WHEELER CORPORATION TO BUILD A 20-MW PROTOTYPE DRY ADSORPTION SYSTEM FOR FLUE GAS DESULFUKIZATION.
CONSTRUCTION ON THE FOSTER WHEELER PROCESS STARTEDFEBRUARY 15, 1974, AT THE SCHOLZ STEAM POWER PLANT
IN CHATTACHOOCHEE, FLA. CONSTRUCTION WAS COMPLETED AND A TESTING PROGRAM WAS INITIATED IN MAY 1975.
THE SYSTEM AT THE SCHOLZ PLANT CONSISTS OF A 20-MW ADSORBER SECTION AND A 47.5-Mw REGENERATION
AND REDUCTION SECTION. THE 20 MW ADSORBER IS DESIGNED TO ACCEPT HALF OF THE MAXIMUM FLUE GAS FLOW
FROM UNIT NO. 2. THE COAL-FIRED BOILER IS RATED AT 40 MW (NOMINAL)* IT FIRES COAL WITH AN AVERAGE
HEATING VALUE OF 12,400 BTU/LB. MAXIMUM ASH AND SULFUR CONTENTS ARE 14 AND 5 PERCENT, RESPECTIVELY.
THE PURPOSE OF THE ADSORPTION SECTION OF THE FWBF DRY REMOVAL SYSTEM IS TO REMOVE SULFUR
DIOXIDE, NITROGEN OXIDES, AND PARTICULATE FROM THE FLUE GAS WITH ACTIVATED CHAR, CONVERTING THE
CAPTURED POLLUTANTS TO SULFURIC ACID. THE REGENERATION SECTION PROVIDES CONTINUOUS OlM-SITE REGENER-
ATION OF THE CHAR, WHICH HAS BEEN LOADED WITH SULFUR DIOXIDE IN THE FORM OF SULFURIC ACID. THE CHAK
IS REGENERATED AND A LOW-VOLUME, SULFUR DIOXIDE-RICH OFF-GAS STREAM IS FED FORWARD TO THE RESQX
REACTOR, WHICH REDUCES THE SULFUR DIOXIDE STREAM TO GASEOUS ELEMENTAL SULFUR THAT IS COLLECTED AND
STORED IN AN INSULATED TANK.
THE DEMONSTRATION UNIT HAS TWO ROWS OF MODULES, EASH ROW CONSISTING OF SIX MODULES, THE
ADSORPTION SECTION IS A TWO-STAGE DESIGN CONSISTING OF VERTICAL COLUMNS OF PARALLEL LOUVER BEDS
WHICH SUPPORT AND CONTAIN THE ACTIVATED CHARCOAL. SULFUR DIOXIDE, OXYGEN, WATER VAPOR, AND NITROGEN
OXIDES ARE ADSORBED BY THE CHAR PELLETS FROM THE CROSS-FLOWING FLUE GAS AT 250 TO 300 F. THE SULFUR
DIOXIDE THEN REACTS WITH OXYGEN AND WATER TO FORM SULFURIC ACID WHICH IS FIRMLY RETAINED IN THE INT-
ERIOR PORE SYSTEM OF THE CHAR PELLETS. THE CHAR IS THEN REGENERATED IN THE REGENERATOR VESSEL BY
HEATING TO 1200 F, DRIVING OFF THE ENTRAINED GASES, AND REDUCING SULFURIC ACID TO SULFUR DIOXIDE.
THE SULFUR OIOXIDE-RICH GAS IS THEN PASSED THROUGH A VESSEL CONTAINING CRUSHED COAL, RESULTING IN
REDUCTION TO GASEOUS ELEMENTAL SULFUR AND CARBON DIOXIDE. THIS LATTER PROCESS IS CARRIED OUT AT
1200 TO 1500 F. A SCHEMATIC OF THE PROCESS COMPONENTS FOR THE FW-8F DRY ADSORPTION IS PRESENTED IN
APPENDIX B.
THE INITIAL SHAKEDOWN ON FLUE GAS BEGAN AUG. 11, 1975, AND PROCEEDED CONTINUOUSLY FOR 10 DAYS.
THE REGENERATION SECTION WAS OPERATIONAL ABOUT 60 PERCENT OF THE TIME. HOWEVER, THE REDUCTION SEC-
TION HAS NOT YET BEEN INTEGRATED INTO SYSTEM OPERATION. SULFUR DIOXIDE REMOVAL WAS WELL ABOVE EX-
PECTATIONS AND PRESSURE DROP ACROSS THE ADSORBER WAS nELL BELOW DESIGN LEVELS. THE SYSTEM WAS SHUT
DOWN FOR CORRECTION OF SEVERAL OPERATING PROBLEMS, EQUIPMENT MODIFICATIONS, AND EVALUATION OF THE
INITIAL OPERATING DATA. OPERATION WAS RESUMED IN OCTOBER 1975, WHEN TWO CONSECUTIVE RUNS WERE COND-
UCTED WITH THE REDUCTION PORTION OF THE SYSTEM PROCESSING FRONT-END OFF-GAS AT FULL OPERATING TEMP-
ERATURES. A PROGRAM OF MODIFICATION WAS COMPLETED ON THIS SYSTEM IN EARLY JANUARY 1976. REINTROD-
UCTION OF FLUE GAS INTO THE INTEGRATED SYSTEM COMMENCED IN FEBRUARY 1976. OPERATIONS THROUGH A
FINAL 4-MONTH TEST PROGRAM WERE PREMATURELY TERMINATED ON MAY 2, 1976.
188
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6ULF POWER CO. FWBF SYSTEM OPERATING HISTORY SCHOLZ UNIT NO. 2A
PERIOD COMMENTS
MAY 75 COMPLETION OF CONSTRUCTION WAS FOLLOWED 8Y A 3-MONTH COMMISSIONING PERIOD DURING WHICH
JUN. 75 VARIOUS PIECES OF EQUIPMENT WERE OPERATED INDIVIDUALLY AND THEN IN COMBINATIONS TO
JUU. 75 SIMULATE SUBSYSTEM OPERATION. SUBSYSTEM OPERATIONS WERE INTEGRATED INTO SECTION OPERA-
AUC. 75 TIONS AND FLUE GAS WAS PASSED THROUGH THE ABSORBER AND REGENERATOR FOR A 10-DAY PERIOD
BEGINNING AUGUST 11. RESOX CONSTRUCTION WAS INCOMPLETE AT THIS TIME.
OCT. 75 TWO CONSECUTIVE RUNS WERE CONDUCTED ON THE RESOX PORTION OF THE SYSTEM ON FRONT-END
PROCESS OFF-6AS AT FULL OPERATING TEMPERATURES. THIS OPERATIONAL PERIOD LASTED 5 DAYS.
NOV. 75 A PROGRAM OF MODIFICATIONS ON THE SYSTEM BEGAN IN LATE AUGUST 1975 AND CONTINUED THROUGH
DEC. 75 JAN. 1976, WITH THE EXCEPTION OF THE 5-DAY RESOX OPERATION IN OCTOBER.
JAN. 76 MODIFICATIONS WERE COMPLETED AND PRE-3TARTUP TESTING WAS CONDUCTED IN LATE JANUARY AND
EARLY FEBRUARY. A 3-OAY CONTINUOUS RUN WAS SUCCESSFULLY COMPLETED.
FEB. 76 ALL MATERIALS-HANDLING LOOPS AND RESOX LOOPS WERE OPERATED AT FULL OPERATING TEMPERATURES
AND PRESSURES. REENTRODUCTION OF FLUE GAS INTO THE SYSTEM COMMENCED, AND A 1-MONTH
FORMAL TEST PROGRAM CONDUCTED BY SOUTHERN SERVICES AND FOSTER WHEELER IS NOW IN PROGRESS.
MAR. 76 THREE OPERATIONAL PERIODS HERE LOGGED BY THE PROTOTYPE SYSTEM DURING THE REPORT MONTHS.
APR. 76 DURING THESE RUNS THE ADSORPTION AND REGENERATION SECTIONS PERFORMED ADEQUATELY. THE
RESOX SECTION OPERATED INTERMITTENTLY BECAUSE OF PLUGGING PROBLEMS IN THE SULFUR CONDEN-
SER. ALSO, THE FRONT END OF THE SYSTEM WAS TAKEN DOWN AT ONE POINT DUE TO FREQUENT HIGH
TEMPERATURE EXCURSIONS. THIS PROBLEM WAS CORRECTED BY MODIFYING SYSTEM OPERATING PRO-
CEDURES. CURRENTLY, WORK IS PROCEEDING ON THE SOLUTION OF THE SULFUR CONDENSER PROBLEM.
MAY 76 THE FW-BF UNIT COMPLETED AN OPERATIONAL PERIOD IN EARLY MAY WHICH HAD COMMENCED ON APRIL
26. THE SYSTEM WAS TAKEN DOWN AT THIS POINT FOR THE FOLLOWING REASONS:
* DEPLETION OF CHAR SUPPLY.
* HIGH CHAR CONSUMPTION RATES DUE TO MECHANICAL ATTRITION.
* CORRECT/MODIFY THE CHAR/SAND SCREEN SEPARATOR.
AT THIS POINT THE DECISION WAS MADE TO PREMATURELY TERMINATE THE Frt-BF DEMONSTRATION
PROGRAM RATHER THAN SHUT DOWN, DEBUG, AND RESTART THE SYSTEM AGAIN. THE SYSTEM SUPPLIER
IS PURSUING ADDITIONAL FUNDING FOR THE CONTINUATION OF THE PROTOTYPE DEMONSTRATION
PROGRAM.
189
-------
TABLE 12
DESCRIPTION OF TERMINATED F6D SYSTEMS 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
F6D VENDOR
PROCESS
NtW OR RETROFIT
START UP DATE
F6D STATUS
EFFICIENCY,
PARTICULATES
GULF POWER CO.
SCHOLZ NOS. IB & 2B
CMATTAHOOCHEE FLORIDA
23 MW
COAL 5.0 PERCENT SULFUR (MAX)
CHIYODA INTERNATIONAL
THOROUGHBRED 101
RETROFIT
3/75
TERMINATED
99.7 PERCENT
S02
90 PERCENT
WATER MAKE UP
OPEN LOOP
SLUDGE DISPOSAL
DRY GYPSUM POND
UNIT COST
SEE APPENDIX A, FGD SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO THE BACKGROUND INFORMATION
AND GULF POWER ANNOUNCED ON MARCH 22
PROGRAM. DURING JANUARY, FEBRUARY,
20 MINUTES OF FORCED SCRUBBER OUTAGE
PERCENT UNTIL PROGRAM TERMINATION.
PERCENT FROM OCT. 17 THROUGH PROGRAM
ABANDONED THE 101 PROCESS DESIGN IN
INCORPORATES LIMESTONE SCRUBBING IN
IN TABLE 12 OF THIS REPORT. CHIYODA
THE COMPLETION OF THIS DEMONSTRATION
AND MARCH OPERATIONS, THERE WERE ONLY
. UTILIZATION WAS ESSENTIALLY 100
PROCESS UTILIZATION WAS GREATER THAN
COMPLETION. CHIYODA HAS SINCE
FAVOR OF THE 121 PROCESS DESIGN WHICH
A JET BUBBLER REACTOR.
190
-------
BACKGROUND INFORMATION
ON
SCHOLZ UMTS 1 AND i. • CHIYOOA
THE SCHOLZ POWER PLANT IS LOCATED IN CHATTAHOOCHEE, FLORIDA, ABOUT SO MILES WEST UF
TALLAHASSEE. THE FGD SYSTEM WAS DESIGNED BY CHIYOOA INTERNATIONAL CORP., FOR TESTING AMD PROCESS
DEMONSTRATION ON A COAL-FIRED APPLICATION. THE PROCESS IS USED IN JAPAN EXCLUSIVELY ON OIL-FIRED
AND GAS-FIRED BOILERS, AND TAIL GAS FROM CLAUS UNITS.
THE SYSTEM AT SCHOLZ CAN HANOLE ONE-HALF THE LOAD 153,000 SCFM) FROM EITHER OF THE <40-M«
NOMINALLY RATED BOILERS, WHICH WERE DESIGNED AND INSTALLED BY BABCOCK AND WILCOX IN 1953. DESIGN
ABSORBER INLET SULFUR OIOXIOE CONCENTRATION IS cjaSO PPM. VARIOUS TESTS COALS WITH SULFUR CONTENTS
RANGING UP TO 5 PERCENT ARE SCHEDULED FOR BURNING.
THE PARTICULATE LOADS FROM NEWLY INSTALLED ELECTROSTATIC PRECIPITATORS ON THE TWO UNITS RANGE
FROM 0.02 TO 0.1 GR/SCF. FLUE GAS FROM THE PRECIPITATORS IS QUENCHED WITH COOLING WATER TO REMOVE
ADDITIONAL FLY ASH AND TO COOL THE GAS BEFORE II ENTERS THE SULFUR DIOXIDE ABSORBER.
SULFUR DIOXIDE IS ABSORBED IN WATER AND CATALYTICALLY OXIDIZED WITH AIR TO FURM SULFURIC ACIU.
THE DILUTE ACID IS RECIRCULATEO THROUGH THE ABSORBER. A PORTION OF THE ACID IS NEUTRALIZED WITH
LIMESTONE TO PRODUCE GYPSUM AS A BY-PRODUCT.
BREAK-IN TESTING COMMENCED IN FEBRUARY 1975. THE FIRST FEW MONTHS OF THE SHAKEDOWN PERIOD WERt
CHARACTERIZED BY MANY MINOR PROBLEMS, RESULTING IN A LOW OPERABILITY INDEX VALUE (30X FUR FtB-MAY).
MANY OF THESE PROBLEMS WERE RESOLVED BY JUNE, (MANIFESTED BY A HIGHER OPERABILITY INDEX 18UX) VALUE
FOR THE JUNE-JULY PERIOD). A 6-WEEK SCRUBBER OUTAGE PERIOD COMMENCED IN AUGUST FROM UNBALANCING UF
THE GYPSUM CENTRIFUGES. AFTER REPAIR OF THE CENTRIFUGES AND INSTALLATION ON SEPTEMBER 15, THE UPtR-
ABILITY INDEX THROUGH DECEMBER 1975, AVERAGED AbOVE 97 PERCENT.
CHIYOOA, GULF POWER, AND SOUTHERN COMPANY SERVICES SUCCESSFULLY CONCLUDED CT-101 OPERATIONS ON
MARCH ZZ, 1977, AFTER MORE THAN TWO YEARS OF INTENSIVE TESTING, EVALUATION, AND DEMONSTRAI ION.
INFORMATION AND DATA CONCERNING THE OPERATION OF THE CT-101 PROTOTYPE UNIT ARE PRESENTED IN THE
PERFORMANCE TABLE THAT FOLLOWS. A PROCESS FLOW DIAGRAM IS PROVIDED IN APPENDIX B.
191
-------
GULF POWER CO.
SCHOLZ IB AND 2B - CHIYODA
SCHOLZ UNIT NOS. IB AND 28
MONTH
FEB. 75
TOTAL
HOURS
672
UNIT OPERATING HOURS
BOILER FGD SYSTEM
FGO SYSTEM PERFORMANCE (X)
OPERABILITY UTILIZATION
APR. 75
720
720
200
26
MAY 75 744 744 100 13 13
THIS IS A PILOT PLANT SIZE DEMONSTRATION UNIT. PRELIMINARY ENGINEERING AND DESIGN WORK BEGAN
IN 1973. INITIAL SHAKEDOWN AND DEBUGGING OPERATIONS COMMENCED ON FEBRUARY 11, 1975. PROB-
LEMS ENCOUNTERED INCLUDED CRACKS IN THE FRP LINING AT THE OXIDIZING TOWER. STARTUP OCCURRED
IN MARCH 1975. AFTER INITIAL OPERATION FOR BREAK-IN TESTS, THE UNIT WAS SHUT DOWN FOR IN-
TERNAL INSPECTION. RELIABILITY TESTS THtN FOLLOWED IN JULY 1975. CHEMICAL PERFORMANCE WAS
SATISFACTORY. EMISSION TESTS HAVE NOT BEEN PERFORMED. SOME PUMP AND INSTRUMENT FAILURES
HAVE OCCURRED.
JUN. 75
JUL. 75
720
744
685
744
685
624
100
84
95
84
A 100 PERCENT OPERABILITY FACTOR WAS REGISTERED FOR THE MONTH Of JUNE. DURING THE MONTH OF
JULY ONE CENTRIFUGE BECAME UNBALANCED, REQUIRING THE SPARE TO BE PLACED IN SERVICE.
AUG. 75
SEP. 75
744
720
720
337
46
DURING THE MONTH OF AUGUST BOTH CENTRIFUGES BECAME UNBALANCED REQUIRING A FORCED OUTAGE WHICH
EXTENDED TO MID-SEPTEMBER. UNIT OPERATED AT A 95 PERCENT S02 REMOVAL EFFICIENCY DURING THIS
PERIOD. GULF POWER IS ATTEMPTING TO UPGRADE THIS VALUE TO A HIGHER EFFICIENCY LEVEL.
OCT. 75
744
744
744
100
WASTE WATER DISCHARGE FROM THIS UNIT STILL A PROBLEM AREA.
NOV. 75
720
720
720
100
100
OUTAGE TIME WAS LESS THAN ONE HOUR DURING NOVEMBER OPERATION DUE TO A BROKEN FLUE GAS BLOWER
INLET VANE AND REPAIR OF A PINHOLE IN THE pRtscfiuBBER FRP LINING.
DEC. 75
744
744
726
98
98
SCRUBBER OUTAGES DURING DECEMBER RESULTED FROM CONTINUING REPAIRS TO A PINHOLE IN THE
PRESCRUBBER FRP LINING.
JAN. 76
744
680
450
66
60
FEB. 76 696 690 77 11 11
OUTAGE TIME IN JANUARY-FEBRUARY WAS PRIMARILY FOR REPAIR AND MODIFICATION OF THE SUCTION AND
DISCHARGE PIPING ON THE ABSORBENT CIRCULATION PUMPS. THESE FRP LINES BROKE IN JANUARY AT
SOME WEAK FIELD JOINTS. S02 REMOVAL EFFICIENCY HAS BEEN AS HIGH AS 95X.
MAR. 76
744
744
741
100
100
APR. 76 720 720 101 14 14
PLANT WAS STOPPED APRIL 5 FOR A SCHEDULED SHUTDOWN TO ALLOW INSTALLATION AND MODIFICATIONS
FOR REDUCING THE QUANTITY OF LIQUID WASTE FROM THE SYSTEM. START-UP AND TESTING OF THIS
MODIFICATION WAS PLANNED FOR THE FIRST WEEK IN MAY.
SITATED A DELAY IN SYSTEM RESTART FOR AN ADDITIONAL
A FIRE AT THE PLANT,
3 TO 4 WEEKS.
HOWEVER, NECES-
MAY 76
JUN. 76
THE SYSTEM WAS SHUTDOWN APRIL 24 BECAUSE OF EXTENSIVE FIRE DAMAGE IN THE OXIDIZING TOWER.
THE FIRE, CAUSED BY A WELDING ACCIDENT, DAMAGED FRP AND POLYPROPYLENE COMPONENTS IN THE
OXIDIZING TOWER. REPAIRS CONTINUED AS THE SYSTEM REMAINED OUT OF SERVICE DURING THE REPORT
PERIOD. SYSTEM RESTART IS SCHEDULED FOR THE END OF JULY.
JUL. 76
AUG. 76 744 744 492 66 66
THE PROTOTYPE UNIT REMAINED OUT OF SERVICE MAY, JUNE AND JULY TO REPAIR THE FIRE-DAMAGEO
AREAS. THE SYSTEM WAS PUT BACK IN OPERATION IN AUGUST. THE SYSTEM WAS AGAIN BROUGHT DOWN
DURING THE MONTH TO COMPLETE ADDITIONAL REPAIRS WHICH WENT UNDETECTED DURING THE PREVIOUS
OUTAGE. 241.67 HOURS OF THE 251.75 HOURS OF AUGUST OUTAGE TIME WAS CONSUMED FOR THESE
ADDITIONAL REPAIRS. THE WATER SAVINGS PROGRAM IS NOW BEING CONDUCTED ON THIS SYSTEM.
BASICALLY, THIS TEST PROGRAM CALLS FOR A REDUCTION IN WASTEWATER SLOWDOWN AND FRESH WATER
MAKEUP REQUIREMENTS BY RECYCLING THE MOTHER LIQUOR BLEED BACK TO THE PROCESS FOR ADDITIONAL
SERVICE.
192
-------
GULF POWER CO.
SCHOLZ 18 AND 2B - CHIYUDA
UNIT OPERATING HOURS
SCHOLZ UNIT NOS. IB AND 2B
MONTH
SEP.
OCT.
TOTAL
HOURS
BOILER FGD SYSTEM
FGD SYSTEM PERFORMANCE CX)
AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
76 720 720 496 99 69 99
TOTAL FORCED OUTAGE TIME DURING THE MONTH AMOUNTED TO 5.1 HOURS.
69
76 704 744 357 70 48 62 48
TOTAL DOWN TIME DURING THE MONTH AMOUNTED TO 386.9 HOURS. OF THIS TOTAL 1.1 HOUR WAS AT-
TRIBUTED TO A FORCED SCRUBBER OUTAGE, 2ie HOURS WAS REQUIRED TO REPAIR EXPECTED DAMAGES
INCURRED IN THE PRESCRUBBER RESULTING FROM OPERATIONS IN THE WATER SAVINGS PROGRAM. SPECI-
FICALLY, THE LINING WAS SUFFERING FROM EXTENSIVE CORROSION DAMAGE BECAUSE OF HIGH ACID
CONCENTRATIONS WHICH DEVELOPED IN THE PRtSCRUBBER SCRUBBER SOLUTION. THIS OUTAGE WAS
SCHEDULED FOR INSPECTION, REPAIR, AND PROVIDE DESIGN DATA FOR FUTURE UNITS. 302 REMOVAL
EFFICIENCY STILL RESIDES IN THE 85-95 PERCENT RANGE.
NOV. 76 720
720
717
99
99
99
99
DEC. 76 744 744 741 99 99 99 99
A TOTAL OF THREE FORCED SCRUBBtR OUTAGES OCCURRED RESULTING IN OUTAGE TIME TOTALLING 6.5 HRS.
PROBLEMS INCLUDED A MALFUNCTION OF A LEVtL INDICATOR, A BROKEN GUIDE VANE, AND AN OPERATOR
ERROR RESULTING IN A LEAK OF SLURRY INTO THE WATER HEADER. ON NOV. 1, SOUTHERN SERVICES
FINISHED ITS SCHOLZ EVALUATION OF THE CT-101. A PERFORMANCE REPORT IS DUE SPRING 1977.
GULF POWER WILL CONTINUE OPERATION OF THE CHIYOOA UNIT FUR AN UNSPECIFIED PERIOD IN 1977.
JAN. 77 744
FEB. 77 672
744
672
744
672
100
100
100
100
100
100
100
100
MAR. 77 744 744 514 100 100
CICr GPC, & SCS SUCCESSFULLY CONCLUDED THE CT-101 TESTING AND DEMONSTRATION PROGRAM ON MARCH
22. DURING THE REPORT PERIOD, THE TOTAL SCRUBBER OUTAGE TIME WAS 0.33 H«. THE SYSTEM HAS
BEEN IN SERVICE ON A VIRTUALLY CONTINUOUS BASIS SINCE OCT. 17, TOTALLING OVER 5 MONTHS OF
100X RELIABLE OPERATION.
THE PROGRAM WAS TERMINATED TO ALLOW CIC 10 DEVELOPS AND DEMONSTRATE A NEW FGD DESIGN.
NO DEMONSTRATION COMMITMENTS HAVE YET BEEN MADE.
193
-------
TABLE 12
DESCRIPTION OF TERMINATED FGD SYSTEMS 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGO STATUS
EFFICIENCYr
PARTICULATES
ILLINOIS POWER
WOOD RIVER NO a
EAST ALTON ILLINOIS
110 MW
COAL 2.9-3.2 PERCENT SULFUR
MONSANTO ENVIRO CHEM SYSTEMS
CATALYTIC OXIDATION
RETROFIT
10/72
TERMINATED
99 PERCENT
S02
85 PERCENT
WATER MAKE UP
SLUDGE DISPOSAL
SULFURIC ACID PRODUCT
UNIT COST
OPERATIONAL
EXPERIENCE
SEE APPENDIX A, FGD SYSTEM ECONOMICS
REFER TO THE BACKGROUND INFORMATION SECTION IN TABLE 12. SYSTEM START-UP
OCCURRED IN OCTOBER 1972. INITIAL AND SUBSEQUENT OPERATIONS hERE
ACCOMPANIED BY A NUMBER OF SEVERE MECHANICAL-RELATED PROBLEMS RESULTING
IN LIMITED OPERATIONS AND EVENTUAL TERMINATION OF THE PROGRAM. TOTAL
OPERATION TIMt WAS <444 HOURS IN 1972, 158 HOURS IN 19/3 AND 55 HOURS IN
1974.
194
-------
BACKGROUND INFORMATION
ON
MOOD RIVER NO. H
THE WOOD RIVER POWER STATION OF THE ILLINOIS POWER COMPANY IS LOCATED NEAR EAST ALTON,
ILLINOIS, NORTH OF ST. LOUIS, MISSOURI. THE NO. 4 BOILER IS A COMBUSTION ENGINEERING PULVERIZED-
COAL-FIRED UNIT THAT HAS A GROSS RATED CAPACITY OF 109 MW AND A NET CAPACITY OF loi MW. THIS UNIT
FIRES A HIGH SULFUR CENTRAL ILLINOIS COAL WITH TYPICAL CHARACTERISTICS OF 3.1 PERCENT SuLFUK, 1U
PERCENT ASH AND A HEAT CONTENT OF 10,800 BTU/LB. ANNUAL COAL CONSUMPTION IS APPRUXIMATELY 275,OUO
TONS/YEAR.
THE EMISSION CONTROL EQUIPMENT FOR THIS BOILER INCLUDES MECHANICAL COLLECTORS, A HIGH EFFIC-
IENCY ESP, AND A MONSANTO CATALYTIC OXIDATION (CATOX) FGD SYSTEM FOR THE CONTROL OF PART1CULATEb AND
SULFUR DIOXIDE. DESI&N REMOVAL EFFICIENCIES UF THIS CONTROL SYSTEM ARE 99.9 PERCENT FOR PARTICUL-
ATES AND 85 PERCENT FOR SULFUR DIOXIDE. INLET SULFUR DIOXIDE CUNCENTHAT IONS TO THE CATuX SYSTEM AWE
GENERALLY IN THE 2000 TO 2200 PPM RANGE.
FOLLOWING PASSAGE THROUGH THE PARTICULATE REMOVAL SYSTEM, THE FLUE GAS ENTERING THfc SCROBbING
SYSTEM IS HEATED TO A TEMPERATURE OF 850 F AND PASSES THROUGH A VANADIUM PENTOXIDt FIXED-BED CATALY-
TIC CONVERTER, WHERE THE SULFUR DIOXIDE IS OXIDIZED TO SULFUR THIOXIDE. THE GAS THEN FLOWS THROUGH
AN ACID ABSORPTION TOWER, WHERE THE SULFUk TRIOXIDE IN THE GAS IS CONVERTED TO SULFuKIC ACID. AN
ACID MIST ELIMINATOR ENSURES REMOVAL OF ENTRAINED ACID MIST FROM THE GAS STREAM. THE CLEANED GAS IS
DISCHARGED TO THE STACK AND THE PRODUCT ACID IS COOLED AND STORED IN TANKS. A SIMPLIFIED PROCF_SS
FLOW DIAGRAM OF THE WOOD RIVER CATOX SYSTEM IS PRESENTED IN APPENDIX B.
THIS DEMONSTRATION SYSTEM, PARTIALLY FINANCED BY EPA, WAS STARTED UP IN SEPTEMBER 1972. WHILE
THE MAIN PARTS OF THE UNIT PERFORMED ACCEPTABLY, VARIOUS TROUBLES WITH ASSOCIATED EQUIPMENT CAUSED
EXTENSIVE SHUTDOWNS AND DELAYS, TO THE EXTENT THAT APPROXIMATELY 27 DAYS OF FULL OPERATION HAVE SEEN
OBTAINED IN ALMOST TWO YEARS. A d«-HOUR PERFORMANCE TEST RUN WAS COMPLETED IN JULY 1973. THE
FOLLOWING GUARANTEES WERE ACHIEVED AND EXCEEDED: 90 PERCENT CONVERSION OF SULFUR DIOXIDE TO SULFUR
TRIOXIDE IA80UT 85 PERCENT NET REMOVAL), 99 PERCENT REMOVAL OF PARTICULATE ENTERING THE SYSTEM, LfcSS
THAN 1 MG/ACF OF ACIO MIST IN GAS LEAVING THE SYSTEM, PRODUCTION OF 60 DEGREES BAUME ACID.
PERFORMANCE SUMMARY
THE WOOD RIVER SYSTEM WAS STARTEO-UP IN SEPTEMBER 1972 BUT WAS SHUT DOWN ALMOST IMMEDIATELY
(IN OCTOBER) TO CONVERT THE BURNERS TO OIL FIRING, WHICH WAS NOT COMPLETED UNTIL JUNE 1973. A
SUCCESSFUL PERFORMANCE TEST WAS THEN MADE, BUT BECAUSE OF THE CATALYST PLUGGING HAZARD,THE SYSTEM
MS SHUT DOWN AGAIN TO INSTALL AN EXTkNAL BURNER SYSTEM, WHICH WAS NOT COMPLETED UNTIL APRIL 19M.
VARIOUS OTHER PROBLEMS WITH STANDARD EQUIPMENT HAVE BEEN ENCOUNTERED SINCE, WITH THE RESULT THAT
ONLY b57 HOURS OF OPERATING TIME HAVE BEEN LOGGED IN TWO YEARS,
SEVERAL OTHER MAJOR PROBLEM AREAS ENCOUNTERED DURING THE INTERMITTENT UPERATION Of THIS REGENE-
RABLE SYSTEM INCLUDED: FROZEN DAMPERS ON REHEAT BURNERS, CRACKS IN THE TEFLON LINEH UN THE ACID
PUMP'S DISCHARGE HEADER, CRACKS IN THE REHEAT DUCTING, FALL OF REFRACTORY BRICKS FROM THE REHEA1EK
BURNER DOME, AND NEED FOR REINFORCEMENT OF THE STRUCTURE SUPPORTING THE HIGH TEMPEKATUR FLUE GAS
DUCT TO THE CATALYTIC CONVERTER.
195
-------
ILLINOIS POWtK OPEKATING LOG WOOD RIVER UNIT NO. 4
CATALYTIC OXIDATION SYSTEM
WOOD RIVtR NO. 4 - ILLINOIS POWER CO.
1972 TO 1973
DATE HOURS DATE HOURS
10-6-72 an 9-4-72 12
10-9-73 en 9-5-72 2"
10-10-72 16 9-6-72 24
10-13-72 20 9-7-72 ^
10-14-72 16 9-11-72 2
10-30-72 24 9-12-72 16
10-31-72 16 9-13-72 24
7-21-73 18 9-14-72 24
7-22-73 24 9-15-72 24
7-23-73 18 9-16-72 24
7-24-73 24 9-17-72 24
7-2b-73 14 9-18-72 24
7-26-73 13 9-19-72 5
7-17-73 19 9-24-72 17
7-28-73 19 10-6-72 12
7-29-73 9 10-7-72 24
NOTE: THE OPERATION TIME LOG DOES NOT INCLUDED INTERMITTENT
SYSTEM OPERATION DURING 1974. SYSTEM OPERATIONS FOR 1974
AMOUNTED TO Sb HRS. TOTAL OPERATION TIME FOR 2.5 YRS. OF
OPERATION WAS 657 HRS.
196
-------
TABLE 12
DESCRIPTION OF TERMINATED FGD SYSTEMS 01/76
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
KEY WEST UTILITY BOARD
STOCK ISLAND PLANT
KEY WEST FLORIDA
37 MW
OIL 2.4 PERCENT SULFUR
ZURN AIR SYSTEMS
LIMESTONE SCRUBBING
NEW
10/72
TERMINATED
90 PERCENT
S02
WATER MAKE UP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL
EXPERIENCE
65 PERCENT-ESTIMATED
OPEN LOOP 2.7 GPM/MW
SOLAR EVAPORATION POND
SEE APPENDIX A, FGO SYSTEM ECONOMICS
REFER TO BACKGROUND INFORMATION IN TABLE 12 OF THIS REPORT. THIS
FGD SYSTEM HAS FIRST PLACED IN SERVICE OCTOBER 1972. THE FSO SYSTEM HAS
BEEN OUT OF SERVICE SINCE JANUARY 28, 1975. EXTENSIVE MODIFICATIONS AND
REPAIRS HAVE BEEN REQUIRED. RESUMPTION OF OPERATIONS IN THE FUTURE
LOOKS VERY DOUBTFUL.
197
-------
BACKGROUND INFORMATION
ON
STOCK ISLAND PLANT
THE UTILITY BOARD OF THE CITY OF KEY WEST OWNS AND OPERATES A NEW 37-MW OIL-FIRED POWER BOILER,
INSTALLED AT THEIR STOCK ISLAND PLANT WHICH IS LOCATED DIRECTLY ADJACENT TO THE ISLAND CITY OF KEY
WEST. THE BOILER IS AN ERIE CITY BALANCED-DRAFT OIL-FIRED UNIT THAT IS NOMINALLY RATED AT 37 Mw AND
CAN ACHIEVE 42 MW AT FULL PERFORMANCE. THE UNIT FIKES NO. 6 RESIDUAL FUEL OIL FROM VENEZUELA WITH
SULFUR AND ASH CONTENTS OF 2.75 AND 0.05 PERCtNT, RESPECTIVELY. THE UNIT'S GROSS HEAT RATE IS
11,380 BTU/KWH. INITIAL OPERATION OF THE UNIT COMMENCED IN NOVEMBER 1973.
THE EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF A MULTIPLE TUBE MECHANICAL OUST COLLECTOR
INSTALLED UPSTREAM OF TWO SULFUR DIOXIDE WET SCRUBBERS DESIGNED AND INSTALLED BY ZURN AIR INDUS-
TRIES. THIS IS A DEMONSTRATION FACILITY CEPA FUNDED) EMPLOYING LIMESTONE IN A SEAWATER SOLUTION FOK
THE REMOVAL OF SULFUR DIOXIDE FROM THE BOILER FLUE GAS STREAM. NO PROVISIONS FOR STACK GAS REHEAT
EXIST AT THE FACILITY.
THE LIMESTONE ABSORBENT IS OBTAINED FROM CORAL DREDGED FROM THE OCEAN. THE CORAL CONSISTS
PRIMARILY OF CAC03 WITH LITTLE OR NO MGC03. THE CORAL IS GROUND TO A FINE POWDER IN A HAMMERMlLL
CRUSHER TO 90 PERCENT MINUS 325 MESH AND SLURRIED IN SEAWATEK.
ZURN DUSTRAXTORS ARE EMPLOYED FOR THE REMOVAL OF SULFUR UIOXIOE AND RESIDUAL PARTICULATE FROM
THE BOILER FLUE GAS. THE TrtO SCRUBBER MODULES ARE DESIGNED TO HANDLE A COMBINED TOTAL OF 126,950
CFM AT 150 F. FLUE GASES FROM THE BOILER ARE DRAWN THROUGH AN INDUCED DRAFT FAN AND FORCED EITHER
THROUGH THE BYPASS DUCT OR THROUGH ONE OR BOTH SCRUBBERS VIA THREE SETS OF DAMPERS BETWEEN THE
INDUCED-DRAFT FAN AND THE STACK. BEFORE ENTERING THE SCRUBBING SYSTEM THE GAS is COOLED FROM 360 F
TO 160 F BY SEAWATER SPRAYS. THIS COOLING PROTECTS THE FIBERGLASS COMPONENTS OF THE SCRUBBER
MODULES. A PRESSURE DROP OF 12 TO It INCHES WATER GAUGE IS THE NORMAL OPERATING RANGE FOR THE
SCRUBBERS. THE SPENT SCRUBBING SLURRY IS BLED OFF TO TWO ON-SITE SETTLING PONDS WITH A RETENTION
CAPACITY OF 21 DAYS. THE SLUDGE SETTLES OUT AND CLARIFIED WATER IS DISCHARGED BACK INTO THE SEA BY
AN OVERFLOW PIPE AND SEEPAGE. THE PARTICULATE AND SULFUR DIOXIDE REMOVAL EFFICIENCIES UF THE
EMISSION CONTROL SYSTEM ARE 64 TO 82 PERCENT AND 68 TO 73 PERCENT, RESPECTIVELY. ACTUAL INLET AND
OUTLET SULFUR DIOXIDE LOADINGS ARE 1300 TO 1500 PPM AND 300 TO 500 PPM. INLET AND OUTLET PARTICU-
LATE LOADINGS ARE 0.20 GR/SCF AND 0.05 GR/SCF.
SYSTEM PERFORMANCE
START-UP OF THE SCRUBBING SYSTEM OCCURRED IN AUGUST 1973. ENSUING OPERATION HAS PROCEEDED UN
AN INTERMITTENT BASIS. THE MAJOR PROBLEM AREAS ENCOUNTERED HAVE INCLUDED:
•SEVERE CORROSION OF GAS UUENCH DUCT AND DAMPER SfcALIuG FANS ON INLET AND OUTLET OF SCRUBBERS.
•PLUGGING AT THE BOTTOM OF SCRUBBER TUBES.
•LIUUIO LEVEL CONTROL FAILURES IN THE SCRUBBER MODULES.
•POOR LIMESTONE UTILIZATION (APPROXIMATELY 20 PERCENT).
•INDUCED DRAFT FAN REPAIRS.
•REPLACEMENT OF INTERNAL STAINLESS STEEL PARTS WITH MONEL COMPONENTS.
•BOILER FOUNDATION AND BOILER TUBE PROBLEMS.
•LIMESTONE SUPPLY SHORTAGES.
ADDITIONAL INFORMATION AND DETAILS ON THE PROGRESS OF THIS INSTALLATION ARE PRESENTED IN THE
PERFORMANCE TABLE BELOW. A PROCESS FLOW DIAGRAM IS PRESENTED IN APPENDIX B.
198
-------
KEY WEST UTILITY BOARD
STOCK ISLAND PLANT
PERIOD TOTAL P
SEP-
OCT.
NOV.
DEC.
JAN.
FEB.
MAR.
APR.
MAY
JUN.
JUL.
AUG.
SEP.
OCT.
NOV.
OEC.
JAN.
FEB.
MAR.
APR.
MAY
JUN.
JUL.
AUG.
AUG.
SEP.
OCT.
NOV.
DEC.
JAN.
FES.
MAR.
APR.
MAY
JUN.
JUL.
AUG.
TOTAL
72
72
72
72
73
73
73
73
73
73
73
73
73
73
73
73
74
74
74
74
74
74
74
74
74
74
74
74
74
75
75
75
75
75
75
75
75
696
744
720
744
744
672
744
720
744
720
744
744
720
744
720
744
744
672
744
720
744
720
744
552
840
672
672
840
672
672
840
672
672
840
672
672
840
26680
BOILER
0
0
528
192
384
672
744
720
744
720
744
744
720
522
720
744
624
600
744
720
30
120
744
552
641
36
672
840
672
672
642
672
672
840
672
672
IbO
20895
AS OF MARCH 1977 IT HAD NOT BEEN DECIDED
WHETHER THERE WOULD BE FUTURE FGO OPERA-
TIONS AT THE STOCK ISLAND PLANT.
0
0
0
0
0
120
0
0
0
0
0
40
0
24
42
72
209
0
0
0
0
0
0
24
216
0
252
362
108
110
0
0
0
0
0
0
0
1579
,HRS)
OPERAblLITY
0
0
0
0
0
18
0
0
0
0
0
5
0
5
6
10
33
0
0
0
0
0
0
4
34
0
38
43
16
16
0
0
0
0
0
0
0
8
U)
199
-------
TABLE 12
DESCRIPTION OF TERMINATED FGO SYSTEMS 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FliD STATUS
EFFICIENCY,
PARTICULATES
POTOMAC ELECTRIC & POWER
DICKERSON NO. 3
OICKERSON MARYLAND
95 MW
COAL 2.U PERCENT SULFUR
CHEMICO
MAGNESIUM OXIDE SCRUBBING
RETROFIT
9/73
TERMINATED
99.3 PERCENT
SU2
90 PERCENT
MATER MAKE UP
3.2 GPM/MW
SLUDGE DISPOSAL
ACID PLANT REGENERATION
UNIT COST
SEE APPENDIX A, FGO SYSTEM ECONOMICS
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 12 OF THIS REPuRT.
A SINGLE, TWO-STAGE VENTURI SCRUBBER-ABSORBER MODULE UTILIZING THE
CHEMICO-BASIC MAGNESIUM OXIDE SULFUR DIOXIDE REMOVAL/RECOVERY PROCESS
WAS RETROFITTED ONTO THE NO. 3 UNIT, HANDLING APPROXIMATELY 50 PERCENT
OF THE COAL-FIREO FLUE GAS. THE MAGNESIUM SULFITE BY PRODUCT WAS REGEN-
ERATED AT AN EPA-FINANCED REGENERATION FACILITY AT THE ESSEX CHEMICAL
COMPANY IN RHODE ISLAND. MAGOX OPERATIONS WERE COMPLETED IN 08/75.
PARTICULATE MODE OPERATIONS ARE CONTINUING.
200
-------
BACKGROUND INFORMATION
ON
DICKERSON NO. 3
THE DICKERSON STATION OF POTOMAC ELECTRIC POWER CO. (PEPCO) IS LOCATED ON THE POTOMAC RIVER
NEAR OICKERSON, MARYLAND, ABOUT 30 MILES NORTHWEST OF WASHINGTON, D.C. THE STATION HAS 3 ELECTRIC
GENERATORS, EACH RATED AT 190 MN. UNIT NO. 3 IS A DRY BOTTOM COAL-FIRED BOILER DESIGNED BY COMBUS-
TION ENGINEERING AND INSTALLED IN 1962. THE COAL NOW BURNEU HAS AN AVERAGE GROSS HEATING VALUE OF
11,700 BTU/LB AND AVERAGE ASH AND SULFUR CONTENTS OF It AND 2 PERCENT, RESPECTIVELY. TH£ 60ILER IS
FITTED WITH AN ELECTROSTATIC PRECIPITATOR DESIGNED AND INSTALLED BY RESEAKCH-COTTfiELL IN 1962. THE
FGD SYSTEM EMPLOYS THE CHEM1CO-6ASIC MAGNESIUM OXIDE SCRUBBING PROCESS. THE RETROFIT SYSTEM HANDLES
APPROXIMATELY 50 PERCENT OF THE EXHAUST GAS FROM THE NO. 3 UNIT.
THE FGD SYSTEM CONSISTS OF A SINGLE, TWO-STAGE SCRUBBER/ABSORBER, WHICH INCORPORATES AN ADJUST-
ABLE-THROAT VENTURI SCRUBBER FOR PART1CULATE REMOVAL AND A SECOND STAGE ABSORBER WITH A FIXED
VENTURI TO REMOVE SULFUR DIOXIDE. THE LIQUOR STREAMS FOR BOTH STAGES ARE SEPARATE AND OPERATE IN A
CLOSED-LOOP MODE. UNTIL MID-1975 THE MAGNESIUM SULFITE GENERATED WAS TRANSFERRED TO AN EPA FINANCED
FACILITY AT THE ESSEX CHEMICAL COMPANY SULFURIC ACID MANUFACTURING PLANT IN RUMFORD, RHODE ISLAND,
WHERE MAGNESIUM OXIDE WAS REGENERATED AND SULFUR DIOXIDE FROM THE REGENERATION PROCESS WAS CONVERTED
TO SULFURIC ACID. THE RUMFORD FACILITY HAS SINCE BEEN CLOSED DOWN. A GENERAL PROCESS FLOW DIAGRAM
OF THE DICKERSON NO. 3 WET SCRUBBING SYSTEM AND REGENERATION FACILITIES IS PRESENTED IN APPENDIX B.
CONSTRUCTION WAS COMPLETED IN AUGUST AND THE SYSTEM STARTED UP IN SEPTEMBER 1973. DURING
INTERMITTENT OPERATIONS FOR SHAKEDOWN THROUGH JANUARY 197
-------
POTOMAC ELECTRIC » POWER FGD SYSTEM OPERATING HISTORY DICKERSON UNIT NO. 3
OPERATING PERIOD COMMENTS
SEP. 73 PROBLEMS DURING THIS PERIOD RANGED FROM CORROSION LEAKS IN EXPANSION JOINTS TO PROBLEMS
TO IN MATERIAL HANDLING EQUIPMENT, FEEDING AND SLAKING OF MGO, PLUGGING IN THE MGO MIX TANK
JAN. 74 AND SUCTION LINES TO THE MGO MAKE-UP PUMPS.
JAN. 74 MAINTENANCE AND MODIFICATIONS WERE PERFORMED ON THE SYSTEM. THE MAJOR SYSTEM REVISION
TO MADE DURING THIS PERIOD WAS THE ADDITION OF A PRE-MIX TANK IN THE MGO SYSTEM.
APR. 74
APR. 74 LIMITED OPERATION BECAUSE THE UTILITY DID NOT HAVE ACCESS TO THE EPA CALCINING FACILITY
TO AT THE ESSEX CHEMICAL COMPANY SULFURIC ACID PLANT. BY THE END OF JUNE 1974, ALL THE
JUL. 74 MGO AT DICKERSON HAD BEEN USED AND A SILO PLUS THREE CARS WERE FULL OF MGS03.
AUG. 74 DURING THIS PERIOD THE SYSTEM GENERALLY OPERATED AT 75 PERCENT OF THE DESIGN GAS FLOW.
TO
DEC. 74
JAN. 75 PROBLEMS DEVELOPED IN THE BUCKET ELEVATOR TRANSPORTING THE MGS03 FROM THE DRYER TO THE
FEB. 75 STORAGE SILO. UNIT NO. 3 WAS TAKEN OUT OF SERVICE FOR AN 8 TO 12 WEEK TURBINE OVERHAUL.
TO THE SCRUBBER WAS INSPECTED, MAINTENANCE AND MODIFICATIONS WERE MADE.
JUL. 75
AUG. 75 THE FGD SYSTEM WAS RESTARTED IN AUGUST. STEAM WAS LOST TO THE MGO MIX TANKr RESULTING
IN A VERY MOIST PRODUCT FROM THE CENTRIFUGE. CAKING IN THE DRYER OCCURRED. AT THIS
POINT, THE UTILITY DECIDED TO TEST ONLY THE FIRST-STAGE OF THE SCRUBBING SYSTEM, TAKING
GAS AHEAD OF THE PRECIPITATOR. FGO OPERATION AT DICKERSON TERMINATED AT THIS POINT.
202
-------
TABLE 12
DESCRIPTION OF TERMINATED FGD SYSTEMS 01/76
UTILITY NAME PUBLIC SERVICE CO OF COLORADO
UNIT NAME VALMONT NO. 5
UNIT LOCATION VALMONT COLORADO
UNIT RATING 50 Mh
FUEL CHARACTERISTICS COAL 0.72 PERCENT SULFUR
FGD VENDOR UOP/PUB SERVICE OF COLORADO
PROCESS LIMESTONE SCRUBBING
NEW OR RETROFIT RETROFIT
START UP DATE 10/74
FGD STATUS TERMINATED
EFFICIENCY,
PARTICULATES 95 PERCENT
802 65 PERCENT
WATER MAKE UP CLOSED LOOP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL REFER TO BACKGROUND INFORMATION IN TAbLE 12 OF THIS REPORT. THIS FGO
EXPERIENCE SYSTEM HAS BEEN OPERATIONAL SINCE NOVEMBER 197
-------
BACKGROUND INFORMATION
ON
VALMONT NO. 5
THt VALMONT POWER STATION OF THE PUBLIC SERVICE OF COLORADO IS LOCATED IN VALMONT (NEAR
BOULDER, COLO.), COLORADO, APPROXIMATELY SO MILES NORTH Of DENVER. VALMONT NO. 5 IS A 166 MW (SOd
SCRUBBING CAPACITY-50 MW MOOULE) PULVERI ZED-COAL FIRED UNIT. VALMONT NO. 5 CAME ON LINE ORIGINALLY
IN i<>64 AND EMPLOYS A ONCE-THROUGH COOLING SYSTEM UTILIZING RESERVOIRS TOTALING APPROXIMATELY 530
SURFACE ACRES. THE STATION BURNS A WYOMING ROSEBUD SUB-BITUMINOUS TYPE COAL WITH A SULFUR CONTENT
OF APPROXIMATELY 0.6 PERCENT, AN ASH CONTENT OF 5.2 PERCENT, AND A CALCIUM OXIDE CONTENT OF APPROX-
IMATELY 2U PERCENT IN THE FLYASH. THE ORIGINAL AIR QUALITY CONTROL EQUIPMENT AT THE PLANT CONSIST-
ED OF A MECHANICAL COLLECTOR FOLLOWED IN SERIES BY A COLD SIDE ESP. PUBLIC SERVICE COMPANY OF
COLORADO LATER EQUIPPED FIVE BOILERS WITH UNIVERSAL OIL PRODUCTS (UOP) TCA WET PAHTICULATE
SCRUBBERS. EACH OF THE TURBULENT CONTACT ABSORBERS (TCA) CONSISTS OF THREE STAGES OF PLASTIC MOBILE
PACKING SIMILAR TO "PING PONG" BALLS, WITH A WATER SPRAY DIRECTED DOWNWARD THROUGH THE PACKING
COUNTER CURRENT TO THE FLUE GAS FLOW. AT VALMONT NO. 5 ALL OF THE FLUE GASES PASS THROUGH A MECH-
ANICAL COLLECTOR AFTER WHICH THEY ARE DIVIDED, WITH APPROXIMATELY 50 PERCENT OF THE GAS FLOW GOING
TO THE PRECIPITATOR AND THE OTHER 50 PERCENT TO THE 2 MODULE SCRUBBER. AFTER EXITING THE ESP AND
SCRUBBER, THE GAS FLOWS ARE JOINED TOGETHER AND DISCHARGED SIMULTANEOUSLY TO THE STACK.
ALTHOUGH THE SCRUBBER WAS ORIGINALLY INSTALLED SPECIFICALLY FOR PARTICULATE REMOVALi SINCE THE
PLANT BURNS LOW SULFUR COAL, 45 PERCENT OF THE SOS WAS REMOVED AS WELL BECAUSE OF THE ALKALINITY OF
THE FLYASH.
DURING THE FIRST YEAR OF OPERATION PROBLEMS INCLUDED DIFFICULTIES WITH THE MODULE PACKING GRID
SUPPORT, GENERAL VESSEL SCALE FORMATION, FLOW DISTRIBUTION PROBLEMS, BALL BREAKAGE, SCALING IN THE
MIST ELIMINATOR SECTION, AND PLUGGING OF THE REHEATER. SCALE FORMATION WAS THE MOST PREDOMINANT
CONTINUING MAJOR CAUSE OF DOWNTIME IN THE SCRUBBER. SCALE ACCUMULATION WAS NOTED ON THE WET-DRY
INTERFACE IMMEDIATELY DOWNSTREAM OF THE PRESATURATION NOZZLES. SCALE ALSO ACCUMULATED HEAVILY ON
THE UNDERSIDE OF THE FIRST LAYER OF GRID BARS.
SCALE ON THE UPPER GRID BARS WAS LESS PREVALENT AS THE ACTION OF THE "PING PONG" BALLS TENDS TO
KEEP THE SCALE OFF OF THESE SECTIONS. SCALE ALSO COLLECTED ON THE WALLS OF THE VESSEL AND INTER-
MITTENTLY SLOUGHED OFF AND FELL INTO THE SUMP IN LARGE PIECES CAUSING BLOCKAGE OF THE RECIRCULATION
PUMP SUCTION SCREENS. SCALING OF THE MIST ELIMINATOR ABATED SOMEWHAT WITH THE INTRODUCTION OF A
CLEAR RINSE WATER WASH. SCALt FORMATION IN THE REHEAT SECTION SOMETIMES REQUIRED SUPPLEMENTAL
CLEANING OF THE REHEATER IN ADDITION TO THE CLEANING OBTAINED BY THE USE OF THE SOOT8LOWERS WHICH
WERE INSTALLED AS PART OF THE REHEATER EQUIPMENT. UNDER NORMAL OPERATION, THE SOOTBLOWERS LOCATED
IN THIS REHEAT SECTION WERE FAIRLY SUCCESSFUL IN REMOVING THE ACCUMULATION OF THE SCALE IN THE
REHEATER.
ALTHOUGH MANY OF THE INITIAL START-UP PROBLEMS WERE SOLVED OVER A PERIOD OF TIME, THE CALCIUM
SULFATE-FLY ASH SCALING CONTINUED TO BE A SIGNIFICANT OPERATING PROBLEM AT THE VALMONT INSTALLATION,
IN ADDITION TO THESE SCALING RELIABILITY PROBLEMS, A WATER QUALITY CONCERN ALSO SURFACED THAT WAS A
DIRECT RESULT OF THE PARTICULATE SCRUBBER OPERATION. THE RELATIVELY HIGH CAO CONCENTRATION IN THE
VALMDNT FLY ASH RESULTED IN FAIRLY HIGH S02 REMOVAL RATES (05-50 PERCENT) WITHIN THE UNITS. SINCE
NO PH CONTROL CAPABILITY FOR EITHER THE RECIRCULATING SLURRY OR THE SYSTEM SLOWDOWN SLURRY WAS
DESIGNED INTO THE SYSTEM, AN ACID CONDITION WAS CREATED IN THE SLURRY AND THE SLOWDOWN STREAM.
PH LEVELS OF THE BLOWDOWN NORMALLY RANGED BETWEEN 1.7 AND 2.0. ALTHOUGH THE STREAM WAS NEUTRALIZED
TO A DEGREE BY ALKALINE FLY ASH, PSCC FELT THAT IT WAS IMPORTANT TO INVESTIGATE VARIOUS CONTROL
MEASURES WHICH COULD BE APPLIED TO THIS STREAM. THE CALCIUM SULFATE SCALING PROBLEM WAS THOUGHT TO
BE THE RESULT OF A SUPER-SATURATED CALCIUM SULFATE CONDITION IN THE RECIRCULATING SLURRY. BECAUSE
OF THIS IT WAS FELT THAT CONTINUOUS PH CONTROL OF THE RECIRCULATING SLURRY, CONVERSION OF THE SYSTEM
TO CLOSED LOOP OPERATION AND ESTABLISHING A HIGHER CONCENTRATION OF SEEDING SOLIDS IN THE RECIRCULA-
TION SLURRY (THEREBY CONTROLLING THE SCALING PROBLEMS WITHOUT CHEMICAL ADDITIVES) WOULD BE NECESSARY
MEASURES.
FOR PH CONTROL, LIMESTONE WAS TESTED INITIALLY, THEN LIME WAS UTILIZED FOR THE ALKALI REAGENT.
IN THE FIRST TEST, SINCE LIMESTONE UTILIZATION WAS A MAJOR CONCERN, A SPECIAL EFFORT WAS MADE TO
REDUCE THE POTENTIAL FOR THE SHORT CIRCUITING OF THE ADDED LIMESTONE AND TO PROVIDE SUFFICIENT
RESIDENCE TIME IN THE REACTOR SECTION OF THE SYSTEM. 6Y UTILIZING FOUR REACTION MIX TANKS IN
SERIES, PLUG FLOW WAS EXPECTED TO BE MORE CLOSELY SIMULATED. TO MAINTAIN A CLOSED LOOP SYSTEM WHtRE
THE QUANTITY OF WATER REMOVED FROM THE SYSTEM WAS HELD TO A MINIMUM, FOUR SYSTEM DESIGN FEATURES
WERE UTILIZED.
1. UTILIZATION OF A COMBINATION OF POND SUPERNATANT AND MAKE-UP WATER FOR RECYCLE WATER.
2. PRESATURATION OF THE INCOMING FLUE GAS WITH RECIRCULATING SLURRY.
3. INTERMITTENT MIST ELIMINATOR WASH,
4. PROPER SELECTION OF MATERIALS OF CONSTRUCTION TO PROTECT AGAINST ATTACK CAUSED BY HIGH
CHLORIDE CONCENTRATIONS.
THE SCRUBBERS R & D FACILITY WAS NOT EQUIPPED WITH A MECHANICAL THICKENER FOR CONTROL OF THE
SUSPENDED SOLIDS CONCENTRATION OF THE RECIRCULATING SLURRY (ALL PURGED MATERIAL WAS SENT TO THE
SLUDGE POND). WITH A 500 PPM S02 CONCENTRATION IN THE FLUE GAS, IT IS EXPECTED THAT THE RECIRCULAT-
ING SLURRY SOLIDS COULD BE REALLY CONTROLLED IN THE S TO 7 PERCENT RANGE. DUE TO THE MIXED FUEL
FIRED AT THE UNIT DURING THE TEST PERIOD, HOWEVER, THE S02 CONCENTRATIONS EMITTED FROM THE BOILER
AND HENCE PRESENT IN THE FLUE GAS STREAM VARIED SIGNIFICANTLY AND FINALLY FELL TO SUCH LOW LEVELS
(OFTEN 100-200 PPM) THAT SUSPENDED SOLIDS CONCENTRATIONS IN THE SLURRY COULD .NOT BE MAINTAINED.
IT IS ALMOST CERTAIN THAT A THICKENER, WITH THE SUBSEQUENT RETURN OF SOLIDS TO THE SCRUBBER LIQUOH,
COULD HAVE BEEN USED TO GOOD ADVANTAGE DURING THIS TIME PERIOD. GENERALLY SPEAKING, THE SEVERE
SCALING CONDITIONS PLAGUING THE TEST MODULE WERE INTENSIFIED DURING THESE PERIODS OF LOW INLET 802
CONDITIONS.
204
-------
TABLE 18
DESCRIPTION OF TERMINATED FGO SYSTEMS 01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
SOUTHERN CALIFORNIA EDISON
MOHAVE NO 1A
LAUGHLIN NEVADA
170 MW
COAL 0.5 - 0.8 PERCENT SULFUR
UNIVERSAL OIL PRODUCTS
LIMESTONE SCRUBBING
RETROFIT
11/74
TERMINATED
93 PERCENT
95 PERCENT
WATER MAKE UP
0.92 GPM/MW
SLUDGE DISPOSAL
EXPERIMENTAL METHODS
UNIT COST
NOT AVAILABLE
OPERATIONAL
EXPERIENCE
THIS EXPERIMENTAL MODULE (VERTICAL TCA TOWER SUPPLIED BY UOP) STARTED up
OCT. 31, 197« AND OPERATED KITH AN AVAILABILITY OF 72X THROUGH 8 MONTHS
OF TESTING, TESTING HAS BEEN COMPLETED, AND THE FGD SYSTEM WAS SHUT DOWN
INDEFINITELY ON JULY 2, 1975. NEVADA ASSEMBLY BILL NO. 706 HAS PLACED A
TWO YEAR MORATORIUM ON THE ENFORCEMENT OF THE COMPLIANCE SCHEDULE FQK THIS
STATION. FURTHER FGD ACTIVITIES WILL BE DEPENDENT ON FUTURE LEGISLATION.
205
-------
TABLE 12
DESCRIPTION OF TERMINATED F6D SYSTEMS
01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
SOUTHERN CALIFORNIA EDISON
MOHAVE NO. 3A
LAUGHLIN NEVADA
160 MM
COAL 0.5-0.8 PERCENT SULFUR
SCE/STEARNS ROGER
LIME SCRUBBING
RETROFIT
11/73
TERMINATED
93 PERCENT
S02
95 PERCENT
MATER MAKE UP
1.0 GPM/MW
SLUDGE DISPOSAL
UNIT COST
NOT AVAILABLE
OPERATIONAL
EXPERIENCE
REFER TO TH£R BACKGROUND INFORMATION SECTION IN TABLE \i OF THIS REPORT A
PROTOTYPE HOIZONTAL SPRAY TOWER WAS FITTED ONTO THE NO. 2 UNIT AT THIS
STATION AND WAS OPERATED IN AN EXPERIMENTAL MODE FROM JAN. 16, 197« TO
FEB. 9, 1975. SOZ AND PARTICULATE REMOVAL EFFICIENCIES IN EXCESS OF 90X
WERE ACHIEVED DURING THE PROGRAM. FOLLOWING TERMINATION OF THE PROGRAM.
THE MODULE WAS SHUT DOWN, DISASSEMBLED AND SHIPPED TO THE FOUR CORNERS
STATION FOR FURTHER EVALUATION.
206
-------
BACKGROUND INFORMATION
ON
THE MOHAVE TEST MODULES PROGRAM: NOS. 1A AND 2A
TWO PHOTOTYPE SULFUR DIOXIDE ABSORBER MODULES WERE INSTALLED IN 1973 AT THE MOHAVE GENERATING
STATION OF THE SOUTHERN CALIFORNIA EDISON COMPANY. A VERTICAL MODULE, HATED AT 170 Mw, HAS INSTALL-
ED TO TREAT 4bO,000 SCFM PORTION OF THE FLUE GAb FROM UNIT NO. 1. A HORIZONTAL MODULE, ALSO RATED
JT 170 MW. WAS INSTALLED TO TREAT A SIMILAR FLUE GAS PORTION FRUM UNIT NO. 2. UNITS 1 AND 2 ARE
IDENTICAL BOILERS, EACH HAVING A MAXIMUM NET CONTINUOUS GENERATING CAPACITY OF 790 MW AND EACH BURN-
ING A WESTERN, LOW-SULFUR COAL WITH A HEATING VALUE OF 11,500 BTU/LB AND ASH AND SULFUR CONTENTS OF
10 AND 0.1 PERCENT RESPECTIVELY.
VERTICAL MODULE
THE VERTICAL MODULE, A UNIVERSAL OIL PRODUCTS TURBULENT CONTACT ABSORBER (TCA), WAS TESTED IN
TWO MOOES; FIRST, AS A TCA UNIT, FROM NOVEMBER 2, 1974 TO APRIL 30, 1975, AND SECOND AS A POLVGWID
PACKED ABSORBER CPPA), WHEN THE "PING PONG BALLS" WERE REPLACED WITH A PLASTIC "EGGCRATE" PACKING
WITH TESTING CONTINUING TO JULY a, 1975.
STARTUP OF THE VERTICAL MODULE WAS INITIATED ON SCHEDULE JANUARY 1, 197fl. ON JANUARY £«, 1971,
A FIRE BURNED MOST Of THE CHLOROBUTYL LINING AND SYSTEM RESTART WAS DELAYED UNTIL OCTOBER 1, 1971.
TESTING OF THIS MODULE FOLLOWED A MONTH LATER AND WAS COMPLETED AFTER 3,131 HRS. OF OP. THE MODULE
IS PRESENTLY SHUT DOWN IN A COLD STAND-BY CONDITION AT THE MOHAVE GENERATING STA.
HORIZONTAL MODULE
THE HORIZONTAL MODULE, A FOUR-STAGE HORIZONTAL CROSSFLOW SPRAY SCRUBBER, WAS OPERATED 8Y THE
UTILITY IN A SHORT SERIES OF STARTUP TESTS THAT ENDED ON JANUARY 16, 1971, WHEN A FORMAL TEST PROG-
RAM WAS INITIATED TO ASSESS THE PERFORMANCE AND RELIABILITY CHARACTERISTICS OF THE SCRUBBING SYSTEM.
THE TEST PROGRAM WAS TERMINATED ON FEBRUARY 9, 1975 FOLLOWING 5,927 HUURS OF OPERATION.
THE MODULE WAS SUBSEQUENTLY DISMANTLED, TRANSPORTED, AND REASSEMBLED AT THE FOUR CORNERS PLANT OF
ARIZONA PUBLIC SERVICE WHERE ADDITIONAL TESTING WAS CONDUCTED AND COMPLETED (DECEMBER 197b).
INFORMATION AND DATA CONCERNING THE PERFORMANCE OF MOHAVE TEST MODULES ARE GIVEN IN THE FOLLOW-
ING PERFORMANCE TABLES. PROCESS FLOW DIAGRAMS OF THE TEST MODULES ARE PROVIDED IN APPENDIX B.
207
-------
SOUTHERN CALIFORNIA EDISON MOHAVE UNIT NOS. 1A AND 2A
MOHAVE NO. 1A - VERTICAL TEST MODULE
OUTAGE TIME HISTORY: NOVEMBER 2, 1
-------
SOUTHERN CALIFORNIA EOISON MOHAVE UNIT NOS. 1A AND 2A
MOHAVE NO. 2A - HORIZONTAL TEST MODULE
OUTAGE TIME HISTORY: JANUARY 16, 1974 TO FEBRUARY 9, 1975
REASON TIME (HR)
1. MODIFY AND REPRIR PLASTIC OEMISTER BLADES 503
2, CORRECT BOOSTER FAN BALANCE PROBLEMS 317
3. PUMP REPAIR 356
4. SPRAY NOZZLE REPLACEMENT 238
5. MODIFY GAS INLET FLOW DISTRIBUTION 162
6. REPAIR HOPPER LEAKS 135
7. REMOVE HARDHAT FROM THICKENER 82
8. MODIFY SLAKING WATER FOR SCALE PREVENTION 45
9. CONDUCT INSPECTION FOR EXTENDED OPERATIONS 19
10. TOTAL OUTAGE TIME 1757
TOTAL OUTAGE TIME: 1757 HOURS
TOTAL CALENDER TIME: 9328 HOURS
TOTAL OPERATING TIME: 7571 HOURS
PERCENT AVAILABILITY: B1.16X
209
-------
TABLE 12
DtSCRIPTION OF TERMINATED F6D SYSTEMS
01/78
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
FUEL CHARACTERISTICS
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FGD STATUS
EFFICIENCY,
PARTICULATES
TENNESSEE VALLEY AUTHORITY
SHAWNEE NO. IOC
PAOUCAH KENTUCKY
10 MW
COAL 2.9 PERCENT SULFUR
TENNESSEE VALLEY AUTHORITY
LIME/LIMESTONE SCRUBBING
RETROFIT
TERMINATED
EXPERIMENTALLY CONTROLLED
S02
EXPERIMENTALLY CONTROLLED
WATER MAKE UP
EXPERIMENTALLY CONTROLLED
SLUDGE DISPOSAL
EXPERIMENTALLY CONTROLLED
UNIT COST
NOT APPLICABLE
OPERATIONAL
EXPERIENCE
REFER TO BACKGROUND INFORMATION SECTION IN TABLE 12. THIS EXPERIMENTAL
FGD UNIT BECAME OPERATIONAL IN APRIL, 1972. THE MARBLE-BED ABSORBER, A
30,000 ACF UNIT (10 MW), MANUFACTURED BY COMBUSTION ENGINEERING CO., WAS
DISCONTINUED EARLY IN THE TEST PROGRAM JULY 1973 BECAUSE OF CONTINUED
OPERATING PROBLEMS WITH NOZZLE FAILURE AND SUBSEQUENT PLUGGING OF THE
MARBLE BED. THIS SYSTEM BECAME OPERATIONAL IN APRIL 1973, AND IT WAS
SHUT DOWN PERMANENTLY IN JULY 1973.
210
-------
BACKGROUND INFORMATION
ON
SHAWNEE NOS. 10 A, 106, AND IOC
IN JUNE 1968, THE EPA INITIATED A PROGRAM TO TEST PROTOTYPE WET LIME AND LIMESTONE SCRUBBING
SYSTEMS FOR REMOVAL OF SULFUR DIOXIDE AND PARTICULARS FROM FLUE GAS. THE PROGRAM rtAS CARRIED OUT
IN A TEST FACILITY INCORPORATED INTO THE FLUE GAS DUCT WORK OF UNIT NO. 10, A COAL-FIRED BOILER AT
THE TVA SHAWNEE POWER STATION, PADUCAH, KENTUCKY. TVA IS THE CONSTRUCTION AND FACILITY OPERATOR AND
THE BETCHEL CORP. IS THE MAJOR CONTRACTOR AND TtST DIRECTOR.
THE TEST FACILITY CONSISTS OF THREE PARALLEL SCRUBBER SYSTEMS OF PROTOTYPE SIZE TREATING PART
OF THE FLUE GAS FROM THE BOILER. EACH SCRUBBER TRAIN IS CAPABLE OF TREATING APPROXIMATELY 30,000
ACFM, OR THE EQUIVALENT OF APPROXIMATELY 10 MW OF POWER PLANT GENERATING CAPACITY.
THREE PARALLEL WET SCRUBBER SYSTEMS WERE SELECTED FOR THE TEST PROJECT: 1) A VENTUHI WITH A
3PRAY TOWER AFTER ABSORBER: 2) A TURBULENT CONTACT ABSORBER (TCA AND 3) A MARBLE-BED ABSORBER. THE
VENTURI SYSTEM, MANUFACTURED BY CHEMICAL CONSTRUCTION CO., CONTAINS AN ADJUSTABLE THROAT THAT
PERMITS CONTROL AND VARIATION OF PRESSURE DROP UNDER A WIDE RANGE OF FLOW CONDITIONS. THE TCA UNIT,
MANUFACTURED BY UNIVERSAL OIL PRODUCTS, EMPLOYS A FLUIDIZED BED OF LOW DENSITY PLASTIC SPHERES THAT
ARE FREE TO MOVE BETWEEN RETURNING GRIDS. THE MARBLE-BED ABSORBER, SUPPLIED BY COMBUSTION ENGINEER-
ING CO., USES A PACKING OF 3/«-INCH GLASS MARBLE SPHERES AND A TURBULENT LAYER OF LIQUID AND GAS
ABOVE THE MARBLE LAYER TO ENHANCE MASS TRANSFER.
THE TEST FACILITY WAS DESIGNED SO THAT MODIFICATIONS AND VARIATIONS OF SCRUBBER INTERVALS AND
PIPING COULD BE READILY EMPLOYED FOR EACH SCRUBBER SYSTEM. EACH SYSTEM CAN TREAT APPROXIMATELY
30,000 ACFM OF FLUE GAS AT 300 F CONTAINING 1800 TO 4000 PPM OF SOa AND Z TO 5 GRAINS/SCF OF PART-
ICULATES. TESTING OF THE TCA AND THE VENTURI SPRAY TOWER IS IN PROGRESS: OPERATION OF THE MARBLE-
BEO ABSORBER UNIT HAS BEEN PERMANENTLY DISCONTINUED.
211
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TABLE 12
DESCRIPTION OF TERMINATED FGD SYSTEMS 01/78
UTILITY NAME UNION ELECTRIC CO.
UNIT NAME MEREMAC NO. 2
UNIT LOCATION ST. LOUIS COUNTY MISSOURI
UNIT RATING 110 MW
FUEL CHARACTERISTICS COAL 3.4 PERCENT SULFUR
FGD VENDOR COMBUSTION ENGINEERING
PROCESS LIMESTONE INJECTION/WET SCRUB
NEW OR RETROFIT RETROFIT
START UP DATE 3/68
FGD STATUS TERMINATED
EFFICIENCY,
PARTICULATES 99 PERCENT
S02 83 PERCENT
WATER MAKE UP CLOSED LOOP
SLUDGE DISPOSAL
UNIT COST
OPERATIONAL THE FIRST COMMERCIAL SCRUBBER APPLICATION ON A UTILITY COAL-FIRED BUILEK
EXPERIENCE OCCURRED AT THIS STATION IN EARLY 1968. THE SCRUBBING STRATEGY INCLUDED
LIMESTONE INJECTION INTO THE FURNACE WITH AN EXISTING COAL PULVERIZER AND
TAIL-END SCRUBBING WITH THE CALCINED REAGENT IN TWO MARBLE-BED ABSORBERS.
THIS FULL-SCALE EXPERIMENTAL SCRUBBING PROGRAM WAS EVENTUALLY TERMINATED
AND THE INSTALLATION WAS ABANDONED. PROBLEMS ENCOUNTERED INCLUDED BOILER
TUBE FOULING BECAUSE OF CLOSE TUBE SPACING, WIDESPREAD SCALING, SEVERE
CORROSION, INEFFICIENT MIST ELIMINATOR AND PROBLEMS WITH WASTE DISPOSAL.
212
-------
TABLE 13
TOTAL FGD MEGAWATT CAPACITY BY YEAR *
YEAR
NO. UNITS MEGAWATTS
1968
1971
1972
1973
1971
1975
1976
1977
1978
1979
1980
1981
1982
1983
1984
1985
1986
UNDEFINED
1
1
4
a
2
4
5
10
19
15
23
11
7
7
3
2
2
10
125
400
260
1410
250
1054
2198
«853
7718
6031
9658
5805
3353
3735
2050
1300
1100
4029
* TOTALS DISPLAYED DO NOT INCLUDE TERMINATED OR INACTIVE SYSTtMS.
213
-------
APPENDIX A
FGO SYSTEMS ECONOMICS
A-l
-------
APPENDIX A. FGD SYSTEM ECONOMICS: OPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Arizona Public Service
Cholla Electric Generating
Station
No. 1
115
Columbus & So. Ohio Electric
Conesville Generating Station
No. 5
400
PROCESS
STATUS
START-UP DATE
Limestone
Operational
10/73
Lime
Operational
1/77
REPORTED CAPITAL
COSTS,
$ MILLION
6.555
15.27
$/KW
57.0
37.90
REPORTED OPERATING
COSTS,
$ ANNUAL
7.765 MM
MILLS/KWH
2.20
5.61
COMMENTS
1. Capital cost figure includes the venturi scrubbers (2)
for particulate control. This figure represents
total expenditures made by the utility through 1973.
2. Capital cost figure does not include limestone prep-
aration, sludge handling facilities and interest on
capital during construction.
3. Additional costs incurred by the system supplier have
not been reported.
4. The operating cost figure includes operating and main-
tenance expenditures only.
1. The capital cost figure includes direct costs only.
2. The capital cost figure includes two scrubber modules,
all ancillary equipment, sludge disposal system -site
preparation, and construction costs. Indirect! are
not included.
3. Annual operating costs are estimated at a load factor
39.5%.
4. Annual costs include capitalization, raw materials
waste disposal, maintenance, labor, and utilities.
5. All cost estimates are given in 1976 dollars.
I
u>
Note: N/A indicates figures are not available.
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: OPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Ouquesne Light
F.R. Phil lips Station
Nos. 1 to 6
410
Elrama Station
Nos. 1 to 4
510
Indianapolis Power & Light
Petersburg Generating Station
No. 3
530
PROCESS
STATUS
START-UP DATE
Lime
Operational
7/73
Lime
Operational
10/75
Limestone
Operational
10/77
REPORTED CAPITAL
COSTS,
$ MILLION
44.219
52.919
32.082
$/KW
114
107
61.891
REPORTED OPERATING
COSTS,
$ ANNUAL
14 MM
16.2 MM
MILLS/KWH
COMMENTS
5.86 j 1. Total capital cost figures for Phillips and Elrama
j include all expenditures required to bring the
entire plants into compliance.
5.35
2. Total capital cost figures include all process equip-
ment, engineering costs, contractor's fees and
interest on capital during construction. Excluded
are the costs of additional long term sludge disposal
facilities that may be required. However, equipment
for short term disposal is inc-luded ($2 MM). The
$/kW values are based upon the station's net generat-
ing capacities with the scrubbers in service. The
Phillips and Elrama Stations net generating capacities
are 387 and 494 MW respectively.
3. Annual operating cost figures of 6 mills/kWh is based
upon the combined operating costs for the Phillips
and Elrama stations when full SO? compliance is
achieved. This amounts to approximately $32 million
annually.
4. A weighted average replacement energy cost based on
system cost and purchased power cost for each plant of
13.69 mills/kWh is not included in the cost figures.
5. All costs are given in 1977 dollars except the re-
placement energy cost which is given in 1976 dollars.
1. Capital cost figure includes scrubbers, pumps, fan
reheat and all auxiliary equipment ($25.9 MM); sludge
stabilization, and disposal ($3.5 to $4.0 MM); and
indirect costs ($1 .616 MM).
2. The cost of the ESP's installed upstream of the
scrubber plant for particulate control ($4.083 MM)
is not included.
3. Interest during construction is not included.
4. FGD design and costs are based upon 4.5% sulfur coal,
which is the maximum allowable sulfur content for the
scrubber plant.
Note: N/A indicates figures are not available.
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: OPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Kansas City Power & Light
La Cygne Power Station
No. 1
820
Kansas Power & Light
Lawrence Energy Center
Nos. 4 & 5
525
PROCESS
STATUS
START-UP DATE
Limestone
Operational
2/73
Limestone
Injection &
Wet Scrubbing
Terminated,
Operational
12/68 & 11/71
REPORTED CAPITAL
COSTS,
$ MILLION
52.4
3.5
$/KW
63.9
7
REPORTED OPERATING
COSTS,
$ ANNUAL
5.35 MM
MILLS/KWH
1.402
N/A
N/A
COMMENTS
1. The capital cost figure includes $45.4 million in
expenditures already made plus an additional $7
million required to reach optimum system performance
($5.2 million for the installation of an eighth
scrubber module) .
2. The annual operating cost figures include operating
labor and materials, maintenance labor and materials,
limestone and reheat energy.
3. The annual operating and maintenance cost figure is
based upon a 1976 capacity factor of 53%.
4. A replacement energy cost of 8.8 mills/kWh is not
included in the cost figures.
5. Cost estimates are given in 1976 dollars.
1. The capital cost figure presented represents a sum
paid by the utility for both systems in 1968. Ex-
penses incurred in many subsequent modifications
over the years were largely underwritten by the
system supplier. Therefore, the figures listed are
unreal istical ly low and are not meaningful.
2. These units have been and are now being replaced with
venturi rod scrubber and spray tower systems utiliz-
ing a limestone-based scrubbing slurry.
3. Lawrence No. 4 rod scrubber and spray tower limestone
scrubbing system was placed in service Jan. 1977. The
original injection unit has been dismantled.
4. Lawrence No. 5 rod scrubber and spray tower scrubbing
system is now being erected. The original injection
unit is still in service. Start up of the new system
scheduled for Mar. 1978
I
LT1
Note: N/A indicates figures are not available.
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: OPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
PROCESS
STATUS
START-UP DATE
REPORTED CAPITAL
COSTS,
MILLION
$/KW
REPORTED OPERATING
COSTS,
ANNUAL
MILLS/KWH
COMMENTS
Kentucky Utilities
Green River Power Station
Nos. 1, 2 & 3
64
Lime
Operational
9/75
3.674
57.4
4.419 MM
2.02
I
CTi
Louisville Gas & Electric
Cane Run Power Station
No. 4
178
Lime
Operational
8/76
10.4
58.4
2.5 j N/A
1. The capital cost figure for this turnkey installa-
tion includes installed cost of FGD equipment,
ancillaries, and sludge disposal-site preparation
and waste transport system.
2. The operating cost figure includes feed material and
chemicals, labor and supervision, waste disposal,
maintenance materials, labor and supervision and
reheat energy cost.
3. The capacity factor for Green River 1,2 and 3 in 1976
was 47.5%.
4. A replacement energy cost of 10.04 mills/kWh is not
included in the cost figures.
5. Cost figures are given in 1976 dollars.
1. The total installed capital cost includes the install-
ed cost of FGD equipment, ancillaries and sludge dis-
posal - site preparation and waste transport system,
and the carbide lime unloading docks for all three
FGD - equipped Cane Run units (Nos. 4,5, and 6). The
total also includes $85,000 to reline the exhaust
ductwork and stack.
2. The reported annual operating cost figure includes
all operating and maintenance charges.
3. The cost figures are given in 1977 dollars.
4. A replacement energy cost of .23 mills/kWh is not
included in the cost figures.
Note: N/A indicates figures are not available.
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: OPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Louisville Gas & Electric
Paddys Run Power Station
No. 6
65
Mlnnkota Power Coop.
M.R. Young Station
No. 2
450
Montana Power Co.
Colstrip Plant
Nos. 1 & 2
720
PROCESS
STATUS
START-UP DATE
Lime
Operational
4/73
Fly Ash/Lime
REPORTED CAPITAL
COSTS,
$ MILLION
3.38
32
Operational
$/KW
52
REPORTED OPERATING
COSTS,
$ ANNUAL
71.11
9/77
i
1
Fly Ash/Lime
Operational
10/75 & 7/76
55.27
83.74
1.185 MM
MILLS/KWH
5.6
0.26
COMMENTS
1. The capital cost figures are based on the boiler
rating minus system power consumption. The costs
includes everything except the final waste disposal
site. This is a borrow pit supplied by the State
highway department at no cost to the utility.
2. The operating costs include feed material and chemi-
cals, labor and supervision, maintenance materials,
labor and supervision and reheat energy cost.
3. Cost of the carbide lime absorbent is confidential.
4. Costs are atypical because the unit is used for peak
loads and the scrubber is a research and development
tool for future full scale installations now opera-
tional, under construction or planned by the utility.
5. A replacement cost of .25 mills/kWh is not included
in the cost figures.
6. The cost figures are given in 1976 dollars.
1. The total installed capital cost figure represents
an estimated value for the unit's entire emission
control system.
2. An upstream ESP for primary particulate control
($12 million) is not included.
3. The capital cost figure does not include the exten-
sive sludge handling and disposal strategy proposed
for this unit (vacuum filters and building, conveyor,
by-pass equipment, trucks and front-end loaders.
1. The reported capital cost includes foundation, field
wiring, insulation, heat tracing, painting, piping
to ponds, piping between modules, field distributions
in addition to the scrubber modules, ductwork, equip-
ment supply and erection. Also included is the
interest costs, cost of fly ash ponds, fly ash slurry
transport systems and evaporation pond, and incre-
mental costs such as auxiliary boiler, F.D. fans.
start-up and auxiliary transformer.
Note: N/A indicates figures are not available.
-------
APPENDIX A
(Continued). FGD SYSTEM ECONOMICS: OPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Nevada Power Co.
Reid Gardner Station
Nos. 1 & 2
250
Northern Indiana Public Serv.
D.H. Mitchell Station
No. 11
115
PROCESS
STATUS
START-UP DATE
Sodium Carbonate
Operational
4/74
Wellman-Lord
Operational
6/77
REPORTED CAPITAL
COSTS,
$ MILLION
11
14,825
$/KW
44
129
REPORTED OPERATING
COSTS,
$ ANNUAL
1.2 MM
6.006 MM
MILLS/KWH
N/A
8.1
COMMENTS
1. The total installed capital cost figure is an
estimate that was originally provided by the
utility for expenditures completed by installation
date (1974). Included are both scrubbing systems
along with all the raw material handling and pond
equipment cost.
2. The annual operating cost figure includes $600,000
annualized for each unit.
1. The capital figure includes interest during con-
struction and overhead charges.
2. Reported operating cost figure is a total annualized
cost value that includes operation and maintenance
costs, and anti-oxidant agent costs.
3. Fixed charges are calculated for a 10-15 year plant
lifetime (26% of $41,825 MM). Assume an annual unit
load factor of 73.5*.
4. The cost figures are given in 1976 dollars.
I
CO
Note: N/A indicates figures are not available.
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: OPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Northern States Power
Sherburne County Generating
Plant
Nos. 1 & 2
1420
Pennsylvania Power
Bruce Mansfield Plant
Nos. 1 S, 2
1650
Philadelphia Electric
Eddyston Generating Station
Unit No. 1A
316
PROCESS
STATUS
START-UP DATE
Limestone
Operational
5/76 & 5/77
Lime
Operational
4/76 & 7/77
Magnesium Oxide
Operational
9/75
REPORTED CAPITAL
COSTS,
$ MILLION
60
249.15
28.44
S/KW
44
151
90
REPORTED OPERATING
COSTS,
$ ANNUAL MILLS/KWH
3.77 MM
28.2 MM
0.40
4.25
COMMENTS
1. The total installed capital cost figure includes
direct costs only, indirect costs are excluded.
2. The total cost figure applies to 1976/1977 installa-
tion and does not include escalation factors.
3. The annual operating cost figure is an estimate that
applies to 1977 operations at an 80% unit load factor.
Included in this figure are direct and indirect costs.
4. The $/KW figure is based upon the net generating
capacity of both units (680 MW/unit, 1360 MW total).
5. The cost of one redundant scrubber train is included
for each system.
1 . Cost figures presented are estimates provided
by the util i ty.
2. The total installed capital cost figures includes
all direct and indirect costs plus escalation factors.
3. The cost of the venturi scrubbers required for par-
j ticulate emission control are included.
1 4. All cost figures are reported in 1977 dollars.
4.7
1. The capital cost figure includes installed cost of
FGD equipment, ancillaries, sludge disposal-site
preparation and waste transport system. The
magnesium oxide regenerating facility cost is also
included. The cost of paniculate scrubbing is also
included.
2. The operating cost figure includes feed material
disposal, maintenance materials, labor and supervision
and reheat energy cost.
3. A replacement energy cost of 12.3 mills/kWh is not
included in the cost figures.
4. The cost figures are given in 1976 dollars.
I
VO
Note: N/A indicates figures are not available.
-------
APPENDIX A (Continued)
FGD SYSTEM ECONOMICS: OPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
South Carolina Public Service
Winyah Generating Station
No. 2
380
Springfield City Utilities
Southwest Generating Station
No. 1
200
Tennessee Valley Authority
Widows Creek Steam Plant
No. 8
550
PROCESS
STATUS
START-UP DATE
Limestone
Construction
7/77
Limestone
Operational
4/77
Limestone
Operational
5/77
REPORTED CAPITAL
COSTS,
$ MILLION
6.345
15
56 . 284
S/KW
22.66
75
102.33
REPORTED OPERATING
COSTS,
$ ANNUAL
"
5.226 MM
MILLS/KWH
0.333
1.72
COMMENTS
1. Fifty percent of the boiler's flue gas is scrubbed
for SO, removal. S0? removal efficiency is 69%.
2. The total direct and indirect cost for the ESP pro-
vided for primary particulate control upstream of the
scrubbers is $1.686 MM (not included in this
table).
3. The capital cost figures include installed cost of
FGD equipment, ancillaries, sludge disposal-site prep-
aration, and waste transport system.
4. The operating cost figure includes feed material and
chemicals, labor and supervision, waste disposal,
maintenance materials, labor and supervision and
reheat energy cost.
5. A replacement energy cost of 20 mills/kWh is not
included in the cost figures.
6. The cost figures are given in 1976 dollars.
1. The capital cost figures are actual FGD system costs
given by the Utility.
2. The $5 MM particulate cleaning cost (ESP) is not
included.
3. The cost figures are given in 1977 dollars.
1. The total installed capital cost figure is an estimate
that includes all expenditures made by February 1977.
2. Included in the total installed figure are the costs
of the existing ESP and venturi scrubbers for control
of particulate emissions, plus all direct and in-
direct costs, and escalation.
3. Sludge handling and disposal facilities are not
included in the above estimate.
4. The annual operating cost figure is an estimate that
applies to operation in 1977.
5. The annual operating cost estimate includes partic-
ulate removal costs. Amortization of investment is
not included.
6. The mills/kWh figure derived from the operating ex-
penditures is the total annual cost estimates (direct
and indirect) at a unit capacity factor of 63%.
I
(-•
o
Note: N/A indicates figures are not available.
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: NONOPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Alabama Electric Coop.
Tombigbee Power Station
Nos. 2 & 3
510
Arizona Electric Power
Apache Station
Nos. 2 and 3
400
Basin Electric Power Coop.
Laramie River Station
Nos. 1 and 2
1100
Big Rivers Electric Coop
Reid Steam Station
No. 2
250
Big Rivers Electric Coop
Reid Steam Station
No. 3
240
PROCESS
STATUS
START-UP DATE
Limestone
Construction
3/78 & 3/79
Limestone
Construction
6/78 & 4/79
Limestone
Contract
Awarded
4/80 8, 10/80
Lime
Contract
Awarded
1979
Lime
Contract
Awarded
1980
REPORTED CAPITAL
COSTS,
$ MILLION
35.464
21
80
10.81
rio "
-i . -----
$/KW
69.54
5.25
68.2
43.24
i
REPORTED OPERATING
COSTS,
$ ANNUAL
240,323
MILLS/KWH
0.77
1.5
COMMENTS
1. Capital cost figures includes S02 scrubber trains,
limestone milling facilities, sludge treatment and
disposal pond, engineering costs, contractors fee
and interest on capital during construction.
2. 70% of the flue gas capacity is scrubbed.
3. Annual operating costs are calculated for 1978 with a
60% boiler capacity factor.
4. Included in the operating costs are all direct costs
minus maintenance and solid waste disposal costs.
5. Indirect costs are not included in the operating cost
figure provided.
6. A replacement energy cost of 15.5 mills/kWh per boiler
is not included in the cost figures.
1. Reported capital. cost includes the 4 scrubbers, 2 feed
tanks, recycle pumps, piping and instrumentation.
Lime handling equipment, the ESP's and waste disposal
system is not included in the figures.
1. The reported capital cost figure provided in the table
applies to the total installed cost for both double-
loop wet limestone scrubbing systems including waste
disposal, piping, and sludge handling.
2. Breakdown of the capital cost is not available.
3. Reported operational cost is an estimate as of
December 1977.
1. The reported capital cost figure applying to the
amount of the contract awarded to AAF for the turnkey
emission control installation was $16 million,
$5.19 million of which covered paniculate controls.
2. All figures are reported in 1976 dollars.
3. The $16 million figure includes an AAF-ELEX ESP, two
spray towers, reheater, ancillary equipment, ductwork,
and modular pre-wired control rooms.
1 . The contract awarded amounted to greater than $10
million for the FGD system.
I
H-
M
Note: N/A indicates figures are not available.
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: NONOPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Boston Edison Company
Mystic Power Station
No. 1
155
Central Illinois Light Co.
Duck Creek Power Plant
No. 1
400
PROCESS
STATUS
START-UP DATE
Magnesium Oxide
Terminated
4/72
Limestone
Construction
8/78
REPORTED CAPITAL
COSTS,
$ MILLION
9.510
37.328
S/KW
63.4
REPORTED OPERATING
COSTS,
$ ANNUAL
615,000
93.32
MILLS/KWH
3.0
3.31
1
COMMENTS
1. All cost figures are reported for the project com-
pletion date of 1974.
2. The total installed capital cost of the Rumford cal-
cination facility was approximately $4.5 MM.
3. Capital charges are not included because of non-
applicability to a 2-year demonstration program.
4. Operating costs for the acid plant regeneration
facility are not included.
5. The cost of make-up magnesium oxide ($150/T) is not
included.
6. 3.0 mills/kWh is an estimate for total operation and
maintenance costs, including calcination.
7. BECO and EPA each subsidized approximately BOX of the
costs of the demonstration program. Chemico also
underwrote some of the program costs.
1. The capital cost figure is an estimate of system
expenditures, including the cost of the installation
of the FGD system ancillaries, the limestone milling
and waste disposal facilities.
2. One module has been completely installed and tempo-
rarily operated from September 1976 to April 1977.
Full system operation is scheduled to commence in
August 1978.
3. The annual cost includes feed material and chemicals,
labor and supervision and $3.390 million for the
sludge/ash disposal pond as well as the power con-
sumption cost.
4. The replacement energy cost of 10 mills/kWh is not
included in the cost figures.
5. Cost figures are given in 1976 dollars.
I
M
to
Note: N/A indicates figures are not available.
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: NONOPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Central Illinois Public Serv.
Newton Station
No. 1
575
Colorado Ute Electric
Craig Station
Nos. 1 & 2
900
Commonwealth Edison
Powerton Station
No. 51
425
PROCESS
STATUS
START-UP DATE
Double Alkali
Construction
11/79
Limestone
Construction
03/79
Limestone
Construction
12/79
REPORTED CAPITAL
COSTS,
$ MILLION
108.5
105
50
S/KW
189
117
117.65
L_^
REPORTED OPERATING
COSTS,
$ ANNUAL
15 MM
. - ..
MILLS/KWH
2.7
8.70
COMMENTS
1. The capital cost figure is an estimate covering all
the scrubber unit operation areas.
2. Capital figure is quite high because of the deliber-
ate overdesign and redundancy incorporated into the
system for achievement of reliable operations.
3. The $/kW figure is calculated on the unit's net
generating capacity of 575 MW. 3% of the unit's net
generating capacity is required to power the scrubber
plant.
1. The total capital cost figure is an estimate provided
by the utility that does not include reagent prepara-
tion and sludge disposal facilities.
2. The total revenues of the contract awarded to Peabody
Engineered Systems for two limestone slurry spray
tower scrubbing systems is expected to exceed $60 MM.
3. Electrostatic precipi tators are included in the
capital cost figure.
4. The annual operating cost figure is a preliminary
utility estimate based upon a 70% load factor.
1. The total installed capital cost expenditures apply
to the following timetable: all expenditures will be
made from May 1976 to December 1978; expenditures
of $16 MM will be made from October 1976 to October
1977.
2. The annual operating cost is an estimate which in-
cludes the following items:
0 2.7 mills/kWh for operation and maintenance.
° 6.0 mills/kWh for auxiliary power requirements.
0 Scrubber life span is estimated for an annual
usage rate of 148,000,000 kWh. This is equivalent
to approximately $900,000 annual for auxiliary
power consumption.
>
I
Note: N/A indicates figures are not available.
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: NONOPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Commonwealth Edison
Will County Station
No. 1
167
Detroit Edison
St. Clair
No. 6
163
Gulf Power
Scholz Steam Plant
Nos. 1 & 2
23
Gulf Power
Scholz Steam Plant
No. 2
20
PROCESS
STATUS
START-UP DATE
Limestone
Terminated
2/72
REPORTED CAPITAL
COSTS,
REPORTED OPERATING
COSTS,
i
$ MILLION
15.542
Limestone
Terminated
5/76
Dilute Acid,
Terminated
2/75
Dry Adsorption
Terminated
2/76
13.089
3.0
N/A
$/KW $ ANNUAL
113 3.985 MM
80.3
MILLS/KWH i COMMENTS
13.06 '' 1. The capital cost figure includes the venturi scrubbers
for particulate control.
9.60
i ;
130
N/A
N/A
N/A
N/A
N/A
2. The $/kW figure is based upon the unit's maximum net
generating capacity with the FGD system, 137 MW.
3. The annual operating cost figure is based on a system
lifetime of 14 years. Sludge treatment costs include
handling to an off-site disposal area. The figure
provided is the cost to own and operate the scrubbing
system for 1975.
4. Unit load capacity factor for 1975 was 49.4%.
1. The capital cost figure includes the installed FGD
cost, ancillaries, sludge disposal -site preparation,
and waste transport system.
2. The annual operating cost figure includes feed mat-
erial and chemicals, labor and supervision, waste
disposal, maintenance materials, labor and super-
vision, and the cost of reheat energy.
3. All costs are given in 1976 dollars.
4. The replacement energy cost of 9.0 mills/kWh is not
included in the cost figures.
1. The total installed capital cost figure provided for
the CT-101 prototype unit includes the scrubbers and
ancillary equipment, engineering costs and contractors
fee. This figure is not representative of a full-
scale application.
1. Actual cost figures for this prototype unit are not
available. Foster Wheeler has published initial
capital cost figures which range from $25 to $35 per
kW for low sulfur removal efficiency and $70 to $75
per kW for high sulfur removal efficiency.
>
I
Note: N/A indicates figures are not available.
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: NONOPERATIONAL SYSTEMS
COMPANY
PLAN!
UNITS
TOTAL CAPACITY, MW
Illinois Power
Wood River Power Station
No. 4
110
Kansas City Power & Light
Hawthorn Power Station
Nos. 3 & 4
525
PROCESS
STATUS
START-UP DATE
Catalytic
Oxidation
Terminated
10/72
REPORTED CAPITAL
COSTS,
$ MILLION
8.5
i
Limestone
Injection &
Wet Scrubbing
Terminated
11/72
5.32
$/KW
82.5
19
REPORTED OPERATING
COSTS,
$ ANNUAL
952.000
MILLS/KWH
2.2-2.5
COMMENTS
1. Reported capital cost figure represents the total
expenditures during the 2.5 year duration of the
program.
2. The $/kW figure is based upon the system's net
generating capacity of 103 MW.
3. ESP cost is included since upstream fly ash removal
is a necessary feature of this regenerable system.
4. The annual cost figure is an estimate representing
system running costs only. Excluded are capital
charges and a credit for product. This figure trans-
lates into a value of $3.46 per ton of coal consumed.
1. This figure is unrealistically low because these
installations were experimental in nature and were
heavily underwritten by the system supplier.
2. This system has been terminated as limestone-based
system and converted to a wet lime scrubbing system.
The costs of additional slakers, feeders, and other
necessary equipment are not included.
3. Sludge disposal facilities are not included in the
total cost figure.
4. The annual operating cost figure does not include
fixed costs.
5. The replacement energy cost of .058 mills/kWh is not
included in the cost figures.
I
h-1
LT!
Note: N/A indicates figures are not available.
-------
APPENDIX A (Continued]
FGD SYSTEM ECONOMICS: NONOPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Key West Utility
Stock Island Power Plant
37
Louisville Gas & Electric
Cane Run Power Station
No. 5
183
Louisville Gas & Electric
Cane Run Power Station
No. 6
277
Montana Power Co.
Colstrip Plant
Nos. 3 & 4
1400
Pacific Power & Light
Idaho Power Company
Jim Bridger Plant
No. 3
PROCESS
STATUS
START-UP DATE
Limestone
Terminated
10/72
Lime
Construction
12/77
Double Alkali
Construction
2/79
Fly Ash/Lime
Contract
Awarded
7/80 & 7/81
Sodium Carbonate
Construction
9/79
REPORTED CAPITAL
COSTS,
$ MILLION
0.750
12
16.3
N/A
50-60 MM
$/KW
20.7
66
58.9
N/A
110-120
REPORTED OPERATING
COSTS,
$ ANNUAL
7.3 MM
N/A
MILLS/KWH
0.7
N/A
COMMENTS
1. This system was jointly funded by the EPA and the
utility. The system supplier has also underwritten
a considerable amount of the capital expenditures.
This figure, therefore, is unreal istical ly low.
2. The utility has had to pay for the cost of a new
primary crushing system.
3. The operating cost figure provided was an original
estimate and has not been corroborated or disputed
by actual experience. This estimate was based upon
the following factors:
° Capitalization rate of 10%; no taxes, no insurance.
0 Maintenance cost of 5% of equipment cost.
° Labor cost at $20,000 per year.
0 Limestone cost at $4.05 per ton.
1. The total installed capital cost is an estimated
figure that includes the costs of lime handling and
sludge disposal facilities.
1. The total installed capital cost figure is an estimate
provided by the utility.
2. The annual operating cost figure provided is an
estimate for one year's service following the first
three months of operations. $4.5 million of this
total will be subsidized by the EPA for technology
research, development and report writing. This sub-
sidy will not be utilized for any capital expenditures
1. Capital cost figures are currently not available for
publication. The contract awarded to the system
supplier is expected to exceed $50 MM for both units.
1. The total installed capital cost figures are estimated
values provided by the utility.
2. The system will be comprised of 3 parallel absorption
towers each handling 33.3% of the flue gas capacity.
3. The reagent, a nominal 30 wt. % Na?C03 purge solution,
will be purchased from a local soda ash manufacturer.
I
h-J
CTi
Note: N/A indicates figures are not available.
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: NONOPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
PROCESS
STATUS
START-UP DATE
REPORTED CAPITAL
COSTS,
MILLION
$/KW
REPORTED OPERATING
COSTS,
ANNUAL M1LLS/KWH
COMMENTS
Potomac Electric Power
Dickerson Station
No. 3
190
Magnesium Oxide
Terminated
9/73
6.5
68
990,000
N/A
1. The total installed capital cost figure is an estimate
provided by the utility in 1973.
2. This figure does not include regeneration and acid
plant costs.
3. The operating cost figure is an estimate provided
for 1974 operations. This figure includes operation
maintenance costs and acid plant freight and opera-
tion charges. Not included in this figure are fixed
charges, utility charges, project management and
engineering costs.
I
I—1
-J
Public Serv. Co. of Colorado
Valmont Station
No. 5
50
Limestone
Terminated
10/74
4.35
87
1. The capital costs reprsent $44/kW for the particulate
scrubber installed in 1971 and $43/kW for the cost of
the retrofit slurry treatment equipment installation
in 1974 to control the pH of the scrubber slurry.
2. The SOj removal system was installed as a research
and development project. It was not operating long
enough for the utility to determine an annual operat-
ing cost.
Public Service of New Mexico
San Juan Station
Nos. 1 & 2
715
Wellman Lord
Construction
11/77
89.510
127.87
7.236 MM ! 5.0
1. The total installed capital cost figure is an esti-
mated value that applies to 1977 installation. In-
cluded are all direct and indirect costs plus an
escalation factor.
2. The $/kW figure is based on a net generating capacity
of 700 MW.
3. The costs of the venturi scrubbers for particulate
removal are included in the total cost figure.
4. The cost of one redundant scrubber train is included.
5. The annual operating costs and the mills/kWh value
derived are estimated for 1978 operations and based
upon a capacity factor of 77%.
6. No credit is allowed for by-product recovery (this
includes both the elemental sulfur product and the
sodium sulfate purge product for use in pulp and paper
processes.
Note: N/A indicates figures are not available.
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: NONOPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, HW
Salt River Project
Coronado Station
Nos. 1 t, 2
700
So. Indiana Gas 4 Electric
A.B. Brown Station
No. 1
250
PROCESS
STATUS
START-UP DATE
Limestone
Contract
Awarded
4/79 & 4/80
Double Alkali
Construction
4/79
REPORTED CAPITAL
COSTS,
$ MILLION
69
10.8
S/KW
98
REPORTED OPERATING
COSTS,
$ ANNUAL
43.2
MILLS/KWH
2.8
1.08
COMMENTS
1. The contracts for the ESP and scrubbing system have
been awarded. The combined cost of these two new
power-generating facilities, including emission con-
trol is estimated at 685 MM.
2. Total capital and operating costs are estimated as
1978 dollars.
3. Total capital costs include direct material and
construction costs, engineering, contingencies,
escalation and interest during construction.
4. The operating costs include energy and demand costs,
limestone supply, operating and maintenance, and
capital carrying charges. Sludge disposal is not
included.
1. FMC was awarded a contract in excess of $8 million for
the design and installation of a double alkali
scrubbing system.
2. Total expensitures for this new plant are estimated
at $134 MM.
3. The total installed capital cost figure includes in-
stalled cost of FGD equipment, ancillaries, sludge
disposal-site preparation and the waste transport
system.
4. The operating cost figures include feed material and
chemicals, labor and supervision, waste disposal as
well as maintenance materials, labor and supervision
and reheat energy costs.
5. The replacement energy cost of 7 mills/kWh is not
included in the cost figures.
6. Costs are given in 1976 dollars.
I
M
CO
Note: N/A indicates figures a^e not available.
-------
APPENDIX A (Continued). FGD SYSTEM ECONOMICS: NONOPERATIONAL SYSTEMS
COMPANY
PLANT
UNITS
TOTAL CAPACITY, MW
Southern Mississippi Power
R.D. Morrow Generating Plant
Nos. 1 & 2
360
Texas Utilities Co.
Montecello Station
No. 3
750
Wisconsin Power & Light
Columbia Plant
No. 2
527
PROCESS
STATUS
START-UP DATE
Limestone
Construction
11/77 & 6/78
Limestone
Construction
2/78
Fly Ash/Lime
Letter of
Intent
1/80
REPORTED CAPITAL
COSTS,
$ MILLION
13.447
18.5
30
i
i
$/KW
37.35
25
57
REPORTED OPERATING
COSTS,
$ ANNUAL
4.2 MM
MILLS/KWH
COMMENTS
1. The total installed capital cost figure is a 1975
estimate.
2. Included in the cost figure are the scrubbers
and ancillary equipment, fans, construction
field expenses, and interest during construction.
3. The ESP costs, ($5.4 MM equipment costs for two
units) are not included.
4. Sludge handling and disposal facilities are not
included in the total cost figure.
1. The capital cost figures include the installed cost
of FGD equipment, ancillaries, sludge disposal-site
preparation and waste transport system.
1. The total installed capital cost figure is a pre-
liminary estimate that includes the scrubbers and
ancillary equipment, erection, disposal piping and
basin area.
2. Sludge handling and disposal equipment and the up-
stream ESP are not included in this figure.
3. The operating cost figures provided are estimated
values.
Note: N/A indicates figures are not available.
-------
APPENDIX B
FGD PROCESS FLOW DIAGRAMS
THIS APPENDIX COMPRISES BOTH ACTIVE AND INACTIVE UNITS
ARRANGED ALPHABETICALLY ACCORDING TO UTILITY
B-l
-------
ca
i
U)
I MODULE (3)
jAi;;:f:''
L :-:•,:•.• : '.-.-.-'r --<•;,? 1
1
«^-,.;. 1
!
i »
'J2
^y7
'
- 3
:
F
X
i:
<
X
i
t »
"
Arizona Public Service, Choi la No. 1 FGD System:
General Flow Diagram.
-------
03
I
Arizona Public Service, Four Corners Prototype Scrubber Module:
Cross Section Diagram.
-------
BOILER
FLUE
GAS
W
I
ui
SULFURIC ACID
CONTACT ACID
PLANT
98% GRADE
- H2S04
MgSO-.6 HO
HgSO^.7
MO
AIR
PUMP
Boston Edison, Mystic No. 6 FGD System and Essex Chemical Plant
Regeneration Facility: Schematic Flow Diagram.
-------
MIST
ELIMINATOR
W
I
CTl
RILEY
VENTRI-SORBER
SCRUBBER
LIMESTONE
SLURRY
ELECTROSTATIC
PRECIPITATOR
SCRUBBER
I D BOOSTER FAN
t »
RECYCLE TANK
RECYCLE
TO FGD
PUMP SETTLING POND
Central Illinois Light Co.,
Duck Creek Mo. 1 FGD System Module:
Simplified Process Diagram.
-------
CLEAN GAS
TO
I
SERVICE
WATER
FLUE GAS
I STEAM _ I
NOT NECESSARY f?'SUFFICIENT
REHEAT GAS IS AVAILABLE
LIME SLAKING
AND DILUTION
WASTE
DISPOSAL
SYSTEM
Columbus and Southern Ohio Electric, Conesville No. 5 FGD System:
Process Flow Diagram.
-------
Commonwealth Edison, Will County No. 1 FGD System
General Process Diagram.
-------
w
i
MAKE UP WATER FRESH
N ID FAN
UNIT 5
NORTH BIN
r\
LIMESTONE
MIXING
TANK
SPRAY WATER
SURGE TANK
#6 FUEL OIL
IGNITION GAS
AlR~
SPRAY WATER PUMP
WASTE SLURRY TO
»
DISPOSAL POND
FROM DISPOSAL'
POND CLEAR WATER
PUMPS
WASTE SLURRY
PUMPS
ABSORBER
RECYCLE PUMPS
LURGI RECYCLE
PUMPS
WASTE SLURRY
SUMP
Detroit Edison, St. Clair No. 6 FGD System:
General Process Diagram.
-------
w
I
1ST STAGE
ADJUSTABLE VENTURI
FOR FLY ASH/S02
RECYCLE RETURN SYSTEM
CaS03/S04
FLY ASH SLURRY
RETURN TO POND
'THICKENE
ASH POND
TO
STABILIZATION
FACILITIES
2ND STAGE
S02 ABSORBER SCRUBBER
REHEATER
STACK
jL
LIME SILO
I |-gLAKER
SLURRY j^U-]
TANK
o
i—
•=£
Duquesne Light, F. R. Phillips FGD System:
General Diagram.
-------
w
i
TEST STACK
FLUE GAS
BLOWER
PRESCRUBBER
L__J
' r~i
THICKENER
WASTE
DISPOSAL
LIMESTONE
SILO
REHEATER
NO. 2 FUEL OIL
MIST
ELIMINATOR
ABSORBER
^
SULFURIC
ACID
TANK
AIR
OXIDIZER
CATALYST
TANK
WASTE
DISPOSAL
MOTHER
LIQUOR
TANK
CRYSTALLIZER
CENTRIFUGE
GYPSUM
Gulf Power, Chiyoda Throuqhbred 101 FGD Prototype:
General Process Diagram.
-------
SCRUBBED
GAS
Cd
i
VACUUM WATER RECOVERY
L.
SOLIDS
Gulf Power, Scholz CEA/ADL Dual Alkali Prototype:
General Process Diagram.
-------
w
I
I—
OJ
REGENERATION
REDUCTION (21
ADSORPTION SECTION
1. INLET FLUE
GAS DUCTING, DILUTION AIR
DESIGN, AND ADSORPTION
SECTION OVERALL LAYOUT.
2. ADSORPTION DISCHARGE FANS.
3. ADSORBER DISCHARGE FEEDERS
CONVEYORS AND SITE GLASSES
WHICH SHOW CHAR MOVEMENT.
4. ADSORBER FEED CONVEYORS.
5. CHAR BUCKET ELEVATORS.
REGENERATION SECTION
6. AIR PREHEATER, SAND
FLUID BED HEATER, HOT
SAND BUCKET ELEVATOR.
7. START UP AIR HEATER.
8. SATURATED CHAR SURGE
TANK, SATURATED CHAR
FEEDER, REGENERATOR.
9. SA'JD HEATER BLOWER.
10. SAND MAKE UP HOPPER,
FEEDER.
11. HOT SAND CONVEYOR.
12. CHAR-SAND SEPARATOR
FEEDER.
13. REGENERATED CHAR
COOLER.
14. REGENERATED CHAR
BUCKET ELEVATOR, CHAR
MAKE UP HOPPER, FEEDER.
REDUCTION SECTION
15. COAL MAKE UP HOPPER.
FEEDER FEED BUCKET
ELEVATOR.
16. COAL FEED BIN.
17. COAL FEED BIN ACTIVATOR,
ROTARY COAL AIRLOCK,
RESOX START UP HEATER.
18. RESOX REACTOR.
19. SULFUR CONDENSER, TAIL
GAS BLOWER.
20. CONTROL AIR BLOWER.
21. ASH DISCHARGE FEEDER
22. ASH RECEIVER VESSEL,
WEIGH SCALE.
23. SULFUR STORAGE TANK,
SULFUR TRANSFER PUMP.
Gulf Power, Scholz FW-BF Dry Adsorption Prototype:
General Equipment Schematic.
-------
Cd
I
CAT-OX MIST
ELIMINATOR
FLUE GAS
FROM EXISTING
ID FAN
STORAGE
Illinois Power, Wood River No. 4 Catalytic Oxidation FGD System:
Simplified Process Diagram.
-------
W
I
M
Ul
COAL
SUPPLY
STACK
.D. FAN.
IIMESTONE
SUPPLY
rEEDER
AIR HEATER
DEMISTER-
PULVERIZER
RECYCLE
PUMP
CLARIFIER
MAKE UP
WATER
TO ASH DISPOSAL
POND
Kansas City Power and Light,
Terminated Hawthorn No. 3 FGD System: General Process Diagram.
-------
COAL
SUPPLY
to
i
LIMESTONE
SUPPLY
FEEDER
STACK
•STACK GAS
AIR HEATER
DEMISTER-
MARBLE-
BED
—•n~-r^.-<*r"7:^^r^
^•f,, •-, ~> •-,'-•• ^ • .
^Wfii^v^.'r^'
STACK GAS
SCRUBBER
RECYCLE
PUMP
Kansas City Power and Light
Terminated Hawthorn No. 4 FGD Svstem:
General Process Diagram.
•STACK GAS
REHEATER
,DRAIN POTS
CLARIFIER
MAKE UP
WATER
TO ASH DISPOSAL
POND
-------
STACK
D. FAN
Cd
I
COAL
SUPPLY
FEEDER
PULVERIZER
STACK GAS
REHEATER
STACK GAS
SCRUBBER
RECYCLE
PUMP
Kansas City Power and Light, Hawthorn Units 3 and 4:
Simplified Process Flow Diagram of the Lime Scrubbing Process
LIME
PREPARATION
TANK
CLARIFIER
MAKE UP
WATER
TO ASH DISPOSAL
POND
-------
03
I
t—'
oo
Kansas City Power and Light, La Cygne No. 1 FGD System:
General Diagram.
-------
STACK
w
i
COAL SUPPLY-
FEEDER
PULVERIZER
I.D. FAN
STACK GAS
IR HEATER
DEMISTER
MARBLE BED-
•STACK GAS REH1IATER
STACK
GAS
SCRUBBER
Kansas City Power and Light,
Original Operational FGD System at Lawrence No. 4.
RECYCLE
WATER
-------
FLUE GAS
DO
I
NJ
O
ROD SCRUBBER
o
00
SPRAY TOWER
A
^EFFLUENT LINE
Kansas City Power and Light, Lawrence No. 4 Operational FGD System:
Simplified Flow Diagram.
-------
STACK
i.D. FAN
CO
I
to
COAL SUPPLY-
FEEDER
PULVERIZER
STACK GAS REMITTER
IR HEATER
DEMISTER
MARBLE BED-
STACK''
GAS
SCRUBBER
Kansas City Power and Light,
Original FGD System Installed at Lawrence Mo. 5;
Simplified Process Flow Diagram.
RECYCLE
WATER
-------
CO
I
t-0
NO
SPARE
Kentucky Utilities, Green River FGD System:
General Process Diagram.
-------
W
I
to
U)
K7
153.000 udn
V 360 F-
Cool-fig sprays '10 qr>m
\ 63 -177 cfm 101 F
\\
Steam generator
250.000 IL/nr
1250 ps, 950 F
1
Roller
3 tph
I
i
— i
V,
Product cyclone
/ Surd* b.r,
f 6 ton
Gt
CJPOCIIV
ID li-t-dur *
20
-------
QUENCHER
W
I
DEMISTER
ELECTROSTATIC
PRECIPITATOR
BOILER
FLUE
GAS
CONTACTOR
SCRUBBER
- MODULE
CONTACTOR
SCRUBBER
MODULE
Louisville Gas and Electric, Cane Run No. 4 FGD System:
Simplified Process Flow Diagram.
-------
Cd
I
ro
Ul
,„
I*) SA5 BtHEfl? F R
50GPM FHPSH WATER ( AVE )
Z5OGPUFWESH WATER {WAX. SHORT-TERM)
pH 6 OR HIGHER
Louisville Gas and Electric,
Paddys Run No. 6 FGD System:
Process Flow Diagram.
-------
FLUE GAS
to
i
NJ
PLENUM
BLEED
SPRAY
MIST
ELIMINATORS
RECYCLE PUMPS
EMERGENCY WATER
PLUMB BOB
*-CLEAN FLUE GAS
SEAL WATER SUPPLY
UNDERSPRAY ^MAKE-UP WATER
TRAY RECYCLE
47
FLYASH POND
POND RETURN
WASH TRAY POND
Montana Power and Light, Cnl strip FGD Sys-terns:
General Process Diagram
-------
FRESH
WATER
INLET
BACKWASH
SPRAYS
STACK GAS
FROM I.D.
FANS
PARTICULATE
SCRUBBER
W
I
M
-J
HUMIDIFIED
GAS STREAM
LLhAil U/\^> UU
MIST ELIMINATORS
MIST ENTRAPMENT SEPARATOR
Mg (OH)2 SLURRY
PARTICULATE
SCRUBBER
SURGE TANK
VENTURI ROD MODULES
S02 SCRUBBER
SURGE TANK
TO WASTE WATER
TREATMENT SYSTEM
Philadelphia Electric Co.,
Eddystone No. 1 FGD System:
General Process Diagram.
SCRUBBING SLURRY INLET
TO Mg S03
RECOVERY
-------
w
i
to
oo
FLUE GAS
TO
SCRUBBER
REHEATER
FIRST
STAGE
000
FLUE GAS
TO STACK
RIVER
MAKE-UP
WATER
MIST
ELIMINATOR
OVERFLOW POTS
& MARBLE BED
OXIDIZER
REACTION
TANK
WEIR
THICKENER
RECIRC
TANK
THICKENER
UNDERFLOW
PUMP
SPRAY
PUMP
LIMESTONE—i
SLURRY
TANK
SLURRY
PUMP
ASH POND
RETURN PUMP
Northern States Power Co. Sherburne No. 1 and 2 FGD system
Simplified Process Diagram.
-------
to
i
to
TO RESERVOIR
Pennsylvania Power Co., Bruce Mansfield No. 1 FGD System:
Simplified Process Diagram.
-------
DISCHARGE
TO STACK
CONDENSER
r^EVAPORATOR/
CR'YSTALLIZER
PRESCRUBBER
(VARIABLE-THROAT
VENTURI)
03
I
U)
o
FLUE GAS FROM
UNIT #11
FLY ASH PURGE TO POND
TRAY TOWER
ABSORBER
TREATED
PURGE STREAM
SODIUM SULFATE
CAKE
Qj COMPRESSOR
DRIED
SULFATE
PRODUCT
Northern Indiana Public Service,
D. H. Mitchell No. 11 Wellman.Lord/Allied System:
General Process Diagram.
-------
03
I
LO
5'F
67.000 ACFM
.TA:K)
^~"
DESIGN
AK3IENT
A[«|
b^-^
r£&^
STEAM 763T
474 PS:A
476.7 LB/KIN
BYPASS
DAMPER
473,000 ACFM
350'r
ISOLATION 169 -f
__ DAMPER 1 485.000 AC
T
'
i SCIATIC;!
OAWERS ^
3500 HP
FM
"1
119'F 3G4.400 AC
/
OEM!
SIEVE
ms-IT x-TEa FR:
123 VX
6 1?M
PUXP SCALS
pH 7
PC:;O
PC
«:!CV
0
Nevada Power, Reid Gardner FGD Systems, Units 1, 2, and 3:
General Process Diagram.
-------
Cd
I
LO
tsj
FLUE GAS BY-PASS j
1ST STAGE
LECTRO-STATIC
PRECIPITATOR
r
J c
i
x\
?,wra
TO DRY ASH HANDLING SYSTEM
n
X-
ASH POND
TRANSFER -,
S^
! _±_
! CENTRATE |
\ TANKl J
i
i
i
i
—>J
MgO FROM
ACID PLANT
HH SCRUBBER/ABSORBER
AIR
___>JFUEL
MgS03 TO ACID PLANT
Potamic Electric and Power,
Dickerson No. 3 Regenerative FGD System:
General Process Diagram.
-------
w
I
U)
u>
FLUE GAS TO REHEATER
DEMISTER WASH
LEASE EQUIPMENT
SCRUBBER BALLS
(3) SECTIONS
SOLID WASTE DISPOSAL POND
MAKE-UP WATER
TO SEAL WATER
Public Service Co. of Colorado, Valmont Station No. 5:
Modified Scrubber Flow Diagram.
-------
Cfl
I
u>
ALKALI
STORAGE SILO
SLURRY 9
MIX TANK
FLUE GAS FROM
PRECIPITATORS
CONTROL
BUILDING
MOTOR CONTROL
THICKENER CENTER
OVERFLOW TANK
ABSORBE
HOLD TANK
POWER
1 PLANT
STACK
ALKALI
MIX TANKS
TURBULENT
CONTACT
ABSORBER
Southern California Edison,
Mohave No. 1 Vertical Test Module:
Simplified Process Diagram.
-------
CO
I
OJ
FOUR SCRUBBER STAGES
>C
HOT AIR
INJECTION
J
BOOSTER FAN
MIST ELIMINATOR
Southern California Edison, Mohave Mo. 2 Horizontal Test Module:
Simp!ified Side View.
-------
03
I
U>
CTi
MAKEUP WATER)
I.D. FAN
SCRUBBER\Y
SAMPLE POINTS
OGAS COMPOSITION
®PARTICIPATE COMPOSITION & LOADING
©SLURRY OR SOLIDS COMPOSITION
GAS STREAM
LIQUOR STREAM
]
PROCESS
WATER
HOLD
TANK
STACK
^MAKEUP WATER[
DISCHARGE
SETTLING POND
Tennessee Valley Authority,
Shawnee No. 10 Prototype Test Unit:
General Process Diagram.
-------
I.D. FAN
03
i
LO
SAMPLE POINTS
OGAS COMPOSITION
®PARTICIPATE COMPOSITION & LOADING
® SLURRY OR SOLIDS COMPOSITION
GAS STREAM
LIQUOR STREAM
PROCESS
WATER
HOLD TANK
VACUUM
FILTER
STACK
0
DISCHARGE
=j
SETTLING POND
Tennessee Valley Authority, Shawnee No. 10 Prototype Unit:
General Process Diagram.
-------
FLUE GAS
MAKE-UP WATER
to
I
to
CO
SPRAY TOWER EFFLUENT
HOLD TANK
OXIDATION
TANK
VENT AIR
A
CLARIFIED LIQUOR
WATER
CfcD
T
I
BLEED TO
DEWATERING
SYSTEM
DESUPERSATURATION
TANK
Tennessee Valley Authority, Shawnee No. 10 Prototype Test Unit:
Modified Venturi/Spray Tower System for 2-Stage Oxidation Testing.
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ca
i
OJ
REHEATER
ENTRAPMENT SEPARATOR
FLUE GAS DUCT
FROM POWER HOUSE
EXISITNG ESP'S
FANS
VENTURI CIRCULATION TANKS
ABSORBER CIRCULATION TANKS
ABSORBER CIRCULATION PUMPS
Tennessee Valley Authority
TVA Widows Creek No. 8 FGD System:
Schematic Diaaram.
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CO
I
TO STACK
^U I S^" I ^U^
REHEATER
DEMISTER
RECYCLE
^-MARBLE BED
SPRAY
FLUE GAS
FROM V R
BOILER
HEAT
EXTRACTOR
•LADDER
VANES
WATER
LIQUID
DISPOSAL
-VACUUM FILTER
Union Electric Co., Meremae No. 2 FGD System:
Simplified Process Flow Diagram of
Injection and Time-End Scrubbing System.
CLARIFIER
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APPENDIX C
DEFINITIONS
C-l
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DEFINITIONS
Boiler Capacity Factor:
Boiler Utilization Parameter:
Efficiency:
Particulates
SO,
o
i
LO
FGD Viability Indexes
(kWh generation in year)/(maximum continuous
generating capacity in kW x 8760 hr/yr).
Hours boiler operated/hours in period, expressed
as a percentage.
The actual percentage of particulates removed by
the emission control system (mechanical collectors,
ESP, or fabric filter and FGD) from the untreated
flue gas.
The actual percentage of SO2 removed from the flue
gas by the FGD system. Design removal efficiency
values are presented for nonoperational systems or
for operational systems for which actual removal
data are not available.
Several parameters have been developed to quantify
the viability of FGD system technology. Various
terms such as "availability," "reliability,"
"operability," and "utilization" are used to
accurately represent the operation of any FGD
system during a given period. The above-mentioned
parameters are defined below and discussed briefly.
The objectives of this discussion are to make the
reader aware that several different definitions
are being used and to select appropriate parameters
that can be used for reporting purposes so that
reasonably consistent comparisons can be made.
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DEFINITIONS
Availability Index
Reliability Index
o
i
FGD Operability Index
Hours the FGD system is available for operation
(whether operated or not) divided by hours in
period, expressed as a percentage. This parameter
tends to overassess the viability of the FGD
system because it does not penalize for election
not to operate the system when it could have been
operated. Boiler downtime may tend to increase
the magnitude of the parameter because FGD failures
generally cannot occur during such periods.
Hours the FGD system was operated divided by the
hours the FGD system was called upon to operate,
expressed as a percentage. This parameter has
been developed in order not to penalize the FGD
system for elected outages, e.g., periods when the
FGD system could have been run but was not run
because of chemical shortages, lack of manpower,
short duration boiler operations, etc. The main
problem in using this formula is the concise
determination whether or not the system was "called
upon to operate" during a given time period. In
addition, an undefined value can result when the
FGD system is not called upon to operate for a
given period (e.g., turbine or boiler outage when
FGD system is available).
Hours the FGD system was operated divided by boiler
operating hours in period, expressed as a percentage
This parameter indicates the degree to which the
FGD system is actually used, relative to boiler
operating time. The parameter does not reflect
the extent of exertion on the FGD system, that is,
the magnitude of the parameter has little or no
correlation with FGD system operating time. Also,
the parameter is penalized when options are exer-
cised not to use the FGD system in periods when
the system is operable. In addition, an undefined
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DEFINITIONS
FGD Utilization Index
n
FGD Status:
Category 1
Category 2
Category 3
Category 4
Category 5
Category 6
value can result when the FGD system is not called
upon to operate for a given period (e.g., turbine
or boiler outage when FGD system is available).
Hours that the FGD system operated divided by
total hours in period. This parameter is a
relative stress factor for the FGD system. It is
not a complete measure of FGD system viability
because the parameter can be strongly influenced
by conditions that are external to the FGD system
(e.g., infrequent boiler operation will lower the
value of the parameter although the FGD system may
be highly dependable in its particular application)
Operational - FGD system is in service removing SO-
Under Construction - ground has been broken for
installation of FGD system, but FGD system has not
become operational.
Planned, Contract Awarded - contract has been
signed for purchase of FGD system but ground has
not been broken for installation.
Planned, Letter of Intent Signed - letter of intent
has been signed, but legal contract for purchase
has not been awarded.
Planned, Requesting/Evaluating Bids - bid requests
have been released but no letter of intent or
contract has been issued.
Considering only FGD Systems - an FGD system is
proposed as a means to meet an SO2 regulation.
-------
DEFINITIONS
Category 7
Category 8
n
i
FGD Vendor
Fuel Characteristics
New
Nonregenerable
Operational Experience
Process
Regulatory Class
Considering an FGD system as well as alternative
methods.
Nonoperational - FGD system has been in service in
the past but has been shut down permanently or for
an extended indefinite period of time.
A firm which fabricates and supplies FGD
systems, most notably the flue gas treating and
ancillary equipment.
Type of fuel, average gross heating value in
Btu/lb. average percent ash and average percent
sulfur content for fuel as fired.
FGD unit and boiler were designed at the same
time or space for addition of an FGD unit was
reserved when boiler was constructed.
The S02 removed from the flue gas is not recovered
in a usable or marketable form and resulting sulfur-
bearing waste products must be disposed in an
environmentally acceptable fashion.
Summary of FGD status and description of current
month's progress.
Company name if process is patented. Generic name
if several companies have similar processes.
A. New boiler constructed subject to Federal New
Source Performance Standards.
B. Existing boiler subject to State Standard
that is more stringent than the Federal New
Source Performance Standard (NSPS).
-------
DEFINITIONS
Regenerable
Retrofit
Sludge Disposal
n
i
Start-up Date
Total FGD System Lost
Unit Cost
C. Existing boiler subject to State Standard
that is equal to or less stringent than NSPS.
D. Other (unknown, undetermined).
The SO2 removed from the flue gas is recovered
in a usable or marketable form (e.g., sulfur,
sulfuric acid, gypsum, ammonium sulfate, sodium
sulfate).
FGD unit must be added to an existing boiler not
specifically designed to accommodate FGD unit.
Disposal method for nonregenerable systems producing
sludge including: lines or unlined ponds, stabil-
ized or unstabilized sludge, and on- or off-site
disposal, disposal type (minefill, landfill,
structural fill). For the regenerable systems,
the form or method of sulfur recovery is provided
(e.g. - molten elemental sulfur, sulfuric acid
plant).
Date when initial S02 removal began or is scheduled
to begin.
The total monthly lost generation hours due to FGD
train outages divided by the total monthly expected
generation if the FGD trains would have been
available for operation, expressed as a percentage.
Capital Cost in $/kW including: SO2 absorption and
regeneration system, SO2 recovery system, solids
disposal, site improvements, land, roads, tracks,
substation, engineering costs, contractors fee and
interest on capital during construction.
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DEFINITIONS
Annualized Cost in mills/kWh including fixed and
variable costs. Fixed costs include: interest on
capital, depreciation, insurance, taxes, and labor
costs including overhead. Variable costs include:
raw materials, utilities, and maintenance.
Unit Location City and State listed in mailing address.
Unit Name Unit identification as it appears in Electrical
World - Directory of Electrical Utilities, McGraw-
Hill - Current Edition - or as indicated by utility
representative for installations in planning
stages.
Unit Rating Operational - Maximum continuous gross generation
capacity in MW; Preoperational - maximum continuous
Q design generation capacity in MW.
i
oo
Utility Name Name of corporation as it appears in Electrical
World - Directory of Electrical Utilities, McGraw-
Hill - Current Edition - as space permits.
Water Make-Up Gallons per minute of make-up water required per
MW of capacity.
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tf-fozw,™,yTE9HNICAL REPORT DATA
(flease read /nuructions on the reverse before completing)
3. RECIPIENT'S ACCESSION NO.
EPA Utility FGD Survey: Dec '77 - Jan '78
l5. REPORT DATE
March 1978
6. PERFORMING ORGANIZATION CODE
|8. PERFORMING ORGANIZATION REPORT NO.
Bernard A. Laseke, Jr.
3. PERFORMING ORGANIZATION NAME AND ADDRESS
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
10. PROGRAM ELEMENT NO.
EHE624
11. CONTRACT/GRANT NO.
68-01-4147, Task 3
. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Periodic; 7-77-1/78
14. SPONSORING AGENCY CODE
EPA/600/13
| '
is.SUPPLEMENTARY NOTES EpA project officers are N.Kaplan (IERL-RTP, 919/541-2556) and
J.C.Herlihy (DSSE, 202/755-8137).
16. ABSTRACT
The report presents a survey of utility flue gas desulfurization (FGD)
systems in the U.S. It summarizes information contributed by the utility industry,
process suppliers, regulatory agencies, and consulting engineering firms. Systems
are tabulated alphabetically, by development status (operational, under construction,
in planning stages, or terminated operations), by utility company, by process sup-
plier, by process, by waste disposal practice, and by regulatory class. It presents
data on system design, fuel sulfur content, operating history, and actual perfor-
mance. It discusses problems and solutions associated with the boilers and FGD
systems. Process flow diagrams and FGD system economic data are appended to
the report.
117.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
COSATI Field/Group
Pollution
Flue Gases
Desulfurization
Electric Utilities
Waste Disposal
Boilers
Maintenance
Pollution Control
Stationary Sources
Utility Boilers
13B
2 IB
07A,07D
15E
13A
3. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (ThisReport)
Unclassified
21. NO. OF PAGES
291
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
C-9
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