CD A U.S. Environmental Protection Agency Industrial Environmental Research EPA-600/7-78-0523
"• • *» Office of Research and Development Laboratory
Research Triangle Park, North Carolina 27711 (vldCOl! 1978
EPA INDUSTRIAL BOILER FGD
SURVEY: First Quarter 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-600/7-78-052a
March 1978
EPA INDUSTRIAL BOILER FGD SURVEY:
First Quarter 1978
by
J. Tuttle, A. Patkar,
and N. Gregory
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
Contract No. 68-02-2603
Task 4
Program Element No. EHE624
EPA Project Officer: J. David Mobley
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
-------
TABLE OF CONTENTS
SLUIOM PAGE
1 INTRODUCTION 1
2 EXECUTIVE SUMriAr\Y 3
5 LIST OF INDUSTRIAL BOILERS vJlTH FGD SYSTEMS 10
'+ SUMMARY OF FGD SYSTEMS 13
5 LIS1 OF VEN&OHS OF FGb SYSTEMS 25
fa uu;i6i_R AWD TOTAL CAPACITY OF FGO SYSTEMS 29
7 STARTUP DATE OF Ft,u SYSTEMS 30
( SUMMARY OF OPERATIOiMAL FGD SYSTEMS 31
9 SuMnARY OF U.vlbLU CONSTRUCT 10i\| FGU SYSTEMS 35
1L SUiVi iAPY OF PLAivMEO FGD SYSTEMS 36
11 SUr'ii^MKY OF WASTE AND bY-PROOUCT DISPOSAL PRACTICES FuR FGD SYSTEMS 37
li DLSCixlPTIOlS OF OPERATIONAL FbD SYSTEMS ^2
13 DEGibu INFORMATION FOK UNDER CONSTRUCTION FGD SYSTEMS 133
m- DESIGN INFORMATION FOR PLANNED FGD SYSTEMS
15 Or.SCKlpTlOrJ OF FbD SYSTEMS NOT OPERATING OK TERMINATED
iii
-------
SECTION 1
INTRODUCTION
THIS REPORT ADDRESSES THE APPLICATION OF FLUE GAS DESULFURIZATION (FGD) TECH-
NOLOGY TO INDUSTRIAL BOILERS, THE NEED FOR SUCH A DOCUMENT HAS ARISEN AS A RESULT OF
THE INCREASED INTEREST IN THE CONTROL OF SULFUR DIOXIDE .(502) EMISSIONS, IN 1975
AN INITIAL SURVEY DEMONSTRATED THAT THE INDUSTRIAL (l,E,, NONUTILITY) SECTOR WAS
BECOMING MORE DEEPLY INVOLVED IN S02 CONTROL, A DIRECT RESULT OF GENERALLY MORE
STRINGENT EMISSION CODES, EPA S INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY IN
RESEARCH TRIANGLE PARK THEN INITIATED A MORE DETAILED SURVEY, ONE WHICH WOULD GENERALLY
FOLLOW THE FORMAT OF THE WELL-ESTABLISHED EPA UTILITY BOILER FGD SURVEY, INFORMATION
WAS OBTAINED FOR APPROXIMATELY 70 S02 CONTROL SYSTEMS, 25 OF WHICH WERE AT INDUSTRIAL
BOILER SITES, AND THE REST OF WHICH WERE AT PULPING OPERATIONS, CHEMICAL PROCESSES,
AND METALS PROCESSING OPERATIONS, THE RESULTS FROM THAT SURVEY WERE PUBLISHED IN A
REPORT TITLED "SURVEY REPORT ON S02 CONTROL SYSTEMS FOR NONUTILITY COMBUSTION AND
PROCESS SOURCES - MAY 1977,"
AS A RESULT OF THE FAVORABLE RESPONSE TO THIS REPORT, INDUSTRIAL ENVIRONMENTAL
RESEARCH LABORATORY DECIDED TO ESTABLISH A PERIODICALLY UPDATED ENGINEERING APPLIC-
ATION/INFORMATION TRANSFER PROGRAM ADDRESSING INDUSTRIAL S02 CONTROL TECHNOLOGY,
THE FIRST PRODUCT WAS A SEVEN-VOLUME, 900-PAGE REPORT TITLED "SUMMARY REPORT ON
S02 CONTROL SYSTEMS FOR INDUSTRIAL COMBUSTION AND PROCESS SOURCES - DECEMBER 1977,"
THIS DOCUMENT REPORTED ON S02 CONTROL SYSTEMS IN TEN SOURCE CATEGORIES AT OVER 200
INDUSTRIAL SITES IN THE UNITED STATES, THOSE TEN CATEGORIES WERE AS FOLLOWS I
INDUSTRIAL BOILERS
PULP AND PAPER PROCESSES
CLAUS PROCESSES
SULFURIC ACID PLANTS
COPPER, LEAD, AND ZINC SMELTERS
METALLIC MINERALS PROCESSING
-------
NONMETALLIC MINERALS PROCESSING
IRON AND STEEL PROCESSES
FOUNDRIES AND CUPOLAS
MISCELLANEOUS PROCESSES
THE CURRENT REPORT ADDRESSES ONLY INDUSTRIAL BOILER APPLICATIONS OF FGD TECH-
NOLOGY, THE OTHER SOURCE CATEGORIES WILL NOT BE INCLUDED IN FUTURE SURVEY WORK FOR
THE INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY, ALTHOUGH THEY MAY BE CONTINUED
UNDER OTHER AUSPICES, THE CURRENT REPORT REPRESENTS AN EXPANSION OVER THE INFORMA-
TION PRESENTED IN THE DECEMBER 1977 REPORT, WITH RESPECT TO BOTH THE AMOUNT OF INFOR-
MATION PRESENTED PER INSTALLATION AND THE NUMBER OF INSTALLATIONS INCLUDED,
THE INFORMATION IN THIS REPORT WILL BE UPDATED FOUR TIMES PER YEAR, ANYONE
DESIRING TO RECEIVE FREE UPDATED VERSIONS OF THIS REPORT MAY REQUEST THE ADDITION OF
HIS OR HER NAME TO THE MAILING LIST, THIS MAY BE DONE BY CONTACTING THE EPA PROJECT
OFFICER OR THE CONTRACTOR,
-------
SECTION 2
EXECUTIVE SUMMARY
THE FIRST FULL-SCALE UNITED STATES APPLICATION OF FLUE GAS DESULFURIZATION (FGD)
TECHNOLOGY TO INDUSTRIAL BOILERS WAS AT A GENERAL MOTOR'S PLANT IN ST, LOUIS, MISSOURI
WHERE TWO SYSTEMS WERE INSTALLED ON TWO COAL-FIRED BOILERS IN 1972, IN THIS 1ST
QUARTER 1978 REPORT, DATA IS PRESENTED ON 135 OPERATIONAL FGD SYSTEMS AT 34 PLANT
SITES, CONTROLLING S02 EMISSIONS FROM 145 BOILERS, FGD UNITS AT NINE PLANTS ARE
KNOWN TO BE UNDER CONSTRUCTION OR IN SOME STAGE OF PLANNING, THE TOTAL COVERAGE
OF THIS REPORT IS THEREFORE 42 PLANT SITES AS SUMMARIZED IN TABLE I,
TABLE I
NUMBER AND TOTAL ACFM OF INDUSTRIAL BOILER FGD SYSTEMS
STATUS
OPERATIONAL
UNDER CONSTRUCTION
PLANNING
CONTRACT
LETTER OF INTENT
REQUESTING/EVALUATING BIDS
CONSIDERING FGD
TOTAL
NO, OF
PLANT SITES '
34
5
2
0
1
0
42
CAPACITY
ACFM
(THOUSANDS)
5,232
1,636
488
0
300
0
7,656
-------
THE REPORT CONTAINS THIRTEEN TABLES FOR DATA PRESENTATION AS LISTED BELOW:
CONTENT OF TABLES
INDUSTRIAL BOILER FGD SURVEY
SUMMARY SECTIONS
1 SUMMARY LIST OF S02 CONTROL SYSTEMS
A SUMMARY OF ALL THE INSTALLATIONS BY NAME, LOCATION, START-UP DATE, AND CURRENT
STATUS,
2 STATUS OF S02 CONTROL SYSTEMS
A BRIEF SUMMARY OF THE SOURCE CHARACTERISTICS, THE CONTROL PROCESS AND CONTROL
SYSTEM SUPPLIER, AND INFORMATION ON RECENT SYSTEM PERFORMANCE,
3 SUMMARY OF S02 CONTROL SYSTEMS BY VENDOR
A LIST OF THE CONTROL SYSTEMS SUPPLIED BY EACH SYSTEM VENDOR OR MANUFACTURER,
4 NUMBER AND TOTAL CAPACITY OF S02 CONTROL SYSTEMS
A SUMMARY OF SYSTEMS BY OPERATIONAL STATUS, NUMBER OF UNITS IN EACH STATUS, AND
VOLUME OF THE EXHAUST STREAM (ACFMJ BEING CONTROLLED,
5 SUMMARY OF S02 CONTROL SYSTEMS BY START-UP DATE
6 SUMMARY OF OPERATIONAL S02 CONTROL SYSTEMS
7 SUMMARY OF S02 CONTROL SYSTEMS UNDER CONSTRUCTION
8 SUMMARY OF PLANNED S02 CONTROL SYSTEMS
9 SUMMARY OF WASTE AND BY-PRODUCT DISPOSAL PRACTICES FOR S02 CONTROL SYSTEMS
-------
DETAILED SECTIONS
10 PERFORMANCE DESCRIPTIONS OF OPERATIONAL S02 CONTROL SYSTEMS
AN IN-DEPTH DATA PRESENTATION FOR THE OPERATIONAL CONTROL SYSTEMS, THIS SECTION
PRESENTS BACKGROUND INFORMATION, OPERATING PARAMETERS, DESIGN INFORMATION,
START-UP PROBLEMS AND SOLUTIONS, OPERATING EXPERIENCE, WASTE AND BY-PRODUCT
DISPOSAL PRACTICES, AND IN SHORT, ALL RELEVANT INFORMATION AVAILABLE CONCERNING
FGD OPERATIONS AT THE VARIOUS INSTALLATIONS,
11 DESIGN DESCRIPTIONS OF S02 CONTROL SYSTEMS UNDER CONSTRUCTION
SAME AS SECTION 10, FOR CONTROL SYSTEMS UNDER CONSTRUCTION,
12 DESIGN DESCRIPTIONS OF S02 CONTROL SYSTEMS IN THE PLANNING STAGES
SAME AS SECTION 10, FOR PLANNED CONTROL SYSTEMS,
13 PERFORMANCE DESCRIPTIONS OF S02 CONTROL SYSTEMS TERMINATED/INDEFINITELY DOWN
SAME AS SECTION 10 FOR CONTROL SYSTEMS WHERE OPERATIONS HAVE BEEN TERMINATED OR
INDEFINITELY SHUTDOWN,
SOME HIGHLIGHTS FROM THE CURRENT INDUSTRIAL BOILER FGD SURVEY ARE OUTLINED BELOW:
ALYESKA PIPELINE SERVICE CO. STARTED-UP OIL FLOW AND S02 CONTROL OPERATIONS AT THE
VALDEZ TERMINAL OF THE ALASKA PIPELINE IN LATE JUNE-EARLY JULY 1977, THIS FMC SODIUM
HYDROXIDE-BASED SYSTEM IS AN INTERESTING APPLICATION IN THAT WHILE, IN A STRICT
SENSE, IT IS CONTROLLING S02 EMISSIONS, ITS PRIMARY FUNCTION IS THAT OF A GAS CON-
DITIONING UNIT, THE FGD SYSTEM TREATS COMBUSTION GASES FROM A BOILER WHOSE PRIMARY
PURPOSE IS THE SUPPLY OF A WARM BLANKET GAS FOR THE OIL IN THE MASSIVE OIL STORAGE
TANKS, OIL LEVELS FLUCTUATE IN THE TANKS AS A FUNCTION OF OIL FLOWING IN FROM THE
PIPELINE AND FLOWING OUT TO TRANSPORT SHIPPING IN PORT VALDEZ, THE BOILER SUPPLIES A
VARIABLE QUANTITY OF WARM AIR TO THE TANKS AS THE LEVELS VARY AND ALL AIR IS TREATED
BY THE FGD SYSTEM, THIS CONTROL SYSTEM IS REMOVING S02 GENERATED IN THE FIRING OF
0.03 PERCENT TO 0.1 PERCENT SULFUR OIL,
-------
CATERPILLAR
HIGH SULFUR
TRACTOR CO. REPORTED THE FOLLOWING ITEMS CONCERNING FGD OPERATIONS ON
(3.2 PERCENT) ILLINOIS COAL:
AT THE JOLIET, ILLINOIS PLANT, FGD OPERATIONS BEGAN ON TWO COAL-FIRED BOILERS IN
OCTOBER 1974, S02 CONTROL IS EFFECTED BY TWO DILUTE-MODE DUAL ALKALI (SODA ASH/
PEBBLE LIME) SCRUBBING SYSTEMS SUPPLIED BY ZURN INDUSTRIES, IN GENERAL, AVAILA-
BILITY INDEX VALUES HAVE AVERAGED 80 TO 85 PERCENT, S02 REMOVAL EFFICIENCY IS
GREATER THAN 90,PERCENT AND MORE THAN ADEQUATE TO MEET THE REGULATION OF 1.8
LBS. S02 PER 106 BTU, HOWEVER, THE UNITS ARE NOT SATISFYING THE PARTICULATE
EMISSION REGULATIONS, POSSIBLE SOLUTIONS TO THIS PROBLEM ARE CURRENTLY BEING
INVESTIGATED, THE FOLLOWING PROBLEMS AND SOLUTIONS ARE SOME OF THOSE WHICH HAVE
BEEN REPORTED BY PLANT PERSONNEL:
PH PROBES SCALING (IMPROVED BY INCORPORATING FRESH WATER FLUSHING)
LOUVRE DAMPERS REQUIRING REPLACEMENT BY GUILLOTINE DAMPERS
CORROSION ATTACK DOWNSTREAM OF SCRUBBERS (REHEAT NOW BEING CONSIDERED)
PLUGGED VACUUM FILTER BELTS
LINING DAMAGE IN BLEED-OFF PUMPS CAUSED BY SOLIDS IN BLEED-OFF LINES
(CORRECTED BY THE INSTALLATION OF SCREENS AND LEVEL CONTROLS IN THE SCRUB-
BERS)
UNRELIABILITY OF S02 MONITORING EQUIPMENT
UNRELIABILITY OF RECIRCULATION LINE FLOW SENSOR (REPLACED BY AN ULTRASONIC
FLOW SENSOR)
INADEQUATE COLD WEATHER PROTECTION
IN
AT THE MOSSVILLE, ILLINOIS PLANT, FGD OPERATIONS ON THREE COAL-FIRED BOILERS BEGAN
OCTOBER 1975. AND A FOURTH BOILER CAME ON-LINE IN JUNE 1977 WITH FGD BYPASS UNTIL
OCTOBER 1977. FMC ENVIRONMENTAL EQUIPMENT DIV, DESIGNED, INSTALLED, AND OPERATED
THESE SYSTEMS UNTIL JUNE 1976. AT THAT TIME, CATERPILLAR PERSONNEL TOOK OVER THE
OPERATION OF THE SYSTEMS, THE FOUR SEPARATE SCRUBBING TRAINS UTILIZE VENTURI SCRUB-
BERS IN CONCENTRATED-MODE DUAL ALKALI S02 CONTROL STRATEGY, THE TWO LARGE BOILERS
-------
(EACH AT 150,000 LBS/HR STEAM) HAVE HAD MECHANICAL COLLECTORS INSTALLED AHEAD OF THE
VENTURIS, AND THE TWO SMALL BOILERS (EACH AT 80,000 LBS/HR STEAM) OPERATE WITH PARTICU'
LATE PRECOLLECTION, THE FLYASH HAS CAUSED EROSION PROBLEMS IN THE SCRUBBER LOOP,
CATERPILLAR REPORTS THAT MOSSVILLE FGD OPERATIONS HAVE AVERAGED 80 TO 85 PERCENT
AVAILABILITY, SIMILAR TO JOLIET, S02 REMOVAL AT MOSSVILLE HAS BEEN ADEQUATE AT
GREATER THAN 90 PERCENT, BUT THE SCRUBBERS HAVE NOT YET BEEN SATISFACTORY WITH
RESPECT TO PARTICULATE CONTROL, THE FOLLOWING PROBLEM AREAS HAVE BEEN REPORTED BY
PLANT PERSONNEL:
OVERSIZED SLURRY PUMPS
LOW SEAL WATER PRESSURE ALLOWING LEAKAGE OF PROCESS LIQUOR
NOZZLE EROSION IN THE SCRUBBERS
SWITCH OVER FROM LOUVRE TO GUILLOTINE DAMPERS
SLUDGE HANDLING
PLUGGING IN MOST OF THE PIPING
INADEQUATE COLD WEATHER PROTECTION
AT THE FIRESTONE TIRE AND RUBBER CO. IN POTTSTOWN, PENNSYLVANIA, A 14,000 ACFM FMC
DUAL ALKALI DEMONSTRATION TEST ON HIGH SULFUR (2.5 TO 3.0 PERCENT) COAL HAS BEEN
UNDERWAY SINCE JANUARY 1975, THE UNIT HAS BEEN DEMONSTRATING GREATER THAN 90 PERCENT
S02 REMOVAL AND AVAILABILITY INDEX VALUES OF 94 PERCENT, FLYASH AND S02 ARE COLLECTED
SIMULTANEOUSLY IN A VENTURI SCRUBBER, AND THE SCRUBBER SLUDGE IS DEWATERED AND
LANDFILLED,
THE FMC SODA ASH PLANT IN GREEN RIVER, WYOMING HAS BEEN OPERATING TWO FMC SODIUM
BASED ONCE THROUGH FGD SYSTEMS SINCE MAY 1976, PARTICULATE CONTROL IS EFFECTED BY A
PRECEDING ESPj DESIGN S02 REMOVAL EFFICIENCY IS 95 PERCENT, LINER PROBLEMS IN THE
ABSORBER MODULES AND PROBLEMS WITH PH MONITORING HAVE OCCURRED OVER THE SUMMER,
-------
GENERAL MOTORS IS CURRENTLY OPERATING FGD SYSTEMS AT FIVE INSTALLATIONS AROUND THE
UNITED STATES, ALL OF THESE SYSTEMS USE SODIUM HYDROXIDE OR SODA ASH FOR S02 CONTROL,
WITH SLAKED LIME REGENERATION BEING IMPLEMENTED AT THE PARMA STEAM PLANT, NEAR CLEVE-
LAND, OHIO, THE INSTALLATIONS ARE AS FOLLOWS:
GENERAL MOTORS CHEVROLET MOTOR DIVISION, TONOWANDA, NEW YORK, THERE ARE
FOUR SEPARATE FGD SYSTEMS CONTROLLING EMISSIONS FROM FOUR COAL-FIRED (l.3
PERCENT SULFUR) BOILERS, STARTUP OCCURRED IN JUNE 1975. THE .SYSTEM EMPLOYS
SODIUM HYDROXIDE FOR ALKALI MAKEUP AND REMOVES 90 TO 95 PERCENT OF THE
INLET S02,
GENERAL MOTORS, ST, LOUIS, MISSOURI, THERE ARE TWO SEPARATE FGD SYSTEMS
CONTROLLING EMISSIONS FROM TWO COAL-FIRED (3.2 PERCENT SULFUR) BOILERS,
STARTUP OCCURRED IN 1972, THE SYSTEM USES SODIUM HYDROXIDE MAKEUP AND
EFFECTS 90+ PERCENT S02 REMOVAL,
GENERAL MOTORS, CHEVEROLET TRANSMISSION PLANT, PARMA, OHIO, THERE IS ONE
DUAL ALKALI (SODA ASH/SLAKED LIME) FGD SYSTEM CONTROLLING EMISSIONS FROM
FOUR COAL-FIRED (2.5 PERCENT SULFUR) BOILERS, STARTUP OCCURRED IN MARCH
1974, THE S02 REMOVAL EFFICIENCY IS 90 PERCENT,
GENERAL MOTORS TRUCK & COACH PLANT, PONTIAC, MICHIGAN, THERE ARE TWO
SEPARATE FGD SYSTEMS CONTROLLING EMISSIONS FROM TWO COAL-FIRED (0.84
PERCENT SULFUR) BOILERS, THE SCRUBBERS WERE INSTALLED PRIMARILY FOR
PARTICULATE CONTROL, BUT SIGNIFICANT S02 REMOVAL OCCURS AS A RESULT OF THE
ADDITION OF SODIUM HYDROXIDE, STARTUP OCCURRED IN APRIL 1976,
GENERAL MOTORS/DELCO MORAINE, DAYTON, OHIO, THERE ARE TWO SEPARATE FGD
SYSTEMS CONTROLLING EMISSIONS FROM TWO COAL-FIRED (l PERCENT SULFUR) BOILERS,
STARTUP OCCURRED IN SEPTEMBER 1974, THE SYSTEM USES SODIUM HYDROXIDE
MAKEUP,
GREAT WESTERN SUGAR HAS BEEN OPERATING PARTICULATE/S02 CONTROL SYSTEMS SINCE LATE
1972, CURRENTLY THERE ARE SEVEN PLANT SITES WITH OPERATIONAL CONTROL SYSTEMS, ONE
SITE UNDER CONSTRUCTION, AND ONE THAT HAS BEEN PERMANENTLY SHUTDOWN, TWO BASIC S02
REMOVAL TECHNOLOGIES ARE BEING EMPLOYED, ONE IS A ONCE-THROUGH APPROACH WHICH USES
CONDENSATE WATER FROM THE SUGAR PRODUCTION PROCESS, THIS WATER HAS A SIGNIFICANT
AMMONIA CONTENT (PH = 8.7) THEREBY EFFECTING S02 CONTROL, THIS TECHNOLOGY IS BEING
8
-------
EMPLOYED AT THE SIX WESTERN OPERATIONAL PLANT SITES, THE OTHER APPROACH BEING
IMPLEMENTED AT TWO PLANTS IN OHIO USES SODIUM CARBONATE MAKE-UP FOR THE CONTROL OF
SULFUR DIOXIDE EMISSIONS FROM THE COMBUSTION OF 3 PERCENT SULFUR COAL, SCRUBBING
LIQUOR IS RECIRCULATED AND A BLEED~OFF STREAM IS TREATED AND THEN DISCHARGED TO CITY
SEWERS, OPERATIONAL EXPERIENCE IS REPORTED TO BE PROBLEM-FREE AT ALL OPERATIONAL
SYSTEMS,
KERR-MCGEE CHEMICAL CORPORATION IS PLANNING AN APRIL 1978 START-UP OF A NEW 1.3
MILLION TON PER YEAR SODA ASH PLANT IN TRONA, CALIFORNIA, APRIL WILL ALSO MARK THE
START-UP OF FGD OPERATIONS AT THE ON~SITE POWER PLANT, CONSISTING OF TWO 32-MW COKE-,
COAL-, AND OIL-FIRED BOILERS GENERATING BOTH ELECTRICITY AND PROCESS STEAM, FLY ASH
WILL BE COLLECTED BY PRECEDING COLD-SIDE ESP'S AND S02 REMOVAL WILL TAKE PLACE IN
COMBUSTION ENGINEERING CARBON STEEL MODULES WITH FIBERGLASS REINFORCED PLASTIC (FRP)
LINERS, THE TWO FLUE-GAS SCRUBBERS WILL USE PROCESS END-LIQUOR TO CONTROL S02 EMIS-
SIONS,
THE MEAD PAPERBOARD CO. IN STEVENSON, ALABAMA HAS BEEN OPERATING A HIGH-SULFUR OIL FGD
APPLICATION SINCE 1975, FLUE GAS FROM TWO BOILERS FLOWS INTO A COMMON DUCT AND INTO
AN AIRPOL INDUSTRIES SCRUBBER MODULE CONSISTING OF THREE BUBBLE CAP TRAYS, A SODIUM
CARBONATE SOLUTION EFFECTS AN S02 REMOVAL OF 95 PERCENT, AND THE GAS EXITS THROUGH
A FIBERGLASS STACK, A BLEED STREAM OF THE SODIUM SOLUTION FORMED IN THE SCRUBBER
OPERATIONS IS PIPED TO THE ON-SITE PULPING OPERATION, THE SCRUBBER LINER HAS PROVEN
TO BE A PROBLEM, THE ORIGINAL GLASS-FLAKE LINER WAS REPLACED BY A CARPENTER 20 LINER, '
WHICH WAS APPARENTLY NOT PROPERLY INSTALLED,
AT ST. JOE MINERALS CORPORATION IN MONACA, PENNSYLVANIA (NEAR'PITTSBURG), CONSTRUCTION
IS UNDERWAY ON THE BUREAU OF MINES CITRATE PROCESS REGENERABLE SCRUBBER SYSTEM, THE
SODIUM CITRATE FGD OPERATIONS WILL CONTROL S02 EMISSIONS FROM THE 60-MW COAL-FIRED
ELECTRIC POWER GENERATING UNIT FIRING 3.0 PERCENT SULFUR COAL, THE REGENERABLE SYSTEM
WILL PRODUCE ELEMENTAL SULFUR, OPERATIONS AT THIS RETROFIT APPLICATION ARE SCHEDULED
TO STARTUP IN OCTOBER 1978,
TEXASGULF INC. HAS BEEN OPERATING AN EMISSIONS CONTROL SYSTEM AT GRANGER, WYOMING SINCE
SEPTEMBER 1976, TWO SCRUBBING SYSTEMS TREAT THE FLUE GAS FROM TWO 30~MW (EQUIVALENT)
BOILERS, THE SCRUBBING LIQUOR, 30 PERCENT SODA ASH BY WEIGHT, IS RECIRCULATED WITH A
CONSTANT BLEED-OFF, HOLDING THE CONTROL PH AT 6 TO 6.5 CAUSED CORROSION IN THE MILD
STEEL RECIRCULATING LINES, WHICH WERE REPLACED WITH FIBERGLASS PIPE, TROUBLE-FREE
OPERATIONS HAVE BEEN REPORTED DURING RECENT MONTHS,
-------
INSTALLATION LAME
SECTION 3
LIST OF INDUSTRIAL BOILERS WITH FGD SYSTEMS
LOCATION
PIPELINE SERVICE CL.
.; THRLAC
AI'T'CL STEEL
C.if 10 . TEXTILES
C Ai< r oK UhDUiJ. ABR AS I V f:S
t. Tt.HPILLAR TRACTOR CO.
CATtLKPILLAK TKACTOK CO.
CATERPILLAR Trv^CTGR CO.
CATEriFiLLAK TtTCi-.'E TIRE:
F.'l (SOU A ASH
GUMERAL MOTORS CHEV. MOTOR UIV
CiEfSiERAL MOTORS CORPORATION
GENERAL MOTORS PAKNA
GENERAL MOTORS TRUCK & COACH
fctl'.MCKAL iviOTOKS/DELCO
t;u
STATUS CODES -
0 - STATUS ijOT
I - OPLFi/»TIUiiAL
2 - CGLiSlKULl r.'I'.AL
3 - PLAMIVLP-CO^TP.ACT
VALDEZt ALASKA
I1ARION, iMORTH C
MONACAt PENNSYLVAfilA
!"iIQDLETO«/Mi OHIO
CAWTONt GEORGIA
BUFFALO* rJEW YO^K
CAST PEORIA, ILLINOIS
JOLIET, ILL I MO IS
HAPLETOUi ILLINOIS
MOKTON, ILLINOIS
lviOSSVILLE» ILLINOIS
bAKCRSFIELDt CALIFORNIA
POTTSTOwNi PENNSYLVANIA
TONOWANDAt NEW YORK
ST. LOUIS, MISSOURI
PARMA» OHIO
POSMTIAC. HICHIBAN
UAYTOh, OHIO
DATE STATUS
b-77
0-73
12-80
0-75
6-74
0- 0
5-78
9-74
10-76
1-76
10-75
7-76
l-7o
5-76
6-7&
0-72
3-74
4-76
9-74
1
1
5
1
1
5
2
1
2
1
1
3
1
1
1
1
1
1
1
4 - PLANNED-LETTER Uh INTEuT
5 - PLMiNiNED-HEQUtLSTING/LVALUATINt BIDS
6 - PLAiMED-COrjSIDEKliJG SOg CONTROLS
7 - TtRMfnATLiJ OH IIvULF.TMlTE.LY SHUT
10
-------
SECTION 3
LIST OF INDUSTRIAL BOILERS wITH FGU SYSTEMS
LOCATION
nc PAPER co.
toRtAT SOUTHER^ PAPLK CO.
iiUCAT WCSTLtuJ SUGAR
GKLAT VESTLRi\i SUGAR
bKEAT hlFSfEKiv SUGAR
GREwT WESTilRK SUbAK
GREAT WESTER! ; SUGAR
GKEAT WESTLFtJv SUbAK
GKE.AT WESTtRK SUGAR
fcREAT WESTERN SUGAFx
GREAT WtlSTtRW SUliAR
HARRIS HlfJlNG CO.
ITT RAYONIER, INC.
KERR-MC6EE CHEMICAL CORP.
MEAD PAPERBOARD CO.
MINN-OAK FARMER'S COOPERATIVE
MOBIL OIL COMPANY
NCR-APPLETON
NEKOOSA PAPERS, INC.
1
§
CROSSETTt ARKANSAS
CEQAK SPRINGS, GEORGIA
BILLINGS, HONTAhA
FIiMDLAY, OHIO
FORT MORGAN, COLORADO
FREL'PiONTiOHIO
bERIMG, NEBRASKA
GREELEY, COLORADO
LONGMONTi COLORADO
LGVELAhD, COLORADO
bCOTTS BLUFF, NEBRASKA
SPRUCE PINE, MORTH CAROLINA
FERMANDINA BEACH* FLORIDA
TRONA, CALIFORNIA
STEVENSON, ALABAMA
WAHPETON, NORTH DAKOTA
SAN ARDO, CALIFORNIA
ROARING SPRINGS, PENNSYLVANIA
ASHDOWN, ARKANSAS
START-UP DATE STATUS
0-75
0-7b
10-77
10-7f
10-76
IU-76
10-7S
10-75
10-73
1U-74
10-75
0-75
0-75
4-76
0-75
6-77
0-7^
6-77
3-76
1
1
1
1
1
2
1
1
7
1
1
7
1
2
1
1
1
1
1
NOT DEFINED
- OPERATIONAL
- PLANNED-CONTRACT AWARDED
6
7
- PLANNED-LETTER OF INTENT SIGNED
- PLANNED-REQUESTING/EVALUATING BIDS
- PLANNED-CONSIDERING SOg CONTROLS
- TERMINATED OR INDEFINITELY SHUT DOWN
11
-------
INSTALLATION NAME
SECTION 3
LIST OF INDUSTRIAL BOILERS WITH FGD SYSTEMS
LOCATION
QUALITY WILLS* INC.
RICKENBACKER AIR FORCE BASE
SHELLER GLOBE CORP.
ST. JOE MINERALS CORP.
ST. KEGIS PAPER CO.
TLXACO INCORPORATED
TEXASGULF
TKANSCO TEXTILES, INC.
U.S. GYPSUM CORP.
START-UP DATE STATUS
MT, AIRYt NORTH CAROLINA
COLUMBUS, OHIO
NORFOLK, VIRGINIA
MONACA, PENNSYLVANIA
CANTONMENT, FLOKICA
SAN AROO, CALIFORNIA
GRANGER, WYOMING
AUGUSTA, GEORGIA
OAKMONT, PENNSYLVANIA
5-70
3-76
0-75
10-78
0-73
0-74
9-76
3-75
0- 0
7
1
1
2
1
1
1
7
7
STATUS CODES -
0 - STATUS NOT DEFIKEQ
1 - OPERATIONAL
2 - CONSTRUCTIONAL
3 - PLANNED-CONTRACT AWARDED
M. - PLANNED-LETTER OF IUTENT SIGNED
5 - PLANNED-REQUESTING/EVALUATING BIDS
6 - PLANNED-CONSIDERING S02 CONTROLS
7 - TERMINATED OR INDEFINITELY SHUT DOWN
12
-------
SECTION q.
SUMMARY OF FGU SYSTEMS
COhPANY INFORMATION
CURREIviT PERIOD
ALYESKA PIPELINE SERVICE CO,
VALDEZi ALASKA
FHC ENVIRONMENTAL EQUIPMENT
FUEL OIL (,03 - ,iSi SULFUR)
SOiOOU SCFi-i a) 70 F
START-UP 6/77
SODIUM SCRUBBING
STATUS - OPERATIONAL
(DESISr/ilAX)
THE ALYESKA FGD SYSTEM IS UNIQUE IN THAT IT WAS,,
IVOT INSTALLED PRIMARILY FOR CONTROL OF EMISSIONS,
bUT TO TREAT GAS USED IN THE OIL STORAGE TANKS.
OPERATIONS FOR THE. PERIOD SEPTEMBER THRU JANUARY
UtRE NEARLY PROBLEM-FREE, THERE HAS BEEN NO
DOWNTIME ATTRIBUTABLE TO THE S02 REMOVAL SYSTEM.
RECENT MEASUREMENTS INDICATE S02 REMOVAL TO BE
BETTER THAN 95%.
AMERICAN THREAD
MARION, NORTH CAROLINA
W.W. SLY MANUFACTURING CO.
COAL (.99 PERCENT SULFUR, 7 PERCENT ASH)
60,000 ACFM 3 HOO DEGREES F
START-UP 0/73
SODIUM HYDROXIDE ADDITION
STATUS - OPERATIONAL
THE FGD INSTALLATION CONSISTS OF TWO SEPARATE
SCRUBBING UNITS OPERATING ON TWO COAL-FIRED
BOILERS FOR THE REMOVAL OF PARTICULATES AND
--- "- THE FGD UNITS HAVE BEEN IN
SULFUR DIOXIDE.
SERVICE SINCE 1973. CORROSION OF I.D.
AND PIPING HAS BEEN THE MAIN PROBLEM.
FANSt STACK
_ . . I.D. FAN
VIBRATIONS HAVE CAUSED SEVERE STRAIN IN PIPING.
ARCO/POLYMERS
MONACA, PENNSYLVANIA
NOT SELECTED
SooVoOo'sCFH 9 70 F (TOTAL - 3 BOILERS)
START-UP 12/80
STATUSL-CPLANNED-REQUESTING/EVALUATING BIDS
ARCO POLYMERS IS PLANNING TO PURCHASE A FGD SYSTEM
FOR THE FLUE GASES FROM THEIR THREE IDENTICAL
BOILERS (EACH 300,000 LBS/HR STEAM AT 700 PSIG &
700 F). WHILE OTHER PROCESSES ARE REPORTEDLY
BEING CONSIDERED, THE TWO PRIMARY FGD PROCESS
CANDIDATES ARE THE WELLMAN-LORO PROCESS AND THE
FMC DOUBLE ALKALI PROCESS, A FINAL DECISION
ON AWARD OF CONTRACT IS EXPECTED IN MAY 1978.
ARMCO STEEL
MIDDLETOWN, OHIO
KOCH ENGINEERING
COAL (O.B% SULFUR*
260,000 ACFM a 425
START-UP 0/75
LIME SCRUBBING
STATUS - OPERATIONAL
958 ASH* 1H,000 BTU/LB)
F (TOTAL - 2 BOILERS)
THIS CONTROL SYSTEM SERVES TWO MULTI-RETORT
UNDERFEED STOKER, COAL-FIRED BOILERS EACH WITH
A CAPACITY OF 100,000 LBS/HR STEAM. EARLIER BOILER
PROBLEMS (HIGH EXCESS AIR) HAVE BEEN GENERALLY
RECTIFIED BY A RETROFITTED BOILER CONTROL SYSTEM.
RECENT OPERATIONS HAVE BEEN PROBLEM-FREE ALTHOUGH
IN MID-FEBRUARY 1976 THE SCRUBBER HAS BEEN
TEMPORARILY SHUTDOWN AS A RESULT OF THE COAL-
STRIKE RELATED POWER SHORTAGE IN OHIO.
13
-------
SECTION «+
SUMMARY OF FGD SYSTEMS
COMPANY INFORMATION
CURRENT PERIOD
TEXTILES
CANTON, GEORGIA
FMC ENVIRONMENTAL EQUIPMENT
INTt:RRUPTIt3LE NATURAL GAS* COAL
^2,000 ACFi"i
START-UP 6/74
SODIUM SCRUBBING- I*ASTE STREAM
STATUS - OPERATIONAL
(U.8B SULFUR)
AT CANTON TEXTILES THE CONTROL SYSTEM CONSISTS
OF AN FMC MEDIUM ENERGY VENTURI SCRUBBER AND
UTILIZES A CAUSTIC WASTE STREAM FOR S02 REMOVAL.
THE UNIT HAS BEEN IN OPERATION SINCE JUNE OF 197<+,
CANTON AGAIN REPORTED NO OPERATIONAL PROBLEMS
DURING THIS KEPORT PERIOD. COAL FIRING WAS RE-
STARTED IN I'-ID-OCTOBER 1977.
CARPORUl.'UUP'. ABRASIVES
BUFFALO, -JE* YOM*
CARBOHUivDUri E'WIR. SYS. LTD.
COAL <*;& S AVERAGE, 3.2?* S uESIGl"
36,000 ACFW A 350 F
START-UP O/ 0
LIME SCK'JbBING
STATUS - PLAIVNED-CONTRACT AWARDED
MAX)
NO DEFINITE PLANS HAVE BEEN MADE FOR THE CONTROL
OF S02 EMISSIONS FROM THIS BOILER. THE FUTURE OF
THE CONTROL SYSTEM WILL BE DETERMINED BY A REGU-
LATORY AGENCY DECISION EXPECTED NEAR THE END OF
1978. THE CURRENTLY OPERATING VENTURI (L/G = 10)
CONTROLS ONLY PARTICULATE, BUT TIE-INS HAVE BEEN
PROVIDED FOR A LIME SCRUBBING SYSTEM USING
A 6-STAGE SPRAY TOWER FOR S02 CONTROL.
CATERPILLAR TRACTOR CO.
EAST PE('*IA, ILLINOIS
FMC ENVIRONMENTAL EQUIPMENT
COAL (S.kSK SULFUR)
360,ooc ACFM
START-UP 3/73
DOUBLE nLKALI (CONCENTRATED)
STATUS - CONSTRUCTION
THE FGD SYSTEM IS STILL UNDER CONSTRUCTION.
Fl"iC CONCENTHATED MODE DOUBLE ALKALI SYSTEMS WILL
REMOVE S02 LMISS10NS FROM «f COAL-FIRED BOILERS.
A SEPARATE SCRUBBER WILL TREAT THE GASES FROM
EACH BOILER. START-UP IS CURRENTLY SCHEDULED
FOR MARCH 1978.
CATERPILLAR TRACTOR CO.
JOL1ET, ILLINOIS
ZURN IIML/USTRIES
COAL (3.25o SULFUR)* 9.65 T/HR FEED
90,000 ALTi-i (TOTAL - 2 BOILERS)
DOUBLE ALKALI (DILUTE)
STATUS - OPERATIONAL
THE FGD SYSTEM CONSISTS OF AN INDEPENDENT
SCRUBBING TRAIN ON EACH OF TWO COAL-FIRED BOILERS,
THESE BOILERS HAVE BEEN OPERATIONAL, EACH HEAT
SEASON SINCE OCTOBER 197«f. SINCE THAT DATE,
SCRUBtJER AVAILABILITY HAS BEEN AVERAGING 80-85%.
OPERATIONS IN THE CURRENT HEAT SEASON HAVE
BEEN IMPROVED BY THE SYSTEM MODIFICATIONS
OF SUMMER 1977.
-------
SECTION 4
SUMMARY OF FGD
COMPANY IT-FORMATION
SYSTEMS
CURRENT PERIOD
CATEFxPH.LAK TRACTOR CO.
MAPLETu.-J, ILLINOIS
FMC EIMViKCiX'-lEf:TAL
COAL C5.2X SULFUFO
360,000 AFCh
START-U^ 10/76
DOHbLL ALKALI (CONCENTRATED)
STATUS - CONSTRUCTION
AT THE CATERPILLAR MAPLETON PLANT. FMC CONCENTRA-
TED MODE DUAL ALKALI TECHNOLOGY WILL BE UTILIZED
TO CONTROL S02 EMISSIONS. THREE SCRUBBER SYSTEMS
WILL CONTROL EMISSIONS FROM THREE COAL-FIRED
BOILERS, CONSTRUCTION DELAYS, PRIMARILY ON THE
STEAM GENERATION SIDE HAVE DELAYED SYSTEM START-UP
bACK TO THE 1978-79 HEAT SEASON.
CATEKPILLAK TKACTOR CO.
MORTON, ILLIMOIS
ZURIM INDUSTRIES
COAL (S.^r SULFUFO
70,000 ACF>i (TOTAL - k BOILERS)
START-UP 1/78
DOUBLE ALKALI (UILUTE)
STATUS - OPERATIONAL
THL CATERPILLAR NORTON PLANT UTILIZES ZURN INDUS-
TRIES1 DILUTE MODE DOUBLE ALKALI TECHNOLOGY
TU CONTROL EMISSIONS FROM THE STEAM PLANT.
FtfU SYSTEM START-UP OCCURRED AT THE BEGINNING
OF 1976. CURRENTLY THE VENDOR IS TRAINING THE
BOILER OPERATORS ON HOW TO OPERATE AND MAINTAIN
THE EMISSIONS CONTROL SYSTEM. THERE HAVE BEEN NO
MAJOR PROBLEMS SINCE START-UP,
CATERPILLAR TRACTOR cO.
MOSSVILLL. ILLINOIS
FMC tJ'-VIRui.f'iENTV.L t'«UIPIJit>T
COAL (3.2?. SULFUK)
240,000 «CFH
STAKT-Ur' 10/75;
DOUBLE ALKALI (Cu.jtEf-iTRATED
STATUS - OPERATIONAL
THE CATERPILLAR MOSSVILLE PLANT HAS
FMC CONCENTRATED MODE FGD SYSTEM EA
SEASON SINCE OCTOBER 1975. THERE A
FIRED BOILERS EACH BEING TREATED BY
SCRUBBING TRAIN, OVERALL AVAILABIL
80-85SS6. OPERATIONS FOR THE 1977-78
HAVE BEEiM MARKED BY SOME PROBLEMS.
ARE NOT YET AVAILABLE.
UTILIZED AN
CH HEATING
RE FOUR COAL-
A SEPARATE
ITY HAS BEEN
HEAT SEASON
BUT DETAILS
CHEVRCVj OIL CO;•!!"'ANY
BAKEPSFILLJ, CALIFORNIA
KOCH E-\i61AiF_ERINii
OIL (1.3sn SULFUR)
450.000 ACF-j: 2 DUO F ( TOTAL-18 BOILERS)
START-UK 7/76
SOOIUh SuPDaBIi'JG
STATUS - PLANNED-CONTRACT AWARDED
CHEVHOiM IS AWAITING A REGULATORY BOARD DECISION
AS TO WHETHER THE ERECTION OF THESE PROPOSED
STLAN GENERATORS AND ACCOMPANYING FGD SYSTEMS
twILL BE APPROVED, IF CHEVRON RECEIVES A GO-AHEAD
FKuM THE REGULATORY BOARD, THE COMPANY PLANS
TO USE PROPRIETARY SCRUBBING STRATEGY
IN MODULES FABRICATED BY KOCH ENGINEERING.
15
-------
SECTION 4
SUMMARY OF FGD
COMPANY INFORMATION
SYSTEMS
CURRENT PERIOD
FIRESTONE TIRE AND RUBBER CO.
POTTSTuWiM, PENNSYLVANIA
FC1C ENVIRONMENTAL EQUIPMENT
2.5-3.0% SULFUR COAL
If,000 ACFM
START-UP 1/75
DOUBLE ALKALI (CONCENTRATED)
STATUS - OPERATIONAL
THE FGO SYSTEM AT FIRESTONE-POTTSTOWN CONSISTS OF
AN FMC DOUBLE ALKALI DUAL THROAT VENTURI SCRUBBER.
THIS S02 CONTROL SYSTEM WAS BUILT AS A DEMONSTRA-
TION PROJECT FUNDED BY FIRESTONE. THE SYSTEM OPER-
ATED WITH AN AVAILABILITY VALUE OF ^l% IN THE FALL
QUARTER OF 1977. . THE MAJOR PROBLEM AREA IS
EROSION OF FAN AND SPRAY NOZZLES BY FLYASH. THIS
EQUIPMENT to ILL BE REDESIGNED.
FMC (SUUA ASH PLANT)
GREEfj RIVER, WYOMING
FMC ENVIRONMENTAL EQUIPMENT
COAL (lio SULFUR* 5fe ASH* 10,000 BTU/LB)
660,000 ACFM a) 320 F (TOTAL - 2 BOILERS)
START-UP 5/7fa
SODIUM SCRUBBING
STATUS - OPERATIONAL
THE FGO SYSTEM CONSISTS OF TWO FMC SODIUM SCRUB-
BING UNITS TO REMOVE SULFUR DIOXIDE AND PARTICU-
LATE MATTER FROM THE FLUE GAS OF TWO BOILERS.
SCRUBBER CORROSION HAS BEEN A PROBLEM. PLANT
PERSONNEL FELT THAT THE LINING WAS IMPROPERLY
APPLIED. FOAMING AND SEDIMENTATION HAS OCCURED
IN THE SCRUBBER DUE TO IMPURITIES IN THE LIQUOR,
GENERAL MOTORS CHEV. MOTOR DIV
TOI\iOWAA,JA, MEW YORK
FMC ENVIRONMENTAL EQUIPMENT
COAL (1.38 S* 9% ASH* 12,500 BTU/LB)
132,700 SCF'I a 70 F (TOTAL - <+ BOILERS)
START-UP 6/75
SODIUM SCRUBBING
STATUS - OPERATIONAL
THE FGD SYSTEM CONSISTS OF FOUR GM SODIUM SCRUB-
BING UNITS FOR THE REMOVAL OF PARTICULATES AND
SULFUR DIOXIDE FROM FOUR COAL-FIRED BOILERS.
THE SCRUBBERS ARE EQUIPPED WITH VENTURI SCRUBBERS
FOR PARTICULATE REMOVAL. UNSTABLE PH CONTROL,
PIPE EROSION AND STACK CORRISION ARE MAIN PROBLEM
AREAS. REPLACEMENT OF CONTROL SENSORS, PIPING
AND RELINING OF STACK ARE THE CORRECTIVE ACTIONS.
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
A.D. LITTLE
COAL (3.2?o SULFUR* IQJK ASH)
100,000 ACFM a 370 F
START-UP 0/72
SODIUM SCRUBBING
STATUS - OPERATIONAL
THIS S02 COlMTROL SYSTEM CONSISTS OF TWO GM DE-
SIGNED SODIUM SCRUBBING UNITS OPERABLE ON TWO OF
FOUR COAL-FIRED BOILERS, DURING THIS REPORT PER-
IOD, STACK CORROSION HAS BEEN THE MAIN PROBLEM.
PLANS ARE BEING MADE TO RELINE THE STACK IN THE
NEAR FUTURE. THE SYSTEM IS PROVIDED WITH BYPASS
AND 60 F REHEAT.
-------
SECTION
SUMMARY OF FGD SYSTEMS
COMPANY INFORMATION
CURRENT PERIOD
GENERAL MOTORS PARMA
PARMAt OHIO
GM ENVIRONKENTAL
COAL <2.kj?o SULFUR* 7.1% ASH* 13,350 BTU/LB)
128,100 SCFM 51 70 F (TOTAL - 4 BOILERS)
START-UP 3/74
DOUBLE ALKALI (DILUTE)
STATUS - OPERATIONAL
iOUBLE
THE
THE FGD SYSTEM CONSISTS OF A GM DESIGN [
ALKALI SCRUBBER OPERATIONAL ON 4 BOILCRU ..._ ,.
SCRUBBERS HANDLE A TOTAL 240,000 ACFM OF FLUE GAS.
THE SCRUBBERS HAVE BEEN OPERATIONAL SINCE MARCH
1974. THE SYSTEM DEVELOPED MIST ELIMINATOR
PROBLEMS DURING THIS REPORT PERIOD, AT THE TIME
OF THIS REPORT, A SATISFACTORY SOLUTION HAD NOT
YET BEEN FOUND.
GENERAL MOTORS TRUCK & COACH
PONTIAC, MICHIGAN
PEABOOY ENGINEERING
COAL (0.84b SULFUR* 6.5?6 ASH* 12,500 BTU/LB)
107,300 SCFM a 70 F (TOTAL - 2 BOILERS)
START-UP 4/76
SODIUM SCRUBBING
STATUS - OPERATIONAL
THE SCRUBBEK SYSTEM CONSISTS OF TWO G.M. SODIUM
UNITS FOR THE REMOVAL OF FLYASH AND SULFUR DIOXIDE
FROM THE. FLUE GAS OF TWO COAL-FIRED BOILERS.
PLANT nAS BEEN EXPERIENCING FLYASH ABRASION IN
PUMPS AND PIPING.
GENERAL MOTORS/DLLCO MORAINE."
DAYTON, OHIO
ENTOLETER, INC.
COAL (0.7-1.38 SULFUR* 5-9.5« ASH* 13,400 BTU/LB)
55,HO SCFH S 70 F (TOTAL - 2 BOILERS)
START-UP 9/74
SODIUM SCRUBBING
STATUS - OPERATIOMAL
THE FGU SYSTEM CONSISTS OF TWO GM SODIUM SCRUB-
BING UNITS ON 2 COAL-FIRED BOILERS. THE UNITS
HAVE BEEN OPERATIONAL SINCE SEPTEMBER 1974. THE
SCRUBBERS REMOVE SULFUR DIOXIDE AND PARTICULATE
MATTER FROM A TOTAL GAS VOLUME OF 45,000 ACFM AT
400 DEGREES F. AVERAGE OPERABILITY OF THE SYSTEM
IS 95%.
GEORGIA-PACIFIC PAPER CO.
CROSSETT, ARKANSAS
AIRPOL INDUSTRIES
BARK AIMU OIL OR COAL (IS - 1.5 % SULFUR)* 62 T/HR
320,000 ACFM 3 310 F
START-UP 0/75
CAUSTIC WASTE STREAM
STATUS - OPERATIONAL
THE FGD SYSTEM CONSISTS OF AN AIR-POL CAUSTIC
SCRUBBING UNIT TO REMOVE SULFUR DIOXIDE AND PAR-
TICULATE MATTER FROM THE FLUE GAS OF A COAL/BARK
OR OIL/BARK POWER BOILER. PROBLEMS HAVE
BEEN ENCOUNTERED WITH THE FIBERGLASS LININGS IN
THE SCRUBBER. THE SYSTEM IS PRECEDED BY CYCLONES
FOR PARTICULATE REMOVAL. NO REHEAT IS PROVIDED
ON THE SYSTEM AND MATERIALS ARE HOLDING UP WELL
WITH NO CORROSION OR ABRASION PROBLEMS. FIBER-
GLASS LININGS IN THE SCRUBBER ARE REPLACED AS
THEY FAIL.
17
-------
SECTION «*
SUMMARY OF FGD SYSTEMS
COMPANY INFORMATION
CURRENT PERIOD
GREAT SOUTHERN PAPER CO.
CEDAR SPRINGS, GEORGIA
AIRPOL INDUSTRIES
BARK AfjU COAL OH OIL (1.0S-2.0SK SULFUR)
700,000 ACFM* TOTAL - 2 SCRUBBERS
START-UP 0/75
CAUSTIC WASTE STREAM
STATUS - OPERATIONAL
THE FGD SYSTEM CONSISTS OF TWO AIR-POL CAUSTIC
SCRUBBERS TO CONTROL PARTICULATE AND SULFUR DI-
OXIDE FROM TWO POWER BOILERS. THE PRIMARY FUEL
is BARK/COAL (BARK/OIL is FIRED OCCASIONALLY.)
THE FOLLOWING PROBLEMS HAVE BEEN ENCOUNTERED*
EROSION AND PLUGGAGE OF THE PH PROBES* INTERNAL
WEAR ON PUMPS, AND EROSION IN THE RECIRCULATION
LINES OF THE POWER BOILER SCRUBBER. THE PLANT IS
IN THE PROCESS OF CHANGING THE PH CONTROL AND
MOVING THE PROBES.
GREAT uESTERN SUGAR
BILLINGS, MONTANA
GREAT WESTERN SUGAR
COAL (0.756 SULFUR)
60,000 SCF!*! S 70 F
START-UP 10/77
AMMONIA-LADEN PROCESS WATER
STATUS - OPERATIONAL
GREAT WESTERN SUGAR USES CONDENSATE PROCESS WATER
PRIMARILY FOR PARTICULATE CONTROL. THE WATER
HAS A HIGH PH (8.71 BUT THE SYSTEM HAS A LOW S02
REMOVAL BECAUSE THE WATER IS INTRODUCED THROUGH
PIPES RATHER THAN SPRAY NOZZLES.
GREAT WESTERN SUGAR
FIIMDLAY, OHIO
GREAT WESTERN SUGAR
COAL (3?o SULFUR)
15,000 SCFM a 70 F (TOTAL
START-UP 10/7H
SODIUM CARBONATE
STATUS - OPERATIONAL
- 2 BOILERS)
PARTICULATE AND SOS EMISSIONS WILL BE CONTROLLED
BY A SCRUBBER/ABSORBER MODULE OF PROPRIETARY
DESIGN. THE FLUE GAS IS GENERATED BY TWO
720 BOILER HP UNITS, SCRUBBING OPERATIONS
BEGAN IN OCTOBER 197H.
GREAT WESTERN SUGAR
FORT WORGANt COLORADO
GREAT WESTERN SUGAR
COAL (O.Sfn SULFUR)
50,000 SCFM S 70 F
START-UP 10/76
AMMONIA-LADEN PROCESS WATER
STATUS - OPERATIONAL
GREAT WESTERN SUGAR USES CONDENSATE PROCESS WATER
PRIMARILY FOR PARTICULATE CONTROL, THE WATER
HAS A HIGH PH (8.7) BUT THE SYSTEM HAS A LOW S02
REMOVAL BECAUSE THE WATER IS INTRODUCED THROUGH
PIPES RATHER THAN SPRAY NOZZLES.
18
-------
SECTION
SUMMARY OF FGD SYSTEMS
COMPANY INFORMATION
CURRENT PERIOD
GREAT riKSTERN
FREEMOhT,OHlO
GREAT WESTERN SUGAR
COAL (3V6 SULFUR)
ifO.OOO bCH*. a 70 F (TOTAL - 2 BOILERS)
START-UP 10/7fl
SODIUM CARBONATE
STATUS - CONSTRUCTION
PARTICULATE AND soa EMISSIONS WILL BE CONTROLLED
BY A SCRUBBER/ABSORBER MODULE OF PROPRIETARY
UESIGN. THE FLUE GAS IS GENERATED BY TWO
UNION BOILERS, EACH RATED 3 70,000 LB/HR STEAM.
STARTUP IS SCHEDULED FOR OCTOBER 1978.
GREAT WESTERN SUGAR
GERING, IVCFirtASKA
GRFAT 'WESTERN SUGAR
COAL (1,71- SULFUR)
50,000 SCFM y 70 F
START-UP 10/7b
Ai"lMCr-!l^-LAt'tN PROCESS wATCK
STATUS - OPERATIONAL
GREAT WESTERN SUGAR USES CONOENSATE PROCESS WATER
PRIMARILY FOR PARTICULATE CONTROL. THE WATER
HAS A HIGH PH (8.7) BUT THE SYSTEM HAS A LOW S02
REMOVAL BECAUSE THE WATER IS INTRODUCED THROUGH
PIPES RATHER THAN SPRAY NOZZLES,
GREAT 'wLSTIRN SUbAR
GREELEY, COLORADO
GREAT tot-STEKN SUGAR
COAL (0.6^ SULFuR)
25,000 SCFh o> 7U F
START-UP 10/7b
AMMONIA-LADEN PRUCESS WATLR
STATUS - OPERATIONAL
GREAT WESTERN SUGAR USES CONDENSATE PROCESS WATER
PRIMARILY FOR PARTICULATE CONTROL. THE WATER
HAS A HIGH PH (8.7) BUT THE SYSTEM HAS A LOW S02
REMOVAL BECAUSE THE WATER IS INTRODUCED THROUGH
PIPE'S RATHER THAN SPRAY NOZZLES.
GREAT kEl'HERN SUbAK
LONGP"OM", COLORADO
GRTAT WLSTERN; SUGAK
COAL (0.7/c SULFUR)
START-UP 10/73
AhMONlA-LACEM PHOCLSS
STATUS - TERMINATED OR INDEFINITELY SHUT DOWN
SUGAR PRODUCTION AND ALL PLANT OPERATIONS
HAVE BEEN TERMINATED AT THE LONGMONT PLANT.
19
-------
SECTION «*
SUMMARY OF F6D
COMPANY INFORMATION
SYSTEMS
CURRENT PERIOD
GREAT WESTERN SUGAR
LOVELANUi COLORADO
GREAT WESTERN SUGAR
COAL (0.626-0.7?* SULFUR)
50,000 SCFM 5) 70 F
START-UP 10/73
AMMONIA-LADEN PROCESS WATER
STATUS - OPERATIONAL
GREAT WESTERN SUGAR USES CQNDENSATE PROCESS WATER
PRIMARILY FOR PARTICULATE CONTROL. THE WATER
HAS A HIGH PH (8.7) BUT THE SYSTEM HAS A LOW S02
REMOVAL BECAUSE THE WATER IS INTRODUCED THROUGH
PIPES RATHER THAN SPRAY NOZZLES.
GREAT 'WESTERN SUGAR
SCOTTS BLUFF, NEBRASKA
GREAT WESTERN SUuAR
COAL (0.656-0.7?o SULFUR)
60,000 SCPiv! a 7U F
START-UP 10/75
AMMONIA-LADEN PROCESS WATER
STATUS - OPERATIONAL
GREAT WESTERN SUGAR USES CONDENSATE PROCESS WATER
PRIMARILY FOR PARTICULATE CONTROL. THE WATER
HAS A HIGH PH (8.7) BUT THE SYSTEM HAS A LOW S02
REMOVAL BECAUSE THE WATER IS INTRODUCED THROUGH
PIPES RATHER THAN SPRAY NOZZLES.
HARRIS f-lHi
SPRUCE PINE i NORTH CAROLINA
W.W, SLY MANUFACTURING CO.
COAL (O.P9? SULFUR, 5JS ASH)
CO,
NORTH
START-UP 0/73
WATER SCRUBBING (NA»NH3 OPTN.)
STATUS - TERMINATED OR INDEFINITELY SHUT DOWN
THE FGD SYSTEM CONSISTS OF A W.W. SLY IMPINJET
SCRUBBER CURRENTLY BEING USED STRICTLY AS A PAR-
TICULATE CONTROL DEVICE. THE SYSTEM HAS THE
CAPABILITY OF SCRUBBING WITH AMMONIA OR CAUSTIC
IF NECESSARY. HOWEVER* AS LONG AS CURRENT
LOW-SULFUR COAL SUPPLIES LAST, THERE IS NO NEED
FOR S02 CONTROLS.
ITT RAYONIErtt
FERNANDINA BEACH, FLORIDA
AIRPOL INDUSTRIES
BARK Ai\ib GIL (2* - 2
3^,000 ACF^i 3 446 F
START-UP 0/75
CAUSTIC SCRUBBING
STATUS - OPERATIONAL
,5X SULFUR)
(TOTAL - 2 BOILERS)
PURPOSES AND THE SPENT CAUSTIC IS BEING MARKETED.
20
-------
SECTION
COMPANY INFORMATION
SUMMARY OF F60 SYSTEMS
CURRENT PERIOD
KEFR-MCGEE CHEMICAL CORP.
TROi'JA, CALIFORNIA
COMBUSTION EQUIPMENT ASSOC
COKE, CUAL, OIL (0.5% - 5%
726,000 ACFM Si 320 DEGREES F
START-UP H/7B
SODIUM SCRUBBING
STATUS - CONSTRUCTION
SULFUR)
THE F&D SYSTEM CONSISTS OF A COMBUSTION EQUIPMENT
(CEA) SODA ASH SCRUBBING SYSTEM WHICH REMOVES FLY-
ASH AND SULFUR DIOXIDE FROM THE FLUE GAS OF TWO
COAL FIRED BOILERS. MAJOR CONSTRUCTION
IS COMPLETE AND PRECOMMISSlONING ACTIVITIES ARE
UNDERWAY. EXPECTED STARTUP DATE IS APRIL li 1978.
MEAD PAPLKBOARD CO.
STEVENSON, ALABAMA
AIRPOL INDUSTRIES
OIL (!.{>* - 3?
-------
COMPANY INFORMATION
SECTION 355 F
START-UP 2/76
AIR POL CAUSTIC SCRUBBING
STATUS - OPERATIONAL
THE FGD SYSTEM CONSISTS OF TWO AIR-POL CAUSTIC
SCRUBBERS WHICH REMOVE FLYASH AND SULFUR DIOXIDE
FROM THE FLUE GAS OF A STEAM BOILER FIRED WITH
COAL OR FUEL OIL. SOME SOLIDS DEPOSITS ON THE PH
PROBES ARE CAUSING SOME PROBLEMS. FLOW METERS
HAVE BEEN INSTALLED TO GAIN MORE PH CONTROL IN
THE SYSTEM,
QUALITY MILLS, INC,
MT. AIRY, NORTH CAROLINA
COMMERCIAL FABRICATION & MACH.
FUEL OIL
START-UP 5/70
WATER SCRUBBING
STATUS - TERMINATED OR INDEFINITELY SHUT DOWN
THIS SMALL INDUSTRIAL BOILER UTILIZED A
COMMERICAL FABRICATION AND MACHINE (CFM) SCRUB-AIR
SYSTEM TO CONTROL EMISSIONS FROM THE COAL-FIRED
BOILER FROM MAY 1970 TO DECEMBER 1973.
AT THAT TIME THEY CONVERTED TO FIRING LOW-SULFUR
OIL, REMOVING THE NEED TO CONTROL EMISSIONS,
RICKENBACKER AIK FORCE BASE
COLUMBUS, OHIO
RESEARLH-COTTRELL/BAHCO
COAL (3.6% SULFUR)
50,000 SCFi1-, 3 70 F
START-UP 3/76
LIMESTONE SCRUBBING
STATUS - OPERATIONAL
THIS RESEARCH-COTTRELL/BAHCO LIME FGD UNIT
WAS FIRST PLACED IN SERVICE MARCH lit 1976. ,
THE SYSTEM WAS SWITCHED OVER TO LIMESTONE IN APRIL
1977, AND HAS REMAINED IN THAT OPERATING MODE TO
DATE, THE NEW OHIO CODE REQUIRES A LESS STRINGENT
S02 REMOVAL EFFICIENCY AND THE PLANT IS NOW RUN-
NING A. STOICHIOMETRIC RATIO OF ABOUT 0.75. AVAIL-
ABILITY HAS
95S SINCE AUGUST 1977.
22
-------
SECTION
COMPANY INFORMATION
SUMMARY OF FGD SYSTEMS
CURRENT PERIOD
SHELLER 6LOJE CORP.
NORFOLK, VIRGINIA
W.W. SLY MANUFACTURING CO.
COAL (Less THAN in, SULFUR,
8,000 SCFM a1 70 F
START-UP 0/7b
SODIUM HYDROXIDE
STATUS - OPERATIONAL
6% ASH, 13,200 BTU/LB)
AFTER SYSTEM RESTART _.
BEEN NO PROBLEMS RESUL'
SCRUBBER OPERATIONS. ',ns. r-»™, *- wwn^ut,
AWAITING CERTIFICATION FROM VIRGINIA EPA,
IN OCTOBER 1?77» THERE HAVE
ILTING FROM EITHER BOILER OR
THE PLANT IS CURRENTLY
ST. JOE. MINERALS CORP.
MONACA, PENNSYLVANIA
BUREAU GF i^IfvES
COAL (3.0* SULFUR, 11000
15 0 . 0 0 U A i, F n
START-UP 10/7-3
CITRATt- PROCESS
STATUS - CONSTRUCTION
BTU/LB)
CONSTRUCTION CONTINUES ON THE CITRATE PROCESS
SCRUBBING SYSTEM WHICH WILL CONTROL S02 EMISSIONS
FROM A 60-MiN COAL-FIRED POWER GENERATING UNIT AT
ST. JOE MINERALS. START-UP is SCHEDULED FOR
OCTOBER 1978. THE REGENERABLE FGD SYSTEM WILL
PRODUCE ELEMENTAL SULFUR AS A BY-PRODUCT.
ST. REGIS PAPER CO.
CANTONMENT« FLOKIDA
AIRPOL INDUSTRIES
INTERRUPTI6LE NATURAL
175,000 ACF.-'l
START-UP 0/73
CAUSTIC SCHUBPIHb
STATUS - OPERATIONAL
GAS* 9AKK & OIL
THE. FGD SYSTEM CONSISTS OF AN AIR-POL CAUSTIC
SCRUBBING SYSTEM TO REMOVE PARTICULATES AND SUL-
FUR DIOXIDE FROM THE FLUE GAS OF A BARK BOILER
S) FIRING INTERRUPTIBLE NATURAL GAS AND OIL. PROBLEMS
WITH VALVES PLUGGING AND FIBERS CLOGGING MIST
ELIMINATOR HAVE BEEN INVESTIGATED AND A DECISION
WAS MADE TO CHANGE THE MAKE-UP WATER SOURCE.
TEXACO INCORPORATED
SAN AHDO, CALIFORNIA
CEILCOTE CO.
OIL (2 PERCF.NT SULFUR)
IB, 100 ACFPi 3 46U F
START-UP 0/74
SODIUM SCRUBBING
STATUS - OPERATIONAL
THE FGD SYSTEM CONSISTS OF A HORIZONTALiPACKED-BED
TYPE SCRUBBER FOR THE FLUE GAS OF OIL FIRED BOIL-
ERS. THE BOILERS PRODUCE STEAM WHICH IS USED
TO FACILITATE OIL FLOW FROM THE OIL WELLS.
THERE ARE SEVERAL SCRUBBERS ON-SITE
ALTHOUGH THE EXACT SITUATION HAS NOT YET BEEN
REPORTED.
23
-------
SECTION H
SUMMARY OF FGD SYSTEMS
COMPANY INFORMATION
CURRENT PERIOD
TEXASGULF
GRANGER. WYOMING
SlmE^CO INC.
COAL (fj.&Jo SULFUR* 7% ASH* 10,500 BTU/LB)
140,000 SCFi", Q) 70 F (TOTAL - 2 BOILERS)
START-LIP 9/76
SODIUM SCRUBBING
STATUS - OPERATIONAL
THIS SODIUM CARBONATE FGD SYSTEM WAS DESIGNED BY
SWEMCO* INC. OF NEW YORK. S02 CONTROL OCCURS IN
THE QUENCHER AND THE SIEVE-TRAY ABSORBER MODULE.
AN INTERESTING FEATURE IS AN INTERNAL DAMPER
WHICH ALLOWS A 4 TO 1 TURNDOWN RATIO.
INITIAL PROBLEMS INCLUDED PLUGGING CAUSED BY
FLYASH CARRYOVER FROM THE ESP, MILD STEEL
PIPING IN THE RECIRCULATIN6 LINES WAS SEVERELY
CORRODED BY THE SLIGHTLY ACIDIC SCRUBBING LIQUOR.
TRANSCO TEXTILES, INC.
AUGUSTft, GEORGIA
FMC ENVIRONMENTAL EQUIPMENT
FUEL OIL (2% MAX. SULFUR)
50,000 ACFM
START-UP 3/75
SODIUM SCRUBBING
STATUS - TERMINATED OR INDEFINITELY SHUT DOWN
THE FGD OPERATIONS HAVE BEEN TERMINATED FOR AN
INDEFINITE PERIOD, THE PLANT BURNS NUMBER 6 FUEL
OIL AND THE SULFUR DIOXIDE EMISSIONS ARE 50» OF
THE EXISTING REGULATIONS. THE BOILER IS RATED
AT 20 MW (EQUIVALENT) AND PRODUCES 150,000 LBS/HR
STEAM. WHEN OPERATIONAL* THE SCRUBBER SYSTEM HAD
FLUE GAS VOLUME OF 50,000 ACFM AT 1**0 DEGREES F,
SYSTEM START-UP OCCURRED IN MARCH 1975 AND SCRUB-
BER OPERATIONS WERE TERMINATED LATER IN THE SAME
YEAR. A DEC. 1977 CHECK REVEALS THAT THE FGD
SYSTEM IS STILL TERMINATED AND THERE ARE CURRENTLY
NO PLANS TO INITIATE OPERATIONS,
U.S. GYPSUM CORP.
OAKMONTf PENNSYLVANIA
AIRPOL INDUSTRIES
COAL
START-UP O/ 0
DOUBLE ALKALI (DILUTE)
STATUS - TERMINATED OR INDEFINITELY SHUT DOWN
AN AIRPOL DOUBLE ALKALI SCRUBBING SYSTEM IS
ON-SITE, INSTALLED, AND READY FOR OPERATIONS,
HOWEVER, US GYPSUM DECIDED NOT TO INITIATE
PRODUCTION AT THIS FACILITY, A DEC. 1977 CHECK
REVEALED THAT THE SITUATION IS UNCHANGED, I.E.,
THE STEAM PLANT WAS NEVER STARTED.
-------
VENDOR
SECTION 5
LIST OF VENDORS OF FGQ SYSTEMS
INSTALLATION NAME / LOCATION
CONTROL SYSTEM PROCESS
A.D. LITTLE.
AIRPOL INDUSTRIES
BUREAU OF MINES
CARBORUNDUM ENVJR. SYS. LTD.
CEILCOTE CO.
COMBUSTION EQUIPMENT ASSOC.
COMMERCIAL FABRICATION & HACH.
ENTOLETERt INC.
GENERAL MOTORS CORPORATION
ST. LOUlSt MISSOURI
GEORGIA-PACIFIC PAPER CO,
CROSSETT, ARKANSAS
GREAT SOUTHERN PAPER CO.
CEDAR SPRINGS* GEORGIA
ITT RAYONIER, INC.
FERNANDIlMA BEACH. FLORIDA
MEAD PAPERBOARD CO.
STEVENSON, ALABAMA
NCR-APPLETON
ROARING SPRINGS, PENNSYLVANIA
Nt-KOOSA PAPERS, INC.
ASHDOWN, ARKANSAS
ST. REGIS PAPER CO.
CANTONMENT, FLORIDA
U.S. GYPSUM CORP.
OAKMONT, PENNSYLVANIA
ST. JOE MINERALS CORP.
MONACA, PENNSYLVANIA
CARBORUNDUM ABRASIVES
BUFFALO, NEW YORK
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
KERR-MCGEE CHEMICAL CORP.
TRONA, CALIFORNIA
QUALITY MILLS, INC.
MT. AIRY, NORTH CAROLINA
GENERAL MOTORS/DELCO MORAINE
DAYTON, OHIO
SODIUM SCRUBBING
CAUSTIC WASTE STREAM
CAUSTIC WASTE STREAM
CAUSTIC SCRUBBING
SODIUM SCRUBBING
SODIUM SCRUBBING
AIR POL CAUSTIC SCRUBBING
CAUSTIC SCRUBBING
DOUBLE ALKALI (DILUTE)
CITRATE PROCESS
LIME SCRUBBING
SODIUM SCRUBBING
SODIUM SCRUBBING
WATER SCRUBBING
SODIUM SCRUBBING
25
-------
VENDOR
SECTION 5
LIST OF VENDORS OF FGD SYSTEMS
INSTALLATION NAME / LOCATION
CONTROL SYSTEM PROCESS
SODIUM SCRUBBING
SODIUM SCRUBBING- WASTE STREAM
DOUBLE ALKALI (CONCENTRATED)
DOUBLE ALKALI (CONCENTRATED)
DOUBLE ALKALI (CONCENTRATED)
DOUBLE ALKALI (CONCENTRATED)
SODIUM SCRUBBING
SODIUM SCRUBBING
SODIUM SCRUBBING
DOUBLE ALKALI (DILUTE)
AMMONIA-LADEN PROCESS WATER
AMMONIA-LADEN PROCESS WATER
AMMONIA-LADEN PROCESS WATER
AMMONIA-LADEN PROCESS WATER
AMMONIA-LADEN PROCESS WATER
FMC EfJVIHOiJMENTAL EQUIPMENT
GM ENVIRONMENTAL
GREAT WESTERN SUGAR
ALYESKA PIPELINE SERVICE CO.
VALDEZ* ALASKA
CANTON TEXTILES
CANTONt GEORGIA
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
CATERPILLAR TRACTOR CO.
EAST PEORIA, ILLINOIS
CATERPILLAR TRACTOR CO.
MOSSVILLE* ILLINOIS
FIRESTONE TIRE AND RUBBER CO.
POTTSTOWNt PENNSYLVANIA
FMC (SODA ASH PLANT)
GREEN RIVER* WYOMING
GENERAL MOTORS CHEV. MOTOR DIV
TONOWANDA, NEW YORK
TRANSCO TEXTILES, INC.
AUGUSTA, GEORGIA
GENERAL MOTORS PARMA
PARMA, OHIO
GREAT WESTERN SUGAR
SCOTTS BLUFF, NEBRASKA
GREAT WESTERN SUGAR
LOVELAND, COLORADO
GREAT WESTERN SUGAR
BILLINGS, MONTANA
GREAT WESTERN SUGAR
GREELEY, COLORADO
GKEAT WESTERN SUGAR
GERING, NEBRASKA
26
-------
VENDOR
SECTION 5
LIST OF VENDORS OF FGD SYSTEMS
INSTALLATION NAME / LOCATION
CONTROL SYSTEM PROCESS
SODIUM CARBONATE
AMMONIA-LADEN PROCESS WATER
SODIUM CARBONATE
AMMONIA-LADEN PROCESS WATER
LIME SCRUBBING
SODIUM SCRUBBING
AMMONIA SCRUBBING
SODIUM SCRUBBING
NOT SELECTED
SODIUM SCRUBBING
LIMESTONE SCRUBBING
SODIUM SCRUBBING
SODIUM HYDROXIDE ADDITION
WATER SCRUBBING
-------
SECTION 5
LIST OF VENDORS OF- F6D SYSTEMS
VENDOR INSTALLATION NAME / LOCATION
ZURM INDUSTRIES CATERPILLAR TRACTOR CO. DOUBLE ALKALI (DILUTE)
CATERPILLAR TRACTOR CO. DOUBLE ALKALI (DILUTE)
JOLIET. ILLINOIS
-------
SECTION 6
NUMBER AND TOTAL CAPACITY OF FGD SYSTEMS
STATUS
OPERATIONAL
UNDER CONSTRUCTION
PLANNING
CONTRACT AWARDED
LETTER OF INTENT
REQUESTING/EVALUATION BIDS
CONSIDER ONLY
TOTAL
NO. OF
UNITS
34
5
2
0
1
0
CAPACITY
ACFM
5231940.
1636000.
468000.
0.
300000.
0.
NO. OF UNITS
ACFM NOT KNOWN
0
0
0
0
0
0
7655940.
29
-------
SECTION 7
STARTUP DATE OF F&O SYSTEMS
NO. OF UNITS
YEAH
1972
1973
1974
1975
1976
1977
1978
19«U
EF1NED
TOTAL
UNITS
1
3
7
12
6
4
7
1
1
42
ACFM
100000.
265000.
652940.
2346700.
1332300.
445000.
2156000.
300000.
36000.
7655940.
ACFH UNKNOWN
0
0
0
0
0
0
0
0
0
0
-------
SECTION 8
SUMMARY OF OPERATIONAL FGD SYSTEMS
COMPANY/LOCATION
NEW/
RETROFIT
SIZE UNIT
(ACFM )
PROCESS/VENDOR
MO/YR
ALYESKA PIPELINE SERVICE CO. MEW 50,OflO
VALDEZ, ALASKA
SOURCE CHARACTERISTICS -FUEL OIL (.03 - .1% SULFUR)
SODIUM SCRUBBING
FMC ENVIRONMENTAL EQUIPMENT
6/77
CAN THREAD RETROFIT 60,000 SODIUM HYDROXIDE ADDITION
MARIOfM, NORTH CAROLINA W.W. SLY MANUFACTURING CO.
SOURCE CHARACTERISTICS -COAL (.99 PERCENT SULFUR, 7 PERCENT ASH)
0/73
ARhCC STEEL
OHIO
RETROFIT
260,000 LIME SCRUBBING
KOCH ENGINEERING
JULL I "Wlv , Uniu r\uv,n LJMOI
SOURCE CHARACTERISTICS -COAL (0.8SS SULFUR* 9* ASH* 1H.OOO BTU/LB)
CANTON TEXTILES RETROFIT «+2»000 SODIUM SCRUBBING- WASTE STREAM
CANTON, GLORGIA FMC ENVIRONMENTAL EQUIPMENT
SOUKCE CHARACTERISTICS -IUTEKRUPTIBLE NATURAL GAS* COAL (o.a» SULFUR)
0/75
CATCRPILLAR TRACTOR CO.
JOLTET, ILLINOIS
RETROFIT
SCUHCf. CHARACTLKISTICS -COAL (6.2% SULFUR)* 9.65 T/HR FEED
90,000 DOUBLE ALKALI (DILUTE)
ZURM INDUSTRIES
9/7«*
CATERPILLAR TRACTOR CO. 1NEW, 3RETROFIT 210,000 DOUBLE ALKALI (CONCENTRATED)
MOSSVILLE, ILLINOIS FMC ENVIRONMENTAL EQUIPMENT
SOURCE CHARACTERISTICS -COAL (3.2» SULFUR)
10/75
CATERPILLAR TRACTOR CO. RETROFIT
MORTON, ILLINOIS
SOUKCE CHARACTERISTICS -COAL (3.25* SULFUR)
70,000 DOUBLE ALKALI (DILUTE)
ZURN INDUSTRIES
1/78
FIRESTC.v'E TIRE AfMD RUBBER CO. RETROFIT
PUTTSTGwi'j, PENiMSYLVAMA
SOURCc CHARACTERISTICS -2.5-3.0!* SULFUR COAL
1H.OOO DOUBLE ALKALI (CONCENTRATED) 1/75
FMC ENVIRONMENTAL EQUIPMENT
(SOuA ASH PLANT)
GREEN RIVLR, WYOMING
NEW
SOURCE CHARACTERISTICS -COAL ( 1* SULFUR* 58J ASH* 10,000 BTU/LB)
660,000 SODIUM SCRUBBING
FMC ENVIRONMENTAL EQUIPMENT
5/76
31
-------
SECTION 8
SUMMARY OF OPERATIONAL FGG SYSTEMS
UNIT
COMPANY/LOCATION RETROFIT ( ACFM )
PROCESS/VENDOR
MO/YR
* • • ^ • • •
6/75
GENERAL ROTORS ChEV. MOTOR UIV RETROFIT 132,700
TONOUAKiJA, i^EW YORK
SOUrtCF. CHARACTERISTICS -COAL (1.38 S* 3% ASH* 12,500 BTU/LB)
GEi'-JERAL i"!OTOKS CORPORATION
ST. LOUIS, MISSOURI
RETROFIT
100,000 SODIUM SCRUBBING
A.D. LITTLE
-------
SECTION 6
SUMMARY OF OPERATIONAL FGD SYSTEMS
COMPANY/LOCATION
NEW/
RETROFIT
SIZE UNIT
(ACFM )
PROCESS/VENDOR
MO/YR
• •» •» ^ • •• «
10/75
GREAT WESTERN SUGAR RETROFIT
GREELEY, COLORADO
SOUKCL CHARACTERISTICS -COAL (0.68» SULFUR)
25,000 AMMONIA-LADEN PROCESS WATER
GREAT WESTERN SUGAR
GREAT WESTERN SUGAR RETROFIT
GERING, NEBRASKA
SOURCE CHARACTERISTICS -COAL (0.75S SULFUR)
50,000 AMMONIA-LADEN PROCESS WATER 10/75
GREAT WESTERN SUGAR
GREAT WESTERN SUGAR RETROFIT 50,000
LOVELANO, COLORADO
SOUKCE CHARACTERISTICS -COAL (Q.6SK-0.7SS SULFUR)
AMMONIA-LADEN PROCESS WATER 10/73
GREAT WESTERN SUGAR
GREAT WESTERN SUGAR RETROFIT
FORT MORGAN, COLORADO
SOUKCE CHARACTERISTICS -COAL (0.5* SULFUR)
50,000 AMMONIA-LADEN PROCESS WATER 10/76
GREAT WESTERN SUGAR
GREAT WESTERN SUGAR RETROFIT
BILLINGS, MONTANA
SOURCE CHARACTERISTICS -COAL (0.7% SULFUR)
60,000 AMMONIA-LADEN PROCESS WATER 10/77
GREAT WESTERN SUGAR
GKEAT WESTERN SUGAR
FINDLAY, OHIO
SOURCE CHARACTERISTICS -COAL (
RETROFIT
3ff SULFUR)
15,000 SODIUM CARBONATE
GREAT WESTERN SUGAR
10/71
ITT RAYOMIER, irtc. RETROFIT 3f«+,ooo
FERNANUINA 3EACH, FLORIDA
SOURCE CHARACTERISTICS -BARK AND OIL (2% - 2.5% SULFUR)
CAUSTIC SCRUBBING
AIRPOL INDUSTRIES
0/75
MEAD PAPERBOARD CO, NEW
STEVENSON, ALABAMA
SOURCE CHARACTERISTICS -OIL (1.5* - 3» SULFUR)
173,000 SODIUM SCRUBBING
AIRPOL INDUSTRIES
0/75
MINN-DAK FARMER'S COOPERATIVE RETROFIT 250,000
WAHPETON, NORTH DAKOTA
SOURCE CHARACTERISTICS -LIGNITE (1.0 PERCENT SULFUR)
AMMONIA SCRUBBING
KOCH ENGINEERING
6/77
33
-------
SECTION 8
SUMMARY OF OPERATIONAL FGD SYSTEMS
COMPANY/LOCATION RETROFIT (ACFM N ) PROCESS/VENDOR __ ___ 52-15.
MOBIL OIL COMPANY RETROFIT 30*»»000 SODIUM SCRUBBING 0/7*
SAN ARDO, CALIFORNIA MOBIL OIL COMPANY
CHARACTERISTICS -OIL (2% - 2.25% SULFUR)
NCR-APPL.ETO.M NEW 85.000 SODIUM SCRUBBING 6/77
RUARING SPRINGS, PENNSYLVANIA AIRPOL INDUSTRIES
SOUNCE CHARACTERISTICS -COAL (2% - 38J SULFUR)
NEKOOSp PAPLKSi INC. NEW 325,000 AIR POL CAUSTIC SCRUBBING 2/76
ASHDOU'h. , ARKANSAS AIRPOL INDUSTRIES
SOURCE CHARACTERISTICS -COAL (1SS-1.5* SULFUR)* 27 TON/HR
RICKFNuACKEK A I* FORCE BASE RETROFIT 50,000 LIMESTONE SCRUBBING 3/76
COLJMbuS, UHIO RESEARCH-COTTRELL/BAHCO
SOURCE CHARACTERISTICS -COAL (3.6* SULFUR)
SHELLEh GLOBE CORP. RETROFIT 8,000 SODIUM HYDROXIDE 0/75
fJORFOLKi VlKGi:\iIA W.)N. SLY MANUFACTURING CO.
SOURCE CHARACTERISTICS -COAL (LESS THAN IK SULFUR, 6% ASH, 13,200 BTU/LB)
SI. REGIS PAPER CO. RETROFIT 175,000 CAUSTIC SCRUBBING 0/73
CAKTOM-.C.M, FLORIPA AIRPOL INDUSTRIES
SOUKCE CHARACTERISTICS -INTERRUPTIBLE NATURAL GAS* BARK & OIL (2X-3X S)
TEXACO il.CuRPORATEO RETROFIT 16,100 SODIUM SCRUBBING 0/7*
SAI\. ARbO, CALIFORNIA CEILCOTE CO.
SOURCE CHARACTERISTICS -OIL (2 PERCENT SULFUR)
TEXASGULF NEW 1*0*000 SODIUM SCRUBBING 9/76
GRANGER , kYOMIfcG SWEMCO INC.
SOURCE CHARACTERISTICS -COAL (0.8S8 SULFUR* 758 ASH* 10,500 BTU/LB)
-------
SECTION 9
SUMMARY OF UNDER CONSTRUCTION FGD SYSTEhS
COMPANY/LOCATIQiM
WE*/
RETROFIT
SIZE UNIT
(ACFM )
PROCESS/VENDOR
MO/YR
» •* • w » «• •
3/78
2IMEW. ^RETROFIT 360,000
CATF.RP1LLAK TKACTOh CO.
EAST PEOhla, ILLINOIS
SCUHLE CHAKflCIEKlSTlCS -CUAL (3.2X SULFUR)
DOUBLE ALKALI (CONCENTRATED)
FNC ENVIRONMENTAL EQUIPMENT
CATLPPILLAK TRACTOk CO. NEw
MAI-LETOd, ILLINOIS
SOUKLE CHARACTERISTICS -COAL (3.2% SULFUR)
360,000 DOUBLE ALKALI (CONCENTRATED) 10/78
FMC ENVIRONMENTAL EQUIPMENT
GRLAf v.LSTtKN SUGAR RETROFIT
FREEf'OuT.OhlO
SOLiRLE LHARACTLklSTlCS -COAL (3K SULKUR)
^•0,000 SODIUM CARBONATE
GREAT WESTERN SUGAR
10/78
CHEMICAL COHP.
TKOhiA, CALIFORNIA
ChiAKACTEhlSTICS -COKE, COAL, OIL (0,58 - 5fc SULFUR)
72fa,000 SODIUM SCRUBBING
COMBUSTION EQUIPMENT ASSOC,
1/78
ST. JOL "IM-'.RALS CUKp.
MONACA, i-
RETROFIT
150,000
SCLKCE ChAKACTERISTICS -COAL (3.0» SULFURi 11000 BTU/Lb)
CITRATE PROCESS
BURLAU OF MIMES
10/76
3b
-------
SECTION 10
SUMMARY OF PLANNED FGU SYSTEMS
/LOCATION RETROFIT (ACFM ) PROCESS/VENDOR MO/YR
BUP! ABRASIVES RETROFIT 36,000 LIME SCRUBBING O/ 0
bUFFALL, IV.U YORK CARBORUNDUM ENVIR. SYS. LTD.
SOL'KCE CHARACTERISTICS -COAL ( 2% S AVERAGE, 3.2SB S DESIGN MAX)
CHEVROU OIL COMPANY RETROFIT 450,000 SODIUM SCRUBBING 7/78
BAKERShiELU, CALIFORNIA KOCH ENGINEERING
SOUKCF CHARACTERISTICS -OIL (1.5*, SULFUR)
ARCO/PCLYMEKS RETROFIT 300,000 NOT SELECTED 12/80
MOMACA, PErj^SYLVrtl'jIA NOT SELECTED
SOURCE CHARACTERISTICS -COAL (3.5* SULFUR)
-------
SECTION 11
SUMMARY OF WASTE Af^D BY-PRODUCT DISPOSAL PRACT1CLS FOR FGD SYSTEMS
INSTALLATION IMAML / LOCATION STATUS/COMMENTS
ALKALINE SULFITE./BISULFITE KECYCLEO~TO~PULP"PROCESS
MEAD PAPFRBOARD CO.
STEVEfjSOM, ALABAMA
NEKOOSA PAPERS* INC,
ASHDOU-J, ARKANSAS
OPERATIONAL
RECOVERED SOLUTION USED AS MAKE-UP TO COOKING LIQUOR IN PULP
MILL.
OPERATIONAL
S02 RECOVERED FROM SODIUM SULFITE/SULFATE LIQUOR AND RE-
CYCLED TO PULPING PROCESS.
DEWATEKED SLURRY TO LANDFILL
CATERPILLAR TRACTOR CO.
MORTONi ILLINOIS
CATERPILLAR TRACTOR CO.
MOSSVILLE, ILLINOIS
CATERPILLAR TRACTOR CO.
JOLIET» ILLINOIS
CATERPILLAR TRACTOR co.
EAST PEOR1A, ILLINOIS
CATERPILLAR TRACTOK CO.
MAPLETON, ILLINOIS
FIRESTONE TIRE AND RUBBER CO.
POTTSTOxkt PENNSYLVANIA
GENERAL MOTORS CHE.V. MOTOR DIV
TONOI/JANOAf NEW YORK
GENERAL MOTORS PARMA
PARMAt OHIO
GENERAL MOTORS TRUCK & COACH
PONTIAC, MICHIGAN
OPERATIONAL
OPERATIONAL
60 + X SOLIDS (CASO
-------
SUMMARY OF WASTE
INSTALLATION NAfiE / LOCATION
SECTION 11
AND BY-PRODUCT DISPOSAL PRACTICES FOR FGD SYSTEMS
STATUS/COMMENTS
EH SLURRY TU LANDFILL
U.S. GYPSUM CORP.
f\ .. i - it,! C\ . "T ; - ,— R . - ! ,-t k» . .
TERMINATED OR INDEFINITELY SHUT OOUN
SLUDGE TO POND FOR DRYING. THEN TO LANDFILL.
HOLDING
FUH EVAPORATION
AMERICAN THREAL)
r-r,ARiOi,,i i'iORTH CAROLINA
ART-CO STE.LL
MiLiDLETU*'\;t OHIO
FtfC (SOOA ASh PLAN1)
GRE.Efi KIVER, WYOMING
KLRR-1SCGEL CHEMICAL CORP.
TKONA, CALIFORNIA
"lOdlL OIL
SAM AROU, CALIFGhM'A
TEXASbULF
OPERATIONAL
THE SODIUM SULFITE/SULFATE SLURRY IS PUMPED TO A RED CLAY
LINED ASH BASIN. LEACHING OF SODIUM SULFITE IS NOT A PROBLEM
DUE TO THE IMPERMEABLE NATURE OF THE RED CLAY LINER.
OPERATIONAL
OPERATIONAL
NA2S03/S04 LIQUOR DISPOSED TO COLLECTION POND - NO PRIOR
AERATION. LANDFILL IN THE FUTURE
CONSTRUCTION
SCRUBBER EFFLUENT IS CLARIFIED AND THEN PUT INTO A MINERAL
DEPOSIT.
OPERATIONAL
OPERATIONAL
SLURRY TO Li:\iEiJ POND
CANTON TEXTILES
GEOhoIA
RICKEf,bACKER AIH FORCE BASE
COLUMKJS, OHIO
OPERATIONAL
NA S03/S0tf LIQUOR DISPOSED TO LINED HOLDING PONDS
OPERATIONAL
UNSTABILIZED CAS03/SOH SLUDGE TO LINED POND
-------
SECTION 11
SUMMARY OF WASTE AND BY-PRODUCT DISPOSAL PRACTICES FOR FGD SYSTEMS
INSTALLATION NAME / LOCATION STATUS/COMMENTS
REGEiviERABLt - ELEMENTAL SULFUR PRODUCT
CONSTRUCTION
ST. jut MINERALS CORP.
, PENNSYLVANIA
ATEh TREATMENT AND DISCHARGE TO CITY SEWER
BUFFALO,
ARRAS I VETS
YORK
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
GENERAL KOTOKS/DELCO
DAYTO.vi, OHIO
GEORGIA-PACIFIC PAPER co,
CROSSE-fT, ARKANSAS
GREAT wESTFKM SUGAR
FIULAAY, OHIO
GREAT wL-.bTERN SUGAR
FREEP.OiMTiOHIO
IMCR-APPLETUN
SPRIrJGS, PENNSYLVANIA
DUALITY MLLS, INC.
MT . MlHY, i'JOKTH CAROLINA
ST. Hfc.GXS PAPER CO,
PLANNED-CONTRACT AWARDED
OPERATIONAL
NA2S03 OXIDIZED TO NA2S04, PH NEUTRALIZED AND DISCHARGED TO
CITY SEWER SYSTEM
OPERATIONAL
NA2S03/SOH LIQUOR AT 35 6PM TO ON-SITE CLARIFICATION AND
FACILITY
OPERATIONAL
OPERATIONAL
CONSTRUCTION
OPERATIONAL
TERMINATED OR INDEFINITELY SHUT DOWN
SCRUBBING LIQUOR DISCHARGED TO NEUTRALIZATION POND
OPERATIONAL
SLUDGE IS DISCHARGED TO AN ON-SITE SEWAGE TREATMENT PLANT
-------
SECTION 11
SUGARY OF kASTE AMD BY-PRODUCT UISPOSAL PRACTICES FOR FGO SYSTEMS
Il\-Sl ALLATiOM i^AI'iE / LOCATION ST ATUS/COMENTS
WASTE in ATEK TREATMENT AND DISCHARGE TO RIVER
GRF.AT cSOUTHFRN PjjPER CO.
CEDAR hPRIivGSt GEORGIA
GREAT *ESTERN
"
LOI\iGK">rJTt COLORADO
GREAT ASTERN SUGAR
LGVELA'VJ. COLORADO
GREAT
SCOTTS
NEBRASKA
GREAT WESTERN SUGAR
GRF.FLLY, COL.ORAUO
GREAT wESTLRM SUGAR
NGt iMEdRASKA
GREAT WESTERN
GKEAT WESTERN SUGAR
FORT riGKGAiM, COLORADO
ThAI\.SCO
AUGUSTA
lEXTILE&t
GEORGIA
IMC.
CLARIFICATION FOLLOWED BY PONDING AND DISCHARGE TO RIVER
TERMINATED OR INDEFINITELY SHUT DOM
OPERATIONAL
OPERATIONAL
OPERATIONAL
OPERATIONAL
OPERATIONAL
OPERATIONAL
TERMINATED OR INDEFINITELY SHUT DOWN r^
NA2S03/SOI* LIQUOR DISCHARGED TO A HOLDING POND
WASTEhATER TREATMENT
ALYESKA PIPELINE SERVICE CO.
VALPEZi ALASKA
1*1 INN-DAK FARMER'S COOPERATIVE
WAHPETON, tMORTH DAKOTA
OPERATIONAL
NA2S03/HS03 AERATED TO NA2S04 AND TRANSFERRED TO WASTEWATLR
TREATMENT PLANT AT A RATE OF 10 6PM. IT IS MIXED WITH ABOUT
10,000 GPM OF BALLAST WATER FROM TANKERS IN PORT VALDEZ.
CLEANED WATER IS THEN DISCHARGED INTO PORT VALDEZ.
BLEED STREAM GOES TO AN ACTIVATED SLUDGE SYSTEM 3 160 GPM
-------
SECTION 11
SUMMARY OF WASTE AND BY-PRODUCT DISPOSAL PRACTICES FOR FGD SYSTEMS
INSTALLATION NAME / LOCATION STATUS/COMMENTS
OVERFLOW TO SEWER/SLUDGE TO LANDFILL
SHELLLK GLOBE CORP. OPERATIONAL
NORFOLK, VIRGINIA
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SQUPCt. CHARACTERISTICS
SOURCL RATING
SCURCt CAPACITY
CONTROL SYSTEM VENDOR
CGiviTRUL PROCESS
iMfcw / KLTKOFIT
START-UP DATE
CONTROL SYSTEM STATUS
SO? EFFICIuMCY
PARTICULATE EFFICIENCY
WATER -'AKE.-UP
SLUDGL OR HY-PKODUCT DISPOSAL
CONTROL SYSTEM COST
ALYESKA PIPELINE SERVICE CO.
VALDEZ» ALASKA
FUEL OIL (.03 - .184 SULFUR)
SOtOOO SCFM a 70 F (DESIGN MAX)
13 MW (EQUIVALENT)
FMC ENVIRONMENTAL EQUIPMENT
SODIUM SCRUBBING
NEW
JUNE. 1977
OPERATIONAL
96+S (150-lbO PPM a) INLET)
PARTICULATE EMISSIONS MEET NSPS.
10 GPM - OPEN LOOP
WASTEWATER TREATMENT
NA2S03/HS03 AERATED TO NA2SO<* AND TRANSFERRED TO WASTEWATER
TREATMENT PLANT AT A RATE OF 10 GPM. IT IS MIXED WITH ABOUT
10*000 GPM OF BALLAST WATER FROM TANKERS IN PORT VALDEZ,
CLEANED WATER IS THEN DISCHARGED INTO PORT VALDEZ.
PLANT PERSONNEL ARE NOT ABLE TO BREAK OUT FGD SYSTEM COSTS
FROM OVERALL PIPELINE PROJECT COSTS.
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS (CONTINUED) -
ALYESKA PIPELINE SERVICE CO. *
OPERATIONAL EXPERIENCE
THE ALYESKA FGD SYSTEM IS UNIQUE IN THAT IT WAS
NOT INSTALLED PRIMARILY FOR CONTROL OF EMISSIONS,
BUT TO TREAT GAS USED IN THE OIL STORAGE TANKS.
OPERATIONS FOR THE PERIOD SEPTEMBER THRU JANUARY
WERE NEARLY PROBLEM-FREE. THERE HAS BEEN NO
DOWNTIME ATTRIE5UTABLE TO THE S02 REMOVAL SYSTEM.
RECENT MEASURLMENTS INDICATE S02 REMOVAL TO BE
BETTER THAN
-------
BACKGROUND INFORMATION
ALYESKA PIPELINE SERVICE CO. - VALDEZ, ALASKA
AT THE VALDEZ TERMINAL OF THE ALASKAN OIL PIPELINE, ALYESKA PIPELINE SERVICE COMPANY OPERATES
THE UTL STORAGE AND TRANSFER FACILITY. OIL FLOWING IN FROM THE PIPELINE IS TEMPORARILY STORED IN
SEVLKAL HUGE TANKS, THEU TRANSFERRED FROM THE TANKS TO OIL TANKER SHIPS IN NEARBY PORT VALDEZ.
ALYESKA h-AWTEU NEUTRAL BLANKET AIR FOR THE OIL STORAGE TANKS, A LOW OXYGEN CONTENT BEING PARTICULAR-
LY OESIRABLE. IT WAS DETERMINED THAT ON-SITE BOILER FLUE GAS WOULD HAVE THE REQUIRED LOW OXYGEN
COUTtllMT. CORROSION PREVENTION DICTATED THE NEED FOR S02 CONTROLS, I.E., THIS DEVICE WAS NOT
INSTALLED TO MEET ANY EMISSIONS REGULATIONS. THE S02 REMOVAL APPROACH CHOSEN WAS A REClRCULATING
SOLdUh-OASED CHEMISTRY DESIGNED AND FABRICATED BY FMC ENVIRONMENTAL EQUIPMENT DIVISION.
THE BOILERS WILL NOT OPERATE AT STEADY STATE CONDITIONS. THIS IS DUE TO THE FACT THAT WHEN OIL
IS REMOVED FROM THE TANKS AT A FASTER RATE THAN IT IS BEING FED BY THE PIPELINE, AN ADDITIONAL INERT
AIR BLANKET WILL BE NEEDED. THIS REQUIRES STEPPING UP THE BOILERS FROM THE NORMAL LEVEL OF PLANT
POWLk PRODUCTION TO RUN THE COMPRESSORS AND PRODUCE ADDITIONAL GAS FOR BLANKET PRODUCTION.
IF THE TANKS ARE FILLING FASTtR THAN THEY ARE BEING EMPTIED, THE AIR FORCED OUT BY THL INCOMING
OIL wILL BE INCINERATED.
THE BOILER PLANT AT THE VALDEZ TERMINAL CONSISTS OF THREE 250 MM BTU/HR OIL-FIRED BOILERS,
MANUFACTURED BY COMBUSTION-ENGINEERING. THE OIL BEING USED IN THE BOILERS PRODUCES A VERY LOW
PAKTICULATE GKAIlM LOADING, AMU HAS AN EXTREMELY LOW SULFUR CONTENT WHICH RANGES FROM 0.03% TO 0.1*.
THEKL IS NO PARTICUL^TE REMOVAL OTHER THAN WHAT OCCURS IN THL FMC S02 ABSORBER MODULE.
THE MAXIMUM DESIGN CAPACITY OF THE SCRUBBER MODULE IS 50,000 SCFM, WHICH REPRESENTS ABOUT 25»
OF THE TOTAL FLUE GAS GENERATED. THE S02 CONTROL SYSTEM IS DESIGNED WITH 100X REDUNDANCY, I.E.,
THEKE AHE TWO MODULES IN PARALLEL. ONLY ONE OF WHICH IS IN USE AT ANYTIME.
CAUSTIC (SODIUM HYDROXIDE) IS USED AS REAGEM MAKE-UP. DESIGN PH CONTROL WAS ABOUT 6.5» BUT
OPERATIONS HAVE INDICATED THAT A HIGHER PH IS MORE DESIRABLE, SO CONTROL PH NOW EQUALS ABOUT 8.0.
A FJLEED STREAM OF SODIUM BISULFITE/SULFITE GOES TO AN AERATOR AT A RATE OF 10 GPM. AFTER COMPLETE
-------
ALYESKA PIPELINE SERVICE CO. (CONTINUED)
OXlUaTIO* TO NAgSOf, THE WASTE STREAM GOES TO A WASTE.WATER TREATMENT AKEA WHERE IT IS MIXED WITH
10,000 GPM OF BALLAST WATER FRUM THE TANKERS IN THE PORT.
f.T THE PKESEm TIME THERE ARE NO CONTINUOUS MONITORS FOR S02t BUT ALYESKA TESTS HAVE DEMON-
STRATLD ABOUT 5 PPM OF S02/S03/S0^ AT THE OUTLET OF THE ABSuRBER. SINCE INLET S02 CONCENTRATION
RANGES FROM 150-lfeO PPf,, THE SYSTEM IS REMOVING ABOUT 97 PERCENT OF THE INLET SULFUR OXIDES.
COMMENTS
3KL) wUAKTER-1977 CORROSIOlJ HAS OCCURED IN THE PIPING FOR THE WATER RECIRCULATION SYSTEM. AT THE
TIFF CF THIS KFPORT, THE CAUSE IS UNKNOWN.
<+TH UUARTER-1977 THE CONTROL SYSTtM HAS BEEN OPERATING UtARLY PROBLEM-FREE* WITH NO DOWNTIME
BEING ASSIGNED TO THE S02 REMOVAL SYSTEM. THE CURRENT LOAD IS APPROXIMATELY 20K OF DESIGN
CAPACITY. THIS IS A RESULT OF OIL FLOW BEING LOW AT PRESENT. THE CORROSION PROBLEM
IN WET AREAS ClAY BE DEALT WITH BY INTRODUCING NEUTRALIZING AMINE SPRAYS.
-------
SECTlu.x 12 - DESCRIPTION OF OPERATIONAL F6D SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE HATING
CAPACITY
COMROL SYSTEM VENDOR
COr.TRUL Pn.OCESS
iMEri / HF.THOFIT
START-UP GATE
CONTROL SYSTEM STATUS
SC.'2 EFFICIENCY
PARTILULATE EFFICIENCY
SLUUGL OR bY-PKODUCT DISPOSAL
OPERATIONAL EXPERIENCE
AMERICAN THREAD
MARION, NORTH CAROLINA
COAL (.99 PERCENT SULFUR, 7 PERCENT ASH)
60,000 ACFPi ft 400 DEGHEES F
(TOTAL - 2 BOILERS)
8 MW (EQUIVALENT)* TOTAL - TWO BOILERS
W.W. SLY MANUFACTURING CO.
SODIUM HYDROXIDE ADDITION
RETROFIT
1973
OPERATIONAL
90*
978
HOLDING POND FOR EVAPORATION
THE SODIUM SULFITE/SULFATE SLURRY IS PUMPED TO A RED CLAY
LINED ASH BASIN. LEACHING OF SODIUM SULFITE IS NOT A PROBLEM
DUE TO THE IMPERMEABLE NATURE OF THE RED CLAY LINER.
THE FGD INSTALLATION CONSISTS OF TWO SEPARATE
SCRUBBING UNITS OPERATING ON TWO COAL-FIRED
BOILERS FOR THE REMOVAL OF PARTlCULATES AND
SULFUR DIOXIDE. THE FGU UNITS HAVE BEEN IN
SERVICE SINCE 1973. CORROSION OF I.D. FANS, STACK
AND PIPING HAS BEEN THE MAIN PROBLEM. I.D. FAN
VIBRATIONS HAVE CAUSED SEVERE STRAIN IN PIPING.
-------
BACKGROUND INFORMATION
AMERICAN THREAD MARION. NORTH CAROLINA
THE AMERICAN THREAD PLANT NEAR MARION, NORTH CAROLINA, SPECIALIZES IN THE DYEING AND FINISHING
OF VARIOUS TYPES oF INDUSTRIAL SEWING THREADS AND RETAIL YARNS. STEAM AND HEAT FOR THE PLANT ARE
PROVIDED BY TWO 4-MW
-------
MKERICA'M THREAD (CONTINUED)
COilhiNTS
'+TH QUARTLR-1977 THE SCRUR&EK I.D. FANS HAVE REEiM THL MAJOR PROBLEM AREA. THE HEAVY FIBERGLASS
LINING OU THE IMPELLFKS HAS STOPPED CORROSION BUT CAUSED SEVERE VIBRATIONS RESULTING IN THE CRACK-
ING OF P\/C PIPING. THL INSTRUMENTATION LINES HAVE PLUGGED OCASSIOiMALLY. PLANT PERSONNEL
FEEL THAT THE SCRUBBER I.D. FANS (<+0 HP) SHOULD BE REMOVED AND THE BOILER I.D. FANSt
FRl.SENTLY 100 HP, BE KtPLACED BY HIGHER CAPACITY FAUS (150 HP). THE OPERABILITY OF THE
i> HAS BLFf.j ABOUT 90 PERCENT DURING THIS PERIOD.
-------
SECTIO.J 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
.INSTALLATION
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCL RATING
CONTROL SYSTEM VEMJOR
CONTROL PROCESS
Nfc> / K£TKOFIT
START-UP OATF
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUOlic. OR '3Y-PRODUCT DISPOSAL
OPERATIONAL EXPERIENCE
ARHCO STEEL
MIUDLETOWNt OHIO
COAL (0.8SS SULFUR* 9% ASH* IHtOOO 8TU/LB)
280*000 ACFft di *f25 F (TOTAL - 2 BOILERS)
200,000 LB/HR STEAM (TuTAL)
KOCH ENGINEERING
LIME SCRUBBING
RETROFIT
1975
OPERATIONAL
NOT AVAILABLE
HOLDING POND FOR EVAPORATION
THIS CONTROL SYSTEM SERVES TtoO MULTI-RETORT
UNDERFEED STOKER. COAL-FIRED BOILERS EACH irflTH
A CAPACITY OF 100,000 LBS/HR STEAM. EARLIER BOILER
PROBLEMS (HIGH EXCESS AIR) HAVE BEEN GENERALLY
RECTIFIED BY A RETROFITTED BOILER CONTROL SYSTEM.
RECENT OPERATIONS HAVE BEEN PROBLEM-FREE ALTHOUGH
IN MID-FEBRUARY 1978 THE SCRUBBER HAS BEEN
TEMPORARILY SHUTDOWN AS A RESULT OF THE COAL-
STRIKE RELATED POwER SHORTAGE IN OHIO.
-------
BACKGROUND INFORMATION
ARMCO STEEL-MIDDLETOWN* OHIO
THE SCRUB6EK UNIT SERVES TWO MULTI-RETORT, UNDERFEED STOKER* COAL-FIRED BOILERS, EACH WITH A
CAPACITY OF 100.000 LBS/HR STEAM, THE COAL BURNED IS TYPICALLY 0.7 TO 0.9 PERCENT SULFUR
AND t»* TO 10?; ASH. NORMALLY THE BOILERS ARE OPERATED IN THE WINTER MONTHS ONLY* HOWEVER FOR THE
PAST T«IO YtARs, OPERATIONS HAVE BEEN YEAR-ROUND WITH REDUCED CAPACITY DURING THE SUMMER.
THE CONTROL SYSTEM CONSISTS OF A VARIABLE-THROAT VENTURI SCRUBBER WITH A PRESSURE DROP CONTROLLED
ADJUSTABLE PLUG. IMMEDIATELY DOWNSTREAM FROM THE VENTURI IS AN ABSORBER MODULE
17 FEET Ii\l OlAMtlTER UITH THREE GAS SCRUBBING TRAYS, A S-TYPE CHEVRON MIST ELIMINATOR
AhiD M 106-INCH DIAMETER STUB STACK. THE SYSTEM IS DESIGNED TO HANDLE 140,000 ACFM AT
i+25 f AUU 15 INCHES w.G. WITH AN OUTLET LOADING OF 0.02 GR PER SCFD. FRESH WATER IS SUPPLIED FROM
CLARIFIED RIVER WATER AT THE RATE OF 1600 GPM TO THE TOP TRAY AND VENTURI THROAT. A LIME SLURRY IS
ADLJEU IN A 10000 GALLON RECYCLE TANK WHICH HOLDS EFFLUENT FROM THE ABSORBER MODULE.
THE LARGEST PROBLEM AFFECTING SCRUBBER PERFORMANCE HAS BEEN CONTROL OF EXCESS AIR IN THE BOILERS.
WITHOUT CONTROL, EXCESS AIR RESULTS IN 1.5 TO 3 TIMES THE SCRUBBER DESIGN FLOW RATE. THESE HIGH
EXCL3S /\IR RATES ALSO RESULT IN THE PRESENCE OF UNBURNED CARBON WHICH COULD NOT BE SCRUBBED AND
COMPOUNDED POOR PERFORMANCE. PROBLEMS WERE ALSO ENCOUNTERED WITH THE CHEVRON MIST ELIMINATOR WHICH
IS 1-muE OF ivlOREL PLASTIC. IT WAS RATED AT 225 F WHICH WAS WELL ABOVE THE TEMPERATURE
AT THAT LOCATION IN THE SYSTEM. HOWEVER, OVERLOOKED WAS THE FACT THAT NOREL IS CREEP SENSITIVE AT
20 DEGREES F ABOVE AMBIENT AWL THE CHEVRONS FAILED WITHIN A FEW MONTHS. NEW CHEVRONS OF THE SAME
MATtrUAL AKE ALSO BEING DAMAGED. STAINLESS STEEL OR FIBERGLASS REINFORCED PLASTIC IS THE PREFERRED
tfATL'KlAL FOR THIS APPLICATION,
THE WATER SYSTEM WAS ORIGINALLY DESIGNED TO BE A ^CIRCULATING SYSTEM. THE RECIRCULATED WATER
HAU <\ SUSPENDED SOLIDS CONCENTRATION OF HOOOO-50000 MILLIGRAMS PER LITER AT THE VENTURI, ALL THE
PIPING IN THIS SYSTEM WAS MILD STEEL AND WAS SEVERLY ABRADED CAUSING NUMEROUS LEAKS.
50
-------
ARMCO STEEL-MIDDLETOWN, OHIO (CONTINUED)
THE SYSTEM HAS BEEN MODIFIED TO A ONCE-THROUGH OPERATION AND THE ABRASION HAS CEASED,
SERIOUS ABRASION PROBLEMS WERE ALSO ENCOUNTERED IN 12-INCH STEEL PIPING CARRYING DIRTY WATER FROM
THE THAYS TO THE: RECYCLE TANK AS WELL AS IN THE PUMPS. THE PROBLEM HAS SOLVED BY REPLACING THE
PIPING WITH RUBBER HOSE, RUBBER LINED ELBOWS, AND RUBBER LINED PUMPS. IN ADDITION, PUMP SPEED WAS
REDUCED FROM 1780 TO 1160 RPM AND FLANGED T-SECTIONS WERE INSTALLED ON THE SUCTION SIDE OF THE
SLUubE PUMPS AMU RECIRCULATIQN PUMPS. THIS MATERIAL HAS WITHSTOOD ABRASION BETTER THAN ANY OTHER
MATERIAL TRIED TO DATE,
A LIME BUILD UP PROBLEM !*AS EXPECTED ON THE ABSORBER TRAYS AT LOW GAS FLOW RATES. THIS
PRUeLEM HAS NOT YET OCCURRED AT SUSTAINED PH LEVELS OF 6-6.5.
THE LIKE SLURRY SYSTEM HAS ALSO PRESENTED A PROBLEM, CLOGGING OF THE LIME SLURRY LINE IS
ATTRIBUTED TO ITS EXCESSIVE LLiMGTH. LIME ADDITION RATE IS A PROBLEM WHICH CAN BE RESOLVED WITH
THE INSTALLATION OF A PROPORTIONAL LIME SLAKER,
COMMENTS
t»TH QUARTEP-1977 THE. PLANT WAS NOT ABLE TO SUPPLY EXTENSIVE UPDATE INFORMATION FOR THIS REPORT
pE-Rioc-, ALTHOUGH REPORTED THAT RECENT OPERATIONS HAVE BEEN RELATIVELY PROBLEM-FREE. THE SCRUBBER
IS DOWh IN FEBRUARY 1978 AS A RESULT OF THE POWER SHORTAGE OHIO IS EXPERIENCING,
PLAivT HAS INDICATED THAT IT WILL SUPPLY MORE DETAILED INFORMATION FOR THE NEXT REPORT
PERIOD.
51
-------
SECT 1C,j le> - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
IfMSTAut-ATiufJ MA FIE
I (.SI ^LLATIOf: LOCATION
SOURCh; CHARACTERISTICS
SOURCE KATIMG
SOUKCC. CAPACITY
C(.'.,Tkul_ SYSTEM VENDOR
CCKiTKUL PROCESS
ME« / HETKOFIT
STAHT-Ur' UATF
COi'TROL SYSTEM STATUS
SOi; FjFlCItMCY
PARTlLULfift EFTIC1LMCY
WATLK ("-./iKt'-uP
SLUL'Gc. UK BY-P^oDUCT OISF-QoAL
COMHOL SYSTEM COST
CAF'I I'AL
OFfCRATiOWAL
CANTON TEXTILES
CANTON, GEORGIA
INTERRUPTIBLE NATURAL GAS* COAL (0.8& SULFUR)
H2fOOO ACFM
10 MW (EQUIVALENT)
FMC ENVIROMMENTAL EQUIPMENT
SODIUM SCRUBBING- IwASTE. STREAM
RETROFIT
JUNE. 197**
OPERATIONAL
70% (1500 PPM 3 INLET)
6Q& - 90% (b.92 LB/MM BTU AT INLET)
OPEN LOOP
NON-FIXATED SLURRY TO LINED POND
NA S03/S0tf LIQUOR DISPOSED TO LINED HOLDING PONDS
$ 74,000.
CAPITAL COST IS FOR AN INSTALLED SYSTEM,
AT CANTON TEXTILES THL CONTROL SYSTEM CONSISTS
OF AN FMC MEDIUM ENERGY VENTURI SCRUBBER AND
UTILIZES A CAUSTIC WASTE STREAM FOR S02 REMOVAL.
.THE UNIT HAS BEEN IN OPERATION SINCE JUNE OF 1974.
CANTON AGAIN REPORTED NO OPERATIONAL PROBLEMS
DURING THIS REPORT PERIOD. COAL FIRING WAS RE-
STARTED IN MID-OCTOBER 1977.
-------
BACKGROUND INFORMATION
CANTON TEXTILES, CANTON, GEORGIA
CANTON TEXTILE MILLS IN CANTON, GEORGIA HAS A 10 MW (EQUIVALENT) COAL-FIRED STEAM BOILER
WHICH IS NORMALLY USED DURING PERIODS OF INTERRUPTED NATURAL GAS SERVICE. THE BOILER
IS A COMBUSTION ENGINEERING
-------
CANTOM TEXTILES, CANTON, GEORGIA (CONTINUED)
COMMENTS
3RP NUA*TEK-l977 NO OPERATIONAL PROBLEMS WERE REPORTED DURING THIS SURVEY PERIOD. THE PLANT
HLPIKTS THE SYSTEM IS hOKKING SATISFACTORILY. THE PLANT HAS BEEN BURNING NATURAL GAS BUT EXPECTS
TO RtTUrtn TC COAL DURING THE HEATING SEASON
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGO SYSTEMS
INSTALLATION NAPIE
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTKUL PROCESS
ME* / RETROFIT
START-UP DATE:
CONTROL SYSTEM STATUS
Su2 EFFICIENCY
PARTICULA1E EFFICIENCY
WATER hAKt-UP
SLUDGE OR QY-PKUDUCT DISPOSAL
OPERATIONAL EXPERIENCE
CATERPILLAR TRACTOR CO.
JOLIET, ILLINOIS
COAL (3.2?o SULFUR)* 9.65 T/HR FEED
90,000 ACFM (TOTAL - 2 BOILERS)
16 MW (TOTAL - 2 BOILERS)
ZURN INDUSTRIES
DOUBLE ALKALI (DILUTE)
RETROFIT
SEPTEMBER, 1974
OPERATIONAL
9U+8
NOT AVAILABLE
0,5 6PM* CLOSED LOOP
DEWATERED SLUKRY TO LANDFILL
THE F6D SYSTEfi CONSISTS OF AN INDEPENDENT
SCRUBBING TRAIN ON EACH OF TWO COAL-FIRED BOILERS,
THESE BOILERS HAVE BEEN OPERATIONAL EACH HEAT
SEASON SINCE OCTOBER 1974. SINCE THAT DATE,
SCRUBBER AVAILABILITY HAS BEEN AVERAGING 80-85*.
OPERATIONS IN THE CURRENT HEAT SEASON HAVE
BEEN IMPROVED BY THE SYSTEM MODIFICATIONS
OF SUMMER 1977,
55
-------
BACKGROUND INFORMATION
CATERPILLAR TRACTOR CO., JOLIET, ILL.
THE. JOLIET PLANT OPERATES TWO COAL-FIRED BOILERS RATED AT 100,000 AND 60,000 POUNDS OF STEAM
PER HOUH. THESE BOILERS ARE ON LINE ONLY DURING WINTER MONTHS,
THE SCRUB8EK SYSTEM ON EACH BOILER IS A ZURN DOUBLE ALKALI SCRUBBER CONSTRUCTED OF 316L STAIN-
LESS STEEL. EACH SCRUBBER EXHAUSTS THROUGH A CARBON STEEL STACK. THE TOTAL FLUE GAS FLOW RATE
IS 103,500 ACFM.
THE SCRUBBER UNITS ARE PRECEDED BY MECHANICAL COLLECTORS FOR PARTICULATE REMOVAL. THE ZURN
SCRUBBER UTILIZES A DUSTRAXTOR MODULE FOR BOTH PARTICULATE AND soz CONTROL. SPENT SCRUBBING
LIQUOR IS THEM PUMPED TO THE REGENERATION AREA WHERE LIME IS ADDED TO PRECIPITATE
THE ABSORBED SULFUR IN CLAR1FIERS. CLARIFIER UNDERFLOW IS DEWATERED BY VACUUM
FILTERS AND THE SLUD&E PRODUCED is READY FOR DISPOSAL AT A LANDFILL. CLARIFIER OVERFLOW
IS KETUKNED TO THE SCRUBBER AS REGENERATED SCRUBBING LIQUOR, SODA ASH IS ALSO ADDED TO
THE REGENERATED LIQUOR TO REPLENISH SODIUM LOST IN THE SLUDGE. LIME AND SODA ASH ARE
STOREJ IN OUTSIDE SILOS AND CONVEYED TO PROCESS USE POINTS PNEUMATICALLY. A CHEMICAL
TREATMENT BUILDING WAS ERECTED TO HOUSE REGENERATION AND SLUDGE HANDLING EQUIPMENT,
COMMENTS
3RD GUARTER-1977 PROBLEMS OCCURED WHEN A TANK RAN DRY AMU DAMAGED A PUMP. SOME PIPE PLUGGING
PROBLEMS ALSO OCCUREU AS A RESULT OF THE PUMP FAILURE.
PROBLEMS ARE INCURRED WITH THE VACUUM FILTERS, THE FILTER CLOTH LASTS ONLY 2 TO 3 WEEKS.
NO SOLUTIONS HAVE BEEiM FOUND BUT FILTER DESIGN MODIFICATIONS ARE BEING CONSIDERED.
THE UNITS WERE ULTRASONICALLY TESTED AND RESULTS SHOW THAT THE SYSTEMS ARE ON THE HIGH
SIDE OF TOLERANCE LEVELS. A MINOR LEAK WAS DETECTED AS A RESULT OF A FAULTY WELD.
QUARTER-1977 FGD SYSTEM RESTART OCCURRED AT THE BEGINNING OF THE HEATING SEASON.
PLANT HAS INITIATED A PROCESS OF DETAILED RECORD KEEPING BUT IS STILL WORKING
ON THE INTERNAL* INFORMATION TRANSFER PROCESS, PLANT HAS INDICATED THAT A
SUMMARY OF THESE RECORDS WILL BE AVAILABLE TO THIS REPORT IN THE NEAR FUTURE.
56
-------
SECTIOfv 12 - DESCRIPTION OF OPERATIONAL FGO SYSTEMS
INSTALLATION IVAi'iE
INSTALLATION LOCATION
SOURCE. CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
OPERATIONAL EXPERIENCE
CATERPILLAR TRACTOR CO.
MORTON, ILLINOIS
COAL (3.2% SULFUR)
70.000 ACFM (TOTAL - 2 BOILERS)
12 MW
ZURN INDUSTRIES
DOUBLE ALKALI (DILUTE)
RETROFIT
JANUARY* 1978
OPERATIONAL
NOT AVAILABLE
DEWATERED SLURRY TO LANDFILL
THE CATERPILLAR MORTON PLANT UTILIZES ZURN INDUS-
TRIES' DILUTE MODE DOUBLE ALKALI TECHNOLOGY
TO CONTROL EMISSIONS FROM THE STEAM PLANT.
FGD SYSTEM START-UP OCCURRED AT THE BEGINNING
OF 1978. CURRENTLY THE VENDOR IS TRAINING THE
BOILER OPERATORS ON HOw TO OPERATE AND MAINTAIN
THE EMISSIONS CONTROL SYSTEM. THERE HAVE BEEN NO
MAJOR PROBLEMS SINCE START-UP.
57
-------
BACKGROUND INFORMATION
CATERPILLAR TRACTOR - MORTON, ILLINOIS
AT THE MORTON PLANT, A PARTS DISTRIBUTION CENTER, CATERPILLAR TRACTOR OPERATES A TWO-BOILER STEAM
PLAf\,T WHICH GENERATES STEAM EQUIVALENT TO ABOUT 12 MW. EMISSIONS ARE CONTROLLED BY A ZURN IN-
DUSTRIES AIR QUALITY CONTROL SYSTEM CONSISTING OF A DUSTRAXTOR SCRiiBBER IN WHICH PARTICULATE AND SOg
REMOVAL OCCUR SIMULTANEOUSLY. SULFUR DIOXIDE REMOVAL IS BROUGHT ABOUT BY THE USE OF ZURN DILUTE
MODE, DOUBLE ALKALI F&0 TECHNOLOGY. THE TWO BOILERS AND THE TWO SCRUBBING TRAINS AND MOST ANCILLARY
EQUIPMENT ARE WITHIN THE BOILER HOUSE.
THE SYSTEM AT MORTON IS VERY SIMILAR TO THAT AT THE CATERPILLAR JOLIET PLANT, WHICH HAS BEEN
OPERATING EACH HtlATIfJG SEASON SINCE OCTOBER 197<+. WHENEVER POSSIBLE, PROBLEM AREAS AND
SOLUTIONS IDENTIFIED IN JOLIET OPERATIONS HAVE BEEN IMPLEMENTED TO IMPROVE THE SYSTEM DESIGN
AT r-iORTOW. SPECIFIC AREAS IN WHICH MODIFICATIONS TO DESIGN HAVE BEEN MADE ARE WATER BALANCE,
PUMPS, PH MONITORING. PIPING, LIME STORAGE, AND COLD WEATHER PROTECTION.
COMMENTS
1ST GUAKTER-1976 SYSTEM START-UP OCCURRED AT THE BEGINNING OF JANUARY. INITIAL OPERATIONS HAVE
BEEN PROBLEM FREE. THROUGH JANUARY AND PART OF FEBRUARY, ZURN PERSONNEL WILL BE TRAINING
CATERPILLAR BOILER PLANT PERSONNEL IN THE OPERATION OF THE FGD SYSTEM.
CATERPILLAR'S OPERATING EXPERIENCES AT JOLIET AND MOSSVILLE HAVE SHOWN THAT EXISTING
BOILER OPERATORS CAN BE EFFECTIVELY TRAINED TO OPERATE AND MAINTAIN FGD SYSTEMS.
CURRENT PLANS CALL FOR ACCEPTANCE TESTING IN THE SPRING, BUT THE COAL SITUATION
MAY DELAY THL TEST PERIOD.
S3
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE. CHARACTERISTICS
SOURCE BATING
SOURCE: CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
OPERATIONAL EXPERIENCE
CATERPILLAR TRACTOR CO,
MOSSVILLEt ILLINOIS
COAL (3.2% SULFUR)
2
-------
BACKGROUND INFORMATION
CATERPILLAR TRACTOR-MOSSVILLE, ILLINOIS
AT THE HQSSVILLE PLANT, CATERPILLAR TRACTOR OPERATES A FOUR-BOILER STEAM PLANT. TWO OF THE
BOILERS ARE RATED AT 150,000 LBS/HR STEAM AND TWO ARE RATED AT 80,000 LBS/HR STEAM. THE ENTIRE
f-UMT PLAfviT IS ROUGHLY EQUIVALENT TO 50 MW OF ELECTRICAL GENERATING POWER. THE COAL FIRED IS
HIGH-SULFUR (3.2S5-H.Q%) ILLINOIS COAL. THE FOURTH BOILER* AT 150,000 LBS/HR, BEGAN IN JUNE 1977
AMD ITS FGO SYSTEM wAS BYPASSED UNTIL OCTOBER 1977.
FMC ENVIRONMENTAL EQUIPMENT DIVISION HAS SUPPLIED AN AIR QUALITY CONTROL SYSTEM CONSISTING OF A
VENTURI SCRUBBER FOR PARTICULATE CONTROL AND AN ABSORBER MODULE FOR soa CONTROL. THE TWO 150,000
LB/HK BOILERS HAVE PRECEDING MECHANICAL COLLECTORS REMOVING ABOUT 90S OF THE INLET FLYASH, THE
SCRUBBING TRAINS ON THE TWO SMALL BOILERS HAVE NO PRECEDING MECHANICAL COLLECTORS.
HHILE THE FLYASH IN THE FINAL FILTER CAKE PROVIDES ADDED MECHANICAL STABILITY, THE HIGH ASH
CONTENT IN THE HECIRCULATING SLURRY CAUSED SEVERE EROSION/ABRASION PROBLEMS IN EARLY OPERATIONS.
THE ORIGINALLY INSTALLED WEIR TYPE CONTROL VALVES HAVE BEEN REPLACED WITH SPOOL PIECES AND A
CONSTflNT VOLUME PUMPING SYSTEf.. THERE WAS ALSO SIGNIFICANT WEAR IN THE VENTURI SCRUBBER BOTTOMS,
WHICH WAS SOLVED BY THE INSTALLATION OF WEAR PLATES.
SEVERAL PROBLEM AREAS WERE IDENTIFIED AND DEALT WITH DURING THE TWO HEAT SEASONS PRIOR TO THE
1977-76 SEASON.
PUMPS - THE RUBBER-LINED SLURRY PUMPS WERE OVERSIZED WHICH CAUSED HIGH PIPE VELOCITIES AND
ACCELERATED WLAR ON THE PUMP LININGS, THESE PUMPS WERE REVISED TO LOWER THEIR OUTPUT.
LOW SEAL WATER PRESSURE ALLOWED PROCESS LIQUOR TO GET INTO THE PUMP AND PACKING. ALL SEAL
WATER IS NOW ONCE THROUGH AND SYSTEM PRESSURES HAVE BEEN ADJUSTED TO MAINTAIN SEAL WATER PRESSURE
ABOVE PROCESS LIQUID PRESSURES.
SLUDGE HANDLING - SLUDGE IS TRANSPORTED FROM THE VACUUM FILTERS TO THE LOADING AREA ON A BELT
60
-------
CATERPILLAR TRAtTOR-MOSSVILLE, ILLINOIS (CONTINUED)
CONVEYOR. SEVERAL STRATEGIES, ALL INVOLVING SCRAPING OR PLOWING THE QEWATERED SLUDGE OFF THE BELT,
RESULTED IN EXCESSIVE WEAR OF EITHER THE BELTS OR THE PLOWS.
THE PRESENT APPROACH SIMPLY DUMPS THE MATERIAL OFF THE END OF THE BELT INTO BINS. THE POSITION
OF THE EMD OF THE BELT IS CHANGEABLE SO THAT EIGHT BINS CAN BE FILLED BEFORE THEY MUST BE EMPTIED.
A FURTHER MODIFICATION HAS A DUAL POSITION CHUTE UNDER EACH BELT END POSITION, SO THAT A TOTAL OF
16 BINS CAN BE IN PLACE AT ONE TIME. SLUDGE BINS ARE THEN LOADED HYDRAULICALLY INTO TRUCKS AND
HAULED TO THE SANITARY LANDFILL AREA. ANOTHER PROBLEM WAS COLD WEATHER ICING ON THE SLUDGE LOADING
AREA* WHICH WAS SOLVED BY ENCLOSING THE AREA.
INSTRUMENTATION - ORIGINAL DESIGN PLANS CALLED FOR CONTROL BY THE MONITORING OF THE S03/S0«f
RATIO AND SODIUM ION CONCENTRATION. THE CONTROL RANGE WAS FOUND TO BE TOO SMALL AND THE PRESENT
APPROACH IS PH CONTROL (o.5) AND CLEANING OF THE PROBES EVERY OTHER DAY.
ORIGINAL DESIGN DID NOT MONITOR SOg CONCENTRATION BUT A COMPLETE MONITOR SYSTEM WAS INSTALLED
PRIOR TO THE 1977-78 SEASON.
PIPING - MODIFICATIONS HAVE BEEN MADE WHICH FACILITATE CLEANING OR SCHEDULED REPLACEMENT.
COMMENTS
4TH QUARTER-1977 CATERPILLAR HAS BEGUN A PROCEDURE OF DETAILED RECORD KEEPING, BUT THE FLOW OF
INFORMATION IS NOT YET SUCH THAT IT IS AVAILABLE TO THIS REPORT.
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP GATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
OPERATIONAL EXPERIENCE
FIRESTONE TIRE AND RUBBER CO.
POTTSTOWN* PENNSYLVANIA
2.5-3*0% SULFUR COAL
m»000 ACFM
3 MW (EQUIVALENT)
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
RETROFIT
JANUARY« 1975
OPERATIONAL
90S (1000 PPM AT INLET)
DEWATERED SLURRY TO LANDFILL
THE FGD SYSTEM AT FIRESTONE-POTTSTOWN CONSISTS OF
AN FMC DOUBLE ALKALI DUAL THROAT VENTURI SCRUBBER.
THIS S02 CONTROL SYSTEM WAS BUILT AS A DEMONSTRA-
TION PROJECT FUNDED BY FIRESTONE. THE SYSTEM OPER-
ATED WITH AN AVAILABILITY VALUE OF 91K IN THE FALL
QUARTER OF 1977. . THE MAJOR PROBLEM AREA IS
EROSION OF FAN AND SPRAY NOZZLES BY FLYASH. THIS
EQUIPMENT WILL BE REDESIGNED.
62
-------
BACKGROUND INFORMATION
FIRESTONE TIRE-POTTSTOWN, PAt
THE FlRFISTOnE TIRE AND RUBBER CO. LOCATED IN POTTSTGWN, PENNSYLVANIA HAS BEEN OPERATING SINCE
JANUARY 1975 AMD IS A DEMONSTRATION-SCALE PLANT DESIGNED TO TEST THE FEASIBILITY OF F6D ON INDUS-
TRIAL BOILERS. THE UNIT IS .DEMONSTRATING 90 PERCENT S02 REMOVAL EFFICIENCIES WITH A SYSTEM
AVAILABILITY CF 94 PERCENT AND A FLUE GAS CAPACITY OF 14,000 CFM OR EQUIVALENT OF 3.0 MW. THIS
FLOW REPRESENTS APPROXIMATELY 1/3 THE TOTAL OUTPUT OF ONE 100,000 LB/HR STEAM BOILERt THE SULFUR
DIOXIDE REGULATION THE PLANT IS 0.86 LBS/MILLIOiM BTU OF HEAT OUTPUT.
THL PLANT is USING THE CONCENTRATED DOUBLE ALKALI PROCESS PATENTED BY FMC CORPORATION. THE LOAD
CAPACITY OF THE. BOILER ON WHICH THE SCRUBBER IS OPERATING IS APPROXIMATELY 12 MW. IN OCTOBER 1976,
THE 8CILt.P. ml AS CONVERTED FROM BURNING RESIDUAL FUEL OIL (2.2% S) TO COAL (2.5-3.OS S).
THt VENTUH.I SCRUBBER IS SPRAYED WITH ALKALINE LIQUOR WHERE THE FLUE GAS ENTERS, THE FAN AND
DAMPER UPSTREAM OF VENTURI CONTROL THE FLUE GAS FEED. SCRUBBING LIQUOR FLOWS FROM THE VENTURI
TO THE buTTGFi OF CYCLONE DEMISTER AND THEN INTO THE RECIRCULATIGN TANK. DROPLETS OF SCRUBBING LIQUO
ART. SPUN OUT IN THE CYCLONE AND RUN BACK DOWN IN THE RECIRCULATION TANK. THE SCRUBBING LIQUOR IS
PARTLY RECIRCULATED TO THE VENTURI THUS COMPLETING THE SCRUBBING CYCLE. ACCUMULATION OF SOLUBLE
SODIUM BISULFITE IS PREVENTED BY CONTINUOUSLY DRAWING OFF A SMALL STREAM OF SCRUBBER SOLUTION TO
THE Lift REACTOK TANK WHERE THE SODIUM SULFITE REACTS WITH LIME TO FORM CALCIUM SULFITE AND SODIUM
HYDROXIDE WHICH IS RECYLCEQ TO THE ABSORBER. CALCIUM SULFITE SLURRY IS TRANSFERRED
TO THF ROTARY FILTER. THE FILTER CAKL FORMED (iso LBS/HR, 55 % SOLIDS) is HAULED TO THE LANDFILL.
THE WATER BALANCE IS MAINTAINED BY MAKING UP FOR THE LOSSES BY EVAPORATION AND IN THE FILTER CAKE,
DURlMG THE FIRST 12 MONTHS OF OPERATION THE SYSTEM EXPERIENCED UTILIZATION OF 9«* PERCENT, ALL
DOWNTIME WAS DUE TO COMPONENT FAILURE (PUMP PACKING) OR MAINTENANCE (FILTER CLOTH REPLACEMENT). NO
SHUTDOWNS OCCURED DUE TO SCALING, PLUGGING OR RELATED PROBLEMS, DURING THE FALL QUARTER OF 1977,
THE SYSTEM HAD AN AVAILABILITY OF 91 K. THE MAJOR PROBLEM AREA IS EROSION OF THE MILD STEEL
FAN AND THE 316 SS SPRAY NOZZLES BY FLYASH. SOME CONTROL VALVES ARE ALSO ERODED. THE COMPONENTS
WILL i>Y KFDESit.MED Ai-D REPLACED. THE PIPELINE FROI*. THE THICKENER TO THE FILTER GETS PLUGGED
FREQUENTLY AND fcEEDS CLEANING.
63
-------
FIRESTONE TIRE - POTTSTOWN, PA (CONTINUED)
FMC CORP. AND NORTHWESTERN UNIVERSITY PERSONNEL ARE STUDYING THE LEACHING AND STRENGTH CHARAC-
TERISTICS OF THE FILTER CAKE, WHEREAS UNITED ENGINEERS OF PHILADELPHIA ARE STUDYING THE OPERATING
COST DATA OF THE UNIT. RESULTS OF NEITHER STUDY ARE YET AVAILABLE.
COMMENTS
MON/YR AVAILABILITY<%)
JAN, 75 DURING THIS PERIOD THE BOILER BURNED RELATIVELY LOW SULFUR
THRU OIL. THE BOILER WAS CONVERTED TO BURN COAL (2.5-3.0 » S) FROM
SEP. 76 OCTOBER 1976 WHEN THE FLUE GAS SCRUBBING WAS STARTED.
OCT. 76 ALL DOWNTIME WAS DUE TO COMPONENT FAILURE OR MAINTENANCE.
THRU 94 SHUTDOWNS OCCURED DUE TO SCALING, PLUGGING OR
SEP. 77 RELATED PROBLEMS.
OCT. 77 THE MAJOR PROBLEM AREA IS EROSION OF THE MILD STEEL F.D, FAN
THRU 91 AND THE 316 SS SPRAY NOZZLES. THESE COMPONENTS WILL BE REDE-
DEC, 77 SIGNED. THICKENER UNDERFLOW PIPES REQUIRES FREQUENT CLEANING.
6
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
.INSTALLATION
INSTALLATION LOCATION
SOURCE. CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PARTICULATE EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CAPITAL
FMC (SODA ASH PLANT)
GREEN RIVERi WYOMING
COAL (1% SULFUR* b% ASH* IGtOOO BTU/LB)
660,000 ACFH & 320 F (TOTAL - 2 BOILERS)
200 m (EQUIVALENT)* TOTAL
FMC ENVIRONMENTAL EQUIPMENT
SODIUM SCRUBBING
NEW
MAY, 1976
OPERATIONAL
95S (800 PPM AT INLET)
REMOVED BY PRECEDING ESP (99.5ft)
OPEN LOOP* L/C = 15-20 GAL/1000 ACF
HOLDING POND FOR EVAPORATION
(MA2S03/SOH LIQUOR DISPOSED TO COLLECTION POND - NO PRIOR
AERATION, LANDFILL IN THE FUTURE
S 10.000 MILLION
CAPITAL COST INCLUDES ESP
65
-------
SECTION 12 - QESCRIPTION OF OPERATIONAL F6D SYSTEMS (CONTINUED) -
FMC (SODA ASH PLANT)
OPERATIONAL EXPERIENCE
THE F6D SYSTEM CONSISTS OF TWO FMC SODIUM SCRUB-
BING UNITS TO REMOVE SULFUR DIOXIDE AND PARTICU-
LATE MATTER FROM THE FLUE GAS OF TWO BOILERS.
SCRUBBER CORROSION HAS BEEN A PROBLEM. PLANT
PERSONNEL FELT THAT THE LINING WAS IMPROPERLY
APPLIED. FOAMING AND SEDIMENTATION HAS OCCURED
IN THE SCRUBBER DUE TO IMPURITIES IN THE LIQUOR.
-------
BACKGROUND INFORMATION
FMC SODA ASH PLANT - GREEN RIVER WYOMING
FMC CHEMICAL CORP, HAS A SODA ASH PLANT IN GREEN RIVERf WYOMING, THE PLANT HAS TWO COAL-FXRED
POWER bOlLERS WHICH BURN 1.1 PERCENT SULFUR COAL. THE FLUE SAS FROM EACH BOILER <330»OOQ ACFM AT
320 F) U HEATED 8Y A HOTSIOE ESP WITH 286 PLATES AND A PARTICULATE REMOVAL EFFICIENCY OF 99.5 8.
THE. FLUE bASES ARE SCRUBBED BY THE PLANT END-LIQUOR IN TWO SCRUBBERS, EACH WITH THREE PAIRS OF
UISC-AND-DOtoUT TRAYS. THE SCRUBBERS AND THE DISCS ARE LINED WITH CEILCOTE 103 WHEREAS THE OONUT
PARTS OF THE TRAYS ARE MADE FROM INCONEL 625. THE SCRUBBER LIQUOR IS MAINTAINED AT A PH OF 6,5 AND
IS RECIRCL'LATL'O AT A RATE OF 10 - 15 GALLONS/1000 ACF OF FLUE GAS. A PART OF THE RECIRCULATING
LIOUOR IS CONTIGUOUSLY PURGED TO REMOVE SULFITES AM3 SULFATES FORMED BY THE REACTION OF S02 WITH
SOOA ASH. ThL KEciKCULATINli PUMPS AND THE RELATED PIPING IS RUBBER LINED. A MESH TYPE DEMISTER IS
USEL IK FACH SCRUBBER. THE GASES ARE REHEATED BY DIRECT FIRING OF NATURAL GAS AT THE EXIT OF THE
SCRUBBERS. THF_ REHEATED FLUE GAS IS MIXED WITH BYPASSED GAS BEFORE GOING TO THE STACK AT ABOUT
IfcO F.
AUTOMATIC CONTROLS MAINTAIN SOLUTION LEVEL IN THE SCRUBBER BASIN. THE PRIMARY SOURCE OF WATER
f'.AKL-L'p IS PROCESS wASTEtoATER i«HlCH IS CHANNELED TO A MAKE-UP TANK, IF MORE MAKE-UP IS REQUIRED*
RIVLK WATER IS TAPPED. THE SCHU8BEK aLEED STREAM IS DISCHARGED TO A WASTE ,POND AT THE SITE.
DAlv!Pt-RS WITH KF.hOTL CONTROLS REGULATE THE FLOW OF OFF GAS THROUGH AIMO AROUND THE SCRUBBERS.
APPKOXJiv;«iT£LY su26 OF TOTAL FLUE GAS IS RUN THROUGH THE SCRUBBERS.
COMMENTS
3RD GUARTER-1977 SOME PROBLEMS HAVE OCCURRED WITH THE SCRUBBER LINING AS A RESULT OF FAULTY
INSTALLATION, THE: POSSIBILITY OF RUNNING THE SYSTEM WITH NO REHEAT IS BEING INVESTIGATED.
<+TH fciUAFUEK-1977 THE SCRUBbtKS HAVE CORRODED AS A RESULT OF FAULTY INSTALLATION OF THE LINING.
THL" IMPURITIES IN THE SCRUBBING LIQUOR CAUSE FOAMING AND SEDIMENTATION ON THE TRAP.
67
-------
SECTIGiM 12 - DESCRIPTION OF OPERATIONAL FGQ SYSTEMS
INSTALLATION
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
SOURCE; CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP CATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PARTICIPATE EFFICIENCY
WATER MAKE-UP
SLUDGE CR oY-PKODUCT DISPOSAL
CONTROL SYSTEM COST
CAPITAL
GENERAL ROTORS CHEV. MOTOR DIV
TONOWANDA, NEW YORK
COAL (1.3% S* 9S'o ASH* 12*500 BTU/LB)
132.700 SCFM 8 70 F (TOTAL - f BOILERS)
340,000 LB/HR STEAM (TOTAL)
32 PtW (EQUIVALENT)* TOTAL
FMC ENVIRONMENTAL EQUIPMENT
SODIUM SCRUBBING
RETROFIT
JUNE. 1975
OPERATIONAL
90*>-95$& (1.000 PPM a INLET)
90ft (1.0 LB/IW BTU AT INLET)
OPEN LOOP
DEWATERED SLURRY TO LANDFILL
FLY ASH AND NA2S03/S01* WASTE LIQUOR DEWATERED AND THEN TO
SANITARY LANDFILL
$ 2,000 MILLION
CAPITAL COST IS IN 197<+ DOLLARS.
-------
SECTION i£
OPERATIONAL EXPERIENCE
FGD SYSTEMS (CONTINUED) -
THE FGD SYSTEM CONSISTS OF FOUR GM SODIUM SCRUB-
BING UNITS FOR THE REMOVAL OF PARTICULATES AND
SULFUR DIOXIDE FROM FOUR COAL-FIRED BOILERS.
THE SCRUBBERS ARE EQUIPPED WITH VENTURI SCRUBBERS
FOR PARTICULATE REMOVAL. UNSTABLE PH CONTROL* •
PIPE EROSION AND STACK CORRISION ARE MAIN PROBLEM
AREAS. REPLACEMENT OF CONTROL SENSORS, PIPING
AND RELINXNG OF STACK ARE THE CORRECTIVE ACTIONS.
69
-------
BACKGROUND INFORMATION
GENERAL MOTORS CORP., TONOWANDA, N,Y.
THE CHEVROLET DIVISION OF GENERAL MOTORS HAS A MOTOR PRODUCTION PLANT AT TONAWANDA, NEW YORK.
ThEKEl ARE
-------
6ENE1NAL rIOTORS - TONOwANOA. NEW YORK (CONTINUED)
COMMENTS
3RD iJUARTE«-1977 AVERAGE OPLRABILITY DURING THIS PERIOD WAS REPORTED TO BE 100K.
4TH JUARTER-1977 MAJOR PROBLEMS HAVE BEEN PH CONTROL AMD RECYCLE PIPE EROSION, CONTROL
SENSORS/MODULATING MIXER VALVE REPLACED FOR PH CONTROL AND CAST IRON PIPE WAS USED TO
REPLACE 3S RECYCLE PIPING. DURING h)QV - DEC CONDENSATION FOLLOWING THE DEMISTER
HAS CORRODED THE STACK LINING. A DECISION HAS BEEN MADE TO RELINE THE STACK.
71
-------
SECTIUM 12 - DESCRIPTION OF OPERATIONAL
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PR.OCESS
fMEU< / RETROFIT
START-UP QATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PARTICULAR EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CAPITAL
OPERATING
F6D SYSTEMS
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
COAL (3*2% SULFUR* 10% ASH)
100,000 ACFM oi 370 F
25 FiW (TOTAL - 2 BOILERS)
AtD. LITTLE
SODIUM SCRUBBING
RETROFIT
1972
OPERATIONAL
90 + SiS (2000 PPM a INLET)
REMOVED BY PRECEDING CYCLONE AND ESP
OPEN LOOP
WASTEWATER TREATMENT AND DISCHARGE TO CITY SEWER
NA2S03 OXIDIZED TO IMA2S04, PH NEUTRALIZED AND DISCHARGED TO
CITY SEWER SYSTEM
$773,000.
5172,000.
CAPITAL COST IS IN 1972 DOLLARS
72
-------
SECTION 13 - DESCRIPTION OF OPERATIONAL F6D SYSTEMS (CONTINUED) -
GENERAL MOTORS CORPORATION
OPERATIONAL EXPERIENCE
THIS S02 CONTROL SYSTEM CONSISTS OF TWO GM DE-
SIGNED SODIUM SCRUBBING UNITS OPERABLE ON TWO OF
FOUR COAL-FIRED BOILERS, DURING THIS REPORT PER-
IOD* STACK CORROSION HAS BEEN THE MAIN PROBLEM.
PLANS ARE BEING MADE TO RELINE THE STACK IN THE
NEAR FUTURE. THE SYSTEM IS PROVIDED WITH BYPASS
AND 60 F REHEAT.
73
-------
BACKGROUND INFORMATION
GENERAL MOTORS CORR.i ST. LOUIS, MO,
THE GENERAL MOTORS CORPORATION PLANT LOCATED IN ST. LOUIS, MISSOURI OPERATES f COAL-FIRED BOIL-
FIRS. TWO BOILERS, WHICH ARE RATED AT A TOTAL OF 25 MW (EQUIVALENT) AND HAVE A TOTAL STEAM GENERA-
TION CAPACITY OF 250»000 LB/HR, ARE EQUIPPED WITH SCRUBBERS. COAL COMPOSITION IS TYPICALLY 3.2*
SULFUR AMD 10% ASH. SULFUR DIOXIDE CONCENTRATION IS APPROXIMATELY 2100 PPM AT THE INLET TO EACH
SCRUBBER. CYCLONES AND ESP»S ARE USED FOR PARTICULATE REMOVAL PRIOR TO S02 REMOVAL IN A 3-STAGE
XKPlNGtPiENT TOWER WITH A CHEVRON MIST ELIMINATOR. DIRECT REHEAT IS ACCOMPLISHED WITH STEAM COILS
THE FGD SYSTEH IS CONSTRUCTED OF 316L STAINLESS STEEL,
COMMENTS
3RD QUARTER-1977 AN OPERABILITY OF 100% WAS REPORTED DURING THE MAY-AUGUST PERIOD,
4.TH UUARTER-1977 IN SPITE OF A CHEVRON DEMISTER AND 60 F REHEAT, THE STACK LINER IS EXPERIENCING
CORROSION ATTACK. THE STACK WILL REQUIRE RELINING IN THE NEAR FUTURE.
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NrtMt
INSTALLATION LOCATION
SOURCE. CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
COiMTRut SYSTEM
COiXTROL PKOCf-SS
MEW / RETKuFlT
START-UP OnTF.
COMTRUi. SYSTEM
S02 EFI-ICIfMCY
PARTICULATE i FF
!"U>KL-UP
SLUDGt CW tJY-PKODUCT DISPOSAL
CONTROL. SYSTEM COST
CAPITAL
GENERAL MOTORS PAHMA
PARMA, OHIO
COAL (2.5?* SULFUR* 7.1% ASH* 13,350 BTU/LB)
128,100 SCFM S 70 F (TOTAL - f BOILERS)
320,000 LB/HR STEAM (TOTAL)
32 MW (EQUIVALENT)* TOTAL
GM ENVIRONMENTAL
DOUBLE ALKALI (DILUTE)
RETROFIT
MARCH, 1974
OPERATIONAL
90?6 (800-1300 PPM a INLET)
83SS (AT INLET* UNITS 1&2 - 1.75 LB/MIN* UNITS 3&t - 1,22
LB/MIN)
CLOSED LOOP
DEWATERED SLURRY TO LANDFILL
50 + X SOLIDS (CAS03/S04) SLUDGE TO DRYING POND AND LANDFILL
$ 3,200 MILLION
OPERATING COSTS ARE $6H3,bOO/YR a 55,000 TPY OF COAL
-------
SECTION
gr^CRIPTlO^OFAOPERATlONAL F6D SYSTEMS (CONTINUED) -
OPERATIONAL EXPERIENCE
THE FGD SYSTEM CONSISTS OF A GM DESIGN DOUBLE
ALKALI SCRUBBER OPERATIONAL OM H BOILERS, THE
SCRUBBERS HANDLE A TOTAL 2^0tOOO ACFM OF FLUE GAS.
THE SCRUBBERS HAVE BEEN OPERATIONAL SINCE MARCH
1974. THE SYSTEM DEVELOPED MIST ELIMINATOR
PROBLEMS DURING THIS HLPORT PERIOD. AT THE TIME
OF THIS REPORT, A SATISFACTORY SOLUTION HAD NOT
YET BEEN FOUiMD.
76
-------
BACKGROUND INFORMATION
GENERAL MOTORS - PARMA, OHIO
THE CHEVROLET PARMA PLANT OF GENERAL MOTORS IS LOCATED NEAR CLEVELAND, OHIO. THE PLANT HAS FOUR
SPREADER-STOKER f?QILE.RS FIRED BY TRAVELING GRATES, CAPABLE OF PRODUCING A TOTAL OF 320,000 LB/HR OF
STEAM OR APPROXIMATELY 32 MW OF EQUIVALENT ELECTRICAL CAPACITY. THE COAL FIRED IN THESE UNITS
ORIGINATES PRIMARILY FROF1 THE SOUTHEASTERN PORTION OF OHIO AND HAS THE FOLLOWING AVERAGE
CHARACTERISTICS- HEAT CONTENT OF 11,300 BTU/LB, SULFUR CONTENT OF 1,7 TO 2,7 PERCENT,
ASH CONTENT OF 6.8 TO 14.8 PERCENT, AND A TOTAL MOISTURE CONTENT OF 0.9 TO 7.8 PERCENT.
THE POWEK BOILERS HAVE BEEN FITTED WITH AN EMISSION CONTROL SYSTEM CONSISTING OF MECHANICAL
COLLECTORS UPSTREAM OF A DILUTE DOUBLE ALKALI SCRUBBING SYSTEM, THE FGD SYSTEM SCRUBBING MODULES
WERE SUPPLIED BY KOCH ENGINEERING. INSTALLATION WAS COMPLETED ON FEBRUARY 28, 1974. THE SYSTEM
CONSISTS OF FOUR SCRUBBEHS OPERATING IN PARALLEL. EACH SCRUBBER CONTAINS THREE BUBBLE-CAP
ABSORPTION TRAYS AMD A MESH MIST ELIMINATOR. THE FLUE GAS RATE IS 61,500 ACFM AT 393 F FOR EACH OF
THE FIRST TWO SCRUBBERS AND THE OUTLET TEMPERATURE IS 137 F. THE INLET S02 CONCENTRATION IS 765
PPM, THE FLUE GAS FLOW RATE IS 58,600 ACFM AT 550 F FOR THE OTHER TWO SCRUBBERS AND THE OUTLET
TEMPERATURE IS 152 F, THE INLET S02 CONCENTRATION IS 720 PPM. THE OUTLET S02 CONCENTRATION VARIES
BETWEEN 76 - 36 PPM FOR THE SCRUBBERS.
THE SULFUR DIOXIDE CONTAINED IN THE BOILER FLUE GAS IS ABSORBED 8Y A REGENERATED CAUSTIC
SOLUTION (0.1 MOLAR NAOH), FORMING A SOLUTION OF SOLUBLE SODIUM SALTS. THE SPENT CAUSTIC IS THEN
REGENERATED BY REACTING THE SODIUM SALT SOLUTION WITH SLAKED LIME, RESULTING IN THE FORMATION OF
CALCIUM SULFITE AND SULFATE SOLIDS, WHICH ARE SEPARATED OUT OF THE SOLUTION. NEXT, SODA ASH IS
ADDED TO THE SOLUTION IN ORDER TO MAKE UP FOR SODIUM LOSSES AND MINIMIZE THE SCALE POTENTIAL FROM
THE CALCIUM WHICH REMAINS IN SOLUTION. THE REGENERATED CAUSTIC FORMED IS THEN RECYCLED BACK TO THE
SCRUBBER FOR ADDITIONAL SULFUR DIOXIDE REMOVAL, THE CALCIUM SALT AND FLY ASH SLUDGE WHICH RESULTS
IS DEWATERED AND HAULED AWAY BY TRUCK TO AN OFF-SITE LANDFILL,
77
-------
GENERAL MOTORS - PARMA* OHIO (CONTINUED)
EQUIPMENT SPECIFICATIONS
SCRUBBERS. EACH OF THE «t SCRUBBERS is 10.5 FT DIA x 22.5 FT HIGH x 11 GAUGE THICK AND CONTAINS 3
BUBbLE-CAP TRAYS. ALL THE SCRUBBERS AND TRAYS ARE MADE OF 316 L SS. THE SCRUBBERS HAVE A TURNDOWN
RATIO OF 3 AHG ALSO HAVE A BYPASS DUCT. THE L/G RATIO HAS A DESIGN VALUE OF 20 GALLONS/ACF BUT IT
MAY r»E VARIED DURING OPERATION. THE PRESSURE DROP ACROSS THE SCRUBBER RANGES BETWEEN e-9 INCHES we.
OF.MISTLKS. ORIGINAL 316 ss DEMISTERS, WERE CORRODED DUE TO CONDENSATION AND ARE REPLACED BY FLEXI-
MtSh TYPC POLYPROPYLENE ONES.
RFCYCLE TANKS/PUMPS. ALL THE <+ RECYCLE TANKS ARE WILD STEEL WITH TAR TYPE RESIN COATING. THE PUMPS
(TOTAL 6, 2 SPAKE) ARE CENTRIFIGALS WITH MILD STEEL CASING AND HAVE RUBBER LINING. THE PUMP MOTORS
HAVE 40 H.P.
CHEMICAL MIX TANKS & AGITATORS. BOTH THE MIX TANKS ARE MILD STEEL WITH 5000 GALLONS CAPACITY. THE
DESIGN RESIDENCE TlFiE IS 7 MINUTES. NEW AGITATORS ARE PROPELLER TYPE. THESE ARE SPECIALLY DESIGNED
TO GIVE HIGHER FLOW RATE THROUGH THE BLADES. THE DRIVE RATINGS ARE 5 HP AND 45 RPM.
CLAUIFIERS. BOTH THE CLAKIFIERS (60 FT DIA X m FT LIQUID DEPTH) HAVE A CONICAL BOTTOM AND 300,000
GALLONS CAPACITY. THE DESIGN RETENTION LINE IS ABOUT 1 HOURS AT FLOW RATE OF 1200 GPM.
VACUUM FILTERS. BOTH THE VACUUM FILTERS HAVE 500 SQ. FT. SURFACE AREA WITH 10 FT DRUM DIAMETER. THE
DRUK DRIVE SPEED IS O.b RPM MAXIMUM*
FILTRATE TANK/PUMPS. THE TANK (f FT DIA X 7 FT HIGH) IS MILD STEEL AND HOLDS 660 GALLONS OF
FILTRATE.. THE PUMPS AKfc! MILD STEELi CENTRIFIGAL AMD HAVE A CAPACITY OF 300 GPM AT 15 FT, OF HEAD.
PROBLEMS AND SOLUTIONS
THE SYSTEM MS STARTED UP ON FEBRUARY 28, 1974 AND BY APRIL 31 IT HAD OPERATED FOR 26«f HOURS,
THERE WERE TWO SCHEDULED SHUTDOWNS DURING THIS PERIOD FOR EQUIPMENT INSPECTION, THE SECOND SHUTDOWN
REVEALED THAT SOLIOS WERE NOT BEING DISCHARGED FROh THE PRIMARY CLARIFIER RAPIDLY ENOUGH.
AS A RESULT, THE CLARIFIER RAKE JAMMED, A PIPING CHANGE WAS MADE TO BLEND THE CAUSTIC FEED
DM WITH THE RECYCLE LIQUOR, THIS HAS IMPROVED PERFORMANCE BUT NOT COMPLETELY ELIMINATED
THE PROBLEM. PREMATURE CAKE CRACKING IN THE VACUUM FILTERS REQUIRED THE PRESENCE OF AN OPERATOR
78
-------
GENERAL MOTORS - PARMA, OHIO (CONTINUED)
DURING OPERATION!, G.M. ANTICIPATES THAT THE CHANGE TO NYLON FROM POLYPROPYLENE WILL SOLVE THIS
PROBLE.M. CAKL WASHING TO REDUCE LOSSES WAS NOT INITIALLY SUCCESSFUL BECAUSE THE SPRAY WATER
TENDED TO KNOCK THE CAKE OFF THE DRUM. ALTERATIONS IN SPRAY PATTERN AND OTHER MEASURES HAVE
APPARENTLY SOLVED THIS PROBLEM. THERE HAS BEEN NO EVIDENCE OF CORROSION OR ABRASION IN THE PUMPS
OR PIPING.
THE SYSTEM WAS SHUT DOWN FROM MAY 1 TO MAY 28, 197H, BECAUSE OF UNEXPECTED BUILDUP OF SOLIDS IN
THE CLARIFIER, WITH SUBSEQUENT OVERFLOW INTO THE SCRUBBER. THE PROBLEM WAS SOLVED BY I) USING
A POLYMERIC FLOCCULATION AGENT TO ATTAIN BETTER SETTLING ANO 2) WITHDRAWING SLUDGE FROM THE
CLARIFIED AT MORE FftEuUENT INTERVALS. SYSTEM AVAILA3ILITY TO THE BOILER WAS 87 PERCENT IN APRIL
1974, LESS THAN 10 PERCENT IN MAY, AND 100 PERCENT IN JUNE, JULY, AND AUGUST AFTER THE SYSTEM WAS
RESTARTED. PLUGGING BY GYPSUM DEPOSITS IN THE OVERFLOW LINE BETWEEN THE CLARIFIERS AND IN THE
LINE FK01 CLARIFIER NO. 2 TO THE MIX TANKS WAS CORRECTED BY RELOCATING A CHEMICAL FEED LINE AND
REPLACING SO*L PIPING. THE SYSTEM WAS DOWN THROUGH JULY AND AUG. 1975 FOR REPLACEMENT OF GRAVITY
FLO', LINES WITH Ah OPE:, FLUME THAT CM BE EASILY CLEANED. ADDITIONAL MODIFICATIONS TO THE DESIGN
AMU OPERATION UF THE." F6D SYSTEM HAVE CONTINUED. THE OPERABILITY INDEX FOR THE FGD SYSTEM HAS
INCREASED SI<™IFICANTLY THROUGHOUT THE COURSE OF 197*. THE MAJOR PROBLEM AND SOLUTION AREAS,
PLUS ^DIFICATICMS IMPLEMENTED TO THE SYSTEM ARE HIGHLIGHTED BELOW IN THE SYSTEM PERFORMANCE TABLE
-------
GENERAL
MOTORS - PARMA, OHIO (CONTINUED)
OPERATION HOURS
BOILER FGD SYSTEM OPERABILITY
-------
GENERAL MOTOHS - PARMA, OHIO (CONTINUED)
OPERATION HOURS
MONTH BOILER FGD SYSTEM OPERABILITY
JAN, 76
FEB. 76 2997 1196 40
MAR. 76 1379
240
APR, 76 1084
647
78
MAY 7b 1149
JUN. 76
1042
616
91
68
JUL. 76 599
AUG. 76 715
599
715
100
100
COMMENTS
G.n. HAS FOUND SOLIDS CONCENTRATION IN THE CLARIFIER
TOO HIGH FOR EFFICIENT SYSTEM OPERATION. A.D. LITTLE
is SCHEDULED TO CONDUCT TESTS ON THE SYSTEM IN APRIL 76
AS PART OF AN EPA EVALUATION PROGRAM.
THE LOW OPERABILITY INDEX DURING THE MONTH OF MARCH RE-
SULTED FROM EXTENSIVE MODIFICATIONS PERFORMED ON THE
SYSTEM BY G.n* DURING THIS PERIOD THE SCRUBBER BLOW-
DOWN AND SCRUBBER FLOW INDICATION SYSTEM WAS REVISED.
FROM APRIL 19 TO THE END OF THE MONTH THE SYSTEM WAS
OPERABLE 100%. DURING THIS PERIOD ALL SYSTEF1 MODlFlCA«
TIONS WERE COMPLETED AND ALL MAJOR PROBLEM AREAS COR-
RECTED.
NO MAJOR PROBLEMS WERE ENCOUNTERED DURING THE REPORT-
ING PERIOD.
ONE SYSTEM UPSET OCCURRED DURING THE PERIOD DUE TO AN
OPERATOR ERROR. BOILER HOURS WERE LOW IN JUNE BECAUSE
OF LOW PROCESS DEMAND. THE SCRUBBING SYSTEM CHARACTER-
IZATION STUDY WAS CONCLUDED ON MAY 14» 1976.
THE BOILER LOAD DEMAND WAS VERY LIGHT DURING THE REPORT
MONTHSt REQUIRING ONLY ONE BOILER BEING CONTINUOUSLY ON
LINE. THE SYSTEM WAS DOWN FOR A ONE-WEEK PERIOD
BECAUSE OF THE ANNUAL PLANT INVENTORY.
61
-------
GENERAL - PARMA, OHIO (CONTINUED)
OPERATION HOURS
MONTH BOILER FGO SYSTEM OPERABILITY (8) COMMENTS
MODIFICATIONS TO THE OPERATION OF THE GAS SCRUBBING
SYSTEM HAVE INCLUDED*
ELIMINATION OF POLYMERIC ADDITION.
ELIMINATION OF SLUDGE BLANKET FOR FILTRATION.
HIGH PERCENT SLJLFATE CONCENTRATION IN THE FILTER
CAKE.
INCORPORATION OF PH CONTROLLER IN THE CHEMICAL MIX
TANK REGULATING THE LIME FEED INTO SYSTEM,
PH CONTROL SHOULD REDUCE THE STOICHIOMETRIC
REQUIREMENTS FROM THE 1.25-1,50 RANGE DOWN
TO 1,10-1.20.
SEP. 7b 809 223 40 TWO BOILERS AND THEIR CORRESPONDING SCRUBBER MODULES
WERE IN SERVICE DURING THE MONTH. OPERATION TIME WAS
LODGED PRIMARY IN THE INITIAL PART OF THE MONTH. A
NUMBER OF PROBLEMS WERE ENCOUNTEREDt FORCING A SHUTDOWN
THROUGHOUT THE REMAINDER OF THE MONTH, THESE INCLUDED*
SOLIDS DEPOSITION AND PLUGGING OF THE CHEMICAL
TANKS AND REACTORS, REQUIRING SHUTDOWN AND CLEAN-
OUT,
AGITATOR PROBLEMS,
BOILER PROBLEMS.
REPLACEMENT OF DEMISTER PADS.
S3
-------
GENERAL rtOTOHS - PARMA, OHIO (CONTINUED)
OPERATION HOURS
MC.MTH BOILER FGD SYSTEK OPE.KABILXTY
OCT. 7b 1174 731 63
r'OV. 76
DEC. 76
1321
1559
767
60
22
COMMENTS
THE SYSTEM WAS RETURNED TO SERVICE THE SECOND WEEK IN
OCTOBER. TWO BOILERS AND THEIR CORRESPONDING SCRUBBERS
WERE PUT BwCK IN THE GAS STREAM, PROBLEMS ENCOUNTERED
STEMMED PRIMARILY FROM A NLCHANICAL COLLECTOR MALFUNC-
TION, RESULTING IN EXCESSIVE DUST LOADINGS IN THE MOD-
ULES AND EVENTUALLY CAUSING WIDESPREAD PLUGGING OF THE
LOWER HUBBLE-CAPE TRAYS. SHUTDOWN AND CLEANOUT OF MOD-
ULES PLUS REPAIRS TO THE MECHANICAL COLLECTOR WERE RE-
QUIRED. SYSTEM RESTART OCCURRED NOVEMBER 8,
MAJOR MODIFICATIONS PERFORMED TO THE DOUBLE ALKALI
SYSTEM CURING THE PERIOD INCLUDED THE INSTALLATION OF
A GREAT LAKES PH MONITOR AND CONTROL UNIT FOR THE REG-
ULATION OF LIME FEED TO THE REGENERATION REACTOR-CLARI-
FIER UNIT. THIS UNIT EMPLOYS A DIGITAL READOUT AND IS
SCHEDULED FOR OPERATION SOMETIME IN NOVEMBER.
SUPERIOR CRYSTAL GROWTH OF THE CALCIUM SULFITE/SULFATE
SALTS HAS RESULTED BY RUNNING A SEEDING LINE BACK TO
THE REACTOR-CLAfUFIER UNIT.
DURING THE LATTtlR PART OF NOVEMBER AND EARLY DECEMBER,
THE SCRUBBERS WERE TAKEN OUT OF THE FLUE GAS PATH BE-
CAUSE OF CONTINUED SOILDS BUILDUP IN THE MIX TANK. IN
ADDITION, SOME PIPING ARRANGEMENTS WERE MODIFIED AND
-------
GENEKAL MOTORS - PARMA, OHIO (CONTINUED)
OPERATION HOURS
MONTH BOILER FGD SYSTEM OPLRABILITY (X)
JAN, 77 1852
FEB. 77 1462
APR, 77 1300
MAY 77 1222
JUN, 77 1160
JUL. 77 702
AUG. 77 755
SEP. 77 764
607.5
891,8
1158,3
ma
1103
276
678
480
32.6
61.0
89,1
91.5
93.5
39.3
71.2
COMMENTS
THE GEAR REDUCEK IN THE MIX TANK HAD TO BE REPLACED.
THE FGD FIGURES REPORTED FOR THE MONTH OF DECEMBER ARE
NOT FULLY REPRESENTATIVE BECAUSE IT IS PART OF THE
LOCAL UAto CONTRACT THAT ONLY UAW PERSONNEL CAN OPERATE
THE FGD SYSTEM AND THEREFORE THE SCRUBBERS COULD NOT
BE OPERATED.
TANK BROKE DOWN, THE AGITATORS ON BOTH THE TANKS WERE
REPLACED BY NEW AND LONGER ONES.
THE PLANT WAS SHUTDOWN FOR SOME PERIOD DUE TO CUTBACK
OF NATURAL GAS SUPPLY AND REQUEST TO CURTAIL ELECTRICAL
CONSUMPTION.
NEW AGITATORS IN THE MIX TANKS, THESE ARE EXPECTED TO
ALLEVIATE SOLIDS PLUGGAGE PROBLEMS,
BOILER HOURS ARE LESS DUE TO LOWER LOAD IN SUMMER,
FGD SYSTEM HAS GIVEN VERY HIGH OPERABILITY.
THE FGD SYSTEM WAS DOWN FOR A CONSIDERABLE PORTION OF
THIS MONTH, THE CHEMICAL MIX TANK BLEED OFF LINES AND
OTHER PIPING HAD TO BE CLEANED OF SEOIMENTED SOLIDS.
DURING THIS LOW-LOAD PERIOD THE LIME FEED PUMP AND
LIME FEED LINES WERE CLEANED. GENERALLY* EVERY SUMMER
ANNUAL OVERHAUL IS CARRIED OUT.
-------
GENEKAL MOTORS - PARMAt OHIO (CONTINUED)
OPERATION HOURS
MONTH 30ILEK FGD SYSTEM OPERABILITY (%)
OCT. 77 1277
396
31.2
NOV. 77
DEC. 77
138U
1790
920
966
66.7
COMMENTS
THE CHEMICAL MIX TANK AGITATORS WERE TOTALLY REDESIGNED
AND REPLACED BY HIGH-C STEEL, PROPELLER TYPES, THE
BLADES ARE SPECIFICALLY DESIGNED TO INCREASE THE FtOW
THROUGH THE PROPELLERS, THUS INCREASING THE INTENSITY
OF MIXING,
DUE TO THANKSGIVING HOLIDAYS IN NOVEMBER AND CHRISTMAS
AND NEW YEAR HOLIDAYS IN DECEMBER, THE FGD SYSTEM HAD
LOWER OPERATION HOURS. SOME OF THE BOILERS HAD TO BE
RUN FOR BUILDING MAINTENANCE.
85
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEF! STATUS
S02 EFFICIENCY
PARTICULATE EFFICACY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CAPITAL
OPERATIONAL EXPERIENCE
GENERAL MOTORS TRUCK & COACH
PONTIAC, MICHIGAN
COAL (0,8158 SULFUR* 8.558 ASH* 12t500 BTU/LB)
ALSO WOOD, PAPERf AND CARDBOARD.
107*300 SCFM S 70 F (TOTAL - 2 BOILERS)
**0 MW (EQUIVALENT)* TOTAL
PEABODY ENGINEERING
SODIUM SCRUBBING
NEW
APRILt 1976
SYSTEM OPERATED TWO MONTHS IN EARLY 1973.
OPERATIONAL
NOT DETERMINED
85%
50 GPM
DEWATERED SLURRY TO LANDFILL
59$ SOLIDS SLURRY QEwATERED AND TO LANDFILL
$600tOOO.
CAPITAL COST IS IN 1972 DOLLARS
THE SCRUBBER SYSTEM CONSISTS OF TWO G,M, SODIUM
UNITS FOR THE REMOVAL OF FLYASH AND SULFUR DIOXIDE
FROM THE FLUE GAS OF TWO COAL-FIRED BOILERS.
PLANT HAS BEEN EXPERIENCING FLYASH ABRASION IN
PUMPS AND PIPING.
86
-------
BACKGROUND INFORMATION
G.M.C. TRUCK & COACH PLANT - PONTIAC, MICHIGAN
THE. G.M.C. TRUCK AND COACH PLANT LOCATED AT PONTIAC, MICHIGAN OPERATES TWO 6.H. SODIUM
SCRUBBING SYSTEMS CONSTRUCTED BY PEABODY EQUIPMENT. TWO BOILERS ARE INVOLVED* NO. 61 RATED 3
150,000 LB/HR STEAM AND NO. 6, RATED ou 200,000 LB/HR STEAM. EMISSIONS FROM THESE TWO BOILERS ARE
CONTROLLED BY tvlECHAMCAL COLLECTORS AND THREE-STAGE TRAY SCRUBBERS. ALL SCRUBBER INTER-
NALS ARE 316L SS, THE MODULES WERE INSTALLED PRIMARILY FOR PARTICULATE CpNTRQLi BUT SIGNIFICANT
S02 CONTROL IS EFFECTED 8Y THE ADDITION OF SODIUM HYDROXIDE IN THE HOLD TANK, THE NEUTRALIZED
SCRU3BLR EFFLUENT IS THEN PUMPED TO A CLARIFIER AND RECYCLED TO THE SCRUBBERS. SCRUBBER EFFLUENT
COMPRISES FLYAbht SODIUM SULFITE, BISULFITE, AND SULFATE. DEWATERED SLUDGE IS LANDFILLED.
CONTROL OF Ph AND WEAK OH MECHANICAL EQUIPMENT HANDLING THE FLY ASH SOLUTION WERE MAJOR START-
UP PUObLtMS.
COMMENTS
3RD 'JUAKTER-1977 SOhL PROBLEMS WITH PUMPS EXIST. NO OTHER MAJOR DIFFICULTIES HAVE OCCURRED.
<+TH yUARTER-1977 DURING THE. SEPTEMBER-DECEMBER REPORT PERIOD, THE ONLY PROBLEMS REPORTED WERE
FLYA3H AdRASlOi! IN THE PUMPS AND PIPING,
87
-------
SECTIC-J 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHAKACTEKISTICS
SOUKCL K
SOURCE CAPACITY
CONTROL SYSTEh
COIMTKUL PKUCf-SS
NEW / RETROFIT
START-UP UATL
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PARTICULAR EFFICIENCY
WATER MAKE-UP
SLUDGE OR ^Y -PRODUCT DISPOSAL
CONTROL SYSTLPi COST
CAPITAL
GENERAL MOTOHS/DELCO MORAINE
DAYTON, OHIO
COAL (0.7-1.3K SULFUR* 5-9.5Si ASH* 13i400 BTU/LB)
55if(+0 SCFP1 o) 7U F (TOTAL - 2 BOILERS)
120,000 LB/HR STEAM (TOTAL)
2** MW (EQUIVALENT)* TOTAL
ENTOLETERt INC.
SODIUM SCRUBBING
RETROFIT
SEPTEMBER, 1974
OPERATIONAL
80fc (1.43 LB/MM BTU & INLET)
65?o (0.4 LB/MM BTU AT INLET)
50 6PM
UASTEWATER TREATMENT AND DISCHARGE TO CITY SEWER
NA2S03/S04 LIQUOR AT 35 GPN TO ON-SITE CLARIFICATION AND
DEWATERING FACILITY
$666,000.
88
-------
SECTZO,, 12
FGD srsTEHS (CONTINUED) -
OPERATIONAL EXPERIENCE
THE FGD SYSTEM CONSISTS OF TWO GM SODIUM SCRUB-
BING UNITS ON 2 COAL-FIRED BOILERS, THE UNITS
HAVE BEEN OPERATIONAL SINCE SEPTEMBER 197**. THE
SCRUBBERS REMOVE SULFUR DIOXIDE AND PARTICULATE
MATTER FROM A TOTAL GAS VOLUME OF 45*000 ACFM AT
fOO DEGREES F. AVERAGE OPERABILITY OF THE SYSTEM
IS 9558.
-------
BACKGROUND INFORMATION
G.M.C./DELCO MORAINE - OAYTONt OHIO
THE FGD SYSTLM AT THE G.M.C. OELCO MORAINE PLANT IN OAYTON, OHIO CONTROLS FLYASH AND SULFUR
UIOX1DE EMISSIONS FROM TWO STOKER-FED, COAL-FIRED BABCOCK & WILCOX BOILERS INSTALLED IN 1954.
THE BOILtlRS ARE RATED AT 60, QUO LBS/HR STEAM AND BURN 3 TONS OF COAL PER HOUR MAXIMUM. THE SCRUBBERS
ARE. CCiJSTPUCTLO OF 316L STAINLESS STEEL AND WERE DESIGNED TO HANDLE A TOTAL GAS FLOW RATE OF
45,000 ACFM AT A TEMPERATURE UF 100 DEGREES F.
oCRUbBER UNDERFLOW CONSISTS OF FLYASH AND SODlUh SULFITE/BISULFITE SOLUTION. THE SLUDGE IS
PROLjCLu AT 55 GPK AMD IS PUMPED TO A WASTEWATER TREATMENT PLANT CLARIFIER WHERE THE SOLIDS ARE
HEKL'VEO AMU EVENTUALLY FILTERED ALONG WITH THE WAbTE TREATMENT SLUDGL, THIS SLUDGE IS THEN
OlSPJSEn OF AT A SANITARY LANDFILL,
UPOr' STAKr-LiP, SEVERAL PROBLEMS WERE ENCOUNTERED. PARTICULATE BUILD-UP WOULD CAUSE PLUGGING
OF THE KtCYCLE TANK DRAIN AND WASTE SUMP PUMPS, THESE PROBLEMS WERE ALLEVIATED BY THE INSTALLATION
OF AlK PURGF LIMLS. .\JUi-iEROUS PROBLEl'IS WERE ENCOUNTERED WITH DAMPERS AMD THE DAMPER CONTROL SYSTEM,
THHLL SLTS OF LXPANSION JOINTS WtRE INSTALLED UNTIL EXPANSION JOINT PROBLEMS WERE SOLVED. FAN
GEARINGS HAH TO [ ;£ REPLACED THREE TINES. INSTRUMENTATION AND CONTROL PROBLEMS PROMPTED WIRING
COMMENTS
•4TH .JUARTER-197b A igEW EXPANSION JOINT WAS INSTALLED ON UNIT TWO. IN DECEMBER UNIT TWO HAD FAN
PROBLEMS A'lQ FAN BEARINGS WERE REPLACED, VANE CAGE CONTROL PROBLEMS WERE ENCOUNTERED AND NUMBER
TWO FAIM rlOTOK GROUNDED.
1ST vrfUARTEK-1976 PROBLEMS OCCURRED WITH THE FAN MOTOR BEARINGS IN UNIT NUMBER ONE* GAS FLOW WAS
SWITCHED TO UNIT TWO.
2ND uUA«TER-197b UNIT ONE THREW A FAN BLADE AND A SWITCH WAS MADE TO SCRUBBER UNIT TWO. A NEW
HEAuCR WAS INSTALLED FOR THE RECYCLE PUMPS,
-------
G.M.C./DELCO MORAINE - DAYTON, OHIO (CONTINUED)
COMMENTS
3RD QUARTER-197b VANES WERE REMOVED FROM RECYCLE TANKS,
2ND HUAKTER-1977 CORROSION UAS DETECTED DOWNSTREAM OF MIST ELIMINATOR, AN EPOXY-COAL TAR RESIN
WAS APPLIED TO. AbATE THE CORROSION PROBLEM,
*TH OUMTER-1977 M> OP-TAILED UPDATE INFORMATION KAS MADE AVAILABLE FOR THIS REPORT PERIOD OTHER
THAPv Tiid FACT THAT THE CORROSION PROBLEM DOWNSTREAM OF THE MIST ELIMINATOR IS STILL PRESENT.
PLA»vS ARE BEIWG MAOt TO RELIVE THE STACK,
-------
SECTION
- INSCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION
INSTALLATION LOCATION
SOURCE. CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CO*\TRGL SY3TE.fi VENDOR
CONTROL PROCESS
NLW / Ht'TaOFIT
START-UP DATE
CONTROL SYSTEM STATUS
SO?. EFFICltNCY
PARTlCULAlL EFFICIENCY
WATER Mf.Kt-UP
SLUDGE OR BY-PKUUUCT DISPOSAL
CONTROL E.
CAP HAL
GEORGIA-PACIFIC PAPER CU.
CROSSETTi ARKANSAS
BARK AND OIL OR COAL (IK - 1.5 % SULFUR)* 62 T/HR
BARK* 22 6PM OIL
32GiOOO ACFI1 a> 310 F
96 MW (EQUIVALENT)
AIRPOL INDUSTRIES
CAUSTIC WASTE STREAM
1975
OPERATIONAL
80?o (500 PPM oi IMLET)
908} (0,5 GR/SCF AT INLET)
OPEN LOOP* SCRUBBED WITH 2,300 GPH *BLACK WATER* FROM PULP
MILL.
WASTEWATER TREATMENT AND DISCHARGE TO CITY SEWER
$275,000.
92
-------
SECTION
F6O SYSTEMS (CONTINUED, -
OPERATIONAL EXPERIENCE
THE FGD SYSTEM CONSISTS OF AN AIR-POL CAUSTIC
SCRUBBING UNIT TO REMOVE SULFUR DIOXIDE AND PAR-
TICULATE MATTER FROM THE FLUE GAS OF A COAL/BARK
OH OIL/BARK POWER BOILER. PROBLEMS HAVE
BEEN ENCOUNTERED WITH THE FIBERGLASS LININGS IN
THE SCRUBBER. THE SYSTEM IS PRECEDED BY CYCLONES
FOR PARTICULATE REMOVAL. NO REHEAT IS PROVIDED
ON THE SYSTEM AND MATERIALS ARE HOLDING UP WELL
UITH NO CORROSION OR ABRASION PROBLEMS. FIBER-
GLASS LININGS IN THE SCRUBBER ARE REPLACED AS
THEY FAIL.
93
-------
BACKGROUND INFORMATION
GEORGIA-PACIFIC PAPER co. - CROSSETT, ARKANSAS
THE. StKUbBQR SYSTEM AT GEORGIA-PACIFIC PAPER CO., CROSSETT, ARKANSAS REMOVES S02 AND PARTICULATES
F-MDK THE FLUt: GAS GENERATED BY A BARK/OIL OR COAL-FIRED BOILER (COAL- 1.0-1.5 * SULFUR), THE BOILER
IS KATcLu AT iUO r 'V- (EuUI V ALEMT) AND PRODUCES 950,000 LB/HR STEAM. THE FLUE GAS RATE IS 320,000
ACM" AT 510 DEGREES F.
&u? CONCENTRATION IN FLUE GAS IS 500 PPM WITH A PARTICULATE LOADING OF 0.5 SR/SCF.
SCHLVPER h'ASTL WATER UlTH AN AVERAGE PH OF 7.5 IS NEUTRALIZED AND DISCHARGED TO CITY SLWERS AT
2C'iiU L-F1;-!. CYCLOPS PRECEDE SCRUBBERS FOR PARTICULATE CONTROL.
COMMENTS
3PD ^UAKTEH-1977 PLA:jT REPORTS SATISFACTORY OPERATION WITH NO MAJOR PROBLEMS. THE FIBERGLASS
LIMNtS IN THL SCRUBBER FAIL FKLuUENTLY AND ARE REPLACED AS THEY FAIL.
4TH »UA*TF.h-1977 1%jQ FIbEKGLASS LINER FAILURE UAS DETECTED DURING THIS REPORT PERIOD. THE PLANT
OPEKATiO''i& wIF.iMT OM AS SCHEDULED wITH NO PROBLEMS ENCOUNTERED.
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCt RATING
SOURCE CAPACITY
CONTROL SYSTE^' VENDOR
CONTROL PROCESS
NEW / RETROFIT
STAKT-UP DATE;
COuTROL SYSTEM STATUS
S02 EFFICIENCY
PARTICULATE EFFICIENCY
UATFR f-tAKE-UP
SLUDGE OK BY-PRODUCT DISPOSAL.
CONTROL SYSTEM COST
CAPITAL
GREAT SOUTHERN PAPER CO.
CEDAR SPRINGS, GEORGIA
BARK AND COAL OR OIL (l.Q»-2«OK SULFUR)
700,000 ACFM* TOTAL - 2 SCRUBBERS
100 MW (EQUIVALENT)* TOTAL - 2 BOILERS
AIRPOL INDUSTRIES
CAUSTIC WASTE STREAM
RETROFIT
OPERATIONAL
65K-90SK (1,000 PPM AT INLET)
99.1% (DESIGN*
-------
12 - DESCRIPTION OF OPERATIONAL FGP SYSTEMS (CONTINUED) -
GKEA1 SOUTHEKM PAPER CO.
OPERATIONAL EXPERIENCE
THE FGD SYSTEM CONSISTS OF T,,0 AIR-POL CAUSTIC
SCRUBBERS TO CONTROL PARTICIPATE AND SULFUR DI-
OXIDE FROM TWO POWER BOILERS. THE PRIMARY FUEL
IS BARK/COAL (BARK/OIL IS FIRED OCCASIONALLY.)
THE FOLLOWING PROBLEMS HAVE BEEN ENCOUNTERED*
EROSION AND PLUGGAGE OF THE PH PROBES, INTERNAL
WEAR ON PUMPS» AND EROSION IN THE RECIRCULATION
LINES OF THE POWER BOILER SCRUBBER. THE PLANT IS
IN THE PROCESS OF CHANGING THE Ph CONTROL AND
MOVING THE PROBES,
-------
BACKGROUND INFORMATION
GREAT SOUTHERN PAPER CEDAR SPRINGS, GA.
THE. FGQ SYSTEM AT GKEAT SOUTHERN PAPER AT CEDAR SPRINGS, GEORGIA CONSISTS OF TWO AIRPOL SOQlUM
SCRUBBING TRAINS CONTROLLING EMISSIONS FROM TWO COAL-FIRED BOILERS* EACH RATED AT 50 MW
(EQUIVALENT) AND EACH PRODUCING 500,000 LB/HR STEAM. THE FULLS FIRED IN THE BOILERS TYPICALLY HAVE
THE. FOLLOWING SULFUR CONTENTS* COAL - 1.5K , OIL - 1.5?6, AND BARK - 2.OX.
THC STAINLESS STEEL SCRUBBLRS HANDLE A COMBINED TOTAL OF 700,000 ACFM AT <*25 DEGREES F, THE
PRESSURE DROP ACROSS THE SCRUBBER IS APPROXIMATELY 7 INCHES ta.G. WITH 85 TO 908 SULFUR DIOXIDE
REMOVAL EFFICIENCY. THE SULFUR CONCENTRATION OF THE FLUE GAS IS 1000-1200 PPM AND-THE PARTICIPATE
LOAL'lNG IS 4.1J &R/SCFD.
THE SCRUbBER UNDERFLOW IS COMPOSED OF FLYASH AND SODIUM SULFITE/SULFATE SOLUTION. SOLIDS
CONTENT (FLYASH) IS TYPICALLY 3 TO 5 ft BY WEIGHT. SCRUBBER WASTE WATER WITH AN AVERAGE PH OF «f.5
IS PONDED AND CLARIFIED WATEh iS RETURNED TO THE RIVER.
COMMENTS
4TH iiUARTER-1977 THE EXPANSION JOINT BETWEEN THE EXISTING STACK AND SCRUBBER HAD TO BE REPLACED
IN SEPTEMBER. SOME INTERNAL WEAR HAS BEEN DETECTED ON THE PUMPS DUE TO THE ASH CONTENT.
EROSICr. AND PLUGGAGE PROBLEMS i*ITH THE PH PROBES HAVE BEEN ENCOUNTERED. THE PLANT IS IN
THE PROCESS OF CHANGING THE CONTROL PH AND MOVING THE PROBES. TANKS AND NECESSARY
EQUIPMENT TO CONTROL THE PROPER PH ARE EXPECTED TO BE COMPLETED IN A COUPLE OF MONTHS.
SOME EROSION wAS DETECTED IN THE RECIRCULATION LINES OF THE POWER BOILER SCRUBBER. THE
LINLb AND SGML OF THE VALVES HAD TO BE REPLACED,
97
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCL RATING
CONTROL SYSTEM VEMJQK
COnTRl.-u (-'I-'OCESS
NL" / KETKiJFlT
START-UP DATE
CONTROL. i-YSTEH STATUS
SCV, EFFICIENCY
SLUDGE OH trY-PRODUCT DISPOSAL
OPERA! KM.AL
GREAT WESTERN SUGAR
BILLINGS, MONTANA
COAL (0.7S SULFUR)
60,000 SCFM a 70 F
GREAT WESTERN SUGAR
AMMONIA-LADEN PROCESS WATER
RETROFIT
OCTOBER, 1977
OPERATIONAL
35?6 (300-HOO PPM a INLET)
WASTEWATER TREATMENT AND DISCHARGE TO RIVER
GREAT WESTERN SUGAR USES CONDENSATE PROCESS WATER
PRIMARILY FOR PARTICULATE CONTROL. THE WATER
HAS A HIGH PH (6.7) BUT THE SYSTEM HAS A LOW S02
REMOVAL BECAUSE THE WATER IS INTRODUCED THROUGH
PIPES RATHER THAN SPRAY NOZZLES,
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGp SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SCURCt. RATING
CONTROL SYSTEM
CONTROL PKGCtSS
NE1-' / KLTROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGE OP. BY-PROLiUCT DISPOSAL
OPERATIONAL EXPERIENCE
GREAT WESTERN SUGAR
FINDLAYt OHIO
COAL (38 SULFUR)
15*000 SCFM a 70 F (TOTAL - 2 BOILERS)
l*fOO BOILER HP (TOTAL - 2 BOILERS)
GREAT WESTERN SUGAR
SODIUM CARBONATE
RETROFIT
OCTOBER* 197«*
OPERATIONAL
WASTEWATER TREATMENT AMD DISCHARGE TO CITY SEWER
PARTICULATE AND soa EMISSIONS WILL BE CONTROLLED
BY A SCRUBBER/ABSORBER MODULE OF PROPRIETARY
DESIGN, THE FLUE GAS IS GENERATED BY TWO
720 BOILER HP UNITS. SCRUBBING OPERATIONS
BEGAN IN OCTOBER 197
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALL AT ION NAME
INSTALLATION LOCATION
SOURCL CHARACTERISTICS
SOURCE RATING
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RLTKJFIT
START-UP LrtTE
CONTROL SYSTEh STATUS
S02 EFFICIENCY
SLUDGE OR BY-PKGDUCT DISPOSAL
OPERATIONAL EXPERIENCE
GREAT WESTERN SUGAR
FORT MORGAN, COLORADO
COAL (0,555 SULFUR)
50,000 SCFM 3 70 F
GREAT WESTERN SUGAR
AMMONIA-LADEN PROCESS WATER
RETROFIT
OCTOBER* X976
OPERATIONAL
35% (300-400 PPM d) INLET)
WASTEWATER TREATMENT AND DISCHARGE TO RIVER
GREAT WESTERN SUGAR USES CONDENSATE PROCESS WATER
PRIMARILY FOR PARTICIPATE CONTROL. THE WATER
HAS A HIGH PH (6.7) BUT THE SYSTEM HAS A LOW S02
REMOVAL BECAUSE THE WATER IS INTRODUCED THROUGH
PIPES RATHER THAN SPRAY NOZZLES.
100
-------
SECTIO.J 12 - DESCFaPTIOINi OF OPERATIONAL. FGD SYSTEMS
INSTALLATION
INSTALLATION LOCATION
SOUKCL CHArtACTEKlSTicS
SOURCE. RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / KF_Tr\UFlT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
OPERATIONAL EXPERIENCE
GREAT WESTERN SUGAR
GERING, NEBRASKA
COAL (0,7* SULFUR)
50.000 SCFM a 70 F
20f5 MW (TOTAL 1 - 15i 1 - 5.5 BOILER)
GREAT WESTERN SUGAR
AMMONIA-LADEN PROCESS WATER
RETROFIT
OCTOBER. 1975
OPERATIONAL
35S5 (300-HOO PPM 8) INLET)
WASTEWATER TREATMENT AND DISCHARGE TO RlVER
GREAT WESTERN SUGAR USES CONDENSATE PROCESS WATER
PRIMARILY FOR PA&TICULATE CONTROL. THE WATER
HAS A HIGH PH (b.7) BUT THE SYSTEM HAS A LOW S02
REMOVAL BECAUSE THE WATER IS INTRODUCED THROUGH
PIPES RATHER THAN SPRAY NOZZLES.
101
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGO SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE. CHARACTERISTICS
SOURCE RATING
CONTROL SYSTEM VLNDOK
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGL OR 8Y-PKOOUCT DISPOSAL
OPERATIONAL EXPERIENCE
GREAT WESTERN SUGAR
GREELEY, COLORADO
COAL (0.6% SULFUR)
25tOOO SCFM 3 70 F
GREAT WESTERN SUGAR
AMMONIA-LADEN PROCESS WATER
RETROFIT
OCTOBER* 1975
OPERATIONAL
35SS (300-HOO PPM a INLET)
WASTEWATER TREATMENT AND DISCHARGE TO RIVER
GREAT WESTERN SUGAR USES CONDENSATE PROCESS WATER
PRIMARILY FOR PARTICULATE CONTROL. THE WATER
HAS A HIGH PH (6.7) BUT THE SYSTEM HAS A LOW S02
REMOVAL BECAUSE THE WATER IS INTRODUCED THROUGH
PIPES RATHER THAN SPRAY NOZZLES.
102
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCL CHARACTERISTICS
SOURCL RATING
CONTROL SYSTEM VENDOR
CONTROL PRUCLSS
NEW / KETRuFIT
START-UP DATE:
COfMTROu SYSTEM STATUS
S02 EFFICIENCY
WATER. hAKL-UP
SLUDGE OR I5Y-PKGPUCT DISPOSAL
COMTRUL SYSTEh COST
OPERATIONAL EXPERIENCE
GREAT WESTERN SUGAR
LOVELAND, COLORADO
COAL <0,6K-0.7K SULFUR)
50,000 SCF-M 3 70 F
GREAT WESTERN SUGAR
AMMONIA-LADEN PROCESS WATER
RETROFIT
OCTOBER, 1973
OPERATIONAL
35?o (300-400 PPM oJ INLET)
800 GPPI (PROCESS CONDENSATE WATER, PH=8.7, L/G=8)
UASTEWATER TREATMENT AND DISCHARGE TO RIVER
TOTAL INSTALLED COST FOR THE TwO SCRUBBERS, NEW BREECHING,
I.D. FANS, AND WATER SYSTEM. (1972 DOLLARS)
GREAT WESTERN SUGAR USES CONDENSATE PROCESS WATER
PRIMARILY FOR PARTICIPATE CONTROL. THE WATER
HAS A HIGH PH (6.7) BUT THE SYSTEfi HAS A LOW S02
REMOVAL BECAUSE THE WATER IS INTRODUCED THROUGH
PIPES RATHER THAN SPRAY NOZZLES,
103
-------
SLCTICi\i 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCt. RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
OPERATIONAL EXPERIENCE
GREAT WESTERN SUGAR
SCOTTS BLUFFt NEBRASKA
COAL (0.685-0.758 SULFUR)
60»000 SCFM S 70 F
30 HW (TOTAL 2 - BOILERS)
GREAT WESTERN SUGAR
AMMONIA-LADEN PROCESS WATER
RETROFIT
OCTOBERi 1975
OPERATIONAL
35SS (300-400 PPM QJ INLET)
WASTEWATER TREATMENT AlMD DISCHARGE TO RIVER
GREAT WESTERN SUGAR USES CONDENSATE PROCESS WATER
PRIMARILY FOR PARTICULATE COiMTROL. THE WATER
HAS A HIGH PH (8.7) BUT THE SYSTEM HAS A LOW S02
REMOVAL BECAUSE THE WATER IS INTRODUCED THROUGH
PIPES RATHER THAN SPRAY NOZZLES.
10
-------
Of. 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PARTICULATE EFFICIENCY
WATER iulAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTRuL SYSTEM COST
CAPITAL
OPERATIONAL EXPERIENCE
ITT RAYONIER, INC.
FERNANDINA BEACH* FLORIDA
BARK AND OIL (2% - 2.5K SULFUR)
3^4,000 ACFM 8 f<+6 F (TOTAL - 2 BOILERS)
120 MW (TOTAL - * BOILERS* EACH BARK BOILER HAS A SCRUBBER
TRAIN) EQUIVALENT
AIRPOL INDUSTRIES
CAUSTIC SCRUBBING
RETROFIT
1975
OPERATIONAL
8058 - 85SS (1,200 PPM AT INLET)
^^% (1.7 GR/SCF AT INLET)
OPEN LOOP
$500,000.
CAPITAL COST IS FOR 2 SCRUBBERS, DUCTWORK, AND STACKS
AT FERNANDINA BEACH, ITT RAYONIER FIRES BARK
AND OIL IN TWO OF THE FOUR PROCESS STEAM BOILERS.
PARTICULATE AND S02 EMISSIONS ARE CONTROLLED IN
TWO AIRPOL SCRUBBING TRAINS. SPENT CAUSTIC is
NORMALLY USED FOR S02 CONTROL. CURRENTLY HOWEVER,
CONDENSATE STEAM IS BEING USED FOR SCRUBBING
PURPOSES AND THE SPENT CAUSTIC IS BEING MARKETED.
105
-------
BACKGROUND INFORMATION
ITT RAYONIER-FERNANDINA BEACH* FLORIDA
ITT RAYONIER OPERATES AN AMMONIUM-BASED SULFITE PULP MILL IN FERNANDINA BEACH* FLORIDA.
THERE ARE FOUR PROCESS STEAM BOILERS OPERATING IN THE FOLLOWING MANNER*
NO. 1 . 100,000 LB/HR STEAM- FIRES FUEL OIL (NO. 6)
fJO. 2 - 125*000 LB/HK STEAM- FIRES A COMBINATION OF BARK AND NO. 6 FUEL OIL
MO. 3 - SAME AS NO. 2
IMO. «+ - 150,000 LB/HR STEAM- FIRES NO. 6 FUEL OIL
AlRPOL INDUSTRIES HAS SUPPLIED TWO SCRUBBING TRAINS, EACH TRAIN CONSISTING OF A VENTURI
SCRUbBER FOLLOwED BY AN ABSORBER MODULE. FLUE GASES FROM BOILERS NO. 1 AND NO. 2 PASS THROUGH
ONE TRAIN, AND THE GASES FROM NO. 3 AND NO. *f PASS THROUGH THE OTHER TRAIN. THE SCRUBBING LIQUOR
IS SPENT CAUSTIC FROM THE MIDDLE STAGE OF THE PULP BLEACHING OPERATION, PH IS MAINTAINED AT 5.5
TO 6.0.
OPERATING HISTORY
4TH QUARTER-1977 PLANT REPORTS THAT BOILERS NO. 2 AND 3 ARE CURRENTLY OPERATING AT REDUCED LOADS,
EACH IN THE RttNGE OF 7b,UOO - 90,000 LBS/HR STEAM. THE SPENT CAUSTIC IS CURRENTLY NOT BEING
USED FOR SCRUBBING LIQUOR. ITT IS SELLING THE SPENT CAUSTIC TO KRAFT MILLS WHO USE IT
FOP THEIR SODA BASE. COMPENSATE STEAM IS BEING RECYCLED AND USED FOR SCRUBBING PURPOSES.
SOME EROSION HAS BEEN NOTED AT THE VENTURI THROAT,
106
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE. RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DuTE
CONTROL SYSTEM STATUS
S02 EHFlCIEi\lCY
PARTICULAR EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CAPITAL
OPERATIONAL EXPERIENCE
MEAD PAPERBGARD CO.
STEVENSON, ALABAMA
OIL (1.5X - 3K SULFUR)
173,000 ACFM a) H5U F
60 MW (EQUIVALENT)* TOTAL - TWO BOILERS
AIRPOL INDUSTRIES
SODIUM SCRUBBING
NEW
1975
OPERATIONAL
9555 (2,000 PPM AT IhlLET)
90&
ALKALINE SULFITE/8ISULFITE RECYCLED TO PULP PROCESS
RECOVERED SOLUTION USED AS MAKE-UP TO COOKING LIQUOR IN PULP
HILL.
£100,000,
CAPITAL COST IS FOR SCRUBBER.
AIRPOL INDUSTRIES HAS SUPPLIED A PARTICULATE
AND S02 CONTROL SYSTEM FOR THE TWO OIL-FIRED
BOILERS AT THIS MEAD PULP MILL. SODIUM CARBONATE
SCRUBBING SOLUTION EFFECTS S02 REMOVAL OF
ABOUT 955K. RECENT MODIFICATIONS HAVE INCLUDED
A NEW RUBBER LINER IN THE SCRUBBER MODULE, AND
THE INSTALLATION OF ADDITIONAL SPRAY NOZZLES.
107
-------
BACKGROUND INFORMATION
MEAD PAPER60ARD, STEVENSON, ALABAMA
ThE MEAD PAPERBOARu COMPANY IN STEVENSON, ALABAMA* IS A NEUTRAL SULF1TE PULP MILL WITH A 500
TOH/i'AY PULP PRODUCTION F;ATE. THE MILL HAS A CHEMICAL RECOVERY SYSTEM THAT ABSORBS S02 FROM THE
BILLCP'UU REACTOR. EFFLUENT FROM THE RECOVERY SYSTEM FLQwS BACK TO THE PULPING OPERATION. ELSEWHERE
OH-SITEt AM AIRPut INDUSTRIES ABSORBER TOWER CONTR/LS PARTICULATE AND S02 EMISSIONS FROM TWO
OIL-FIREP (1.556 - 3.08 SULFUR) COMBUSTION-ENGINEERING PACKAGE BOILERS. FLUE GAS VOLUME INTO THE
SCRUbBER SYSTEM Is ABOUT 175,000 ACFI1 o> 450 F. HOT GASES PASS THROUGH A STAINLESS STEEL
VEfTUKI/UUEMCH SECTION FOR COOLING AND INITIAL SOa REMOVAL. THE FLUE GAS THEN ENTERS THE BOTTOM OF
THE ABSORBER SECTION AND PASSES UP THROUGH THREE BUBBLE-CAP TRAYS. A SODIUM CARBONATE SOLUTION IS
IMTHODUCLD THROUGH A BAlMK OF 1.5 INCH NOZZLES AND SPIN VANES. THE GAS EXITS THROUGH A FIBERGLASS
STACK.
SCRUBBER EFFLUENT , MOSTLY SODIUM SULFITE, is SENT TO THE MILLS PULPING OPERATIONS FOR
EVENTUAL USE IM THE DIGESTERS. PH IS CONTROLLED AT 7.0-8.5 IN THE RECIRCULATION TANK.
THE so2 SCRUBBING SYSTEM WAS DOWN FROM MARCH THROUGH JULY 1976 OUE TO ABRASION PROBLEMS. THE
ABRASION WAS CAUSED PARTIALLY BY HIGH STREAM VELOCITY THROUGH THE EXISTENT VENTURI PARTICULATE
SCRUBBER INTO THE SG2 SCRUBBER. SODIUM CARBONATE AND CARBON PARTICLES THAT HAD NOT GONE INTO SOLU-
TION ALSO WERE VERY ABRASIVE TO THE S02 SCRUBBER LINING. IN ADDITION, THE ORIGINAL GLASS-FLAKED
LlhJLR (5 MM THICK) WAS EXPERIENCING STRESS CRACKING.
THE HIGH VELOCITIES INTRODUCED BY THE VENTURI WERE ELIMINATED BY REMOVING THE PARTICULATE
VLNTURI SECTION OF THE SYSTEM. THE GLASS-FLAKED LINING WAS PATCHED WITH $60,000 WORTH OF
CARPENTER 20 LINER. THESE CORRECTIVE ACTIONS HELPED FOR A wHILE, BUT AS IT TURNED OUT* THE CARPEN-
TER 20 WAS NOT INSTALLED PROPERLY AND SOLUTION WAS GETTING BETWEEN IT AND THE MILD STEEL SHELL. IT
WAS FINALLY DECIDED TO INSTALL NEW RUBBER LINING INSIDE THE ENTIRE SCRUBBER, INCLUDING THE SPIN
VANES, AT A COST OF $150,000. TO PREVENT ANY HEAT PROBLEMS, ADDITIONAL NOZZLES WERE INSTALLED. TO
DATE, NO MAJOR PROBLEMS HAVE OCCURRED WITH THE RUBBER LINING.
COMMENTS
tfTH UUARTER-1977 hllMOR EMBRITTLEMENT, DUE TO LOCALIZED HIGH TEMPERATURE, HAS BEEN DETECTED ON THE
LINING SURFACE, SOME METAL* NOZZLES, AND RUBBER HAVE BEEN REPLACED.
108
-------
SECTIGM 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOUPCu CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM LOST
OPERATIONAL EXPERIENCE
MINN-DAK FARMER'S COOPERATIVE
WAHPETON, NORTH DAKOTA
LIGNITE (l.o PERCENT SULFUR)
250,000 ACFM a 350 F - TOTAL TWO BOILERS
TWO BOILERS, EACH dl 275,000 LBS/HR STEAM (250 PSIG - **55 F)
KOCH ENGINEERING
AMMONIA SCRUBBING
RETROFIT
JUNE, 1977
OPERATIONAL
TESTS TO DATE HAVE BEEN INCONCLUSIVE,
200 GPfl POND WATER
WASTEWATER TREATMENT
BLEED STREAM GOES TO AN ACTIVATED SLUDGE SYSTEM 3 160 GPM
TOTAL PURCHASE COST WAS $300,000 (1977)
KOCH ENGINEERING HAS SUPPLIED TWO AMMONIA-BASED
S02 CONTROL SYSTEMS FOR THESE COAL-FIRED BOILERS.
ORIGINAL DESIGN USED LIME SLURRY, BUT EXCESSIVE
PLUGGING AND SCALING BROUGHT ABOUT THE SWITCH
TO AMMONIA.
109
-------
BACKGROUND INFORMATION
MINN-DAK FARMER'S COOP.t WAHPETON. N.O.
viINN-DAK FARMER'S COOP. HAS A SUGAR FACTORY AT WAHPETON, NORTH DAKOTA. THERE ARE TWO BOlLERSt
EACH WITH A CAPACITY OF 27b»000 LBS STEAM/HR AT 250 PSIG AND f55 F. THE FUEL BURNED IS 1* SULFUR
LIbuITE. SULFUh DIOXIDE REMOVAL IS EFFECTED BY AMMONIA ADDITION TO THE RECIRCULATING SCRUBBER
KOCh ENGINEERING HAS SUPPLIED TWO SCRUBBERS FOR THE BOILERS EACH OF WHICH GENERATES 125*000 ACFM
OF FLUE GASES AT 350 F. THE SCRUBBER SYSTEMS WENT ONSTREAM IN JUNE 77. EACH SCRUBBER IS A VARIABLE
THKDAT VENTUKI i,. ITH OPEN ENDED PIPE INLETS FOR LIQUID AND WAS PRIMARLY DESIGNED FOR PARTICULATE
CONTROL. THE SCRUBBER LIQUOR IS RECIRCULATED AT A RATE OF 800 GPM AND THE BLEED-OFF RATE GOING TO
THE ACTIVATED SLUPGE. SYSTEM IS 160 GPil. THE MAKEUP POND WATER FLOW RATE IS 200 GPM. THE PRESSURE
DPUP ACROSS A SCRUBbER IS 11 IN. WG. THERE IS ONE COMMON ChEVERON TYPE DEMISTER AND ONE STACK.
THE INLET CONCENTRATION RANGES ARE 76-193 LBS/HR OF S02 AND ,3-.
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL. FGD SYSTEMS
INSTALLATION NA!vlE
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
souRct CMPACITY
CONTROL SYSTEM
CO !THUL PHOCLSS
3TAKT-OF uATL
CONTKGL SYSTU-i is
$02 LHFIL1LNCY
WATEK MAKL-Ui"
SLL'p.bt, OK ;;Y-PRUL)UCT
COi\THUL SYSTL1U! COST
MOBIL OIL COMPANY
SAN ARDO, CALIFORNIA
OIL <2!& - 2, 2556 SULFUR)
304,000 ACFH a 270 F
20 SCRUBBERS TREATING 6,000 ACFM EACH
a SCRUBBERS TREATING 16,000 ACFM EACH
840 MM BTU/HR (60 HW EQUIVALENT)* TOTAL - 28 SCRUBBERS
MOBIL OIL COMPANY
SODIUM SCRUBBING
RETROFIT
OPERATIONAL
90S (X300 PPM S02 a INLET)
OIL FIELD WASTEtuATER
HOLDING POND FOR EVAPORATION
CAPITAL = $2,300,000 FOR 20 FGD SYSTEMS 8 $65,000 EACH
AND 8 FGD SYSTEMS a a-125,000 EACH.
OPERATING COSTS ARE $500,000 YEARLY FOR 20 FGD SYSTEMS
£ $15,OOG/YR EACH A|\|D 8 SYSTEMS a $25,000/YR EACH.
Ill
-------
SECTlUii 1?. -
r-
DESCRIPTION OF OPERATIONAL FGD SYSTEMS (CONTINUED) -
OBIL ulL COMPANY
OPERATIONAL CXPLR1U\,CE
MOBIL OPERATED 26 SMALL STEAM GENERATORS AT THEIR
OIL FIELDS IN SAW ARDO, CALIFORNIA. EACH OF
THESE STEAM GENERATORS HAS ITS OWN soa CONTROL
SYSTEM UTILIZING CAUSTIC AiJD ALKALINE OIL FIELD
vOASTEWATEK, PRIMARY PKUbLEMS HAVE BEEN CORROSION
OF STAINLESS STEEL COMPONENTS DUE TO HIGH CHLORIDE
CONTENT.
112
-------
BACKGHOUND JixiFOKMAT ION
MOBIL OIL COMPANY, SAM ARDO, CALIFORNIA
THE hOBIL OIL COMPANY HAS AIM OIL SITE IN SAN AROO, CALIFORNIA WHERE 26 STEAM GENERATORS ARE
USED TO FCKCE OiL OUT Op THE WELL. THE FUEL USED IS CRUDE OIL WITH 2-2.25% SULFUR. EACH STEAM
FF.ULKATOK is FOLLOWED BY AN INDIVIDUAL FGD SYSTEM INSTALLED SPECIFICALLY FOR S02 CONTROL. THE UNITS
EXPERIENCED STARTUP IN THE PLrUOQ FROM 1972 THROUGH 197«f.
THERE ARE. TlPvG SIZES OF STEAM GENERATORS- 22 MM BTU/HR (20 UNITS) AND 50 MM BTU/HR (8 UNITS).
THE SMALL UNITS GENERATE 6»OOG, AND THE LARGE UNITS IStOOO SCFM OF THE FLUE GAS, THE GASES ARE
SCRUi'iBLY, BY A LIQUOR CONSISTING OF r-'AOH AND ALKALINE OIL FIELD WASTErfATER (NA2C03). THE PROCESS IS
ON'CL THHOUGH «MD PH VALUES OF 8.0 AND 6.0 ARE MAINTAINED AT THE INLET AND OUTLET OF THE SCRUBBERS*
RESPECTIVELY, THE SPENT LIQUOR FROM THE BOTTOM OF THE SCRUBBERS IS DISPOSED OF IN THE WASTEWATER
DISPOSAL ZONE. THEKE IS NO RECYCLE FROM THE DISPOSAL ZOi\JE SO THE SYSTEM OPERATES IN AN OPEN LOOP.
THE LIUUID FLOl-J KftTES TL< THE T^O SIZES OF THL SCRUBBERS ARE 75 GPP! AND 200 GPM. THE SCRUBBER SIZES
ARE* 4 FT. DIAMETER X 20 FT. HIGH AND 6.5 FT, DIANETER X 25 FT. HIGH. EACH SCRUBBER HAS THREE
V-GKATE TYPE TRuYS. THE I.D. FANS ON EACH SCRUBBER EXPERIENCE 3-H INCHES kG PRESSURE DROP, THE
S02 iitMOVAL EFFICIENCY OF THE PROCESS IS 90 PERCENT WITH INLET S02 CONCENTRATION OF 1500 PPM,
CHEVRON-TYPE LEMISTEPS AKE USED.
THL SCrtUBbERS ARE 31b L SS AMD THE TRAYS 31b S3. THE INLET DUCTWOKK IS CS UP TO THE ECONOMIZER
ANC; THEr, 316 L SS. THE. iiOwiMSTREAM DUCT IS HEAVY FIBERGLASS AND THE I.D. FANS ARE CS WITH 316 L SS
LINING CiM THE CASING. THE STACK IS FIBERGLASS, THE FLUL GAbES ARE NOT REHEATED AND CANNOT BE BY-
PASSED. THE MST ELlMfMATORS, ORIGINALLY 31fa SS, HAVE BEEN LINED WITH PHENOLIC EPOXY RESIN TO COM-
BAT CORROSICHi. INADEQUATE iv>Ii>T REMOVAL HAS ALSO RESULTED IN CORROSION OF THE I.D. FAN IWPELLERt
BLAbLS, AND HUBS, WHICH f«EED REPLACEMENT EVERY YEAK. THE HIGH CHLORIDE CONTENT OF WASTE WATER IS
THE F^Rir-iARY CAUSE OF PITTING OF SS MATERIAL.
THE SPENT LltfUOK IS INJECTED INTO A WASTEWATER WELL (LARGE WASTE WATER DISPOSAL ZONE).
113
-------
SECTICM 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
bOURCL CHARACTERISTICS
SOURCE BATING
SOURCE, CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
.vl FW / KETrtCFIT
START-UP DATE
CONTROu SYSTEM STATUS
S02 EFFICIENCY
SLUDGE OF- ^Y-PKOCUCT DISPOSAL
OPERATIONAL EXPERIENCE
NCR-APPLETON
ROARING SPRINGS, PENNSYLVANIA
COAL (2% - 3K SULFUR)
85,000 ACFM a <+00 F
12 MW (EQUIVALENT)
AIRPOL INDUSTRIES
SODIUM SCRUBBING
NEW
JUNE, 1977
OPERATIONAL
80% - 85%
WASTEWATER TREATMENT AND DISCHARGE TO CITY SEWER
THIS NEW BOILER* RATED AT 12 MW (EQUIVALENT),
WAS SUPPLIED WITH AN EMISSION CONTROL SYSTEM BY
AIRPOL INDUSTRIES, THE SODIUM-BASED CHEMISTRY
UTILIZES SOQIUH HYDROXIDE FOR S02 REMOVAL,
ALTHOUGH NO GUARANTEE WAS MADE WITH RESPECT TO S02
REMOVAL. BOILER-RELATED PROBLEMS HAVE DELAYED
ACCEPTANCE TESTS ALTHOUGH START-UP OCCURED IN
JUNE 1977.
lit
-------
BACKGROUND INFORMATION
NCR-APPLETON - ROARING SPRING, PENNSYLVANIA
NCR-APPLETON RUNS A KRAFT PULP AND PAPER OPERATION IN ROARING SPRING, PENNSYLVANIA. PROCESS
STE^i IS SUPPLIED BY A COAL-FIRED BOILER. THE COAL USED HAS A SULFUR CONTENT RANGING FROM 2K TO
385. THE BOILER Is EQUIVALENT TO ABOUT 12 MW, GENERATING ABOUT 65,000 ACFM AT fOO F. THIS IS A NEW
STEAM PLANT WHICH BEGAN PRODUCTION Ii\| JUNE 1977. PARTICULATE AND S02 EMISSIONS ARE CONTROLLED BY
AN AIKPOL SCRUBBING SYSTEM CONSISTING OF A VENTUKI FOLLOWED BY AN ABSORBER MODULE. SCRUBBER AND
ABSOKBEK INTERNALS AKE LliMED rtlTH AN ACID RESISTANT MATERIAL (CRUSHED AGGREGATE WITH EPOXY BINDER,
RATE.U 1\ PH RANGE 1 TO 2). THE STACK IS FRP LINED.
SO? KE'";GVAL AMD CORROSION PREVENTION ARE IMPLEMENTED BY THE ADDITION OF CAUSTIC (SODIUM
HYDKOXIO£) TO THE RECYCLE TANK. PH CONTROL IS IN THE b TO 7 RAN&E.
OPERATING HISTORY
4TH UUARTER-1977 SINCE START-UP IN JUNE 1977, THEHE HAVE BEEN SOME MECHANICAL PROBLEMS RELATED T0
60ILEH OPERATION. THE COAL BEING FIRED IN THE STEAM GENERATOR IS NOT THE DESIGN COAL
HAVI.M^ A LOWEK Ht'AT \*ALVE AND HIGHER ASH COlMTENT THAN PLANNED. THE SCRUBBER OPERATIONS
ARE KtPORTEn bY THE VENDOR TU BE GOING FAIRLY WELL. THERE HAVE BEElM LINER PROBLEMS.
THE UNIT HAS hOT 3EEN THROUGH ACCEPTANCE TESTING BY THE INSTALLATION.
lib
-------
SEC! K>h> 12 - DESCRIPTION OF OPERATIONAL F6D SYSTEMS
INSTALLATION
IlVSTALLATIOlV LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
COMTKUL PKOCt'SS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PARTICULATE EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
COiMTROL SYSTEM COST
CAPITAL
NEKOOSA PAPERS, INC,
ASHDOWNf ARKANSAS
COAL US-1.5* SULFUR)* 27 TON/HR
325»000 ACFM 3 355 F
50 WW (EQUIVALENT)* DESIGN - bOOtOOO LB/HR STEAM
AIRPOL INDUSTRIES
AIR POL CAUSTIC SCRUBBING
NEW
FEBRUARY, 1976
OPERATIONAL
90+* <600 PPlI X! INLET)
98% - 99% (1.42 GK/SCF AT INLET)
OPEN LOOP
ALKALINE SULFITE/BISULFITE RECYCLED TO PULP PROCESS
S02 RECOVERED FRUPs SODIUM SULFITE/SULFATE LIQUOR AND RE-
CYCLED TO PULPING PROCESS.
$250
-------
SECTIO.J
OPERATIONAL EXPERIENCE
FGD SYSTEMS (CONTINUED) -
THE FGD SYSTEM CONSISTS OF TwO AIR-POL CAUSTIC
SCRUBBERS WHICH REMOVE FLYASH AND SULFUR DIOXIDE
FROM THE FLUE GAS OF A STEAM BOILER FIRED WITH
COAL OR FUEL OIL* SOME SOLIDS DEPOSITS ON THE PH
PROBES ARE CAUSING SOME PROBLEMS. FLOW METERS
HAVE BEEN INSTALLED TO GAIN MORE PH CONTROL IN
THE SYSTEM,
117
-------
BACKGROUND INFORMATION
NEKOOSA-EDWARDS, INC., ASHDOWN, ARKANSAS
THE NEKOOSA-EDWARDS PAPER PULP MILL IN ASHDOWN, ARKANSAS HAS TWO AIRPOL SCRUBBERS ON A 50-MW
EQUIVALENT STEAM BOILER FIRED WITH COAL OR FUEL OIL, THE VENTURI SCRUBBERS ARE DESIGNED TO REMOVE
BOTH SULFUR DIOXIDE AND PARTICULATES, THE INTENT OF NEKOOSA-EDWARDS WAS TO MAKE» FROM THE SCRUBBER
EFFLUENT, SALTCAKE WHICH WOULD BE USED AT THE MILL. THE COAL HAS 1-1.5% SULFUR AND A HEATING VALUE
OF 12,000 BTU/LB. IT IS BURNED AT A RATE OF 27 TONS/HR.
THE SCRUBBER HANDLES 325,000 ACFM AT 355 DEGREES F. SCRUBBER INLET S02 CONCENTRATION
IS TYPICALLY bOQ PPH WITH A PARTICULATE LOADING OF I.*f2 GR/SCFM. HECIRCULATED WATER IS BLED
OFF AT 150-250 GPtf. REAGENT MAKE-UP AMOUNTS TO 12 LB/MIIM OF SODIUM HYDROXIDE. SCRUBBER UNDERFLOW
CONSISTS OF FLYASH AfJD A SOLUTION OF SODIUM SULFITE/SULFATE. THE ASH SLURRY GOES TO A SETTLING
POMU.
THE PREDOMINANT DIFFICULTIES WITH THE FGD SYSTEM HAVE BEEN TWO-FOLD. FIRST, THE PLANT HAS BEEN
UMABLE TO DEVELOP AM AUEGUATfc. PH CONTROL MECHANISM. THE PH CONTROL SYSTEM MONITORS THE AMOUNT OF
CAUSTIC AGENT, I.E., SODIUM HYDROXIDE, WHICH GOES INTO THE RECYCLE TANK, KEEPING THE PH OF THE
SCRUBBER SOLUTION AT A NONCORROSIVE LEVEL. THE PLANT HAS BEEN PLAGUED WITH PROBLEMS IN
OPERATING THE PH CONTROL SYSTEM AND HAS SUFFERED A GREAT DEAL OF CORROSION. THE SECOND PROBLEM
CONCERNS THE CHEMICAL REGENERATION PORTION OF THE SYSTEM. THE INTENT OF THE PLANT WAS TO SEPARATE
THE FLY ASH FROK THE SCRUBBER LIQUID AND TAKE THE SCRUBBER LIQUID THROUGH A SERIES OF EVAPORATORS
WHFRtl SODIUM SULFATL, I.E.t SALTCAKE, WOULD BE GENERATED. THE PLANT HAS BEEN UNABLE TO OPERATE THE
FLY ASH SEPARATION SYSTEM PROPERLY, AND THERE IS NOT ENOUGH EVAPORATION CAPACITY FOR THE PLANT TO
PROCESS THE SCRUBBER EFFLUENT AT FULL OPERATIONAL CAPACITY.
IN SPITE OF THE OPERATIONAL PROBLEMS, THE SULFUR DIOXIDE AND PARTICULATE REMOVAL EFFICIENCIES
OF THE FGD SYSTEM ARE 90 AND 99 PERCENT, RESPECTIVELY, ACCORDING TO THE PLANT ENGINEER, THE WASTE
PRODUCT FROM THE. SCKUBBER IS NOT RECYCLED, AT PRESENT, AND IS PUMPED TO THE WASTEWATER TREATMENT
PLANT. CLEANED WASTEWATER IS RETURNED TO THE RIVER.
iia
-------
NEKOOSA PAPERS - ASHDOWN, ARKANSAS (CONTINUED)
UPON STARTUP, PROBLEMS OCCURED WITH THE PIPING AND VALVES WHICH WERE CONSTRUCTED OF CARBON
STEEL, THE CARBON STEEL SYSTEM WAS REMOVED AND REPLACED WITH STAINLESS STEEL VALVES AND PIPING,
SOPE PIPING LEAKS OCCURRED AND WERE REWELDED. SOME CORROSIOM OF DUCT DAMPERS OCCURED AND WERE RE-
LIEVED BY ADJUSTING THE PH OF THE SCRUBBING LIQUOR. THE PH IS MAINTAINED BETWEEN 5.5 - 6.0.
THE SCRUBBER SYSTEM OPERATES WITHOUT REHEAT, EXHAUSTING TO A FIBERGLASS COATED STACK. PARTIC-
ULARS ARE CONTROLLED WlTh CYCLONES AND TWO VARIABLE THROAT VENTURI SCRUBBERS WITH AN AVERAGE PRES-
SURE. OROP OF 14 TO 16 INCHES rf.G.
COMMENTS
3RD iUAHTER- 1.977 NO MAJOR PROBLEMS HAVE BEEN REPORTED.
CORROSION PROBLEMS STILL EXIST AND PH CONTROL IS STILL A PROBLEM. FLOW METERS ARE
BEIIN.G INSTALLED TO MONITOR SCRUBBER WATER.
UUARTER-1977 TWO FLOW METERS HAVE BEEN INSTALLED AT EACH SCRUBBER, ONE AT THE THROAT INLETF
OF THE VENTIWI A^D ONE AT THE THROAT. THE PLANT REPORTS THAT PH CONTROL IS STILL A PROBLEM.
SOMt PROBLEMS ABE BEING ENCOUNTERED WITH THE PH PROBES DUE TO THE CONSTANT FLOW OF LARGE
AMOUNTS OF SOLIDS, AND SOLIDS DEPOSITS ON THE PROBES,
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PARTICULATE EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CAPITAL
RICKENBACKER AIR FORCE BASE
COLUMBUS* OHIO
COAL (3.68 SULFUR)
50,000 SCFPt 5) 70 F
20 MW (EQUIVALENT)
RESEARCH-COTTRELL/BAHCO
LIMESTONE SCRUBBING
RETROFIT
MARCH* 1976
OPERATIONAL
9056 (AVERAGE)
9858
OPEN LOOP - 2.5 GPM/MW (MAX)
NON-FIXATED SLURRY TO LINED POND
UNSTABILIZED CAS05/SO<+ SLUDGE TO LINED POND
$ 2.200 MILLION
FOR 1977* OPERATING COSTS WERE S5.92/TON COAL.
THIS INCLUDES OPERATING AND MAINTENANCE LABOR AND PARTS,
CAPITAL COST INCLUDES ADJACENT ELECTRICAL SUBSTATION* SLUDGE
DISPOSAL* EXTERNAL FLUES« AND OTHER ATYPICAL EQUIPMENT.
120
-------
SECTION 12 p:ig^CRI.PTIUNAOF OPERATIONAL FGD SYSTEMS (CONTINUED) -
OPERATIONAL EXPERIENCE
THIS RESEARCH-COTTRELL/BAHCO LIME FGD UNIT
WAS FIRST PLACED IN SERVICE MARCH uf 1976.
THE SYSTEM WAS SWITCHED OVER TO LIMESTONE IN APRIL
1977. AND HAS REMAINED IN THAT OPERATING MODE TO
DATE. THE iviEW OHIO CODE REQUIRES A LESS STRINGENT
S02 REMOVAL EFFICIENCY AND THE PLANT IS NOW RUN-
NING A STOICH10HETRIC RATIO OF ABOUT 0.75. AVAIL-
ABILITY HAS BEEN 95S SINCE AUGUST 1977.
121
-------
BACKGROUND INFORMATION
RICKENBACKER AIR FORCE BASE-COLUMBUS, OHIO
IN 1971 RESEARCH-COTTRELL CONCLUDED AN AGREEMENT WITH A.B. BAHCO VENTILATION, ENKOPING SWEDEN.
THIS CONTRACTUAL ARRANGEMENT ALLOWS RESEARCH-COTTRELL TO BE THE EXCLUSIVE LICENSEE OF THE BACHO
SULFUR DIOXIDE SCRUBBING PROCESS IN THE UNITED STATES, TO DATE, THERE ARE 19 BACHO SULFUR DIOXIDE
SCRUBBING SYSTEMS IN THE VARIOUS STAGES OF DEVELOPMENT THROUGHOUT THE WORLD. THE FIRST U.S. BACHO
INSTALLATION HANDLES SEVEN STOKER-TYPE COAL-FIRED BOILERS AT THE RICKENBACKER AlR FORCE BASE IN
COLUMBUS, OHIO. THREE BOILERS WERE PLACED IN SERVICE IN 1952 AND THE REMAINING FOUR IN 195«*, THE
UMTS FIRE A HIGH-SULFUR COAL, 3.6 PERCENT SULFUR, 3 HIGH COMBUSTION AIR RATES, 150-1608 EXCESS AIR,
THE RICKENBACKER EMISSION CONTROL SYSTEM CONSISTS ESSENTIALLY OF A MECHANICAL COLLECTOR, BACHO
SCRUBBER TOWER, LIME STORAGE AND HANDLING SYSTEM, CLARIFIER, BOOSTER FAN AND ASSOCIATED DUCTWORK,
PUMPS, CONTROLS, AND A SLUDGE DISPOSAL POND.
SOLID PARTICULATE AND SULFUR DIOXIDE-LADEN FLUE GAS TAKEN FROM EACH OF THE EXISTING SEVEN
STACKS IS FED THROUGH A COMMON HEADER AND INTO A MECHANICAL COLLECTOR WHERE PRIMARY PARTICULATE
REMOVAL TAKES PLACE. THE MECHANICAL COLLECTOR HAS A DESIGN REMOVAL EFFICIENCY OF 70 PERCENT AND
WAS INSTALLED PRIMARILY TO REDUCE FAN WEAR. THE PARTLY CLEANED GAS THEN FLOWS INTO THE BACHO TONER
WHERE ADDITIONAL PARTICULATE AND PRIMARY SULFUR DIOXIDE REMOVAL TAKES PLACE.
THE BACHO SCRUBBING VESSEL IS A VERTICAL TOWER CONSISTING OF TWO SCRUBBING STAGES. GAS FLOWS
THROUGH THE TOWER WHERE IT IS CONTACTED WITH A LIME SLURRY SOLUTION. AFTER PASSING THROUGH THE
FIRST SCRUBBING STAGE, ENTRAINED MOISTURE IS REMOVED BY A CYCLONIC TYPE MIST ELIMINATOR. THE
GAS THEN PASSES THROUGH A SECOND SCRUBBING STAGE AND A SECOND CYCLONIC MIST ELIMINATOR, THE
CLEANED GAS IS DISCHARGED TO THE ATMOSPHERE THROUGH A STACK MOUNTED DIRECTLY TO THE TOWER,
PEBBLE LIME IS EMPLOYED AS THE REAGENT IN THE SCRUBBING SYSTEM AND IS PREPARED BY SLAKING AND
DISSOLUTION IN A MIX/HOLD TANK. THE SCRUBBING SLURRY IS THEN PUMPED TO THE ABSORBER WHERE IT IS
CONTACTED WITH THE FLUE GAS IN A COUNTERCURRENT FASHION.
122
-------
RICKENBACKER AIR FORCE BASE - COLUMBUS, OHIO (CONTINUED)
THE. SPENT SCRUBBING SOLUTION is DISCHARGED TO THE THICKENER WHERE THE WASTE SOLIDS SETTLE OUT.
THICKENER OVERFLOW IS RETURNED TO THE MIX/HOLD TANK. THICKENER UNDERFLOW IS DISCHARGED TO A 5-
ACRE HYPALON-LINED DISPOSAL POND, THIS POND IS LOCATED APPROXIMATELY *00 FEET FROM THE SCRUBBING
TOWER. CLEAR WATER FROM THE POND IS RETURNED TO PROCESS AS SLAKING WATER.
THE SYSTEM hAS INITIALLY PLACED IN SERVICE MARCH 11, 1976. INITIAL OPERATION PROCEEDED IN AN
OPEN WATER LOOP MODE BECAUSE THE THICKENER WAS NOT YET COMPLETELY INSTALLED. SULFUR DIOXIDE IN-
LLT CONCENTRATIONS WERE IN THt. 1800 TO 2000 PPM RANGE. HIGH OXYGEN CONCENTRATIONS ALSO EXIST IN
THE FLUE GAS BECAUSE THESE OLDER, INEFFICIENT BOILERS OPERATE AT 150 TO 160 PERCENT EXCESS AIR
RATE.S, SULFUR DIOXIDE RLMOVAL EFFICIENCY HAS BEEN IN THE LOW 90 PERCENT PLUS RANGE. LIME UTIL-
IZATION HAS BEEN VERY GOOD. PROBLEMS ENCOUNTERED TO DATE HAVE BEEN PRIMARILY OF A MECHANICAL NA-
TURt USUALLY ASSOCIATED wlTh STARTUP, THE MAJOR PROBLEMS ARE ITEMIZED BELOW.
ELECTRICAL CIRCUITS AND SYSTEM CONTROL PANEL.
PUMP MALFUNCTION-SPARE PARTS SHIPMENT DELAY.
SLDIrtLMTATION BUILDUP IN THE SCRUBBER VESSEL (THIS WAS DUE PRIMARILY TO OPERATION AT
HIGHER THAN DESIGN SOLIDS CONCENTRATION IN THE SCRUBBING SOLUTION BECAUSE THE THICKENER
WAS NOT Y£T IN SERVICE PLUS GRlT GETTING THROUGH THE LIME SLAKER GRIT REMOVAL STEP).
FAMILIARIZATION OF THE OPERATING STAFF WITH THE MECHANICS OF THE PROCESS.
1.0. BOOSTER FAN PROBLEMS. ADDITIONAL BRACING, AND EPOXY GROUTING WAS REQUIRED TO STOp
THL LLE.VATED FAM CONCRETE SUPPORT FROM VIBRATING WHILE THE FAN WAS OPERATING.
123
-------
RICKENBACKER AFB-COLUMBUS, OHIO (CONTINUED)
OPERATING HISTORY
MOV, 76 DOWNTIME UAS LESS THAN 5%. OPERATING PROBLEMS HAVE BEEN MECHANICAL AND CONTROL RATHER
TO THAN PROCESS-RELATED. FAN-RELATED PROBLEMS ACCOUNTED FOR OVER 75SS OF THE ACTUAL DOWIM-
JUN. 77 TIME. THIS RESULTED FROM EXCESSIVE FAN VIBRATIONS CAUSED 8Y BEARING, SUPPORT, AND
INSTRUMENTATION DIFFICULTIES, IN APRIL 1977. THE FAN WHEEL DEVELOPED A CRACK IN THE
RIM ATTRIBUTED TO FATIGUE FROM RESONANT VIBRATION. THE FAN WAS SENT BACK TO THE MANU-
FACTURER, AMERICAN STANDARD, WHO MADE THE REQUIRED MODIFICATIONS. THE ORIGINAL FAN WAS
KAD1AL BLADE WITH RIHS, AND A MAJOR MODIFICATION WAS CHOPPING THE RIMS OFF, THEREBY
REDUCING THE DIAMETER, THE FAN WAS RETURNED IN EARLY MAY AND THE VIBRATION PROBLEM WAS
SULVE.U. OTHER OPERATIONS WERE RELATIVELY PROBLEM-FREE. THERE WERE NO CORROSION,
EROSION, SCALING, OR PLUGGING PROBLEMS.
THE SYSTEM BEGAN RUNNING ON LIMESTONE IN APHIL, AS PART OF THE EPA TEST PROGRAM,
LIMESTONE PERFORMED WELL, YIELDING ADEQUATE REMOVAL.
Ofa JUivE 3RD, THE STEAM PLANT WAS SHUTDOWN THE TIE-IN OF THE NEW NO. 8 BOILER, THIS
UivilT REPLACED UNITS NO, 1 AND NO, 2, AND NO, 3 WILL BE ON STANDBY. TIE IN WAS
COMPLETED IN JUNE.
AUG. 77 THE ARMS BROKE OFF IN THE 25-FOOT DIAMETER THICKENER TANK, CAUSING A 30-OAY DOWN
PERIOD.
SEP. 77 A MAKE-UP WATER BOOSTER PUMP HAD TO BE REPLACED.
OCT. 77 THE MOTOR DRIVE ON THE SLAKER BELT HAD TO BE REPAIRED. ALTHOUGH THE SLAKER IS NO LONGER
USED WITH THE LIMESTONE REAGENT, THE BELT IS USED TO CONVEY THE LIMESTONE TO THE
DISSOLVING TANK.
-------
RICKENBACKETR AF6-COL.UMBUS, OHIO (CONTINUED)
JAN. 76 IT HAS BEEN DISCOVERED THAT WITH A STOICHIQMETRIC RATIO OF 0.75 THE REQUIRED DEGREE OF
S02 REMOVAL CAM BE ACHIEVED. THE CURRENT REGULATION LIMITS EMISSIONS TO 2,2 LBS/MW BTU
HEAT INPUT. DURING THE JANUARY BLIZZARD, SOME FREEZE-UP PROBLEMS WERE ENCOUNTERED.
OVERALL SYSTEM AVAILABILITY HAS BEEN ABOUT 95S8 SINCE AUGUST 1977.
A RECENT COST ANALYSIS INDICATED THAT 1977 SCRUBBER COSTS, EXCLUSIVE OF CAPITAL
DEPRECIATION, WERE $5,92/TON OF COAL FOK 35,000 TONS/YR. THIS FIGURE REFLECTS OPERATING
COSTS AND MAINTENANCE LABOR ANU PARTS. THIS IS STILL CHEAPER THAN FIRING LOW-SULFUR
COAL, WITH THE CURRENT fcPREAU BETWEEN LOW-SULFUR AND HIGH-SULFUR COAL AT ABOUT S7/TON.
125
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHAKACTEhlSTjCS
SOURCE RATING
COMTROu SYSTEM VENDOR
CONTROL PROCESS
NEW / KETKGFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PARTICULATE EFFICIENCY
SLUDGE OR OY-PROOUCT DISPOSAL
OPERATIONAL EXPLRIENCE
SHELLER GLOBE CORP.
NORFOLK, VIRGINIA
COAL (LESS THAN 1% SULFUR, 6fc ASH, 13,200 BTU/LB)
8,000 SCFM a 70 F
W.W, SLY MANUFACTURING CO,
SODIUM HYDROXIDE
RETROFIT
1975
OPERATIONAL
NOT DETERMINED
NOT DETERMINED
OVERFLOW TO SEWER/SLUDGE TO LANDFILL
AFTER SYSTEM RESTART IN OCTOBER 1977, THERE HAVE
BEEN NO PROBLEMS RESULTING FROM EITHER BOILER OR
SCRUBBER OPERATIONS. THE PLANT IS CURRENTLY
AWAITING CERTIFICATION FROM VIRGINIA EPA.
126
-------
BACKGROUND INFORMATION
SHELLER GLOBE CORP., NORFOLK. VIRGINIA
IN NORFOLK, VIRGINIA, SHELLER GLOBE CORPORATION OPERATES THE MITCHELL SMITH DIVISION PLANT,
WHERE THE PRIMARY PRODUCT IS CORK RUBBER GASKET MATERIAL. PROCESS (AUTOCLAVE) AND HEATING STEAM
ARE SUPPLIED bY A BOILER RATED AT 350 BOILER HP (ABOUT 3.5 MW EQUIVALENT). STEAM CONDITIONS ARE
125 PSI AT 325 F, THE BOILER WAS ORIGINALLY ERECTED IN 1939t BUT UNDERWENT A COMPLETE OVERHAUL IN
1977. BOILER TUBES, REFRACTORY BRICK, GRATE, AND SOOT BLOWERS WERE REPLACED DURING THE OVERHAUL.
THE BOILER FIRES COAL SUPPLIED BY GENERAL COAL - NOMINAL SIZE IS 1.25 X 0.25 INCHES. COAL
CHARACTERISTICS ARE AS FOLLOWS* HHV=13,200 BTU/LB, ASH=6K, AND SULFUR IS LESS THAN 1*.
THE EMISSIONS CONTROL SYSTEM AT SHELLER GLOBE CONSISTS OF A W.W. SLY IMPIN6JET SCRUBBER
WHICH REMOVES PARTICIPATE AND SOg FROM THE FLUE GAS. THE SYSTEM USES A SODIUM HYDROXIDE MAKE-UP
FOR S02 CONTROL. RECYCLE TANK SUPERNATANT IS PH NEUTRALIZED AND IS DISCHARGED TO CITY SEWERS.
FLYASH AND SEDIMENT ' ARE. SUMPEO OUT AND HAULED TO A SANITARY LANDFILL.
127
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAhE.
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
SOURCL CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PARTICULATE EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CAPITAL
OPERATIONAL EXPERIENCE
ST. REGIS PAPER CO,
CANTONMENT, FLORIDA
INTERRUPTIBLE NATURAL GAS* BARK & OIL (25S-3K S)
175*000 ACFM
60 MW (EQUIVALENT)* DESIGN - 300,000 LB/HR STEAM
AIRPOL INDUSTRIES
CAUSTIC SCRUBBING
RETROFIT
1973
OPERATIONAL
80S - 90%
9
-------
BACKGROUND INFORMATION
ST. REGIS PAPER CO. CANTONMENT* FLORIDA
THE SCRUBBER SYSTEM AT ST. REGIS PAPER LOCATED AT CANTONMENT, FLORIDA WAS MANUFACTURED BY
AIRPOL, THE UNIT IS CONSTRUCTED OF 316 L STAINLESS STEEL AND HANDLES A TOTAL FLUE GAS VOLUME OF
175,000 ACFM. PARTICULATES ARE CONTROLLED WITH CYCLONES PRECEEDINS THE SCRUBBER. SCRUBBER PRESSURE
DROP IS APPROXIMATELY 20 INCHES W.G. WITH 80 TO 90S SULFUR DIOXIDE REMOVAL EFFICIENCY,
THE BOILER IS RATED AT 60 MW AND PRODUCES 300,000 LBS/HR STEAM, THE TYPICAL SULFUR CONTENT
OF THE FUEL (OIL X BARK, NATURAL GAS) IS BETWEEN 2 AND 3X. SULFUR DIOXIDE CONCENTRATION IN THE
SCRUBBER INLET is APPROXIMATELY 500 PPM WITH A PARTICULATE LOADING OF 400 LBS/HR,
SCRUBBER UNDERFLOW CONSISTS OF ASH AND A SODIUM SULFITE/SULFATE SOLUTION, THE SLUDGE IS DIS-
CHARGED TO AN ON-SITE SEWAGE TREATMENT PLANT.
COMMENTS
3RD QUAKTER-1977 WOOD FIBERS FROM BARK WERE CLOGGING SEPARATORS AND CONTROL VALVES, INSPECTION
WAS MADE Af,D SOLUTION TO PROBLEM IS BEING INVESTIGATED.
UUARTER-1977 AFTER INVESTIGATION OF THE CLOGGING PROBLEM IT niAS DECIDED TO CHANGE THE MAKE-UP
UP WATER SOURCE, WATER IS NOW OBTAINED FROM A CLEANER PORTION OF THE PROCESS LOOP.
PLANT REPORTS SATISFACTORY OPERATIONS WITH NO OTHER MAJOR PROBLEMS.
129
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCL CHARACTERISTICS
SOURCE RATING
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-uP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
OPERATIONAL EXPERIENCE
TEXACO INCORPORATED
SAN AROO, CALIFORNIA
OIL (2 PERCENT SULFUR)
16*100 ACFM a 460 F
THERE ARE MANY SCRUBBERS OF THIS APPROXIMATE SIZE AT THIS
INSTALLATION. CURRENTLY, THE ACTUAL NUMBER OF SCRUBBING
SYSTEMS HAS NOT BEEN REPORTED.
CEILCOTE CO.
SODIUM SCRUBBING
RETROFIT
OPERATIONAL
HALF OF SCRUBBER UNDERFLOW is RECIRCULATED»
HALF GOES TO WASTEWATER DISPOSAL WELLS.
THE F6D SYSTEM CONSISTS OF A HORIZONTALtPACKED-BED
TYPE SCRUBBER FOR THE FLUE GAS OF OIL FIRED BOIL-
ERS. THE BOILERS PRODUCE STEAM WHICH IS USED
TO FACILITATE OIL FLOW FROM THE OIL WELLS.
THERE ARE SEVERAL SCRUBBERS ON-SITE
ALTHOUGH THE EXACT SITUATION HAS NOT YET BEEN
REPORTED.
130
-------
BACKGROUND INFORMATION
TEXACO, INC, - SAN ARDO, CALIFORNIA
TEXACO USES OIL-FIRED STEAM GENERATORS AT THE SAN AROO, CALIFORNIA SITE TO FORCE OIL OUT OF THE
WELL. THE OIL HAS A TYPICAL SULFUR CONTENT OF 1.1%,
A TYPICAL SCRUBBER HANDLES 18,000 ACFM AT t60 F AND HAS PLASTIC PACKINGS TO AVOID CORROSION OF
INTERNALS. SODIUM HYDROXIDE SOLUTION IS USED AS SCRUBBING LIQUOR. THE SCRUBBER UNDERFLOW IS SPLIT
WITH HALF BEItvG RECYCLED AND HALF DISPOSED OF IN WASTE WATER DISPOSAL WELLS,
COMMENTS
2ND QUARTER-1977 A PROBLEM OF AMMONIA CONDENSING ON SURROUNDING FOLIAGE EXISTS, THE PROBLEM IS
UNDEK INVESTIGATION BY TEXACO.
131
-------
SECTION 12 - DESCRIPTION OF OPERATIONAL FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-JP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PARTICIPATE EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
OPERATIONAL EXPERIENCE
TEXAS6ULF
GRANGER* WYOMING
COAL (0.635 SULFUR* 1% ASH* 10,500 BTU/LB)
140,000 SCFM S 70 F (TOTAL - 2 BOILERS)
600,000 LB/HR STEAM (TOTAL)
65 MW (EQUIVALENT)* TOTAL
SWEMCO INC.
SODIUM SCRUBBING
NEW
SEPTEMBER, 1976
OPERATIONAL
90+SS
99.3S (HOT-SIDE ESP W/PRECEDHMG MECHANICAL COLLECTOR)
HOLDING POND FOR EVAPORATION
THIS SODIUM CARBONATE FGD SYSTEM WAS DESIGNED BY
SWEMCO, INC. OF NEW YORK. S02 CONTROL OCCURS IN
THE QUENCHER AND THE SIEVE-TRAY ABSORBER MODULE.
AN INTERESTING FEATURE IS AN INTERNAL DAMPER
WHICH ALLOWS A f TO 1 TURNDOWN RATIO.
INITIAL PROBLEMS INCLUDED PLUGGING CAUSED BY
FLYASH CARRYOVER FROM THE ESP. MILD STEEL
PIPING IN THE RECIRCULATING LINES WAS SEVERELY
CORRODED BY THE SLIGHTLY ACIDIC SCRUBBING LIQUOR,
132
-------
SECTION 13 - DESIGN INFORMATION FOR UNDER CONSTRUCTION FGD SYSTEMS
INSTALLATION NAME.
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / KETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
OPERATIONAL EXPERIENCE
CATERPILLAR TRACTOR CO.
EAST PEORIAt ILLINOIS
COAL (3.2SS SULFUR)
360,000 ACFM
100 MW (TOTAL - H BOILERS)
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
2NEW» 2RETROFIT
MARCHt 1978
CONSTRUCTION
908 (2*000 PPM a INLET)
DEWATERED SLURRY TO LANDFILL
60+K SOLIDS (CAS04) SLUDGE DIRECTLY TO LANDFILL
THE FGD SYSTEM IS STILL UNDER CONSTRUCTION.
FMC CONCENTRATED MODE DOUBLE ALKALI SYSTEMS WILL
REMOVE S02 EMISSIONS FROM <+ COAL-FIRED BOILERS.
A SEPARATE SCRUBBER WILL TREAT THE GASES FROM
EACH BOILER. START-UP IS CURRENTLY SCHEDULED
FOR MARCH 1978.
133
-------
BACKGROUND INFORMATION
CATERPILLER TRACTOR, EAST PEORIA, ILLINOIS
THE CATERPILLAR TRACTOR COMPANY PLANT LOCATED IN EAST PEORIA ILLINOIS HAS FOUR COAL FIRED BOIL-
ERS. TWO OF THE BOILERS ARE RATED AT 200,000 POUNDS OF STEAK PER HOUR AND THE REMAINING TWO ARE
RATED AT 210,000 POUNDS OF STEAM PER HOUR. THE TOTAL BOILER CAPACITY IS ABOUT 100 MW (EQUIVALENT).
MECHANICAL COLLECTORS ARE USED FOR FLY ASH CONTROL.
THE AIK QUALITY CONTROL SYSTEMS HAVE BEEN SUPPLIED BY Fhc ENVIRONMENTAL EQUIPMENT DIVISION,
THE.RL IS CHE SCKUbBEP TRAIN FOR EACH OF THE FOUK BOILERS, AND THEY WILL EACH CONTROL BOTH
PARTICULAR AND S02 EMISSIONS FROM ABOUT 90,000 ACFM.
COMMENTS
yUAKTER-1977 STARTUP IS NOW SCHEDULED FOR MARCH 1978. CONSTRUCTION IS PROGRESSING SMOOTHLY.
-------
SECTION 13 - DESIGN INFORMATION FOR UNDER CONSTRUCTION F6D SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE. CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
COMTPOL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGE OK 3Y-PNOUUCT DISPOSAL
OPERATIONAL EXPERIENCE
CATERPILLAR TRACTOR CO,
MAPLETON, ILLINOIS
COAL (3,28 SULFUR)
360,000 AFCM
100 PiW (TOTAL - 3 BOILERS)
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
NEW
OCTOBER, 1978
CONSTRUCTION
NOT AVAILABLE
DEWATERED SLURRY TO LANDFILL
60+58 SOLIDS (CASO^) SLUDGE DIRECTLY TO LANDFILL
AT THE CATERPILLAR MAPLETON PLANT, FMC CONCENTRA-
TED MODE DUAL ALKALI TECHNOLOGY WILL BE UTILIZED
TO CONTROL S02 EMISSIONS. THREE SCRUBBER SYSTEMS
WILL CONTROL EMISSIONS FROM THREE COAL-FIRED
BOILERS, CONSTRUCTION DELAYS, PRIMARILY ON THE
STEAM GENERATION SIDE HAVE DELAYED SYSTEM START-UP
BACK TO THE 1978-79 HEAT SEASON.
135
-------
BACKGROUND INFORMATION
CATERPILLAR TRACTOR CO. MAPLETON, ILLINOIS
AT THE MAPLETON, ILLINOIS PLANT, CATERPILLAR TRACTOR IS INSTALLING A NEW BOILER PLANT WHICH
WILL DE COMPLETED IN THE EARLY 1980'S. PLANS CALL FOR THE ERECTION OF EIGHT BOILERS, EACH RATED
AT ABOUT p.00,000 LBS/HR STEAM. THE TOTAL STEAM GENERATING CAPACITY WILL BE 1,650,000 LBS/HR STEAM.
THRE1E OF THESE BOILERS WILL BE COMPLETED BY THE 1978-79 HEA1 SEASON AND THE FLUE GAS FROM THESE
BOILERS wILL BE TREATED IN AN FMC ENVIRONMENTAL EQUIPMENT DIVISION SCRUBBER SYSTEM. THE SYSTEM
WILL CONTROL PARTiCULATES IN A VENTURl SCRUBBER (MECHANICAL PRECOLLECTION 85-90%). A CONCENTRATED-
MODE DUAL ALKALI CHEMISTRY WILL CONTROL S02 EMISSIONS. THE FINAL CONTROL SYSTEM WILL CONSIST OF
TWO SCRUBBING SYSTEMS, ONE TREATING GAS FROM FOUR OF THE BOILERS AND ONE TREATING GAS FROM THE OTHER
FOUR.
COMMENTS
3RD eUARTER-1977 SYSTEM IS UNDER CONSTRUCTION. START-UP IS EXPECTED LATE IN THE FALL OF 1977.
tfTH QUARTER-1977 CONSTRUCTION DELAYS ON THE STEAM GENERATIONS SIDE HAVE PUSHED PLANT START-UP
BACK TO THE FALL OF 1978.
-------
SECTION 13 - DESIGN INFORMATION FOR UNDER CONSTRUCTION FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
OPERATIONAL EXPERIENCE
GREAT WESTERN SUGAR
FREEMONT.OHIO
COAL (38 SULFUR)
40,000 SCFM a 70 F (TOTAL - 2 BOILERS)
1HO,000 LB/HR STEAM (TOTAL - 2 BOILERS)
GREAT WESTERN SUGAR
SODIUM CARBONATE
RETROFIT
OCTOBER, 1978
CONSTRUCTION
WASTEWATER TREATMENT AND DISCHARGE TO CITY SEWER
PARTICULATE AND so2 EMISSIONS WILL BE CONTROLLED
BY A SCRUBBER/ABSORBER MODULE OF PROPRIETARY
DESIGN. THE FLUE GAS IS GENERATED BY TWO
UNION BOILERS, EACH RATED 3 70,000 LB/HR STEAM.
STARTUP IS SCHEDULED FOR OCTOBER 1978.
137
-------
SECTION 13 - DESIGN INFORMATION FOR UNDER CONSTRUCTION FGD SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE HATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-OP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PARTICULATE EFFICIENCY
WATER MAKE-LP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
KERR-MCGEE CHEMICAL CORP.
TRONAt CALIFORNIA
COKE* COAL* OIL (0,558 - 58 SULFUR)
726*000 ACFM a 320 DEGREES F
(TOTAL - 2 BOILERS)
6
-------
SECTION 13 - DESIGN INFORMATION FOR UNDER CONSTRUCTION FGD SYSTEMS (CONTINUED) -
KERR-MCGEE CHEMICAL CORP.
OPERATIONAL EXPERIENCE
THE FGD SYSTEM CONSISTS OF A COMBUSTION EQUIPMENT
(CEA) SODA ASH SCRUBBING SYSTEM WHICH REMOVES FLY-
ASH AND SULFUR DIOXIDE FROM THE FLUE GAS OF TWO
COAL FIRED BOILERS. MAJOR CONSTRUCTION
IS COMPLETE AND PRECOMMISSIONING ACTIVITIES ARE
UNDERWAY. EXPECTED STARTUP DATE IS APRIL X, 1978.
139
-------
BACKGROUND INFORMATION
KERR-MCGEE CHEMICAL CORP. TRONAt CALIFORNIA
KERR-MCGEE CHEMICAL CORP. HAS A NEW 1,3 MM TON/YR SODA ASH PLANT AT TRONA, CALIFORNIA. THE
PLANT LOCATED ALONG THE SHORE OF SEARLES LAKEt IS THE LARGEST YET BUILT TO YIELD SODA ASH BY DIRECT
CARBONATlOfti OF BRINE AND IS EXPECTED TO ONSTREAM BY APRIL* 1978. THE PROCESSING INNOVATIONS, WHICH
HAVE IMPROVED THE PLANT EFFICIENCY* INCLUDE CARBONATION UNDER 13.5 LB/SQ. IN. PRESSURE, USE OF
A COAL-FIRED POWER PLANT, AND RECOVERY OF C02 FROM THE FLUE GASES.
THE PLANT HAS TWO BOILERS, EACH RATED AT 32 MW, WHICH PRODUCE PROCESS STEAM AND ELECTRICITY.
EACH BOILER PRODUCES 600,000 LBS/HR OF STEAM AT 1500 PSI AND BURNS A MIXTURE OF WESTERN COAL
(0.7 PERCENT SULFUR) AND PETROLEUM COKE (1.5 PERCENT SULFUR). THE HIGH SULFUR COKE IS MIXED WITH
THE COAL IN ORDER TO IMPROVE THE PARTICAL IONIZATION AND IN TURN FLY-ASH COLLECTION IN THE ESP
WHICH OPERATES ON THE COLD SIDE OF THE PREHEATER AT 98.5 PERCENT EFFICIENCY AND 300 F, THE FLUE
GAS FLOW RATE FROM EACH BOILER IS 363,000 ACFM AT 320 F AND MAY CONTAIN S02 BETWEEN 335 TO 5985 PPM
DEPENDING UPON THE FUEL, THE AIR POLLUTION REGULATIONS DICTATE THAT EACH BOILER MAY RELEASE NOT
MORE THAN 10 LBS/HR PARTICULATE, 200 LBS/HR OF S02 AND ItQ LBS/HR OF NOX.
THE FLUE GASES ARE SCRUBBED BY THE END LIQUOR FROM THE SODA ASH PLANT IN TWO SCRUBBERS
(30 FT DIA X 35 FT HIGH EACH) WHICH ARE MILD STEEL VESSELS WITH FLAKE LINING AND POLYPROPYLENE SIEVE
TRAYS. THE TOP TRAY RECEIVES PLAIN WATER WHEREAS THE SECOND TRAY RECEIVES THE RECIRCULATING LIQUOR
AT PH OF 6 - b.5. THE SPENT LIQUOR FROM THE BOTTOM OF THE SCRUBBERS IS RECIRCULATED BY RUBBER
LINED PUMPS TO A MILD STEEL SURGE TANK WHERE FRESH END-LIQUOR IS ADDED TO IT WITHOUT AGITATION. A
BLEED OFF STREAM IS CONTINUOUSLY TAKEN BACK TO THE SALT PONDS.
THE BOILER I.D. FANS (1600 HP.) FORCE THE GASES THROUGH THE SCRU3BERS AND EXPERIENCE 6 IN. WG
PRESSURE DROP. THE FANS HAVE MILD STEEL CASING. THE DOWNSTREAM DUCTWORK IS MILD STEEL WITH FLAKE
-------
KEKR-CtCGEE CHEMICAL CORP. IRONAt CALIFORNIA (CONTINUED)
LINIiviG WHEREAS THE STACK IS CONCRETE WITH FRP LINER. AMBIENT AIR IS HEATED IN AN EXTERNAL
STEA-1 HEATER AND MIXED UlTH THE EXIT FLUE GASES TO INCREASE THE TEMPERATURE FROM 125 F TO ABOUT
175 F. AT MAXIMUM L.UADIMG, THE SCRUBBERS HAVE A soa REMOVAL EFFICIENCY OF 98 PERCENT, THE SCRUBBED
FLU£ GASES WILL 3E PROCESSED THROUGH TWO MONOETHANOLAMINE (MEA) PLANTS FOR EXTRACTION OF C02. EACH
PLANT WILL PRODUCE 300 TONS/DAY OF COg AND WILL BE THE MAIN SOURCE OF MAKEUP C02 IN THE CARBONATION
PLANT,
COMMENTS
1ST QUAKTER-iy?ti THE MAJOR CONSTRUCTION WORK IS OVER. PRECOMMISSIONIN6 ACTIVITIES ARE
UNDEKWAY. THE PLANT IS EXPECTED TO GO ONSTREAM BY APRIL 1« 1978.
141
-------
SECTION 13 - DESIGN INFORMATION FOR UNDER CONSTRUCTION FGD SYSTEMS
INSTALLATION NAhE
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGE OR BY-PHODUCT DISPOSAL
CONTROL SYSTEM COST
CAPITAL
OPERATIONAL EXPERIENCE
ST. JOE MINERALS CORP.
MONACAi PENNSYLVANIA
COAL (3.0% SULFUR* 11000 BTU/LB)
150,000 ACFM
50 MW (DESIGN CAPACITY-ACTUAL ELECTRICAL POWER GENERATION)
BUREAU OF MINES
CITRATE PROCESS
RETROFIT
OCTOBER* 1978
CONSTRUCTION
REGENERABLE - ELEMENTAL SULFUR PRODUCT
$ 12.700 MILLION
CONSTRUCTION CONTINUES ON THE CITRATE PROCESS
SCRUBBING SYSTEM IwHICH WILL CONTROL S02 EMISSIONS
FROM A 60-MW COAL-FIRED POWER GENERATING UNIT AT
ST. JOE MINERALS. START-UP IS SCHEDULED FOR
OCTOBER 1978, THE REGENERABLE FGD SYSTEM WILL
PRODUCE ELEMENTAL SULFUR AS A BY-PRODUCT.
-------
BACKGROUND INFORMATION
ST. JOE MINERALS - MONACA, PENNSYLVANIA
IN THE SUMMER OF 1977, CONSTRUCTION BEGAN AT MONACA, PA. ON A CITRATE PROCESS (BUREAU OF MINES)
F6D SYSTEM FOK Ol\i£ OF THE TWO 60-MEGAWATT BOILERS OF THE GEORGE F. WEATON POWERPLANT USED BY ST.
JOE MINERALS CORP. TO GENERATE ELECTRICITY FOR A ZINC SMELTER. IT IS THE FIRST SMALL COMMERCIAL
SIZE EXPERIMENTAL CITRATE CONTROL SYSTEM BEING BUILT FOR SCRUBBING SULFUR DIOXIDE OUT Op COAL-
FIRED POWERPLAWT STACK bAS.
U;-ju£R A'*12.7 MILLION COST-SHARING AGREEMENT BETWEEN THE BUREAU AND ST. JOE* COSTS FOR TESTING
THE CITRATE PROCESS FOR A FULL YEAR ARE BEING SHARED ABOUT 50-50. THE CITRATE PROCESS WAS DEVELOPED
BY THE BUREAU IN THE 1960'S TO HELP CURB SULFUR DIOXIDE EMISSIONS FROM BASE METAL SMELTERS.
THE CITRATE PROCESS OEKIVES ITS NAME FROM THE UATER SOLUTION OF SODIUM CITRATE AND CITRIC ACID
USED TO ABSORB bUg CONTAINED IN THE FLUE GAS. ADDING HYDROGEN SULFIDE TO THE CITRATE-S02 SOLUTION
PRECIPITATES SOLID ELEMENTAL SULFUR, WHICH IS EASY TO SHIP AND CAN BE SOLD TO HELP OFFSET
COSTS, OK STGREu WITHOUT CAUSING DETRIMENTAL EFFECTS ON THE ENVIRONMENT.
ltd
-------
SFICTlGi'j in - DESI(if., INFORMATION FOR PLANNED FGD SYSTEMS
INSTALLATION
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
COIVTROL PROCESS
NLU / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SO? EFFICIENCY
SLUPGE OR BY-PRODUCT DISPOSAL
OPERATIONAL. EXPERIENCE
ARCO/POLYMERS
MONACA, PENNSYLVANIA
COAL (3,5?6 SULFUR)
300,000 SCFK a 70 F (TOTAL - 3 BOILERS)
900,000 LB/HR STEAM 3 700 PSIG AND 700 F
100 Mw (EQUIVALENT)
NOT SELECTED
NOT SELECTED
RETROFIT
DECEMBER, 1960
PLANNED-REQUESTING/EVALUATING BIOS
90% (2,300 PPh a INLET)
IF A REGENERATE PROCESS IS CHOSEN, PLANS ARE TO
PRODUCE LIQUID SOi.
IF DOUBLE ALKALI, A DEtoATERED CAS04 LANDFILL FILTER
CAKE WILL BE PRODUCED,
ARCO POLYhERS IS PLANNING TO PURCHASE A FGD SYSTEM
FOR THE FLUE GASES FROM THEIR THREE IDENTICAL
BOILERS (EACH 300,000 LBS/HR STEAM AT 700 PSIG &
700 F). WHILE OTHER PROCESSES ARE REPORTEDLY
BEING CONSIDERED, THE TWO PRIMARY FGD PROCESS
CANDIDATES ARE THE WELLMAN-LORD PROCESS AND THE
FMC DOUBLE ALKALI PROCESS, A FINAL DECISION
ON AWARD OF CONTRACT IS EXPECTED IN MAY 1978.
-------
SECTIOiM l*f - DESIGN INFORMATION FOR PLANNED FGO SYSTEMS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE. CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETKOFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
SLUDGc OR BY-PRODUCT DISPOSAL
OPERATIONAL EXPERIENCE
CARBORUNDUM ABRASIVES
BUFFALO, NEW YORK
CCAL (2% S AVERAGE, 3.2% S DESIGN MAX)
38*000 ACFFi 8 350 F
80,000 - 85,000 LBS/HR STEAM (PROCESS AND HEATING STEAM)
10 HW (EQUIVALENT)
CARBORUNDUM ENVIR. SYS. LTD.
LIME SCRUBBING
RETROFIT
PLANNED-CONTRACT AWARDED
92%
WASTEHATER TRtATMENT AND DISCHARGE TO CITY SEWER
NO DEFINITE PLANS HAVE BEEN MADE FOR THE CONTROL
OF S02 EMISSIONS FROM THIS BOILER. THE FUTURE OF
THE CONTROL SYSTEM WILL BE DETERMINED BY A REGU-
LATORY AGENCY DECISION EXPECTED NEAR THE END OF
1978. THE CURRENTLY OPERATING. VENTURI (L/G = 10)
CONTROLS ONLY PARTICULATE, BUT TIE-INS HAVE BEEN
PROVIDED FOR A LIME SCRUBBING SYSTEM USING
A 6-STAGE SPRAY TOWER FOR S02 CONTROL.
-------
SECTION 14 - DESIGN INFORMATION FOR PLANNED FGO SYSTEMS
INSTALLATION ,\AME
INSTALLATION) LOCATION
SOURCE CHARACTERISTICS
SOURLt RATING
CONTROL SYSTEM VE
COiiTRuL PROCESS
NEW / KLTKQFIT
START-UP DATE
COF,ITRGL SYSTEM STATUS
S02 EFUCIEP.CY
SLUDGL OR bY-PKGlJUCT DISPOSAL
OPLRATIOUAL EXPERIENCE
CHEVRON OIL COMPANY
BAKERSFIELD, CALIFORNIA
OIL (1.5% SULFUR)
450*000 ACFM S 500 F (TOTAL-IB BOILERS)
THERE WILL BE THREE ABSORBERS»EACH HANDLING
FLUE GAS FROM SIX STEAM GENERATORS
KOCH ENGINEERING
SODIUM SCRUBBING
RETROFIT
JULYi 1978
PLANNED-CONTRACT AWARDED
90%
CHEVRON IS AWAITING A REGULATORY BOARD DECISION
AS TO WHETHER THE ERECTION OF THESE PROPOSED
STEAM GENERATORS AND ACCOMPANYING FGD SYSTEMS
WILL BE APPROVED. IF CHEVRON RECEIVES A GO-AHEAD
FROM THE REGULATORY BOARD, THE COMPANY PLANS
TO USE PROPRIETARY SCRUBBING STRATEGY
IN MODULES FABRICATED BY KOCH ENGINEERING.
-------
SECTION 15 - DESCRIPTION OF FGD SYSTEMS NOT OPERATING OR TERMINATED
INSTALL AT I ON NAi"'E
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
CONTROL SYSTEM VLNOOR
CCWTRUL PROCESS
NEW / RETROFIT
START-UP OME
CONTROL SYSTEM STATUS
S0£ EFFICIENCY
SLUDGE Oi:< &Y-PKODUCT DISPOSAL
OPEKATICNAL EXPLRi
GREAT 1AJESTERM SUGAR
LONGNONT* COLORADO
COAL (0.7K SULFUR)
GREAT WESTERN SUGAK
AMMONIA-LADEN PROCESS WATER
RETROFIT
OCTOBER. 1973
TERMINATED OR INDEFINITELY SHUT DOWN
35S (300-400 PPM ol INLET)
WASTEWATER TREATMENT AND DISCHARGE TO RIVER
SUGAK PRODUCTION AND ALL PLANT OPERATIONS
HAVE BEEN TERMINATED AT THE LONGMONT PLANT.
-------
SECTION 15 - DESCRIPTION Of FGL SYSTEMS NOT OPERATING OH TERMINATED
INSTALLATION I'vAhL
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
SOURCE, CAPACITY
CONTROL SYSTEM VENDOR
COMTKUL I-KUCLSS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PARTItULATE EFFICIENCY
SLUDGE OR 6Y-PKOGUCT DISPOSAL
CONTROL SYSTEM COST
CAPITAL
OPERATIONAL EXPERlLNCt
HARRIS MINING CO.
SPRUCE PINE, NORTH CAROLINA
COAL (0.8K SULFUR, 5» ASH)
2 MW (EQUIVALENT)
W.W. SLY MANUFACTURING CO.
WATER SCRUBBING (NA,iih3 CPTN.)
RETROFIT
1973
TERMINATED UR INDEFINITELY SHUT DOWN
S 15,000,
CAPITAL COST INCLUDES INSTALLATION COST,
THE FGD SYSTEB CONSISTS OF A W.W, SLY IMPINJET
SCRUbbEK CUKRENTLY BEH-jfa USED STRICTLY AS A PAR-
TICULATE CONTROL DEVICE, THc SYSTEM HAS THE
CAPABILITY DF SCRUBBING WITH AMMONIA OR CAUSTIC
IF NECESSARY. HOWEVERt AS LON3 AS CURRENT
LOW-SULFUR COAL SUPPLIES LAST, THERE IS NO NEED
FOR S02 CONTROLS.
-------
BACKGROUND INFORMATION
HARRIS MINING SPRUct PINEi N.C.
THE FGD SYSTEM AT THL HARRIS MINING COMPANY LOcATLD AT SPRUCE PINEt NORTH CAROLINA REMOVES FLY-
ASH AND SULFUR DIOXIDE FKOI"! THE FLUE GAS OF A COAL FIRED BOILER. THE SCRUBBER IS A U.W, SLY
IMPir.it.EhT TYPt SCRUBBER CONSTRUCTED OF 304 STAINLESS STEEL. THE BOILER IS RATED 1.9 MW
(EQUIVALENT 200 BuILER HORSEPOWER). COAL COMPOSITION IS TYPICALLY 0.8ft SULFUR AND 5X ASH. PRIMARY
INTEREST IN FLUE GAS. SCRUBBING IS IN FLYASH REMOVAL AND NO TESTS FOR SULFUR DIOXIDE REMOVAL EFFI-
CIENCY HAVE BEEN KAUE.
COMMENTS
2ND QUARTEP.-1977 NO OPERATIONAL PROBLEMS HAVE BEEN REPORTED,
1ST uUARTER-197ti THIS PLANT HAS BEEN MOVED TO THL INACTIVE SYSTEMS FILE UNTIL SUCH TIME AS ACTUAL
FGD OPERATIONS bCGliM. THE. SCRUBBER IS EQUIPPED WITH ALKALI ADDITION CAPABILITY, BUT WITH
THE LOW SULFUU COAL CURRENTLY BEING FIRED, NO ALKALI ADDITION OR PH CONTROL IS OCCURRING,
If 9
-------
SECTION 15 - DESCRIPTION OF FGD SYSTEMS NOT OPERATING OR TERMINATED
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTEl-ISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
PARTICULATE EFFICIENCY
WATER '"1AKE-UP
SLUDGE OR HY-PKODliCT DISPOSAL
CONTROL SYSTEM COST
CAPITAL
OPERATIONAL EXPERIENCE
QUALITY MILLSt INC.
PIT. AIRYi NORTH CAROLINA
FUEL OIL
5 MW (EQUIVALENT)* TOTAL - THREE BOILERS
52*000 LB/HR STEAM
COMMERCIAL FABRICATION & MACH.
WATER SCRUBBING
RETROFIT
MAY, 1970
TERMINATED OR INDEFINITELY SHUT DOWN
H7% (600-800 PPM a) INLET)
80K-958o (0.05-0.16 GRAIN/SCF a) INLET)
40 GPM* OPEN LOOP
WASTEWATER TREATMENT AND DISCHARGE TO CITY SEWER
SCRUBBING LIQUOR DISCHARGED TO NEUTRALIZATION POND
$ 18*000,
THIS SMALL INDUSTRIAL BOILER UTILIZED A
COMMERICAL FABRICATION AND MACHINE (CFM) SCRUB-AIR
SYSTEM TO CONTROL EMISSIONS FROM THE COAL-FIRED
BOILER FROM MAY 1970 TO DECEMBER 1973.
AT THAT TIME THEY CONVERTED TO FIRING LOW-SULFUR
OIL, REMOVING THE NEED TO CONTROL EMISSIONS.
150
-------
SECTION 15 - DESCRIPTION OF F6D SYSTEMS NOT OPERATING OR TERMINATED
INSTALLATION
INSTALLATION LOCATION
SOURCE. CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 EFFICIENCY
WATER 'TAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
TRANSCO TEXTILES* INC.
AUGUSTA, GEORGIA
FUEL OIL (2% MAX, SULFUR)
SOfOOO ACFM
20 MW
FMC ENVIRONMENTAL EQUIPMENT
SODIUM SCRUBBING
NEW
MARCH* 3,975
TERMINATED OR INDEFINITELY SHUT DOWN
808-85& (610 LB/HR 3 INLET)
HB GPM* OPEN LOOP
WASTEWATER TREATMENT AND DISCHARGE TO RIVER
NA2S03/S04 LIQUOR DISCHARGED* TO A HOLDING POND
151
-------
SECTION ID - nrSCHIPTIOu OF F&P SYSTEMS NOT OPERATING OR TERMINATED (CONTINUED) -
TR/M-jSCO TEXTILES. INC.
OPERATIONAL EXPERIENCE.
THE FGO OPERATIONS HAVE BEEN TERMINATED FOR AN
INDEFINITE PERIOD, THE PLANT BURNS NUMBER 6 FUEL
OIL AND THE SULFUR DIOXIDE EMISSIONS ARE 50% OF
THE EXISTING REGULATIONS. THE BOILER IS RATED
AT 20 MW (EQUIVALENT) AND PRODUCES 150*000 LBS/HR
STEAM, WHEN OPERATIONAL* THE SCRUBBER SYSTEM HAD
FLUE GAS VOLUME OF 50,000 ACFPi AT 1<+0 DEGREES F9
SYSTEM START-UP OCCURRED IN MARCH 1975 AND SCRUB-
BER OPERATIONS WEKE TERMINATED LATER IN THE SAME
YEAR. A DEC, 1977 CHECK REVEALS THAT THE FGD
SYSTEM IS STILL TERMINATED AND THERE ARE CURRENTLY
NO PLANS TO INITIATE OPERATIONS.
152
-------
SECTION 15 - DESCRIPTION OF FGD SYSTEMS NOT OPERATING OR TERMINATED
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE. CHARACTERISTICS
SOURCE RATING
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / KETKOFIT
START-UP DATE
CONTROu SYSTEM STATUS
S02 EFFICIENCY
PARTICULAR EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
OPERATIONAL EXPERIENCE
U.S. GYPSUM CORP.
OAKMONT, PENNSYLVANIA
COAL
19t30Q SCFM (TOTAL -
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-600/7-78-052a
2.
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
EPA Industrial Boiler FGD Survey: First Quarter 1978
5. REPORT DATE
March 1978
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
8. PERFORMING ORGANIZATION REPORT NO.
J. Tuttle, A. Patkar, and N. Gregory
9. PERFORMING ORGANIZATION NAME AND ADDRESS
PEDCo Environmental Inc.
11499 Chester Road
Cincinnati, Ohio 45246
10. PROGRAM ELEMENT NO.
EHE624
11. CONTRACT/GRANT NO.
68-02-2603, Task 4
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Periodic; 4/77-3/78
14. SPONSORING AGENCY CODE
EPA/600/13
15. SUPPLEMENTARY NOTES jERL-RTP project officer is J.
541-2915.
David Mobley, Mail Drop 61, 919/
16. ABSTRACT
The report presents detailed technical information concerning application
of flue gas desulfurization (FGD) systems to industrial boilers. The information was
obtained by a survey of plant personnel, control system vendors, regulatory agen-
cies , and consulting engineering firms. The data is given in two types of tables:
one gives summary information; the other, detailed information. Summary tables
present information as a function of control process, control system vendor, dis-
posal techniques, operation status, start-up date, and flue gas capacity. Detailed
information includes: control system design, economics, operating experience,
problems and solutions, waste disposal techniques, and maintenance practices.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS
c. COS AT I Field/Group
Pollution
Flue Gases
Desulfurization
Boilers
Waste Disposal
Maintenance
Pollution Control
Stationary Sources
Industrial Boilers
13B
2 IB
07A,07D
13A
15E
3. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
157
20. SECURITY CLASS (Tills page)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
154
------- |