United States Industrial Environmental Research EPA-600/7-78-052c
Environmental Protection Laboratory November 1978
Agency Research Triangle Park NC 27711
EPA Industrial Boiler
FGD Survey:
Third Quarter 1978
Interagency
Energy/Environment
R&D Program Report
-------
RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories were established to facilitate further development and application of en-
vironmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:
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 endorsemertt or recommendation for use.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
-------
EPA-600/7-78-052C
November 1978
EPA Industrial Boiler FGD Survey:
Third Quarter 1978
by
J. Tuttle, A. Patkar, D. Welch,
M. Hessling, and M. Eckstein
PEDCo. Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
Contract No. 68-02-2603
Task No.36
Program Element No. EHE624
EPA Project Officer: R. Michael McAdams
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
-------
NOTICE
This report (prepared by PEDCo Environmental, Inc.,
Cincinnati, Ohio under EPA Contract No. 68-02-2603, Task No. 36)
is provided as an information transfer document. Data in this
report are supplied voluntarily by industrial representatives;
flue gas desulfurization (FGD) system designers, vendors, and
suppliers; regulatory personnel; and others. Neither EPA nor the
designated contractor warrants the accuracy or completeness of
information contained in this report.
Initial distribution of the report is limited to organiza-
tion and individuals indicating a specific interest in the field
of FGD technology. Additional copies of this report and succeed-
ing issues can be purchased from National Technical Information
Service, Springfield, Virginia 22151.
-------
TABLE OF CONTENTS
SECTION PAGE
NOTICE ii
TABLE OF CONTENTS ±ii
EXECUTIVE SUMMARY iv
1 INTRODUCTION I
^ STATUS OF INDUSTRIAL BOILERS WITH FGO SYSTEMS 3
A SUMMARY OF ALL INSTALLATIONS BY NAME, LOCATION, START-UP DATE,
CURRENT STATUS, AND PAGE LOCATION FOR ADDITIONAL DATA.
3 SUMMARY OF FGD SYSTEMS ON INDUSTRIAL BOILERS 6
A BRIEF SUMMARY OF THE SOURCE CHARACTERISTICS, THE CONTROL PROCESS AND
CONTROL SYSTEM SUPPLIER, ANO INFORMATION ON RECENT SYSTEM PERFORMANCE.
0 SUMMARY BY VENDOR OF FGD SYSTEMS ON INDUSTRIAL BOILERS 16
A LIST OF THE CONTROL SYSTEMS SUPPLIED BY EACH SYSTEM VENDOR OR MANUFACTURER.
5 OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS 19
b UNDER CONSTRUCTION FGO SYSTEMS ON INDUSTRIAL BOILERS 22
7 PLANNED FGO SYSTEMS ON INDUSTRIAL BOILERS as
s SUMMARY OF DISPOSAL PRACTICES FOR FGD SYSTEMS ON INDUSTRIAL BOILERS 2«
9 PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS 38
AN IN DEPTH DATA PRESENTATION FOR THE OPERATIONAL CONTROL SYSTEMS.
THIS SECTION PRESENTS BACKGROUND INFORMATION, OPERATING EXPERIENCE,
DESIGN DATA, DISPOSAL PRACTICES, ANO ANY OTHER RELEVANT INFORMATION
AVAILABLE CONCERNING THE FGO SYSTEMS AT THE VARIOUS INSTALLATIONS.
10 DESIGN INFORMATION FOR UNDER CONSTRUCTION FGD SYSTEMS ON INDUSTRIAL BOILERS 106
SAME AS SECTION 9, FOR CONTROL SYSTEMS UNDER CONSTRUCTION.
11 DESIGN INFORMATION FOR PLANNED FGD SYSTEMS ON INDUSTRIAL BOILERS 118
SAME AS SECTION 9, FOR PLANNED CONTROL SYSTEMS.
ia DESCRIPTION OF INDUSTRIAL BOILER FGD SYSTEMS NOT OPERATING 139
SAME AS SECTION 9» FOR CONTROL SYSTEMS WHERE FOR SOME REASON, THE SYSTEM
IS NOT OPERATING.
13 INDUSTRIAL BOILER FGD COSTS 135
14 PROCESS DIAGRAMS FOR INDUSTRIAL BOILER FGD SYSTEMS 147
-------
ETXFf.lJ T I VE SUMMAWY
THE FIRST FLU L-SCALE uwutD STATES APPLICATION! OF FLUK GAS oFSULFuHiZATinN IFGD> UCHNOLOGY TU
INDUSTRIAL ROTLFRS WAS AT THE GENERAL MOTORS PLANT IN ST. LOUIS, MISSOURI WHtRE TWO FGD SYSTEMS HFRE
INSTALLED ON TWO CUAL-FIRED BOILERS IN 1972. IN THIS 3RD UIIARTFR 1978 REPORT, 121 OPERATIONAL FGfl
SYSTEMS ARE DESCRIBED. THESE SYSTEMS ARE CONTROLLING S02 EMISSIONS FRO" 165 ROTLFRS, LOCATED AT 39
PLANT SITES ACROSS THE UNITFD STATES. FGD SYSTEMS AT 19 PLANTS ARE KNOWN TO RE UNDER CONSTRUCTION
OR IN SOME STAGE OF PLANNING. IN ADDITION THEKF ARE b INSTALLATIONS INCLUDED IN THF REPORT WHERE
EGO OPERATIONS HAVE EITHER BEEN TERMINATED, INDEFINITELY SHUT DOWN, OR NEVER STARTED-UP. THE TOTAL
COVERAGE OF THIS REPORT IS THEREFORE 64 INSTALLATIONS. TABLE I SUMMARI7ES THF NUMBER AND SCFM OF
THOSE SYSTEMS OPERATING, UNOER CONSTRUCTION, OR IN SOME PLANNING PHASE.
TABLE I
NUMBER AND SCFM OF INDUSTRIAL BOILER FGD SYSTEMS
STATUS
OPERATIONAL
UNOER CONSTRUCTION
PLANNING*
CONTRACT AWARDED
LETTER OF INTENT
REOUEST1N6/EVALUATING BIDS
CONSIDERING USING FGD
TOTAL 58 9,245,510 165 308
*NOTEJ THERE ARE PROBABLY SEVERAL FGO SYSTEMS BEING PLANNED WHICH HAVE NOT BEEN LOCATED BY THIS
SURVEY AND THEREFORE ARE NOT COVERED IN THIS REPORT.
TABLE II SUMMARIZES THE PLANTS ACCORDING TO THE YEAR OF FGD STARTUP, AND THE SCFM CAPACITY.
TWO ADDITIONAL SECTIONS ARE PRESENTED IN THIS QUARTERLY UPDATE; SECTION 13, "INDUSTRIAL BOILER
F6D COSTS," AND SECTION 14, "PROCESS DIAGRAMS FOR INDUSTRIAL BOILER FGO SYSTEMS."
SECTION 13, WHICH BEGINS ON PAGE 135 PRESENTS CAPITAL AND OPERATING COSTS FOR THE VARIOUS FGD
INSTALLATIONS. IT IS IMPORTANT TO NOTE THAT THESE ARE REPORTED COSTS AND HAVE NOT BEEN ADJUSTED IN
ANY MANNER. INCLUDED IS A DESCRIPTION OF THE ITEMS COVERED WITHIN THE COST FIGURES.
SECTION 14, WHICH BEGINS ON PAGE 14ft, PRESENTS PROCESS DIAGRAMS WHICH ARE STANDARDIZED IN FORMAT
AND SYMBOLS! ALSO INCLUDED ARE EQUIPMENT LISTS, AND STREAM-FLOW CHARACTERISTIC TABLES TO PROVIDE A
BETTER DESCRIPTION OF THE VARIOUS SYSTEMS.
HIGHLIGHTS FROM THE CURRENT INDUSTRIAL BOILER SURVEY ARE GIVEN BELOW:
NO. OF
INSTALLATIONS
39
10
2
0
2
5
CAPACITY
SCFM
5,040,760
1,836,750
266,000
0
176,000
1,924,000
NO. OF SEPERATE
FGD SYSTEMS
121
33
4
0
3
4
NO. OF BOILERS
CONTROLLED
165
107
5
0
15
16
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TABLE II
STARTUP YEAR AND SCFM OF INDUSTRIAL BOILER FGO SYSTEMS
YEAR
UMTS
SCFM
1972
1973
1974
1975
1976
1977
1978
1979
1980
1982
1983
1987
YEAR NOT YET
DETERMINED
TOTAL
1
4
6
12
6
4
13
5
1
1
1
i
3
•)8
64,000
621,300
503,630
1 ,473,300
1,024,530
342,000
2,430,750
596,000
236,000
320,000
1,200,000
280,000
151,000
9,245,510
THE ALYESKA PIPELINE SERVICE CO. FMC SODIUM HYDROXIDE 502 CONTROL SYSTEM CONTINUED TO DEMONSTRATE A
IOCS AVAILABILITY INDEX. IT IS IMPORTANT TO NOTE THAT THE SYSTEM IS SUPPLIED WITH 100S REDUNDANCY
(1 MODULE ON-LINE, ! MODULE SPARE AT ALL TIMES). THE MILD CORROSION WHICH WAS OCCURRING IN THE
DUCTWORK DOWNSTREAM Of THE ABSORBER HAS BEEN BROUGHT UNDER CONTROL BY CYCLOMEXAKINE SPRAYS.
AMERICAN THREAD PLANS TO REMOVE THE F6D I.D. FAN AND UPGRADE THE BOTLER I.Do FAN. FAN IMBALANCE,
CAUSED BY EROSION OF THE FIBERGLASS FAN LINER, HAS CAUSED VIBRATION CRACKS IN THE PVC PIPING.
CATERPILLAR TRACTOR CO. REPORTED THE FOLLOWING ITEMS FOR THEIR SEVERAL INSTALLATIONS:
EAST PEORIA - THE NEW FMC SYSTEM HAS BEEN RUNNING TROUBLE-FREE SINCE BOILER PLANT RESTART FOR
THE FALL HEAT SEASON.
JOLIET - PROBLEMS ARE STILL IN EVIDENCE FOR THIS ZURN INDUSTRIES INSTALLATION, WITH RESPECT TO
SHORT FILTER CLOTH LIFE AND PLUGGED, CORRODED, AND UNRELIABLE S02 MONITORS. HASTELLOY C PROBES
HAVE BEFN INSTALLED, BUT AS YET NOT EVALUATED.
MAPLETON - CONSTRUCTION OF FMC FGD SYSTEMS FOR THREE OF THE BOILERS IS NEARING COMPLETION.
START-UP FOR THESE SYSTEMS IS SCHEDULED FOR OCTOBFR 1978.
MORTON - ACCEPTANCE TESTING OF THE ZURN FGD SYSTEM IS SCHEDULED FOR LATER THIS YEAR.
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CHEVRON U.S.A., INC. REPORTED THAT ONLY 2 OF THE FGD SYSTEMS WERE OPERATING, DUE TO LOWERED STEAM
DEMAND. THESE ? SYSTEMS CONTROL EMISSIONS FROM 1? STEAM GENERATORS. SYSTEM OPERABILITY INDEX FOR
THE QUARTER WAS REPORTED TO BE 95X; THE ONLY PROBLEM HAS REEN NA2C03 FEED CHUTE PLUGGING. IN THIS
KOCH ENGINEERING FGO SYSTEM.
DUPONT, INC. ANNOUNCED THAT LONG-RANGE FGO PLANS INCLUDE THE FOLLOWING:
IN TEXAS, A 160 MW (EQUIVALENT) SYSTEM SCHEDULED FOR START-UP IN 1983. DUPONT HAS DECIDED ON A
LIMESTONE SCRUBBING STRATEGY FOR THIS SYSTEM, ALTHOUGH A VENDOR HAS NOT BFEN SELECTED.
IN GEORGIA, A iaO MW (EQUIVALENT) SYSTEM SCHEDULED FOR START-UP IN 1987. DUPONT HAS DECIDED
THAT THIS WILL BE A DOUBLE ALKALI SYSTEM ALTHOUGH, AGAIN, A VENDOR HAS NOT BEEN SELECTED.
GENERAL MOTORS REPORTED THAT THE GM ENVIRONMENTAL-DESIGNED PARMA DOUBLE ALKALI FGD SYSTEM DEMONSTRA-
TED A 100X OPERABILITY INDEX VALUE FOR THE THIRD QUARTER.
GETTY OIL IS EXPERIMENTING WITH A SILICON DISPERSANT TO ASSIST IN AMELIORATING SCALING PROBLEMS IN
THE SLOWDOWN TANK OUTLET LINE FOR THIS FMC FGD INSTALLATION.
GRISSOM AIR FORCE BASE HAS ANNOUNCED THAT AIRPOL INDUSTRIES HAS TENTATIVELY BEEN SELECTED AS THE FGD
SYSTEM SUPPLIER. THE SYSTEM WILL CONTROL 32,000 SCFM, FOR COAL WITH A SULFUR CONTENT RANGING FROM
0.9 TO 4.6X, AT A DESIGN RATE OF 1.2 LBS OF S02/MM BTU HEAT INPUT. THE REPORTED EMISSIONS CONTROL
SYSTEM COST IS 1.8 TO 2 MILLION DOLLARS.
ITT RAYONIER, INC. REPORTED THAT THE BOILER AND THE AIRPOL FGD SYSTEMS OPERATED APPROXIMATELY 95X OF
THE PERIOD. THE ONLY OUTAGE DURING THE PERIOD WAS A 3-DAY DOWNTIME THAT WAS BOILER-RELATED.
KERR-MC6EE SODA ASH PLANT, UTILIZING A COMBUSTION EQUIPMENT ASSOCIATES DESIGN FOR S02 REMOVAL, RE-
PORTED TWO BOILER/FGD OUTAGES DURING THE QUARTER. BOTH OUTAGES WERE DUE TO THE NEED TO REPLACE
SIEVE TRAYS IN THE ABSORBER MODULES. THE BOILERS ARE NOW BURNING 90-95X OF THE HIGH SULFUR MIXTURE
OF COKE AND LOW-SULFUR WESTERN COAL.
MEAD PAPER80ARD CO. REPORTED AN AVAILABILITY INDEX VALUE OF 100X FOR THIS AIRPOL FGD SYSTEM FOR THE
QUARTER.
THE MOBIL OIL DESIGNED SODIUM HYDROXIDE FGD SYSTEM AT THE SAN ARDO PLANT HAD AN ESTIMATED RELI-
ABILITY INDEX VALUE OF 90X.
PHILIP MORRIS IN CHESTER, VIRGINIA, HAS PURCHASED A SODIUM CARBONATE FGO SYSTEM FROM FLAKT, INC.
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THE S02 RFMQVAL SYSTEM 4ILL rir PMMiFOM) BY » Ci.Ml-.S T [>F FbP ALSO SlJPPLItD RY FLAKf. THE SCRU8RER
IS DESIGNFQ TO REMOVE ^OX OF THF TNLfcT SO? FHOK 2/3 OF THF FLUE GAS, ABOUT 39,000 SCFM; THE REMAIN-
ING i/3 OP THE FLUE GAS ^m. HE ustn FO» ctHtii. START-UP TS SCHEDULED FOK JANUARY 1979.
RICKEN6ACKEP AT" FORCF BASE hiEI-'ORTtn THFlf* RfcSt AHCH-cn T TRFLL /H AHCO SCRUBBER TO HAVE AN FGO SYSTEM
AVAILABILITY TNOEX OF BETTEH THAN 99. S% FOR THE UHAPTFR.
AT THF ST. JOE ZIMC co. CONSTRUCTTON is NEARING COMPLFTION; THE BURFAU OF MINFS CITRATE PROCESS
F60 SYSTEM IS NOW SCHEDULED TO START-HP IN OtCtMBF.R 1978.
Vll
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SECTION 1
INTRODl.'CT ION
THIS REPORT ADDRESSES THE APPLICATION OF FLUE hAS OFSHLFURI 7 AT I ON (F(,l!) TECHNT'OGY TO INDUSTRIAL
BOILERS. AN INDUSTRIAL BOILER KILL BE DEFINED AS A BOIIER OR STEAM GF.NFR»tO(v WHITH IS OPERATING OH
SCHEDULED FOR OPERATION AT AM INDUSTRIAL SITE. THIS TS IN CONTRAST TO A UTILITY BOlLFK WHEREIN THE
PRIME FUNCTION IS STEAM GENERATION AND SUBSEQUENT CONVERSION TO ELECTRICAL POWER FOR SALE TO THE
PUBLIC. THE NEED FOR SUCH A DOCUMENT HAS ARISEN AS A RESULT OF MORE STRINGFNT EMISSION REGULATIONS
DESIGNED TO REDUCE SULFUR DIOXIDE (S02) EMISSIONS. IN VIEW OF THE DEVELOPMENTAL STATUS OF FGD TECH-
NOLOGY, EPA'S INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY IN RESEARCH TRIANGLE PARK, NORTH CARO-
LINA, IS ESTABLISHING A PERIODICALLY UPDATED ENGINEERING APPLICATION/INFORMATION TRANSFER PROGRAM
FOR INDUSTRIAL USE OF SOS CONTROL TECHNOLOGY.
FIRST ISSUED IN DECEMBER 1977 AS A COMPREHENSIVE 900-PAGE REPORT ON SOS CONTROL SYSTEMS ON ALL
NONUTILTTY COMBUSTION AND PROCESS SOURCES, THE CURRFNT SERIES, IN THE INTEREST OF ECONOMIZING ON THF.
OPERATION, ADDRESSES ONLY INDUSTRIAL BOILER APPLICATIONS OF FGD TECHNOLOGY. THE FIRST ISSUE OF THIS
SERIES, ENTITLED "EPA INDUSTRIAL BOILER FGD SURVEY: FIRST QUARTER 1978," PRESENTED DETAILED TECH-
NICAL INFORMATION ON INDUSTRIAL BOILER F60 INSTALLATIONS. THE INFORMATION WAS OBTAINED BY A
SURVEY OF PLANT PERSONNEL, CONTROL SYSTEM VENDORS, REGULATORY AGENCIES, AND ENGINEERING FIRMS.
THE CURRENT REPORT REPRESENTS AN EXPANSION OVER THE SECOND QUARTER S978 ISSUE WITH RESPECT TO
BOTH THE NUMBER OF INSTALLATIONS, AND THE INFORMATION PRESENTED FOR EACH INSTALLATION. THE I1ATA
ARE GIVEN IN TWO TYPES OF TABLES! ONE GIVFS SUMMARY INFORMATION; THE OTHER DETAILED INFORMATION.
SUMMARY TABLES PRESENT INFORMATION AS FUNCTIONS OF TYPE OF CONTROL PROCESS, CONTROL SYSTEM VENDOR,
DISPOSAL TECHNIQUES AND OPERATIONAL STATUS (OPERATIONAL, UNDER CONSTRUCTION, PLANNED, OR NOT OPERAT-
ING). NUMBERS, OPERATIONAL STATUS, AND OVERALL CAPACITY OF THE FGD SYSTEMS ARE SUMMARIZED in THE
EXECUTIVE SUMMARY. DETAILED INFORMATION INCLUDES? CONTROL SYSTEM DESIGN PARAMETERS, OPERATING EX-
PERIENCE, ECONOMICS, PROBLEMS AND SOLUTIONS, WASTE DISPOSAL TECHNIQUES, AND MAINTENANCE PRACTICES.
THE INFORMATION IN THIS REPORT WILL SE PERIODICALLY UPDATED AND EXPANDER »1 MEANS OF TELEPHONE
AND MAIL SURVEYS, AND PUBLISHED EACH QUARTER. IN FUTURE ISSUES, THE DATA BASE ON SELECTED PLANTS
WILL BE EXPANDED BY ON-SITE SURVEYS.
CERTAIN ENGINEERING SYMBOLS AND TERMS ARE USED VERY FREQUENTLY IN THE FIELD OF FGD TECHNOLOGY.
TABULATED BELOW ARE THE DEFINITIONS OF PERTINENT SYMBOLS AND TERMS USED IN THIS REPORT.
SYMBOL/TERM DEFINITION
ACF ACTUAL CUBIC FEET, UNIT OF GAS VOLUME MEASURED AT ITS ACTUAL TEMPERATURE AMD
PRESSURE
ACFM ACTUAL CU8TC FEET PER MINUTE, UNIT OF GAS FLOW RATE MEASURED AT ITS ACTUAL
TEMPERATURE AND PRESSURE
AVAILABILITY HOURS THE FGO SYSTFM hAS AVAILABLE (WHETHER OPERATED OR NOT) DIVIDED BY HOURS IN
PERIOD, FXPRESStO AS PFRCEMTAGE
F DEGREES FARENHEIT, UNIT OF TEMPERATURE
-------
DEFINITIONS (CONTINUED)
SYMBOL/TERM
DEFINITION
F.D.
FRP
GAL
GPM
I.D.
L/6
MM
MW(EQUIVALENT)
OPERABILITY
PSIG
RELIABILITY
SCFM
T
W.G.
0/XX
0/0
FORCED DRAFT
FIBEHGLASS-KFINFORCED POLYESTER (OR PLASTIC)
GALLONS
GALLONS PER MINUTE
INDUCED DRAFT
LIQUID-TO-GAS RATIO, RECIRCULATING LIQUID FLOW DIVIDED BY THE ACTUAL GAS FLOW,
GAL/1000 ACF
MILLION (DOLLARS, GALLONS, BTU, ETC.)
?ooo SCFM/MW is THE CONVERSION FACTOR USED FOR THIS REPORT. ALTHOUGH THERE ARE
SEVERAL METHODS IN USE FOR ARRIVING AT EQUIVALENT MW, SUCH AS, LB/HR OF STEAM,
MM BTU/HR OF HEAT INPUT, THE FACTOR MOST INFLUENTIAL IN AFFECTING EQUIPMENT
SIZING is FLOW RATE.
HOURS THE FGD SYSTEM OPERATED DIVIDED BY BOILER OPERATING HOURS IN PERIOD,
EXPRESSED AS PERCENTAGE
POUNDS PER SQUARE INCH, UNIT OF PRESSURE
HOURS THE FGD SYSTEM WAS OPERATED DIVIDED BY HOURS IT MAS CALLED UPON TO OPERATE,
EXPRESSED AS PERCENTAGE
STANDARD CUBIC FEET PER MINUTE, UNIT OF GAS FLOW RATE MEASURED AT 70 F AND 1 ATM.
PRESSURE
IF THE PRESSURE IS ASSUMED TO BE ONE ATMOSPHERE, THEN THE FOLLOWING RELATION
EXISTS: SCFM = ACFM(060 + 70)/(«60 * ACTUAL TEMP)
TEMPERATURE
MATER GAUGE, UNIT OF PRESSURE DROP EXPRESSED AS INCHES OF MATER
SYMBOL USED MHEN THE MONTH OF A STARTUP DATE IS NOT AVAILABLE
SYMBOL USED WHEN NEITHER THE MONTH NOR THE YEAR OF A STARTUP DATE IS AVAILABLE
THE ENGLISH SYSTEM IS USED IN THIS REPORT. SOME OF THE CONVERSION FIGURES BETWEEN THE ENGLISH
AND METRIC SYSTEMS AND ABBREVIATIONS ARE SHOWN BELOW:
1 F (FOOT) s 0.30a8 METER
1 T (SHORT TON) s 0.91 METRIC TON
1 LS (POUND) = 0.45 KILOGRAM
1 GAL (GALLON) s 3.79 LITER
1 BBL (BARREL) = O.lfe KILOLITER
1 SCFM = 1.58 NORMAL CUBIC METERS PER HOUR
1 GALLON/1000 ACF = 0.135 LITERS/NORMAL CUBIC M£T£R
1 BTU = 0.35 KCAL
ANYONE DESIRING TO RECEIVE THE QUARTERLY UPDATED VERSIONS OF THIS REPORT FREE OF COST, MAY
REPUEST ADDITION OF HIS OR HER NAME TO THE MAILING LIST BY CONTACTING THE EPA PROJECT OFFICER OR THE
CONTRACTOR.
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STATUS TO OCTOBER 1978
SECTION ?.
STATUS OF INDUSTRIAL BOILERS WITH FGD SYSTEMS
INSTALLATION NAMF
ALYESKA PIPELINE SERVICE CO,
AMERICAN THREAD co.
ARCO/POLYMERS, INC.
ARMCO STEEL
BELRIDGE OIL CO.
BELRIDGE OIL CO.
9ELRIDGE OIL COMPANY
BUNGEr INC.
C.A.M.(CARBIDE-AMOCO-MONSANTO)
CANTON TEXTILES
CARBORUNDUM ABRASIVES
CATERPILLAR TRACTOR CO.
CATERPILLAR TRACTOR CO.
CATERPILLAR TRACTuR CO.
CATERPILLAR TRACTOR CO.
CATERPILLAR TRACTOR CO.
CATERPILLAR TRACTOR CO.
CHANSLOR WESTERN OIL & DEV. CO
CHEVRON U.S.A. INC.
CHEVRON U.S.A. INC.
DUPONT, INC.
DUPONT, INC.
FIRESTONE TIRE AND RUBBER co,
FMC (SODA ASH PLANT)
GENERAL MOTORS CORPORATION
GENERAL MOTORS CORPORATION
GENERAL MOTORS CORPORATION
GENERAL MOTORS CORPORATION
LOCATION
VALDEZ, ALASKA
MARION, NORTH CAROLINA
MONACA, PENNSYLVANIA
MinDLETOWN, OHIO
MCKITTRJCK, CALIFORNIA
MCKITTRICK, CALIFORNIA
MCKITTRICK, CALIFORNIA
CAIRO, ILLINOIS
HOUSTON, TFXAS
CANTON, GEORGIA
BUFFALO, NEW YORK
EAST PEORIA, ILLINOIS
JOLIFT, ILLINOIS
MAPLETON, ILLINOIS
MAPLETON, ILLINOIS
MORTON, ILLINOIS
MOSSVILLE, ILLINOIS
BAKERSFIELD, CALIFORNIA
BAKERSFIELD, CALIFORNIA
BAKERSFIELD, CALIFORNIA
GEORGIA
TEXAS
POTTSTOWN, PENNSYLVANIA
GREEN RIVER, WYOMING
DAYTON, OHIO
PARMA, OHIO
PONTIAC, MICHIGAN
ST. LOUIS, MISSOURI
START-UP
DATE
1
fe-77
0-73
6-80
0-75
1-78
7-78
6-78
9-77
10-85
6-74
0- 0
a-78
9-74
10-78
10-79
1-78
10-75
12-78
7-78
4-79
0-87
0-82
1-75
S-76
9-74
3-74
4-76
0-7i
STATUS*
1
1
3
1
2
1
1
8
6
1
3
1
1
2
2
1
1
2
t
5
6
6
1
1
I
1
1
1
28(
31C
nac
33(
106(
35(
36 (
129(
120(
37 (
121(
39(
41C
107C
109(
43(
45t
110(
46C
122(
123(
124(
50(
53(
55 (
58(
64(
66(
PAGE
6,
6,
6,
6,
6,
6,
6,
7,
7,
7,
7,
7,
7,
7,
8,
8,
8,
8,
8,
8,
8,
9,
9,
9,
9,
9,
9,
9,
16
18
16
17
16
IB
17
16
18
16
16
16
18
16
17
18
17
17
17
17
NUMBER*
,19
,19
,23
.19
,22
,19
,19
, 0
,23
,19
,23
.19
,19
,22
,22
,19
r 1 °
,22
,19
,23
,26,
,25,
,2«
,25,
, Of
,26,
,26,
,24,
,27
135)
135)
)
135)
135)
135)
136)
136)
)
,25,136)
,26
,24,
,24,
,24,
,24,
,24,
t 24 ,
,24,
,26,
,27
5
136)
136)
137)
137)
137)
137)
137)
138)
)
18,23,24 )
18
17
17
16
17
18
16
,23
,19
.19
,20
,20
,24
,24,
,25,
,25,
,24,
,20,24,
,20
,25,
)
138)
138)
138)
138)
139)
139)
* STATUS CODES
0 - STATUS NUT DEFINED
1 - OPERATIONAL
2 - CONSTRUCTIONAL
3 - PLANNEO-COIMTkACT AWARDED
4 - PLANNED-LETTER OF INTENT SIGi-iFD
S - PL ANNEO-REQUEST I NG/EV ALUA T I NG BIOS
6 - PL ANNtD-CONS IDEKING SO? CONTROLS
7 - TERMINATED
fl - TfJDEF INI TtL V SHUT DOWN
" - NEVER STARTEO-UP
-------
STATUS tn ncTOPER
ivi 2 (CONTINUED!
STATUS OF INDUSTRIAL BOILERS I/.TTH FGO SYSTEMS
INSTALLATION NAME
GENERAL MOTORS CORPORATION
GEORGIA-PACIFIC PAPER CO.
GETTY OIL COMPANY
GETTY OIL COMPANY
GREAT SOUTHERN PAPER CO.
GREAT WESTERN SUGAR
GREAT WESTERN SUGAR
GREAT WESTERN SUGAR
GREAT WESTERN SUGAR
GREAT WESTERN SUGAR
GREAT WESTERN SUGAR
GREAT WESTERN SUGAR
GREAT WESTERN SUGAR
GREAT WESTERN SUGAR
GRISSOM AIR FORCE BASE
HARRIS MINING CO.
ITT RAYONIER. INC.
KERR-MCGEE CHEMICAL CORP.
MEAD PAPERBOARD CO.
MINN-OAK FARMER'S COOPERATIVE
MOBIL OIL COMPANY
MOBIL OIL CORPORATION
NEKOOSA PAPERS, INC.
PHILLIP MORRIS, INC.
QUALITY MILLS, INC.
RICKENBACKER AIR FORCE BASE
SHELL OIL COMPANY
SHELL OIL COMPANY
LOCATION
TONQWANOA, NEW YORK
CROSSETT, ARKANSAS
BAKERSFIELO, CALIFORNIA
BAKERSFIELD, CALIFORNIA
CEDAR SPRINGS, GEORGIA
BILLINGS, MONTANA
FINOLAY, OHIO
FORT MORGAN, COLORADO
FREEMONT, OHIO
GERING, NEBRASKA
GREELEY, COLORADO
LON6MONT, COLORADO
LOVELAND, COLORADO
SCOTTS BLUFF, NEBRASKA
BUNKER HILL, INDIANA
SPRUCE PINE, NORTH CAROLINA
FERNANDINA BEACH, FLORIDA
TRONA, CALIFORNIA
STEVENSON, ALABAMA
WAHPETON, NORTH DAKOTA
BUTTONWILLOW, CALIFORNIA
SAN ARDO, CALIFORNIA
ASHDOWN, ARKANSAS
CHESTER, VA.
MT. AIRY, NORTH CAROLINA
COLUMBUS, OHIO
BAKERSFIELD, CALIFORNIA
TAFT, CALIFORNIA
START-UP
HATE
6-75
0-75
6-77
12-78
0-75
10-77
10-74
10-76
10-78
10-75
10-75
10-73
10-73
10-75
9-79
0-73
0-75
6-78
0-75
6-77
9-78
0-7«
2-76
1-79
•5-70
3-76
0- 0
0- 0
STATUS*
1
•
1
2
1
1
1
1
2
1
1
7
1
1
5
8
1
1
1
1
2
1
1
p
7
1
fe
6
PAGE NUMBER*
67(10,17,20,24,139)
69(10, 16,20,25,139)
71(10,17,20,25,139)
111(10,18,22,26,140)
74(10,16,20,26,140)
76(10,17,20,26,140)
77(10,17,20,25,140)
78(11,17,20,26,141)
112(11,17,22,25,141)
79(11,17,20,26,141)
80(11,17,20,26,141)
130(11,17, 0,26,141)
81(11,17,21,26,142)
82(11,17,21,26,1«2)
125(12,18,23,24 )
131(12,18, 0,27,142)
63(12,16,21,26,142)
85(12,16,21,25,142)
87(12,16,21,24,143)
89(12,18,21,27,143)
113(12,17,22,25,143)
91(13,18,21,25,143)
93(13,16,21,24,144)
114(13,16,22, 0,144)
132(13,16, 0,26,144)
95(13,18,21,25,144)
127(13,18,23,27 )
128(13,18,23,27 )
» STATUS CODES
0 - STATUS NOT DEFINED 5 - PLANNED-REQUEST ING/EVALUATING BIDS
1 - OPERATIONAL 6 - PLANNED-CONSIDERING S02 CONTROLS
2 - CONSTRUCTIONAL 7 - TERMINATED
3 - PLANNED-CONTRACT AWARDED fl - INDEFINITELY SHUT DOWN
4 - PLANNED-LETTER OF INTENT SIGNED 9 - NEVE" STARTED-UP
+ FOR COMPLETE INFORMATION ON THE INDICATED FGO SYSTEM REFER TO FIRST PAGE LISTFD
THE INSTALLATION APPEARS IN OTHER SUMMARY SECTIONS ON THE PAGFS IN PARENTHESES "
A ZERO INDICATES THAT INFORMATION IS NOT AVAILABLE FOR AN INSTALLATION IN A
PARTICULAR SECTION SEARCHED BY THE COMPUTER SYSTEM. SECTION la PROVIDES PROCESS
DIAGRAMS FOR SEVERAL INSTALLATIONS: A LISTING OF FIRURES IS GIVFH IN SECTION 1
-------
STATUS TO OCTOBER 1978
SECTION 2 (CONTINUED)
STATUS OF INDUSTRIAL BOILERS WITH FGO SYSTEMS
INSTALLATION NAME
SHELLER GLOBE CORP,
ST. JOE ZINC CO.
ST. REGIS PAPER CO.
TEXACO INCORPORATED
TEXACO INCORPORATED
TEXASGULF
TRANSCO TEXTILES, INC.
U.S. GYPSUM CORP.
LOCATION
NORFOLK, VIRGINIA
MONACA, PENNSYLVANIA
CANTONMENT, FLORIDA
SAN AROO, CALIFORNIA
SAN AROO, CALIFORNIA
GRANGER, WYOMING
AUGUSTA, GEORGIA
OAKMONT, PENNSYLVANIA
START-UP
DATE
STATUS* PAGE NUMBER*
0-75 1 98(14,18,21,27.145)
12-78 2 115(11,16,22,25,144)
0-73 1 100(14,16,21,27,145)
11-73 1 102(14,16,21,27,145)
3-79 2 1I6(14,16,22,27,14!>)
9-76 1 104(14,18,21,27,146)
3-75 « 133(14,17, 0,26,14t)
0-0 9 134(15,16, 0,24,146)
* STATUS CODES
0 - STATUS NOT DEFINED 5 - PLANNED-REQUESTING/EVALUATING BIDS
1 - OPERATIONAL 6 - PLANNED-CONSIDERING 802 CONTROLS
2 - CONSTRUCTIONAL 7 - TERMINATED
3 - PLANNED-CONTRACT AWARDED ft - INDEFINITELY SHUT DOWN
4 - PLANNED-LETTER OF INTENT SIGNED «» - NEVER STAKTED-UP
+ FOR COMPLETE INFORMATION ON THE INDICATED FGO SYSTEM REFER TO FIWST PAGE LISTED.
THE INSTALLATION APPEARS IN OTHER SUMMARY SECTIONS ON THE PAGES IN PARENTHESES.
A ZERO INDICATES THAT INFORMATION IS NOT AVAILABLE FOR AN INSTALLATION IN A
PARTICULAR StCriON SEARCHED BY THE CQMPUTFK SYSTEM. SECTION 14 PROVIDES PKOCESS
DIAGRAMS FOR SEVERAL INSTALLATIONS: A LISTING OF FIGURES IS GIVEN IN SECTION 14.
-------
STATUS TO OCTOBER 1978
SFCTION 3
S'IMMARY OF FGD SYSTEMS ON INDUSTRIAL BOILERS
COMPANY INFORMATION
SUMMARY OF RF.CFNT OPERATIONS
ALYESK* PIPELINE SERVICE co.
VALOFZ, ALASKA
FMC ENVIRONMENTAL FUUIPMENT
OIL (0.03Z - O.lt SULFUR)
SO,000 SCFM (DESIGN MAXIMUM)
START-UP 6/77
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
THE ALYESKA FGD SYSTEM IS UNIQUE IN THAT IT WAS
NOT INSTALLED PRIMARILY FOR CONTROL OF EMISSIONS,
RUT TO TREAT GAS USED IN THE OH. STORAGE TANKS.
FGD OPERATIONS FOR THIS REPORT PERIOD WERE PROB-
LEM-FREE. CYCLOHEXAMINE IS NOW BEING USED INSTEAD
OF HYDRAZINE. PH IS NOW b - 7 AND THE MILD DUCT-
WORK CORROSION SEEMS TO BE UNDER CONTROL. ADDI-
TIONAL CYCLOHEXAMINE SPRAY POINTS MAY BE INSTALLED
IF FURTHER PH CONTROL TS REQUIRED.
AMERICAN THREAD CO.
MARION, NORTH CAROLINA
W.W. SLY MANUFACTURING CO.
COAL (1 - 1.5Z SULFUR)
18,bOO SCFM [TOTAL - 2 BOILERS)
START-UP 0/73
CAUSTIC WASTE STREAM
STATUS - OPERATIONAL
AMERICAN THREAD IN MARION, NORTH CAROLINA USES A
CAUSTIC SCRUBBING APPROACH TO CONTROL PARTTCULATE
AND 802 EMISSIONS FROM TWO COAL-FIRED BOILERS.
THE PLANT REPORTS THAT CORROSION OF PRESSURE
GAUGES AND COPPER LINES IS_A PROBLEM AREA. PLANS
ARE BEING MADE TO REMOVE THE SCRUBBER 1.0. FAN
AND UPGRADE THE BOILER 1.0. FAN. A PUMP LINING
REPLACEMENT CAUSED 3 DAYS DOWNTIME.
ARCO/POLYMERS, INC.
MONACA, PENNSYLVANIA
FMC ENVIRONMENTAL EQUIPMENT
COAL (3.0% SULFUR)
236,000 SCFM (TOTAL - 3 BOILERS)
START-UP 6/80
DOUBLE ALKALI (CONCENTRATED)
STATUS - PLANNED-CONTRACT AWARDED
ARCO/POLYMERS HAS AWARDED A CONTRACT TO FMC EN-
VIRONMENTAL EQUIPMENT DIVISION FOR A DOUBLE
ALKALI FGD SYSTEM. THE SYSTEM WILL CONSIST OF A
SEPARATE SCRUBBER TRAIN FOP EACH OF THE THREE
IDENTICAL BOILERS. EACH ABSORBER MODULE WILL
HAVE FOUR OISC-AND-DONUT TRAYS AND BE FOLLOWED
BY A CHEVRON MIST ELIMINATOR. THE TOTAL INSTALLED
CAPITAL COST IS S8,000,000.
ARMCO STEEL
MIDDLETOWN, OHIO
KOCH ENGINEERING
COAL (0.8JS SULFUR)
8«,000 SCFM (TOTAL - 2 BOILERS)
START-UP 0/75
LIME SCRUBBING
STATUS - OPERATIONAL
THIS CONTROL SYSTEM SERVES TWO MULTI-RETORT
UNDERFEED STOKER, COAL-FIRED BOILERS EACH WITH
A CAPACITY OF 100,000 LBS/HR STEAM. ABRASION IS
A PROBLEM. PLANS CALL FOR INSTALLATION OF RUBBER
PIPE LINING FABRICATED ON SITE. FIBERGLASS PIPING
IS ON ORDER. EXCESS AIR HAS BEEN REDUCED TO ABOUT
flOX BY PATCHING LEAKS AND REDUCING COMBUSTION AIR.
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
C-E NATCO
CRUDE OIL (Lit SULFUR)
12,000 SCFM
START-UP 11/78
SODIUM HYDROXIDE SCRUBBING
STATUS - CONSTRUCTION
BELRIDGE IS SCHEDULED TO START-UP A C-E NATCO FGO
SYSTEM IN NOVEMBER 197S. THIS CONTROL SYSTEM WILL
BE OPERATING ON A SMALL OIL-FIRED (l.lJt SULFUR)
STFAM GENERATOR. CONSTRUCTION IS NEARTNG COMPLE-
TION.
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
THERMOTICS INC.
CRUDE OIL (Lit SULFUR)
12,000 SCFM
START-UP 7/78
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
BELRIDGE IS UTILIZING A THERMOTICS, INC. FGD
SYSTEM TO CONTROL 802 EMISSIONS FROM A SMALL OIL-
FIRED (1.1X SULFUR) STEAM GENERATOR AT THE MCKITT-
RICK ENHANCED OIL RECOVERY SITE. START-UP
OCCURRED IN JULY 1978.
BELRIDGE OIL COMPANY
MCKITTRICK, CALIFORNIA
HEATER TECHNOLOGY
OIL ci.ix SULFUR)
12,000 SCFM (1 BOILER)
START-UP 6/78
SODIUM HYDPOXIDE SCRUBBING
STATUS - OPERATIONAL
BELRIDGE IS UTILIZING A HEATER TECHNOLOGY FGD SYS-
TEM TO CONTROL 80S EMISSIONS FROM A SMALL OIL-
FIRED (Lit SULFUR) STEAM GENERATOR AT AN ENHANCED
OIL RECOVERY SITE. START-UP OCCURRED IN JUNE
1978.
-------
ST41US TO OCTOBER 1978
SECTION ' (C.ONTINUFD)
SUMMARY OF FGD SYSTEMS ON INDUSTRIAL ROTLFRS
COMPANY INFORMATION
SUMMARY OF RFCFNT OPERATIONS
8UNGE, IMC.
CAIRn, ILLINOIS
ORAV" CORP./NAT'L II^t ASS'N
COAL (3% SULFUR)
«4,000 SCFM (TOTAL - 2 BOILERS)
START-UP 9/77
LIME SCRUBBING
STATUS - INOFFINITELY SHUT DOWN
BUNUE PURCHASED THIS LIME FGD SYSTEM FOR TESTING
PURPOSES. THE PLANT RFPORTS THAT THE LEWIS
SCRUBBER, A HORIZONTAL ROTARY SCRUBBER WITH
INTERNAL CHAINS, PERFORMED WELL DURING THE TEST,
EFFECTING 9il% SO? CONTROL. 9UNGE IS CURRENTLY
FIRING LOW SULFUR CO.9%) COAL AND HAS NO PLANS TO
REUSE THF SYSTEM.
C. A.M.fCARBIDE-AMQCU-MONSAW! 0)
HOUSTON, TEXAS
VENOOR NOT SELECTED
FUEL NOT SELECTED
1,200,000 SCFM (i BOILFR)
STASY-UP 10/S3
PROCESS NOT SELECTED
STATUS - PLANNED-CONSIDERING SOS CONTROL.
UNION CARHTDF, AMOCO, AND MONSANTO HAVE ENTERED
INTO A JOINT VENTURE (C.A.N.) WHICH WILL PRODUCE A
bOCi-MW (FUUIVALENT) COGENEPATION FACILITY. THE
PLANNED BOILER HILL PRODUCE ELECTRIC POWER AND
STFfiM FUR PROCESS REQUIREMENTS FOR THE 3 PLANTS.
START-UP FOR THE POWER GENERATION FACILITr IS
SCHEDULED FOR LATE 5.963.
CANTON TEXTILES
CANTMN. GEORGIA
FMC ENVIRONMENTAL EQUIPMENT
COAL (0.8J£ SULFUR)
25,000 SCFM (I BOILER)
START-UP fc/73
CAUSTIC WASTE STREAM
STATUS - OPERATIONAL
AT CAfcTON TEXTILES THE CONTROL SYSTEM CONSISTS
OF- AN FWC MEDIUM ENERGY VENTtJRI SCRUBBER AND
UTILIZES A CAUSTIC WASTE STREAM FOR S02 REMOVAL.
THE UNIT HAS BtEN IN OPERATION SINCE JUNE 197«.
CANTON AGAIN REPORTED NO OP£»4fIONAL PROBLEMS
DURING THIS REPORT PERIOD. GAS FIRING WAS RE-
STARTED IN MTO^MAY 1977, SO THE SCRUBBER WILL NOT
OPERATE UNTIL COAL USE RESUMES IN OCT. THg PLANT
REPORTS AN QPERSBILITY OF 100% DUFUNS COAL, FIRING
OPERATIONS.
CARBORUNDUM ABRASJv'ES
BUFFALO, NEW YORK
C»«6nRUNOUM ENVIH. SYS, LTD.
COAL 12,?.% SULFUR)
30,000 SCFM (TOTAL - 2 BOILERS)
START-UP O/ 0
LIME SCRUBBING
STATUS - PLANNED-CONTRACT AWARDED
NO DEFINITE PLANS HAVE BFEN MADE FOR THE CONTROL
OF S02 EMISSIONS FROM THTS BOILER. THE FUTURE OF
THE CONTROL SYSTEM WILL RE DETERMINED BY A REGU-
LATORY AGENCY DECISION EXPECTED NEAR THE END OF
1978* THE CUHRENTLY OPERATING VENTURI (L/G = 10)
CONTROLS ONLY PARTICIPATE? BUT TIE-INS HA'/E BEEN
PROVIDED FOR A LIME SCRUBBING SYSTEM USIWik
A h-STAGE SPRAY TOWER FOR S02 CONTROL. "^
TRACTOR CO,
EA-5T f>e:ORIA, ILLINOIS
FMC ENVIRONMENTAL EQUIPMENT
COAt (3.at SULFUR)
210,000 r,CFM (TOTAL -
STAPT"liP a/78
DOUBLE ALKALI (CONCENTRATED)
STATUS - OPERATIONAL
START-UP OCCURRED TN APRIL 1978. FGD OPERATIONS
PROCEEDED FOR 30 DAYS OEFORE BOILER PLANT SHUT-
DOWN FOR THE SUMMER. THE « FMC CONCENTRATED
DOUBLE ALKALI SYSTEMS WERE STILL IN A START-UP
MODE WHEN SHUTDOWN OCCURRED. THE PLANT CONDUCTED
NO PERFORMANCE TESTS. THE SYSTEMS ARE DESIGNED TO
REMOVE 90% OF THE INLET sos WHILE THE BOILERS ARE
BURNING HIGH-SULFUR ILLINOIS COAL. THE FGO SYSTEM
HAS JUST STARTED UP AFTER SUMMER SHUTDOWN.
CATERPILLAR TRACTOR CO.
JOLIET, ILLINOIS
7URN INDUSTRIES
COAL (3.2X SULFUR)
67,000 SCFM (TOTAL - S BOILEBS3
START-UP 9/7«
DOUBLE ALKALI (DILUTE)
STATUS - OPERATIONAL
THE FGD SYSTEM CONSISTS np AN INDEPENDENT
SCRUBBING TRAIN ON EACH OF TWO COAL-FIRED BOILERS.
THESE BOILERS HAVE BEEN OPERATIONAL EACH HEATING
SEASON STNCE OCTOBER *<»?«„ SINCE THAT DATE,
SCRUBBFR AVAILABILITY HAS BEEN AVERAGING 80-85%.
so? MONITORING PROBES OF 500 ss, JI&L ss, AND
TEFLON COATING rtEHE T8IEO WITHOUT SUCCESS, HAST"
F.LLOY C PROBFS ARE NOW BEING EVALUATED.
CATERPILLAR TRACTOR CO.
MAPL^TON, ILLINOIS
FMr ENVIRONMENTAL FUUJPMFNl
COAL <3.?% SULFlJf?)
•157,000 SCFM CTOTAL - ? BOILERS)
START-UP 10/78
DOUBLE ALKALI (CONCENTRATED)
STATUS - CONSTRUCTION
AT THE CATERPILLAR MAPLETON PLANT, FMC CONCENTRA-
TED MODE DUAL ALKALI TECHNOLOGY WILL BE UTILIZED
TO CONTROL SOa EMISSIONS. THREE SCRUBBER SYSTEMS
WILL START-UP IN OCT. 1978, CONTROLLING EMISSIONS
FHOM THRFt COAL-FIRED BOILERS. CONSTRUCTION IS
NEARING COMPLETION. SPECIAL MODIFICATIONS ARE
DEIftYING OPERATION.
-------
MATHS TH OCTOBbH
SFCTION 5 (cn.MTINUF.U)
SUMMARY OF F(;n SYSTEMS ni\i INDUSTRIAL HOTLFWS
COMPANY INFORMATION
SUMMARY ne KECENT OPFRATTONS
CATERPTLI AR TRACTOR CD.
MAPLFTflN, ILLINOIS
FMC ENVIRONMENTAL EQUIPMENT
COAL (3.?% SULFUR)
2b2,000 SCFM (TOTAL - 5 BOILERS)
START-UP 10/79
DOUBLE ALKALI (CONCENTRATED)
STATUS - CONSTRUCTION
AT THL MAPI tTON PLANT, AN ADDITIONAL 5 NEW BOHERS
AHF SLATED TO HE EQUIPPED WITH FMC DOUBLE ALKALI
FGH SYSTEMS. TwO HF THESE ARE SLATED TO BEGIN S02
CONTROL OPERATIONS IN THE 1978 - 1979 HEAT SEASON.
AS OF NOW, THF.RE is NO FIRM STAHT-UP SCHEDULED FOR
THF OTHER 3 SYSTEMS.
CATERPILLAR TRACTOR CO.
MORTON, ILLINOIS
ZURN INDUSTRIES
COAL (3.ax SULFUR)
40,000 SCFM (TOTAL •? BOILERS)
START-UP 1/78
DOUBLE ALKALI (DILUTE)
STATUS - OPERATIONAL
THE CATERPILLAR MORTON PLANT UTILIZES ZURN INDUS-
TRIES' DILUTE MODE DOUBLE ALKALI TECHNOLOGY
TO CONTROL EMISSIONS FROM THE STEAM PLANT.
F6D SYSTEM START-UP OCCURRED AT THE BEGINNING
OF 1978. ACCEPTANCE TESTING HAS BEEN DELAYED DUE
TO A PUFFING PROBLEM BUT WILL BE ATTEMPTED LATE
THIS FALL.
CATERPILLAR TRACTOR CO.
MOSSVILLE, ILLINOIS
FMC ENVIRONMENTAL EQUIPMENT
COAL (3.2X SULFUR)
1«0,000 SCFM (TOTAL - 4 BOILERS)
START-UP 10/75
DOUBLE ALKALI (CONCENTRATED)
STATUS - OPERATIONAL
THE CATERPILLAR MOSSVILLE PLANT HAS UTILIZED AN
FMC CONCENTRATED MODE FGD SYSTEM EACH HEATING
SEASON SINCE OCTOBER 1975. THERE ARE FOUR COAL-
FIRED BOILFRS EACH BEING TREATED BY A SEPARATE
SCRUBBING TRAIN. PROBLEMS WITH THF VENTURI SPRAY
NOZZLES HAVE BEEN ENCOUNTERED. 316L 3S NOZZLES
ARE BEING USED AT THIS TIME. THE VENTURI AUTO-
MATIC CONTROL HAS NOT YET BEEN DEBUGGED. THE
SLUDGE HANDLING SYSTEM IS BEING REEVALUATEO DUE
TO MANY PROBLEMS. GUILLOTINE DAMPERS EXPERIENCING
SAME PROBLEM AS AT JOLIET PLANT. WEAR PLATES AT
SCRUBBER ARE WORKING WELL.
CHANSLOR WESTERN OIL & DEV.'CO
BAKERSFIELO, CALIFORNIA
FMC ENVIRONMENTAL EQUIPMENT
OIL (1.5X SULFUR)
70,000 SCFM (TOTAL - 8 BOILERS)
START-UP 12/78
DOUBLE ALKALI (CONCENTRATED)
STATUS - CONSTRUCTION
CHANSLOR WESTERN HAS PURCHASED A DOUBLE AtKALI FGD
SYSTEM FROM FMC. CONSTRUCTION IS WEARING COMPLE-
TION AND START-UP IS SCHEDULED FOR DECEMBER 1978.
FLUE GAS FROM 8 SMALL OIL-FIRED (1.55! SULFUR)
STEAM GENERATORS WILL BE MANIFOLDED INTO ONE FGO
SYSTEM.
CHEVRON U.S.A. INC.
BAKERSFIELD, CALIFORNIA
KOCH ENGINEERING
OIL C1.1X SULFUR)
248,000 SCFM (TOTAL - 18 BOILERS)
START-UP 7/78
SODIUM CARBONATE SCRUBBING
STATUS - OPERATIONAL
CHEVRON U.S.A. HAS PURCHASED THREE FGD SYSTEMS
FROM KOCH ENGINEERING. THE SODIUM CARBONATE SCRU-
BBING SYSTEMS WENT ON-STREAM IN JUNE/JULY 1979.
THE STARTUP HAS BEEN SUCCESSFUL. THE SYSTEMS ARE
DESIGNED TO REDUCE S02 EMISSIONS BELOW 70 PPM.
ONLY TWO OF THE THREE FGH SYSTEMS ARE OPERATING
DUE TO LOW STEAM DEMAND. NO MAJOR PROBLEMS HAVE
OCCURRED. OPERABILITY WAS 95?.
CHEVRON U.S.A. INC.
BAKERSFIFLD, CALIFORNIA
KOCH ENGINEERING
OIL (1.1% SULFUR)
l«fe,000 SCFM (TOTAL - !2 BOILERS)
START-UP 4/79
SODIUM CARBONATE SCRUBBING
STATUS - PLANNED-REQUESTING/FVALIIAT ING BIDS
CHEVRON U.S.A. IS PLANNING TO INSTALL TWO MORE
FGO SYSTEMS AT BAKERSFIELO OIL SITE. THESE WILL BE
ONCE-THROUGK, SODIUM CARBONATE SCRUBBING SYSTEMS
AND ARE SCHEDULED TO GO ON-STREAM PY APRIL 1979.
A CONTRACT HAS BEEN AWARDED TO KOCH ENGINEERING
FOR THE DESIGN AND INSTALLATION OF THE 2 SYSTEMS,
CONSTRUCTION IS SCHEDULED TO BEGIN IN JANUARY.
OUPONTr INC.
GEORGIA
VENDOR NOT SELECTED
COAL (1.555 SULFUR)
280,000 SCFM (TOTAL - 3 BOILERS)
START-UP 0/fl7
DOUBLE ALKALI
STATUS - PLANNED-CONSIDERING SD2 CONTROL
DUPONT HAS ANNOUNCED PLANS TO ERECT A COAL-FIRED
BOILER AT AN AS YET UNSPECIFIED SITE IN GEORGIA.
THE COMPANY HAS DECIDED UPON A DOUBLE ALKALI FGO
STRATEGY TO CONTROL SO? EMISSIONS FROM 3 COAL-
FIRED BOILERS. START-UP IS SLATED FOR 1987.
-------
STATUS TO OCTOBER 1978
SECTION 3 CCOMTIIMUFUl
SUMMARY OF FGD SYSTEMS ON INOUSTkYAL BOTLERS
COMPANY INFORMATION
SUMMARY OF RECENT OPERATIONS
OUPONT, INC.
TEXAS
VENDOR NOT SELECTED
COAL (0.5X SULFUR)
320,000 SCFM (TOTAL - S 90ILEHS)
START-UP 0/82
LIMESTONE SCRUBBING
STATUS - PLANNED-CONSIDERING S02 CONTROL
nUPONT HAS ANNOUNCED PLANS TO ERECT A COAL-FIRED
BOILFR AT AN AS YET UNSPECIFIED SITE IN TEXAS,
THE COMPANY HAS DECIDED UPON A LIMESTONE FGD STRA-
TEGY TO CONTROL S02 EMISSIONS FROM £ COAL-FIRED
BUILERS. START-UP IS SLATED FOR 1982.
FIRESTONE TIRE ANO RUBBER CO.
POTTSTOWN, PENNSYLVANIA
FMC ENVIRONMENTAL EQUIPMENT
COAL (2.5 - 3.OS SULFUR)
8070 SCFM (13,000 ACPM a 300 F)
START-UP 1/75
DOUBLE ALKALI (CONCENTRATED)
STATUS - OPERATIONAL
THE FGO SYSTEM AT FIR£STONE-POTTSTOWN CONSISTS OF
AN FMC DOUBLE ALKALI OUAL THROAT VENTUPI SCWUBBER,
THIS $02 CONTROL SYSTEM WAS 9UILT *S A DEMONSTRA-
TION PROJECT FUNDED 8Y FIRESTONE. THE SYSTEM OPER-
ATED WITH AN AVAILABILITY VALUE OF o F REHEAT AND HC.S THE CAPABILITY FOR FGO
SYSTEM BYPASS.
-------
STATUS TO OCTOBER I97B
SFCTION 3 (CONTINUED)
SUMMARY OF FfcD SYSTEMS Oh INDUSTRIAL BOILERS
COMPANY INFORMATION
SUMMARY OF RECENT OPERATIONS
GENERAL MOTORS CORPORATION
TQNOWANOA, NF.W YORK
FMC ENVIRONMENTAL EQUIPMENT
COAL (l.?% SULFUR)
92,000 SCFM (TOTAL - « BOILERS)
START-UP 6/75
SODIUM HYQROXIOE SCRUBBING
STATUS - OPERATIONAL
THE FGD SYSTEM CONSISTS OF FOUR GM SODIUM SCRUB-
BING UNITS F0« THE REMOVAL OF PARTICULATES AND
SUIFIIR DIOXIDE FROM FOUrt COAL-FIRED BOILERS.
THE SCRUBBERS ARE EQUIPPED WITH VfNTURI SCRUBBERS
FOR PARTICUL4TE REMOVAL. UNSTABLE PH CONTROL,
PIPE EROSION AND STACK CORROSION HAVE BEEN THE
MAIN PROBLEM AREAS. TO CORRECT THESE PROBLEMS,
THE SOLUTIONS HAVE BEEN, RESPECTIVELY, REPLACE-
MENT OF CONTROL SENSORS, PIPING AND RELINING OF
THE STACK.
GEORGIA-PACIFIC PAPER CO.
CROSSETT, ARKANSAS
AIRPOL INDUSTRIES
BARK,COAL/OIL (IX - 1.5X SULFUR)
220,000 SCFM C1 BOILER)
START-UP 0/75
CAUSTIC WASTE STREAM
STATUS - OPERATIONAL
THE FGD SYSTEM CONSISTS OF AN AIRPOL CAUSTIC
SCRUBBING UNIT TO REMOVE SULFUR DIOXIDE AND PAR-
TICULATt MATTER FROM THE FLUE GAS OF A COAL/BARK
OR OIL/BARK POWER BOILFR. THE SYSTEM IS PRECEDED
BY CYCLONES FOR PARTICULATE REMOVAL. A RECIR-
CULATION PUMP WAS REPLACED DUE TO LOSS OF IMPELLER
LINING. SCRUBBER WAS DOWN ABOUT 36 HRS. DUE TO
PUMP FAILURE.
GETTY OIL COMPANY
BAKERSFIELO, CALIFORNIA
FMC ENVIRONMENTAL EQUIPMENT
COAL (l.U SULFUR)
72,000 SCFM (TOTAL - 6 BOILERS)
START-UP 6/77
SODIUM CARBONATE SCRUBBING
STATUS - OPERATIONAL
THE SODIUM CARBONATE SCRUBBING FGD SYSTEM WAS
RETROFITTtO BY FMC IN JUNE 1977. THE SYSTEM HAS
AN S02 REMOVAL EFFICIENCY OF 90*. NEW 316L SS
RECIRCULATION LINES HAVE BEEN INSTALLED, A SILI-
CON DISPERSANT IS BEING EVALUATED. THE SYSTEM
EXPERIENCED A 2-OAY OUTAGE TO REPLACE FAN
BEARINGS.
GETTY OIL COMPANY
BAKERSFIELD, CALIFORNIA
PROPRIETARY DESIGN
OIL (i.lt SULFUR)
993,750 SCFM (TQTAL-72 BOILERS)
START-UP 12/78
SODIUM CARBONATE SCRUBBING
STATUS - CONSTRUCTION
GETTY OIL COMPANY HAS DESIGNED 9 MORE SODIUM
CARBONATE SCRUBBING FGD SYSTEMS IN-HOUSE. EACH
SYSTEM, UNLIKE THE OPERATING UNITS. WILL HAVE A
SCRUBBER PURCHASED FROM KOCH CONTAINING 3 FLEXI-
TRAYS AND i FLEXIMESH DEMISTER. EACH SCRUBBER
WILL TREAT GASES FROM 8 BOILERS. CONSTRUCTION IS
IN PROGRESS AND STARTUP OF THE FINAL UNIT IS
SCHEDULED FOR MID-FEBUARY 1979.
GREAT SOUTHERN PAPER CO.
CEOAR SPRINGS, GEORGIA
AIRPOL INDUSTRIES
BARK,COAL/OIL (1.0% - S.OX SULFUR)
920,000 SCFM (TOTAL - 2 BOILERS)
START-UP 0/75
CAUSTIC WASTE STREAM
STATUS - OPERATIONAL
THE FGD SYSTEM CONSISTS OF TWO AIRPOL CAUSTIC
SCRUBBERS TO CONTROL PARTICULATE AND SULFUR DI-
OXIDE FROM TWO POWFR BOILERS. THE PRIMARY FUEL
IS BARK/COAL (BARK/OIL IS FIREO OCCASIONALLY).
THE FOLLOWING PROBLEMS HAVE BEEN ENCOUNTEREDI
EROSION AND PLUGGAGE OF THE PH PROBES, INTERNAL
WEAK ON PUMPS, AND EROSION IN THE RECIRCULATION
LINES.
GREAT WESTERN SUGAR
BILLINGS, MONTANA
GREAT WESTERN SUGAR
COAL (0.7X SULFUR)
60,000 SCFM (TOTAL - 3 BOILERS)
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 (8.7) BUT THE SYSTEM HAS A LOW S02
REMOVAL BECAUSE THE WATER IS INTRODUCED THROUGH
PIPES RATHER THAN SPRAY NOZZLES.
GREAT WESTERN SUGAR
FINDLAY, OHIO
GREAT WESTERN SUGAR
COAL (1.2% SULFUR. AVERAGE)
b5f£30 SCFM (TOTAL - 2 BOILERS)
START-UP 10/7«
SODIUM CARBONATE SCRUBBING
STATUS - OPERATIONAL
THE VENTURI TOWER WAS MAINLY DESIGNED FOR
ULATE CONTROL, AND WAS STARTED UP IN OCT.'7«. THE
PARTICULATE AND SO? REMOVAL EFFICIENCIES ARE 90X
AND 76* RESPECTIVELY. THE 802 CONTROL IS EFFECTED
BY THE PROCESS CONDENSATE USED FOR SCRUBBING
(PH=8.7). THE PLANT OPERATES ONLY DURING THE FALL
QUARTER.
-------
STATUS TO OCTOBER 1978
SECTION 3 (CONTINUE!))
SUMMARY OF FGD SYSTFMS ON INDUSTRIAL ROILFRS
COMPANY INFORMATION
SUMMARY ot RECENT OPERATIONS
GREAT WESTERN SUGAR
FORT MORGAN, COLORADO
GREAT WESTERN SUGAR
COAL (1.2X SULFUR, AVERAGE)
65,250 SCFM (TOTAL - £ BOILERS)
START-UP li)/7fe
AMMONIA-LADEN PROCESS
STATUS - OPERATIONAL
THE VENTIIRT SCRUBBED kAS DESIGNED FOR PARTICULATE
CONTROL AND STARTED IN OCT'76. THE CONOENSATE
PROCESS WATER USED HAS A HIGH PH (8.7) WHICH
REMOVES SOME S02, THE PARTICL'LATE AMD S02 CONTROL
EFFICIFNCIFS ARF 9feS AND 4ft% RESPECTIVELY.
GREAT WESTERN SUGAR
FREEMQNT, OHIO
GREAT WESTERN SUGAR
CO«L (3.1 SULFUR)
40,000 SCFM (TOTAL » 2 BOILERS)
START-UP 10/76
SODIUM CARBONATE SCRUBBING
STATUS - CONSTRUCTION
PARTICULATE &ND 302 EMISSIONS WILL 3E CONTROLLED
BY A SCRUBBER/ABSORBER MODULE Oh" PROPRIETARY
RESIGN. THE FLUE SAS IS GENFRAKEO BY TWO
UNION POTLF.RS, EACH RATED 3 70,000 LB/HR ST^AM.
STARTUP IS SCHroilLFO TOt* OCTOBER 1978.
GREAT WESTERN SUGAR
GERINS, NEBRASKA
GREAT WESTERN 306AB
COAL U.2X SULrURj AVERAGE)
itfl.OOO 9CFM (TOTAL - 2 90ILEHS)
START»iJP 10/75
AMMONIA-L*OEN PROCESS
STATUS • OPERATIONAL
GliEAT WtSTERM SUGA» USES CONDENS4T?: PROCESS WATER
PRIMARILY FUR PA»T ICi'L A Tt" CONTROL. THE W*i"£R
HAS A HJ.I-H PH fe.T) RUT THE SYSTEM HAS A LOfc S0<
REMOVAL. THE VENIURI SCRUBBERS WERC »wsfA«.LED IN
oc'f'vs. PLANT OPERATES ONLY DURING THE FALL
aiJARTEP.
GREAT WESTERN SUGAR
GREELEYj COLORADO
GREAT WE3TERW SUGAR
COAL CO.feS SULFUR)
?5,000 SCFM (1 80TLER)
START*UP 10/75
AMMOKI««LAOEK PROCESS WATER
STATUS " OPERATIONAL
GREAT WESTERN SUGAP USES CONDENSATE PROCESS WATER
PRIMAH1LV FOS PARTICULATE CONTROL. THE WATER
HAS A HIGH PH (8.7) S'JT THE SVSTEM HAS A LOW SOa
REMOVAL BECAUSF THE WATES IS INTRODUCED THROUGH
PIPES RATHER THAN SPRAY NOZZLES.
GREAT WESTERN SU6ftR
GREftT WESTERN SUSAR
COAL {0.7% SULFUR)
9CFM-f4/*
START»UP 10/73
AMMONIA-LAOEN PROCESS WATER
STATUS - TERMINATED
SUGAR PRODUCTION AND ALL PLANT OPERATIONS
HAVE SEEN TERMINATED AT THE LQNGMONT PLANT.
GREAT WESTFRf"! SUGAR
LOVELAND, COLORADO
GREAT WESTERN SUGAR
COAL (1.5S SULFUR, AVERAGE)
121,800 SCFM (TOTAL - 2 BOILERS}
START-UP 10/73
AMMONIA-LADEN PROCESS WATER
STATUS - OPERATIONAL
GkEAT WESTERN SUGAR USES CONDEMS&TE PROCESS WATER
PRIMARILY FOR PARTICIPATE CONTROL. THE WATER
HAS A HIRH PH (s«7) BUT THE SVSTEM HAS A LOW sos
REMOVAL, THr SCRUBBERS WERE INSTALLED IN OCTOBER
1973. PLANT OPERATES ONLY DURING THE FALL
GREAT WESTERN SUGAR
SCnTTS BLUFFj NEBRASKA
GREAT WESTERN SUGAR
COAL (1.2X SULFUR, AVERAGE)
65,a30 SCFM (TOTAL " 2 r«r>ILERS3
START-UP 10/75
AMMONIA-LADEN PROCESS
ST/TUS - OPERATIONAL
THE PLANT OPERSTFS ONLY DURING THE F»LL QUAR'ER OF
EACH YEAK>. THE VENTU&I SCRUBBER WAS DESIGNED FOR
PARTlCtlLAtE CONTROL AI\iD WAS STARTED IN OCT'75. THE
PAPTIC"LATE *Nn SQ2- REMOVAL EFFICIENCIES ARE 95%
6fMC 761! RESPECTIVELY. THE S02 CONTROL IS CAUSED 8Y
THE PROCESS CONDENSoTE USER FOR 8CRUBBING(PH = 8.7) .
1 1
-------
70
SFCTIfllM ^ f CONTINUE!.))
()F FGn SYSTFMS ON INDUSTRIAL
INFORMATION
SUMMARY OF RECENT
AIR FORCF BARE
RUNKFR HILL, INDIANA
VENDOR NOT SELFCTED
COAL (0.9X - <|.6* SULFUR)
^2,000 SCFM (TOTAL - 3 ROILERS)
START-UP 9/79
DOUBLE ALKALI (CONCENTRATED)
STATUS - PLANNFD-REQUeSTING/FVALUATING RIDS
THF AIR FDRCF. HAS INITIATED A PROJECT WHICH WILL
ADD ONF NfcW COAI-FTKEH HOHER TO THE EXISTING
STFAM PLANT. A PORTION OF THE PROJECT INCLUDES AN
FGD SYSTFM FOR THt Mw BOILER AND TWO EXISTING
UNITS. THE A-F FIR'". FOSOICK AND HILMER, HAS
SPECIFIED A CONCFNTRAfFD OOUBLt ALKALI FGO SYSTEM,
AND RIDS ARE CURRENTLY BEINC, EVALUATED. PROJECT
COMPLETION IS SCHEDULED FUR AUGUST 30, 1979.
HARRIS MINING CO.
SPRUCE PINE, NORTH CAROLINA
W.W. SLY MANUFACTURING CO.
COAL (0.8X SULFUR)
fl,000 SCFM (TOTAL - 2 80ILFRS)
START-UP 0/73
WATER SCRUBBING (NA,NH3 OPTN.)
STATUS - INDEFINITELY SHUT DOWN
THE FGD SYSTFM CONSISTS OF A W.W. SLY IMPINJET
SCRUBBER CURRENTLY BEING USED STRICTLY AS A PAR-
TICULATE CONTROL DEVTCE. THF SYSTEM HAS THE
CAPABILITY OF SCRUBBING WITH AMMONIA OR CAUSTIC
IF S02 CONTROL IS NECESSARY. HOWEVER, AS LONG AS,
CURRENT LOW-SULFUR COAL SUPPLIES LAST, THERE IS NO
NEED FOR S02 CONTROLS.
ITT RAYONIER, INC.
FERNANOINA BEACH, FLORIDA
AIRPflL INDUSTRIES
BARK,OIL (?.OX - 2.5X SULFUR)
201,000 SCFM (TOTAL - 2 BOILERS)
START-UP 0/75
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
AT FERNANDINA BEACH, ITT RAYONIER FIRES BARK
AND OIL IN TWO OF THE FOUR PROCESS STEAM BOILERS.
PARTTCULATE AND SQ2 EMISSIONS ARF CONTROLLED IN
TWO AIRPOL SCRUBBING TRAINS. THE PLANT HAS PERMA-
NENTLY CONVERTED FROM WASTE STREAM CAUSTIC SCRUB-
RING TO A SODIUM HYDROXIDE CONTROL. APPROXIMATE
SCRUBBER OPERABILITY SINCE JAN. HAS BEEN 95X.
BEARINGS IN THE I.D. FAN HAD TO BE REPLACED. THE
SYSTEM WAS DOWN FOR 3 DAYS DUE TO BOILER-RELATED
PROBLEMS
KEPR-MCGEE CHEMICAL CORP.
TRONA, CALIFORNIA
COMBUSTION EQUIPMENT ASSOC.
COKE/COAL/OIL (0.5* - 5.0% SULFUR)
090,000 SCFM (TOTAL - 2 BOILERS)
START-UP 6/78
SODIUM CARBONATE SCRUBBING
STATUS - OPERATIONAL
THF. 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. THE SYSTEM WENT ON STREAM IN
JUNE. SIEVE TRAYS WERE REPLACED BY 317L S3 IN
AUGUST AND SEPTEMBER. COAL AND COKE CONSTITUTED
90 - 95X OF THE FUEL. OIL WAS NOT USED.
MEAD PAPERBOARD CO.
STEVENSON, ALABAMA
AIRPOL INDUSTRIES
OIL (1.5X - 3Z SULFUR)
100,000 SCFM (TOTAL - 2 BOILERS)
START-UP 0/75
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
AIRPOL INDUSTRIES HAS SUPPLIED A PARTICIPATE
AND SQ2 CONTROL SYSTEM FOR THE TWO OIL-FIRED
BOILERS AT THIS MEAD PULP MILL. DURING A JUNE
PULP MILL SHUTDOWN, THE RUBBER LINER IN THE
ABSORBER WAS REPAIRED. ALSO, MODIFICATIONS WERE
IMPLEMENTED AT THE ABSORBER MODULE INLET WITH THE
INTENT OF PREVENTING FLY ASH EROSION IN THE
MODULE. FGD SYSTEM OPERABILITY WAS REPORTED TO
BE 100X.
MINN-OAK FARMER'S COOPERATIVE
WAHPETON, NORTH DAKOTA
KOCH ENGINEERING
LI6NITF (l.OX SULFUR)
160,000 SCFM (TOTAL - 2 BOILERS)
START-UP 6/77
AMMONIA SCRUBBING
STATUS - OPERATIONAL
KOCH ENGINEERING HAS SUPPLIED TWO AMMONIA-BASED
S02 CONTROL SYSTEMS FOR THESE COAL-FIRED BOILERS.
EACH YEAR THE PLANT ONLY PRODUCES SUGAR DURING THE
SEPT. - FEB. PERIOD. THE SYSTEM WAS STARTED ON
SEPTEMBER 12 AND DID NOT OPERATE DURING THIS
REPORT PERIOD. START-UP PROCEEDED SMOOTHLY. THE
PLANT HAS MADE SOME FGD PROCESS MODIFICATIONS DUR-
ING THE SCHEDULED SHUTDOWN.
MOBIL OIL COMPANY
SUTTONWILLO", CALIFORNIA
HEATFR TECHNOLOGY
OIL (l.lt SULFUR)
as,000 SCFM (TOTAL - 7 BOILERS)
START-UP 9/78
SODIUM CARBON4TE SCRUBBING
STATUS - CONSTRUCTION
MOBIL OIL HAS PURCHASED SEVEN EDUCTOR SCRUBBERS
FROM HEATER TECHMOLOfiY FOR THE CONTROL OF
EMISSIONS FWOM 7 STEAM GFNFRATORSC ?5 MM BTU/Hfl),
FACH SYSTEM CONSISTS OF A VEMTI1RI SECTION, A
RECYCLE TANK, AND AN OUTLET DUCT WITH A MIST
ELIMINATOR. START-UP is SCHEDULED FOR SEPT. 1978.
-------
STATUS TO OCTOBER 1976
SECTION 3 (CONTINUED)
SUMMARY OF F6D SYSTEMS ON INDUSTRIAL BOILFHS
COMPANY INFORMATION
SUMMARY OF RECENT OPERATIONS
MOBIL OIL CORPORATION
SAN ARDO, CALIFORNIA
MOBIL OIL COMPANY
OIL (a.OX - 2.25X SULFUR)
182,000 8CFM (TOTAL - 30 BOILERS)
START-UP 0/74
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
MOBIL HAS DESIGNED THE FGD SYSTEM BY IN-HOUSE
ENGINEERING 8ASEO ON A PATENTED SODIUM rl*jROXIDE
SCRUBBING PROCESS. CORROSION OF MIST ELIMINATOR
AND 1.0. FAN BLADES HAVE BEEN THE MAJOR PROBLEM
AREAS« THF S03 REMOVAL EFFICIENCY IS CHANGED PY
ADJUSTING THE PH OF INLET LIQUOR. FRO SYSTEM
RELIABILITY WAS ESTIMATED TO BE 90X*
NEKOOSS PAPERS* INC.
ASHDOWN, ARKANSAS
AIRPOL INDUSTRIES
COAL (IX - 1.5X SULFUR)
211,000 SCFM (TOTAL - ! BOILER)
START-UP 2/7&
CAUSTIC SCRUBBING
STATUS - OPERATIONAL
THE FGD SYSTEM CONSISTS OF TWO AIR-POL CAUSTIC
SCRUBBERS CONTROLLING FLYASH AND SULFUR DIOXSDEc
THE ONLY PROBLEM REPORTED RURINg THIS ^ERIOO WAS
A RECYCLE PUMP BEARING FAILURE. HOWEVER ALL FLUE
GAS WAS TREATED BY THE OTHER SCRUBBED HHILE THE
BEARING WAS REPLACED*
PHILLIP MORRIS, INC-
CHESTER.- V*.
FL6K7, INC.
CCSL (1.71! SULFUR)
39,000 SCFM (TOTAL - i BOILER)
START-UP 1/79
SODIUM CARBONATE SCRU6S1NG
STATUS - CONSTRUCTION
CONSTRUCTION IS WEARING COMPLETION DN A NON»REGEN-
ERABLE SODIUM CARBONATE '5P SYSTEM SUPPLIED BY
F-..AKT, INC. THE SYSTEM WILL CONTROL EMISSIONS
FROM A 20 »fi (EQUIVALENT) CQAL-FIHED(!.7Z SULFUR';
BOILES, START-UP ]S SLAf£D FOR JANUARY 1979.
QUALITY MILLS, INC.
MTo ftlRYr NORTH CAROLINA
COMMERCIAL FABffXCATIOM & MACK0
OIL
10,000 SCFM (TOTAL • 3 BOILERS)
START-UP 5/70
WATER SCRUBBING
STATUS - TERMINATED
THIS SMALL INDUSTRIAL BOILER UTILIZED A CGMMERICAL
FABRICATION AND M9.CBINF (CFM) SCRUB-AIR SYSTEM TO
CONTROL EMISSIONS FROM THE COAL-FIRED BOILER FROM
WAY 1970 TO DECEMBER 1971, AT THAT TIME THEY CON"
VERTED TO FIRING LOW-SULFUR OILc REMOVING THE
NEED TC CONTROL EMISSIONS.
RJCKENBACKER AIR FORCE 8A3E
COLUMSlfSr OHIO
SESEARCH-COTTRELL/SAHCQ
COAL (3B6Z SULFUR)
55,000 SCFM (TOTAL - 7 BOILERS)
START-UP 3/76
LIMESTONE SCRUBBING
STATUS - OPERATIONAL
THIS RESEARCH-COTTRELL/bAHCO LIME FGD UNIT
WAS FIRST 5>L6C£D IN SERVICE MARCH li, )976.
THF SYSTEM WAS SWITCHED OVER TO LIMESTONE IN APRIL
1977, AND HAS REMAINED IN THAT OPERATING MODE TO
DATE, AN AVAILABILITY OF ?9.SX W*.S REPORTED FOR
THIS PERIOD, DURING THIS REPORT PERIOD THE 3CRUB<=
8£R WAS INSPECTED AND FOUND TO BE FAIRLY FSEE OF
CORROSION AND SCALING.
SHELL OIL COMPANY
BAKER3FIELO, CALIFORNIA
VENDOR NOT SELECTED
OIL (i.1% SULFUR)
99,000 3CFM (TOTAL - 6 SOILERS)
START-UP O/ 0
PROCESS NOT SELECTED
STATUS - PLANNED-CONSIDERING so^ CONTROL
SHELL OIL IS CONSIDERING IMPLEMENTING FGD TECHNO-
LOGY TO CONTROL EMISSIONS FROM 8 SMALL OIL- FIRED
(1.1% SULFUR) STEAM GENERATORS, NO PROCESS OR
START-UP DATE HAVE AS YET SEEN SPECIFIED. AN S02
RfMOVAL EFFICIENCY OF 94X WILL BE REQUIRED,
SMELL OIL COMPANY
YAFT, CALIFORNIA
VENDER NOT SELECTED
OIL (l.iX SULFUR)
25,000 SCFM (TOTAL - 2 BOILERS)
START-UH O/ 0
PROCESS NOT SELECTED
STATUS - PLANNED-CONSIDERING S03 CONTROL
SHELL OIL IS CONSIDERING IMPLEMENTING FGD TECHNO-
LOGY TO CONTROL EMISSIONS FROM 2 SMALL OIL-FIRED
(1.1X SULFUR) STEAM GENERATORS. NO PROCESS OR
STAKT-UP 0*TE HAVE AS YET B£Erg SPECIFIED. AN S0
REMOVAL EFFICIENCY OF 9a?. WILL BE
-------
STATUS TO OCTOBER 1978
SFCTION 3 (CONTINUED)
SUMMARY OF FKH SYSTFMS ON INDUSTRIAL HOILFHS
COMPANY INFORMATIOW
SUMMARY OF RECENT OPERATIONS
SHELI.ER GLOBE CORP.
NORFOLK, VIRGINIA
W.W. SLY MANUFACTURING CO.
COAL (< l.OX SULFUR)
8,000 SCFM (TOTAL - 1 BOILER)
START-UP 0/7b
SODIUM HYDROXIOE SCRUBBING
STATUS - OPERATIONAL
AFTER SYS1FM RESTART IN OCTOBER 1977, THERE HAVE
HEFN NO PROBLEMS RESULTING FROM EITHER BOILER OR
SCRUBBER OPERATIONS. THF PLANT UNDERWENT A
VIRGINIA EPA INSPECTION AND WAS FOUND TO BF IN
COMPLIANCE WITH THE PARTICULATE EMISSION REGULA-
TIONS. NU SCRUBBER-RELATED PROBLEMS HAVE OCCURRED
DURING THIS REPORT PERIOD.
ST. JOE ZINC CO.
MONACA, PENNSYLVANIA
BUREAU OF MINES
COAL (2.5X - 4.5X SULFUR)
104,000 SCFM (TOTAL - 1 BOILFR)
START-UP 12/78
CITRATE PROCESS
STATUS - CONSTRUCTION
CONSTRUCTION CONTINUES ON THE CITRATE PROCESS
SCRUBBING SYSTEM WHICH WILL CONTROL 802 EMISSIONS
FROM A 60-MW (NOMINAL PEAK CAPACITY) COAL-FIRED
POWER GENfcRATING UNIT. STARTUP WILL BE DEC. 1978.
THIS SYSTEM WILL ALSO BE REPORTED IN THE EPA/PEOCO
UTILITY FGO SURVEY, SINCF THE SYSTEM WILL BE
OPERATED WITH A UTILITY-TYPE LOAD PROFILE, DURING
THE ONE-YEAR DEMONSTRATION PERIOD.
ST. REGIS PAPER CO.
CANTONMENT, FLORIDA
AI0POL INDUSTRIES
HARK,OIL/GAS (< l.OX SULFUR)
115,000 SCFM (1 BOILER)
START-UP 0/73
CAUSTIC SCRUBBING
STATUS - OPERATIONAL
AIRPOL HAS SUPPLIED THE CAUSTIC SCRUBBING FGD
SYSTEM TO REMOVE PARTICULATE AND SULFUR DIOXIDE
FROM THE FLUE GAS OF A BARK BOILER, WHICH CAN ALSO
FIRE NATURAL GAS AND OIL. PLANT HAS NOT YET
CHANGED THE FEED WATER SOURCE TO ALLEVIATE
PROBLEMS DUE TO FIBERS PLUGGING LINES AND MIST
FLTMINATOK. THE SCRUBBER EXHIBITED 100X AVAIL-
ABILITY. BOILER OPERATION WAS 4888 HRS.
TEXACO INCORPORATED
SAN ARDO. CALIFORNIA
CEILCOTE
OIL (1.7X SULFUR)
366,000 SCFM (TOTAL - 24 BOILERS)
START-UP 11/73
SODIUM HYDROXIDE SCRUBBING
STATUS - OPERATIONAL
EACH FGO SYSTEM CONSISTS OF A HORIZONTAL, PACKED-
BED SCRUBBER FOR EACH OF THE OIL-FIRED BOILERS.
POOR SCRUBBING LIQUOR QUALITY CAUSES PLUGGING OF
PACKED BEDS AND SPRAY NOZZLES. THE SYSTEMS HAVE
HIGH MAINTENANCE REQUIREMENTS AND RELATIVELY LOW
SO? REMOVAL C73X). TEXACO IS PLANNING TO PHASE
OUT THIS GROUP OF SCRUBBERS BY LATE 1979. AVAIL-
ABILITY OF THE SCUBBER FOR THIS PERIOD WAS APPROX-
IMATELY 94X.
TEXACO INCORPORATED
SAN AftDO, CALIFORNIA
DUCON COMPANY
OIL (1.7t SULFUR)
117,000 SCFM (TOTAL - 9 BOILERS)
START-UP 3/79
SODIUM HYDROXIDE SCRUBBING
STATUS - CONSTRUCTION
TEXACO is PLANNING TO PHASE OUT THE EXISTING FGD
SYSTEMS AT THEIR SAN ARDO, CALIFORNIA OIL SITE.
AS THE FIRST STEP OF THE PROGRAM, 9 OF THE PRESENT
31 SCRUBBERS ON 50 MM BTU/HR STEAM GENERATORS ARE
BEING REPLACED BY A NEW SYSTEM, SUPPLIED sr DUCON
COMPANY. THE NEW FGD SYSTEM WILL CONSIST OF THREE
TRAINS OF A VEN7URI SCRUBBER/SPRAY ABSORBER COMBI-
NATION. TEXACO HAS TAKEN DELIVERY ON ONE UNIT,
WITH DELIVERY ON THE OTHER UNITS EXPECTED SOON.
TEXASGULF
GRANGER, WYOMING
SWEMCO INC.
OIL C1.1X SULFUR)
140,000 SCFM (TOTAL - 2 BOILERS)
START-UP
-------
3 TO n;;TQRFR
SFCTION ^ (LONTJNIIFO)
Of FGP SYSTF.MS ON INDIISTMAI
COMPANY
SUMMARY (IF RFCFWT OPEHATIOHS
U.S. GYPSUM CORP.
OAKMONT, PENNSYLVANIA
AIRPOL INDUSTRIES
COAL
19,300 SCFM (TOTAL - H BOILERS)
START-UP O/ 0
DOUBLE ALKALT (DILUTE)
STATUS - NEVER STARTFD-UP
AW ATRPOI DOUBLE AI-KALT SCRUBBING SYSTEM IS
ON-SITE, INSTALLEOt AND READY FOR OPERATIONS.
HOWEVER, us GYPSUM DECIDED MT TO INITIATE
PRODUCTION AT THIS FACILITY FOR ECONOMIC REASONS.
A CHF.CK DURING THIS REPORT PERIOD REVEALED THAT
THE PLANT HAS NOT BEFN STARTED YET.
-------
S TO OCTOBER 1978
bFLTlON 4
BY VFNDUR op FGC/ SYSTEMS UN INDUSTRIAL UOILERS
VENDOR
INSTALLATION NAME / LOCATION
CONTROL SYSTEM PROCESS
A.D. LITTLE
ATRPOL INDUSTRIES
BUREAU OF MINES
C-E NATCO
CARBORUNDUM ENVIR. SYS. LTD.
CEILCOTE
COMBUSTION EQUIPMENT ASSOC.
COMMERCIAL FABRICATION & MACH.
DRAVO CORP./NAT'L LIME ASS'M
DUCON COMPANY
ENTOLETER, INC.
FLAKT, INC.
FMC ENVIRONMENTAL EQUIPMENT
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
GFORGIA-PACIFTC PAPFR CO.
CROSSETT, ARKANSAS
GREAT SOUTHERN PAPER CO.
CFOAR SPRINGS,
ITT RAYONIER, INC.
FFRNANOINA PEACH, FLORIDA
MEAD PAPERBOARD CO.
STEVENSON, ALABAMA
NEKOOSA PAPERS, INC.
ASHDOWN, ARKANSAS
ST. REGIS PAPER CO.
CANTONMENT, FLORIDA
U.S. GYPSUM CORP.
OAKMONT, PENNSYLVANIA
ST. JOE ZINC CO.
MONACA, PENNSYLVANIA
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
CARBORUNDUM ABRASIVES
BUFFALO, NEW YORK
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
KERR-MCGEF CHEMICAL CORP.
TRONA, CALIFORNIA
QUALITY MILLS, INC.
MT. AIRY, NORTH CAROLINA
BUNGE, INC.
CAIRO, ILLINOIS
TFXACO INCORPORATED
SAN ARDO, CALIFORNIA
GENERAL MOTORS CORPORATION
DAYTON, OHIO
PHILLIP MORRIS, INC.
CHESTER, VA.
ALYESKA PIPELINE SERVICE CO.
VALDEZ, ALASKA
ARCO/POLYMERS, INC.
MONACA, PENNSYLVANIA
CANTON TEXTILES
CANTON, GEORGIA
CATFRPILLAR TRACTOR CO.
EAST PEORIA, ILLINOIS
CATERPILLAR 1RACTOH CO.
MAPLETON, ILLINOIS
SODIUM HYOROXIDE SCRUBBING
CAUSTIC WASTE STREAM
CAUSTIC WASTE STREAM
SODIUM HYDROXIDE SCRUBBING
SODIUM HYDROXIDE SCRUBBING
CAUSTIC SCRUBBING
CAUSTIC SCRUBBING
DOUBLE ALKALI (DILUTE)
CITRATE PROCESS
SODIUM HYDROXIDE SCRUBBING
LIME SCRUBBING
SODIUM HYDROXIDE SCRUBBING
SODIUM CARBONATE SCRUBBING
WATER SCRUBBING
LIME SCRUBBING
SODIUM HYDROXIDE SCRUBBING
SODIUM HYDROXIDE SCRUBBING
SODIUM CARBONATE SCRUBBING
SODIUM HYDROXIDE SCRUBBING
DOURLF ALKALI (CONCENTRATED)
CAUSTIC WASTE STREAM
UOURLF ALKALI (CONCENTRATED)
UOURLI- ALKALI (CONCENTRATED)
-------
STATUS
i<)76
SECTION 4 (CONTINUED)
SUMMARY BY VENDUR OK FGD-SYSTEMS ON INDUSTRIAL BORERS
VENDOR
INSTALLATION NAM£ / LOCATION
CONTROL SYSTEM PROCESS
FMC ENVIRONMENTAL EQUIPMENT
GM ENVIRONMENTAL
GREAT WESTERN SUGAR
HEATER TECHNOLOGY
KOCH ENGINEERING
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
CATERPILLAR TRACTOR CO.
MOSSVILLE, ILLINOIS
CHANSLOR WESTERN OIL & DEV.
BAKERSFIELO, CALIFORNIA
CO
FIRESTONE TIKE AND RUBBER CO.
POTTSTOWN, PENNSYLVANIA
FMC (SODA ASH PLANT)
GREEN RIVER, WYOMING
GENERAL MOTORS CORPORATION
TONOWANDA, NEW YORK
GETTY OIL COMPANY
BAKERSFIELD, CALIFORNIA
TRANSCO TEXTILES, INC.
AUGUSTA, GEORGIA
GENERAL MOTORS CORPORATION
PARMA, OHIO
GREAT WESTERN SUGAR
BILLINGS, MONTANA
GREAT WESTERN SUGAR
FINDLAY, OHIO
GREAT WESTERN SUGAR
FORT MORGAN, COLORADO
GREAT WESTERN SUGAR
FREEMONT, OHIO
GREAT WESTERN SUGAR
GERING, NEBRASKA
GREAT WESTERN SUGAR
GREELEY, COLORADO
GREAT WESTERN SUGAR
LONGMONT, COLORADO
GREAT WESTERN SUGAR
LOVELAND, COLORADO
GREAT WESTERN SUGAR
SCOTTS BLUFF, NEBRASKA
BELRIDGE OIL COMPANY
MCKITTRICK, CALIFORNIA
MOBIL OIL COMPANY
BUTTONWILLOW, CALIFORNIA
ARMCO STEEL
MIDOLFTOWN, OHIO
CHEVRON U.S.A. INC.
BAKERSFIELU, CALIFORNIA
CHEVRON U.S.A. INC.
BAKFRSFIELI), CALIFORNIA
ALKALI (CONCENThATI 0)
DOUBLE ALKALI (CONCENTRATED)
DOUBLE ALKALI (CONCENTRATED)
DOUBLE ALKALI (CONCENTRATED)
SODIUM CARBONATE SCRUBBING
SODIUM HYDROXIDE SCRUBBING
SODIUM CARBONATE SCRUBBING
SODIUM CARBONATE SCRUBBING
DOUBLE ALKALI (DILUTE)
AMMONIA-LADEN PROCESS WATER
SODIUM CARBONATE SCRUBBING
AMMONIA-LADEN PROCESS WATER
SODIUM CARBONATS SCRUBBING
AMMONIA-LADEN PROCESS WATER
AMMONIA-LADEN PROCESS WATER
AMMONIA-LADEN PROCESS WATER
AMMONIA-LADEN PROCESS WATER
AMMONIA-LADEN PROCESS WATER
SODIUM HYDROXIDE SCRUBBING
SODIUM CARBONATE SCRUBBING
LIME SCRUBBING
SODIUM CARBONATE SCRUBBING
SODIUM CARBONATE SCRUBBING
-------
STATUS TO OCTOBER 1978
SECTION It (CONTINUED)
SUMMARY BY VENDOR OF FED SYSTEMS UN INDUSTRIAL BOILERS
VENDOR
INSTALLATION NAME / LOCATION
CONTROL SYSTEM PROCESS
KOCH ENGINEERING
MOBTL OIL COMPANY
PFARODY ENGINEERING
PROPRIETARY DESIGN
RESEARCH-COTTRELL/BAHCO
SWEMCO INC.
THERMOTICS INC.
VENDOR NOT SELECTED
.W. SLY MANUFACTURING CO.
ZURN INDUSTRIES
MINN-OAK FARMER'S COOPERATIVE
MHPETON, NORTH DAKOTA
MOBIL OIL CORPORATION
SAN ARDO, CALIFORNIA
GENERAL MOTORS CORPORATION
PONTIAC» MICHIGAN
GETTY OIL COMPANY
BAKFRSFIELl), CALIFORNIA
RICKENBACKER AIR FORCE RASE
COLUMBUS, OHIO
TEXASGULF
GRANGER, WYOMING
BELRIOGE OIL CO.
MCKITTRICK, CALIFORNIA
C.A.M.(CARBIDE-AMOCO-MONSANTO)
HOUSTON, TEXAS
DUPONT, INC.
GEORGIA
OIIPDNT, INC.
TEXAS
GRISSOM AIR FORCE BASE
BUNKER HILL, INDIANA
SHELL OIL COMPANY
BAKERSFIELD, CALIFORNIA
SHELL OIL COMPANY
TAFT, CALIFORNIA
AMERICAN THREAD CO.
MARION, NORTH CAROLINA
HARRIS MINING co.
SPRUCE PINE, NORTH CAROLINA
SHELLER GLOBE CORP.
NORFOLK, VIRGINIA
CATERPILLAR TRACTOR CO.
JOLIET, ILLINOIS
CATERPILLAR TRACTOR CO.
MORTON, ILLINOIS
AMMONIA SCRUBBING
SODIUM HYDROXIDE SCRUBBING
SODIUM HYDROXIDE SCRUBBING
SODIUM CARBONATE SCRUBBING
LIMESTONE SCRUBBING
SODIUM CARBONATE SCRUBBING
SODIUM HYDROXIDE SCRUBBING
PROCESS NOT SELECTED
DOUBLE ALKALI
LIMESTONE SCRUBBING
DOUBLE ALKALI (CONCENTRATED)
PROCESS NOT SELECTED
PROCESS NOT SELECTED
CAUSTIC WASTE STREAM
HATER SCRUBBING (NA,NH3 OPTN.)
SODIUM HYDROXIDE SCRUBBING
DOUBLE ALKALI (DILUTE)
DOUBLE ALKALI (DILUTE)
-------
STATUS TO OCTOBER 1979
SECTION 5
OPERATIONAL FGD SYSTFMS ON INDUSTRIAL ROILERS
COMPANY/LOCATION/FUEL
NEW/
RETROFIT
UMT SIZE
(SCFM)
PROCESS/VENDOR
START-UP
MO/YR
ALYESKA PIPELINE SERVICE co.
VALDEZ, ALASKA
OIL (0.03X - O.IX SULFUR)
NEW
50,000 SODIUM HYDROXIDE SCRUBBING
FMC ENVIRONMENTAL EQUIPMENT
fc/77
AMERICAN THREAD CO.
MARION, NORTH CAROLINA
COAL (1 - 1.5X SULFUR)
RETROFIT
IS.SOO CAUSTIC WASTE STREAM
W.W. SLY MANUFACTURING CO.
0/73
ARMCO STEEL
MIODLETOWN, OHIO
COAL (O.flX SULFUR)
RETROFIT
8«,000 LIME SCRUBBING
KOCH ENGINEERING
0/75
8ELRIOGE OIU CO.
MCKITTRICK, CALIFORNIA
CRUDE Oil (1.1X SULFUR)
NEW
12,000 SODIUM HYDROXIDE SCRUBBING
THERMOTTCS INC.
7/78
BELRIDGE OIL COMPANY
MCKJTTRICK, CALIFORNIA
OIL C1.1X SULFUR)
NEK
i?,ooo
SODIUM HYDROXIDE SCRUBBING
HEATER TECHNOLOGY
6/78
CANTON TEXTILES
CANTON, GEORGIA
COAL CO.BX SULFUR)
INTERRUPTIBLE NATURAL 6AS
HFTROF1T
85,000
CAUSTIC WASTE STREAM
FMC ENVIRONMENTAL EQUIPMENT
6/74
CATERPILLAR TRACTOR CO,
EAST PEORJA, ILLINOIS
COAL (3.2X SULFUR)
2 NFW, 2 RETRO
DOUBLE ALKALI (CONCENTRATED)
FMC ENVIRONMENTAL EQUIPMENT
«/78
.CATERPILLAR TRACTOR CO.
MOSSVItLE, ILLINOIS
COAL (3.?% SULFUR)
1 NEW 1 RETRO 140,000 DOUBLE ALKALI (CONCENTRATED)
FMC ENVIRONMENTAL EQUIPMENT
10/75
CATERPILLAR TRACTOR CO,
JOLIFTr ILLINOIS
COAL (3.2X SULFUR)
RETROFIT
67,000
DOUBLE ALKALI (DILUTE)
ZORN INDUSTRIES
9/74
CATERPILLAR TRACTOR CO.
MORTON, ILLINOIS
COAL (3.?X SULFUR)
RETROFIT
40,000
DOUBLE ALKALI (DILUTE)
ZURN INDUSTRIES
1/78
CHF.VRON U.S.A. INC.
BAKERSFIFLD, CALIFORNIA
OIL (1.1* SULFUR)
RETROFIT
2«8,000 SODIUM CARBONATE SCRUBBING
KOCH ENGINEERING
7/78
FIRtSTONE TIRE AND RUBBER CO.
POTTSTOWN, PENNSYLVANIA
COAL (a.5 - 3.OX SULFUR)
RETROFIT
«070
DOUBLE ALKALI (CONCENTRATED)
FMC ENVIRONMENTAL EQUIPMENT
1/75
FMC (SODA ASH PLANT)
GREEN RIVER. WYOMING
COAL (IX SULFUR)
NFW
446,000 SODIUM CARBONATE SCRUBBING
FMC ENVIRONMENTAL EQUIPMENT
-------
MATHS
OCTOBER
SECTION b (criM i-.iiiF.oi
OPERATIONAL FGO SYS1FMS OfM INDUSTRIAL
COMPANY/LOCATION/FUEL
NEW/
RfcTKOFIT
UNIT Sl7t
PROCESS/VENDOR
START-UP
MO/YR
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
COAL (3.2X SULFUR)
RETROFIT
61,000 SODIUM HYOROXIDF SCRUBBING
A.D. LITTLE
0/72
GENERAL MOTORS CORPORATION
DAYTON, OHIO
COAL(0.7X • 2.OX SULFUR)
RETROFIT
36,000 SODIUM HYDROXIDF SCRUBBING
ENTOLETF.R, INC.
9/74
GENERAL MOTORS CORPORATION
TONOWANDA, NEW YORK
COAL (1.2X SULFUR)
RETROFIT 92,000 SODIUM HYDROXIDF SCRUBBING
FMC ENVIRONMENTAL EQUIPMENT
6/75
GENERAL MOTORS CORPORATION
PARMA, OHIO
COAL (2.5X SULFUR)
RETROFIT
128,«00 DOUBLE ALKALI (DILUTE)
GM ENVIRONMENTAL
3/74
GENERAL MOTORS CORPORATION
PONTIAC, MICHIGAN
COAL (0.84X SULFUR)
ALSO WOOD, PAPER, AND CARDBOARD.
MEM
107,300 SODIUM HYDROXIDE SCRUBBING
PEABODY ENGINEERING
4/76
GEORGIA-PACIFIC PAPER CO. NEW
CROSSETT, ARKANSAS
BARK,COAL/OIL ClX - l.SX SULFUR)
220,000 CAUSTIC WASTE STREAM
AIRPOL INDUSTRIES
0/75
GETTY OIL COMPANY
BAKERSFIELD, CALIFORNIA
COAL (1.1X SULFUR)
RETROFIT
72,000 SODTUM CARBONATE SCRUBBING
FMC ENVIRONMENTAL EQUIPMENT
6/77
GREAT SOUTHERN PAPER CO. RETROFIT
CEDAR SPRINGS, GEORGIA
BARK,COAL/OIL Ci.ox - 2.ox SULFUR)
«20,000 CAUSTIC WASTE STREAM
AIRPOL INDUSTRIES
0/75
GREAT WESTERN SUGAR
BILLTNGS, MONTANA
COAL (0.7X SULFUR)
RETROFIT
60,000 AMMONIA-LADEN PROCESS WATER
GREAT WESTERN SUGAR
10/77
GREAT WESTERN SUGAR
FINOLAY, OHIO
COAL (1.2X SULFUR, AVERAGE)
RETROFIT
65,230 SODIUM CARBONATE SCRUBBING
GREAT WESTERN SUGAR
10/74
GREAT WESTERN SUGAR
FORT MORGAN, COLORADO
COAL (1.2X SULFUR, AVERAGE)
RETROFIT
65,230 AMMONIA-LADEN PROCESS WATER
GREAT WESTERN SUGAR
10/76
GREAT WESTERN SUGAR
GERING, NEBRASKA
COAL (1.2X SULFUR, AVERAGE)
RETROFIT
110,000 AMMONIA-LADEN PROCESS WATER
GREAT WESTERN SUGAR
10/75
GREAT WESTERN SUGAR
GRF.ELEY, COLORADO
COAL (0.6X SULFUR)
RETROFIT
25,000 AMMONIA-LADFN PROCESS WATFR
GREAT WESTERN SUGAR
10/75
-------
ST4TUS TO OCTOBER 1978
SFCTION 5 (CONTINUED)
OPERATIONAL F6D SYSTEMS ON INDUSTRIAL BOILFRS
COMPANY/LOCATION/FUEL
NEW/
RETROFIT
UNIT SIZE
(SCFM)
PROCESS/VFNDOR
START-UP
MO/YR
GREAT WESTERN SUGAR
LOVELANO, COLORADO
COAL (1.2X SULFUR, AVERAGE)
RETROFIT
121,800 AMMONIA-LADEN PROCESS WATER
GREAT WESTERN SHG6R
10/73
GREAT WESTERN SUGAR
SCOTTS BLUFF, NEBRASKA
COAL (l.ax SULFUR, AVERAGE)
RETROFIT
65,330 AMMONTA-LADEN PROCESS WATER
GREAT WESTERN SUGAR
SO/75
ITT RAYONIER, INC.
FERNANDINA BEACH, FLORIDA
BARK,OIL (2.0% - 2.5* SULFUR)
RETROFIT
201,000 SODIUM HYDROXIDE SCRUBBING
AIRPOL INDUSTRIES
0/75
KERR-MCGEE CHEMICAL CORP. NEW
TRONA, CALIFORNIA
COKE/COAL/OIL (OoSS - 5.OX SULFUR)
490,000 SODIUM CARBONATE SCRUBBING
COMBUSTION EQUIPMENT ASSOC.
6/76
MEAD PAPE8BOARO CO.
STEVENSON, ALABAMA
OIL (1.5X - 3% SULFUR)
NEW
100,000 SODIUM HYDROXIDE SCRUBBING
AIRPOL INDUSTRIES
0/75
MINN-DAK FARMER'S COOPERATIVE
WAHPETON, NORTH DAKOTA
LIGNITE (1.0% SULFUR)
RETROFIT
AMMONIA SCRUBBING
KOCH ENGINEERING
6/77
MOBIL OIL CORPORATION
SAN ARDOf CALIFORNIA
OIL C2.0X - 2.25% SULFUR)
RETROFIT
182,000 SODIUM HYDROXIDE SCRUBBING
MOBIL OIL COMPANY
0/74
NEKOOSA PAPERS, INC.
ASKDOWN, ARKANSAS
COAL (U - 1.5X SULFUR)
NEW
CAUSTIC SCRUBBING
AIRPOL INDUSTRIES
RICKENBACKER AIR FORCE BASE
COLUMBUS* OHIO
COAL (3.6X SULFUR)
RETROFIT
55,000 LIMESTONE SCRUBBING
RESFARCH-COTTRELL/BANCO
5/76
SHELLER GLOBE CORP.
NORFOLK, VIRGINIA
COAL (< l.OX SULFUR)
RETROFIT
6,000
SODIUM HYDROXIDE SCRUBBING
w.w. SLY MANUFACTURING co.
0/75
ST. REGIS PAPER CO.
CANTONMENT, FLORIDA
BARK,OIL/GAS c< 1.0% SULFUR)
RETROFIT
115,000 CAUSTIC SCRUBBING
AIRPOL INDUSTRIES
0/73
TEXACO INCORPORATED
SAN AROO, CALIFORNIA
OIL (1.7X SULFUR)
RETROFIT
366,000 SODIUM HYDROXIDE SCRUBBING
CE1LCOTF
11/73
TEXASGULF
GRANGER, WYOMING
OIL (1.1X SULFUR)
NEW
140,000 SOUIUM CARBONATF SCRUBBING
SWEMCO TNC.
9/76
21
-------
STATUS TO OCTOBER 1978
SFCTION f>
UNOFR CONSTRUCTION FGP SYSTEMS ON INDUSTRIAL ROILERS
COMr'ANY/LOCATION/f-UEL
NF'V/
RETROFIT
UNIT SIZE
(SCFM)
PROCESS/VENDOR
START-UP
MO/YR
8ELRIUGE OIL CO.
MCKITT&ICK, CALIFORNIA
CRUDE OIL u.ix SULFUR)
RETROFIT
12,000 SODIUM HYDROXIDE SCRUBBING
C-E
11/78
CATERPILLAR TRACTOR co.
MAPLFTON, ILLINOIS
COAL (3.2X SULFUR)
NEH
157.000 DOUBLE ALKALI (CONCENTRATED)
FMC ENVIRONMENTAL EQUIPMENT
10/78
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
COAL (3.2X SULFUR)
NFW
262,000 DOUBLE ALKALI (CONCENTRATED) 10/79
FMC ENVIRONMENTAL EQUIPMENT
CHANSLOR WESTERN OIL & DEV. CO NEW
BAKERSFIELO, CALIFORNIA
OIL (1.5X SULFUR)
70,000 DOUBLE ALKALI (CONCENTRATED) 12/78
FMC ENVIRONMENTAL EQUIPMENT
GETTY OIL COMPANY
BAKERSFIELD, CALIFORNIA
OIL (l.lt SULFUR)
RETROFIT
993,750 SODIUM CARBONATE SCRUBBING
PROPRIETARY DESIGN
12/78
GREAT WESTERN SUGAR
FREEMONT, OHIO
COAL (3X SULFUR)
RETROFIT
40,000 SODIUM CARBONATE SCRUBBING
GREAT WESTERN SUGAR
10/78
MOBIL OIL COMPANY
BUTTONWILLOW, CALIFORNIA
OIL (1.1X SULFUR)
RETROFIT
42,000 SODIUM CARBONATE SCRUBBING
HEATER TECHNOLOGY
9/76
PHILLIP MORRIS, INC.
CHESTER, VA.
COAL C1.7X SULFUR)
NEW
39,000 SODIUM CARBONATE SCRUBBING
FLAKT, INC.
1/79
ST. JOE ZINC CO.
MONACA, PENNSYLVANIA
COAL (2.5X - 4.5X SULFUR)
RETROFIT
104,000 CITRATE PROCESS
BUREAU OF MINES
12/78
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
OIL (1.7X SULFUR)
RETROFIT
117,000 SODIUM HYDROXIDE SCRUBBING
DUCON COMPANY
3/79
-------
STATUS TO OCTOBER 1978
SECTION 7
PLANNED FGD SYSTEMS ON INDUSTRIAL BOILERS
COMPANY/LOG AT I ON/FUEL
NEW/
RETROFIT
UNIT SI7E
(SCFM)
PROCESS/VENDOR
START-UP
MO/YR
ARCO/POLYMERS, INC.
MONACA, PENNSYLVANIA
COAL C3.0X SULFUR)
RETROFIT 2^6,000 DOU8LF ALKALI (CONCENTRATED)
FMC ENVIRONMENTAL EQUIPMENT
6/80
CARBORUNDUM ABRASIVES
BUFFALO. NEW YORK
COAL (?.2X SULFUR)
HETROF1T
30,000
LIME SCRUBBING
CAHKQRUNDUM ENVIR. SYS. LTD.
o/ u
CHEVRON U.S.A. INC,
BAKERSFIELD, CALIFORNIA
OIL tl.i* SULFUR)
RETROFIT
SODIUM CARBONATE SCRUBBING
KOCH ENGINEERING
a/79
58ISSOM AIR FORCE BASE
BUNKER KILL, INDIANA
COAL (0.9X - «,6* SULFUR)
1 NEW 2 RFTSO 3?,000
DOUBLE ALKALI (CONCENTRATED)
VENDOR NOT SELECTED
9/79
C.A.H.(CARBIOE-AMOCO-MONSANTO)
HOUSTON? TEXAS
FUEL NOT SELECTED
NEW
1,200,000 PROCESS NOT 3ELFCTED
VENDOR NOT SELECTED
10/83
DUPONT, INC.
GEORGIA
COAL (1.52 SULFUR)
NEW
880,000 DOUBLE ALKALI
VENDOR NOT SELECTED
0/67
DUPONT, INC.
TEXAS
COAL (0.5Z SULFUR)
NEW
320,000 LIMESTONE SCRUBBING
VENDOR NOT SELECTED
0/82
SHELL OIL COMPANY
BAXERSFIELO, CALIFORNIA
OIL (1.1X SULFUR)
NEW
99,000
PROCESS NOT SELECTED
VENDOR NOT SELECTED
O/ 0
SHELL OIL COMPANY
TAFT, CALIFORNIA
OIL (l.U SULFUR)
NEW
25,000
PROCESS NOT SELECTED
VENDOR NOT SELECTED
O/ 0
-------
STATUS TO OCTOBtR 1978
SECTION R
SUMMARY OF DISPOSAL PRACTICES FOR FfU) SYSTEMS ON INDUSTRIAL ti'ULERS
INSTALLATION NAME / LOCATION
STATUS/COMMFNTS
ALKALINE SULF ITE/B ISULFITE RECYCLED TO PULP PROrtSS
MEAD PAPERBOARD CO.
STEVENSON, ALABAMA
NEKOOSA PAPERS, INC.
ASHOOWN, ARKANSAS
OPERATIONAL
RECOVERED SOLUTION USED AS MAKE-UP TO COOKING LIOUOR IN PULP
MILL.
OPERATIONAL
S02 RECOVERED FROM SODIUM SULFITE/SULFATE LIQUOR AND RE-
CYCIED TO PULPING PROCESS.
DEWATEREO SLURRY TO LANDFILL
ARCH/POLYMERS, INC.
MONACA, PENNSYLVANIA
BUNGE, INC.
CAIRO, ILLINOIS
CATERPILLAR TRACTOR CO.
EAST PEORIA, ILLINOIS
CATERPILLAR TRACTOR CO.
MOSSVILLE, ILLINOIS
CATERPILLAR TRACTOR CO.
JOLTET, ILLINOIS
CATERPILLAR TRACTOR CO.
MORTON, ILLINOIS
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
CHANSLOR WESTERN OIL * OEV. CO
BAKERSFIELD, CALIFORNIA
OUPONT, INC.
GEORGIA
OUPONT, INC.
TEXAS
FIRESTONE TIRE AND RUBBER CO.
POTTSTOWN, PENNSYLVANIA
GENERAL MOTORS CORPORATION
TONOWANDA, NEW YORK
GENERAL MOTORS CORPORATION
PARMA, OHIO
GENERAL MOTORS CORPORATION
PONTIAC, MICHIGAN
GR1SSOM AIR FORCE BASE
BUNKER HILL, INDIANA
U.S. GYPSUM CORP.
OAKMONT, PENNSYLVANIA
PLANNED-CONTRACT AWARDED
FLYASH ADDITION TO OEWATEREO CAS03/CAS04 FILTER CAKE,
THEN TO LANDFILL.
INDEFINITELY SHUT DOWN
OPERATIONAL
60+X SOLIDS CCASOfl] SLUDGE DIRECTLY TO LANDFILL
OPERATIONAL
SOLIDS CCAS01) SLUDGE DIRECTLY TO LANDFILL
OPERATIONAL
OPERATIONAL
CONSTRUCTION
60 + X SOLIDS (CASO«) SLUDGE DIRECTLY TO LANDFILL
CONSTRUCTION
60+2 SOLIDS (CASOfl) SLUDGE DIRECTLY TO LANDFILL.
CONSTRUCTION
PLANNED-CONSIDERING 303 CONTROL
PLANNED-CONSIDERING SOS CONTROL
OPERATIONAL
OPERATIONAL
FLY ASH AND NA2S03/SOO WASTE LIQUOR DErtATERED AND TH£N TO
SANITARY LANDFILL
OPERATIONAL
50+r SOLIDS ICAS03/SO«) SLUDGE TO DRYING POND AND LANDFILL
OPERATIONAL
5% SOLIDS SLURRY DEWATEREO AND TO LANDFILL
PLANNED-REQUESTING/FVALUATING BIDS
NEVER STARTEO-UP
SLUDGE TO POND FOR DRYING. THEN TO LANDFILL.
-------
STATUS TO OCTOBER 1978
SECTION 8 (CONTINUED)
SUMMARY OF DISPOSAL PRACTICES FOR FGD SYSTEMS UN INDUSTRIAL BOILERS
INSTALLATION NAME / LOCATION
STATUS/COMMENTS
HOLDING POND FOR EVAPORATION
AMERICAN THREAD CO.
MARION, NORTH CAROLINA
ARMCO STEEL
MIDDLETOWN, OHIO
FMC (SODA ASH PLANT)
GREEN RIVER. WYOMING
GETTY OIL COMPANY
BAKERSFIELDf CALIFORNIA
KE9H-MCGEE CHEMICAL CORP.
TRONA, CALIFORNIA
MOBIL OIL COMPANY
BUTTONWILLOW, CALIFORNIA
MOBIL OIL CORPORATION
SAN ARDO, CALIFORNIA
OPERATIONAL
THE SODIUM SULFITF/SULFATE WASTE LIQUOR IS PUMPED TO
A RED CLAY LINED ASH BASIN. LtACHING OF THE SOLUBLE SODIUM
SALTS is THEREBY PREVENTED,
OPERATIONAL
OPERATIONAL
NA2S03/S04 LIQUOR DISPOSED TO COLLECTION POND - NO PRIOR
AERATION, LANDFILL IN THE FUTURE
OPERATIONAL
10 GPM SLEEOGFF TO A SLOWDOWN TANK. THE SLOWDOWN is THEN
SENT TO A DISPOSAL POND ONCE A WEEK.
OPERATIONAL
SCRUBBER EFFLUENT IS CLARIFIED AND THEN PUT INTO A MINERAL
DEPOSIT.
CONSTRUCTION
INTERMITTENT SLOWDOWN TO WASTE DISPOSAL SITE.
OPERATIONAL
NON-FIXATED SLURRY TO LINED POND
CANTON TEXTILES
CANTON, GEORGIA
RICKENBACKER AIR FORCE BASE
COLUMBUS, OHIO
OPERATIONAL
NA S03/S04 LIQUOR DISPOSED TO LINED HOLDING PONDS
OPERATIONAL
UNSTABILIZEO CAS03/S01 SLUDGE TO LINED POND
REGENERA8LE • ELEMENTAL SULFUR PRODUCT
ST. JOE ZINC CO.
MONACA, PENNSYLVANIA
CONSTRUCTION
WASTEWATER TREATMENT AND DISCHARGE TO CITY SEWER
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
GENERAL MOTORS CORPORATION
DAYTON, OHIO
GEORGIA-PACIFIC PAPER CO.
CBOSSETT, ARKANSAS
GREAT WESTERN SUGAR
FINDLAY, OHIO
GREAT WFSTERN SUGAR
FREEMONT, OHIO
OPERATIONAL
N«2S03 OXIDIZED TO NA2S04, PH NEUTRALIZED AND DISCHARGED TO
CITY SEWER SYSTEM
OPERATIONAL
NAaS03/S04 LIQUOR AT 35 GPM TO ON-SITE CLARIFICATION AND
OEWATERING FACILITY
OPERATIONAL
OPERATIONAL
BLEFO-OFF STREAM TO HOLDING TANK
CONSTRUCTION
-------
STATUS TO OCTOBER 1978
SFCTION 8 CCONTINUEO)
SUMMARY OF DISPOSAL PRACTICES FOR FGD SYSTt^S ON INDUSTRIAL BOILERS
INSTALLATION NAME / L
STATUS/COMMENTS
WASTtWATER TREATMFNT AND DISCHARGE TO CITY SEWER
QUALITY MILLS, INC.
MT. AIRY, NORTH CAROLINA
TERMINATED
SCRUBBING LIQUOR DISCHARGED TO NEUTRALIZATION PONO
WASTEWATER TREATMENT AND DISCHARGE TO RIVER
GREAT SOUTHERN PAPER CO.
CEDAR SPRINGS, GEORGIA
GREAT WESTERN SUGAR
BILLINGS, MONTANA
GREAT WESTERN SUGAR
FORT MORGAN, COLORADO
GREAT WESTERN SUGAR
GERTNG, NEBRASKA
GREAT WESTERN SUGAR
6REELEY, COLORADO
GREAT WESTERN SUGAR
LOVELAND, COLORADO
GREAT WESTERN SUGAR
SCOTTS BLUFF, NEBRASKA
GREAT WESTERN SUGAR
LONGMONT, COLORADO
TRANSCO TEXTILES, INC.
AUGUSTA, GEORGIA
OPERATIONAL
CLARIFICATION FOLLOWED BY PONOING AND DISCHARGE TO RIVER
OPERATIONAL
OPERATIONAL
OPERATIONAL
EFFLUENT TO HOLDING POND
OPERATIONAL
OPERATIONAL
EFFLUENT STREAM TO HOLDING POND
OPERATIONAL
EFFLUENT STREAM TO HOLDING PONO.
TERMINATED
INDEFINITELY SHUT DOWN
NA3S03/S04 LIQUOR DISCHARGED TO A HOLDING POND
WASTEWATER TREATMENT AND DISCHARGE TO TAILINGS POND
CHEVRON U.S.A. INC.
BAKERSFIELD, CALIFORNIA
GETTY OIL COMPANY
BAKER9FIELD, CALIFORNIA
ITT RAYONIER, INC.
FERNAA1DINA BEACH, FLORIDA
OPERATIONAL
CONSTRUCTION
OPERATIONAL
WASTEWATER TREATMENT
AUYESKA PIPELINE SERVICE co.
VALDEZ, ALASKA
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
8FLRIDGE OIL COMPANY
MCKITTRICK, CALIFORNIA
CARBORUNDUM ARRASUHS
BUFFALO, NEW YORK
OPERATIONAL
NA2S03/HS03 AERATED TO NAaS04 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.
OPERATIONAL
OPERATIONAL
PLANNED-CONTRACT AWARDED
-------
STATUS TO OCTORER 1978
SFCT10N « (CONTINUED!
SUMMARY OF DISPOSAL PRACTICES F-Ok FRO SYSTtMS UN TNDUSTHIAL BOILERS
INSTALLATION NAME / LOCATION STATUS/COMMENTS
WASTEWATER TREATMENT
CHEVRON U.S.A. INC. PLANNED-REQUESTING/FVALUATING HIOS
BAKERSrTELD, CALIFORNIA
MINN-DAK FARMER'S COOP£3ATIVf OPERATIONAL
WAHPETQN, NORTH DAKOTA BLEED STREAM GOES TO AN ACTIVATED SLUDGF SYSTEM a 360 GPM
ST. RFGJS PAPER CO. OPERATIONAL
CANTONMENT, FLORIDA EFFLUENT IS TREAfFD IN AW ON-SITE SEKASE TREATMENT PLANT
TEXACO INCORPORATED OPERATIONAL
SAN AROO, CALIFORNIA HJLF OF THE SCRUBPEP UNDERFLOW IS TREATED AND RECVCLEO AS
8CILEB FEEDWATER? THE OTHER HALF GOFS TO WASTEWATER
DISPOSAL WELLS.
TEXASGULF OPERATIONAL
GRANGER, WYOMING
OVERFLOW TO SEWER/SLUDGE TO LANDFILL
SHELLES GLOBE CORP. OPERATIONAL
NORFOLKp VIRGINIA
DISPOSAL TECHNIQUE NOT KNOWN
C.A.M.CCARBIDE-AHOCO-MONSANTOS PLANNED-CONSIDERING soz CONTROL
HOUSTON. TEXAS
HARRIS MINING co. INDEFINITELY SHUT DOWN
SPRUCE PINE, NORTH CAROLINA
SHELL OIL COMPANY PLANNED-CONSIDERING SOd CONTROL
BAKERSFIELD, CALIFORNIA
SHELL OIL COMPANY PLANNED-CONSIDERING S02 CONTROL
TAFT, CALIFORNIA
SCRUBBER EFFLUENT DISPOSED OF IN WASTE WELLS
TEXACO INCORPORATED CONSTRUCTION
SAN ARDO, CALIFORNIA
-------
STATUS TO OCTOBER 147»
SECTION 9
PERFORMANCE DESCRIPTION FUR OPFRATIUML Ft;n SYSTEMS ON INDUSTRIAL RDHFKS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICIPATE REMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
ALYESKA PIPELINE SERVICE CO.
VALDEZ, ALASKA
OIL (0.03* - 0.1Z SULFUR)
50,000 SCFM (DESIGN MAXIMUM)
1
3
25 MW (EQUIVALENT)
FMC ENVIRONMENTAL EQUIPMENT
SODIUM HYDROXIDE SCRUBBING
NEW
JUNE, 1977
OPERATIONAL
96+X (150-160 PPM 3 INLET)
PART1CULATE EMISSIONS MEET NSPS.
2 GPM - OPEN LOOP
WASTEWATER TREATMENT
NA2S03/HS03 AERATED TO NA2S04 AND TRANSFERRED TO WASTENATEff
TREATMENT PLANT AT A RATE OF 10 GPM. IT IS MIXED WITH ABOUT
10,000 GPM OF BALLAST WATER FROM TANKERS IN PORT VAUDEZ.
CLEANED WATER IS THEN DISCHARGED INTO PORT VALOEZ.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AT THE VALDEZ TERMINAL OF THE ALASKAN OIL PIPELINE, ALYESKA PIPELINE SERVICE. COMPANY OPERATES
THE OIL STORAGE AND TRANSFER FACILITY, OIL FLOWING IN FROM THE PIPELINE IS TEMPORARILY STORED IN
SEVERAL HUGE TANKS, THEN TRANSFERRED FROM THE TANKS TO OIL TANKER SHIPS IN NEARBY PORT VALDEZ.
ALYESKA NEEDED NEUTRAL BLANKET AIR FOR THE OIL STORAGE TANKS, A LOW OXYGEN CONTENT BEING PARTICULAR-
LY DESIRABLE. IT WAS DETERMINED THAT ON-SITE BOILER FLUE GAS WOULD HAVE THE REQUIRED LOW OXYGEN
CONTENT. CORROSION PREVENTION IN THE OIL STORAGE TANKS DICTATED THE NEED FOH S02 CONTROLS.
THAT IS, THF DEVICE WAS NOT INSTALLED TO MEFT AN EMISSIONS REGULATION. NEVFRTHFLESS, THE
"INERT GAS" SYSTEM IS BASICALLY A SODIUM HYOROXTDF FGf) SYSTEM AND WAS DESIGNED AND INSTALLED BY
FMC ENVIRONMENTAL EQUIPMENT DIVISION.
THE BOILERS DO NOT OPERATE AT STEADY STATE CONDITIONS. THIS IS DUE TO THE FACT THAT WHEN OIL
IS REMOVED FROM THE TANKS AT A FASTFR RATE THAN IT IS BFING FEU BY THF PIPELINE, AN ADDITIONAL INERT
AIR BLANKET IS NEEDED. THIS REQUIRES INCREASING THE BOILER LOAD FROM THE NORMAL LEVEL OF PLANT
POWER PRODUCTION TO RUN THE COMPRESSORS AND PRODUCE ADDITIONAL GAS FOR BLANKET PRODUCTION.
IF THE TANKS ARF FILLING FASTER THAN THEY ARE BEING EMPTIED, THE AIR FORCED OUT BV THE INCOMING
-------
STATUS TO OCTOBER i47a
SECTION 9 (CONMNUFD)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
ALYESKA PIPELINE SERVICE CO.? VALDEZ, ALASKA (CONTINUED)
OIL IS INCINERATED.
THE BOILER PLANT AT THE VALDEZ TERMINAL CONSISTS OF THREE 250 MM BTU/HR OJL-FIRER BOILERS,
MANUFACTURED 8Y COMBUSTION-ENGINEERING. THE OIL BEING USED IN THE BOILERS PRODUCES A VERY LOh
PARTICULATE GRAIN LOADING, AND HAS AN EXTREMELY LOrt SULFUR CONTENT WHICH RAMSES FROM 0.03'i TO (MX.
THERE 13 NO PfeSTlCULATE CONTROL OTHER THAN WHAT OCCUKS IN THE FMC S02 ABSORBER MODULE-
THE MAXIMUM DESIGN CAPACITY OF THE SCRUBBER MODULE IS 50,000 SCF*, WHICH REPRESENTS S80UT P5Z
OF THE TOTAL FLUE GAS GENERATED., THE 802 CONTROL SYSTEM IS DESIGNED WITH 100X REDUNDANCY, T.E.,
THERE ARE TWO MODULES IN PARALLEL.. ONLY ONE OF WHICH IS IN USE AT ANYTIME,, THE MODULES A9E IDENT-
ICAL ««STA6E D1SH«AK)D»OONUT TRAY TYPE ABSORBERS WITH A MAXIMUM RECIRCULATION KATE OF 600 6PM AND A
L/G RATIO OF 12 SAL/iOOO CU FT.
CAUSTIC (SODIUM HYDROXIDE) IS USED AS REAGENT MAKE-UP, OF.3IGN PM CONTROL WAS ABOUT 6.5, 3UT
OPERATIONS HAVE INDICATED THAT A HIGHER PH IS MORE DESIRABLE* SO CONTROL PH IS NOW ABOUT 8,0.
A BLEED STREAM OF SODIUM BISULFITE/SULFITE GOES TO AN AERATOR AT A RATE OF 10 6PM. AFTER COMPLETE
OXIDATION TO NA2S04, THE WASTE STREAM GOES TO A WASTEWATER TREATMENT AREA WHERE IT SS MIXED WITH
10,000 6PK! OF BALLAST WATER FROM THE TANKERS IN THE PORT, AND DISCHARGED INTO THE PORT.
OPERATING HISTORY
3RD QUARTER-1977 CORROSION HAS OCCURRED IN THE PIPING FOR THE WATER RECIRCULATION SYSTEM.
AT THE TIME OF THIS REPORT, THE CAUSE WAS NOT KNOWN. ALYESKA TESTS HAVE DEMONSTRATED ABOUT
5 PPM 803/303/304 AT THE ABSORBER OUTLET. INLET 302 CONCENTRATION RANGES FROM 150 TO 160 PPM.
THE SYSTEM MAS THEREFORE REMOVING ABOUT 96Z OF THE INLET SULFUR OXIDES. AT THE TIME OF THIS REPORT,
THERE WAS NO CONTINUOUS 302 MONITOR ON THE SYSTEM.
«TH QUARTER-1977 THE CONTROL SYSTEM OPERATED NEARLY PROBLEM-FREE, WITH NO DOWNTIME
BEING ASSIGNED TO THE 302 REMOVAL SYSTEM. THE CURRENT LOAD IS APPROXIMATELY 20% OF DESIGN
CAPACITY. THIS is A RESULT OF OIL FLOW BEING LOW AT PRESENT. PLANS WERE BEING MADE TO DEAL WITH
THE WET AREAS CORROSION PROBLEM BY INTRODUCING NEUTRALIZING AMINE SPRAYS.
1ST QUARTER-1978 DURING THIS PERIOD, THE CORROSION PROBLEM WAS ALLEVIATED BY SPRAYING HYDRAZINE
INTO THE SYSTEM UPSTREAM OF THE MTST ELIMINATOR. THIS MEASURE RAISED FROM It TO 6.5 THE PH OF THE
LIQUOR RECOVERED BY THE MIST ELIMINATOR. CYCLOHEXAMINE MAY BE TESTED IN PLACE OF THE HYORAZINE.
THE PLANT WAS NOT YET AWARE OF THE CAUSE OF THE CORROSION, ALTHOUGH THEY SUSPECTED CARBON, SULFUR,
AND NITROGEN ACID GASES. CHLORIDFS HAVE VIRTUALLY BEEN RULED OUT AS THE SOURCE OF THE CORROSION.
2ND QIIARTER-1978 THE FMC FGD SYSTEM CONTINUED TO OPERATE ON A CONTINUOUS BASIS, BEING RESPONSI-
BLE FOR NO DOWNTIME. ANY MAINTENANCE OPERATIONS WERE EFFECTED WHILE THE SYSTEM WAS OPERATING.
IT IS IMPORTANT TO NOTE AGAIN THAT THF SYSTEM IS DESIGNED WITH 100Z REDUNDANCY.
-------
STATUS 70 OCTOBER 19?8
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FSO SYSTEMS ON INDUSTRIAL BOILERS
ALYFSKA PIPELINE SERVICE co.; VALDEZ, ALASKA (CONTINUED)
3RD QUARTER-1<»78 THE SYSTEM CONTINUED TO DEMONSTRATE 100X AVAILABILITY DURING THIS PERIOD.
CYCLOHEXAMJNE IS NOW BEING USED INSThAO OF HYOKAZINE TO CONTROL PH ROHiNSTREAM OF THE ABSORBER. PH
IS NOW IN THE 6-7 RANGE AND CORROSION SEEMS TO HAVE STOPPED. IF FURTHER CONTROL OF PH IS NEEDED,
ADDITIONAL CYCLOHEXAMINE SPRAY POINTS MAY BE INSTALLED.
-------
STATUS TO OCTOBER 1978
SFCTION P fr-ONTINUFO)
PERFORMANCE DfSC«tPTION FOR OPERATIONAL F&D SYSTEMS ON IND'ISTHIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SnUPCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OP BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
303 REMOVAL EFFICIENCY
PARTICIPATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
AMERICAN THREAD CO.
MARION, NORTH CAROLINA
COAL (1 - 1.5X SULFUR)
19,500 SCFM (TOTAL - 2 BOILERS)
9 MW (EQUIVALENT); TOTAL S BOILERS
W.W. SLY MANUFACTURING CU.
CAUSTIC WASTE STREAM
RETROFIT
1971!
OPERATIONAL
70% (500 PPM 9 INLET)
97%
HOLDING POND FOR EVAPORATION
THE SODIUM SUIFITE/SULFATE WASTE LIQUOR IS PUMPED TO
A RED CLAY LINED ASH BASIN. LEACHING OF THE SOLUBLE SODIUM
SALTS IS THEREBY PREVENTED.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AMERICAN THREAD COMPANY, LOCATED IN MAfilON, NORTH CAROLINA OPERATES TWO COAL-FIRED BOILERS, EACH
WITH A DESIGN CAPACITY OF 30,000 ACFM 3 400 F. DURING THE WINTER MONTHS ONE BOILER IS OPERATED
7 DAYS/WEEK AT 75% LOAD AND THE OTHER OPERATED 5 DAYS/WEEK ALSO AT 75% LOAD. BOTH BOILERS
OPERATE 5 DAYS/WEF.K AT 50% LOAD DURING THE SUMMER MONTHS.
THE SCRUBBERS WERE SUPPLIED BY W.W. SLY MANUFACTURING CO. AMD WERE ORIGINALLY INSTALLED TO CONT-
ROL PARTICULATE. EACH HAS A DESIGN CAPACITY OF 30,000 ACFM 3 160 F AND IS CONSTRUCTED OF 30tt SS AND
316 SS. EACH SCRUBBER IS APPROXIMATELY SO FEET IN DIAMFTF.H AND I? FEET HIGH WITH TWO SPRAY LEVELS.
THE SCRUBBING LIQUOR IS A 7% CAUSTIC WASTE STREAM FROM A MERCERIZING STF.P IN WHICH THREAD IS CLEANED
AND SHRUNK, THF CONTROL PH IS fl.S IN THE HF.CIRCULAT ION TANK, SPENT LIQUOR ENTERING THE TANK IS AT
A PH OF 5.5. THE SCRUBBERS HflVF BEEN FXHIBITING 90% RELIABILITY.
A 3S-«0% BLEED STREAM FROM THE REC IRCIIL ATION TANK RFMOVFS WASTE SOLIDS TO AN ASH POND FOR SETT-
LING.
KFFER TO FIGURE 14-1 TN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
fi HISTORY
2*0 (JUARTFW-197B PLANT WFP'IKTS THAT T1 IS SI ILL EXPERIENCING SCWUBBfcP. I.D. FAN PROBLEMS DUE To
-------
STATUS TO nCTOBff 1978
SECTION 9 (CPNT INiJFI))
PERFORMANCE DtSCRIPTTON FOR OPERATIONAL FGn SYSTFMS ON TNOUSTKIAL RUTLEKS
AMERICAN THREAD CO.; MARION, MORTH CAROLINA (CONTINUED)
VIBRATION AND CORROSION. TO OVFRCUME THIS PRObLEM, PLANS ARt BEING MADE TO ELIMINATE THE I.D. FANS
ON THE SCRUBBER AND UPGRADE BOILER I.D. FANS.
OTHER PROBLEMS HAVE 8FEN AS FOLLOWS:
1. VIBRATION CRACKS IN PVC PIPING.
2. FAILURE OF PUMP RUBBER LINING.
3. THF NEFO TO ORAJN THE REC IRCULAT I ON TANK AND PAINT IT WITH EPOXY PAINT TO ALLEVIATE
CORROSION PROBLEMS.
3RD QUARTER-1978 THE VIBRATION CRACKS IN THt PVC PIPING ARE LOCATED AT THE ENTRANCE TO THE SCRU-
BBER AND WERE CAUSED BY AN UNBALANCED FAN. THE FAN BECAME UNBALANCED WHEN ITS FIBERGLASS COATING
WAS ERODED AWAY. TWO WEEKS WERE REQUIRED TO PATCH THE COATING. THE CRACKED PIPE SECTIONS WERE RE-
PLACED. PLANS ARE BEING MADE TO REMOVE THE SCRUBBER I.D. FAN COMPLETELY FROM THE SYSTEM AND TO
UPGRADE THE EXISTING BOILER I.D. FAN SO THAT IT HAS THE CAPACITY TO OVERCOME THE SCRUBBER SYSTEM
PRESSURE DROP.
THE REPLACEMENT OF A PUMP LINING CAUSED THREE DAYS DOWNTIME.
EPOXY PAINT USED ON THE RECIRCULAT ION TANK WAS INEFFECTIVE. ONE-HALF INCH PLATES WERE WEL-
DED TO THE TANK TO PATCH HOLES CAUSED BY THE CORROSIVE LIQUOR. THE SCRUBBER WAS DOWN FOR A WEEK.
CORROSION OF PRESSURE GAUGES AND COPPER LINES HAS ALSO REEN A PROBLEM AREA.
-------
STATUS TO OCTOBER 197e
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BUILFHS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLER
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
ARMCO STEEL
MIDDLETOWN, OHIO
COAL (0.«X SULFUR)
84,000 SCFM (TOTAL - 2 ROILEWS)
200,000 LB/HR STEAM (TOTAL)
1
2
KOCH ENGINEERING
LIME SCRUBBING
RETROFIT
1975
OPERATIONAL
NOT AVAILABLE
HOLDING PONO FOR EVAPORATION
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE SCRUBBER 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 o.
-------
STATUS TO OCTOBER 19?g
SECTION 9 (CONTINUED)
PERFORMANCE- DESCRIPTION FOR OPFRA1TONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
ARMCO STEEL! MIDDLETCJWN, OHTO (CONTINUED)
LOCATION IN THt SYSTEM. HOWEVER. OVERLOOKED WAS THF FACT THAT NOREL IS CREEP SENSITIVE AT
20 DEGREES F AbOVF AMBIENT AMD THE CHEVRONS FAILED WITHIN A FEW MONTHS. NEW CHEVRONS OF THE SAME
MATERIAL ARE ALSO BEING DAMAGED. STAINLESS STF.EL OR FIBERGLASS REINFORCED PLASTIC IS THE PREFERRED
MATERIAL FOR THIS APPLICATION.
THE WATEK SYSTEM WAS ORIGINALLY DESIGNED TO BE A RECIRCULATING SYSTEM. THE RECIRCULATED WATER
HAD A SUSPENDED SOLIDS CONCENTRATION OF (10,000-50,000 MG/L AT THE VENTURI, ALL THE
PIPING TN THIS SYSTEM WAS MILD STFEL AND WAS SEVERLY ABRADED CAUSING NUMEROUS LEAKS.
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 TRAYS TO THE RECYCLE TANK AS WELL AS IN THE PUMPS. THE PROBLEM WAS SOLVED BY REPLACING THE
PIPING WITH RUBBER HOSE, RUBBER LINED ELBOWS, AND RUBBER LINED PUMPS. IN ADDITION, PUMP SPEED WAS
REDUCED FROM 1780 TO H«0 RPM AND FLANGED T-SECTIONS WERE INSTALLED ON THE SUCTION SIDE OF THE
SLUDGE PUMPS AND RECIRCULATION PUMPS. THIS MATERIAL HAS WITHSTOOD ABRASION BETTER THAN ANY OTHER
MATERIAL TRIED TO DATE.
A LIME BUILD UP PROBLEM WAS EXPECTED ON THE ABSORBER TRAYS AT LOW 6AS FLOW RATES. THIS
PROBLEM HAS NOT YET OCCURRED AT SUSTAINED PH LEVELS OF 6-6.5.
THE LIME SLURRY SYSTEM HAS ALSO PRESENTED A PROBLEM. CLOGGING OF THE LIME SLURRY LINE is
ATTRIBUTED TO ITS EXCESSIVE LENGTH. LIME ADDITION RATE IS A PROBLEM WHICH CAN BE RESOLVED WITH
THE INSTALLATION OF A PROPORTIONAL LIME SLAKER.
REFER TO FIGURE 11-2 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
«TH QUARTER-1977 THE PLANT WAS NOT ABLE TO SUPPLY EXTENSIVE UPDATE INFORMATION FOR THIS REPORT
PERIOD, ALTHOUGH REPORTED THAT RECENT OPERATIONS HAVE BEEN RELATIVELY PROBLEM-FREE. THE SCRUBBER
WAS DOWN IN FEBRUARY 1978 AS A RESULT OF THE POWER SHORTAGE OHIO WAS EXPERIENCING.
2ND QUARTER-1978 NO INFORMATION WAS OBTAINED FOR THIS UPDATE.
3RD QUARTER-1978 ABRASION CONTINUES TO BE A PROBLEM. NEW RUBBER LININGS FABRICATED IN ARMCO'S
ON-SITE RUBBER SHOP WILL BE INSTALLED. FIBERGLASS-LINED PIPE WAS ON ORDER.
THE EXCESS AIP PROBLEM HAS BEEN REDUCED TO ABOUT 40% BY PATCHING LEAKS FOUND ON THE BOILER AND
REDUCING THE COMBUSTION AIR TO THE BOILFR. HOWEVER, DUE TO THE AGE AND CONDITION OF THE BOILER
IT IS NOT LIKELY THAT THE EXCESS AIR WILL BE REDUCED FURTHER. THE BOILER IS OPERATED AN ESTIMATED
10 MO/YR. THE SCRUHBER NORMALLY OPERATES APPROXIMATELY 2 TO 3 MONTHS BEFORE IT HAS TO BE SHUT DOWN
FOR REPAIRS. THE PLANNED PROPORTIONAL LIME SLAKER WAS NEVER INSTALLED.
ifl
-------
STATUS TO OCTOBER 1978
SECTION 9 (CONTINUED)
PEKFOKMANCF RESCRIPT ION FOR OPERATIONAL FGO SYSTEMS ON INUUSTKIAL BUILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FC-0 UMTS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP HATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
9FLRIDGF OIL CO.
MCK.ITT8ICX, CALIFORNIA
CRUDE UIL (UU SULFUR)
13,000 SCFM
24,000 ACFM oi ^70 'r
1
a
b MW CEOUIVALENT)
50 MM BTU/HR
THERMOTICS TNH.
SOOJUN HYDKOXIUF SCRUBBING
NEh
JULY, 1978
OPERATIONAL
90X (500 PPM SO? a INLET)
hASTtWATER TREATMENT
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
-------
SfAIIIS TO nCTuBf.W 197H
SUIT ION « fcnNTJMJFI!)
PERFORMANCE DtSCHTPTION FOP OPFH « 1 TUNAI. FGD SYSTFMS On IMH.'STHTAI Bl)TLF«S
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCF RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOS REMOVAL EFFICIENCY
MATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
KFLR10GF OIL COMPANY
MCKITTnICK, CALIFORNIA
UTL M.1X SULFUR)
1?,000 SCFM (I BUILFK)
24,000 «CFM a 570 F
1
1
50 MM BTU/HR
HEATER TECHNOLOGY
SODIUM HYDROXIDF SCRUBBING
NEW
JUNE, 1978
OPERATIONAL
90X [500 PPM S02 AT INLET)
10 GPM
WASTEWATER TREATMENT
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
OPERATING HISTORY
3RD OUARTER-1978 SINCE FGD SYSTEM START-UP ON JULY fe, 1978 THE SCRUBBER HAS EXPERIENCED
APPROXIMATELY 1 1/2 WEEKS OF DOWNTIME. MAJOR PROBLEMS HAVE BEEN FAULTY RELAYS TN THE INSTRUMEN-
TATION, AND PUMP FAILURE. THE RECIRCULAT ION PUMP WAS REPLACED.
-------
STATUS TO OCTOBER 1978
SECTION 9 (CONtlNUFD)
PERFORMANCE DESCRIPTION FOR .OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FED UNITS
NUMBE3 OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR aY-PHODUCT DISPOSAL
CONTROL SYSTEM COST
CANTON TEXTILES
CANTON, GEORGIA
COAL (0.8X SULFUR)
INTERRUPTI8LE NATURAL GAS
25,000 3CFM (1 BOILER)
1
1
13 MW (EQUIVALENT)
FMC ENVIRONMENTAL EQUIPMENT
CAUSTIC WASTE STREAM
RETROFIT
JUNE, 1974
OPERATIONAL
70* (500 PPM 9 INLET)
80% - 90% (5.92 L8/MM BTU AT INLET)
OPEN LOOP
NON-FIXATED SLURRY TO LINED POND
MA S03/S04 LIQUOR DISPOSED TO LINED HOLDING PONDS
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
CANTON TEXTILE MILLS IN CANTON, GEORGIA HAS A 10 MW (EQUIVALENT) STEAM BOILER WHICH FIRES COAL
FROM OCTOBER TO MAY AND INTERRUPT IBLE NATURAL GAS THE REMAINDER OF THE YEAR. THE BOILER IS A COM-
ENGINEERING (C-E) VERTICAL UNIT EQUIPPED WITH A CYCLONIC DUST COLLECTOR. THE DUST COLLECTOR
CAPTURES APPROXIMATELY 75 TO 100 POUNDS OF FLY ASH PER HOUR. THE TYPICAL COAL BURNED HAS A SULFUR
CONTENT OF 0.8 PERCENT AND AN AS-RECEIVED HEAT VALUE OF 13,600 BTU PER POUND COAL. SULFUR DIOXIDE
CONCENTRATION IN FLUE GAS IS 1500 PPM KITH A PARTICULATE LOADING OF 5.92 LB/MM BTU.
THE FGO SYSTEM CONSISTS OF AN FMC MEDIUM ENERGY, VENTDRI-TYPE SCRUBBER. CAUSTIC DYEING WASTE-
WATER CONTAINING SODIUM HYDROXIDE AND SODIUM SULFATE WITH A PH OF APPROXIMATELY 11 TO 12 IS THE
SCRUBBING LIQUOR. THE SCRUBBING LIQUID IS INJECTED INTO THE FLUE GAS STREAM THROUGH SPRAY NOZZLES
AHEAD OF THE VENTURI THROAT. THE WASTEWATER IS COLLECTED IN AN EQUALIZATION BASIN. DEPENDING ON
THE DFSTRED DEGREE OF NEUTRALIZATION, THE WASTfcWATER IS TH&N RtCYCLF.D TO THE SCRUBBER OR PUMPED TO
THE WASTEWATER TREATMENT FACILITY.
SEVERAL OPERATIONAL PROBLEMS WERE ENCOUNTERED UPON INITIAL STAKTUP. A SEVERE PLUGGING PROBLEM
WAS ENCOUNTERED IN SEVERAL PUMPS DUE TO THE PRfcSENCE OF COTTON FIBERS IN THE WASTEMTER. A SCREEN
BASKET AROUND THE INITIAL SCRUBBER SYSTEM INTAKE PIPfc IN THF DYE COLLECTION MANHOLE WAS BEING USED
TEMPORARILY UNTIL FURTHER INVESTIGATION IS COMPLETED. SURFACE-ACTIVE AGENT* IN THE DYEING WASTE-
-------
STATUS TO OCTOBER 1976
SECTION 0 (CONTINUED)
PERFORMANCE DESCRIPTION! FOP OPERATIONAL FGP SYSTEMS ON INDUSTRIAL BOILERS
CANTON TEXTILES? CANTON, GEORGIA (CONTINUED)
WATERS WHICH PRODUCE FOAMING IN THfc SCHU6RER PUMP WERE DETECTED AND A DEFOAMER ADDITIVE IS NOW
INJECTED INTO THE SCRUBBER FEED FROM THE DTE RETENTION BASIN. FOULING OF THE PH PROBES AND MIST
CARRYOVER ARE OTHER PROBLEM ARfcAS THAT HAVE BEEN INVESTIGATED.
OPERATING HIS10NY
3RD QUAR1ER-1977 NO OPERATIONAL PROBLEMS WERE REPORTED DURING THIS SURVEY PERIOD. THE PLANT
REPORTER THE SYSTEM WAS WORKING SATISFACTORILY. THE PLANT WAS BURNING NATURAL GAS BUT EXPECTED
TO RETURN TO COAL DURING THE HEATING SEASON (DECEMBER-MAY).
4TH QIIARTFR-1977 THE PLANT STARTED BURNING COAL AND OPERATING THE SCRUBBER 100 PERCENT OF THE
TIME IN MID-OCTOBER. NO OPERATIONAL PROBLEMS WERE ENCOUNTERED DURING THIS PERIOD.
1ST QUARTER-1978 THE SCRUBBER DEMONSTRATED AN OPERABILITY OF 100X.
3ND OUARTER-1978 THE SCRUBBER WAS SHUTDOWN IN MID-MAY WHEN GAS FIRING RESUMED FOR SUMMER. COAL-
FIRING WILL RESUME IN MID-OCTOBER. DURING COAL-FIRED OPERATIONS IN 1977 AND 1976. THE SCRUBBER RAN
AT A 100X OPERAfllLITY.
3RD QUARTER-1978 NO UPDATE INFORMATION WAS AVAILABLE FOR THIS REPORT PERIOD.
38
-------
STATUS TO OCTOBER 1976
SECTION 9 (CONTINUED
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
3LU06E OR BYPRODUCT DISPOSAL
CONTROL SYSTEM COST
CATERPILLAR TRACTOR CO,
EAST PEOHIA, ILLINOIS
COAL (3.e!S SULFUR)
atOrOOO SCFM (TOTAL - t BOILERS)
60,000 ACFM id 359 F, FOR EACH OF H FGO SYSTEMS
105 MW (EQUIVALENT) ! TOTAL - fl BOILERS
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATE!))
2 NE!Nt 2 RETRO
APRIL. 1976
OPERATIONAL
-------
STATUS TH OLTOBER lS
SFCTION 9 (CONTINUH))
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGP SYSTFMS ON INDUSTRIAL BUTLEKS
CATERPILLAR TRACTOR CO.; EAST PEORIA, IILINOIS (CONTIMUFD)
BUILDING GOOD FILTER CAKfc DURING THE START-HP PHASt OF OPERATIONS. FINAL STEADY STATE OPERATIONS
WERE NOT ACHIEVED BEFORE SUMMER SHUTDOWN.
3RD QUARTER-1978 THE FGD SYSTEM HAD JUST STARTED UP AGAIN AFTER SUMMER SHUTDOWN.
NO MAJOR START-UP PROBLEMS WERE REPORTED.
-------
STATUS TO OCTOBER 1978
SECTION "9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAHF,
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE F60 UNITS
NUMBER OF BORERS 8EIM6 CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
HATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CATERPILLAR TRACTOR CO.
JOLIET, ILLINOIS
COAL C3.2X SULFUR)
6*,000 SCFM (TOTAL « 2 BOILERS)
2
2
34 MtS (EQUIVALENT)? TOTAL • 2 BOILERS
ZURN INDUSTRIES
DOUBLE ALKALI (DILUTE)
RETROFIT
SEPTEMBER, 1974
OPERATIONAL
90+% (2000 PPM S INLET)
NOT AVAZLA8LE
CLOSED LOOP? 0.5 6PM
DEWATERED SLURRY TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE JOLIET PLANT OPERATES TWO COAL-FIRED BOILERS RATED AT 100,000 AND so,coo POUNDS OF STEAM
'ER HOUR. THESE BOILERS ARE ON-LINE ONLY DURING WINTER MONTHS, ONE OF WHICH OPERATES 2« MR/DAY
IND THE OTHER ONLY WHEN A GREATER STEAM RATE IS REQUIRED DUE TO COLD WEATHER. THE COAL HAS A
BATING VALUE OF 10,500 BTU/LB AND IS FIRED AT A RATE OF 9.65 TONS/HR. TOTAL 502 EMISSIONS FROM
THE BOLER IS 6.74 L8S/MMBTU.
THE FGD SYSTEM ON EACH BOILER IS A ZURN DOUBLE ALKALI SCRUBBER CONSTRUCTED OF 3UL STAIN-
.ESS STEEL. EACH SCRUBBER EXHAUSTS THROUSH A CARSON STEEL STACK. THE TOTAL Fl_UE GAS FLOW RATE
IS 103,500 ACFM S 350 F. THE SCRUBBER UNITS ARE PRECEDED BY MECHANICAL COLLECTORS FOR PARTICULATE
REMOVAL.
THE ZURN SCRUBBER UTILIZES A OUSTRAXTOR MODULE FOR BOTH PARTICULATE AND S02 CONTROL. SPENT
SCRUBBING LIQUOR IS PUKPED TO THE REGENERATION AREA WHERE LIME IS ADDED TO PRODUCE CALCIUM
JULFITE/SULFATE IN CLARIFIERS. CLARIFIER UNDERFLOW, WHICH IS 15-50% SOLIDS B» WEIGHT, IS
3EWATEREO BY VACUUM FILTERS TO APPROXIMATELY 65X SOLIDS BY WEIGHT. THE THIXOTHOPIC SLUDGE
PRODUCED IS READY FOR DISPOSAL AT A LANDFILL. CLARIFIER OVERFLOW IS RETURNED tn THE SCRUBBFR AS
'^GENERATED SCRUBBING LIQUOR. SODA ASH IS ALSO ADDED TO THF "EGENE^ATm LICU"" TO RtPLENlbH
SODIUM LOST IN THE SLUDGE. LIME AND SODA ASH ARE STORED IN OUTSIDE SILOS AND -NEUMATICALLY CONVEYED
TO USE POINTS. A CHEMICAL TREATMENT BUILDING WAS ERECTED TO HOUSE REGENERATE AND SLUDGE HANDLING
EQUIPMENT.
-------
STATUS TO OCTOBER 1978
SECTION 9 (CONTINUED)
PERFORMANCE INSCRIPTION FOR OPERATIONAL F60 SYSTEMS ON INDUSTRIAL BOILERS
CATERPILLAR TRACTOR co.; JOLIET, ILLINOIS (CONTINUED)
REFER TO FIGURE 14-3 OF SECTION 1« FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD QtlARTFR-1977 PROBLEMS OCCURRED WHEN A TANK RAN DRY AND DAMAGED A PUMP. SOME PIPE PLUGGING
PROBLEMS ALSO OCCURRED AS A RESULT OF THE PUMP FAILURE. A MAJOR PROBLEM AREA WAS THE HEAVY
HEAR OF THE FILTER CLOTHS ON THE VACUUM FILTERS. THE FILTER CLOTH LASTS ONLY a TO 3 WEEKS.
NO SOLUTIONS HAD BEEN FOUND BUT FILTER DESIGN MODIFICATIONS WERE BEING CONSIDERED.
THE UNITS WERE ULTRASONICALLY TESTED AND RESULTS SHOW THAT THE SYSTEMS ARE ON THE HIGH
SIDE OF TOLERANCE LEVELS. A MINOR LEAK MS DETECTED AS A RESULT OF A FAULTY WELD.
4TH QUARTER-1977 FGO SYSTEM RESTART OCCURRED AT THE BEGINNING OF THE HEATING SEASON.
PLANT HAD INITIATED A PROCESS OF DETAILED RECORD KEEPING BUT WAS 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 FUTURE.
1ST OUARTER-1978 FILTER CLOTH PROBLEMS CONTINUED WITH REPLACEMENT BEING REQUIRED EVERY a-3 WEEKS.
THE SYSTEMS WERE DOWN IN MARCH BECAUSE OF PLUGGED PIPELINES.
2ND QUARTER-1978 UNRELIABLE S02 MONITORS WERE A PROBLEM DURING THIS PERIOD. HEAVY ATTRITION OF
FILTER CLOTHS CONTINUED.
3RD QUARTER-1978 DUE TO SHORT FILTER FABRIC LIFE AND SLUDGE FREEZE UP PROBLEMS, FILTER DESIGN
MODIFICATIONS HERE STILL BEING CONSIDERED, BUT HAD NOT YET BEEN MADE.
S02 MONITORS ARE STILL A PROBLEM EXHIBITING PLUGGING, CORROSION, AND UNRELIABLE PERFORMANCE.
PROBES OF 304 SS, 316L S3 AND TEFLON COATING HAVE ALL BEEN TRIED WITHOUT SUCCESS. HASTELLOY C
PROBES HAVE BEEN INSTALLED, BUT THE PLANT HAS NOT HAD TIME TO EVALUATE THEIR PERFORMANCE. REHEAT
EQUIPMENT WAS SCHEDULED TO BE INSTALLED BUT HAS NOT BEEN AS OF THIS UP-DATE. GUILLOTINE-TYPE
DAMPERS REPLACED THE LOUVER-TYPE ISOLATION DAMPERS ORIGINALLY INSTALLED. HOWEVER, THE GUILLOTINE-
TYPE CANNOT BE CLOSED TIGHTLY BFCAUSE FLY ASH COLLECTS IN THE BOTTOM OF THE GUILLOTINE SHEATH.
-------
STATUS TO OCTOBER 1978
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR Opf I, A1 T ONAI FGO SYSTEMS Ol\i INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATF FRO UNI IS
NUMBER OF BOILERS BFIN6 CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL. PROCESS
NErt / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTSOL SYSTEM COST
CATERPILLAR TRACTOR CO.
MORTON, II LINOIS
COAL (i.a% SULFUR)
40,000 SCFM (TUTAL -£ BOILERS)
SO Mh (EQUIVALENT); TOTAL if BOILERS
ZURN INDUSTRIES
DOUBLE ALKALI (DILUTE)
RETROFIT
JANUARY, 1978
OPERATIONAL
90% C2000 PPM a INLET)
DEWATERED SLURRY TO LANDFILL
SEE SECTION 13 FUR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AT THE MORTON PLANT, A PARTS DISTRIBUTION CENTER, CATERPILLAR TRACTOR OPERATES A TWO«=BOILER STEAM
PLANT WHICH GENERATES FLUE GAS EQUIVALENT TO ABOUT 20 MH. EMISSIONS ARE CONTROLLED BY A ZURN IN-
DUSTRIES AJR QUALITY CONTROL SYSTEM CONSISTING OF A DUSTRAXTOR SCRUBBER IN WHICH PARTICULATE AND 302
REMOVAL OCCUR SIMULTANEOUSLY. SULFUR DIOXIDE REMOVAL IS BROUGHT ABOUT 8Y THE USE OF ZURN DILUTE
MODE, DOUBLE ALKALI FGO TECHNOLOGY, THE TWO ROILERS 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 HEATING SEASON SINCE OCTOBER 197". WHENEVER POSSIBLE, PROBLEM AREAS AND
SOLUTIONS IDENTIFIED IN JOLIET OPERATIONS HAVE BEEN IMPLEMENTED TO IMPROVE THE SYSTEM DESIGN
AT MORTON, SPECIFIC AREAS TN WHICH MODIFICATIONS TO DESIGN HAVE BEEN MADF ARE WATER BALANCE,
PUMPS, PH MONITORING, PIPING, LIME STORAGE, AND COLD WEATHER PROTECTION.
OPERA!ING HISTORY
1ST GUARTER-1978 SYSTEM START-UP OCCURRED AT THE BEGINNING OK JANUARY. INITIAL OPERATIONS I*FRE
PRORLFM-FREE. THROUGH JANUARY AND PAR! OF FEBRUARY, ZURN PFRSONNEL WERF TRAINING THE BOILER PLANT
PERSONNEL IN THE OPERATION OF THE FGU SYSTfcM. QPFRAT!ONAL EXPERIENCES AT JPLTET AND MoSSVILLE HAVt
SHOWN THAT THF ROILFP OPERATORS CAN 8F FFFtCTJVFLY TRAINED TO UPERATt AND MAINTAIN THE FGD SYSTEMS.
CURRENT PI ANS CALLED FOR ACCEPTANCE TFhTIMU IN THE SPRING, BUT ThF COAL SITUATION MAY DELAY 1 HE TFST
PERIOD.
2 "10 UHARTFK-19/P1 FT,P OHFHATIU"b COM IM.FD in R£ 1 RijUftLE-FPt f-. THE BOTLFrf i^AS tXPERItNCTNG SOME
-------
STATUS TO OCTilBtK
SFCTjnrj
-------
STATUS 10 OCTOBER 1978
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL ROILEKS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEh / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
803 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CATERPILLAR TRACTOR P.O.
MOSSVILLE, ILLINOIS
COAL (S.?% SULFUR)
IflOfOflO SCFM (TOTSL -
-------
STATUS TO OCTOBER 1978
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
CATERPILLAR TRACTOR CO.: MOSSVILLE. ILLINOIS (CONTINUED)
ACCFLFRSTFD WF.AP ON TI'E >LV,r nUiiM.,?.. THESE PUMPS WERE REVISED TO LOWER THEIR OUTPUT. LOW SEAL
WATER PRESSURE ALLOWED PROCESS LinuOk TO GET INTO THE PUMP AND PACKING. ALL SEAL HATER
IS NOW ONCE-THROUGH AND SYSTtM 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
CONVEYOR. SEVERAL STRATEGIES, ALL INVOLVING SCRAPING OR PLOWING THE OEWATEREO 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 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 WORKED AT A TIME.
SLUDGF HINS ARE THEN LOADED HYDRAULIC ALLY INTO TRUCKS AND HAULED TO THE SANITARY LANDFILL AREA.
ANOTHER PROBLEM, COLD WEATHER ICING ON THE SLUDGE LOADING AREA, WAS SOLVED BY ENCLOSING THE AREA.
INSTRUMENTATION - ORIGINAL DESIGN PLANS CALLED FOR CONTROL BY THE MONITORING OF THE S03/S01
RATIO AND SODIUM ION CONCENTRATION. THE CONTROL RANGE WAS FOUND TO BE TOO SMALL AND THE PRESENT
APPROACH IS PH CONTROL (6.5) AND CLEANING OF THE PROBES EVERY OTHER DAY.
ORIGINAL DESIGN DID NOT MONITOR S02 CONCENTRATION BUT A COMPLETE MONITOR SYSTEM MAS INSTALLED
PRIOR TO THE 1977-78 SEASON.
PIPING - MODIFICATIONS HAVE BEEN MADE WHICH FACILITATE CLEANING OR SCHEDULED REPLACEMENT.
REFER TO FIGURE !«-« IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
1TH QUARTF.R-1977 CATERPILLAR BEGAN A PROCEDURE OF DETAILED RECORD KEEPING, BUT THE FLOW OF
INFORMATION WAS NOT YET SUCH THAT IT WAS AVAILABLE TO THIS REPORT.
2ND QUARTER-1978 NUMEROUS BOILER-RELATED PROBLEMS HAVE COMPOUNDED FGD SYSTEM PROBLEMS. MAJOR
FGD PROBLEM AREAS WERE AS FOLLOWS:
EROSION OF SCRUBBER LINER MATERIAL.
EXCESSIVE WEAR OF PIPING, PUMPS, AND CONTROL VALVES.
SLUDGE FREEZE-UP ON THE CONVEYOR BELT PLUGGED SLUDGE CHUTES.
3RD OUARTER-1978 PERFORMANCE OF THE VENTURI SPRAY NOZZLE HAS NOT BEEN SATISFACTORY. NOZZLES OF
316L SS ,VERE ORIGINALLY INSTALLED AND LASTED ABOUT FOUR MONTHS. CERAMIC NOZZLES WERE THEN TRIED BUT
BROKE WHFN BEING REMOVED. THE PLANT RETURNED TO USTNG 3i6L ss SINCE THF, STEEL NOZZLES WERE CHEAPER
THAN THE CERAMIC NOZZLES. PLANS ARE BEING MADE TO MODIFY THE NOZZLE CONFIGURATION. THE VENTURI
IS BEING I1PF.HATEO MANUALLY SINCE PLANT PERSONNEL HAVE NOT HAD TIME TO DEBUG THE AUTOMATIC CONTROL.
tWD-uISCHAHGING DISH CONVEYORS FUR THF SL"UGE CONVEYOR SYSTEM HAVE NUT YET BEEN INSTALLED
BECAUSE THE ENTIRE SLUDGE HANDLING FACILITY IS CURRENTLY REING DEVALUATED. THIS REEVALUATION IS
-------
STATUS TO OCTOBER 1979
SECTION 9 (CONTIMUFD)
PERFORMANCE nfSCRIPTTUN FUR OPERATIONAL FGD SVSTFMS ON INDUSTRIAL BOIiEHS
CATERPILLAR TRACTOR CO.J M(i.';sviLLEf iLlTf.OiS (COi-jT IMUFD1
A RESULT OF THE MANY PROBLEMS CATFRPILLAh HAS HAD WITH THEIR SLUDGt HANOLr'vlfl SVSiFM0
MODIFICATIONS TO PIPING IN OrtDF.R TU FACILHAIE PI«£ CLEANING 4NO SCHEDULED RtPLACEMENTS HAVE NOT
3EEN SIGNIFICANT, THE RUILLtlUNE DAMPfcRS AT THIS Pi ANT ARE EXPERIENCING THE SAME PROBLEMS AS THE
OAMPtRS AT THE JOLIET F-LANFj FLTASH COLLECTING IN THE BOTTuM Of- TH£ OAMPfr< pH£VFNTS THE DAMPER FKOM
9EING CLOSED TIGHTLY. WF.A« PLATES WfcRE INSTALLED IN THE BOTTOM OF THf VENTURE SCRUBBERS TO PREVENT
ABRASIVE WEAR AND ARE WORKING WELL, PLANT PERSONNEL FEEL THEY ARE STILL IN A DEBUGGING PHASE.
-------
<•. SATUS TO
197B
btf T JO « Q Crn^Tl MJH;)
PERFORMANCE DESCRIPTION FOR OPFKAITONAI. Fi>n SYSTFC.S ON INDUSTRIAL ROTLFRS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCF CHARACTERISTICS
SOURCF RATING
NUMRER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
U.S.A. INT.
BAKEKSF ILI.b, CALIFORNIA
OIL ( 1 . 1 X. SULFUR)
248,000 bCFM (TOTAL - 1" BOTLFRS)
150,000 ACf-M 9 SoOK, FOR EACH OF 3 FGD SYSTEMS.
3
IB
1?5 KiW (EQUIVALENT); TOTAL - 18 BOILERS
900 MM BTU/HK (TOTAL - 16 BOILERS; 6 BOILERS/FGD SYSTEM)
KOCH ENGINEERING
SODIUM CARBONATE SCRUBBING
RETROFIT
JULY, 1978
OPERATIONAL
90% (70 PPM 5) OUTLET)
WASTEWATER TREATMENT AND DISCHARGE TO TAILINGS POND
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
CHEVRON U.S.A. HAS AN OIL SITE AT RAKERSF1ELO, CALIFORNIA. THERE ARE ABOUT 50 STEAM GENERATORS
WHICH BURN 1.1X SULFUR CRUDE OIL. EACH GENERATOR IS RATED AT 50 MM BTU/HR. THE STEAM IS USED TO
HEAT OIL AND FACILITATE ITS FLOW UPWARDS FROM THE OIL WELLS.
KOCH ENGINEERING HAS COMMISSIONED THREE FGD SYSTEMS IN JUNE/JULY 1978. THE SODIUM CARBONATE
SCRUBBING PROCESS IS USED, WITH EACH SCRUBBER TREATING FLUE GASFS FROM fe GENERATORS WITH A TOTAL
FLOW RATE OF 150,000 ACFM AT 500 F. THERE ARE 3 KOCH FLEXITRAYS AND A KOCH FLEXJMESH MIST
ELIMINATOR IN EACH SCRU8BEH. THE SPENT LIQUOR IS MIXEO WITH FRESH SODIUM CARBONATE IN THE BOTTOM OF
THE SCRUBBER. A CONTINUOUS BLEEO-OFF STREAM IS TAKEN TO A DISPOSAL HOMO, WHEREAS THE REST OF THE
LIQUOR IS RFCTRCULATED. A PH OF b-6.5 TS MAINTAINED AT THE TOP TRAY AND AN L/G RATIO OF 5 GAL/1000
ACF IS USED. THERE IS NO RFHFAT FACILITY BUT THE SCRUBBER CAN RE BYPASSED. THE ROlLER 1.0. FANS
WILL BE UPGRADED TO OFFSET THF PRESSURE DROP Of- 9 IN. WG. THE SCRURRFRS ARE DESIGNED TO REMOVE <*OX
OF THE SO? AND MAINTAIN AN EXIT S0£ CONCENTRATION BFLOw 70 PPM. FACH SCURBFR IS 16.5 FEET IN
DIAMETER AND 55 FFET HIGH. THE HEIGHT INCLUDES THAT OF A STUB STACK SITUATED ON TOP OF EACH
SCRUBBER.
THF SCRUBBERS tun TR6YS ARF MADE OF ?1hL SS AMD THE FLEXIMESH IS INCDLPY 825. THE STACK IS MADE
OF 31>> SS ANO THE PTPTfv", TS FRH.
3RD QIIARTER-1978 BECAUSE OF LOW STFAM DEMAND UNLY TWO OF THE EXISTING THRtF SCRUBBERS ARF
-------
SFAUIS in OCTOBER
SECTION 9 (CONTINUFD)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON jNDUSTHTAi ROILfHS
CHEVRON U.S.A. INC,,? HAKERSFIELD, CALIFORNIA (CONTINUFD)
TIONAL. OF THE 18 STFAM GENERATORS 12 ARE OPERATIONAL. ONE SCRUBHfR CONTROLS 7 GENERATORS WHILE
THE OTHER CONTROLS 5 GENERATORS* THE. REMAINING 6 STEAM GENERATORS HMD THFIR RESPECTIVE SCRUBBERS
WILL BE BROUGHT DIM-LINE AS STEAM DEMAND INC&EASFS (POSSIBLY IN DECEMBER OR JA.'vUAHV),
NO MAJOR PROBLEMS HAVE OCCURRED SINCE START-UP IN JUNE-JULY. HOWtVER, SOME CLOGGING OF THE
SODA ASH FEED CHUTE FROM THE STORAGE SILU DOES OCCUR. THIS CLOGGING TS EASILV CORRECTED HUH NO
DOWNTIME NECESSARY.
SYSTEM OPERABILITY FOR THE PFRIOD WAS 95%.
GOOD OPERATION IS ATTRIBUTED TO REGULAR MAINTENANCE PRACTICE WITH EMPHASIS ON DAILY CLEANING OF
THE PH PROBES.
<*
-------
STATUS TO OCTOBER 1978
SFCT10N 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTFMS ON INDUSTRIAL BOILERS
INSTALLATION NAM£
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLfcD
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
PARTICIPATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
FJrVESTUNt Tlkt AND RUBBER CO.
POTTSTOWN, PENNSYLVANIA
COAL (£.5 - 4.OX SULFUR)
6070 SCFM (13,000 ACF-M a 300 F)
1
t
-------
PERFORMANCE n£SC« I P T T UN FOR OPERATIONAL Far) SYSTFM5 riM INDUSTRIAL BulL'-kS
FIRESTONE TIRF AND RUBBER CO. ; POM MOWN, PENNSYLVANIA (CONTINUED)
THF VFNTURI SCRUBRLR HAS A VARIABLE THROAT (6 I\. TO IS JTJ.) AND IS MADF OF 21bL SS. THE OPER-
ATING VELOCITY THROUGH ThF. VEWTUWT THHUAT IS POO FT/SEC id 150 F. THE OPERATING i_/G IS 10 GAL/
1000 ACF. THE SPRAY NOZZLES ARE »LSO Mil)*" OF J516L SS. THE CYCLONIC OEMISTFK (a97S rT DIA X
7 FT HIGH) OPERATES ftJTH 8 PRESSURt DROP OF ^" WG. GA3 VfLOC.'TY THROUGH TH" nSHMTSTEK !S iuO FT.'Sf
a HO F. THE OEMISTfcR, flFCIRCUL*TIOM TAMK, AGITATOR, RFC 1RCULA1 ] ON PIFIKGt AND THE FILTER ftFf MADE
OF 5i*L SS. THF INLET DUCTWORK* F.D. FAN, THICKENED, AND LIME REACTOR TANK *RE CARBON S'FEL,
THE RECIRCUI.ATION PUMP TS CAST IRON WITH RUBBER LINING ACiD THE STACK ;S FRP,
REFER TO FIGURE Jfi-5 IN SECTION 14 FOR * DETAILED PROCESS FLOW DIAGRAM OF THJS SYSTEM.
OPERATING HISsTORY
1ST QUARTER-J975 THE SYSTEM WtMT ONSTRFAM BURNING 2»a% SULFUR OIL. THE FSD SYSTEM OPERATED &87
HOURS AND WAS CALLED UPON TO OPERATE BJ«J HOURS, YIELDING A RELIABILITY Of 84.5X. DOWNTIME WAS DUE
PRIMARILY TO FAILURES OF COMPONENTS SUCH AS PUMP PACKING.
2ND OUARTER-1975 THE SYSTEM OPERATED ItSt HOURS AND WAS CALLED UPON TO OPERATE 1509 HOURS,
YIELDING » RELIABILITY INDEX VALUE OF 9fc.«X.
3RD QUARTER-1975 SYSTEM OPERATED 1«36 HOURS, WAS CALLED UPON TO OPERATE 1503 HOURS, YIELDING
A RELIABILITY INDEX VALUE OF 95.5%.
«TH QUARTER-1975 SYSTEM OPERATED 1320 HOURS, WAS REQUIRED To OPERATE 119? HOURS, YIELDING A RELI-
ABILITY INDEX VALUE OF 88. 4Z. LIME FEEDER MALFUNCTIONING AND THICKENER PLUGGING WERE PROBLEMS.
1ST 9UARTER-1976 SYSTEM OPERATED 1961 HOURS, WAS CALLED ON TO OPERATE 2035 HOURS, YIELDING A
RELIABILITY INDEX VALUE OF 96. «X.
2ND QUARTER-1976 SYSTEM OPERATED 1380 HOURS, WAS CALLED UPON TO OPERATF i335 HOURS, YIELDING A
RELIABILITY INDEX VALUE OF 95»9%.
3RD QUARTER-1976 SYSTEM OPERATED 1157 HOURS, nAS CALLED UPON TO OPERATE 1S66 HOURS, THUS DEMON-
STRATING TTS HIGHEST RELIABILITY INDEX VA> UF, 99, ?z.
"TH QUARTER-1976 IN OCTOBER, IHF SVSTeM OPEM1EP AT A RELIABILITY IIMOEX OF in.jX, UNTIL THE UNIT
VAS CONVERTED TO COAL F I R T K'. f<>,S - ^(iv ViT'lk!. T'-iT ^ViL''' 0 1- L .-: A T t P f ui- «„ uHuilToMAL -ii nilllWS,
UF THF 526 PtQUIREL-, OF. MUMS 1 <-. U 1 nr, /. kKl lAblLlTY I..nn< VA, :,f •> S7.?Z. II-: f'(lVtM,iFW »NI, i)FCFMHtR.
IHF SYSTEM OPKRATFU F Ok M^ MUUP5 Af,MN^T THE Rt.R,)T«R.Fr,T <-.f \?.\\ M-ju.S. THFREFO*F. I H^ A.E-'AG'
-------
STATUS 10 OC1UP-ER 1978
P (CONT tMJFi;!
PERFORMANCE DESCRIPTION FDR CJHERATTUNAL Fun SYMFMS HIM INUUSTHTAL BUILFHS
FIRESTONE TIRE AND RUBtlER CD. ; PnTTSfOWM, PENNSYLVANIA (PONT INIIEn)
RELIABILITY INDEX FOR THE TWO MONTHS WAS 9fa.7X.
1ST QIIARTER-1977 SYSTEM OPERATED 119'? HQHWS, WAS KFOIIIREH Tu OPERATE FOK I«b9 HUUNS, YIELDING A
RELIABILITY INDEX VALUE OF B1.7X. SYSTEM WAS DESIGNED FOR A MUCH LOWER PARTICIPATE LOADING THAN
THAT ACTUALLY ENCOUNTERED ON COAL FIRING. THE HIGH GRAIN LOADING CAUSED ABNORMAL WEAR AND DOWNTIME
OF THE F.D. FAN.
2ND QUARTER-1977 SYSTEM OPERATED 139« HOURS, WAS REQUIRED TO OPERATE 1690 HOURS, YIELDING A
RELIABILITY INDEX VALUE OF 8a.7t. THE MAJOR CAUSES OF DOWNTIME WEKE F.D. FAN EROSION ANO PUMP
COMPONENT FAILURES.
3RD QUARTER-1977 SYSTEM OPERATED 1131 HOURS, WAS REQUIRED TO OPERATE 1197 HOURS, YIELDING A
RELIABILITY FIGURE OF 94.5X. THE TOTAL REQUIRED HOURS WERE LOW IN JULY DUE TO BOILER HOUSE
SHUTDOWN AND SUBSEQUENT START-UP.
4TH OUARTER-1977 IN OCTOBER, THE SYSTEM OPERATED 432 HOURS OUT OF THE 511 REQUIRED AS THE BOILER
WAS FIRING COAL. THE RELIABILITY VALUE WAS THEREFORE 84.6X. DOWNTIME WAS CAUSED BY PROBLEMS WITH
THE LIME CONVEYOR. WHEN OIL WAS BEING FIRED THE SYSTEM OPERATED 95 OF THE 102 HOURS REQUIRED,
DEMONSTRATING A RELIABILITY VALUE OF 92.bX. IN NOVEMBER AND DECEMBER, THE SYSTEM OPERATED 792 HOURS
OF THE REQUIRED 854, WHILE BURNING COAL, YIELDING A RELIABILITY OP 86.7*. DOWNTIME WAS CAUSED BY
FAN PROBLEMS AND LIME FEEDER PROBLEMS.
1ST QUARTER-1978 THE SPRAY NOZZLES, ORIGINALLY 316 STAINLESS STEEL, WERE REPLACED BY 316L S3.
THE SPRAY BARS WERE METALLIZED WITH 316 SS.
2ND QUARTER-1978 THE FAN WAS REPLACED PY A NEW FAN CONSTRUCTED OF AN ABRASION RESISTANT CARBON
STEEL. THE FAN HOUSING WAS METALLIZED WITH 316 S3, LEAKS IN THE VENTURi SECTION AND DOWNSTREAM
DUCTWORK WERE REPAIRED. THE FGD SYSTEM EXHIBITED AN AVAILABILITY UF 89.5X FOR THIS REPORT PERIOD.
3RD QUARTER-1978 NO UNUSUSAL PROBLEMS WERE ENCOUNTERED DURING THIS PERIOD. DOWNTIME WAS DUE
TO NORMAL MAINTENANCE. PRELIMINARY ENGINEERING FOR THE FULL SCALE-UP SYSTEM IS COMPLETE. FINAL
DESIGN WILL BE DELAYED UNTIL THE ENERGY rilLL CURRENTLY BEFORE CONGRESS IS FINALIZED. PLANT
PERSONNEL ATTRIBUTE THEIR SUCCESSFUL OPERATION OF THE FGD SYSTfcM TO A GOOD UNDERSTANDING AND
IN-DEPTH KNOWLEDGE OF PROCESSES AND CONTROLS.
5?
-------
'!-., Ui |(.
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATION*! FGO SYSTEMS ON INOUSTOFAl BIH
1978
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER Of SEPARATE f-'Gd UNITS
NUMBER OF 90ILERS 8EING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENT
WATER MAKE-UP
SLUOGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
FMC (SODA ASH PLANT 1
GREEN RIVER, WYOMING
COAL (U SULF'JR)
««6,000 SCFM (TOTAL -
2
80H.&RS1
MW (EQUIVALENT); TOTAL - S BOILERS
FMC ENVIRONMENTAL EQUIPMENT
SODIUM CARBONATE SCRUBBING
NEW
MAY, 1976
OPERATIONAL
95% (800 PPM AT INLET)
REMOVED BY PRECEDING ESP (99.53E)
OPEN LOOP: L/G s 15-20 SAL/1000 ACF
HOLDING POND FOR EVAPORATION
NA2S03/S04 LIQUOR DISPOSED TO COLLECTION POND - NO PRIOR
AERATION. LANDFILL IN THE FUTURE
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
FMC CHEMICAL CORP. HAS A SODA ASH PLANT IN GREEN RIVER, WYOMING. THE PLANT HAS TWO COAL-FIRED
POWER BOILERS WHICH BURN 1.1 PERCENT SULFUH COAL. THE FLUE GAS FROM EACH BOILER (330,000 ACFM AT
320 F) IS TREATED BY A HQTSIDE ESP WITH 288 PLATES AND A PAHTICULATE REMOVAL EFFICIENCY OF 99.5 X.
THE FLUE GASES ARE SCRUBBED BY THE PLANT END-LIQUOR IN TWO SCRUBBERS, EACH WITH THREE PAIRS OF
OISC-ANO-DONUT TRAYS. THE SCRUBBERS AND THE DISCS ARE LINED WITH CEILCOTE 103 WHEREAS THE DONUT
PARTS OF THE TRAYS ARE MADE FROM INCONEL 825. THE SCRUBBER LIQUOR IS MAINTAINED AT A PH OF 6.5 AND
IS RECIRCULATED AT A RATE OF 10 - 15 GALLONS/1000 ACF OF FLUE GAS. A PART OF THE RECALCULATING
LIQUOR IS CONTINUOUSLY PURGED TO REMOVE SULFITES AND SULFATES FORMED BY THE REACTION OF S02 WITH
SOOA ASH. THE RECIRCULATING PUMPS AND THF RELATED PIPING is RURBFR LTNFU. A MESH TYPE DFMISTER is
USED IN EACH SCRUBBER. THE GASES ARE RFHFATED BY DIKECT FIRING OF NATURAL GAS AT THE EXIT OF THE
SCRUBBERS. THE REHEATED FLUE GAS IS MIXED WITH BYPASSED R&S BEFORE GOING TO THF ST«CK AT ABOUT
18" f. DAMPERS WITH REMOTE CONTROLS REGULATE THE FLOW OF UFF GAS THROUGH AM) ABOUND THE SCRUBBERS.
*PPROXIMATF.LY ""OX OF THC TOTAL FLUE G-G IS Rui- TiidGliuH "i I't nL rt-ibMt RS.
AUTOMATIC CONTROLS MAINTAIN SOLUTION LEVEI In THE SCRURPt" BASIN. THF CJTMARY SU'ikCE OF HATE?
M«KF-UP IS PROCESS WASTEKATFR A,HJCH IS CHANNfcLtf. TO A -A«.F-UP MNK. IF ^,OKF MAKE-"P T5 HFOUIRED.
"TVFR MtEH JS TAPPEU. THE SCHHHHEH PtFtP STWtAM IS DISCHARGE Til 4 WAS'F ^JM) AT THfc SITE.
-------
STATUS TO OCTOBER 1978
SFCTIOtM 9 (CONTINUFO)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
FMC (SODA ASH PLANT); GREEN RIVER, WYOMING (CONTINUED)
OPERATING HISTORY
3RD QIJARTFR-1977 SOME PROBLEMS OCCURRED WITH THt SCRUBBER LINIMG AS A RESULT OF FAULT*
INSTALLATION. THE POSSIBILITY OF RUNNING THE SYSTEM WITH NO REHEAT WAS BEING INVESTIGATED.
«TH QIIARTFR-1977 THE SCRUBBERS CORRODED AS A RESULT OF FAULTY INSTALLATION OF THE LINING.
THE IMPURITIES IN THE SCRUBBING LIQUOR CAUSE FOAMING AND SEDIMENTATION ON THE TRAYS.
1ST QUARTFR-1978 PIPELINE FREEZUPS, AND LEAKS FROM THE VANE DAMPERS WERE THE MAIN PROBLEM AREAS.
2ND QIIARTER-1978 THE OEMISTER WAS PLUGGED, AND THE RECIRCOLATION PUMP WAS DOWN FOR SOME PERIOD,
PH CONTROL IS NOT VERY EFFECTIVE, CAUSING PH EXCURSIONS TO ABOUT 3.0. THIS HAS CAUSED SCALING IN
THE PIPELINES AND IN THE TOWER. FMC TESTS HAVE MEASURED 802 REMOVAL EFFICIENCY IN THE RANGE OF 87X-
94X, DEPENDING ON L/G AND PH.
3RD QUARTER-197S TWO ANNUAL SCHEDULED OUTAGES OCCURRED DURING THIS PERIOD. ONE LASTED Z WEEKS
IN AUGUST WHILE THE OTHER LASTED 1 WEEK IN SEPTEMBER. MAINTENANCE ON THE FGD SYSTEM DURING THESE
OUTAGES INCLUDED CLEANING OF THE SYSTEM AND FREEING OF THE DAMPER. THE DAMPERS HAD A PROBLEM
OPERATING PROPERLY DURING COLD WEATHER. IT WAS DETERMINED THAT THE PUMP OUTAGE DURING THE 2ND
QUARTER WAS CAUSED BY A BROKEN SHAFT. THE SHAFT WAS REPLACED.
-------
STATUS TO OCTOBER 1978
SECTION UNITS
NUMRF.R OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCiSS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 R£HOVAL EFFICIENCY
PSRTICULATE REMOVAL EFFICIENCY
MATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
MOTORS CORPORATION
DAYTON, OHIO
COAL(0.?X - e.OX SULFUR)
Sb,000 SCFf (TuTAL - ? 30lL£ftS)
3«,000 ACFM oi SOOF, Ffifi EACH OF TWO BOILtRS,
120,000 LP/HR STEAM (TOTAtj
8 MW (EQUIVALENT); TOTAL - 2 BOILERS
ENTOLETER, INC.
SODIUM HYDROXIDE SCRUBBING
RETROFIT
SEPTEMBER, 1974
OPERATIONAL
86* li.«3 L8/MM 6TU 3 INLET)
97.5X (0.107 LB/MM STU S OUTLET)
50 GPM
WASTEWATER TREATMENT AND DISCHARGE TO CITY SEWER
NA2SG3/S04 LIQUOR AT 35 GPM TO ON-SITE CLARIFICATION AND
DEWATERING FACILITY
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
IN DAYTON, OHIO, GENERAL MOTORS OPERATES A FACTORY WHICH MANUFACTURES BRAKES AND OTHER PARTS
FOR THEIR AUTOM08ILES. THE PLANT HAS TWO STOKER-FEED, COAL-FIKEO BOILERS WHICH WERE INSTALLED IN
19S« BY BABCOCK AND WILCOX. EACH BOILER IS RATED AT 60,000 LB/HR STEAM, AND BURNS A MAXIMUM OF 3
TONS OF COAL PER HOUR. THE BOILERS ARE EQUIPPED WITH INTERNAL MULTICLONES FOR PRIMARY PARTICULATE
CONTROL. THE STEAM GENERATED BY THESE BOILERS IS USED FOR BUILDING HEAT AND PROCESS NEEDS. ONE
BORER IS OPERATED CONTINUOUSLY THROUGHOUT THE YtAR AND THE OTHER IS OPERATED APPROXIMATELY b MONTHS
PER YEAR. THF MAJORITY OF THE TIME (8 - 10 MONTHS/Yk) ONLY ONE BOILER IS IN SERVICE.
THE EMISSION CONTROL SYSTEM WAS DESIGNED TO CONTROL BOTH FLYASH AND S02, ANO WAS SUPPLIED AS A
RETROFIT APPLICATION BY ENTOLETEK, INC. IN SEPTEMBER 1974. E6CH ROILFR IS FOLLOWED BY A 80ILEK 1.0.
FAN, A PLENUM, AND A SCRUBBER P.O. FAN. THE PLFUUM CAN FUNCTIUN IN ONE OF THREE WAYS: IT CAN FEED
FLUE RASES TO THE. SCRUBBER MODULE? IT CAN BYPASS THF GAStS TO THE ATMOSPHEHF IN CASE OF A SCRUBBER
MALFUNCTION; nw IT CAN MIX AMBIFNT MR WITH m FLUE RASES IN CASE OF LOW LOAD IN ORDER TO MAINTAIN
CONSTANT AIM FLOiv TO THF .SC*UHHF(« FAN.
THE srK.IBMtB CO'lM-,!'. OF THF f.MT,.L:-H» • v Al. = -f »r,fc - <- FT. OTA. * s FT. M^Ml
>• I S nr.. SEH IN
-------
STATUS 10 OCTl.'UFS 1978
SFCTIHK
-------
STATUS TO OCTOBER
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRY BOILERS
6ENER»l MOTORS CORPORATION? DAYTON, OHIO (CONTINUED!
1ST QUABTER-1977 THERE WERF MECHANICAL PROBLEMS WITH TH£ VANE CAGE. DRIVE. THE ACCESS 000*
DEVELOPED LEAKS AND THE LICIUOR CORRODED THE OUTF.R SURFACE OF THE INLET DUCT AROUND THF ACCESS DOOR.
4TH QUARTER-i'm CORROSION AND PLUGGING PROBLEMS CONTINUED TO HAMPER SCRUBBER OPERATIONS.
HOWEVER, USUALLY WHEN A SCRUBBER IS DOWN, ?HE OTHER BOILF.R US FIRED UP WHILE PEPAIHS ARE MADE TO THE
DOWNED UNIT.
1ST OUARTER-mS THE PRIMARY DEMISTED WAS SEVERELY CORRODED DUE TO AC'O DROPPING DOWN ONTO IT
FROM THF UPPER DEWISTER.
2ND QUARTER-1978 THE FOLLOWING SYSTEM MODIFICATIONS WERE BEING PLANNED; THE INTERMEDIATE SECTION
KILL BE REMOVED, THE PRIMARY DEMISTER WILL BE REPLACED BY A SIMILAR VANE-TYPE HASTELLOY-G DEMISTER,
THE SECONDARY DEMISTER WILL BE REPLACED BY i RADIAL VANE HASTELLOY-G DEMISTER, AND A CONVEX
IMPINGEMENT BAFFLE PLATE OF HASTELLOY-G WILL BE INSTALLED ABOVE THE PRIMARY DEMISTER TO ASSI3T IN
RAPID DRAINAGE OF THE ACID DROPLETS.
JRD QUARTEB-1978 THE MODIFICATIONS DESCRIBED IN THE 2ND QUARTER 1978 ARE STILL IN THF DESIGN PRO-
CESS. WORK INCORPORATING THE MODIFICATIONS SHOULD BEGIN ABOUT THE END OF OCTOBER.
THE SCRUBBER LINING OF COAL TAR EPOXY WAS ABRADED OFF AND A CAR80LENE LINFR WAS INSTALLED.
THIS LINING HAS BEEN FLAKING OFF IN PLACES AS A RESULT OF IMPROPER APPLICATION.
THE PH PROBES AND PH MONITORING SYSTEM ARE BEING REDESIGNED SINCE THE SYSTEM CURRENTLY IN USE
SEEMS TO BE CONTINUALLY OUT OF CALIBRATION. AN ULTRASONIC CLEANER WAS INSTALLED BUT IS NOT WORKING
WELL. THE PH MONITORING SYSTEM IS A DUAL PROBE SYSTEM WHICH ALLOWS A PROBE TO BE IN USE WHILE THE
OTHER IS CLEANED.
-------
STATUS TO OCTOBER 1978
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
WATER MAKE-UP
3LU05E OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GENERAL MOTORS CORPORATION
PARMA, OHIO
COAL (2.5X SULFUR)
128,400 SCFM (TOTAL - 4 BOILERS)
320,000 LB/HR STEAM (TOTAL)
1
4
64 MW (EQUIVALENT); TOTAL - 4 BOILERS
GM ENVIRONMENTAL
DOUBLE ALKALI (DILUTE)
RETROFIT
MARCH, 1974
OPERATIONAL
90X (800-1300 PPM 3 INLET)
83x (AT INLET: UNITS us - 1.75 LB/MIN? UNITS 3*4 - 1.22
LB/MIN)
CLOSED LOOP
DENATEREO SLURRY TO LANDFILL
50+X SOLIDS (CAS03/S04) SLUDGE TO DRYING POND AND LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE CHEVROLET PARMA PLANT OF GENERAL MOTORS IS LOCATED NEAR CLEVELAND, OHIO. THE PLANT HAS FOUR
SPREADER-STOKER BOILERS FIREO BY TRAVELING GRATES, CAPABLE OF PRODUCING A TOTAL OF 320,000 LB/HR OF
STEAM OR APPROXIMATELY 33 MW OF EQUIVALENT ELECTRICAL CAPACITY. THE COAL FIRED IN THESE UNITS
ORIGINATES PRIMARILY FROM 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 7.6 PERCENT.
THE POWER BOILERS HAVE 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 SCRUBBERS OPERATING IN PARALLEL. EACH SCRUBBER CONTAINS THREE BUBBLE-CAP
ABSORPTION TRAYS AND A MESH MIST ELIMINATOR. THE FLUE GAS RATE IS 61,500 ACFM AT 393 F FOR EACH OF
THE FIRST TWO SCRUBBERS AMU THE OUTLET TEMPERATURE IS 137 F. THE INLET S02 CONCENTRATION IS 765
PPM. THE FLUE GAS FLO* R
-------
STATUS TO OCTOBER
SFCTtON 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGn SYSTEMS ON INDUSTRIAL BOILERS
GENERAL MOTORS CORPORATION; PAKMA, OHIO (fuNTT.NUt.OJ
THE SULFUR OJOXIDF CONTAINED TN THE BOILER FLUE GAS IS ABSORBED BY A REGELATED CAUSTIC
SOLUTION fO.l MOLAR N*OH), FORCING A SOLUTION OF SOLU*LF SODIUM SALTS. THE SPENT CAUSTIC IS THtN
REGENERATED 8Y R£*CT!N. THE SODIUM SALT SOLUTION WITH SLAKED LIME, RESULTING IN THE FORMATION OF
CALCIUM SULFITE/SULFATE SI'LIDS, rtHlCh ARE SEPARATED OUT OF IKE SOLUTION. NEXT. SODA ASH IS
AODEO TO THF SOLUTION IN ORDER TO MAKE UP FOR SODIUM LUSSFS AND MINIMIZE THE SCALE POTENTIAL FROM
THE CALCIUM WHICH REMAINS IN SOLUTION, THE REGENERATED CAUSTIC FORMED fS THEN RECYCLED BACK TO THE
SCRUBBER FOR ADDITIONAL SULFUR DIOXIDE REMOVAL. THE CALCIUM SALT AMD FLY ASH SLUDGE WHICH RESULTS
IS DEWATERED AND HAULcD AWAV 3Y TRUCK TO A»J OFF-SIir iflNDFILL,
EQUIPMENT SPECIFICATIONS
SCRUBBERS. £ACH OF THE H SCKUB9ERS IS 10.5 FT 01A K 2e,5 FT HIGH X ll GAUGE THICK AND CONTAINS 3
BUBBLE-CAP TRAITS. ALL THE SCRUBBERS AND 7RAYS ARE MADE OF 316L S3. THE SCRUB8ERS HAVE A TURNDOfcN
RATIO OF 3 AND ALSO HAVE A BYPASS DUCT. THE DESIGN L/6 RATIO IS 30 GALLON3/ACF BUT THIS
MAY BE VARIED DURING OPERATION. THE PRESSURE DROP ACROSS THE SCRUBBER RANGES BETWEEN 8-9 IN. WG.
OEMTSTERS,. ORIGINAL 3I& S3 MIST ELIMINATORS WERE CORRODED DUE TO CONDENSATION AND WERE REPLACED BY
FLEXIMESH-TYPE POLYPROPYLENE MIST ELIMINATORS.
RECYCLE TANKS/PUMPS. ALL THE It RECYCLE TANKS ARE MILD STFEL WITH TAR TYPE RESIN COATING. THE PUMPS
(6 TOTAL, 2 SPARE) ARE CENTRIFUGALS WITH MILD STEEL CASING AND HAVE RUBBER LININGS, THE PUMP MOTORS
ARE 40 HP.
CHEMICAL MIX TANKS ft A67TATORS. BOTH THE MIX TANKS ARE MILD STEEL WITH 5000 GALLONS CAPACITY. THE
DESIGN RESIDENCE TIME IS ? 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 «5 RPM.
CLARIFIERS. BOTH THE CLARIFIERS (60 FT 01A X 1« FT LIQUID DEPTH) HAVE A CONICAL BOTTOM AND 300,000
GALLONS CAPACITY. THE DESIGN RETENTION TIME IS ABOUT 4 HOURS AT A FLOW RATE OF 1200 GPM.
VACUUM FILTERS, BOTH THE VACUUM FILTERS HAVE soo so. FT. UF SURFACE AREA WITH A 10 FT DRUM DIA-
METER. THE DRUM DRIVE SPEED IS 0.5 RPM MAXIMUM.
FILTRATE TANK/PUMPS. THE TAMK (0 FT DIA X 7 FT HIGH) IS MILD STEEL AND HOLDS 660 GALLONS OF
FILTRATE. THE PUMPS ARE MILD STtEL, CENTRIFUGAL AMD HAVE A CAPACITY OF 300 GPM AT 15 FT. UF HEAD.
EARLY PROBLEMS AND SOLUTIONS
Tri* SYSTEM WAS STAPTE!) UP Or; f-FH^.'^'V ?C. 197" AND B" A:'RIL 3!, I! MAO OPERATED FOK 26- HULKS.
THERE WE^ T*,, scHtOULfcD ShlMOOrfNS 'HJPl'T, 'HIS PE»K'U KOK f°U'HMENT INSPECTION. THE SECOND SHUTDOWN
THAI SOLIDS ^t^e NOT HFINT, nisru^ctn FII» i«i PPI*AWV ILAPIFIF- R^PTOLY ENOUGH.
-------
STATUS TO OCTOBER 1978
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPEKATTQNAL Ftn SYSTEMS ON INDUSTRIAL HUILEWS
GENERAL MOTORS CORPORATION; PAkMA, OHIO (CONTINUED)
AS A RESULT, THE CLARIFItR RAKE JAMMED. A PIPING CHANGE WAS MADE TO BLEND THE CAUSTIC FEED
IN WITH THE RECYCLE LIQUOR. THIS IMPROVED PERFORMANCE RUT DID NOT COMPLETELY ELIMINATE
THE PROBLEM. PREMATURE CAKE CRACKING IN THE VACUUM FILTERS REQUIRED THE PRESENCE OF AN OPERATOR
DURING OPERATION. CAKE WASHING TO REDUCE LOSSES WAS NUT INITIALLY SUCCESSFUL bECAUSE THE SPRAY
WATER TENDED TO KNOCK THE CAKE OFF THE DRUM. ALTERATIONS IN SPRAY PATTERN AND OTHER MEASURES
APPARENTLY SOLVED THIS PROBLEM. THERE WAS NO EVIDENCE OF CORROSION OR ABRASION IN THE PUMPS
OR PIPING.
THE SYSTEM WAS SHU1 DOWN FROM MAY 1 TO MAY 28, 1974, BECAUSE OF UNEXPECTED BUILDUP OF SOLIDS IN
THE CLARIFIES, WITH SUBSEQUENT OVERFLOW INTO THE SCRUBBER. THE PROBLEM WAS SOLVED BY 1) USING
A POLYMERIC FLOCCULATION AGENT TO ATTAIN BETTER SETTLING AND 2) WITHDRAWING SLUDGE FROM THE
CLARIFIER AT MORE FREQUENT INTERVALS. SYSTEM AVAILABILITY TO THE BOILER WAS 87 PERCENT IN APRIL
1974, LESS THAN 10 PERCENT IN MAY, AN.D 100 PERCENT IN JUNE, JULY, AND AUGUST AFTER THE SYSTEM WAS
RESTARTED. PLUGGING 8Y GYPSUM DEPOSITS IN THE OVERFLOW LINE BETWEEN THE CLARIFIERS AND IN THE
LINE FROM CLARIFIER NO. 2 TO THE MIX TANKS WAS CORRECTED BY RELOCATING A CHEMICAL FEED LINE AND
REPLACING SOME PIPING. THE SYSTEM WAS DOWN THROUGH JULY AND AUG. 1975 FOR REPLACEMENT OF GRAVITY
FLOW LINES WITH AN OPEN FLUME THAT CAN BE EASILY CLEANED. THE OPERABILITY INDEX FOR THE F6D SYSTEM
INCREASED SIGNIFICANTLY THROUGHOUT THE COURSE OF 1976.
REFER TO FIGURE 14-7 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
OPERATION HOURS
MONTH BOILER F6D SYSTEM OPERABILITY (*)
MAY-JUN. 75
THE SYSTEM WAS RESTARTED AND PARTICULATE TESTS WERE CONDUCTED IN MAY. THE SYSTEM WAS SHUT DOWN DUE
TO PLUGGED CHEMICAL FEED LINE TO THE CLARIFIER AFTER RESTART. AROUND JUNE 10, THE SYSTEM WAS
SHUTDOWN BECAUSE OF SIMILAR PLUGGING IN ANOTHER PART OT THE LINE. THE UNIT RAN FOR ABOUT TWO WEEKS
IN JUNE.
JUL.-AUG. 75
THE FGD SYSTEM WAS DOWN IN JULY AND AUGUST FOR REPLACEMENT OF GRAVITY FLOW LINE WITH AN OPEN FLUMF.
OCT. 75 2331 1848 79
THE FGD SYSTEM RESTARTED ON SEPTEMBER 8, AND OPERATED DURING THIS PERIOD AT AN AVAILABILITY FACTOR
OF 80 PERCENT. THE FIGURES GIVEN FOR OCTOBER REPRESENT THE OPERATION HOURS FROM SEPTEMBER B TO
NOVEMBER 9.
DEC. 75 2135 1250 59
THE FGD SYSTEM OPERATED WELL DURING THE REPORT PERIOD EXCEPT FOR A SCHEDULED HOLIDAY SHUTDOWN FROM
DECEMBER 23 TO JANUARY 4, 1976. BECAUSE OF PROBLEMS WITH SOLIDS AND SOLIDS CARRY-OVER, G.M. CON-
faO
-------
STATUS TO OCTOBER 1978
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILESS
GENERAL MOTORS CORPORATION? PARMA, OHIO (CONTINUED)
OPERATION HOURS
MONTH BOILER F60 SYSTEM OPERABILITY U)
DUCTED STREAM TESTS DURING DECEMBER TO DETERMINE WHETHER THE CARRY-OVER OF SOLIDS HAS Ql,c T0 A HIGH
SOLIDS RECIRCULATIQN RATE. THE FGO SYSTEM WAS DOWN MOST OF DECEMBER BECAUSE OF THESE TESTS, WHICH
CAUSED THE LOW DURABILITY FACTOR.
FEB. 76 a1??? 1196 ao
G.M. HAS FOUND SOLIDS CONCENTRATION IN THF CLARIFIER TOO HIGH FOR EFFICIENT SYSTEM OPERATION. A.O.
LITTLE WAS SCHEDULED TO CONDUCT TESTS ON THE SYSTEM IN APRIL AS PART OF AM EPA EVALUATION PROGRAM.
MAR. 76 J37«J £30 7
SPR. 76 I0@*l 887 76
THE LOW OPERA8XLITY INDEX DURING THE MONTH OF MARCH RESULTED FROM EXTENSIVE MODIFICATIONS PERFORMED
ON THE SYSTEM BY G.M3 DURING THIS PERIOD THE SCRUBBER SLOWDOWN AND SCRUBBED FLOW INDICATION SYSTEM
WAS REVISED, FROM APRIL 19 TO THE END OF THE MONTH THE SYSTEM WAS OPEKABLE 100%. DURING THIS
PERIOD ALL SYSTEM MODIFICATIONS WERE COMPLETED AND ALL MAJOR PROBLEM AREAS CORRECTED.
HAY 76 1149 1042 91
JUN. 76 924 816 88
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 CHARACTERIZATION STUDY WAS CONCLUDED ON MAY iJ|.
JUL. 76 599 599 100
AUG. 76 715 715 100
THE BOILER LOAD DEMAND WAS VERY LIGHT DURING THE REPORT MONTHS, REQUIRING ONLY ONE BOILER BEING
CONTINUOUSLY ON LINE. THE SYSTEM WAS DOWN FOR A ONF-WEEK PERIOD BECAUSE OF THE ANNUAL PLANT
INVENTORY. MODIFICATIONS TO THE OPERATION OF THE OF THE GAS SCRUBBING SYSTEM HAVE INCLUDED:
ELIMINATION OF POLYMERIC ADDITION.
ELIMINATION OF SLUDGE BLANKET FOR FILTRATION.
HIGH PERCENT SULFATE 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 STOICHIOMETR]C REQUIREMENTS FROM THE 1.25-1.50 RANGE DOWN TO
1.10-1.20.
SEP. 76 809 223 40
OCT. 76 H71 73
-------
STATUS TO OCTOBER 1978
SFCTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FUR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
GENERAL MOTORS CORPORATION; PARMA, OHIO (CONTINUED)
OPERATION HOURS
MONTH BOILER FGD SYSTEM OPERABILITY (X)
REPLACEMENT OF DEMISTER PADS.
AGITATOR PROBLEMS.
THE SYSTEM WAS RETURNED TO SERVICE THE SECOND WEEK IN UCTOBER. TWO BOILERS AND THEIR CORRESPONDING
SCRUBBERS WERE PUT BACK IN THF GAS STREAM. PROBLEMS ENCOUNTERED STEMMED PRIMARILY FROM A MECHANICAL
COLLECTOR MALFUNCTIONING RESULTING IN EXCESSIVE PARTICULATE LOADING IN THE MODULES AND EVENTUALLY
CAUSING WIDESPREAD PLUGGING OF THE LOWER BUBBLE-CAP TRAYS. SHUTDOWN AND CLEANOUT OF MODULES PLUS
REPAIRS TO THE MECHANICAL COLLECTOR WERE REQUIRED. SYSTEM RESTART OCCURRED NOVEMBER 8.
MAJOR MODIFICATIONS PERFORMED TO THE DOUBLE ALKALI SYSTEM DURING THE PERIOD INCLUDED THE INSTAL-
LATION OF A GREAT LAKES PH MONITOR AND CONTROL UNIT FOR THE REGULATION OF LIME FEED TO THE REGEN-
ERATION REACTOR-CLARIFIER UNIT. THIS UNIT EMPLOYS A DIGITAL READOUT AND WAS SCHEB4JLED FOR OPERATION
SOMETIME IN NOVEMBER. SUPERIOR CRYSTAL GROWTH OF THE CALCIUM SULFITE/SULFATE SALTS RESULTED BY
RUNNING A SEEDING LINE BACK TO THE REACTOR-CLARIFIER UNIT.
NOV. 76 1321 787 60
DEC. 76 1559 3«9 22
DURING THE LATTER PART OF NOVEMBER AND EARLY DECEMBER, THE SCRUBBERS WERE TAKEN OUT OF THE FLUE GAS
PATH BECAUSE OF CONTINUED SOLIDS BUILDUP IN THE MIX TANK. IN ADDITION, SOME PIPING ARRANGEMENTS
HERE MODIFIED AND THE GEAR REDUCER 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 UAH CONTRACT THAT
ONLY UAW PERSONNEL CAN OPERATE THE FGD SYSTEM AND THEREFORE THE SCRUBBERS COULD NOT BE OPERATED.
JAN. T7 1852 608 33
FEB. 77 1162 892 61
THERE WAS A FAILURE OF THE AGITATORS AT THE MIX TANKS. THEY WERE LATER REPLACED WITH NEW ONES.
THE PLANT WAS SHUTDOWN FOR SOME PERIOD DUE TO CUTBACK OF NATURAL GAS SUPPLY AND REQUEST TO CURTAIL
ELECTRICAL CONSUMPTION.
APR. 77 1300 1158 fl9
MAY 77 1222 1118 98
BOILER HOURS WERE LOW DUE TO REDUCED SUMMER REQUIREMENTS.
JUN. 77 1180 1103 94
JUL. 77 702 276 39
THE FGO SYSTEM GAVE A VERY HIGH OPERABILITY FOR JUNE. THE FGO SYSTEM MAS DOWN FOR A CONSIDERABLE
PORTION OF JULY. THE CHEMICAL MIX TANK BLEED OFF LINES AND OTHER PIPING HAD TO BE CLEANED OF
SEDIMENTED SOLIDS.
AUG. 77 755 678 90
SEP. 77 76« 1BO 71
it?
-------
' 6 TO
PERFORMANCE 'MSI'MPITIIN FUR (IFF R A T ION AL Fi,r, SYSTFMr, ON I MllJSTk T fl t nUrLFf6 ^U
THE CHEMICAL MIX TANK AGITATORS WFkE TOTALLY REDESIGNED AND REPLACED RY HIUH-CARbOM STEEL. PROPELLER
TYPES. THE BLADES WERE SPECIFICALLY DESIGNED TO INCREASE THE FLOW THROUGH THF PROPELLERS, THUS
INCREASING THE INTENSITY OF- MIXING. OUF TO THANKSGIVING HOLIDAYS IN NOVEMBFfi AND CHRISTMAS AND t
-------
STATUS TO OCTOBER 1176
SFCTIdN 9 (CONTINUED)
PERFORMANCE DESCRIPTION FUR OPERATIONAL F&D SVSTFMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
PARTICIPATE REMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GFNFRAL MOTORS CORPORATION
PONTIAC. MICHIGAN
COAL (0.8
-------
sums TO n:rljJtt, ,c7t,
SECTION 9 (CO' r |K;jF|)l
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGT CYSTFMS :.)N 1 OI.S'KUL
S Cl'^PORAT TOM? PONTIftC, MICHIGAN ino^TIM
2ND QUARTER-197f, UNSTABLE PH CONTROL ANH WFAF, OF VECMANTCAL tQUfH^LLT ,'(.,,riL K.- THF FLTA3H
MAJOR STARTUP PROBLEMS.
3RD QUARTER-l1??? AN AVAILABILITY Of- 10U PERCf.NT HAD BFEN REPORTED rtHEfU BURNING A f IX TURF OF CO*.
UNO REFUSE. THE SCRU«BF_R DISCHARGE SLURRY CAUSED AFAR DUE TO ITS FLYASH CONTENT.
«TH QIIARTER-1977 FLYASH ABRASION IN THE PUMPS AMD PIPING CONTIWlJcO TO BE THE PROBLEM.
1ST QUARTF.R-1978 FLYASH CAUSED SERIOUS EROSION OF LIQUID HANDLING EQUIPMENT.
ZND QHARTER-197S IT WAS DECIDED TO INSTALL PRESSURE FILTERS IN THE SCRUBBER EFFLUENT LINES TO
REMOVE FLYASH.
3RD dUARTER-1978 THE PRESSURE FILTERS WERE INSTALLED AND ARE WORKING WELL. NO OTHER
PROBLEMS OCCURRED DURING THE REPORT PERIOD.
-------
STATUS TO OCTOBER !978
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
HATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
COAL (3.2Z SULFUR)
ba.ooo SCFM (TOTAL - 2 BOILERS)
2
2
32 MW (TOTAL - 2 BOILERS)
A.D. LITTLE
SODIUM HYDROXIDE SCRUBBING
RETROFIT
1972
OPERATIONAL
90 + X (2000 PPM 3 INLET)
REMOVED BY PRECEDING CYCLONE AND ESP
OPEN LOOP
WASTEWATER TREATMENT AND DISCHARGE TO CITY SEWER
NA2S03 OXIDIZED TO NA2S04, PH NEUTRALIZED AND DISCHARGED TO
CITY SEWER SYSTEM
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE GENERAL MOTORS CORPORATION PLANT LOCATED IN ST. LOUIS, MISSOURI OPERATES a COAL-FIRED BOIL-
ERS. TWO BOILERS, WHICH ARE RATED AT A TOTAL OF 32 MW (EQUIVALENT) AND HAVE A TOTAL STEAM GENERA-
TION CAPACITY OF 250,000 LB/HR, ARE EQUIPPED WITH SCRUBBERS. COAL COMPOSITION IS TYPICALLY 3.21
SULFUR AND 101 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 302 REMOVAL IN A 3-STAGE
IMPINGEMENT TOWER WITH A CHEVRON MIST ELIMINATOR. DIRECT REHEAT IS ACCOMPLISHED WITH STEAM COILS
THE FGD SYSTEM IS CONSTRUCTED OF MfeL STAINLESS STEEL.
OPERATING HISTORY
3RD QUARTER-1977 AN OPERABlLITY OF 100X WAS REPORTED DURING THE MAY-AUGUST PERIOD.
4TH QUARTER-1977 IN SPITE OF A CHEVRON DEMISTER AND 60 f REHEAT, THE STACK LINER WAS CORRODED.
1ST OUARTER-1978 THE DUCTWORK DOWNSTREAM OF THE SCRUBBERS DEVELOPED SOME LEAKS.
2ND OUARTER-1978 A HORIZONTAL PORTION OF THE DOWNSTREAM DUCTWORK,ABOUT 15-20 FEET IN LENGTH, WILL
8F REDESIGNED TO AVOin STAGNATION OF EXHAUST GASES
3RD OUARTER-1978 THE DOWNSTREAM DUCTWORK WAS RECONSTRUCTED DURING THE REPORT PERIOD.
66
-------
STATUS TO OCTOBER
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHASACTF.RISTHS
SOURCE RATING
NUMBER OF SEPARATE FGD UNIT"?
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFTCTfcNCY
PARTICULATE REMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
C I ION 9 (COM
OPFKAITUNM F
rNOUSTRTAL
GFMEKAL MOTORS CliRPOK AT ION
TONOrtANOA, Nth YORK
COAL U.dX SbLHJR)
9?,000 3CFM (TOTAL - U ROTtFRS)
36,000 ACFM a. <40S F, FOR EACH OF 3 FGD SYSTEMS
39,600 ACFM ai 350 F, ^OR I FGD SYSTEM
3
-------
STATUS TO OCTOBER 1978
SECTION 9 (COMTINUEi))
PERFORMANCE DESCRIPTION F()R OPEKATIONAL, FGO SYSTEMS ON INDUSTRIAL BOILF.KS
GENERAL MOTORS CORPflHATTON; TONOWANOA. NEW YORK (CONTIiMUEH)
THAT OF PARTICIPATE REMOVAL IS BOX-95X.
EACH SCRUBBER AND THE CYCLONIC DEMISTF.R IS MArtE OF 316L SS. PLUME REHEAT IS NOT INCORPORATED
INTO THE SYSTEM. THE ENERGY REQUIREMENTS FOR THE SYSTEM AHF ABOUT 3 - 5Z OF THE FUEL BURNED.
OPERATING HISTORY
3RD OUARTER-1977 AVERAGE OPERABILITY DURING THIS PERIOD WAS REPORTED TO 8E 100X.
4TH OUARTER-1977 MAJOR PROBLEMS HAVE BEEN PH CONTROL AND RECYCLE PIPE EROSION. CONTROL
SENSORS/MODULATING MIXER VALVE REPLACED FOR PH CONTROL AND CAST IRON PIPE WAS USED TC
REPLACE SS RECYCLE PIPING. DURING NOV - DEC CONDENSATION FOLLOWING THE OEMISTER
HAS CORRODED THE STACK LINING. A DECISION HAS BEEN MADE TO RELINE THE STACK.
1ST QUARTER-1978 THE STACK WAS NOT RELINED.
ZNO QUARTER-1978 ONE MORE CYCLONE WILL BE RETROFITTED AFTER EACH BOILER IN ORDER TO REDUCE THE
PARTICIPATE LOADING TO THE SCRUBBERS.
3RD QUARTER-1<»78 A MIST ELIMINATOR WILL BE INSTALLED TO PREVENT FURTHER CORROSION OF THE STACK
LINER. THE LINER WILL EITHER BE REPLACED OR COATED WITH AN ACID-RESISTANT MATERIAL.
hft
-------
STATUS TO nCTuHFP I9?f
SECTION 9 (CONTIMJEO)
PERFORMANCE DESCRIPTION FOR npFKMJUNAL FGH SYSTFMS ON TN-OUSTRTAl floILEHS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FQO UNITS
NUMBER (IF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
KATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GEORGIA-PACIFIC PAPF* CO.
CROSSETT, ARKANSAS
HARK,COAL/OIL (IX - l.SX SULFUR)
aao.ooo SCFM ti BOILER)
i
\
110 MW (EQUIVALENT); 1 BOILER
AIWPOL INDUSTRIES
CAUSTIC WASTE STREAM
NEW
1975
OPERATIONAL
85% - 90X (500 PPM a INLET)
90X (0.5 GR/SCF AT INLET)
OPEN LOOP? SCRUBBED WITH 2,300 GPM "BLACK HATER" FROM PULP
MILL.
wASTtWATER TREATMENT AND DISCHARGE TO CITY SEWER
SEE SECTION 13 FUR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE FGO SYSTEM AT GEORGIA-PACIFIC PAPER CO., CROSSETT, ARKANSAS UTIIZES A CAUSTIC PULP MILL
WASTEWATER STREAM (BLACK WATER) TO REMOVE PARTlCULATt AND Sne FROM FLUE GAS GENERATED BY A BARK/OIL
OR HARK/COAL BOILER. THE BOILER IS AN EHIE CITY POWER BOILER HATED AT 600,000 L8S. STEAM/HOUR
(110 MW EQUIVALENT). THE, NORMAL OPERATING RANGE IS BETWEEN UOO.OOO AND 500,000 LBS STEAM/HOUR WITH
AN OPERATING SCHEDULE OF 24 HOURS/DAY 359 DAYS/YEAN. IT IS ONE OF ELEVEN BOILERS THAT TURN 5
TURBINES AND GENERATE «5 Mw.
THE FLUE GAS IS OUCTEO TO A SINGLE SCWURBEh AT THF RATF. OF 320,000 ACFM 9 310 F BY MEANS OF A
BUFFALO FORGE 1.0. FAN WHICH IS DRIVEN BY A 4000 HP «FST 1NGHOUSF TURBINF. THE SCRUHBFR ITStLF IS
MAOF OF 304 SS AND CONSISTS OF AN UNLINED VENTliPI THROAT (9.5 FT X W FT) AND AN IJNLINED LIQUID-GAS
SEPARATOR (24 FT X 55 FT) WITH NO INTERNAL PARTS. THE DUCTING LEAIjTNG TO AND FROf THE SCRUR8EW IS
^Of. flF STEEL AND THE DOWNSTREAM PORTION IS FIBERGLASS LINED. NO MIST ELIMINATION OR REHFAT IS USED
BECAUSE THE 30D S3 STACK IS FIBFRGLASS LINED. THF REC IRCtlLAT ION SYSTEM CONSISTS f)F A JOa SS UNLINEO
RfCIRCULATlON TANK AND A 5000 GPM IMGEHSOLL-RAND PUMP. Ar, IDENTICAL SPJHE PU«P IS ALSO ON HAND
*t'T IS NOT TIFO INTO THE SYSTEM. THESE PU(-,PS ARE t-,AOF '.,r 30a bS AND W RURtiEK LINF.I;. ThtY OPE«AIF
*' MAXIMUM CAPACITY. TMt PIPING IS MADE OF FTBEHHLASS. ThF t>LEED STH£»M FRUH THF REri»CUL»MON
SYSTEM IS FFD TO THF CITY SEwFRS AT A RATE OF 2POO r,PM AND THE MAKE-UP
THE SYSTEM AT A RATE OF 5100 GP".
", LIDUOH IS FED TO
-------
STATUS TO OCTOBER tS7«
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INDUSTRIAL BOILERS
GEORGTA-PACIFIC PAPfk CO.; CROSSETT, ARKANSAS (CONTINUED)
OPERATING HISTORY
3RD QUARTER-1977 PLANT REPORTED SATISFACTORY OPERATIONS WITH NO MAJOR PROBLEMS. THE FIBERGLASS
LINING IN THE SCRUBBER FAILED FREQUENTLY AND WAS REPLACED AS IT FAILED.
OTH QUARTER-197T NO FIBERGLASS LINER FAILURE WAS DETECTED DURING THIS REPORT PERIOD.
QUARTER-1978 PLANT REPORTED NO MAJOR PROBLEMS DURING THE FIRST SIX MONTHS OF 1978. TOTAL
BOILER-SCRUBBER DOWNTIME SINCE JANUARY 1, MAS ABOUT IS DAYS. THE PROBLEMS WERE THE LOSS OF A PUMP
LINER AND A BOILER I.D. FAN TROUBLE.
3RD QUARTER-1978 THE PUMP WITH LINING PROBLEMS HAS REPLACED. THIS CAUSED A SCRUBBER DOWN TIME OF
APPROXIMATELY 36 HOURS. THE REASON FOR THE PUMP FAILURE IS UNKNOWN, BUT UNEVEN LINING APPLICATION
IS LIKELY. THIS PUMP LASTED ROUGHLY 3 MONTHS BEFORE THE LINING OF THE IMPELLER BEGAN COMIN6 OFF IN
CHUNKS. THE NEW PUMP IS THE SAME TYPE AND HAS HAD NO PROBLEMS. THE SPARE IS ALSO OF THE SAME TYPE.
SINCE REPLACEMENT OF THE RECIRCULATION PUMP THE SCRUBBER HAS OPERATED CONTINUOUSLY (SCRUBBER SHUTS
DOWN WHEN THE RECIRCULATION PUMP GOES OUT).
70
-------
SFCT10N 9
PERFORMANCE DESCRIPTION FOR OPEKATTDNAI FGO SYSTEMS ON INDUSTRIAL BOILERS
STATUS TO nriJHER iq78
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BFING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S03 REMOVAL EFFICIENCY
SLUOGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GFTTY OIL COMPANY
BAKERSf-TEl 0, CAI If"ORnlA
COAL (1.1% SUI FIIW)
7?,00(1 SCFM (TOTAL - f, BOILERS)
1
f,
36 Mh (EQUIVALENT); fa BOILERS, EACH „ 50 MM BTU/HR
FMC ENVIRONMENTAL EQUIPMENT
SODIUM CARBONATE SCRUBBING
RETROFIT
JUMF, 1977
flPERATlONAL
90+% (600 PPM a INLET)
HOLDING POND FOR EVAPORATION
10 GPM BLEEDOFF TO A SLOWDOWN TANK. THE SLOWDOWN is THEN
SENT TO A DISPOSAL POND ONCE A WEEK.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
GETTY OIL COMPANY HAS AN OIL FIELD NEAR BAKERSFIELO, CALIFORNIA WHICH OCCUPIES ABOUT 15 SQUARE
MILES. THERE ARE 136 STEAM GENERATORS; 100 WITH A HEAT RATE OF 50 MM BTU/HR AND 36 WITH A HEAT
RATF OF 20 MM BTU/HR. THE FUEL USED IS CRUDE OIL WITH l.U SULFUR AND A HEATING VALUE OF 6.1 MM
8TU/BBL. STEAM IS DISTRIBUTED THROUGHOUT THE OIL FIELD BY INSULATED PIPELINES AND INJECTED INTO
THE OIL WELLS. CONDENSATION OF THE STEAM REDUCES THE VISCOSITY OF THE OIL, WHICH FLOWS FREELY TO
THE SURFACE ALONG WITH THE WATER. THE OIL IS SEPARATED FROM WATER BY DECANTATION IN SETTLING TANKS,
AND PURIFIED BY DISTILLATION IF REQUIRED.
THE FLUE GASES (130,000 ACFM $ 500 F) FROM SEVEN ROTLEKS (50 MM BTU/HR) ARE MANIFOLDED
INTO A TRAY ABSORBER (13.5 FEET DIA X 35 FEFT HIGH) WHICH «AS RETROFITTED IN JUNE 1<>77 BY FMC
ENVIRONMENTAL EQUIPMENT DIVISION. OF THE SEVFlM, FIVE ARfc USUALLY OPERATING AT ONE TIME; OPERATION
IS iH HR/DAY. THE PROCESS IS SODIUM CARBONATE SCRUBBING. THE LIQUOR IS MAINTAINED AT A PH OF fe.S,
AND RFCIRCULATED WITH AN L/G RATIO OF 6.1 (,AL/lOOO ACF. THE RECIPCULAriON FLOW IS 1000 GPM. A
8LEFU STREAM OF 10 GPM IS CONTINUALLY SENT TO THE hLOWUOWN TANK WHICH IS EITHER EMPTIED INTO A
DISPOSAL POND OR INJECTED INTO DEFP KF.LLS EVERY WFEK. THE INLET so? CONCENTRATION is 600 PPM
IHE OUTIET IS IS 80 PPM. THE ABSORRtR, THEREFORE, HAS 90* SO? REMOVAL FFFIflFNrY. THE ORIGINAL
•» CONTAINED THREE OI SK-,1 M> -00 ,| IT TPAYS AMD AM TNCO"(-L WIRE MFSH WIST ELIMINATOR-
MOOulE AMD THE STAC, ARK MADE OE JIM. VS, WHERFAb THF n^NSTPEAM W T«««K »NO THF
'rfF •..,,., ;;T(-H . Ml- r.M.T,
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STAIM:> ro
5FCT10lM 9 'CONT PujFD)
PERFORMANCE DESCRIPTION FOR OPF^S r [IJ-MAI FiiD SYMEIS ON INDUSTRIAL ROILFWS
GETTY OTL COMPANY; BAKtRSF IF Ln, C«LT(-0«NIA (CONTINUED)
THt FGL) SYSTEM WAS S«OU,000 IS 1977 (JtUtARS, Which INCLUDES ALL THE EmirP^ENT HUT DOES NOT INCLUDE
STACK DUCTING, OVERHEADS, AND ENGTNFt91 MR. 1Hfc OPERATING COSTS ARE iO.lfc/MM HTU ($390,000/YR el Jau
DAYS/YR}, WHICH INCLUnt ELECTRICAL, SCRUBBER MAINTENANCE, AMD SODA ASH. THF STOICHlOMfcTRIG RATIO
IS l.fcl LBS OF NA2C03/LB SO? REMOVED.
SOMF IMPORTANT MAINTENANCE PRACTICES ARE:
1. DAILY CHECK AND CALIBRATION 01- PH CONTROLLERS.
^. FREQUENT CHECKS ON FLOW WATERS (MAKEUP wATFR, SUDA ASH, REC IRCULATTON LIQUOR, AND SLOWDOWN)
AND FLUID LEVELS (SLOWDOWN TANK, SODA ASH TANK, AND SCRUBBER).
3. WEEKLY FILLING OF SODA ASH TANK AND DISPOSAL OF BLOWDOWN.
a. SCHEDULED LUBRICATION OF PUMPS AND FAN, SEAL REPLACEMENT.
REFER TO FIGURE l«-8 IN SECTION 11 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD QUARTF.R-1977 THE RECIRCULATION PUMP LINER WAS CHANGED FROM BUNA-N TO NATURAL RUBBER, DUE TO
THE SWELLING OF THE FORMER LINER. THF RUBBER PINCH VALVE ON THE RECIRCULATION PUMP WAS REPLACED BY
A ss GLOBE VALVE. THERE WERE SOME MINOR PROBLEMS WITH THE PH AND LEVEL CONTROLLERS.
aTH QUARTER-1977 THE FAN ROTOR WAS STRENGTHENED AND CLEANED OF THE SCALING. THE FAN BEARING
BURNED UP. IT WAS REPLACED AND THE FAN WAS REALIGNED.
1ST QUARTFR-1978 HIGH STACK DISCHARGE VELOCITY (60 FPS) CAUSED BY SMALL STACK DIAMETER AND POOR
LOCATION OF MIST ELIMINATOR (TOO CLOSE TO STACK TRANSITION SECTION) RESULTED IN HIGH ENTRAPMENT OF
DROPLETS. THE STACK AND TOP SECTION OF THE SCkUBBER WERE REDESIGNED.
2ND QUARTER-1978 THE MESH DEMISTER HAS TO BE REPLACED BY A MUNTERS CHEVRON TYPE MIST ELIMINATOR.
A KOCH FLEXITRAY WAS TO BE INSTALLED ABOVE THE 3RD TRAY IN ORDER TO IMPROVE sog REMOVAL
EFFICIENCY, PARTICULARLY DURING TURNDOWN CONDITIONS. THE PH PROBES ARE FOULED FREUUENFLY. SEVERAL
TYPES OF CONTROLLERS ARE PRESENTLY BEING TESTED FOR HIGH RELIABILITY. THE MILD STEEL RECIRCULATION
LINES WERE ERODED, AND WILL BF REPLACED BY 316L SS. THF AIR BUBdLER IN THE SODA ASH TANK LEVEL
CONTROLLER IS OFTEN PLUGGED. IT WILL tiE REPLACED BY A DIAPHRAGM-TYPE LEVEL CONTROL DEVICE. THE
BLOWDOWN TANK OUTLET LINE HAS DEVELOPED SCALING. A POSITIVE DISPLACEMENT PUMP WAS TO BE INSTALLED
IN THIS LINE, AND A SCALING INHIBITOR WAS POSSIBLY TO BF ADDED IN THE TANK LIQUOR.
3RD QUARTER-1978 THE SLOWDOWN TANK OUTLET LINE WAS KFPIACED WITH A ONE-INCH LINE TO INCREASE
VELOCITY ANO THUS SOLVE THE SCALING PROBLEM. NFW 31hL SS RECIRCULATION UNFS HAVE BEEN INSTAL-
LED, AS HAS THE OIAPHRAGM-TYPF LEVEL CONTROL DtVICF IN THE SOOA ASH TANK. PH CONTROLLERS ARE STILL
BEING TESTED. A SCREW-TYPE POSITIVE DI PP( ACEMfcNT PUMP In AS INSTALLED, REPIACING AN EARLIER PUMP
WHICH ERODED DUE TO HIGH RPM. A SILICON OISPFKSAN1 IS MjW BEING ADDED TO THE LIUUOR TU ASSIST IN
-------
ST«ri's 10 ncToPt^ i^7-
SECTION <) (tf.'i.
PERFORMANCE DESCRIPTION FOR OPERATIONAL F(jn SYSTFMS Oh IM)USTRTAI P(
/
GETTY OIL COMPANY; BAKERSFIFLO, CALIFORNIA (CONTINUED!
ALLEVIATING THE SCALING PROBLEM, HUT THERE HAS NUT BEEN SUFFICIENT TIME Hi EVALUATE ITS
EFFECTIVENESS. SINCE AUGUST 7 THF SYSTEM HAS EXPFKIENCEO ONLY ^ "AYS OOwNlTMF DUE TO REPLACEMENT
OF FAN BEARINGS.
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STATUS TO OCTOBER l<)7e
SFCTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FUR OPERATTONAL FGfl SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOUPCF. CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS 6FING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VtNDOK
CONTROL PROCESS
NFW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PART1CULATE RFMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GKLAT SOUTHERN PAPER CU.
CEDAR SPRINGS, GEORGIA
BARK,COAL/OIL Cl.OX - 3.OX SULFUR)
4?0,00(l SCFM (TOTAL - 2 BOILtRS)
2
2
100 MW (EQUIVALENT); TOTAL - 2 BOILERS
AIRPUL INDUSTRIES
CAUSTIC WASTE STREAM
RETROFIT
1975
OPERATIONAL
B5X-90X (1,000 PPM AT INLET)
99.IX (DESIGN: 4.5 GR/SCF AT INLET)
OPEN LOOP; 350 - 400 6PM PER ABSORBER
WASTEWATER TREATMENT AND DISCHARGE TO RTVER
CLARIFICATION FOLLOWED BY PONDING AND DISCHARGE TO RIVER
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE FGD SYSTEM AT GREAT SOUTHERN PAPER AT CEDAR SPRINGS, GEORGIA CONSISTS OF TWO AIRPOL SODIUM
SCRUBBING TRAINS CONTROLLING EMISSIONS FROM TWO COAL-FIRED BOILERS, EACH RATED AT 105 MW
(EQUIVALENT) AND EACH PRODUCING 500,000 LB/HR STEAM. THE FUELS FIRED IN THE BOILERS TYPICALLY HAVE
THE FOLLOWING SULFUR CONTENTS: COAL - 1.5X , OIL - 1.5Z, AND BARK - 2. OX.
THE STAINLESS STEEL SCRUBBERS HANDLE A COMBINED TOTAL OF 700,000 ACFM AT 425 DEGREES F. THE
PRESSURE DROP ACROSS A SCRUBBER IS APPROXIMATELY 7 INCHES W.G. WITH 85 - 90X SULFUR DIOXIDE
REMOVAL EFFICIENCY. THE SULFUR CONCENTRATION OF THE FLUE GAS IS 1000 - 1200 PPM AND THE PARTICULAR
LOADING IS 4.5 GR/SCFD.
THE SCRUBBER UNDERFLOW IS COMPOSED OF FLYASH AND SODIUM SULFITE/SULFA TE SOLUTION. SOLIDS
CONTENT (FLYASH) IS TYPICALLY 3 TO 5X BY WEIGHT. SCRUBBER WASTE WATER WITH AN AVERAGE PH OF a. 5
IS PONDED AND CLARIFIED WATER IS RETURNED TO THE RIVER.
OPFRA1ING HISTORY
4TH nilARTFR-1977 TH£ EXPANSION JOiMT BFlWfcEN THE EXISTING STACK AND SCRUBBER HAD TO BE REPLACED
IP.' SEPTEMBER. SOMt INTERNAL V'tAR WAS OFTFCTE" flN THE PUMPS DUE. TO THF ASH CONTENT. EkOSIOM AND
PLUGGING PROBLEMS WITH THE PH PRQRfcS HAVE flFEN FNCOUIyiTEREO . T"E PLANT WAS IN THE PROCESS OF CHANG-
ING THE CONTROL PH AND MOVING THE PROBES. TANKS AND NECESSARY EQUIPMENT TO CONTROL THE PROPER PH
-------
STATUS TO OCTORft, is7e
SFCTIOI\ q CCOuTINUFUl
PERFORMANCE DESCRIPTION FOP OHFRAIIONAI KUD SYS[F>S ON INDUSTRIAL ROILEWS
GREAT SnUTHFRM PAPER CO.! CFOAK SPuTNGS, REflKRjA (C0.\ T
ARE EXPECTED TU BF COMPLETED TM A COUPLF OF MONTHS. Sl.ME EROSION *»S DETFCTEP IN THE RFC TRCUL AT I ON
LINES OF THF POWER RUlLEK SCRUBBER. IriF UNES AND SUM£ OF THE VALVFS HAD 10 BE REPLACED
2ND UUARTEK-1978 NO UPDATE INFORMATION WAS OHTAINFD F Ok THIS REPORT PERIOD.
3RD UUARTER-1978 NO SCKUBBER-RtL ATtD PROBLEMS rtERF REPORTED FOR THIS PERIOD.
-------
'arus it ncioHtw
1 J ON Q (l.flN'T J M.lf '))
m HVAT KJI^AL F ,1. SY
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
MUMPER OF BOILERS BEING CONTROLLED
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
(, *h A 1 WESTERN b II G A P
BHLlNliS, MONTANA
COAL (0.7* SULFUR)
60, (100 SCFM (TOTAL - ? ROILEHS]
GREAT WESTERN SUGAR
AMMONIA-LADEN PROCESS WATFR
RETROFIT
UCTOBFW, 1977
OPERATIONAL
3"5X (500-UOO PPM 3 INLET)
WASTtWATER TREATMENT AND OISCHARGF TO RIVER
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE FGD SYSTEM AT GREAT WESTERN SUGAR, BILLINGS, MONTANA PLANT HAS BEEN PRIMARILY DESIGNED
FOR PARTICULATE CONTROL. HOWEVFR, THF SCRUBBING LIRIJOR CONTAINS ENOUGH NH3 (PH=6.7) TO OBTAIN
A REMOVAL EFFICIENCY OF J5X FOK S02. THE CONCENTRATION OF S02 AT THE INLET IS 300-400 PPM.
TH£ SYSTEM CONSISTS OF A VARIABLE THROAT VENTUKI SCRUBBER AND A SINGLE PASS, THREE STAGE CHEVRON
OEMISTER. THE SCRUBBER WAS INSTALLED IN OCTOBER, 1977 AND HAS BfcFN OPERATING SATISFACTORILY.
THE SCRUBBER EFFLUENT IS BLED OFF TO A PQNO wHt»E IT IS BLENDED AND COOLED WITH OTHER PROCESS
WASTE STREAMS AND THEN PUMPED TO A RIVER.
3RD QUARTER-1978
OPERATING HISTORY
NO INFORMATION WAS REPORTED FOR THIS UPDATE. PFRIOD.
-------
STATUS TO ncTORE" 1976
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPF.rtAT TuNAI FGf) SVSTFMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
502 REMOVAL EFFICIENCY
P4RTICULATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GREAT WESTERN SUGAR
FTNOLAY, OHIO
COAL (1.2X SULHIR, AVERAGE)
65,530 SCFM (TOTAL - Z BOILERS)
100,000 LBS/HR STEAM- (TOTAL - 2 BOILERS)
33 Mh (EQUIVALENT), 90MM BTU/HR (TOTAL); TOTAL - S BOILFHS
GREAT WESTERN SUGAR
SODIUM CARBONATE SCRUBBING
RETROFIT
OCTOBER, 197
-------
STATUS TO OCTOBER I97g
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SCUOGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GREAT WESTERN SUGAR
FORT MORGAN, COLORADO
COAL (1.2X SULFUR, AVERAGE)
65,230 SCFM (TOTAL - 2 BOILERS)
100,000 ACFM EACH d «00 F (TOTAL - 2 BOILERS)
250,(JOO LRS/HR STEAM (TOTAL - 2 BOILERS)
2
2
326 MM BTU/HH, 32 MW (EQUIVALENT); TOTAL - 2 BOILERS
GREAT WESTERN SUGAR
AMMONIA-LADEN PROCESS WATER
RETROFIT
OCTOBER, 1976
OPERATIONAL
«8X (300-400 PPM 5) INLET)
95X (730 LBS/HR 3 INLET)
WASTEWATER TREATMENT AND DISCHARGE TO RIVER
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE GREAT WESTERN SUGAR COMPANY HAS TWO COAL FIRED BOILERS AT THEIR FORT MORGAN, COLORADO PLANT.
EACH BOILER IS RATED AT 125,000 LRS/HR OF STEAM? AND BURNS COAL WITH 0.54 PERCENT AVERAGE SULFUR,
6.7 PERCENT AVERAGE ASH, AND AN AVERAGE HEATING VALUE OF 10,176 BTU/LB. THE SUGAR FACTORY IS OPER-
ATIONAL ONLY 3 MONTHS OF EVERY YEAR, DURING THE FALL QUARTER.
THE FGD SYSTEM WAS RETROFITTED IN OCTOBER 1976 AS A PROPRIETARY DESIGN PRIMARILY FOR PARTICULATE
CONTROL. THE FLUE GASES FROM EACH BOILER (100,000 ACFM a) 100 F) PASS THROUGH MULTICLONES, AND THEN
ARE SFNT THROUGH A VENTURI SCRUBBER, WHICH OPERATES WITH A PRESSURE DROP OF 6 IN. W.G. AND L/G
VALUE OF 8 GAL/1000 ACF. THE SCRUBBERS ARE FOLLOWED BY A COMMON VESSEL WHICH CONTAINS A SINGLE-
PASS, THREE-STAGE CHEVRON MIST ELIMINATOR (M-E). HASH WATER FLOHv TO THE M-E IS 120 GPM, WITH A
FREQUENCY OF 15 MINUTES EVERY 8 HOURS. THE PRESSURE DROP ACROSS THE M-E IS 0.5 IN. W.G. A CONSTANT
HLEFD-UFF STREAM OF tiOU GPM FROM EACh SCRUBBER IS SFNT TU A POND, WHICH OVERFLOWS INTO ANOTHER
HOLDING POND.
THE VENTURI SCRUBBED, THE PLUG, M-E VESSEL, AND THE M-E ARE ALL MADE OF 316L S3.
7ft
-------
STATUS TO OCTOBER 1978
SECTION q (CONTIMJFD1
PERFORMANCE INSCRIPTION FUR OPFhAl[UNAL FG0 SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNTTS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
SLUDGE OB BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
bRkAT WESTERN SUGAR
fiERINR, NEBRASKA
COAL (i.gx SULFUK,
110,000 SCFM (TOTAL - £ BOILERS)
97,000 ACFM EACH a
-------
STATUS TO OCTORfc" !"7h
SECTION 9 (COMINUEU)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGH SYSTEMS ON INUHSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SO? REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GREAT WESTERN SUGAR
GREELEYr COLORADO
COAL (0.6X SULFUR)
25,000 SCFM (J BOILER)
t
1
GREAT WESTERN SUGAR
AMMONIA-LADEN PROCESS WATER
RETROFIT
OCTOBER, 1975
OPERATIONAL
35X (300-flOO PPM 3 INLET)
WASTEWATER TREATMENT AND DISCHARGE TO RIVER
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AT THE GREELY, COLORADO PLANT, GREAT WESTERN SUGAR HAS IN OPERATION 6 COAL FIRED BOILERS
MANUFACTURED BY STERING AND PLACED IN SERVICE IN 1920. THE BOILERS OPERATE 2796 HOURS PER YEAR
DURING THE FALL AND EARLY WINTER MONTHS. EACH BOILER POSSESSES THE FOLLOWING CHARACTERISTICS;
AN OPERATING HEAT INPUT OF 39.7 MM BTU/HR, A DESIGN STEAM CAPACITY OF 12,235 LB/HR AND A DESIGN
FLUE GAS FLOW RATE OF 28,333 ACFM «D 550 F. THE COAL USED AS FUEL HAS AN AVERAGE HEATING VALUE
OF 9208 BTU/LB, AN AVERAGE SULFUR CONTENT OF 0.66X AND AN AVERAGE ASH CONTENT OF 5.39*.
THE SCRUBBER SYSTEM IS A WET VENTURI FOLLOWED BY A CHEVRON TYPE, ONE PASS MIST ELIMINATOR.
THE MIST ELIMINATOR IS CONSTRUCTED OF 3/16" 316 STAINLESS STEEL AND THE SCRUBBER IS CONSTRUCTED
OF 10 GA. 316L SS. DEMISTER WASH FLOW RATE IS 120 GPM. DESIGN FLUE GAS FLOW SATE IS 16«,000
ACFM 3 550 F AND THE L/G RATIO IS 5.5 GAL/1000 CFM. THE FLOW OF SCRUBBING LIQUOR TO THE VENTURI
IS 550 GPM. THE PRESSURE DROP ACROSS THE SCRUBBER IS 7" WG.
THE WASTE WATER FROM THE SCRUBBER IS AN ASH/WATFR SLURRY WHICH IS CONTINUOUSLY DISCHARGED
TO A POND AT 1100 GPM.
OPERATING HISTORY
3RD QUARTER-197B NO INFORMATION WAS REPORTED FOR THIS REPORT PERIOD.
-------
STATilb TO PCTQBEf
SECTION 9 (CONTINUFD)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS ON INUIJSTHTAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTER1STTCS
SOURCE RATING
NUMBER OF SEPARATE FGO UNI IS
NUMBER OF BOILERS BEING CONTROLLED
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GREAT WESTERN SUGAR
LOVELANO, COLORADO
COAL (1.2X SULFUR, AVF.RAGE)
121,600 SCFM (TOTAL - 2 BOILERS)
100,000 ACFM EACH S 410 F
100,000 LBS/HR STEAM (TOTAL - 2 BOILERS)
GREAT WESTERN SUGAR
AMMONIA-LADEN PROCESS WATER
RETROFIT
OCTOBER, 1973
OPERATIONAL
30X (.95 LB/MM RTU 8 INLET)
800 GPM (PROCESS CONDENSATE WATER, PH=8.7, L/G=B)
WASTEWATER TREATMENT AND DISCHARGE TO RIVER
EFFLUENT STREAM TO HOLDING POND
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE GREAT WESTERN SUGAR COMPANY HAS TWO COAL-FIREO BOILERS AT THEIR LOVELAND, COLORADO PLANT.
EACH BOILER IS RATED AT 135,000 LBS/HR OF STEAM AND BURNS COAL WITH 0.53 PERCENT AVERAGE SULFUR,
9.9 PERCENT AVERAGE ASH, AND AN AVERAGE HEATING VALUE OF 10,3a5 BTU/LB. THE SUGAR FACTORY IS OPER-
ATIONAL ONLY 3 MONTHS OF EVERY YEAR, DURING THE FALL QUARTER.
THE FGO SYSTEM WAS RETROFITTED IN OCTOBER 1971 AS A PROPRIETARY DESIGN PRIMARILY FOR PARTICULATE
CONTROL. THE FLUE GASES FROM EACH BOILER (100,000 ACFM 8 410 F) PASS THROUGH CYCLONES AND ARE MIXED
IN A COMMON DUCT, AND THEN SENT THROUGH TWO VENTURI SCRUBBERS, WHICH OPERATE WITH A PRESSURE DROP
OF 7 IN. W.G. AND L/G VALUE OF 7.5 GAL/1000 ACF . THE OPERATING GAS VELOCITY AT THE VENTURI INLET
IS «3 FPS. THE SCRUBBERS ARE FOLLOWED BY A MIST ELIMINATOR (M-E) VESSEL WHICH CONTAINS A ONE-PASS,
THREE-STAGE CHEVRON M-E. WASH WATER FLOW TO THE M-E IS 120 GPM, WITH A FREQUENCY OF 15 MINUTES
EVERY 6 HOURS. THE PRESSURE DROP ACROSS THF M-E TS 0.5 IN. W.G. THE EFFLUFNT STREAM FROM EACH
SCRUBBER, 750 GPM, IS SENT TO A POND, WHICH OVERFLOWS INTO ANOTHER HOLUING POND.
THE VENTURI SCRUBBERS, VARIABLE DIAMETER PLUGS, M-E VESSEL, AND THE M-E ARE ALL MADE
-------
STATUS TO OCTOBER 1978
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GREAT WESTERN SUGAK
SCOTTS BLUFF, NEBRASKA
COAL (1.2X SULFUR, AVERAGE)
65,230 SCFM (TOTAL - 2 BOILERS)
130,000 ACFM EACH a) 400 F (TOTAL - 2 BOILERS)
300,000 LBS/HR STEAM (TOTAL - 2 BOILERS)
2
2
32 MK (EQUIVALENT)} TOTAL 2 - BOILERS
315 MM BTU/HR (TOTAL)
GREAT WESTERN SUGAR
AMMONIA-LADEN PROCESS MATER
RETROFIT
OCTOBER, 1975
OPERATIONAL
3SX (400 PPM 3 INLET)
95X
WASTEWATER TREATMENT AND DISCHARGE TO RIVER
EFFLUENT STREAM TO HOLDING POND.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE GREAT WESTERN SUGAR COMPANY HAS TWO COAL-FIRED BOILERS AT THEIR SCOTTS BLUFF, NEBRASKA
PLANT. EACH BOILER IS RATED AT 150,000 LBS/HR OF STEAM AND BURNS COAL WITH 0.61 PERCENT AVERAGE
SULFUR, 5.2 PERCENT AVERAGE ASH, AND AN AVERAGE HEATING VALUE OF 9,300 BTU/LB. THE SUGAR FACTORY IS
OPERATIONAL ONLY 3 MONTHS OF EVERY YEAR, DURING THE FALL QUARTER.
THE FGD SYSTEM WAS RETROFITTED IN OCTOBER 1975 AS A PROPRIETARY DESIGN PRIMARILY FOR PARTICULATE
CONTROL. THE FLUF GASES FROM TWO BOILERS (130,000 ACFM EACH S aOO F) PASS THROUGH CYCLONES AND ARE
MIXED, AND THEN SENT THROUGH TWO VENTURI SCRUBBERS, WHICH OPERATE WITH A PRESSURE DROP OF b IN.
W.G. AND L/G VALUE OF 6.5 GAL/1000 ACF. THE OPERATING GAS VELOCITY AT THE VENTURI INLET IS 56 FPS.
THE SCRUBBERS ARE FOLLOWED BY A DEMISTER VESSEL WHICH CONTAINS A SINGLE-PASS, THREE-STAGE CHEVRON
MIST ELIMINATOR (M-F.) . WASH WATER FLOW TO THE M-E IS 150 GPM, WITH A FREQUENCY OF 10 MINUTES EVERY
a HOURS. THE PRESSURE DROP ACNOSS THE M-E IS 0.5 IN. W.G. THE SCRUBBER EFFLUENT, 825 GPM FROM EACH
SCRUBBER, IS SENT TO A PQND.
THE VENTURI SCRUBBERS, VARIABLE DIAMETER PLUGS, M-E VESSEL, AND THE M-E ARE ALL MADE
OF 316L SS.
-------
SFCTJON
°ERFORMANCF_ DESCRIPTION FOR
(CONT I" UFD)
^AL FC,P SYSTFKS ON
STATUS TP OCTOBkR 1978
HUlLEWS
INSTALLATIOM NAMfc
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BFING CONTROLLtn
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP OATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
ITT KAYOMfcR, JMC.
FFKNANDfM RfiACH, FLC'TTA
HAhK,rtL (5.02 - ?.5Z SULFUR)
c?01,000 SCFM (THIAL - 2 BOHfHS)
2
4
100 MW (EQUIVALENT) i TOTAL - « BUILFRS
AIHPUL INDUSTRIES
SODIUM HYOKOXTUF SCRUBBING
RFTROF1T
OPERATIONAL
802 - 85% (1,?00 PPM AT INLET)
9751 (1.7 GR/SCF AT INLET)
OPEN LOOP
WASTtWATER TREATMENT ANO OISCHAR6F TO TAILINGS POND
SFE SECTION 11 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
ITT RAYONIER OPERATES AN AMMONIA-BASED SULFITE PULP MILL TN FERNANDINA REACH, FLORIDA. THERE
ARE FOUR PROCESS STEAM BOILERS. TWO RATED AT 125,000 LB/HS STEAM, ONE AT 100,000 LB/HR STEAM AND
ONE AT 150,000 LB/HR STEAM.
FLUE GASES LEAVING THE NUMBER TWO AMD THREE BOILERS ENTFR INTO SEPARATE MECHANICAL COLLECTORS
(BUELL CYCLONE COLLECTORS) FOR PARTICULATE REMOVAL OF ABOUT 97% u.7 GR/SCF a INLET). TWO IDENTICAL
FGO SYSTEMS ARE USED TO REMOVE RO TO B5 PEKCENT OF THE 502 FROM THE GAS FRON' ALL FOUR BOILERS.
BOILERS ONE AND TWO ARE MANIFOLDED INTO ONE SCKUBBFB SYSTEM WHILE GASES FROM THREE AND FOUR ARE
MANIFOLDED INTO THE SECOND SCRUH8FR SYSTEM. EACH SYSTEM USES A VARIABLE-THROAT VENTuRI SCRUBBER FOR
S02 REMOVAL WHICH IS PRECEEDED RY AN I.D. FAN. A 10X CAUSTIC SOLUTION TS INJECTED AT THE THROAT OF
THE VENTURI FOR USE AS THE SCRUBBING LIQUOR. CONTROL PH TS IN THE RANGF (It- 5.5 TO 6.0. THE LIOUID-
6*3 MIXTURE ENTERS A SbPARATUR (3ft FT HIGH X 16.5 FT OIA.) WHICH TNCORPORAFFS SPIN VANES FOR LIQUID
SEPARATION. THF LIOUIO DROPS TO THE BOTTOM OF THE SEPARATOR INTO THfc RFCIHCULAT ION 1ANK. THE PUMPS
OPERATE AT 75 HP DURING FULL LOAD REQUIREMENTS. THE GASES LKAVE THF TOP OF ine SEPARATOR AND LEAD
DIRECTLY TO THE STACK.
THE VFNTURIS, SEPARATORS (INCLUDING SPI" VANtS), SHEi\lT LinuOR PIPJIMR AND HOLD TANKS ARE ALL
CONSTRUCTED OF -iihL bS.
WFFFR T1 FIRURt il-1 !N SFCTIIKJ \ U FOR A ntTATLF;; PWllCESa FL(".il HIA.^'AN' nf THIS SYSTEM.
-------
STATUS TO OCTOBER 1978
SFCTTDN 9 (COr.TINUFO)
PERFORMANCE DESCRIPTION FUR HPFKAIM^AL FGn SYSTEMS OIM INDUSTRIAL HUILEKS
ITT RAYONTER, INC.; FERNANUTNA BEACH, KIl'filDA ( C'»M TMIt D J
OPERATING HISTORY
«TH QIIARTER-1977 PLANT REPORTED THAT BOILERS NO, 2 UNO 1 WERE OPERATING AT REDUCED LOADS.
EACH IN THE RANGE OF 75,000 - 90,000 L8S/HR STEAM. THE SPENT CAUSTIC WAS NOT BFING
USED FOR SCRUBBING LIQUOR. ITT WAS SELLING THE SPENT CAUSTIC TO KRAFT MILLS WHO USE IT
FOR THEIR SODA BASE. CONDENSATE STEAM WAS BEING RECYCLED AND USED FOR SCRUBBING PURPOSES.
SOME EROSION HAS BEEN NOTED AT THE VbNTURl THROAT.
2ND OUARTFR-1978 THE PLANT WAS STILL UTILIZING CONDENSATE WATER FOR SCRUBBER LIQUOR. APPROX-
IMATELY 3 TONS PER DAY OF SODIUM HYDROXIDE WAS 8ETNG USED TO MAINTAIN PH. THE ORIGINAL HOT WASTE
STREAM CAUSTIC WAS NOT USED FOR SCRUBBER PURPOSES, BECAUSE OF PROCESS-RELATED PROBLEMS THAT
DEVELOPED.
SCRUBBER EFFLUENT MAS STILL BEING SOLO TO KRAFT MILLS. THE SYSTEM HAS TWO SCRUBBERS, "A" AND "B".
A-MODULE WAS OOWN 1 WFEKS IN JUNE AND JULY BECAUSE OF AM F.D. FAN FAILURE, BELIEVED TO RE A RESULT
OF POORLY OPERATED MECHANICAL COLLECTORS. NEW MECHANICALS WERE BEING INSTALLED TO PREVENT FURTHER
ABRASION. THE PLANT REPORTED THAT SINCE JANUARY, SCRUBBER OPEHABILITY HAD BEEN APPROXIMATELY 95X.
3RD QUARTER-1978 THE BOILER AND FGD SYSTEM OPERATED APPROXIMATELY 9555 OF THE PERIOD. THE
ONLY OUTAGE DURING THE PERIOD WAS BOILER-RELATED AND LASTED THREE DAYS. THE BEARINGS IN THE I.D.
FAN HAD TO BE REPLACED.
-------
STATUS in OCTOBER 1978
SECTION 9 (cnNTirnjf-0)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD Sr.STF.MS ON INuUSTRTAI BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTflOL PROCESS
NEW / RETROFIT
START-UP HATE
CONTROL SYSTEM STATUS
502 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
WATER MAKf-UP
SLUDGE OR BY-PROOUCT DISPOSAL
CONTROL SYSTEM COST
KFRR-MCGEE CHEMICAL CORP.
TRONA, CALIFORNIA
COKF/COAL/OIL (0.5X - S.OX SULFUR)
490.000 SCFM (TOTAL - 2 BOILERS)
7?6,000 ACFM 9 350 F (TOTAL - 2BOTLERS)
a
?
fefl Mk» (ELECTRIC POhER AND PROCESS STEAM) TOTAL - 2 BOILERS
COMBUSTION EQUIPMENT ASSOC.
SODIUM CARBONATE SCRUBBING
NEW
JUNE, 197«
OPERATIONAL
98 + X (AT MAXIMUM LOADING)
98. 5X (COLLECTED BY PRECEDING ESP'S)
OPEN LOOP* ia5 GPM BURKITE SCRUBBING LIQUOR (47% NA8C03 AND
HOLDING POND FOR EVAPORATION
SCRUBBER EFFLUENT IS CLARIFIED AND THEN PUT INTO A MINERAL
DEPOSIT.
SEE SFCTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
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 LAKE, IS THE LARGEST YET BUILT TO YIELD SODA ASH BY DIRECT
CAR80NATION UF BRINE ANO WAS COMMISSIONED IN JUNE 1978. THE PROCESSING INNOVATIONS, WHICH
H»VE IMPROVED THE PLANT EFFICIENCY, INCLUDE CARBONATION UNDER 13.5 LB/SQ. IN. PRESSURE, USE OF
* COAL-FIRED POWER PLANT, AND RECOVERY OF COS FROM THE FLUE GASES.
THE PLANT HAS TWO BOILERS, EACH RATED AT 12 MK, WHICH PRODUCE PROCESS STEAM AND ELFCTRICITY.
E»CH BOTLER PRODUCES 600,000 L8S/HR OF STEAM AT 1500 PSI ANH BURNS A MIXTURF OF WESTERN COAL
(°.7 PERCENT SULFUR) AND PETROLEUM COKE (5.5 PERCENT SUIFUR). THE HIGH SULFUR COKE is MIXED WITH
THE COAL IN ORDER TC IMPROVE THE PARTIAL TONIZATION ANO THEREFORE IMPRUVt Fl Y-ASH COLLECTION IN THt
ESP WHICH OPERATES ON THE COLD SIDE OF THE PREHEATER AT 9fl.<5 PhRCFNT FFFICIFNCY AND 300 F. THE FLUE
G*S FLOW PATE FRUM FACH BOILER TS 3*3,000 ACFM AT 3?o F AND MAY CONTAIN sn^ BETWEEN 335 TO S9«s HPM
UPON THF FUEL. THE AIR POLLUTION REGULATIONS DICTATE THAT EACH BOILER MAY RELEASE NOT
THAN in LHS/HR PARTICULAR, 200 LBS/HR OF so? AND 1^0 LBS/HR (IF NUX.
T"E FI.UF GASES AHF SCRUBBED BY THF FND LinilHR FROM THE SODA ASh FLAN I IN TH(J SC
-------
STATUS TO OCTOBER 1978
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOP OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
KERR-MCGEE CHEMICAL CORP.; TRONA, CALIFORNIA (CONTINUED)
(30 FT DIA X 35 FT HIGH EACH) WHICH ARE MILD STFEL VESSELS WITH FLAKE LINING AND POLYPROPYLENE SIEVE
TRAYS. THE TOP TRAY RECEIVES PLAIN WATER WHEREAS THE SECOND TRAY RECEIVES THE REC IRCULATING LIQUOR
AT PH OF 6 - fe.5. THE SPENT LIQUOR FROM THE BOTTOM OF THE SCRUBBERS IS RECIRCULATED BY RUBBER
LINED PUMPS TO A MILD STEEL SURGE TANK WHERE FkESH END-LIQUO« IS ADDED TO IT WITHOUT AGITATION. A
BLEED OFF STREAM IS CONTINUOUSLY TAKEN BACK TO THE SALT PONDS.
THE BOILER 1.0. FANS (1600 HP) FORCE THE GASES THROUGH THE SCRUBBERS AND EXPERIENCE 6 IN. WG
PRESSURE DROP. THE FANS HAVE MILD STEEL CASING. THE DOWNSTREAM DUCTWORK IS MILD STEEL WITH FLAKE
LINING WHEREAS THE STACK IS CONCRETE WITH FRP LINFR. AMBIENT AIR IS HEATED IN AN EXTERNAL
STEAM HEATER AND MIXED WITH THE EXIT FLUE GASES TO INCREASE THE TEMPERATURE FROM 125 F TO ABOUT
175 F. AT MAXIMUM LOADING, THt SCRUBBERS HAVE A S02 REMOVAL EFFICIENCY OF 98 PERCENT. THE SCRUBBED
FLUE GASES ARE PROCESSED THROUGH TWO MONOETHANOLAMINE (MEA) PLANTS FOR EXTRACTION OF COS. EACH MEA
PLANT WILL PRODUCE 300 TONS/DAY OF C02 AND WILL BE THE MAIN SOURCE OF MAKEUP COS FOR THE CARBONATION
STEP.
REFER TO FIGURE 14-10 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
1ST QUARTER-1978 THE MAJOR CONSTRUCTION WORK WAS OVER. PRECOMMISSIONING ACTIVITIES WERE UNDERWAY.
THE PLANT WAS PROJECTED TO GO ONSTREAM BY APRIL 1, 1978.
aUARTER-1978 THE FGD SYSTEM WAS COMMISSIONED DURING THE REPORT PERIOD. THE BOILERS WERE RUN
TO FULL CAPACITY WITH 100X OIL FEED. COAL AND COKE WERE USED UP TO BOX AS THE FUEL. THE MAJOR
STARTUP PROBLEM WAS TRAY TIEDOWN. THE POLYPROPYLENE SIEVE TRAYS WERE NOT STRONG ENOUGH TO TAKE THE
LOAD OF INVENTORY LIQUID. THESE WILL BE REPLACED BY 31feL SS OR A HIGHER GRADE ALLOY. THE PRESENCE
OF CHROMATE IONS IN THE MAKEUP WATER CAUSED SOME CONCERN.
3RD CUARTeR-1978 THERE WERE ONLY Z BOILER AND FGO OUTAGES DURING THE PERIOD. BOTH OUTAGES WERE
FOR REPLACING THE SIEVE TRAYS IN THE ABSORBER MODULES. TRAYS WERE REPLACED BY 317L SS: IN THE
FIRST MODULE DURING A 5-DAY OUTAGE IN AUGUST, AND IN THE SECOND DURING A 0-OAY OUTAGE IN SEPTEMBER.
COAL AND COKE WERE USED FOR 90 TO 95 PERCENT AS THE FUEL. OIL WAS NOT USED AT ALL, WHILE GAS WAS
AVAILABLE ONLY AS A BACK-UP.
-------
STATUS TO OCTOBER 1978
SFCT10N 9 (CDMTINUFin
PERFORMANCE DESCRIPTTON FOR OPFWATTUNAI FGD SYSTEMS ON INDUSTRIAl BUILFRS
INSTALLATION NAME
INSTALLATION LUCATIOM
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
PARTICIPATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
MEAD PAPE&BnARO CO.
STt vt NSOto, ALA6AMA
OIL (1.5X - 3Z SULFUR)
100,000 3CFM (IflTAL - 2 BOILERS)
1
2
50 Mh (EQUIVALENT); TOTAL - TWO BOILERS
AIRPOL INDUSTRIES
SODIUM HYDROXIDE SCRUBBING
NEW
OPERATIONAL
95% (1,500 PPM a INLET)
90%
ALKALINE SULFITE/BISULFITF RECYCLED TO PULP PROCESS
RECOVERED SOLUTION USED AS MAKE-UP TO COOKING LIQUOR IN PULP
MILL.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE MEAD PAPERBQARD COMPANY IN STEVENSON, ALABAMA, IS A NEUTRAL SULFITE PULP MILL WITH A 500
TON/DAY PULP PRODUCTION RATE. THE MILL HAS A CHEMICAL RECOVERY SYSTEM THAT ABSORBS S02 FROM THE
BILLERUO REACTOR. EFFLUENT FROM THE RECOVERY SYSTEM FLO«S BACK TO THE PULPING OPERATION. ELSEWHERE
ON-SITE, AN AIRPOL INDUSTRIES ABSORBER TOWER CONTROLS PART ICULATE AND S02 EMISSIONS FROM TWO
OIL-FIRED (1.5X - 3.OX SULFUR) COMBUSTION-ENGINEERING PACKAGE BOILERS. FLUE GAS VOLUME INTO THE
SCRUBBER SYSTEM IS ABOUT 175,000 ACFM 5) 450 F„ HOT GASES PASS THROUGH A STAINLESS STEEL
VENTURI/QUENCH SECTION FOR COOLING AND INITIAL S02 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
INTRODUCED THROUGH A BANK OF 1.5 INCH NOZZLES AND SPIN VANES. THF SOLUTION IS ADDED TO THE RECIR-
CULATION LINE ON THE SUCTION SIDE OF THE RECIRCULATION PUMP AT A RATE OF 20 - 25 GPM. SCRUBBER
EFFLUENT (600 GPM), MOSTLY SODIUM SULFITE, IS SENT TO THE MILLS PULPING OPERATIONS FQR EVENTUAL USE
IN THE FIBERGLASS RECIKCULATION TANK. THE PH MONITORING SYSTEM CONSISTS OF A FIBERGLASS BOX
ACCEPTING OVERFLOW FROM THE RECYCLE TANK. THE r,AS EXITS THROUGH A FIBERGLASS STACK.
THF S02 SCRUBBING SYSTEM WAS OOWN FkOI" MARCH THROUGH JULY 1976 DUE TO ABRASION PROBLEMS. THF
ABRASION WAS CAUSED PARTIALLY n Y HIGH STRMM VHOCITY THROUGH THE EXISTENT Vt^URI PARTICULATF
SCRUBBER INTO THE SOd SCRUtJBER. SilOIllM CAKHONATE AMD CARRON PARTICLES THAT HAD NOT bONE INTO SOLU-
TION ALSO WERE VF.PY ABRASIVE TO THK ;>oa sc«u«Ht» LINING, iw AUDITION, THE ORIGINAL GLASS-FLAKED
-------
STATUS TO OCTOBER 1976
N P (cnr>iT itvurn)
PFRFORMANCF DESCRIPTION FOR OPF i< A I 1 ON AL F[;n SrSTFMS ON INDUSTRIAL BOlLEkS
MEAD PAPERBOARO en.? STFVENSON, ALABAMA (ri/N
LINFK (5 MM THICK) WAS EXPERIENCING STWFSS CRACKING.
THE HIGH VFLOCITIES INTRODUCED BY THF VENTUKI WERE ELIMINATED BY REMOVING THE PARTICIPATE
VENTURI SECTION OF THE SYSTEM. THt GLASS-FLAKED LINING WAS PATCHED WITH $bO,000 WORTH OF
CARPENTER 20 LINER. THF.SF CORRECTIVE ACTIONS HELPED FUR A WHILF, BUT AS IT TURNED OUT, THE CARPEN-
TER 20 WAS NOT INSTALIED PROPERLY AND SOLUTION WAS GETTING BETWEEN IT AND THE MlLO STEEL SHELL. IT
WAS FINALLY DECIDED TD INSTALL NEW RUBBFR LINING INSIDE THE ENTIRE SCRUBBER. INCLUDING THE SPIN
VANES, AT A COST OF SlbO.OOO. TO PREVENT ANY HEAT PROBLEMS, ADDITIONAL NOZZLES WERE INSTALLED. TO
DATE, NO MAJOR PROBLEMS HAVE OCCURRED WITH THE RUBBER LINING.
SCRUBBER MAINTENANCE IS PERFORMED WHENEVER MILL OPERATIONS CEASE FOR ROUTINE PLANT MAINTENANCE
WHICH OCCURS SEVERAL TIMES PER YEAR. THE PH CuNTROL SYSTEM RECEIVES CONTINUING MAINTENANCE AND THE
PH PROBES ARE CLEANED ONCE PER WEFK.
REFER TO FIGURE 1«-H IN SECTION \H FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
4TH QUARTER-J977 MINOR EMBRITTLEMENT, DUE TO LOCALIZED HIGH TEMPERATURE, HAS BEEN DETECTED ON THE
LINING SURFACE, SOME METAL, NOZZLES, AND RUBBER HAVE BEEN REPLACED.
2ND QUARTER-1<)78 THE PLANT WAS DOWN 13 DAYS IN JUNE FOR A MAJOR PAPER MACHINE UPDATE, AND THE
BOILERS WERE DOWN 9 DAYS DURING THAT PERIOD. DURING BOILER DOWN TIME, THE RUBBER LINERS IN THE
ABSORBER MODULE WERE REPAIRED AND MODIFICATIONS WFRF MADE AT THE INLET TO THE ABSORBER, REDIRECTING
AIR FLOW TO MINIMIZE FURTHER FLY ASH ABRASION OF THE LINERS. THE PLANT REPORTED AN OPERABIL1TY OF
1001 FOR THE FGD SYSTEM.
3RD QIJARTER-1<»78 AN AVAILABILITY OF 100% WAS REPORTED FOR THE SCRUBBER SYSTEM DURING THIS PERIOD.
-------
STATUS TO OCTOBER 1978
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS DM INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE F60 UNITS
NUMBER OF BORERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
MTNN-OAK FARMER'S COOPERATIVE
i*AHPETON, NOWTH DAKOTA
LIGNITE (l.OX SULFUR)
160,000 SCFM (TOTAL - 2 BOILERS)
80 MW (EQUIVALENT); TOTAL - ^ BOILEPS
TWO BOILERS, EACH o) £75,000 LRS/HR STEAM (250 PSIG - 455 l
KOCH ENGINEERING
AMMONIA SCRUBBING
RETROFIT
JUNE, 1977
OPERATIONAL
TESTS 1NCONCLUSTVE.
200 GPM AMMONIACAL WASTE STREAM
WASTEWATER TREATMENT
BLEED STREAM GOES TO AN ACTIVATED SLUDGE SYSTEM 3 160 GPM
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
MINN-DAK FARMER'S COOP. HAS A SUGAR FACTORY AT WAHPETDN, NORTH DAKOTA. THERE ARE TWO BOILERS,
E»CH WITH A CAPACITY OF 875,000 LBS STEAM/HR AT 250 PSIG AND
-------
STATUS TO OCTOBER 1978
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGf> SVSTFMS ON INDUSTRIAL BOILEHS
MINN-DAK FARMER'S COOPERATIVE : WAHPETON, NORTH DAKOTA (CONTINUED)
PROCESS IN EARLY 1978.
EACH YEAR, THE PLANT ONLY (JPERATLS FROM SEPTEMBER - FEBUARY. THIS IS THE BFET SUGAR PRODUCTION
PERIOD. DURING THE REMAINDER OF THE YEAR, PRODUCTION DISTRIBUTION is THE MAIN PLANT ACTIVITY.
OPERATING HISTORY
3RD OUARTER-1978 THE FGD SYSTEM BEGAN OPERATIONS FOR THE 1978-1979 SEASON ON SEPTEMBER 12. NO
FGD-RELATEO PROBLEMS OCCURRED. THE HASTE TREATMENT HAS BEEN MODIFIED TO INCLUDE AN ANAEROBIC
DIGESTER FOLLOWED BY AN OPEN POND AND AN AEROBIC DIGESTER.
90
-------
STATUS TO OCTOBER 1978
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGF> SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOa REMOVAL EFFICIENCY
SLUD6E OR BY-PRODUCT DISPOSAL
COHTROL SYSTEM COST
MOBIL OIL CORPORATION
SAN ARDO, CALIFORNIA
OIL (2.OX - 2.25Z SULFUR)
182,000 SCFM (TOTAL - 30 BOILERS)
8000 ACFM a 470F, FOR EACH OF 22 FGO SYSTEMS
18,000 ACFM S 4TOF, FOR EACH OF 8 FGD SYSTEMS
30
40
91 Mh (EQUIVALENT)? 810 MM BTU/HR: TOTAL - 30 BOILERS
MOBIL OIL COMPANY
SODIUM HYDROXIDE SCRUBBING
RETROFIT
1971
OPERATIONAL
90X (1500 PPM 9 INLET)
HOLDING POND FOR EVAPORATION
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE MOBIL OIL COMPANY HAS AN OIL SITE IN SAN ARDO, CALIFORNIA WHERE 28 STEAM GENERATORS ARE
USED TO FORCE OIL OUT OF HELLS BY A DEEP WELL STEAM INJECTION PROCESS. THE FUEL USED IS CRUDE OIL
WITH 2 - 2.SX SULFUR. EACH STEAM GENERATOR IS FOLLOWED BY AN INDIVIDUAL FGD SYSTEM INSTALLED
SPECIFICALLY FOR 302 CONTROL. THE UNITS EXPERIENCED STARTUP IN THE PERIOD FROM 1972 THROUGH 1970.
THERE ARE TWO SIZES OF STEAM GENERATORS* 22MM BTU/HR (20 UNITS) AND 50MM BTU/HR (8 UNITS).
THE SMALL UNITS GENERATE 0,000 SCFM, AND THE LARGE UNITS 18,000 SCFM. THE GASES ARE
SCRUBBED BY A LIQUOR CONSISTING OF NAOH AND ALKALINE OIL FIELD WASTEWATER (NA2C03). THE PROCESS IS
ONCE-THROUGH AND 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. THERE IS NO RECYCLE FROM THE DISPOSAL ZONE. THE LIDUOR FLOW RATES TO THE TWO SIZES
OF THE SCRUBBERS ARE 75 GPM AND 200 6PM. THE SCRUBBER SIZES ARE 1 FT DIAMETER X 20 FT HIGH, AND
6.5 FT DIAMETER X 25 FT HIGH. EACH SCRUBBER HAS THREE V-GRATE TYPE TRAYS. THE I.D. FANS ON EACH
SCRUBBER EXPERIENCE 3 - a IN. W.G. PRESSURE DROP. THE 802 REMOVAL EFFICIENCY OF THE PROCESS IS 90
PERCENT WITH INLET CONCENTRATION OF 1500 PPM. CHFVRON-TYPE MIST ELIMINATORS ARE USED.
THE SCRUBBERS ARE 316L SS AND THE TRAYS 316 S3. THE INLET DUCTWORK IS CS UP TO THE ECONOMIZER
AND THEN 316L S3. THE OOWNSTRF.AM DUCT IS HEAVY FIBEKGLAS3 AND THE I.D. FANS ARE CS WITH 316L SS
LINING ON THE CASING. THE STACK IS FIBFRGLASS. THE FLUE GASES ARE NOT REHEATED AND CANNOT BE BY-
PASSED. THE MIST ELIMINATORS, ORIGINALLY 316 SS, HAVE PEEN LINED WITH PHENOLIC EPOXY RESIN TO COM-
91
-------
HT»TU> III OCTUBFH 19/e
Sf-CMON 'J f LO.JT i 'HIF,i)
PERFORMANCE OtSC" IpT Tljr; F,iR OHFWA1 J ONAI. F(,0 SYSTEMS 'Vj INDUSTRIAl ROIL^S
MOBIL OIL CORPORATION; PAN ARDO. CALjFuHNIA ( C('N ! JNIlF f))
BAT CORROSiniM. 1NADEQUAIE MIST RFMDVAL HAS ALSO RtSuMFI) IH CORK(nSH)\ ft THE l.i,. FAN IMPELLFR,
BLADES, AND HUBS, WHICH MFF.O RtPLACFMFNT FVFRV YEAR. THE HIGH CHLORIDE CONTEIVT IN THt WASTEWATER IS
THE PRIMARY CMJSE OF PITTTNG OF SS MATERIAL.
OPERATING HISTUM
3RD QUARTFK-197« FOR THIS PERIOD THERE *AS NO MAJOR DOWNTIME REPORTED AS A RFSULT OF EQUIPMENT
OR PROCESS FAILURE. RELIABTLITY WAS ESTIMATED AT AROUT 90%. A BECKMAN PH CONTROL UNIT WAS
INSTALLED ON A SCRUBBING UNIT CONTROLLING EMISSIONS FROM FIVE STEAM GENERATORS.
-------
STATUS TO OCTOBER 1978
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATIN6
NUMBER OF SEPARATE F6D UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
MEN / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
HATER MAKE-UP
SLU06E OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
NEKOOSA PAPERS, INC.
ASHDOHN, ARKANSAS
COAL UX - 1.5X SULFUR)
ZH,000 SCFM (TOTAL - I BOILER)
1
1
105 MH (EQUIVALENT)! DESIGN - 500*000 LB/HR STEAM
AIRPOL INDUSTRIES
CAUSTIC SCRUBBING
NEW
FEBRUARY, 1976
OPERATIONAL
90»X 1600 PPM 3 INLET)
98X - 99* (1.42 GR/SCF AT INLET)
OPEN LOOP
ALKALINE SULFITE7BI3ULFITE RECYCLED TO PULP PROCESS
302 RECOVERED FROM SODIUM SULFITE/SULFATE LIQUOR AND RE-
CYCLED TO PULPIN6 PROCESS.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE NEKOOSA-EDWARDS PAPER PULP MILL IN ASHOOWN, ARKANSAS HAS TWO AIRPOL SCRUBBERS ON A 105-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-EDWAROS WAS TO MAKE, FROM THE SCRUBBER
EFFLUENT, SALTCAKE WHICH WOULD BE USED AT THE MILL. THE COAL HAS 1 - 1.5Z 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 600 PPM WITH A PASTICULATE LOADING OF 1.42 GR/SCFM. RECIRCULATED WATER IS BLED
OFF AT 150 - 250 GPM. REAGENT MAKE-UP AMOUNTS TO 12 LB/MIN OF SODIUM HYDROXIDE. SCRUBBER UNDERFLOW
CONSISTS OF FLYASH AND A SOLUTION OF SODIUM SULFITE/SULFATE. THE ASH SLURRY GOES TO A SETTLING
POND.
THE PREDOMINANT DIFFICULTIES WITH THE FGD SYSTEM HAVE BEEN TWO-FOLD. FIRST, THE PLANT HAS BEEN
UNABLE TO DEVELOP AN ADEQUATE PH CONTROL MECHANISM. THE PH CONTROL SYSTEM MONITORS THE AMOUNT OF
C»USTIC 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 THF PLANT WAS TO SEPARATE
93
-------
STATUS TO OCTOBER 1978
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTFMS ON INDUSTRIAL BOILERS
NFKOOSA PAPFRS, INC.; ASHOOWN, ARKANSAS (CONTINUED)
THE Fir ASH FROM THE SCRUBBED LIUHID Amp TAKE THE SCRUBBER LIQUID THROUGH A SERIES OF EVAPORATORS
WHERE SODIUM SULFATE, I.e., SALTCAKE, WOULD 8F GENERATED. THE PLANT HAS BEEN UNABLE TO OPERATE THE
FLY ASH SEPARATION SYSTEM PROPERLY, AND THERE IS NOT ENOUGH EVAPORATION CAPACITY FQR THE PLANT TO
PROCESS THE SCRUBBER EFFLUENT AT FULL OPERATIONAL CAPACITY.
IN SPITE OF THE OPERATIONAL PROBLEMS, THE SULFUR DIOXIDE AND PARTICULATE REMOVAL EFFICIENCIES
UF THE FGO SYSTEM ARE 90 AND 99 PERCENT, RESPECTIVELY, ACCORDING TO THE PLANT ENGINEER. THE WASTE
PRODUCT FROM THE SCRUBBER IS NOT RECYCLED, AT PRESENT, AND IS PUMPED TO THE WASTEWATER TREATMENT
PLANT. CLEANED WASTEWATER IS RETURNED TO THE RIVER.
UPON STARTUP, PROBLEMS OCCURRED 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.
SOME PIPING LEAKS OCCURRED AND WERE REWELDEO. SOME CORROSION OF OUCT 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-
ULATES ARE CONTROLLED WITH CYCLONES AND TWO VARIABLE THROAT VENTURI SCRUBBERS WITH AN AVERAGE PRES-
SURE DKOP OF 1« - 16 IN. W.G.
OPERATING HISTORY
JRD QUARTER-1977 NO MAJOR PROBLEMS WERE REPORTED. CORROSION PROBLEMS STILL EXIST AND PH CONTROL
IS STILL A PROBLEM. FLOW METERS ARE BEING INSTALLED TO MONITOR SCRUBBER WATER.
4TH QUARTER-1977 TWO FLOW METERS WERE INSTALLED ON EACH SCRUBBER, ONE AT THE THROAT INLET
OF THE VENTURI AND ONE AT THE THROAT. THE PLANT REPORTED THAT PH CONTROL WAS STILL A PROBLEM.
SOME PROBLEMS WERE BEING ENCOUNTERED WITH THE PH PROBES DUE TO THE CONSTANT FLOW OF LARGE
AMOUNTS OF SOLIDS, AND SOLIDS DEPOSITS ON THE PROBES.
2ND Q:.IARTFR-1978 NO MAJOR PROBLEMS OCCURRED DURING THE REPORT PERIOD. IN JUNE A PARTICULATE
COMPLIANCE TEST WAS RUN. PARTICULATE EMISSIONS WERE 0.05 LB/MM BTU AGAINST THE U.I LB/MM BTU
REGULATION. CAUSTIC SCRUBBING SOLUTION IS CYCLED TO THE SCRUBBER FROM THE PULP BLEACH PLANT
AT «OI> SPv. THE ROILER OPERATED ?153 HOURS AT ao* TO 60X CAPACITY. DURING THAT PERIOD THE SCRUBBER
DEMONSTRATED 1OOX OPERA8ILITY.
3RD UHARTER-197B DURING THIS REPORT PERIOD THt ONLY PROBLEM THAT WAS REPORTED WAS A RECYCLE
PUMP FAILURE CAUSING ONE SCRUH6ER TO BE DOWN FOR APPROXIMATELY 1.5 DAYS. HOWEVER, DUE TO THE
PAKALLcL ARRANGEMENT OF 7H£ SCxUrtBIfoG TRAINS AND LOW OPERATING LEVEL OF THE BOILER UO - bOX)r THE
TOTAL FLUE GAS FLOW WAS KfluTEn THROUGH THE REMAINING SC&USHFR TRAIN. THE BOILER WAS REPORTED
TH npF>VATF ?U HOURS PFk DAY DllKlMG THIS PERIOD.
-------
STATUS TO OCTOBER 1973
SFCTION 9 (LOiMT [MljKm
PERFORMANCE DESCRIPTION FUR OPFK«TIUNAI FGO SYSIEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOUPCF RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BFING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
AIR FURCF BASE
COLUMBUS, OHIO
COAL (5,bTi SULFUR)
SS,000 SCFM (TOTAL - 7 flOTLFMS)
277,000 LH/HR STl-AM
1
7
?7 M* (FQUIVAlENT1
RFSEARCH-COTTRELL/aAHCO
LIMESTONE SCRUBBING
RETROFIT
MARCH, 1976
OPERA riONAL
90X+ (DESIGN)
ACTUAL REMOVAI IS N0«v LOWER DUE TO EASING OF REGULATIONS.
SSZ
OPEN LOOP - 2.5 GPM/MW (MAX)
NON-FIXATFO SLURRY TO LINED POND
UNSTARILTZED CASUVSO4 SLUDGE TO LINED POND
SEE SECTION 15 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
ON MARCH 11, 1976 THE FIRST U.S. INSTALLATION OF THE SWEDISH RAHCO SULFUR DIOXIDE REMOVAL SYSTEM
WAS PLACED IN SERVICE AT RICKENBACKEfc ATR FORCE BASF IN COLUMBUS, OHIO. THF SYSTEM, MANUFACTURED
BY A.B. BAHCO VENTILATION OF FMKOPING, SwFUFN, DISTRIBUTED EXCLUSIVELY TN THE UNITED STATES dY
RESEARCH/COTTRELL, 'IAS ORIGINALLY INSTALLED AT R 1 CKFNRACKFR TO HANDLE THF_ FLUE GAS FROM SEVFN
31 MM BTU/HR STOKER-TYPE COAL FIRED BOILERS INSTALLED BETWEEN 1<»54 AND IS'ib. IN JUNE 1977, A NEW
60 MM BTu/hR HOILFR CAMF INTO sEwviCb. THIS UNTI RFPLArtn ? OF THE OLDER BOILERS, AND A THIRD WAS
PLATED ON STAND-HY. THE BUTLERS «LL FIRE & HK,H SULFUH (?.e%) COAL.
THE KICKENBACKFR EMISSION CONTROL bYSTEM CONSISTS hSSFMIAU.Y UF A MECHANICAL COLLECTOR, 2-STAGE
BACHO SCRUBBER TOWtR, LIME'S TUNF. STORAGE ANi) HAwOLTNG SYSTEM, CLARTFTKR, BOOSTFK FAN AND ASSOCIATED
DUCT-WORK, PUMPS, CONTROLS, AND A oLUObF OlSPObAL POND.
SDLIU HARTICulATt AMD SULFiiR 01 0 X 11) F -I A D E N FLUF bA:> TAKEN FRU" FACh UF THF EXISTING SIX
STACKS IS FFD TMWOUGH A COMVOM HhfluFk AMU JMlD « MtChAMCAi. unLLECTOK WHERE PRIMARY PARTICULATE
KFMiivAL IAKES PLATE. IH£ MFLHANICAI COIIFLTOH ^AS A DESIGN KFMOVAL EFFICIENCY OF 70 PtRCFNT AND
«AS INSTALLED PRIMARILY TO REilUTI (-An '.-.FAR. T^F PAWlTilLY TLFANtO GAS THF-\i rLOI«S INTO THF BACHO
TDWFR AHERt ADL)T I Tii"AI PARfTCULATF Ar^n |-WTi.-Ah» SilLU't.' Olt'TDh hi'F-iOVAL TAKES PIAT.t.
-------
SFAIUs TO OCTOBER 1978
PERFORMANCE DESCRIPTION f\l>> OPfKAl TONAI Fb'l SYSTEMS Ou 1 NOUS T « T A I. H
KICKENBACKER AIR FORCE *ASE: ClILUMBUS, OHIO ( CO,M 1 T ivUt H )
THE BACHO SCRUBBING VESSEL I S A VERTICAL TOAfcR CONSISTING uF T«n SCRUBBING STAGES. GAS FLUHS
THROUGH 1HE TOrtFR ^HERE IT TS CONTACTED MTH A LIMESTOlMF SLURRY. AFTER PASSING THHOUGM THfc
FIRST SCRUBBING STAGt, F.NTRAJNEO MUlSTURt IS REMOVED BY A CYCLONIC TYPfc MIST FL T M IN A TOR . THE
GAS THEN PASSES THROUGH A SECOND SCRUBBING STAGF AND A SECOND CYCLONIC MISI ELIMINATOR. THE
CLEANED GAS is DISCHARGED TO TMF ATMOSPHERE THROUGH A STUB STACK ATOP THE ABSORBER TowtR.
FINE MESH LIMFSTONE IS EMPLOYED AS ThF REAGFMT TN 1 HE SCHUBHING SYSTEM. THE SCRUBBING SLURRY IS
PUMPED TO THE ABSURBFR *HERE IT is CONTACTED ATTH THE FLUE GAS IM A COUNTERCIIHRENT FASHION.
THE SPENT SCRUBBING SOLUTION IS DISCHARGED TO THE THICKENER rtHERE THE WASTE SOLIDS SETTLE OUT.
THICKENER OVERFLOW IS RETURNED TO THE MIX/HOLD TANK. THICKENER UNDERFLOW IS DISCHARGED TO A 5-
ACRE HYPALON-LINEO DISPOSAL POND. THIS POND TS LOCATED APPROXIMATELY 400 FFET FROM THE ABSORBER
TOWER. CLEAR WATER FROM THE POND IS RETURNED TO THE PROCESS AS MAKE-UP WATER IN THF. SLURRY TANK.
REFER TO FIGURE 11-13 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
MAR. 76 THROUGH OCT. 76 THE INITIAL OPERATION PROCEEDED IN AN
OPEN-WATER-LOOP MODE BECAUSE THE THICKENER WAS NOT YET COMPLETELY INSTALLED. SULFUR DIOXIDE IN-
LET CONCENTRATIONS WERE IN THE 1800 TO 2000 PPM RANr,£. HIGH OXYGEN CONCENTRATIONS ALSO EXISTED IN
THE FLUE GAS BECAUSE THESE OLDER. IMEFFICIENT BOILERS OPERATE AT IbO TO 160 PERCENT EXCESS AIR
RATES. SULFUR DIOXIDE REMOVAL EFFICIENCY WAS IN THE LOW 90 PERCENT PLUS RANGE. EARLY
PROBLEMS WERE PRIMARILY OF A MECHANICAL NATURE USUALLY ASSOCIATED WTTH START-IJP. THE MAJOR START-
UP PROBLEMS WERE AS FOLLOWS:
1. ELECTRICAL CIRCUITS AND SYSTEM CONTROL PANEL.
Z. PUMP MALFUNCTION-SPARE PARTS SHIPMENT DELAY.
?. SEDIMENTATION BUILDUP IN THE SCRUBBER VESSEL (THIS WAS DUE PRIMARILY TO OPERATION AT
HIGHER THAN DESIGN SOLIDS CONCENTRATION IN THF SCRUBBING SOLUTION BECAUSE THE THICKENER
WAS NOT YET IN SERVICE PLUS GRIT GETTING THROUGH THE LIME SLAKER GRIT REMOVAL STEP).
4. FAMILIARIZATION OF THE OPERATING STAFF WITH THE MECHANICS OF THF PROCESS.
5. I.D. BOOSTER FAN PROBLEMS. ADDITIONAL BRACING, AND EPOKY GROUTING WAS REQUIRED TO STOP
THE ELEVATED FAN CONCRfcTh SUPPORT FRQf^ VIBRATING WHILE THE FAN WAS OPERATING.
NOV. 76 THROUGH JUN. 77 DOWNTIME WAS LFSS THAN 5%. OPERATING PROBLEMS WFRF MECHANICAL- AND
CONTROL- RATHER THAN PROCESS-RELATED. FAN-RELATED PROBLEMS ACCOUNTED FOR OVER 75* OF THE ACTUAL
DOrtN-TIME. THIS RESULTED FROM FxCESSTVF FAN VIBRATIONS CAUSED Rf HEARING, SUPPORT, AND INSTRUMENT-
ATION DIFFICULTIES. IN APRTL 1977, THE FAN WHfcEL OFVFLOPFI) A CRACK IN THE RI« ATTRIBUTED TO
FATIGUE FROM RESONANT VIBRATION. THE FAN i\AS SENT HACK [0 THF MAMUF AC HIRER , AMERICAN STANDARD, WHO
MADE THE REUUTRED MODIFICATIONS. THE ORIGINAL FAN WAS RACIAL. BLADE *TTH RIMS, AND A MAJOR MODIFJ-
9f>
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STATUS TO OCTOBER 1978
SECTION) 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGP SYSTEMS ON INDUSTRIAL BOILERS
RICKENBACKER AIR FORCE BASE; COLUMbUSr OHIO (CONTINUED)
CATION WAS CHOPPING THE RIMS OFF, THEREBY REDUCING THF H1AMFTFR. THE FAM WAS RETURNED IN EARLY MAY
AND THE VIBRATION PROBLEM rtAS SOLVEO. OTHER OPERATIONS WFWE RELATIVELY PROBLF.M-FREE. THFRF WERE
NO CORROSION, EROSION, SCALING, OR PLUGGING PROBLEMS. THE SYSTEM BEGAN KUNMING ON LIMESTONE IN
APRIL, AS PART OF THE EPA TEST PROGRAM. LIMESTONE PERFORMED WELL, YIELDING ADEQUATE REMUVAL.
ON JUNE 3RD, THE STEAM PLANT WAS SHUTDOWN FOR THE TIE-IN DF THE NEW NO. 8 BOILER. TIF IN WAS COM-
PLETED IN JUNE.
AUG. 77 THE ARMS BROKE OFF IN THE 25-FOOT DIAMETER THICKENER TANK, CAUSING A 30 DAY DOWNTIME.
SEP. 77 A MAKE-UP WATER BOOSTER PUMP HAD TO BE REPLACED.
OCT. 77 THE MOTOR DRIVE ON THE 5LAKER BELT HAD TO 8F REPAIRED. ALTHOUGH THE SLAKER IS NO LONGER
USED WITH THE LIMESTONE REAGENT, THE BELT IS USED TO CONVEY THE LIMESTONE TO THE DISSOLVING TANK.
1ST QUARTER-1978 IT WAS DISCOVERED THAT WITH A STOICHIOMFTRIC RATIO OF 0.75 THE REQUIRED DEGREE
OF S02 REMOVAL CAN BE ACHIEVED. THE CURRENT REGULATION LIMITS EMISSIONS TO 2.2 LBS/MM BTU HEAT
INPUT. DURING THE JANUARY BLIZZARD, SOME FREEZE-UP PROBLEMS WERE ENCOUNTERED.
DURING JANUARY THE BOILERS OPERATED 74U HOURS AND THE FGD SYSTEM OPERATFO 596 HOURS YIELDING OPER-
ABILITY AND AVAILABILITY INDEX VALUES OF 80X. ALL DOWNTIME WAS ATTRIBUTABLE TO FREEZE-LIPS DURING
BLIZZARD CONDITIONS. DURING FEBRUARY, THE BOTLEhiS OPERATED 672 HOURS AND THE CONTROL SYSTEM OPERA-
TED 168 HOURS. HOWEVER THE FGO SYSTEM WAS AVAILABLE 551 HOURS. THEREFORE THE OPERABILIIY INDEX WAS
25Z WHILE THE AVAILABILITY WAS 82%. THE ABSORBER LINES WERE THAWED OUT FEBRUARY (,, BUT DURING
FEBRUARY, THE GOVERNOR OF OHIO TEMPORARILY SHELVED POLLUTION CONTROL REGULATIONS. THEREFORE THF.
FGO SYSTEM WAS NOT OPERATED ALTHOUGH IT WAS AVAILABLE FOR OPERATION. THE SYSTEM WAS SHUTDOWN ON
FEBRUARY 13 AMD DID NOT OPERATE DURING MARCH.
2ND UUARTER-197B SYSTEM WAS RESTARTED APRIL 10 AND WAS REPORTED TO HAVE HUN WITH A 100% OPFRA-
BILITY INDEX VALUE FOR THE REMAINING PERIOD. PLANT REPORTED THAT ALL PREVIOUS PROBLEMS HAVE
BEEN CORRECTED. DURING THE LAST PORTION OF THE 2ND QUARTER THE BOILER LOAD DROPPED TO ITS SUMMER
LEVEL, ABOUT 30 MM BTU/HR, AS OPPOSED TO THE MAXIMUM COLD SEASON LOAD OF 150 MM HTU/HR.
JRO 8UARTER-197fl THE SYSTEM OPERATED WITH AN AVAILABILITY INDEX OF OVER 99.5% FUR THE
PERIOD. THE SCRUBBER WAS CLEANED AND INSPECTED DURING A 5-DAY BOILER MAINTENANCE OUTAGE AND
FOUND TO BE RELATIVELY FREE OF CORROSION AND SCALING. THE SYSTEM WAS OBTAINING ABOUT 75X S02
REMOVAL, WHICH WAS SUFFICIENT TO MEET THE REGULATION. WHILE THE BOILER IS OPERATING AT ITS REDUCED
SUMMER LOAD, FRESH MAKE-UP AIR IS BEING MIXED WITH THF FLUE GAS ENTERING THF F.n. FAN TO MAINTAIN
FULL GAS PRESSURE AND VELOCITY THROUGH THE ABSORBER.
97
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STATUS TO OCTOBER 1978
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPEKATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
SHELLER CLOSE CORP.
NOKFOLK, VIRGINIA
COAL (< l.OX SULFUR)
8,000 SCFM (TOTAL - 1 BOILER)
1
1
<1 MW (EQUIVALENT) ; TOTAL - 1 BOILFK
W.W. SLY MANUFACTURING CO.
SODIUM HYDROXIDE SCRUBBING
RETROFIT
1975
OPERATIONAL
NOT DETERMINED
NOT DETERMINED
OVERFLOW TO SEWER/SLUDGE TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
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
135 PSI AT 325 F. THE BOILER WAS ORIGINALLY ERECTED IN 1939, 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: Hnv=i3,aoo BTU/LB, Asn=6x, AND SULFUR is LESS THAN ix.
THE EMISSIONS CONTROL SYSTEM AT SHELLER GLOBE CONSISTS OF A W.W. SLY SINGLE-STAGE IMPINJET
SCRUBBER (W170) WHICH REMOVES PARTICULATE AND S02 FROM THE FLUE GAS. THE SYSTEM USES A NAOH MAKE-UP
PRIMARILY FOR CORROSION CONTROL BUT S02 CONTROL IS AN ADDITIONAL BENEFIT. RECYCLE TANK SUPERNATANT
IS PH NEUTRALIZED AND IS DISCHARGED TO CITY SEWERS WHILE FLY ASH AND SEDIMENT ARE SETTLED, SCRAPED
OUT AND HAULED TO A SANITAWY LANDFILL.
THE SCRUBBER MODULE IS CONSTRUCTED OF STAINLESS STEEL (19,200 CFM DESIGN MAX.). THE RECYCLE
TANK IS CONSTRUCTED OF UNLINED STEEL (20 FT X 10 FT X 6 FT) AND THE PIPING IS OF PVC.
UPOM INITIAL STARTUP NO CAUSTIC WAS INTRODUCED TU THE SYSTEM AND WITHIN A FEW MONTHS THE INTER-
NALS flF THE MODULF AND THF STFEL PIPING SYSTEM WERE CORRODED BEYOND USE. THIS NECESSITATED REPLACE-
MENT OF THE INTERNALS, SUBSTITUTION OF SIFEL PIPE «ITH PVC, AND ADDITION OF NAOH TO THE SCRUBBING
LIQUOR.
CHEMICALS n»t PURCHASED FROM THF CHEMICAL TREATMENT co. WHO ALSO OPERATE THE SCRUBBING SYSTEM.
98
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STATUS TO OCTOBER 1978
ri
-------
PERFORMANCE DESCRIPTION
STA1IIS IP OCTOBER 1978
ION <> f cnpuT JNtlFOl
ipF K A T 1 uNAl FGH SYSTEMS HIM 1MHJSTWTAI HU1LFHS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLER
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
WATER MAKF-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
ST. KElilS HAPFR Cll.
CAfMTUNMEMT, H.URIDA
HAKK,01L/RAS (< I.OX SULFUH)
I 15,000 SCFM (1 BOIl tH)
1
1
57 MW (EQUIVALENT); DESIGN - 300,000 LB/HR STEAM
AIRPOL INDUSTRIES
CAUSTIC SCRUBBING
RETROFIT
1973
OPERATIONAL
SOX - 90X
94.5Z (100 LB/MR AT INLET)
OPEN LOOP; 200 GPM-250 GPM SCRUBBING LIQUOR FEED
wASTEWATER TREATMENT
EFFLUENT IS TREATED IN AN ON-SITE SEWAGE TREATMENT PLANT
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE SCRUBBER SYSTEM AT ST. RERIS PAPER LOCATED AT CANTONMENT, FLORIDA WAS MANUFACTURED BY
AIRPOL. THE UNIT IS CONSTRUCTED OF JlfaL STAINLESS STEEL AND HANDLES A TOTAL FLUE GAS VOLUME OF
175,000 ACFM. PARTICULATES ARE CONTROLLED WITH CYCLONES PHECEEOING THE SCRUBBER. SCRUBBER PRESSURE
DROP IS APPROXIMATELY 10 IN. W.G. WITH 80-90% SULFUR DIOXIDE REMOVAL EFFICIENCY. THE SCRUBBER IS
FOLLOWED BY A CHEVRON-TYPE MIST ELIMINATOR.
THE BOILER IS RATED AT 57 MW EQUIVALENT AND PRODUCES 300,000 L8S/HR STEAM. THE TYPICAL SULFUR
CONTENT OF THE FUEL (OIL OR 6AKK, NATURAL GAS) TS LESS THAN U. THE HEATING VALUES OF THE FUELS ARE
AS FOLLOWS; BARK Z> 50* MOISTURE IS «030 BTu/LR, THE OIL IS 6,000,000 RTII/RARRFL AND THE GAS IS
1000 BTII PER FT?.
SCRUBBER UNDERFLOW CONSISTS OF ASH AND A SODIUM SULFITE/SULFATE SOLUTION. BLOWDOWN FROM THE
SCRUBBER OCCURS EVERY FEW MTNUTES. TO M/iTi\,TAlM THE HFC TWfULATION TANK AT A CONSTANT VOLUME, A SOL-
ENOID IS USED hHICH «HTOM»T!CALl 1 OPENS A VALVE AND INTRODUCES MAKE-UP WATER WHFN THE LEVEL OF THE
LIQUOR DROPS TU A CFHTATN POjNT. THE FAMK HAS A CAPACITY OF flOOu-5000 GALLONS AND IS MADE OF 30)N A^n AER AT ION/ST AR | L I Z AT J ON FOR HEOUCFU BOO.
•-4ARGFO TO ^N JN-SIT£ SF.VAQF TprATMF|T pLa|vT .hFwfr n ^FCFIVES PRTMAIVY CLARIFICATION ANP AERATION
i^ i HJi l7*T I.IN K)H HFDMCTinN ,,F -* 1 (lL()i-i f A L i • x Y (^ fl n)- ^ A ML, ( rtni)) .
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STATUS TO OCTOBER 1978
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL ROTLERS
ST. REGIS PAPER CO.; CANTONMENT, FLORIDA (CONTINUED)
REFER TO FIGURE 11-14 IN SECTION 14 FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD QUARTFR-1977 WOOD FIBERS FROM BARK WERE CLOGGING SEPARATORS AND CONTROL VALVES. INSPECTION
WAS MADE AND SOLUTION TO PROBLEM WAS BEING INVESTIGATED.
4TH QIIARTFR-1977 AFTER INVESTIGATION OF THE CLOGGING PROBLEM IT WAS DECIDED TO CHANGE THE MAKE-UP
HATER SOURCE. WATER IS NOW OBTAINED FROM A CLE&NER PORTION OF THE PROCESS LOOP. PLANT REPORTS
SATISFACTORY OPERATIONS WITH NO OTHER MAJOR PROBLEMS.
HMD QUARTER-1978 PLUGGING DUE TO FIBERS IN THE SCRUBBER FEEDWATER REMAINED TO BE AN UNSOLVED
PROBLEM DURING THE REPORT PERIOD. PLANT HAD NOT YET CHANGED THE SCRUBBER LIQUOR FEED SOURCE. IN
THE JANUARY THROUGH MAY PERIOD, THE BOILER OPERATED 3473 HOURS. SCRUBBER RELIABILITY INDEX WAS NEAR
loox. THE PLANT INDICATED THAT THIS REPORT HAD BEEN REPORTING TOO HIGH A SULFUR CONTENT IN THE
FUEL (2-3 X), AS COMPARED TO THE CORRECT VALUE OF LESS THAN IX.
3RD QUARTER-197R THE SCRUBBER LIQUOR FEED SOURCE HAS NOT BEEN CHANGED, HENCE, PLUGGING STILL
REMAINS AN UNSOLVED PROBLEM. HOWEVER, THE PLANT REPORTED GOOD OPERATION FOR THIS QUARTER. FROM
JANUARY THROUGH JULY, THE BOILER BURNED BARK FOR 4323 HOURS AND GAS AND OIL FOR 665 HOURS. THE
TOTAL TIME THE BOILER WAS IN OPERATION WAS 4888 HOURS. THE SCRUBBER EXHIBTED 1001 AVAILABILITY.
101
-------
STATUS TO OCTOBER 1978
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FUR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
SLUOGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
TEXACO INCORPORATED
SAN ARDO, CALIFORNIA
OIL (1.7X SULFUR)
366,000 SCFM (TOTAL - 2
-------
STATUS TO OCTOBER 1978
SFCTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FUR OPERATIONAL FGD SYSTEMS ON INDUSTRIAL BOILERS
TEXACO INCORPORATED! SAN ARDO, CALIFORNIA (CUNT I NlJfcP)
SOFTENING, THE OTHER IS DISPOSED OF IN WASlF-WATfcR DISPOSAL WELLS.
THE ABSORBER MODULES, DOWNSTREAM DUCTWORK, STACK AND THF I.n. FAN ARE MADE OF FRP, WHFREAS THE
PACKING IS POLYPROPYLENE. THE OUFwCHEK SECTION IS 3 1 f> S3, WHEREAS THE SPENT LIQUOR PIPING, CAUSTIC
TANKS, AND THE CAUSTIC FEED LINFS ARE MILT. STFtL.
REFER TO FIGURE 14-15 IN SECTION 14 FOR A OFTAlLtO PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPFRATTNG HISTORY
THE MAJOR OPERATIONAL PROBLEM AREAS ARE:
1. THE QUENCHER SECTION HAS SUFFFREO SEVERF CORROSION OUF TO ACID ATTACK.
2, FRP LINER DETERIORATES Out TO MECHANICAL ABRASION DURING CLEANING OPERATIONS. IT NEEDS
OCCASIONAL RESURFACING.
3. THE PACKED BEDS ARE FREQUENTLY PLUGGED BY FLYASH. THE OIL IN THE NATURAL LIQUOR HAS CAUSED
FOULING OF THE PACKED BEDS.
«. OCCASIONAL OVERINJECTION OF CAUSTIC HAS RESULTED IN PLUGGING OF SPRAY NOZZLES BY SCALES.
1ST QUARTER=1978 DUE TO THE LOW SO? REMOVAL AND HIGH MAINTENANCE COST OF THE ABOVE DESIGN, TEXACO
HAS UNDERTAKEN A TEST PROGRAM WHICH, IF SUCCtSFUL, WILL PHASE OUT THE PRESENT SCRUBBERS BY THE END
OF 1979. FOR MORE INFORMATION ON THE PROGRAM SEE THE OTHER TEXACO, SAN ARDO BACKGROUND INFORMATION
ENTRY IN SECTION 10 OF THIS REPORT.
2ND QUARTFR-1978 THE AVAILABILITY OF EACH FGO SYSTEM WAS APPROXIMATELY 94X. ON AN AVERAGE, ONE
SYSTEM WAS SHUTDOWN TWO DAYS A MONTH FOR MAINTENANCE.
3RD QUARTER-1978 THERE WAS NO MAJOR DOWNTIME DUE TO EQUIPMENT OR PROCESS FAILURE. THE SCRUBBERS
HERE DOWN FOR SCHEDULED MAINTENANCE FOR ABOUT 8 HOURS PER MONTH REQUIRING ABOUT 24-MAN-HOURS PER
UNIT. GENERALLY DURING THIS REGULAR MAINTENANCE PERIOD THE PACKING IS REPLACED AND THE INTERNALS
INSPECTED AND CLEANED. TEXACO TS CONSIDERING CONVERTING FROM NAOH TO NA2C03 AS THE REAGENT. NO
TIMETABLE HAS BEEN ESTABLISHED FOR SUCH A TRANSITION.
-------
31AIIJS TO OCTUBfR 1978
SECTION 9 (LONTINUFD)
PtRFORMANCF. OtSCRJPTTON FO* riPFKAIIONAl FbO SySTFhS rim INUUbTKTAl BOILFhiS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCF CHAHACTbRISTTCS
SOURCF RATING
NUMBER OF SFPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOa KF.MOVAL EFFICIENCY
PARTICIPATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
TFXASGULF
OIL (1.1* SULFUR)
110,000 SCFM (TOTAL -
600,000 LB/HW STEAM (TOTAL)
70 Mh (EQUIVALENT); TOTAL - 2 BOIIERS
SWEMCO INC.
SODIUM CARBONATE SCRUBBING
NFW
SEPTEMBER, 1976
OPERATIONAL
90X (680 PPM S INLET)
99. 3X (HOT-SIDE ESP W/PRECEDING MECHANICAL COLLECTOR)
WASTEWATER TREATMENT
SEE SECTION H FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
TFXASGULF INC. HAS BEEN OPERATING A NEW SODA ASH PLANT (1 MM TONS/YR) AT GRANGERf wVOMINGr SINCE
SEPTEMBER 1976. TWO BOILERS GENERATE A TOTAL OF 600,000 LSS/HH SATURATED STEAM 9 300 FSIG.
UNIT EFFICIENCY IS 85T WHEN BURNING WYOMING SUB-BITUMINOUS COAL, WHICH HAS 13.97X MOISTURE, 6.«3X
ASH, AND 0.75X SULFUR ON AN AS-RECtIVF.0 BASIS. THE HEATING VALUfc OF THE COAL IS 10,424 BTU/LB ON AN
AS-RECEIVED BASIS. EACH BOILER BURNS APPROXIMATELY 55,000 LB/HR OF THE COAL.
AFTFR FLUE GASES LEAVE EACH BOILER, U5fe,lbO ACFH <,) 350 F) THRY PASS THROUGH A MECHANICAL
COLLECTOR, ESP, ECONOMIZER, AND rtF.T SCRUBBER. (THE ECONOMIZER IS LOCATED AFTER THE PRECIPITATER
BECAUSE THE ASH FROM WESTERN COAL IS COLLECTED MORE EFFICIENTLY WHEN THF GAS IS HOT). THE CYCLONE
AND ESP TOGETHER HAVE A PARTICIPATE REMOVAL EFFICIENCY OF 99.3Z. THE SCRUBBING SYSTEMS, WHICH
WERE INSTALLED DOWNSTREAM OF THF ECONOMIZER BY SWEMCO INC. ALONG WITH THE NEW PLANT IN SEPTEMBER
1976, CONSISTS OF A QUENCHER, A SIEVE TRAY ABSORBER (15 FT nIA X 30.5 FT HIGH) AND A BYPASS. FLUE
GAS IS SPRAY-COOLFD FROM 550 F TO 1?5 F AS IT ENTERS THF (JUFNCHFR AND IS DIRECTED INTO THE CIRCULA-
TING LIQUOR IN THE RESERVOIR. THF GAS BURBLES UP THROUGH THE LIQUOR, EMFHS THE ADJACENT ABSORBER
AND TRAVELS UP THROUGH TWO SIEVE TRAYS. SCRUBBING LIQUOR (7000 GPM TO THE ABSORBER, 300 GPM TO THE
QUENCHER) IS RECIRCULATEO FROM THE SCRUBBFR PUMP TANK WHICH KFCEJVES THF SCRUBBER EFFLUENT (10£3
&PM). A CONSTANT BLEFD-OFF (850 TO 487 LB/MJN) CONTAINING «X OF SOOIUM SALTS IS PURGED TO A HOLDING
POND FOR EVAPERATION. A CHEVRON-TYPE MIST ELIMI.MAIOW (M-F) IS USFO. 1H£ CLARIFIED MAKFUP WATER
(60 TO 93 GPM) IS USED FOR M-F HASHING (IS GP") AND QUENCHER SPRAY (45 TO 66 GPM). MAKEUP SODA
loa
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STATUS TO OCTOflER 1976
SECTION 9 (CONTINUED)
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTFMS ON INDUSTRIAL BUTLERS
TEXASGULF: GRANGER, WYOMING (CONTINUED)
ASH 30X BY WEIGHT, IS FEO FROM A LIQUOR HEAD TANK TO TMF SCSURBFK PUMP TANK AT A MINIMUM MATE OF
56 LB/MIN AND MAX. RATE OF 119 LB/MIN.
EACH ABSORBER IS DIVIDED VERTICALLY INTO TyMO SECTIONS, ONE OF WHICH HAS A DAMPER AT THE TOP.
THIS PERMITS CURTAILMENT np GAS FLOW THROUGH HALF OF THE UNITS AT LOW LOADS. THE ABSORBER,
THEREFORE, CAN OPERATE AT THE DESIGN EFFICIENCY WHEN THE ROILER PRODUCES FROM £5X TO iOOi OF ITS
RATED OUTPUT. THE ABSORBER BYPASS ALLOWS UP TU S5Z OF THE INCOMING HOT FLUE GAS TO BE DIVERTED.
TYPICALLY, TEXASGULF USES THE BYPASS TO KEEP THE FLUE GAS IN THE ST«CK 10 F WAHMER THAN THAT AT THE
SCRUBBER OUTLET. THE SCRUBBERS ARE. MAUF OF 316L SS, THE TRAYS ARE UDDEHOLM 904-L, THE PUMP TANKS
ARE FRP AND THE STACK (7.5 FT ID X 150 FT HIGH) IS DOUBLE-wALL, INSULATED STEEL TYPE WITH FLAKELINE
COATING BY CEILCOTE COMPANY.
REFER TO FIGURE 1«-16 IN SECTION Ifl FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
1ST OUARTER-1978 THE OUTLET DUCTWORK, WHICH WAS CORRODED DUE TO ACID CONDENSATE, WAS TO BE
REPLACED. THE SYSTEM OPERATED WITHOUT ANY MAJOR PROBLEMS.
2ND OUARTER-1978 OURTNG A MAJOR ELECTRICAL TURNAROUND, THE SCRUBBER MODULES WERE CLEANED AND
REPAIRED, SLUDGE FROM THE TRAYS WAS REMOVED AND THE OUTLET DUCTWORK WAS REPLACED BY 304 SS. THE
503 MEASURING INSTRUMENTS WERE BEING UPGRADED BY LEAR STEGLFR, THE SUPPLIER.
3RD QUARTER-1978 DURING THE REPORT PERIOD, THE BOILER AND FGD SYSTEM WERE DOWN TWICE FOR
SCHEDULED INSPECTION OUTAGES. DOWNTIME WAS H DAYS FOR ONE MODULE AND 3 DAYS FOR THE OTHER. SOME
MINOR PLUGGING WAS OBSERVED DURING THE INSPECTION PERIODS.
105
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STATUS TO OCTOBER 1978
SECTION 10
OFSTGN INFORMATION FOR UNDER CONSTRUCTION FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
CONTROL SYSTEM COST
BELRIOGE OIL CO.
MCKITTMCK, CALIFORNIA
CRUDE OIL C1.1X SULFUR)
1?,000 SCFM
2«,000 ACFM «l 570 F
1
2
5 MW (EQUIVALENT), *iO HTU/HR
C-E NATCU
SODIUM HYDROXIDE SCRUBBING
RETROFIT
NOVEMBER, 197fl
CONSTRUCTION
90X (500 PPM S02 S INLET)
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
10f>
-------
STATUS TO OCTOBER 1978
SFCTION 10 (CONTINUED)
DFSTGN INFORMATION FOR UNDER CONSTRUCTION FRO SYSTtMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CATFRPJ! LAN TRACTOR CO.
MAPL.ETON, ILLINOIS
COAL (3.2% SULFUR)
157,000 SCFM (TOTAL •• 3 BOILERS)
80,000 ACFM ai 350 f, FUR FACH OF 3 FGO SYSTEMS
3
3
79 Mto (EQUIVALENT!? TOTAL - 5 BOILERS
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
NEW
OCTOBER, 1978
CONSTRUCTION
90X (?OOG PPM 3 INLET)
DEwATERFD SLURRY TO LANOFILL
60+X SOLIDS (CASOO) SLUDGF DIRECTLY TO LANDFILL
SEfc SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AT THE MAPLETQN, ILLINOIS PLANT, CATERPILLAR TRACTOR IS INSTALLING TWO NEW BOILER PLANTS WHICH
"ILL BE COMPLETED BY THE EARLY 1980'S. PLANS CALL FOR THE ERECTION OF EIGHT BOILFRS, EACH RATED
AT ABOUT 200,000 L8S/HR STEAM, THE TOTAL STEAM GENERATING CAPACITY WILL BE 1,650,000 LBS/HR STEAM.
THREE OF THESE BOILERS WILL BE COMPLETED BY THE 1978-79 HFAT SEASON. 1WO MORE WILL COME ON-LINE
DURING THE 1979-1980 HEAT SEASON. THE START-UP DATES FOR THE UTHER THREE HAVF. NOT YET BEEN DETER-
MINED. CATERPILLAR HAS AWARDED A CONTRACT TO FMC ENVIRONMENTAL EQUIPMENT TO PROVIDE CONCENTRATED-
MODE DUAL ALKALI FGD SYSTEMS FOR ALL EIGHT BOILERS.
THERE ARE TWO CATERPILLAR FACILITIES Al MAPLETijN, LOCATED NEXT TO EACH OTHER. THERF WILL BE
FOUR ROILF.RS AT EACH FACILITY. EACH BOILER WILL HAVL A SFPARATE FGD SYSIFM. THE a FMC SYSTEMS AT
ESCH FACILITY WILL SHARE REGENERATION FACILITIES, VACUUM FII.IEK, AND SLUDGE DISPOSAL. EACH FGD
'RAIN WILL BE TREATING APPROXIMATELY «o,ooo ACFM a 3^0 F.
QtlARTEK-1977
OPFRATTNG HISTORY
SYSTEM WAS UNPtR CONSTRUCTION. START-UP WAS FXPECTKD LATF IN THE FALL OF 1977.
1TH QUARTFR-1977 CONS T RUC T TUN ntLAYa UN THE STFAM RE NLRA 1 1 ON SIDE PUSHED PLANT START-UP BACK TO
'He FALL OF 197H.
t"0 OUARTFR-197fl START-UP WAS STILL
INDIVIDUAl FMC FGO SYSTEMS WILL
FOB ThF 197H-1979 HkATTNG SEASON. THRFE BOILERS AND
On-l I MF AI THAT TIMt.
107
-------
STATUS rn OCTOBER 1978
SFCTIHN in (LflNTIMlFDl
DFSIGN INFORMATION FOP UNDER CONSTRUCTION FPf) oVSTt^S ON T (\iOUS TP I *L B011.E.RS
CA^ERPILL^R TRACTOR CO.: MAPLETON, ULINUTS CCOM1 T fjlILD )
JRD OIIARTFR-197S CuNS TRIIC T ] (IN WAS NFAPING COMPLFTtUN. SPECIAL M(jn IF 1C A T I Pf^S WEWE 8FIN6 MADE
WHICH WERE DELAYING START-UP. FXPERIFIMCF GAINtn AT MOSSVTLLt IS UtlfoG APPLIED TO MAPLtTON SINCE THE
SYSTEMS ARE SIMILAR.
1 os
-------
STATUS TO OCTOBER
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCTION FGD SYSTEMS ON INDUSTRIAL riOlLERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
503 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CATERPILLAR TRACTOR CO.
MAPLETON, ILLINOIS
COAL (3.2X SULFUR)
afea.ooo SCFM (TOTAL - 5 BOILERS)
80,000 ACFM d 350 F, FOR EACH OF 5 FGD SYSTEMS.
5
5
131 MW (EQUIVALENT); TOTAL - 5 BOILFRS.
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
NEW
OCTOBER, 1979
I SYSTEMS WILL START UP IN 1979-1979 HEATING SEASON
3 SYSTEMS AS OF YET HAVE NO FIRM START-UP SCHEDULE.
CONSTRUCTION
90X (2000 PPM a INLET)
DEWATERED SLURRY TO LANDFILL
60 + X SOLIDS (CASOO) SLUDGE DIRECTLY TO LANDFILL.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
AT THE MAPLETON, ILLINOIS PLANT, CATERPILLAR TRACTOR IS INSTALLING TWO NEW BOILER PLANTS WHICH
HILL BE COMPLETED BY THE EARLY 1980'S. PLANS CALL FUR THE ERECTION OF EIGHT BOILERS, EACH RATED
»T ABOUT 200.000LB/HR STEAM. THE TOTAL STEAM GENERATING CAPACITY WILL BE 1,650,000 LB/HR STEAM.
THREE OF THESE BOILERS WILL BE COMPLETED BY THfc 1978-79 HEAT SEASON. TWO MORE WILL COME ON-LINE
DURING THE 1979-80 HEAT SEASON. THE START-DP DATES FOR THE OTHER THREE HAVE NOT YET BEEN DETER-
MINED. CATERPILLAR HAS AWARDED A CONTRACT TO FMC ENVIRONMENTAL EQUIPMENT TO PROVIDE CONCENTRATED-
MODE DUAL ALKALI FGO SYSTEMS FOR ALL EIGHT BOILERS.
THERE ARE TWO CATERPILLAR FACILITIES AT MAPLETON, LOCATED NEXT TO EACH OTHER. THERE WILL BE
FOUR BOILERS AT EACH FACILITY. EACH 80ILFR WILL HAVE A SEPARATE FGD SYSTEM. THE « FMC SYSTEMS AT
"CH FACILITY WILL SHARE REGENERATION FACILITIES, VACUUM FILTFR, AND SLUDGE DISPOSAL. EACH FGD
TRAIN WILL BE TREATING APPROXIMATELY 80,000 ACFM 3350 F.
109
-------
STATUS TO OCTOBER 1978
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCTION FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLER
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
CHANSLOR WESTERN OIL *• OEV. CO
BAKERSFIELD. CALIFORNIA
OIL (1.5X SULFUR)
70,000 SCFM (TOTAL - 8 BOILERS)
310 MM BTU/HR (TOTAL - 8 BOILERS)
133,aOO ACFM 3 550 F (TOTAL - 8 BOILERS)
1
8
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
NEW
DECEMBER, 1978
CONSTRUCTION
9fel (710 PPM a INLET)
71 GPM
DEWATEHED SLURRY TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
OPERATING HISTORY
CHANSLOR-WESTERN HAS AWARDED THE CONTRACT TO FMC FOR THE DUAL ALKALI FGD SYSTEM, WHICH WILL GO
ON STREAM IN DECEMBER, 1978. THE ABSORPTION TOWER WILL CONTAIN H DTSC-AND-DONUT TRAYS, AND A
CHEVRON DEMISTER.
110
-------
STATUS TO OCTOBER 197B
Dfj 10 (CONTINUED)
DESIGN INFORMATION FUR UNDER CONSTRUCTION FGO SYSTEMS ON INDUSTRIAL BORERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP HATE
CONTROL SYSTEM STATUS
803 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GFTTY OIL COMPANY
BAKERSFTtLD, r At I FORNT A
OIL (1.1% SULFUR)
993,7SO SCFM fIOTAL-72 BOILERS)
9 EGU SYSTEMS, EACH TREATING 2uO,000 ACFM a, 500 F
q
7?
3600 MM BTU/HR, 495-MW EQUIVALENT (TOTAL-72 BOILERS)
EACH BOILER RATED AT U2,000 LBS/HR STFAM
PROPRIETARY OFSIGN
SODIUM CARBDNATF SCRUBBING
RETROFIT
DECEMBER, 197S
CONSTRUCTION
96% (70 PPM S02 3 OUTLET)
WASTEWATER TREATMENT ANO DISCHARGE TO TAILINGS POND
SEE SECTION 1^ FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
GETTY OIL, BAKERSFIELD, CALIFORNIA IS PRESENTLY CONSTRUCTING 9 NEW FGD SCRUBBERS SUPPLIED BY
KOCH ENGINEERING. EIGHT BOILERS MANUFACTURED BY STRUTHERS * C.E. NATCO WILL BE HEADERED INTO EACH
SCRUBBER. EACH BOILER IS HATED AT 42,000 LBS/HR STEAM.
EACH SCRUBBER (33* HEIGHT X 18' DIAMETER) WILL EMPLOY 3 KOCH BUBBLE CAP TRAYS AND CLEANSE
200,000 ACFM 9 500 F INLET TEMPERATURE WITH A DESIRED EFFICIENCY OF 962. THE INLET S02 CONCEN-
TRATION WILL BE APPROXIMATELY 600 PPM. DESIRED CONTROL PH WILL BF WITHIN THE RANGE OF 6.5 - 6.fl
NITH SCRUBBER LIUIJOR BEING RECIRCULATED AT 1000 GPM 10 THF TOP TRAY. THE DESIGN L/G RATIO IS
9 GPM/1000 SCFM. EACH AHSURBER MODULE AND STACK WILL BE CONSTRUCTED OF 316L S3. THE DEMISTERS WILL
BE KOCH FLEXIMESH DFMISTfcRS. THE F.O. FANS WILL BE 500 HP RADIAL TIP AMERICA^ STANDARDS OR
CHAMPION F.D. FANS.
THF WASTE SLUDGE WILL roNTiwiiousLY BF RLFL> UFF AT AN APPROXIMATE RATE HE 10 GPM TO A DISPOSAL
T*NK. THE SLUDGE WILL BE HAUIEO TO AM OPFIM PONO iw INJFCTED INTO A DEEP WELL.
OPERATING HISTORY
3"D QUAPTFR-197S UF THE 9 Fr,f> SYSTEMS IINHEP CONSTRUCTION, ONE rtAS STARTEH UP UN SEPT. 18, 1978
•NO ANOTHER IS SCHEDULED FOR START-UP THE FIRST rtFEK T^ UC10BKR.
)R START-UP BY MIu FEbRUAKY.
THE LAST UF THE SYSTEMS IS
1 1 1
-------
STMUS rn
Sl i T 1 ;>I'J I 0 f [.():,! !'"'.iri> )
DFSIGN INFORMA r fUN FIIH ht\Ot-W r ,i". s 1 h 11C T I 'i u F^U SYSUMS 0" ?MHIS1H1AL bOILt.RS
INSTALLAMUN MA^t
INSTALLATION I.UCATIOIM
SnUKCF CHAHACTtRlSTTCS
SOURCE RATING
NUMBER flF SFPARATr FGD UNITS
NUMBER OF BHILt'RS BE1NU CONIHOLLED
CONTROL SYSTEM VBNOOH
CONTROL PROCESS
NEw / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
308 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COS1
G^Al rt F. S T t W N bllUAH
F&t K^ONT , UH in
COAL fix SULFUR)
00,000 SCFlv. (TijrAI_ - ? BOILEkS)
laOiUOo LR/HK STfeAM (TOTAL - ?. ROILERS)
2
URfcAl
SODIUM CARBONATF
RETROFIT
OTTOBFR, 1978
CONSTRUCT ION
WASTtWATER TREATMENT ANO OISCHARGE TO CITY SEWER
SEE SECTION IT FOR RETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE FGO SYSTEM CURRENTLY UNDER CONSTRUCTION AT THE FREEMONT, OHIO PLANT OF GREAT WESTERN SUGAR
HAS BEEN DESIGNED FOR BOTH SO? AND PARTICULATE CONTROL. THF SYSTFM CONSISTS OF A VARIABLE THROAT
VENTURI SCRUBBER WITH A SINGLE PASS, THREE STAUE CHEVRON DEM1STF.R.
A BLEEDOFF STREAM OF SCRUBBER EFFLUENT IS CONTINUOUSLY DISCHARGED TO A HOLDING POND FOR
TREATMENT.
I 1?
-------
STATUS TO OCTOBER 1978
SECTION! 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCT I Ol\i FRO SYSTEMS UN INDUSTRIAL BOILERS
!NSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNTTS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
MOBTL OTL COMPANY
BUTTONrtlLLOW, CALIFORNIA
OTL (1.1% SULFUR)
12,000 SCFM (TOTAL - 7 B 0 1 L F R S)
7 FGD SYSTEMS, EACH TREATING 11,400 ACFM S 550F.
7
7
£1 MW (EQUIVALENT); 17S MM BTil/HR (TOTAL - 7 BOILERS)
HEATER TECHNOLOGY
SODIUM CARBONATE SCRUBBING
RETROFIT
SEPTEMBER, 1978
CONSTRUCTION
85% (500 PPM a INLET)
15 GPM; OIL FIELD WASTE WATER
HOLDING POND FOR EVAPORATION
INTERMITTENT BLOwDOWN TO WASTF DISPOSAL SITE.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
MOBIL OIL HAS PURCHASED SEVEN HEATER TECHNOLOGY EDUCTOR SCRUBBER SYSTEMS FUR THE CONTROL OF S02.
113
-------
STATUS TO OCTOBER 1978
SECTION 10 (CONTINUED)
UFSTGN INFOWMATTON FUR UNDER CONSTRUCT I ON FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAMt
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCF RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BF1NG CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RFTROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
CONTROL SYSTEM COST
HHILLIP MORRIS, INC.
CHESTER, VA.
COAL U.7Z SULFUR)
39,000 SCFM (TOTAL - 1 BOILER)
1
7
£0 Mn (EQUIVALENT); 2?7 MM BTU/HR
FLAK1, INC.
SODIUM CARBONATE SCRUBBING
NEW
JANUARY, 1979
CONSTRUCTION
90* (DESIGN MINIMUM)
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
PHILLIP MORRIS INC. OPERATES A 237 MM BTU/HR COAL-FIRED BOILER AT THEIR TOBACCO PROCESSING PLANT
IN CHESTER, VIRGINIA. THE COAL. WHICH HAS APPROXIMATELY 1.7Z SULFUR, IS MINED IN VIRGINIA, WEST VIR-
GINIA AND KENTUCKY.
FLAKT INC. IS CURRENTLY RETROFITTING A COMPLETE POLLUTION CONTROL SYSTEM WHICH IS SCHEDULED TO
START-UP IN JANUARY 1979. THE BOILER FLUE GAS (8R.900 ACFM oi 350F) WILL FIRST PASS THROUGH A COLD-
SIDE ESP WITH A GUARANTEED MINIMUM EFFICIENCY OF 99.6%. THF. FGO SYSTEM WILL USE SODIUM CARBONATE
SCRUBBING LIQUOR AND IS DESIGNED TO TREAT TWO THIRDS OF THE UAS DISCHARGED FROM THE PRECIP ITATQR;
THE OTHER THIRD BEING USED FOR REHEAT. THE SCRUBBER IS DESIGNED FOR A MINIMUM 80S REMOVAL EFFI-
CIENCY OF 90X. AN OXIDATION TOWER WILL FOLLOW THF SCRUBBER TO OXIDTZE SODIUM SULFITE TO SOOIUM SUL-
FATE.
-------
STATUS TO OCTOBER 1973
SECTION 10 (CONTINUED)
DESIGN INFORMATION! FOR UNDER CONSTRUCTION FRD SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME ST. J0£ ZINC CO.
INSTALLATION LOCATION MONACA, PENNSYLVANIA
SOURCE CHARACTERISTICS C06L (8.5X - «.5fc SULFUR)
SOURCE SATING 100,OOlJ SCf-M (TOTAL - 1 BOILER)
NUMBER OF SEPARATE FGO UNITS i
NUMBER OF BOILERS BEING CONTROLLED 1
SOURCE CAPACITY 57 MK [NOMINAL PEAK CAPACITY)
CONTROL SYSTEM VENDOR BUREAU OF MINES
CONTROL PROCESS CITRATE PROCESS
NEW / RETROFIT RETROFIT
START-UP DATE DECEMBER, 1978
CONTROL SYSTEM STATUS CONSTRUCTION
S03 REMOVAL EFFICIENCY 90+X
SLUDGE OR BY-PRODUCT DISPOSAL REGENERABLE - ELEMENTAL SULFUR PRODUCT
CONTROl, SYSTEM COST SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
IN THE SUMMER OF 1977, CONSTRUCTION BEGAN AT MONACA, PA. ON A CITRATE PROCESS (BUREAU OF MINES)
F60 SYSTEM FOR ONE OF THE TWO 60-MW (NOMINAL PEAK CAPACITY) BOILERS OF THE GEORGE F. HEATON POWER
PLANT USED BY ST. JOE ZINC CO. TO GENERATE ELECTRICITY FOR A ZINC SMELTER. ST. JOE HAS A RECIPROCAL
AGREEMENT WITH THE LOCAL UTILITY COMPANY, OUOUESNE LIGHT, WHEREBY ST. JOE CAN SELL UP TO 25-MN OF
ITS TOTAL .120-MW CAPACITY TO DUOUESNE. IN RETURN ST. JOE CAN BUY SUFFICIENT POWER TO MAINTAIN
SMELTING OPERATIONS IN THE EVENT OF AN EMERGENCY. IT IS THE FIRST SMALL COMMERCIAL SIZE
EXPERIMENTAL CITRATE CONTROL SYSTEM BEING BUILT FOR SCRUBBING SULFUR DIOXIDE OUT OF COAL-FIRED
POWER PLANT STACK GAS.
UNDER 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
B¥ THE BUREAU IN THE 1960'S TO HELP CURB SULFUR DIOXIDE EMISSIONS FROM BASE METAL SMELTERS.
THE CITRATE PROCESS DERIVES ITS NAME FROM THE rtATER SOLUTION OF SODIUM CITRATE AND CITRIC ACID
USED TO ABSORB SO? CONTAINED IN THE FLUE GAS. ADDING HYDROGEN SULFIDE TO THE CITRATE-SOB SOLUTION
PRECIPITATES SOLID ELEMENTAL SULFUR.
REFER TO FIGURE 1«-13 IN SECTION 1« FOR A DETAILED PROCESS FLOW DIAGRAM OF THIS SYSTEM.
OPERATING HISTORY
3RD OUARTEK-1978 ALL MAJOR EQUIPMENT HAS BEEN INSTALLED; INSTALLATION OF PIPING AND WIRING IS IN
PROGRESS.
-------
STAIUS (0 OCTl/RfcR
S F C T T n 'Y ) 0 ( C i ' N T [ M.I F I .' )
DFS1GN INFORMATION FOP UNOFR CONS Tk 1 1C T 1 PI, FU> bY
DM TNDUS1MAL HOHKPS
INSTALLATION NAMf
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOUPCF RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BFING CONTROLI HD
SOURCF. CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
SLUDGE OH BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
TNCURP'lKA I FII
SAN ARUO, CALIFORNIA
OIL 11 .7% SULFUR)
117.000 S C F M frOHL - <5 BORERS)
,?fc,000 ACFK xl oOU F, FOR EACH OF 9 ROILFRS.
5« MW (EQUIVALENT); 50 MM B TU/HR/ROI LFR
OUCON COMPANY
SODIUM HYDROXIDE SCRUBBING
RETROFIT
MARCH, 1979
CONSTRUCTION
95X (1000 PPM a INLET)
SCRUBBER EFFLUENT DISPOSED OF IN WASTE WELLS
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
TEXACO SAN ARDO HAS CHOSEN TO PHASE OUT THE EXISTING CEILCOTE SCRUBBER SYSTEMS DUE TO LOW S02
REMOVAL AND HIGH MAINTENANCE COST. AS THE FIRST STEP OF THE PHASE-OUT PROGRAM, 9 OF THE PRESENT 33
CEILCOTE SCRUBBERS ON THE 50 MM BTU/HR STEAM GENERATORS VvILL BE kFPLACED BY 3 DUCON CO. SCRUBBERS
HEADERED IN PARALLEL. SIART-UP OF THE NEW EQUIPMENT IS SCHEDULED FOR MARCH 1979. THE NEXT STEP OF
THE PHASE-OUT PROGRAM IS DEPENDENT ON THE PERFORMANCE OF THE OUCON SYSTEM.
A MAJOR PROBLEM OF THE PRESENT DESIGN HAS BEEN SCRUBBER FOULING BECAUSE OF HIGH ASH CONTENT IN
IN THF FLUE GAS. EACH DUCON SCRUBBING UNIT HILL CONSIST OF A VENTljRl FOR PARTICULATE REMOVAL FOL-
LOWED BY A HORIZONTAL 3-STAGE SPRAY ABSORBER (2 IN USE, 1 STAND-BY). IT IS HOPFL) THAT THF VENTURI
DESIGN WILL ALLEVIATE THE FOULING PROBLEM.
ANOTHER DESIGN FEATURE OF THE DUCON SYSTEM ARE INDEPENDENT RECYCLE TANKS FOR VENTURI AND AB-
SORBER. FRESH SCRUBBING LIQUOR IS INTRODUCED AT THE ABSORBER, FNTF.RS THE ABSORBER RECYCLE TANK AND
PARTIALLY OVERFLOWS TO THF VtNTURT WHERE TT IS RECYCLED AND FINALLY DISPOSED OF IN ON-SITE WASTE
WELLS. IN A COMPLETE CYCLE THE SCRUBBER LIQUOR IS RECYCLED a TIMFS BFFORF DISPOSAL.
A VOLUME OF 7«,000 ACFM a> 600 F HILL PE HANDLED BY FACH SCKUBBfcR. FURTHERMORE, EACH TRAIN CAN
TREAT 50* OF THF LOAD AND CAN BF ISOLATED FROM THF FLUE GAb FLOW. TT IS HOPED THAT THIS SYSTEM DE-
SIGN WILL YIELD SIGNIFICANTLY HIGHER A V » 11. AB It. 1 T I FS THAN THF DESIKN CURRENTLY IN USE. (FOR INFORMA-
TION ON THE CFIL1TE L'FSTG^ SEF TEXACU, SAN ARDU hNTRY IN SECTION 9 OF THIS REPORT.)
THE UUCOlM ABSORBER MODULE IS CONSTRUCTED (IF FIBERC.LAbS WITH POLYPROPYLENE INTERNALS,. THE VEN-
TUHI IS MADE OF 625 IMLOiMFL. THE UVtfALL DIMENSIONS OF [HE SYSIF" AKF 11 F'T X ?0 FT X 3U FT. THE
-------
STATUS TO OCTOPtK 1976
SECTION 10 (CONTINUED)
DESIGN INFORMATION FOR UNDER CONSTRUCT I ON FED SYSTtMS ON INDUSTRIAL BOILERS
TEXACO INCORPORATED; SAN ARDO, CALIFORNIA (CONTINUED)
SPRAY NOZZLES WILL BE NYLON OR STAINLESS STEEL. BOTH THE ARSOKBEW AND VENTURI RECYCLF PUMPS ARE
*
MANUFACTURED BY GALLAGER. THEY ARE RUBBER-LINED AND SIZED 800 AND i£00 GPM KESPECTIVEL* AT 00 HP.
THERE ARE 2 GARDEN CITY FANS PER UNIT RATED AT 100 HP EACH.
DUCON HAS GUARANTEED
-------
STATUS TO OCTOBER 1978
SECTION 11
DFSIbN INFORMATION FOR PLANNED FGO SYSTEMS ON INDUSTRIAL BOILERS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOa REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SLUDGE OK BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
ARCO/PULYMtRS, INC.
MONACA, PENNSYLVANIA
COAL (3.05! SULFUR)
236,000 SCFM (TOTAL - 3 BOILERS)
900,000 LB/HR STEAM 3 700 PSIG AND 700 F.
3
3
11B MW (EQUIVALENT)? TOTAL - 3 BOILEWS
FMC ENVIRONMENTAL EQUIPMENT
DOUBLE ALKALI (CONCENTRATED)
RETROFIT
JUNE, 1980
PLANNED-CONTRACT AWARDED
90Z (1,800 PPM 3) INLET)
99.52
DEWATF.RED SLURRY TO LANDFILL
FLYASH ADDITION TO DEWATERED CAS03/CAS01 FILTER CAKE,
THEN TO LANDFILL.
CAPITAL: se,000,000 (1978). THIS TOTAL INSTALLED COST
INCLUDES EQUIPMENT, INSTALLATION, DUCTWORK, STACK, PIPING,
COST OF THE FGD SYSTEM, ENGINEERING, START-UP. AND TESTING.
INSTRUMENTATION, ENGINEERING, AND OVERHEADS.
OPERATING: PROJECTED COSTS AHE NOT YET AVAILABLE.
BACKGROUND INFORMATION
ARCO/POLYMERS, BEAVER VALLEY PLANT LOCATED NEAR MONACA, PENNSYLVANIA HAS AWARDED A CONTRACT
IN JUNE 1978 TO FMC TO INSTALL THREE MULTI-STAGE RISC CONTACTOR SCRUBBERS. THE SYSTEM
WILL UTILIZE THE FMC DOUBLE ALKALI PROCESS WITH THE SCRUBBERS SHARING A COMMON REGENERATION UNIT.
THREE BOILERS GENERATE PROCESS STEA" USED TO OPERATE A TURBINE WHICH GENERATES la TO ^0
KVA (CAPIC1TY 3"5 KVA). THE STEAM RATE FOR EACH BOILtR IS 300,000 LB/HH il 700 PSIG AND 70" F.
TOTAL HEAT INPUT IS 1100 MM BTU/HR. PULVERIZED COAL (3.OX SULFUR) IS THE FUEL USED WITH AN ASH
CONTENT OF 15t. IT HAS A HFAT VALUE OF 1?,000 B1U/LB a) 4-bX MOISTURE CONTENT. THE COST FUR THE
COAL IS $8.8il/TriN.
HOPPERS ESH'S HRECLEAN THF FLUE GAS BEFORE TF tMTERS THE SCRUBBEkS. THF INLET CONCENTRATION
OF PARTICULATE TO THE 6SP'S IS *> r,K/bCF. GAS tNTFKlNK THE SCRUHHEKS WILL HAVE AN SOS CONCENTRATION
UF APPROXIMATELY 1800 PPM. THE SCRUBBERS WILL BE CONSTRUCTED OF CARBON STEEL WITH CEILCOTE LININGS
1 IB
-------
STATUS TO OCTOPER 1978
SFCTiniV. 11 (CONTIMUFO)
DESIGN INFORMATION FOR PLANNED FGD SYS1FMS ON INDUSTRIAL BOILERS
ARCH/POLYMERS, INC.; MONACA, Pt NFJSY L \l AN T A (CONlINUtO)
(FLAKED GLASS LIMING) AND THE MIST ELIMINATES (1 FOR E«CH SCRURHFR) ARE SINGLE STARE CHEVRON PAD
TYPE CONSTRUCTED OF PVC PLASTIC WITH PROVISIONS FOR A SECOND STAGE. FACH STRUBHER WILL EXHAUST
TO INDIVIDUAL INSULATED STACKS LINED WITH KRP. ASSOCIATED riITH tACH STUCK IS A (*EHFAT£W USING
STEAM HEATED AMBIENT AIR. THF SCRUBBERS WILL HANDLE 100% OF THE FLUt GASFS WITH BY-PASS ONLY
AVAILABLE FOR EMERGENCIES. THE L/G RATIO FOH THE SCRUbRtkg IS APPROXIMA IfLY 10.
CALCIUM SULFATE (CASOU) «MAST£ WILL H£ HAULED RY TRUCK ID A DISPOSAL SITF.
OPERATING HISTORY
3RD Q1IARTER-1978 CONSTRUCTION IS TO BEGIN IN SFPTEMBFR 197fl.
-------
SIAT
T'l ICT'jhEK 197H
SF r | i n,\, ; I ( 1.11,4 ' ! f-inf 0)
OF.SfbN INFORMATION FIJW PLANNtD F iiP SYSIf.-iS ni,
INSTALLATION NAMt
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BFING CONTROLLED
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
FUEL NOT Stl.tCTFO
1,i?0(J,000 SCKW Cl
hOy N«( (Eni)IVALKNT) ; 1
1
t
VENDOR NOT SfcLtCFEU
PROCESS N01 SELECTED
OCTOBER, 19S3
PLANNED-CONSIDERING S03 CONTROL
NO! DETERMINED
DISPOSAL TECHNIQUE NOT KNOWN
BACKGROUND INFORMATION
UNION CARBIDE, AMOCO. AND MONSANTO HAVE ENTERED INTO A JOINT VENTURE (C.A.M.) TO ERECT
A COGENERATION FACILITY NEAR HOUSTON, TEXAS. THE bOO-MW CEQUI V ALENT) BOILER WILL PRODOCE ELEC-
TRICITY AND PROCESS STEAM FOR THE NEARBY PLANTS OF THE THREE COMPANIES.
THE TYPF OF FUEL TO BE USED IS NOT FINALIZED. HOWEVER, IT TS A SURETY THAT AN FGD SYSTEM WILL
BE REQUIRED. STARTUP FOR THE POWFR GENERATING FACILITY IS SCHEDULED FOR LATE 1983.
3RD QUARTER-1978 THE SYSTEM IS STILL IN THE VtRY EARLY STAGES OF DEVELOPMENT. STEARNS-ROGERS HAS
BEEN CONTRACTED TO 00 PRELIMINARY ENGINEERING AND AIU IN THF CHOICE OF AN FGO SYSTEM AND VENDOR.
AS OF THIS REPORT PERIOD, COAL TYPE HAS NOT BEEN CHOSEN AND A CONTHOL SYSTEM OR SYSTEM VENDOR HAS
NOT SEEN SELECTED.
-------
STATUS TO OCTOBER 5978
SECTION 11 (CONTINUED)
DESIGN INFORMATION FOR PLANNED FGO SYSTFMS ON INDUSTRIAL BOTLFRS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
Sna REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CARBORUNDUM ABHASIVFS
BUFFALO, MEW YORK
COAL (2.^5! SULFUR)
30,000 SCFM (TOTAL - 2 BOILERS)
160,000 LRS/HR STEAM (TOTAL - I BOILERS)
1
2
15 MM (EQUIVALENT)
CARBORUNDUM ENVIR. SYS. LTD.
LIME SCRUBBING
RETROFIT
PLANNED-CONTRACT AWARDED
95X
WASTEWATER TREATMENT
BACKGROUND INFORMATION
AT THE CARBORUNDUM ABRASIVES PLANT IN BUFFALO, NtW YORK THERE ARE a COAL-FIRED BOILERS BURNING
2.2X SULFUR COAL WITH AN AVERAGE HEAT VALUE OF 13,000 BTU/LB. TrtO OF THESE BORERS ARE IDENTICAL
»NO HAVE A TOTAL STEAM GENERATING CAPACITY OF 160,000 LB/HR.
THE FLUE GASES FROM THE TWO BOILERS WILL Bfc CONTROLLED RY A VFNTURI SCRUBBER (a FT INLET, 13 IN
THROAT, 13 FT HIGH) FOLLOWED BY A 6-STAGE SPRAY TOWER (8.5 FT UIA X 39 FT HIGH). THE FGD SYSTEM WAS
OfSIGNEO BY CARBORUNDUM ENVIRONMENTAL SYSTEMS LTD., AND WILL HANDLE 40,000 ACFM, OR 100X OF THE FLUE
G»S FROM BOTH BOILERS. LIME WILL BE USED AS THE SCRUBBING MEDIUM AND THE DESIGN S02 REMOVAL
EFFICIENCY IS 95Z. THE SPKAY TOWER IS DESIGNED TO OPERATE AT 125 F rtTTH AN L/G RATIO OF
80 KAL/1000 ACF. THE MAXIMUM LTUUID FLOW RATE IS 3000 GPM. MAKE-UP WATER WILL BE FED TO THE TOP
OF THF A8SOR8FR AT A RATE OF 45 GPM, WHILE A 30 GPM BLEED STREAM WILL FLOW FROM THE REC IRCULAT ION
"UK DIRECTLY TO AN EXISTING TERTIARY WASTE TREATMENT FACILITY.
ARTICULATE REMOVAL OPERATING HISTORY
THE VENTURI AND ABSORBER MODULE WERE INSTALLED IN 1975. THE VENTURI WAS PUT INTO SERVICE FOR
P«»TICULATE REMOVAL AT THAT TIMF USING WATER AS THE SCRUBBING MEDIUM. THF HIGH CHLORIDE CONTENT OF
™E FLUF GAS HAS CAUSED SEHIOUS CORROSION PROBLEMS. EFFLUENT FROM THF VENTURI HAS A PH OF 2.8.
!HE MbL SS VENTURI WILL BE REPLACED WITH A HASTEl LOY UNIT BEFORE START-UP FOM S02 REMOVAL THE
'"SOURER, ALSO 316L SS WILL BE LINED WITH HASTELLOY UR FRP. AN AC I n-RESISTANT COATING WAS RECENTLY
TO THE STACK LINER.
121
-------
STATUS TO OCTOBER 1978
SECTION II (CONTINUED)
DESIGN INFORMATION FOR PLANNED FGD SYSTFMS ON INDUSTRIAL POTLFRS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BFING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
502 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CHEVRON U.S.A. INC.
BAKERSFIELO, CALIFORNIA
OTL (l.JX SULFUR)
146,000 SCFM (TOTAL - 12 BOTLERS)
2 FGO SYSTEMS, EACH TREATING 150,000 ACFM a) 500F.
73 Mkv [EQUIVALENT); TOTAL - 12 BOILERS
600 MM BTU/HR (TOTAL - 12 BOILERS: 6 BOILERS/FGD SYSTEM)
KOCH ENGINEERING
SODIUM CARBONATE SCRUBBING
RETROFIT
APRIL, 1979
PLANNED-REQUEST ING/EVALUATING BIDS
90X (&80 PPM 3 INLET)
WASTEWATER TREATMENT
BACKGROUND INFORMATION
A CONTRACT WAS AWARDED TO KOCH ENGINEERING TO CONSTRUCT THE TWO FGD SYSTEMS. THE DESIGN WILL BE
SIMILAR TO EXISTING NA2C03 SCRUBBING UNITS. ENGINEERING AND PURCHASING BEGAN IN SEPTEMBER WITH
CONSTRUCTION SCHEDULED TO BEGIN IN JANUARY.
-------
STATUS TO OCTOBER 1978
bt-C T in:, 1 1 f rrr.'T IiMbKDl
INFORMATION F(i(> F'LAiViN'tn F ,;p SYSTFMS ON INDUSTRIAL PUTLFWS
INSTALL ATinr
INSTAI LATTON I
SOURCF CHAWACTERIST TCS
RATINt;
OIIPPM, IMC.
NUMHER OF SEPAWAIF FGH IIMTTS
NIIMRfcR OF BOILF&S bFING COWTROLLEn
SntlRCF CAPACITY
CONTROL SYSTEM VENDOK
CONTROL PROCESS
NErt / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
503 RFMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
tl.'j« SULF-IIR1
£«o,uf»o srt-M (TniAu - i BOILERS)
t.ifOu,000 L.R/HK STEAM (TUTAI - ^ TOILERS)
1
^
1«0 MW (tnilTVALEMT)
VENDOR NUT SEI tHTFD
f ALKALI
1987
Pl.ANNED-CnNSIDERING SO
90X
DfWATFRFD SLURRY TO LANDFILL
BACKGROUND INFORMATION
OUPONT INC. HAS 3 COAL-FIRED BOILERS, EACH RATED AT «00,000 LH/HH STEAM GENERATION. IT IS PLAN-
NED THAT THE FGD SYSTEM CONTROL ONLY TWO OF THE BOILERS AT ANY GIVEN TIME: ONE ROILEH WOULD ALWAYS
8E ON A STANDBY STATUS. FLUE GAS FLOW WOULD BE CONTROLLED RY DAMPERS LOCATED ON EACH BOILER.
-------
STATUS 10 HCTOBbR 1<*78
SF r: T i IIM 11 i r ni\,T i MJFO i
UFSIGM INFURMA T TON FIjP P |_ /! m 0; t n F(,ll SYSTEMS III, I IVil) I IS T h T A i.
INSTALLATION NAMfc
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPAKATF FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 KEMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
TF* Ab
l.OAL (O.'D/C SUl F Ilk)
3?0,00o SCf-M (TfTAL - i. BOILERS)
1 f b 0 0 > 0 0 U LP/HH STEAM (TOTAL - ? BOILERS)
1
?
lf>0 !"W CEDUIVALFNT) ; TOTAL - 2 BOILERS
VENDOR NOT SELECTED
LIMESTONE SCRUBBING
NEW
PLANNED-CONSIDERING S02 CONTROL
90X
DEWA1ERED SLURRY TO LANDFILL
-------
*TAri|S in OCTQPE'W 1S78
SFCTinN 1! (CONTINUED)
DFSTGN INFORMATION FOR PLANNED FGn SYSTEMS ON INDUSTHIAI RotLFfS
INSTALLATION NAME GRISbOM ATR FnWCE BASF
INSTALLATION LOCATION BUNKER HILL. INDIANA
SOURCE CHARACTERISTICS COAL (U.9% - a.ftZ SULFuRJ
SOURCE RATING 3?,000 SCFM (TOTAL - 3 BUTLERS)
NUMBER OF SEPARATE FGD UNITS 1
NUMBER OF BOILERS BEING CONTROLLED 3
SOURCE CAPACITY 16 Mw (FQUIVALENT); TOTAL - 3 BOILERS
CONTROL SYSTEM VENDOR VENDOR NOT SELECTED
CONTROL PROCESS DOUBLE ALKALI (CONCENTRATED)
NEW / RETROFIT ! NElft a RFTRQ
START-OP OATE SEPTEMBER, 1979
CONTROL SYSTEM STATUS PLANNED-REOUESTING/EVALUATING BIDS
S03 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL OEWATERED SLURRY TO LANDFILL
CONTROL SYSTEM COST CAPITAL: SI,800,000 - $2,000,000 (197fl). THIS IS THE
PROJECTED TOTAL INSTALLED COST.
BACKGROUND INFORMATION
AT GRISSOM AIR FORCE BASE NEAR BUNKFk HILL, INDIANA, THE AIR FURCE HAS INITIATED A PROJECT WHICH
INCLUDES THE ERECTION OF A NEW (.5,000 LB/Hfi COAL-FIRED BOILER AND AN FGD SYSTEM FOR THE NEW UNIT AND
TWO EXISTING 40,000 LB/HR COAL-FIRFD UNITS. 1 HE AMOUNT OF CAPITAL ALLOCATED FOM THE EMISSIONS
CONTROL SYSTEM IS IN THE $1.8 - S2.0 MILLION RANGE. THE NAVY IS THF MILITARY CONSTRUCTION AGENT
FOR THE PROJECT. ARNOLD M. DIAMOND HAS THE OVERALL CONSTRUCTION CONTRACT AND FOSDICK AND HILMER
(CINCINNATI) IS THE A-E FIRM FOR THF FGD PORTION OF THE PROJECT.
THE A-E FIRM HAS SPECIFIED A CONCENTRATED DOUBLE ALKALI SYSTEM FOR THE CONTROL APPROACH, AND
AIR POLLUTION INDUSTRIES, INC. CAIRPOL) HAS TENTATIVELY BEEN SELECTED AS THF VENDOR. FLUE
GAS FROM EACH BOILER WILL PASS THROUGH A MECHANICAL COLLECTOR. 1 HE GAS FROM ALL THREE BOILERS WILL
THEN BE MANIFOLDED TOGETHER AND PASS THROUGH TkiO PARALLEL ABSOKBER TRAINS, EACH TRAIN CAPABLE OF
HANDLING 50Z OF THE FLUE GAS. THF MAXIMUM FLOW RATE IS 80,373 ACFM a) <16i F.
THE BOILERS FIRE APPROXIMATELY «0% EXCESS AIR. COAL MAY RANGE FROM 0.9X -
-------
STATUS TO OCTOBER 1978
SFCTJON 11 (CONTINUED)
DFSIGN INFORMATION FOR PLANNED FGD SYSTEMS ON INDUSTRIAL BOILERS
GRISSHM AIR FORCE BASE; BUNKER HILL, INDIANA (CONTINUED)
PIPES WILL BE MADE OF FRP.
A ioo-?oo GPM BLEED STREAM FROM THE RECIRCULATIQN TANK GOES TO * 3ifa ss LIME REACTION TANK
WHERE THE SODIUM SULFI1E/SULFATE IS REACTED WITH SLAKED LIME PRODUCING CALCIUM SULFATF AND
REGENERATING THE SODIUM HYDROXIDE. FROM THE REACTION TANK THE MIXED SLURRY FLOWS TO A THICKENER/
CLARIFIFR, WHERE INSOLU9LF. CALCIUM COMPOUNDS ARE SEPARATED FROM THE CLEAR OVERFLOW CONTAINING THE
REGENERATED NAOH. THE CLARIFIER OVERFLOW IS RETURNED TO THE ABSORBER, WHILE THE UNDERFLOW IS
REACTED ONCE AGAIN WITH LIME IN A PIPELINE MIXER TO PRECIPITATE ANY RESIDUAL SULFITE AS SULFATE.
THE SLURRY IS THEN FILTERED IN A ROTARY FILTER, AND THE FILTRATE IS RETURNED TO THE REACTION TANK.
THE FILTER CAKE WILL BE LANOFILLED. THE TANKS WILL BE MADE OF M6 SS AND THE PIPING OF FRP. THE
LIME STORAGE TANK AND SLAKER WILL HE CARBON STEEL.
-------
STATUS TO OCTOBER 1978
SECTION II (CONTINUED)
DESIGN INFORMATION FOR PLANNED FGP SYSTFMS HIM INDUSTRIAL BOILFKS
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGPi UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NF« / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
SHtLL OIL COMPANY
6AKEKSFIELOF CALIFORNIA
OIL (1.1% SULFUP)
99,000 SCFM (TOTAL - B BOTLFRS)
1
a
«00 MM BTU/HR (50 MM 9TIJ PER BOILFH5
VFNDUR NUT SELECTED
PROCESS NOT SELFCTfcO
PLANNEU-CONSIHERING SOg CONTROL
94% (575 PPM S02 S INLET)
DISPOSAL TECHNIQUE NOT KNOWN
-------
STATll.s TO nCTQRtH 197R
SfLT ION II I (. "NT l".uri»
UESTC.N INFORMATION FuW PLA(\.NH> F i- ' SYSIFrtS (IN T i-JI)l IS T H T Al Ml
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTkOLLtn
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOa REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
I (Hi COMPANY
1AFT, CALIFORNIA
UTL I 1 . 1 X SULFUR)
ti^.OOO SCF-M (TIJTAI.
n
- f ROILEHS)
100 MM BTU/Hk (TOTAL )
VENDOR NOT SELECTED
PROCESS NOT SELECTED
NEW
PLANMED-CONSIDER1NG S0£ CONTROL
9«Z (575 PPM SO? 9 INLET)
DISPOSAL TECHNIQUE NOT KNOWN
-------
STATUS TO OCTOBER
SECTION i?
DESCRIPTION OF INDUSTRIAL RGILEH FGD SYSTEMS NOT OPERATING
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
h
CONTROL SYSTEM COST
BUNGE, IMC.
CAIRO, ILLINOIS
COAL C3X SULFUR)
44,000 SCFM (TOTAL - 2 ROTLERSJ
61 ,400 ACFM a) 520 F
1
2
22 MW (EQUIVALENT); TOTAL - 2 BOILERS
180,000 LBS/HR STEAM (TOTAL)
DRAVO CORP./NAT'L LIME ASS'N
LIME SCRUBBING
RETROFIT
SEPTEMBER, 1977
INDEFINITELY SHUT DOWN
94X (2700 PPM INLET)
DEWATERED SLURRY TO LANDFILL
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
BUNGE PURCHASED THIS LIME SCRUBBING SYSTEM FOR TESTING PURPOSES. THE LErtIS SCRUBBER, WHICH IS
A HORIZONTAL ROTARY VESSEL WITH INTERNAL CHAINS, PERFORMED VERY WELL DURING THE TEST (94 PERCENT 802
REMOVAL). PRESENTLY, BUNGE IS USING LOW SULFUR COAL (." PERCENT) AND HAS NO PLANS TO RESTART
FGO OPERATIONS.
129
-------
STATUS TO OCTOBER 1978
SECTION 1? (CONTINUED)
DESCRIPTION OF INOUSTHIAL BOILFK FGO SYSTEMS NOT OPERATING
INSTALLATION NAME
INSTALLATION LOCATION
SOUPCF CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE EGO UNITS
NUMBER OF BOILERS BFING CONTROLLED
CONTKOL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
302 REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
GREAT WFSTtRN SUGAR
LONGMONT, COLORADO
COAL (0.7X SULFUR)
SCFM-N/A
2
2
GREAT WESTERN SUGAR
AMMONIA-LAOEN PROCESS WATER
RETROFIT
OCTOBER, 1973
TERMINATED
35X (300-400 PPM 3> INLET)
WASTEWATER TREATMENT AND DISCHARGE TO RIVER
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
130
-------
STATUS TO OCTOBER 1978
SECTION 1? (CONTINUED)
DESCRIPTION OF INDUSTRIAL HOILER FGO SYSTEMS NOT OPERATING
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGO UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
HARRIS MINING co.
SPRUCE PINE, NORTH CAROLINA
COAL (U.8X SULFUR)
a. 000 SCFM (TOTAL - 2 BOILERS)
£ MW (EQUIVALENT) ; TOTAL - 2 BOILERS
w.w. SLY MANUFACTURING co.
WATER SCRUBBING (NA.NH3 OPTN.)
RETROFIT
1973
INDEFINITELY SHUT DOWN
96*
DISPOSAL TECHNIQUE NOT KNOWN
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
BACKGROUND INFORMATION
THE FGD SYSTEM AT THE HARRIS MINING COMPANY LOCATED AT SPRUCE PINE, NORTH CAROLINA REMOVES FLY-
ASH AND SULFUR DIOXIDE FROM THE FLUF GAS OF A COAL FIRED BOILER. THE SCRUBBER IS A n.W. SLY
IMPINGENT TYPE SCRUBBER CONSTRUCTED OF 30« STAINLESS STEEL. THE BOILER IS RATED 1.9 Mw
(EQUIVALENT 200 BOILER HORSEPOWER). COAL COMPOSITION IS TYPICALLY 0.8* SULFUR AND 5Z ASH. PRIMARY
INTEREST IN FLUF GAS SCRUBBING IS IN FLYASH REMOVAL ANU NO TESTS FOR SULFUR DIOXIDE REMOVAL EFFI-
CIENCY HAVE-BEEN MADE.
2ND QUARTER-1977
OPERATING HISTORY
NO OPERATIONAL PROBLEMS HAVE BEEN REPORTED.
1ST QIIARTER-197B THIS PLANT HAS BEEN MOVED TO THE INACTIVE SYSTEMS FILE UNTIL SUCH TIME AS ACTUAL
FGD OPERATIONS BEGIN. THE SCRUBBFR IS EQUIPPED MTH ALKALI ADDITION CAPABILITY, BUT WITH
THE LOW SULFUR COAL CURRENTLY BEING FIRED, MO ALKALI ADDITION UR PH CONTROL IS OCCURRING.
2ND UUARTFR-197R PLANT WFPOWTEO NO CHANGE.
3RD OUARTFR-iq/fl PLAN! HFPOrtTfO NO CHANGE.
1 31
-------
STATUS 10 OCTOBER 1976
N 1? (CONT
DESCRIPTION OF INDUSTRIAL ROILF*
SYSTEMS 1-01 OPtPATIMi
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGn UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
802 REMOVAL EFFICIENCY
PAKTICULATE REMOVAL EFFICIENCY
MATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
QUALITY MILLS, INC.
d T. AIRY, .NORTH CAROLINA
OIL
in,000 SCFM (TOTAL - 3 BOILERS)
0
5
5 MW (EQUIVALENT), Sd,000 LB/HR STEAM: TOTAL - 3 BOILERS
COMMtRCIAL FABRICATION * MACH.
WATER SCRUBBING
RETROFIT
MAY, 1970
TERMINATED
47X (600-800 PPM 3 INLET)
80X-95X (0.05-0.16 GRAIN/SCF 3 INLET)
«0 GPM« OPEN LOOP
hASTEWATER TREATMENT AND DISCHARGE TO CITY SEWER
SCRUBBING LIQUOR DISCHARGED TO NEUTRALIZATION POND
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
132
-------
STATUS TO OCTOBER 1978
SECTION 1? (CONTINUED)
DESCRIPTION OF INDUSTRIAL BOILER FGO SYSTEMS NOT OPERATING
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
SOURCE CAPACITY
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
S02 REMOVAL EFFICIENCY
HUTER MAKE-UP
SLUDGE OR BY-PROOUCT DISPOSAL
CONTROL SYSTEM COST
TRANSCO TEXTILES, INC.
AUGUSTA, GEORGIA
^UEL OIL (2X MAX. SULFUR)
50,000 ACFM
1
1
30 MH (EQUIVALENT)
FMC ENVIRONMENTAL EQUIPMENT
SODIUM CARBONATE SCRUBBING
NEW
MARCH, 1975
INDEFINITELY SHUT DOWN
80I-85Z (610 LB/HR 3 INLET)
48 GPM* OPEN LOOP
WASTEWATER TREATMENT AND DISCHARGE TO RIVER
NA2SU3/S01 LIOUOR DISCHARGED TO A HOLDING POND
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
1 13
-------
STATUS TO OCTOBER 1978
SECTION 12 (CONTINUED)
DESCRIPTION OF INDUSTRIAL BOILER FGD SYSTEMS NOT OPERATING
INSTALLATION NAME
INSTALLATION LOCATION
SOURCE CHARACTERISTICS
SOURCE RATING
NUMBER OF SEPARATE FGD UNITS
NUMBER OF BOILERS BEING CONTROLLED
CONTROL SYSTEM VENDOR
CONTROL PROCESS
NEW / RETROFIT
START-UP DATE
CONTROL SYSTEM STATUS
SOS REMOVAL EFFICIENCY
PARTICULATE REMOVAL EFFICIENCY
WATER MAKE-UP
SLUDGE OR BY-PRODUCT DISPOSAL
CONTROL SYSTEM COST
U.S. GYPSUM COUP.
OAKMONT, PENNSYLVANIA
COAL
19,300 SCFM (TOTAL - 4 BOILERSJ
1
4
AIRPOL INDUSTRIES
DOUBLE ALKALI (DILUTE)
NEW
NEVER STARTED-UP
SUFFICIENT TO MEET REGULATION
MEETS CODE
10 GPM (CLOSED LOOP)
DEWATERED SLURRY TO LANDFILL
SLUDGE TO POND FOR DRYING. THEN TO LANDFILL.
SEE SECTION 13 FOR DETAILED ECONOMIC INFORMATION
134
-------
COMPANY
LOCATION
CAPACITY (SCFM)
M.YESKA PIPELINE SERVICE CO.
VULDEZ, ALASKA
50(000
STATUS TO OCTOBER 1978
SFLTION I?
INDUSTRIAL ROTLFR FGD COSTS
PKOCFSS
STATUS
START-UP DATE
COST
CAPI T
OPERATING
SODIUM HYDROXIDE SCRUBBING
OPERATIONAL
b/77
PLANT PtRSONNtL HAVE NOT SEPARATED OUT FGD SYSTEM
COSTS FKOM OVERALL HROJLCT COSTS (MO« DO THEY KELP
OPERATING COSTS FOR THE FGO SYSTEM.
AMERICAN THREAD CO.
MARION. NORTH CAROLINA
18,500
CAUSTIC WASTE STREAM $138,000.
OPFHATIONAL
1973
THE CAPITAL COST REPRESfcNTS TOTAL INSTALLED COST
IN 1973 DOLLARS. THE OPERATING COST INCLUDES NEW
FIBERGLASS LININGS IN DUCTWORK AND ON FANS AND
OPERATING LABOR AND MATERIALS FOR 1977.
$16,300.
AHMCO STEEL
MIODLETOWN, OHIO
84,000
LIME SCRUBBING $7<»,000.
OPERATIONAL
1975
THIS is THE REPORTED CAPITAL COST IN 1975 DOLLARS.
BELRIOGE OIL co.
MCKITTRICK, CALIFORNIA
15,000
SODIUM HYDROXIDE SCRUBBING $135,000.
CONSTRUCTION
1 1/78
THIS IS THE REPORTED CAPITAL COST IN 197" DOLLARS.
BELRIDGE OIL CO.
MCKITTRICK, CALIFORNIA
12,000
SUOIUM HYDROXIDE SCHUBRING
OPFkAlTONAL
7/7H
$100,000,
THIS IS THE REPORTED CAPITAL COST IN 1978 DUILARS.
-------
STAIIJb Td nCTORtR 1976
SFCI ] n,\ i ^ (criivT i>unn
. fUiUFh i-r.i) cnsr^
COMPANY PwtUF.SS COST
LOCATION STAHJS ------------------------
CAPACITY (SCFM) START-UP DATF CAPITAL OPERATING
9ELRIOGE OIL COMPANY SODIUM hYUROXIHE SCkllBPING S10U,000.
MCKITTRICK, CALIFORMTA OPERATIOMAI
ia.000 b/78
THF CAPITAL COST INCLUOtS THF SCKURBFR, RECYCLF
TANK, ST4CK, OFMISTERr PIPIMG, DUCTWORK, AND
INSIRUMENTATION IN 197« DOLLARS.
8UNGF, INC. LIME SCRUBBING $1,000,000,
CAIRO, ILLINOIS INDEFINITELY SHUT DOWN
44,000 9/77
THE CAPITAL COST REPRESENTS THE TOTAL INSTALLED
COST OF THF FGD SYSTEM, ENGINEERING, START-UP, AND
TESTING IN 1977 DOLLARS.
CANTON TEXTILES CAUSTIC WASTE STREAM 874,000.
CANTON, GEORGIA OPERATIONAL
25,000 6/74
THE CAPITAL COST REPRESENTS THE TOTAL COST FOR THE
INSTALLED SYSTFM, IN 1974 DOLLARS.
CATERPILLAR TRACTOR CO. DOUBLE ALKALI (CONCENTRATED)
EAST PEORIA, ILLINOIS OPERATIONAL
210,000 4/78
NO ECONOMIC INFORMATION HAS BEEN SUPPLIED FOR THE
CATERPILLAR FGD SYSTEMS.
CATERPILLAR TRACTOR CO. DOUBLE ALKALI CDILUTF)
JOLIET, ILLINOIS OPERATIONAL
f>7,000 9/74
NO ECONOMIC INFORMATION HAS BEEN SUPPLIED FOR THE
CATERPILLAR FGD SYSTEMS.
-------
STATUS TO OCTOBER ma
SECTION 13 (CONTINUED)
INDUSTRIAL BOILFR FRO COSTS
COMPANY PROCESS rQST
LOCATION STATUS
CAPACITY (SCFM) START-UP DATE CAPITAL OPERATING
CATERPILLAR TRACTOR CO. DOUBLE ALKALI (CONCENTRATED)
MAPLETON, ILLINOIS CONSTRUCTION
157,000 10/78
NO ECONOMIC INFORMATION HAS BEEN SUPPLIED FOR THE
CATERPILLAR FGD SYSTEMS.
CATERPILLAR TRACTOR CO. DOUBLE ALKALI (CONCENTRATED)
MAPLETON, ILLINOIS CONSTRUCTION
2b2fOOO 10/79
NO ECONOMIC INFORMATION HAS REEiM SUPPLIED FOR THE
CATERPILLAR FGf> SYSTEMS.
CATERPILLAR TRACTOR CO. DOUBLE ALKALI (DILUTE)
MORTON, ILLINOIS OPERATIONAL
10,000 1/78
NO ECONOMIC INFORMATION HAS BEEN SUPPLIED FUR THE
CATERPILLAR FGD SYSTEMS.
CATERPILLAR TRACTOR CO. DOUBLE ALKALI (CONCENTRATED)
NOSSVILLE, ILLINOIS OPERATIONAL
110,000 10/75
NO ECONOMIC INFORMATION HAS BEEN SUPPLIED FOR THE
CATERPILLAR FGD SYSTEMS.
CHANSLOR WESTERN OIL & DFV. co DOUBLE ALKALI (CONCENTRATED) 11,500,000.
RAKERSFIELD, CALIFORNIA CONSTRUCTION
'0,000 12/78
THE CAPITAL COST INCLUDES THE SCRURBEH, L10UOW
REGENERATION EQUIPMENT, AND DUCTWORK IN 1973
OOLLAKS.
137
-------
STATUS TO OCTOBER 1978
SECTION 15 (CONTINUED)
INDUSTRIAL BOILER FRO COSTS
COMPANY PROCESS COST
LOCATION STATUS " " —
CAPACITY (SCFM) START-DP DATE CAPITAL OPERATING
CHEVRON U.S.A. INC. SODIUM CARBONATE SCRUBBING $2,800.000. 5930,000.
8AKERSFIELD, CALIFORNIA OPERATIONAL
218,000 7/78
THE CAPITAL COST IS IN 1978 DOLLARS. THIS REPRE-
SENTS THE TOTAL INSTALLED COST OF THE FGD SYSTEM
INCLUDING SITE PREPERAUON. THE OPERATING COST IN-
CLUDES ELECTRICITY, SODA ASH, AND MAINTENANCE
(LABOR AND MATERIALS). THIS CORRESPONDS TO A 340
DAY YEAR AND APPROXIMATELY S900/OAY PER SCRUBBER
IN 1978.
FIRESTONE TIRE AND RUBBER CO. DOUBLE ALKALI (CONCENTRATED) 8163,000. $60,000.
POTTSTOWN, PENNSYLVANIA OPERATIONAL
8070 1/75
THE CAPITAL COST INCLUDES EQUIPMENT, ENGINEERING
AND STARTUP. THE COST DOES NOT INCLUDE LABOR AND
MATERIALS FOR ELECTRICAL SYSTEM, PIPING, OR STRUC-
TURAL AND FOUNDATIONS ERECTION IN 1974 DOLLARS.
THE OPERATING COST INCLUDES CHEMICALS, LABOR,
ELECTRICITY, DISPOSAL, MATERIALS, AND LAB WORK FOR
1977.
FMC (SODA ASH PLANT) SODIUM CARBONATE SCRUBBING $10,000,000.
SREEN RIVER, WYOMING OPERATIONAL
446,000 5/76
THIS TOTAL CAPITAL COST, IN 1975 DOLLARS,
INCLUDES ESP AND FSO PURCHASE AND INSTALLATION
COSTS.
GENERAL MOTORS CORPORATION SODIUM HYDROXIDE SCRUBBING 1668,000.
DAYTON, OHIO OPERATIONAL
36,000 9/74
THE CAPITAL COST IS THE TOTAL INSTALLED COST FOR
THE TWO FGD SYSTEMS, IN 1974 DOLLARS.
GENEPAL MOTORS CORPORATION DOUBLE ALKALI (DILUTE) $3,200,000. $644,000.
PARfA, OHID OPERATIONAL
128,«00 3/74
THE OPERATING COST REPRESENTS S11.70/TON COAL.
138
-------
STATUS TO OCTOBER 1S7B
"? (cnNTINUFO)
INDUSTRIAL HUKEk FGl) COSTS
LOCATION
C»PA(UTY (SCFM)
PROCESS
STA1US
START-UP DATE
COST
CAPITAL OPERATING
GENERAL MOTORS CORPORATION
PONTIAC, MICHIGAN
IOT.300
SODIUM HYDROXIDE SCRUBBING
OPERATIONAL
4/7b
$600,000.
THE CAPITAL COST REPRESENTS THE TOTAL INSTALLED
COST IN 1972 DOLLARS.
GENERAL MOTORS CORPORATION
ST. LOUIS, MISSOURI
84,000
SODIUM HYDROXIDE SCRUBBING
OPERATIONAL
1972
$773,000.
1172,000,
THE CAPITAL COST IS IN 1973 DOLLARS. THE OPERAT-
ING COST INCLUDES MAINTENANCE MATERIALS, LABOR AND
ELECTRICITY IN 1976.
GENERAL MOTORS CORPORATION
TONOWANDA, NEW YORK
12,000
SODIUM HYDROXIDE SCRUBBING
OPERATIONAL
fa/75
$2,200,000.
THE CAPITAL COST IS IN 1974 DOLLARS.
GEORGIA-PACIFIC PAPER CO.
CR05SETT, ARKANSAS
220,000
CAUSTIC WASTE STREAM
OPERATIONAL
1975
$275,000.
THE CAPITAL COST REPRESENTS THE ABSORBER COST ONLY
AND IS IN 1974 DOLLARS.
GETTY OIL COMPANY
B»KERSFIELO, CALIFORNIA
'2,000
SODIUM CARBONATE SCRUBBING
OPERATIONAL
b/77
$400,000.
$390,000,
THE CAPITAL COST INCLUDES THE ABSORBER MODULE,
SODA ASH TANK, PUMPS, AND PIPING IN 1977 DOLLARS.
IT DOES NOT INCLUDE THE STACK, DUCTING, ENGINEER-
ING, OR OVERHEADS. ThE OPERATING COST IS EQUIV-
ALENT TO SO.lb/MM BTU, INCLUDES THF COST FOR
SODA ASH, ELECTRICITY, AND SCRUBBER MAINTENANCE,
AND REPRESENTS A S^O-DAY YEAR.
-------
<; I A T!,'i TO DC TOI'f W 1 97fl
;>F t 1 I Of I 4 ( rr»r:T I *v'ii^ L. '
J NbUijTh 1M ^iJll.Fw M'-U C'KSlb
COMPANY PROCESS COST
LOCATION S'AT;';,
CAPACITY (SCFM) STAHi-.lP DATF CAPITAL OPERATING
GETTY OIL COMPANY SODIUM CARBONATE SCRUBBING $^4,500.000. 15,280.000.
BAKERSFIELD, CALIFORNIA CONSTRUCTION
993,750 12/78
THE CAPITAL COST INCLUDbS COST OF SCRUBBER, SODA
ASH TANK, PIPING, AND PUMPS IN 1978 DOLLARS FOR
9 SCRUBBER SYSTtMS. THE OPERATING COST INCLUDES
ELECTRICITY, SCWU8RER MAINTENANCE, AND SODA ASH,
IS BASED ON A 340-DAY YtAR, AND REPRESENTS
J0.16/MM BTU FOR 9 SCRUBBING UNITS.
GREAT SOUTHERN PAPER CO. CAUSTIC WASTE STREAM S600fOOO.
CEDAR SPRINGS, GEORGIA OPERATIONAL
420,000 1975
THE CAPITAL COST IS THE EQUIPMENT COST FOR THE TWO
SCRUBBER MODULES IN 1974 DOLLARS.
GREAT WESTFRN SUGAR AMMulM I A-l. ADt N PROCESS WAThN
BILLINGS, MONTANA OPERATIONAL
60,000 10/77
NO COST INFORMATION HAS BEEN SUPPLIED FOR THE
BILLINGS FGD SYSTEM.
GREAT WESTERN SUGAR SODIUM CARBONATE SCRUBBING 5523,000. $30,200.
FINDLAY, OHIO OPERATIONAL
65,230 10/74
THE CAPITAL COST IS THE TOTAL INSTALLED COST OF
THE FGD SYSTEM IN 1974 DOLLARS. THE OPERATING
COST INCLUDES ELECTRICITY, MAINTENENCE, LABOR, AND
MATERIALS.
1 40
-------
STATUS TO OCTOBER 1978
SECTION 13 (CONTINUED)
INDUSTRIAL ROILFrt FGD COSTS
LOCATION
CAPACITY (SCFM)
PROCESS
STATUS
START-UP DATE
COST
CAPITAL
OPERATING
WESTERN SUGAR
FOR! MORGAN, COLORADO
65,230
AMMONIA-LADEN PHOCFSS WATER
OPERATIONAL
10/76
THE CAPITAL COST IS THE TOTAL INSTALLED COST OF
THE FGD SYSTEM IN 1976 DOLLARS. THE OPERATING
COST INCLUDES ELECTRICITY, STEAM, MAINTENENCE,
LAABOR, AND MATERIALS.
$707,000.
$88,200.
GREAT WESTERN SUGAR
FREEMONT, OHIO
110,000
SODIUM CARBONATE SCRUBBING
CONSTRUCTION
10/78
NO COST INFORMATION HAS BEEN SUPPLIED FOR THE
FREEMONT FGO SYSTEM.
SREAT WESTERN SUGAR
CEDING, NEBRASKA
110,000
AMMONIA-LADEN PROCESS WATER $643.000.
OPERATIONAL
10/75
THE CAPITAL COST is THE TOTAL INSTALLED COST OF
THE FGD SYSTEM IN 1975 DOLLARS. THE OPERATING
COST INCLUDES ELECTRICITY, MAINTENENCE, LABOR, AND
MATERIALS.
$34,600.
GREAT WESTERN SUGAR
GREELEY, COLORADO
25,000
AMMONIA-LADEN PROCESS WATER
OPERATIONAL
10/75
NO COST INFORMATION HAS BEEN SUPPLIED FOR THE
GREELEY FGO SYSTEM.
GREAT WESTERN SUGAR
LONGMONT, COLORADO
AMMONIA-LADEN PROCESS WATER
TERMINATED
10/7?
NO COST INFORMATION HAS BEEN SUPPLIED FOR THE
LONGMONT FGD SYSTEM.
141
-------
STATUS TO OCTOBER 1976
SFCTIDN 13 (CONTINUED)
INDUSTRIAL ROILER KGD COSTS
COMPANY PROCESS COST
LOCATION STATUS •"
CAPACITY CSCFMl START-UP DATE CAPITAL OPERATING
GREAT WESTERN SUGAR AMMONIA-LADEN PROCESS WATER $431,000. S8«,
-------
STATUS TO OCTOBER 1978
M (CONTINUED)
1NDMSTNTAL BOILF.R FRO COSTS
COMP»NY
LOCATION
CAPACITY (SCFM)
MEAD PAPER80ARD CO.
STEVENSON, ALABAMA
100,000
PROCESS
STATUS
START-UP UATF
COST
CAPITAL OPERATING
SODIUM HYDROXIDE SCRUBBING
OPERATIONAL
1975
THE CAPITAL COST REPRESENTS THE ORIGINAL EQUIPMENT
AND INSTALLATION COST IN 1974. SINCE THEN, EXTEN-
SIVE MODIFICATIONS HAVE BEEN REQUIRED. ANOTHER
$173,000 WAS SPENT FOR REPAIRS AND UPGRADING IN
1976. OVER THE SCRUBBER PLANT LIFE, AN ADDITIONAL
1136,000 HAS BEEN SPENT, INCLUDING:S 35,000 CRUB-
8ER LINERS), S5a,000 (STAINLESS STEEL LINERS), AND
147,000 (GENERAL REPAIRS).
THE OPERATING COST INCLUDES $<10,000/YR FOR
OPERATING LABOR, $flO,000/YR FOR MAINTENANCE
LABOR, AND $760,000/YR FOR REAGENT (8586 TONS).
1173,000.
$840,000.
MINN-DAK FARMER'S COOPERATIVE
HAHPETON, NORTH DAKOTA
160,000
AMMONIA SCRUBBING
OPERATIONAL
6/77
$300,000.
THE CAPITAL COST REPRESENTS THE TOTAL EQUIPMENT
COST IN 1977 DOLLARS.
MOBIL OIL COMPANY
BUTTONHILLON, CALIFORNIA
12,000
SODIUM CARBONATE SCRUBBING
CONSTRUCTION
9/78
$500,000.
THE CAPITAL COST INCLUDES ABSURBFH MODULES, RE-
CYCLE TANKS, STACK, DEMISTERS, PUMPS, AND PIPING
IN 1978 DOLLARS. IT DOfcS NUT INCLUDE CAUSTIC
TANK, FEED PUMPS, OR FEED PIPES.
MOBIL OIL CORPORATION
SAN AROO, CALIFORNIA
182,000
SODIUM HYDROXIDE SCRUBBING
OPERATIONAL
197«
$2,900,000.
$1,390,000.
THE CAPITAL COST HFPREStNTS FUUIPMFNT, INSTAL-
LATION, PIPING, DUCTWORK, STACK. WATER TREATMENT
FACILITY, AND INSTRUMENTATION IN 1978 DOLLARS.
THE OPERATING COST INCLUDES ELECTRICITY, CAUSTIC,
LABOR, AND MAINTENANCE. IT DOES NOT INCLUDE IN-
DIRECT (FIXED) COSTS. THE AVERAGE OPERATING COST
FOR THE 22 SMALLER SYSTEMS IS $35,000/YR EACH, AND
FOR THE 8 LARGER SYSTEMS IS $65,000/YR EACH.
1 a?
-------
STATUS TO OCTOBER
SEf TiON 1 < (I.ONT If UFU)
INDUSTRIAL PDTLFk FRtl CUbTS
COMPANY PWOCF5S COST
LOCATION Slafi.S -------- " ------------ " —
CAPACITY (SCFM) STAM-IIP 0*TF CAPITAL OPERATING
NEKOOSA PAPERS, INC. CAUSTIC SCRUBBING $550,000.
ASHDOWN, ARKANSAS OPERATIONAL
211.000
THE CAPITAL COST REPRESENTS THE EQUIPMENT COST IN
1975 DOLLARS.
PHILLIP MORRIS, INC. SODIUM CARBONATE SCRUBBING
CHESTER, VA. CONSTRUCTION
39,000 1/79
NO COST INFORMATION IS AS YET AVAILABLE.
DUALITY MILLS, INC. WATER SCRUBBING 110,000,
MT. AIRY, NORTH CAROLINA TERMINATED
10,000 5/70
THIS is THE TOTAL INSTALLED CAPITAL COST IN
1970 DOLLARS.
RICKENBACKER AIK FORCE BASE LIMESTONF SCRUBBING sa,200,000. $207,000.
COLUMBUS, OHIO OPERATIONAL
55,000 3/76
THF CAPITAL COST INCLUDES ADJACENT ELECTRICAL SUB-
STATION, SLUDGE DISPOSAL, EXTERNAL FLUES, AND
OTHER ATYPICAL EQUIPMENT IN 1975 DOLLARS. THE OP-
ERATING COST REPRESENTS THE OVERALL 1977 COST FOR
35,000 TONS OF COAL. DURING THE 1"77 U.S.E.P.A.
DEMONSTRATTUN TEST, OPERATING COSTS WERE i5.6i/TON
OF COAL. THESE COSTS INCLUDE OPERATING AND MAIN-
TENANCE, LABOR, POWER, ftATER, MAINTENANCE PARTS,
AND SLUDGE DISPOSAL, BUT DOES NOT INCLUDE DEPRE-
CIATION.
t ua
-------
STATUS TO OCTOBER i<>7s
SECTION 13 (CONTINUED)
INDUSTRIAL BOILER FED COSTS
COMPANY PROCESS
LOCATION STATUS
in r\ A -r f
CAPITAL
SMELLER GLOBE CORP. SODIUM HYDROXIDE SCKUB8ING SflO.OOu
NORFOLK, VIRGINIA OPERATIONAL
J,000
THE CAPITAL COST IS THE ESTIMATED REPLACEMENT COST
IN 1978. AN ESTIMATED MAINTENANCE COST OF S160/MO
WAS REPORTED (2 MAN-OAYS/MO).
ST. JOE ZINC CO. CITRATE PROCESS $15,700,000.
MONACA, PENNSYLVANIA CONSTRUCTION
104,000 12/78
THE CAPITAL COST IS IN 1977 DOLLARS AND IS BEING
JOINTLY FUNDED BY ST. JOE ZINC, THE US EPA, AND
THE U.S. BUREAU OF MINES.
ST, REGIS PAPER CO. CAUSTIC SCRUBBING $100*000,
CANTONMENT, FLORIDA OPERATIONAL
115,000 1973
THE CAPITAL COST IS FOR THE ABSORBER ONLY AND IS
IN 1973 DOLLARS.
TEXACO INCORPORATED SODIUM HYDROXIDE SCRUBBING
SAN ARDO, CALIFORNIA OPERATIONAL
366,000 11/73
NO ECONOMIC INFORMATION HAS AS YET BEEN PROVIDED
BY TEXACO.
TEXACO INCORPORATED SODIUM HYDROXIDE SCRUBBING
SAN ARDO, CALIFORNIA CONSTRUCTION
117,000 3/79
NO ECONOMIC INFORMATION HAS AS YET BEEN PROVIDED
BY TEXACO.
145
-------
STATUS TO OCTOBER 1978
SFCTION n (CONTINUED)
INDUSTRIAL BOILER FGD COSTS
COMPANY PROCESS COST
LOCATION STATUS -— -----— — — -
CAPACITY (SCFM) START-UP DATE CAPITAL OPERATING
TEXASGULF SODIUM CARBONATE SCRUBBING
GRANGER, WYOMING OPERATIONAL
140,000 9/76
NO ECONOMIC INFORMATION HAS AS YET BEEN PROVIDED
BY TEXASGULF.
TRANSCO TEXTILES, INC. SODIUM CARBONATE SCRUBBING
AUGUSTA, GEORGIA INDEFINITELY SHUT DOWN
50,000 3/75
NO ECONOMIC INFORMATION WAS MADE AVAILABLE.
U.S. GYPSUM CORP. DOUBLE ALKALI (DILUTE)
OAKMONT, PENNSYLVANIA NEVER STARTEO-UP
19,300
NO ECONOMIC INFORMATION WAS MADE AVAILABLE.
146
-------
SECTION 14
PROCESS DIAGRAMS FOR INDUSTRIAL BOILER FGD SYSTEMS
THIS SECTION CONTAINS 16 PROCESS FLOW DIAGRAMS FOR
SELECTED FGD SYSTEMS INCLUDED IN THIS REPORT. EACH DIAGRAM
IS IDENTIFIED BY THE NAME OF THE COMPANY AND THE CITY AND
STATE IN WHICH IT IS LOCATED. INCLUDED WITH EACH DIAGRAM IS
A STREAM FLOW CHARACTERISTICS CHART AND AN EQUIPMENT LIST.
THE STREAM FLOW CHARACTERISTICS CHART IDENTIFIES
VARIOUS PARAMETERS OF EACH STREAM IN THE DIAGRAM. INFORMA-
TION FOR A PARTICULAR STREAM CAN BE OBTAINED BY REFERRING TO
DATA UNDER EACH NUMBER IN THE CHART. EACH STREAM IN THE
DIAGRAM IS MARKED BY A NUMBER, CIRCUMSCRIBED BY A HEXAGON.
BLANK SPACES INDICATE THAT DATA EITHER IS NOT YET AVAILABLE
OR THAT THE CHARACTERISTIC DOES NOT APPLY FOR THAT PARTICULAR
STREAM.
THE EQUIPMENT LIST IDENTIFIES EACH PIECE OF EQUIPMENT
IN THE DIAGRAM BY A LETTER/NUMBER LABEL (E.G., T12). THIS
LIST IDENTIFIES EACH PIECE OF EQUIPMENT BY NAME AND GIVES
THE SIZE, MATERIAL OF CONSTRUCTION AND THE NUMBER OF SUCH
ITEMS AT A PARTICULAR PLANT SITE. BLANK SPACES INDICATE
THAT INFORMATION HAS NOT YET BEEN MADE AVAILABLE TO THIS
REPORT.
147
-------
LIST OF FIGURES
NO. PAGE
14-1 AMERICAN THREAD, MARION, NORTH CAROLINA 149
14-2 ARMCO STEEL, MIDDLETOWN, OHIO 150
14-3 CATERPILLAR TRACTOR, JOLIET, ILLINOIS 151
14-4 CATERPILLAR TRACTOR, MOSSVILLE, ILLINOIS 152
14-5 FIRESTONE TIRE AND RUBBER, POTTSTOWN,
PENNSYLVANIA 153
14-6 GENERAL MOTORS, DAYTON, OHIO 154
14-7 GENERAL MOTORS, PARMA, OHIO 155
14-8 GETTY OIL, BAKERSFIELD, CALIFORNIA 156
14-9 ITT RAYONIER, FERNANDINA BEACH, FLORIDA 157
14-10 KERR-MCGEE, TRONA, CALIFORNIA 158
14-11 MEAD PAPERBOARD, STEVENSON,ALABAMA 159
14-12 RICKENBACKER AFB, COLUMBUS, OHIO 160
14-13 ST. JOE ZINC CO., MONACA, PENNSYLVANIA 161
14-14 ST. REGIS PAPER, CANTONMENT, FLORIDA 163
14-15 TEXACO, SAN ARDO, CALIFORNIA 164
14-16 TEXASGULF, GRANGER, WYOMING 165
148
-------
IN n
Al
CO
Tl
CAUSTIC
WASTE
PI (D
ASH
POND
P2
FIGURE 14-1. PROCESS FLOW DIAGRAM;
AMERICAN THREAD,
MARION, NORTH CAROLINA
EQUIPMENT LIST
EQ NO.
Al
Fl
n
PI
P2
Tl
NAME
ABSORBER
F.D. FAN
I.D. FAN
RECYCLE PUMP
WASTE PUMP
RECIRCULAT10N TANK
SIZE.
10 OIA.
60 HP
60 HP
13 x 12
FEET MATERIAL
x 12 HIGH 304SS, 316SS
« 8 HIGH 3/8" C.S.
NO.
2
2
2
STREAM NO.
RATE, Ib/hr
«cf» » 1000
V»
PAMTICULATES. Ib/hr
S02. Ib/hr
TfMPERATURE. *F
TOTAL SOLIDS, I
SPECIFIC GRAVITY
HjO. Ib/hr
P«
SUUlTE.nig/l
SULFAH.-9/I
CHLORIDE, 119/1
$)
60
400
(7)
41.2
110
®
2.5
0
8.5
0
r«p
-------
GAS S
IN Fl
en
o
EQUIPMENT LIST
£0 NO.
Al
Fl
PI
Tl
T2
VI
NAME
SIZE, FEET
ABSORBER
17 DIA.
F.O. FAN
RECIRCULATION PUMP
RECIRCULATION TANK 10,000 GAL.
LIME SLURS*
HOLD TANK
VENTURI
MATERIAL
C.S., FIBERGLASS
LINED TRAYS, 3I6L SS
RUBBER-LINED C.S.
RUBBER-LINED C.S.
316L SS
'NO.
FIGURE 14-2. PROCESS FLOW DIAGRAM;
ARMCO STEEL,
MIDDLETOWN, OHIO
STREAM NO.
HATE, Ib/hr
icfn x 1000
9pn
PARTICULATES, Ib/hr
SOj. Ib/hr
TEMPERATURE, 'T
TOTAL SOLIDS. %
SPECIFIC GRAVITY
MjO, Ib/hr
PH
SULFITE.mg/l
SULFATE,««/1
CHLORIDE, »q/l
"CT)
140
425
©
8J
33
71
CT)
1600
(?)
^)
.
0
3200
0
0
1600
7.0
(?)
300
(i$
1600
-------
n$t
DRY
FLUE GAS IN
FLUE GAS IN &
FIGURE 14-3. PROCESS FLOW DIAGRAM;
CATEPILLAR TRACTOR,
JOLIET, ILLINOIS
- »- LANDFILL
eg M>.
Al
n
LS1
n
n
n
H
n
n
H
ft
SSI
tl
TZ
TJ
T4
Ti
Tt
VFI
VF2
ni
v«
RAMt SIZE, FEE!
AISORBEI
F.D. FAX
11* STORAGE TANK
ILIEO-OTF PUWS
LI* H1I TANK PUWS
SODA ASH Mil
TAW PUMPS
FEED HATH PUKPS
siuDGf PV»
SLUDGE PUMP
ULTHATE «WS
VACUUM fUWS
SOOA ASH STOKAGC TA»
niMJUIl LINE Nil TANK
SECOMOAIII LIIC MIX TAHK
SOOA ASH Mil TAHK
SUDU TAHK
TH1CUHER SO 000 GAl
CLWHEf
VACUUM FILTER
VACUUM FILTER SPADE
VACUUM KCEIVEII
VACUUM HECEItEK SPAIE
NATEIIAL
316 S.S.
C.S.
C.I.
C.S.
C.S.
C.S.
C.S.
C.S.
C.S.
VET SURFACES
104 SS
VET SURFACES
304 SS
C.S.
C.S.
no.
}
2
1
4
2
2
I
1
1
2
2
1
1
1
t
1
1
1
1
1
1
1
bI«W HO
Mil. Ik/hr
«clo < 1000
«*i
rAlllCULATES. It/h-
S0;. l>/«r
TlWtMIU"!. -F
TOIAL UHIDS. I
ifUIIIC OUHIII
K,0.lb/hr
pH
ULFIH,««/I
UIIF*IE,«9/I
CW«iK.»g/l
i!WW HO
MTC. !b/kr
/hr
IEMHUTUKE, T
TOIU SOLIDS. 1
SPECIFIC UAVI11
NjO.lb/Hr
*
S4AIITE.1VI
SU.f*U.«g/l
CW.WIOE,««/1
1,')
)SO
%
w
».«
130
I/?
u.o
^
)50
(fi>"
15-20
It]
15.0
lii
^
15-20
t,v
,rt,
0
?»
5200
L "
f')
W
r»)
(21)
.6
I'O
(**l
12.0
huj
1040
(*i)
11.0
H U
IIS
(24)
0^
ft
Cul
A'
-------
TO STAC^ DRY LIME STORAGE
IN
(4)
to
®
<3)
1
r"S
]L
si
^-T
sec* ASH
_
w
A
ti
p?
~ 4 ' '
T2
EQUIPMENT LIST
® FROM LIME SODA SOFTNFR fQ NO NAME SIZE, FEET MATERIAL HO.
WATERj£^_
©
o
^xA
P3
1 1 '
L
©
h
* I
n
^•^ " _-— -^
©
—
j
> ^r ®
W®_
tr^
T. P6
LJU
P»-
J
~1
FI F.O. FAN I
Fill FILTRATE RECEIVER 1
PI MCIRCULATION PUMP
n ILEEO OFF PUMP
PJ WUSTIC PUMP
R£l
rSL
P4 FILTRATE PUMP
P5 EXHAUST PUMP
W UNDERFLOW PUMP
RFI ROTARY FILTER 1
SI SEPARATOR 4
Tl RECIRCULAT10N TANK 4
T2 LIME MIX TANK
(Ok
UXT^'l-TER T3 TMIC«NER
rfrf "CAKE TO
^1 DISPOSAL T4 SURGE TANK
*«
P4
T
FR1
VI VARIABLE TMROAT VCNTURI 4
_®__EXHAUST
& ""
P5
FIGURE 14-4. PROCESS 1'LOW DIAGRAM;
CATEPILLAR TRACTOR,
MOSSVILLE, ILLINOIS
STRLAM NO.
RATE, Ib/hr
*cf» x 1000
9("
PARTICULATES. Ib/hr
S0r Ib/hr
TEMPERATURE. *F
TOTAL SOLIDS, I
SPECIFIC GRAVITY
M.Whr
I*
SULFITE,i>9/l
SULFATE .mgf}
CHLOR1 D£. «9/l
^
40
604.8
440.1
413
@
28.4
10.5
23.4
1S9
(i)
C«)
345
130
1.131
6.48
24.2
86.9
®
292.1
_
G)
110
1.13]
6.48
24.2
86. »
r')
ft
®
CioD
8.3
Oi)
(jzp
120
1.101
8.4
13.7
70.8
^
(u)
Ql>
(gi
(T^
©
2352
60*
® 1
f
-------
EQUIPMENT LIST
cn
00
EO NO.
Fl
LSI
PI
n
RFl
SI
SSI
Tl
M
&
T3
J
VI
D p
^^ ^FILTER
RF1 CAKE
NAME SIZE, FEET
F.D. FAN
LIME STORAGE TANK
RECIRCULATION PUMP
LIME REACTOR PUMP
ROTARY FILTER
SEPARATOR 4.67 DIA x 7.17 HIGH
SODA ASH STORAGE
RECIRCULATION TANK
LINE REACTOR
THICKENER
SURGE TANK
DUAL THROAT VENTURI .5-1.25 THROAT LENGTH
MATERIAL
C.S.
RUBBER-LINED
CAST IRON
RUBBER-LINED
CAST IRON
316L S.S.
316L S.S.
316L S.S.
C.S.
C.S.
C.S.
316L S.S.
NO.
I
1
1
1
I
1
1
1
1
1
1
1
FIGURE 14-5. PROCESS FLOW DIAGRAM
FIRESTONE TIRE AND RUBBER,
POTTSTOWN, PENNSYLVANIA
STREAM NO.
RAU, Ib/hr
tcfffl x 1000
9P«|
PARTICIPATES, )b/hr
S0?. Ib/hr
TEMPERATURE, °F
TOTAL SOLIDS, t
SPECIFIC GRAVITY
H,0, Ib/hr
pH
SULFITE,m9/l
SULfATE.mg/l
CHLORIDE. 119/1
0)
13
450
360
300
Q
10
H.7
34.2
130
-
1
1
ft
L— ,—_^
1
ft
130
ft
.OB 3
Q
fTi
Q
ft
rin)
1 '
fnl
1 1
fi?l
fnl
180
55
-------
TO STACK
FLUE GAS IN
CJ1
FLUE GAS ,N
FIGURE 14-6. PROCESS FLOW DIAGRAM;
GENERAL MOTORS,
DAYTON, OHIO
EQ NO.
A1
Fl
PI
PZ
P3
Tl
TZ
T3
NAME
ABSORBER
F.D. FAN
RECIRCULATION
PUMP
CAUSTIC PUMP
BLEED-OFF PUMP
RECYCLE TANK
CAUSTIC TANK
BLEED-OFF TANK
SIZE, FEET
6 DIA. x 10 HIGH
35,000 SCFM, 9 IN. W.G.
ZOO GPM, 25 HEAD
80 GPM
50 GPM
7.5 DIA. « ^^ HIGH
9 DIA. x 18 HIGH
6 DIA. x 6.5 HIGH
MATERIAL
316L SS
C.S.
RUBBER-LINED C.S.
C.S.
RUBBER-LINED C.S.
31 6L SS
C.S.
316L SS
NO.
2
Z
3
1
Z
1
1
1
STREAM NO.
«ATt, Ib/hr
«cfm x 1000
9f»
PARTICULATES. Ib/hr
S0?, Ib/hr
TEHPERATURE, °F
TOTAL SOLIDS. X
SPECIFIC GRAVITY
M?0, Ib/hr
PM
SULFITE,mg/l
SULFATE.mg/l
CHLORIDE. ng/l
'^
45
55. J
^HUi
400
^
30. S
e. 3
_!!,«
125
l.tf
50
(4)
200
7.0
W
50
CftJ
ro
fa;
f.o
flQ)
no
35
®
35
^
50
t!J>
-------
EQUIPMENT LIST
HI
^Ti
X^7
<3>
FLUE Fl
^-
ft5®16"*
TQ sTar-tf '
(I;
— -^
~^f
*
<4>
h- '
U1
CJ1
\
— -^
•L
Dl
a
r]
fl
IJ
ft
I
dc
T
tr
p?
r <=
v
T2
-1
1
©
1
T6
J
LSI
1 I
1
V
=L
T3
^S
I
.^.J
r
L-3
&
P3
II
Sr
SSI 1 j
It
I
T4
\
<0
*
~~^
RF
PROCESS FLOW DIAGRAM;
rNF.Ri
M.
MOT
'ORS.
EQ NO. NAME SIZE. FEET MATERIAL NO.
J
^.
Al ABSORBER 10. S OIA. x 22.5 HIGH 316L SS 4
Fl F.D. FAN 200 HP. 12 IN. W.6. C.S. 4
,r-i
Ml REHEATER
4
PI RECIRCULATION 2-750 GPM C.S., 4
PUMP 2-550 GPM RUBBER-LINED
P2 RECIRCULATION
PUMP 700 GPM RUBBER-LINED 3
P3 UNDERFLOW PUMP 100 GPM RUBBER-LINED 2
P5 FILTRATE PUMP 300 GPM RUBBER-LINED 2
J5 ®
FILTER 500 SQ. FT. AREA CLOTH 2
Br — i
V 'T» I TS
L-fl SSI SODA ASH STORAGE 35 TON C.S. 1
1 J ""
P5 Tl CHEMICAL MIX TANK 5000 GAL C.S. 1
T2 CHEMICAL MIX TANK 5000 GAL C.S. 2
T3 . CLARIFIER *1 60 DIA. x 14 HIGH 1
T4 CLARIFIER 12 60 DIA. x 14 HIGH 1
T5 FILTRATE TANK 4 DIA. x 7 HIGH C.S. 1
T6 RECIRCULATION TANK 2-3700 GAL C S TAR
2-3000 GAL COATING 4
PARMA, OHIO
STRlAM NO.
RAH, Ib/hr
iCfm x 1000
9pm
PARTICULATES, Ib/hr
SOj, Ib/hr
TEMPERATURE, 'F
TOTAL SOLIDS, *
SPECIFIC GRAVITY
H^O, Ib/hr
pH j
SULMTE.mg/l
SULFATE.PH9/1
CHLORIDE, "19/1
10
Sfl. 6
73.2
.. ^V.
550
eo
35.5
60. 8
41.5
152
(3l
(4)
®
. , .
_
OP
,
„
ro
.
Tap
_
^
_
fiq)
1200
fill
6i]
15-20
fu)
1
«0l
iftl
f!6l
H>
(t»1
50
-!-'-- ' ' —
(ft)
l~
e» -_
~
-------
Fl
en
FLUE
GAS
IN
AT
„ <5>
PI
MAKE-UP
WATER
T2
Tl
TANK TO
DISPOSAL
EQ NO.
EQUIPMENT LIST
NAME
SIZE. FEET
MATERIAL
W.
Al ABSORBER
Fl F.D. FAN
PI RECYCLE PUMP
Tl DISPOSAL TANK
T2 SODA ASM MIX TANK 42,000 GAL
13.5 DIA. x 35 HIGH
500 HP
40 HP
316L SS
1/4" C.S.
FIGURE 14-8. PROCESS FLOW DIAGRAM;
GETTY OIL,
BAKERSFIELD, CALIFORNIA
STREAM NO.
MTL. Ib/hr
Ktm * 1000
9PM
P*RTICULATES. Ib/hr
S0?. Ib/hr
TEMPERATURE, 'F
TOTAL SOLIDS, X
SPECIFIC GRAVITY
HjO.lb/hr
P«
SULFITE.ng/l
SULFATE.mg/l
CHLORIO£,mq/l
ro •
200
500
0
127
150
0)
)0
0
1000
e.a
0
0
-------
t— '
en
-3
FLUE r, A\
GAS H (D
IN £*.
CAUSTIC (10
SOLUTION
FROM
PULP
BLEACHING
OPERATION
MAKE UP <£>
WATER *"
*)
/T\ I
:9fec
^\s
/
(
1
(?)
S
V
\
_.
Tl
® ^ WASTEWATFR
TREATMENT
NO.
z
2
2
1
2
FIGURE 14-9. PROCESS FLOW DIAGRAM;
ITT RAYONIER,
FERNANDINA BEACH, FLORIDA
STREAM NO.
RATt, Ib/hr
«cfm « 1000
«P»
PARTICULATES, Ib/hr
S0?. Ib/hr
TEMPERATURE. *F
TOTAL SOLIDS, »
SPtCIFlC GRAVITY
MjO, Ib/hr
P«
SULFlTl.mg/1
SULFATE.mg/]
CHlORIDE.mq/l
Ct)
165
1300
460
®
30
0)
ino
<"«P
0
H70
f£
160
r?)
1620
G)
-------
GAS IN
tn
oo
1
^ — » — *-
Fl
^
TO
STACK
"^X
AAAA/W\
Al
^^__ --•
®
—
-------
CJ1
MAKE-UP
WATER
TO PULP MILL
FIGURE 14-11. PROCESS FLOW DIAGRAM;
MEAD PAPERBOARD,
STEVENSON, ALABAMA
EQUIPMENT LIST
EQ NO.
Al
Fl
PI
P2
T1
T2
NAME SIZE, FEET
ABSORBER
F.O. FAN
RECYCLE PUMP
CAUSTIC PUMP
RECIRCULAT10N
TANK
SODIUM CARBONATE
TANK
MATERIAL NO.
316 SS 1
1
1
1
FIBERGLASS 1
1
bTRCAN NO.
Mil, Ib/hr
-------
••EXHAUST TO ATMOSPHERE
Q- _J MCI L, (LUE GAS IK
Ol
o
EQUIPMENT LIST
TO SLUIXit POKE
EO NO.
A1
Fl
LSI
MCI
PI
P2
P3
ST1
Tl
T2
T3
T4
NAME SIZE. FEET
ABSORBER 12 DIA. x 61 HIGH
F.D. FAN 600 HP
LIME STORAGE 12 DIA. x 67 HIGH (120 TONS)
MECHANICAL COLLECTOR
RECIRCULATION PUMP
RECIRCULATION PUMP
UNDERFLOW PUMP
STACK 5.5 DIA. x 20 HIGH
LIME MIX TANK
2ND STAGE LEVEL TANK
1ST STAGE LEVEL TANK
CLARIFER 25 DIA.
MATERIAL
316L SS
3/16" A-36 STEEL
RUBBER LINED
RUBBER LINED
RUBBER LINED
FRP
316L SS
HOOD
NO.
t
1
1
1
1
1
1
1
1
1
1
1
FIGURE 14-12. PROCESS FLOW DIAGRAM;
RICKENBACKER AFB,
COLUMBUS, OHIO
STREAM NO.
RATE, Ib/hr
«cfm « 1000
9P»
PARTICIPATES. Ib/hr
S0?, Ib/hr
TEMPERATURE, °F
TOTAL SOLIDS. I
SPECIFIC GRAVITY
H,0, Ib/hr
pH
SULFITE.raq/l
SULFATE,«9/1
CHlORIDE.n9/!
CO
108
577. 9.
6-13LJ
471
CO
lX.fi
L_LiL
CO
(£)
OP
Ui0
b.S-
CO
(8)
(9)
4.8
fiq)
'40
CM)
0?)
5.5
tn)
©
i
Q5
(jD
8.5
-------
1®
TO SETTLING POND
FIGURE 14-13. PROCESS FLOW DIAGRAM;
ST. JOE ZINC CO.,
MONACA, PENNSYLVANIA
(Sheet 1 of 2)
1C HO.
A?
n
n
HI
PI
n
PS
P4
PS
P6
P7
»«
P»
no
SHI
ST1
tl
T2
tl
T4
IS
1*
n
rt
t»
TIC
Til
TIZ
Tl]
»i
EQUIPICNT
»«« SIZE, FEtl
AJSOWER 26 1.0. > 85 HIGH
F.D. FAN 234.000 ACfH. 1000
FLOTATION Alt 9JI PSI. PRESSURE
flLOUEB (NOT DIFFERENT!*!.
SHOyi)
BEHEATER
mm -UP PUMP 100 GF». v PSI. s
SCRUBBER RECYCLE 4500 GPH, 118 PSI,
PUMP
LEAN SOLUTION PUI» 120 HP
«1CH CITRATE SOLUTION 40 HP
PUMP
SULFER 5LUR«r Pit* 61 CM, 105 PS1.
SULFtK SlUKST Htv M 0«. 105 PS| .
LEAN SaUTICM PtXP 120 HP
IICH C1TMTE 10 NP
SOLUTION PUW
SULFIP. TRANSFER KtV 15 CPU. 72 PSI. 7
SULFER LOADING PUW SO OP". 20 PSI. 3
SULFER NELTER 4.111*1 ITU/HR. aT,
S'MI 10 1.0. > 102 HIGH
DIGESTER 12 1.0. > la HIGH
SUITE* PttCIPIMTlOII 12. BJ I.D. • IB 13
»E*CTO« 13,000 GAL
SUIFE« PREC1P1TAT1DH 12. U 1.0. • 18 B]
RE«CTOS 13.000 G«L
L1« NEUTtAllUTION
TMI
SW.FER FLOTATION 15 1.0. « 20 HIGH.
TA» le.SOO GAL
JW.FE1 Stl*M TA» H I.D. . IS MIO.
CITWn STOMCC TUt M 1.0. . JO HIGH
OTSTILL1ZER
SULFER OCCAMR (5 rtig > 2SO°F
STEW HE«TEO SULFER 20 1.0. . 2« HIGH,
STOHAGE TANK 54,000 GAL
HAtf-UP TANI; J t.O. I 7.5 HIGH
LEAN SOLUTION 5.41*1 ITU/HI
COOLER (NOT SHOMI) 7> PS IS » lii°F
VEN7UKI WSH MTER 1«.**4 ITU/HR,
COOLED (NOT SHOW) M PSIG
««n«l 10 01A. • 45 HIGH
N-S a»E«ATO« m SCFK t 45 PSIG.
JOOOI
LIST
WTEHIAL
C.S. FHKEGLAS5 LINED
HP
C.5
HP HASTELlOf
250 HP RUB8EP-L1NE3
CAST IRON
CHLOR1HET 3
CXIORI«! 3
20 HP RUI8t»-ll«0
HASTELLO" C
20 HP lUtBED-LlNED
MASTELLOl C
CHLOR|«t 3
CHLOHIHCT 3
.5 HP CAST STEEL
HP UST STEEL
•I30°F C.S. SHEEL
HASTELLOT TUBES C-276
C S., FLAKEGLASS
LINED
HIGH. t.S. FLAKEGIAS5
UNCO
HIGH. C.S. FLA«GLASS
LINED
-
C.S FLAKEGLASS -
L1NEO
C.S.^EGLASS
C.S., FLAKEGLASS
LINED
C.S., !/•• HASTELLO'-
C LINER
C.S
U1NFORCED FIBERGLASS
MLLAOIUH-STABILUED
T1TUI1UH
PALlADIlP-SIABHlZtD
TITANIUM
C.S., NOZZLE OF INCONEL
U5, ACID PDOOF lltlCI
LINED OVER RUBBER WMtRANE
S.S SHELLS
"0.
1
1
2
1
1
4
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
-------
03
CO
STREAK NO.
RATE. Ib/hr
«cf« x 1000
90
PARTICULATES. Ib/hr
SOj. Ib/hr
TEMPERATURE. *F
TOTAL SOLIDS, I
SPECIFIC GRAVITY
M,0. Ib/hr
(*
SIM.FITE.Bg/1
SULFATE.Bg/1
CHL
156. (
120
(7)
120
(4)
(?)
(?)
16000
112
0
100
®
0
(19)
4.5
4200
123
4.5
®
4.S
O
STKM NO.
HATE. Ib/hr
•cf« i 1000
M>
r/WTICUUHS. Ib/hr
SO.,. Ib/hr
TEMPERATURE. *F
TOTAL SOLIDS. X
SPECIFIC GRAVITT
H;0. Ib/hr
PH
SULFITE.ag/l
SULFATE.nj/l
CHLORIDE.-g/l
$
111
m
120
fa
(PJ
@
1300
131
(ft)
1300
131
f^
(Ft)
^J
(fl|
130
10
®
64
131
@ 1
130
260
9
260
^
1292
50
(S5j
15
L^)
®
iS)
^
FIGURE 14-13. OSheet 2 of 2)
-------
EQUIPMENT LIST
TO
h— i
01
GO
w\:> — LJ
IN n
-------
EQUIPMENT LIST
FLUE
IN
n ®
M
I
PI
r
V<
r1
\
I
TV
i>
|
—-
^
(
i/n
' — -^
T2
-r^
(3)
f
\
(5
" ""
1 J / t i 1
\
P
/qi
\ Vi
T.
7T
^,
]}'
2,
!
7-77
<«Jc
1
1
Tl
EO NO. NAME SIZE, FEET MATERIAL NO.
Al ABSORBER 11 x 20 x 30 FIBERGLASS SHELL 9
POLYPROPYLENE INTERNALS
Fl F D FAN 100 HP FIBERGLASS REINFORCED 9
PLASTIC
F2 I.D. FAN 100 HP 9
PI RECYCLE PUMP 40 HP, 1200 GPM 9
RECYCLE TANK
T "///< \ Tj VENTURI M.S. 9
> \ Cl ^ RECYCLE TANK
J> I i~^ -rn cTAftf
t-l- illll\ 1 TANK
_. VI VENTURI 625 INCONEL 9
's
WASTE
FIGURE 14-15. PROCESS FLOW DIAGRAM;
TEXACO
SAN ARDO, CALIFORNIA
STWAK NO.
RATE, Ib/hr
•cfn K 1000
W"
PAKTICULATES. Ib/hr
S0?. Ib/hr
TEMPERATURE, *F
TOTAL SOLIDS. X
SPECIFIC GRAVITY
HjO, Ib/hr
I*
SULFITE.ng/l
SULFAn. 1*9/1
CHLODIOE.ing/l
[Tl
234
600
(7)
136.8
160
cn
(J)
©
(?)
o
1200
fB)
0
(10)
BOO
-------
TO STACK
FLUE GAS IN
O1
-"-a
H
Tl
L
r*
;• —
W
/H\
/r\
g_p
r^
•^
P
® 1 1 MAKE-UP HATER
T3 $$ EQUIPMENT LIST
EQ NO. NAME SIZE, FEET MATERIAL NO.
Al ABSORBER IS DIA. x 20.5 HIGH 316L SS TRAYS 1
INCONEL 625
<2> PI RECIRCULATION 550 6PM 9 15 PSIG 2
PUMP
Q1 QUENCHER 1
TANK
<5) ^ T2 RECIRCULATION 1
1 T3 HEAD TANK 1
FIGURE 14-16. PROCESS FLOW DIAGRAM;
TEXASGULF,
GRANGER, WYOMING
STREAM NO.
RATE, Ib/hr
tcfm » 1000
9V1
PART1CULATES. Ib/hr
SO Ib/hr
TEMPERATURE, 'f
TOTAL SOLIDS, I
SPECIFIC GRAVITY
H 0 Ib/hr
pH
SULFITE mq/\
SULFATE .ng/1
CHLO*IOi.ii>9/l
m
156.1
350
m
121.1
120
rTi
1023
rri
JWn
30
m
r?)
292?
120
fTl
700
raj
300
f9)
300
flQ)
(ft
116
1?)l
66
LIJ)
0-50
®
200
^
200
^
100
®
IS
(Ti)
*T-
_116
(ft)
60-9
-------
TECHNICAL REPORT DATA
(Please read laUmctions on the reverse before completing)
!1. REPORT NO
i
EPA-600/7-78-052C
2.
3. RECIPIENT'S ACCESSION NO.
•4. TITLE AND SUBTITLE
EPA INDUSTRIAL BOILER FGD SURVEY: Third
Quarter 1978
5. REPORT DATE
November 1978
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
8. PERFORMING ORGANIZATION REPORT NO.
J.Tuttle, A. Patkar, D.Welch, M.Hessling, and
M.Eckstein
3. PERFORMING ORGANIZATION NAME AND ADDRESS
PEDCo. Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
10. PROGRAM ELEMENT NO.
EHE624
11. CONTRACT/GRANT NO.
68-02-2603, Task 36
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
Task Final; 7-9/78
14. SPONSORING AGENCY CODE
EPA/600/13
15. SUPPLEMENTARY NOTES jERL-RTP project officer is R.
919/541-2915.
Michael McAdams, Mail Drop 61,
16. ABSTRACT
The report presents detailed technical Information concerning application of
flue gas desulfurization (FGD) systems to industrial boilers. Design and operation
data is presented for 161 FGD control systems (121 of them operational), designed to
control SO2 emissions from 147 industrial boilers at 57 plants. With a 1978 capacity
of 9. 3 million scfm, an average of more than seven new FGD systems have been put
on line each year since 1972. Information in the report was obtained by a survey of
plant personnel, control system vendors, regulatory agencies, and consulting engin-
eering 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, disposal technique, operational 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.lDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Group
Pollution
Flue Gases
Desulfurization
Boilers
Waste Disposal
Maintenance
Pulping
Chemical Industry
Pollution Control
Stationary Sources
Industrial Boilers
13B
2 IB
07A,07D
ISA
15E
11H
18. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
173
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EPA Form 2220-1
166
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