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

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                  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.

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                                          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

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                             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.

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                               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

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                                        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.

-------
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.

-------
                                                                               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.

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                                                                             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.

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                                                                              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

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                                                                                    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.

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                                                                              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

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                                                                             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,
-------
                                                                               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.

-------
                                                                               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>

-------
                                                                              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

-------
                                                                             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

-------
                                                                               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)) .

-------
                                                                              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

-------
                                                                              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

-------
                                                                            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.

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                                                                              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

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                                                                             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.

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                                                                              <; 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

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                                                                             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







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41.2



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0









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-------
             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







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1600










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0


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-------
                                                                                            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
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ft
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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
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1
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1
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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
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R£l
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P4 FILTRATE PUMP
P5 EXHAUST PUMP
W UNDERFLOW PUMP
RFI ROTARY FILTER 1

SI SEPARATOR 4
Tl RECIRCULAT10N TANK 4
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(Ok
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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
^

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413







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-------
                                                                                 EQUIPMENT LIST
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M
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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
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13

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300







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   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
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Fl F.D. FAN 200 HP. 12 IN. W.6. C.S. 4
,r-i
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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
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                                 PI
                                           MAKE-UP
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                                                                   T2
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                                              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
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(
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V
\







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TREATMENT
NO.

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2
2
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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







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30









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ino










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0


H70










f£


160










r?)


1620










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-------
                GAS IN
tn
oo
1
^ — » 	 — *-
Fl
^
TO
STACK
"^X
AAAA/W\


Al
^^__ 	 --•

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— 
-------
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







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lX.fi









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-------
  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. (



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112







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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
$





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                                     FIGURE  14-13.   OSheet 2 of 2)

-------
                                                                                                    EQUIPMENT LIST
TO
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01
GO
w\:> — LJ
IN n

-------
                                                                              EQUIPMENT LIST
 FLUE
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<«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



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                                 TO STACK
        FLUE GAS IN
O1







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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



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121.1



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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

-------