c/EPA
EPA Utility FGD Survey:
August-September 1978
Interagency
Energy/Environment
R&D Program Report
-------
RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories were established to facilitate further development and application of en-
vironmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7. Interagency Energy-Environment Research and Development
8. "Special" Reports
9. Miscellaneous Reports
This report has been assigned to the INTERAGENCY ENERGY-ENVIRONMENT
RESEARCH AND DEVELOPMENT series. Reports in this series result from the
effort funded under the 17-agency Federal Energy/Environment Research and
Development Program. These studies relate to EPA's mission to protect the public
health and welfare from adverse effects of pollutants associated with energy sys-
tems. The goal of the Program is to assure the rapid development of domestic
energy supplies in an environmentally-compatible manner by providing the nec-
essary environmental data and control technology. Investigations include analy-
ses of the transport of energy-related pollutants and their health and ecological
effects; assessments of. and development of, control technologies for energy
systems; and integrated assessments of a wide range of energy-related environ-
mental issues.
EPA REVIEW NOTICE
This report has been reviewed by the participating Federal Agencies, and approved
for publication. Approval does not signify that the contents necessarily reflect
the views and policies of the Government, nor does mention of trade names or
commercial products constitute endorsement or recommendation for use.
This document is available to the public through the National Technical Informa-
tion Service. Springfield. Virginia 22161.
-------
EPA-600/7-79-022a
January 1979
EPA Utility FGD Survey:
August-September 1978
by
M. Melia, M. Smith, T. Koger, and B. Laseke
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
Contract No. 68-02-2603
Task No. 24
Program Element No. EHE624
EPA Project Officers:
N. Kaplan
Industrial Environmental Research Laboratory
Office of Energy. Minerals, and Industry
Research Triangle Park. NC 27711
J. C. Herlihy
Division of Stationary Source Enforcement
Office of Enforcement
Washington. OC 20460
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington. DC 20460
-------
NOTICE
This report, (prepared by PEDCo Environmental, Inc., Cin-
cinnati, Ohio, under EPA Contract No. 68-02-2603, Task No. 24) is
provided as an information transfer document. Data in this
report are supplied voluntarily by utility representatives; flue
gas desulfurization (FGD) system designers, vendors, and suppli-
ers; regulatory personnel; and others. Neither EPA nor the
designated contractor warrants the accuracy or completeness of
information contained in this report.
This report is the fourth of five supplementary issues to
the December 1977-January 1978 report. Supplementary issues are
cumulative, so that it is necessary to retain only the latest
issue and the December 1977-January 1978 report (EPA-600/7-78-
051a).
Initial distribution of the report (generally, one copy per
company) is limited to organizations and individuals indicating a
specific interest in the field of FGD technology. Additional
copies of this report and succeeding issues can be purchased from
National Technical Information Service, Springfield, Virginia
22151.
ii
-------
CONTENTS
Notice
Tables
Executive Summary and Highlights
Section 1 Summary List of FGD Systems
Section 2 Status of FGD Systems
Alabama Electric
Tombigbee 2
Arizona Electric Power
Apache 2
Arizona Public Service
Cholla 1
Cholla 2
Central Illinois Light
Duck Creek 1
Columbus and Southern Ohio Electric
Conesville 5
Conesville 6
Duquesne Light
Elrama 1 through 4
Phillips 1 through 6
Gulf Power
Scholz IB and 2B
Indianapolis Power and Light
Petersburg 3
Kansas City Power and Light
Hawthorn 3
Hawthorn 4
La Cygne 1
Kansas Power and Light
Jeffrey 1
Lawrence 4
Lawrence 5
Kentucky Utilities
Green River 1, 2, and 3
1
4
Section 3 Performance Description of Operational FGD Systems 22
22
23
24
25
27
28
29
30
32
34
35
36
37
38
39
40
41
42
iii
-------
CONTENTS (continued)
Louisville Gas and Electric
Cane Run 4
Cane Run 5
Mill Creek 3
Paddys Run 6
Minnkota Power Cooperative
Milton R. Young 2
Montana Power
Colstrip 1
Colstrip 2
Nevada Power
Reid Gardner 1
Reid Gardner 2
Reid Gardner 3
Northern Indiana Public Service
Dean H. Mitchell 11
Northern States Power
Sherburne County Station 1
Sherburne County Station 2
Pennsylvania Power
Bruce Mansfield 1
Bruce Mansfield 2
Philadelphia Electric
Eddystone 1A
Public Service Company of New Mexico
San Juan 1
San Juan 2
South Carolina Public Service
Winyah 2
Southern Mississippi Electric
R. D. Morrow 1
Springfield City Utilities
Southwest 1
Tennessee Valley Authority
Shawnee 10A
Shawnee 10B
Widows Creek 8
Texas Utilities
Martin Lake 1
Martin Lake 2
Monticello 3
Utah Power and Light
Huntington 1
Section 4 Summary of FGD Systems by Company
Section 5 Summary of FGD Systems by Vendor
44
45
46
47
48
49
50
51
53
55
57
59
61
63
65
67
68
69
70
71
72
74
75
77
79
80
81
82
83
84
iv
-------
CONTENTS (continued)
Page
Section 6 Summary of New and Retrofit FGD Systems by
Process 86
Section 7 Summary of Operating FGD Systems by Process
and Generating Units 87
Section 8 Summary of Sludge Disposal Practices for
Operational FGD Systems 89
Section 9 Summary of FGD Systems by Process and
Regulatory Class 91
Section 10 Summary of FGD Systems Under Construction 93
Section 11 Summary of Planned FGD Systems 95
Section 13 Total of FGD Megawatt Capacity by Year 98
Appendix A FGD Systems Economics A-l
Appendix B FGD Process Flow Diagrams B-l
Appendix C Definitions C-l
-------
TABLES
No. Page
I Number and Total MW of FGD Systems vii
II Summary of Changes: FGD Summary Report, August -
September 1978 x
III Performance of Operational Units during August -
September Period xi
vi
-------
EXECUTIVE SUMMARY
This report is prepared every other month by PEDCo Environmental,
Inc., under a contract to the Industrial Environmental Research
Laboratory/RTF and the Division of Stationary Source Enforcement
of the U.S. Environmental Protection Agency. Table 1 summarizes
the current status of the FGD systems addressed in this 2-month
period.
Table I
NUMBER OF TOTAL MW OF FGD SYSTEMS
Status
Operational
Under construction
Planning :
Contract awarded
Letter of intent
Requesting/evaluating bids
Considering only FGD systems
TOTAL
No. of
units
46
38
23
1
4
27
139
MW
16,054
16,128
12,450
240
2,350
12,160
59,382
Table II (page x) summarizes the individual units that changed
status during the reporting period.
The performance of the operating systems is summarized in Table
III (page xi). other activity highlights during the months of
August and September are summarized below:
The present total power-generating capability of the electric
utility industry in the United States is approximately 532.4 GW.
Of this total, approximately 250 GW,b representing 47 percent of
the total, is generated by coal. As indicated in Table I, 46
vii
-------
PGD-equipped coal-fired units (representing 16,054 MW of power
capability) are now in service. Thus, 3 percent of the total
utility power generating capacity and a little over 6 percent of
the utility coal-fired capacity are controlled by FGD. By 1986,
the projected total power generating capacity of the electric
utility industry in the United States will be approximately 812.7
GW.a This represents an increase of 53 percent over the present
total and includes retirements of older units (0.4 percent annual
average based on year-end power-generation capability). Of the
1986 total, approximately 363.2 GW,a,b,c (representing 45 percent
of the total) will be generated by coal. 132 of the 139 FGD-
equipped coal-fired units shown in Table I, (representing 55,782
MW of power capacity) are now scheduled for operation by 1986;
therefore, approximately 7 percent of the projected total gener-
ating capacity and 15 percent of the projected coal-fired capac-
ity will be controlled by FGD by the end of 1986.
HIGHLIGHTS: AUGUST-SEPTEMBER 1978
Tombigbee 2 of Alabama Electric Cooperative achieved initial FGD
operations over the August-September period. This new coal-fired
unit uses ESP's for particulate control and a limestone FGD
system for SO- control.
Arizona Electric Power Cooperative announced that Apache 2 became
operational in September. This 200-MW unit controls particulates
by an ESP and S02 with a limestone FGD system. Compliance test-
ing is scheduled in early November.
Arizona Public Service reported that Cholla 1 was in service
through the month of August with the A-module logging 744 hours
of operation, and B-module, 708 hours. The boiler operated 744
hours in February. Reliability index values for Cholla 1 were
100 and 95 percent for A and B modules respectively.
A contract was awarded for the particulate and SO2 control
installation of Basin Electric Power Cooperative. Particulates
will be controlled by a baghouse and SOo by a lime FGD system.
Construction is scheduled to begin at this 455-MW unit in June
1979. The utility announced that it is now requesting bids for
the emissions control system at Laramie River 3. Larami River
Nos. 1 and 2 are currently under construction.
The 23-MW jet bubbling-reactor demonstration plant on Gulf
Power's Scholz Power Generating Station (Units IB and 2B) became
operation during September 1978. This new limestone system
features a large gas/liquid interfacial area and provides partic-
ulate as well as SO2 removal. In the S02 removal operation, the
CT-121 system produces gypsum, which is stacked in the existing
pond.
viii
-------
Because of a continuing strike at Kansas City Power and Light, no
information was reported for Hawthorn 3 or 4; however, the
utility reported La Cygne 1 achieved an average system availability
of 94 percent in August and 96 percent in September.
Jeffrey 1 of Kansas Power and Light began initial FGD operations
in September 1978. The 680-MW limestone unit is expected to
become fully operational by the October-November report period.
The utility reported that no forced outages occurred on Lawrence
4 or 5 during this period.
Louisville Gas and Electric announced that the FGD system on Mill
Creek 1 is now under construction. The combination lime/lime-
stone system is scheduled to become operational in early 1981.
Mill Creek 3 of Louisville Gas and Electric became operational or.
August 13, 1978. The FGD system is now undergoing shakedown and
debugging operations. Operabilities for Cane Run 4 and 5 were 94
and 86 percent for August and 100 and 80 percent for September.
Nevada Power reported that during the period availabilities
ranged from 94 to 100 percent for Reid Gardner 1, 2, and 3, while
reliabilities were between 93 and 100 percent.
The Wellman Lord FGD system on Dean H. Mitchell 11 of Northern
Indiana Public Service Company achieved reliabilities of 98 and
99 percent during August and September, respectively. Boiler
hours were 707 and 319 for August and September.
The FGD systems at Sherburne 1 and 2 of Northern States Power
demonstrated total-system availabilities of 91 and 93 percent for
August. Total-system availabilities for September were 97 and 96
percent for Units 1 and 2, respectively.
The Public Service Company of New Mexico announced that initial
operations began at San Juan 2 in early September; the utility
added that a contract was awarded for the remainder of San Juan
3 and the total FGD system on Unit 4.
Seminole Electric announced plans to construct one and possibly
two new 600-MW coal-fired units, Seminole 1 and 2, that will
utilize ESP's for particulate removal and a limestone FGD system
for SO2 control. The utility expects to initiate bid requests in
May 1979.
R. D. Morrow 1 of Southern Mississippi Electric began initial FGD
operations during the August-September report period. The accep-
tance test is scheduled in November.
Construction began at the Widows Creek 7 FGD facility of Tennessee
Valley Authority and the retrofit unit is expected to begin FGD
operations in October 1980.
ix
-------
TABLE II. SUMMARY OF CHANGES: FGD SUMMARY REPORT,
AUGUST - SEPTEMBER 1978
PCD statin report
7-31-71
AlcbeM Electric Coop
TDBblqbe* 2
Arisen* Electric Power Coop
Aptche 2
•••In Electric Power Coop
Antelope Valley 1
•••In Electric Power Coop
Laruie River J
Gulf Paver
Scholl IB wid JB
Kansas Power and Light
Jefferey 1
Louisville Cae and Electric
Mill Creek 1
New England Electric Bysten
•rayton Point )
Northern State* Power
Sherburne 3
northern State* Power
Sherburne 4
Public Service of New Mexico
San Juan 2
Public Service of New Mexico
San Juan 4
Sealnole Electric
Saolnole 1
Southern Mississippi Electric
B.D. Morrow 1
Tennessee Valley Authority
Mldows Creek 7
Total
Operational
NO.
40
»1
+1
+1
*1
+1
«•!
46
«w
14.440
22S
200
23
610
306
ISO
16,054
Under
construction
No.
42
-1
-1
-1
-1
+1
-1
-1
*1
38
MH
16.134
22S
200
20
610
330
306
180
S7S
16.128
Contract
awarded
No.
21
*1
-1
+1
+1
41
-1
23
MH
10,708
455
330
860
860
472
575
12,450
Letter of
Intent
No.
3
-1
-1
1
Mtf
1,960
860
860
240
Raqueitlng/
ev«l bid*
No.
4
-1
»1
MW
2,255
455
550
2,350
Considering
rco
No.
2*
-1
-1
-1
+1
MM
13.232
550
150
472
600
12,160
Total
No.
139
_»
+1
MH
59.469
650
600
59,382
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TABLE III.
PERFORMANCE OF OPERATIONAL UNITS DURING
AUGUST - SEPTEMBER PERIOD
Plant
Toafclgbaa 2
Apacha 2
Cholla 1
Cholla 2
Duck Cr««k 1
Conaavllla 5
Conaavllla 6
Elrau
Phillip*
Scholt IB and 21
Pataraburg 3
Havthom 3
Hawthorn 4
La Cygna
Jaffray 1
Lawranca 4
Lavranca 5
Craan Klvar 1,2, and
Cana Ihm 4
Cana tun .5
Hill Craak 3
Paddy* lun 6
Ml Icon 1. Tounf 2
Colatrlp 1
Colatrlp 2
Raid Cardnar 1
•aid Gardnar 2
•aid Cardnar 3
Daan H. Hltchall 11
Sharburna 1
Sharburna 2
Bruca Hanaflald 1
Bruca Hanaftald 2
Eddyatona U
San Juan 1
San Juan 2
Vlnyah 2
•. D. Morrow 1
Southvaat 1
Shavnaa IDA
Shawnaa 108
Widow* Craak 8
Martin Uka 1
Martin Uka 2
Hontleallo 3
Huntington 1
TOTAL
-CD ayataa
daal(n
capacity
22}
200
11)
250
400
400
400
510
410
23
$30
100
100
820
680
12S
400
64
178
18)
425
65
450
360
360
125
125
125
US
710
710
825
825
120
314
306
280
180
200
10
10
550
793
793
750
41S
6,054
PCD unit
on-llna during
period
22S
200
115
250
400
400
400
510
410
23
530
100
100
820
680
125
400
64
178
183
425
65
450
125
125
125
115
710
710
120
314
306
280
180
100
10
10
793
793
750
415
13.014
Ho
intonation
(or thla
parted
360
360
825
825
550
2.920
Shutdown
throughout
parlod
100
100
PCD ayatra
availability,
X
Augua t
18
5)
94
61
94
95
98
98
91
93
30
Scptrabar
58
62
99
96
76
99
100
100
44
97
96
11
PCD ay|taa
oparablllty,
X
Auguat
21
53
99
94
86
93
93
98
38
30
100
Septeabar
45
53
100
100
80
81
99
100
100
78
14
100
PCD ayatav
reliability.
X
Auguat
98
21
74
99
94
82
98
98
30
Septnbtr
54
55
98
97
97
97
99
14
PCD ayataa>
utllltatlon.
X
Auguat
IB
48
28
94
62
89
81
97
98
32
30
73
S«p tester
44
52
41
19
67
80
87
94
32
44
56
14
69
XI
-------
REFERENCES
a. Sixth Biennial Survey of Power Equipment Requirements of the
U.S. Electric Utility Industry: 1977-1986, sponsored by the
Power Equipment Div., National Electrical Manufacturers
Association.
b. Policy Testing Model for Electric Utilities, Exhibit II-3,
Developed by Temple, Barker, and Sloane, Inc.
c. 12 Annual Power Engineering Survey. Power Engineering, April
1978.
xii
-------
COMPANY NAME
EPA UTILITY FGD SURVEY: AUGUST i<»78 - SEPTEMBER i«»7B
SECTION I
SUMMARY LIST OF FGO SYSTEMS
UNIT NAME
START UP DATE STATUS
KEG
CLASS
ALABAMA ELECTRIC COOP
ALABAMA ELECTRIC COOP
ALLEGHENY POWER SYSTEM
ALLEGHENY POwFR SYSTEM
ARIZONA ELECTRIC POWER COOP
ARIZONA FLECTRIC POWt» COOP
ARIZONA PUBLIC SERVICE
ARIZONA PUBLIC SERVICE
ARIZONA PUBLIC SFRVTCF
ARIZONA PUBLIC SERVICE
ARIZONA P'IRLTC SERVICE
ARIZONA PUBLIC SERVICE
ARIZONA PUBLIC SERVICE
ARIZONA PUBLIC SERVICE
ASSOCIATED ELECTRIC COOP
BASIN ELECTRIC POWER COOP
BASIN F.LECTRIC POWER COOP
BASIN ELECTRIC POWER COOP
BASIN ELECTRIC POWER COOP
BASIN ELECTRIC POWER COOP
BIG RIVERS ELECTRIC
HIG RIVEkS ELECTRIC
CENTRAL ILLINOIS LIGHT
CENTRAL ILLINOIS LIGHT
CFNTRAL ILLINOIS PUBLIC SEHV
CENTRAL MAINE POnER
CINCINNATI GAS * FLECTRIC
COLORADO UTF ELECTRIC ASbN.
COLORADO UTF. FLECTRIC ASSN.
COLUMBUS t SOUTHERN OHIO FLtC.
COLUMBUS * SOUTHERN OHIO ELEC.
COLUMBUS ft SOUTHERN OHIO ELEC.
COLUMBUS ft SOUTHERN OHIO ELEC.
COMMONWEALTH EDISON
COOPERATIVE POWER ASSOCIATION
COOPERATIVE POWF.K ASSOCIATION
DF.LMARVA POWER ft LIGHT
DHQUESNF LIGHT
OUOUESNE LIGHT
EAST KENTUCKY POWER COOP
GENERAL PUBLIC UTILITIES
GENERAL PUBLIC UTILITIES
GULF PONER
HOOSIER ENERGY
HOOSIFR ENERGY
INDIANAPOLIS POWER ft LIGHT
INDIANAPOLIS PONER ft LIGHT
KANSAS CITY POWER ft LIGHT
KANSAS CITY POWEH ft LIGHT
KANSAS CITY POWER ft LIGHT
KANSAS POWER ft LIGHT
KANSAS POWER ft LIGHT
KANSAS POWER ft LIGHT
KANSAS POWER ft LIGHT
KENTUCKY UTILITIES
L»KFLANO UTILITIES
LOUISVILLE GAS ft ELECTKIC
LOUISVILLE GAS ft ELECTRIC
LOUISVILLE GAS ft ELECTKIC
LOUISVILLE GAS ft ELECTRIC
TUMBIGBEE 2
TUMHIGREE *
PLEASANTS t
PlEASANTS 2
AHACHt 2
APACHf 3
CHOLLA t
CHOLLA 2
CHOLLA 0
FOUR CORNERS 1
FOUR COMNERS 2
FUUH CORNERS J
FOUR CORNERS a
FOUR CORNERS 5
THOMAS MILL 3
ANTELOPE VALLEY I
ANTELOPE VALLEY 2
LARAMIF RIVER 1
LARAM1E RIVER 2
LA9AMIE RIVER 1
GkEEN 1
GWFF.N 2
DUCK CREEK 1
DUCK CREFK 2
NEWTON i
SEARS ISLAND 1
EAST BENO 2
CRAIG 1
CRAIG 2
CONESVILLE 5
CONESVILLE 6
POSTON 5
POSTOH 6
POWERTON si
COAL CREEK 1
COAL CREFK 2
DtLnARE CITY 1, 2 ft I
ELKAMA POWER STATION
PHILLIPS POWER STATION
SPURLUCK 2
COHO 1
SEWARD J
SCHOL/ IB ft 2B
ME ROM t
MEROM 2
PETERSBURG 3
PETERSBURG 4
HAWTHORN 3
HAWTHORN 4
LA CVGNE 1
JEFFREY 1
JEFFREY 2
LAWRENCE 4
LAWRENCE 5
GREEN RIVER 1.2 ft 3
MCINTOSH 3
CANE RUN 4
CANE HUN 5
CANE RUN 6
MILL CREEK 1
9-78
8-79
3-79
3-80
8-78
0-79
10-73
6-78
6-80
0-79
0-79
0-79
0-82
0-82
1-82
11-81
11-83
a-eo
10-80
0-82
12-79
12-80
7-78
1-82
11-79
11-86
1-81
3-79
3-79
1-77
6-78
0-83
0-8S
3-79
P-79
11-79
4-80
10-75
7-73
3-80
5-87
5-84
8-78
0-81
1-82
10-77
4-82
11-72
8-72
2-73
8-78
6-80
12-68
11-71
9-75
10-81
8-76
12-77
12-78
1-81
1
2
2
2
1
2
1
1
2
6
6
6
3
3
3
3
6
2
2
5
2
2
1
5
2
h
3
2
2
1
1
6
6
2
2
2
2
1
1
3
6
6
1
2
2
1
2
1
1
1
1
2
1
1
1
3
1
1
2
2
1. OPERATIONAL UNITS
2. UNITS UNDER CONSTRUCTION
3. PLANNED - CONTRACT AWARDED
o. PLANNED - LETTER OF INTENT SIGNED
5. PLANNED - REQUESTING/EVALUATING BIOS
6. CONSIDERING ONLY FGD SYSTEMS
7. CONSIDERING FGO SYSTEMS AS WELL AS ALTERNATIVE METHODS
A. BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
B. BOILER SUBJECT TO STATE STANDARD THAT IS MORE STRINGENT THAN THE FEDERAL NSPS
C. BOILER SUBJECT TO STATE STANDARD THAT IS EQUAL TO OR LESS STRINGENT THAN NSPS
0. OTHER
E. REGULATORY CLASS UNKNOWN
-------
EPA UTILITY FGO SUUVFY: AUGUST i<»?8 - stPTFMHtR i97«
COMPANY NAMfc
SFCT10N 1
SUMMARY LIbT OF FRI) SYSTEMS
UNIT NAME
START UP DATE STATUS
HFG
CLASS
LOUISVILLE KAS &
LOUISVILLF GAS &
LOUISVILLE GAS *
LOUISVILLE GAS *
ELECTKIC
FLFCTBIC
ELECTKIC
ELECTRIC
MINNESOTA POwEH K LIGHT
HINNKOTA POKER COOPERATIVE
MONTANA POKED
MONTANA POnER
MONTANA Pn«FH
MONTANA POWER
NEVAD* POWER
NFVADA POWER
NEVADA POWER
NFVADA PQWEP
NEVADA POKE*
NEVADA POWER
NEVADA POWER
NEVADA POWER
NFVAOA POWFR
NEVADA POKE"
NEN ENGLAND ELEC SYSTEM
NTACARA MOMAftK POWER CUOH
NOHTHFRN INDIANA PUR SERVICE
NORTHERN INDIANA PUR SERVICE
NORTHERN INDIANA PUB SERVICE
NORTHERN STATES POWER
NORTHERN STATES POWFK
NORTHERN STATES POWER
NORTHERN STATES POWFR
OTTER TAIL POWER
PACIFIC GAS AND ELECTRIC
PACIFIC GAS AND ELECTRIC
PACIFIC POnER ft LIGHT
PENNSYLVANIA POWER
PFNNSYLVANIA POWER
PENNSYLVANIA POWER
PHILADELPHIA ELECTRIC
PHILADELPHIA ELECTRIC
PHILADELPHIA ELECTRIC
PHILADELPHIA ELECTRIC
POTOMAC ELECTRIC POWER
POWER AUTHORITY OF NEW YORK
PUBLIC SERVICE OF INUTANA
PUBLIC SERVICE OF NEw MEXICO
PUBLIC SERVICE OF NEW MEXICO
PUBLIC SERVICE OF NEW MEXICO
PUBLIC SERVICE OF NEW MEXICO
SALT RIVER PROJECT
SALT RIVER PROJECT
SALT RIVER PROJECT
SAN MIGUEL ELECTRIC COUP
SEMINOLE ELECTRIC
STKESTON BOARD OF MUNIC. UTIL.
SOUTH CAROLINA PUBLIC SERVICE.
SOUTH CAROLINA PUBLIC SERVICE
SOUTHERN ILLINOIS POWER COOP
SOUTHERN ILLINOIS POWER COOP
SOUTHERN INDIANA GAS ft ELEC
SOUTHERN MISSISSIPPI ELECTRIC
SOUTHERN MISSISSIPPI ELECTRIC
MILL CREFK 2
MILL CWEFK 3
MILL CRfcFK a
PAOOYS R'lN 6
CL»Y UOSWblL «
MILTON K. YOUNG 2
CULSTHIP 1
COLSTHIP i
COLSTRtP ?
COLSTRIP a
HARRY ALLEN 1
HARRY ALLEN I
HARRY ALLFN *
HAPHY ALLEM a
RE 10 GAHDNEH I
Rt-IO GARDNER 2
RE II) bARONEK •>
"»t ID GARDNER 4
WARNER VALLEY 1
WARNFW VALLEY i
BRAY TON POINT 3
CHAKI tS R. HUNTLEY b
8AILLY 7
RAlLLY 6
DEAN H. MITCHELL 11
SHERRURNE i
SHERRURNE 2
SHERRURNE 3
SHEHBURNE 4
COYOTE I
FOSSIL 1
FOSSIL 2
JIM RRTDGER 9
BkUCE MANSFIELD 1
BRUCF MANSFIELD 2
BRUCE WANSFIELO 3
CHOMBY
EDOYSTONF 1A
EODVSTONE IB
EDDYS10NE 2
OICKERSUN a
ARTHUR KILL PLANT
GIBSON S
SAN JUAN 1
SAN JUAN 2
SAN JUAN 3
SAN JUAN a
CORONADO 1
CORONADO 2
CURONADO 3
SAN MIGUEL i
SEMINOLE 1
SIKESTON POhEK STATION
WINYAH 2
WINYAH 3
MARION a
MARION 5
A. B. RROwN 1
R. o. MORROW i
R. o. MORROW 2
1-82
8-78
6-80
a-7$
5-80
9-77
11-75
8-7b
7-80
7-81
b-85
b-ftb
b-87
b-BB
«-7a
0-1 a
7-7b
0-83
h-fla
b-85
0- 0
0-80
0- 0
0- 0
Il-7b
3-7b
fl-77
5-84
0-87
5-81
0-85
0-Bb
9-79
4-7b
7-77
4-80
6-80
9-75
6-80
b-BO
5-85
11-84
0-82
0-78
7-78
b-79
1-82
1-79
1-80
0-87
b-80
6-83
6-81
7-77
5-80
9-7«
0-84
4-79
8-76
1-79
3
I
2
I
2
I
I
1
3
3
b
b
b
b
I
1
1
b
b
6
7
3
b
b
I
1
1
3
3
2
b
b
2
1
1
2
6
1
4
6
7
7
5
1
1
3
3
2
2
b
2
b
2
1
3
2
6
2
1
2
C
c
C
c
c
B
R
B
B
A
B
B
B
B
B
B
B
B
B
B
D
B
A
B
B
B
B
B
B
B
1. OPERATIONAL UNITS
Z. UNITS UNDER CONSTRUCTION
y. PLANNED - CONTRACT AWARDED
4. PLANNED - LETTER OF INTENT SIGNED
5. PLANNED - REQUESTING/EVALUATING BIOS
6. CONSIDERING ONLY FGO SYSTEMS
7. CONSIDERING F60 SYSTEMS AS HELL AS ALTERNATIVE METHODS
A. BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
B. BOILER SUBJECT TO STATE STANDARD THAT IS MORE STRINGENT THAN THE FEDERAL NSPS
C. BOILER SUBJECT TO STATE STANDARD THAT IS EQUAL TO OR LESS STRINGENT THAN NSPS
D. OTHER
E. REGULATORY CLASS UNKNOWN
-------
EP» UTILITY F6T) SURVEY: »U6oS I 1978 - SEPTEMBER 1978
SFCTIUN 1
SUMMARY LIST OF FGI) SYSTEMS
COMPANY
SnuThMESTEHN ELFCTKIC POnEk
SPRlNGFTfcLD CIFY UTILITItS
SPRlNGFItLU nATEk LIGHT ft PHH
ST. JOF I INC
TFNNESSEE VALLEY AUTHORITY
TENNESSFE VALLEY AUTHORITY
TFNNESSFE VALLEY AUTHORITY
TENNESSEE VALLEY AUTHUklT*
TFXAS MUNICIPAL POHF/H AGtNCY
TFXAS POwFR ft LH
-------
EP» UTILITY FGO SURVEY! AUGUST 197H - SEPTFMBU? 1978
UNIT IDENTIFICATION
SECTION i
STATUS OF FGO SYSTkMS
CURRENT STATUS
ALABAMA ELECTRIC COUP
TOMBIGHEE ?
225 MH - NEW
COAL: i.isx SULFUR
PEAHODY ENGINEERING
LIMFSTONE
STARTUP 9/7H
REFEW TO SECTIUN ? W 1HIS REPORT FOR ADDITIONAL INFORMATION.
PFAROnr tNUINFERING «Ab AMAKOEI) A CONTRACT FOR THE INSTALLATION OF A LIME-
STONE FGU SYSTEM ON THIS UNIT. A HIGH-fcFF1C IFNCV ESP INSTALLED IIPSTRfcAM OF
THt FGO SYSTEM PROVIDES PRIMARY PARTICULAR CONTROL. THE FGD SYSTEM CON-
JAINS TKO SCRUBBING TRAINS. TREATING APPROXIMATELY 70X OF THF FLUE GAS FOR
RFMOVAL OF SU2. SlACK i;AS HFHFAT IS NOT REQUIRED. IHt UNIT IS CURRENTLY IN
THE SHAKtOUWN-DEBUbGlNfc PHASt OF OPERATIONS.
ALABAMA FLECTKIC COOP
TQMRIGBEE 3
225 MH - NE«
co»u: 1.1sz SULFUR
PEABOOY ENGINEERING
LIMESTONE
STARTUP 6/79
PFABOOY ENGINEERING HAS BEEN AWARDED A CONTRACT FOR THE INSTALLATION
OF A LIMESTONF FGO SYSTEM ON THIS UNIT. A HlGH-EFF1CIFNCV ESP WILL
F)F INSIALLtn IIPSl»tAM OF THE FGO SYSTFM TO PROVIOF PRIMARY
PARTICULATE CONTROL. THE FGO SYSTEM CONSISTS OF TfcO TRAINS, TOGETHER
IREATING APPROKIMA1ELY 70t OF THE Fl UE GAS FOR REMOVAL OF SULFUR
DTUXIDt. STACK GAS REHEAT nILL NOT HE REUUIRED. CONSTRUCTION ON THE UNIT 3
TURAINt ANO BOILER IS NOfl bOI COMPLETE.
ALLEGHENY po«t»
PLEASANTS i
625 MH - NEH
CO»L: «.5x SULFUR
BABCOCK * HILCOX
LIME
STARTUP 3/79
THE THCEE PRINCIPAL OPERATING UTILITY COMPANIES OF THE ALLEGHENY POWER
SYSTEM ARE INSIALLING AN EMISSION CONTROL SYSTEM FOR THIS NFH COAL-FIRED
UNIT WHICH INfLUDES A HIGH EFFICIENCY ESP UPSTRFAM OF FOUR TRAY TONERS
FOR THE CONTROL OF PARTICIPATES ANU SULFUR DIOXIDE. DESIGN REMOVAL
EFFICIENCIES FOR THIS EMISSION CONTROL SYSTEM ARE 99.5 ANO 90 PERCENT
RESPECTIVELY. IHt ORAVII CO. IS SUPPLYING THtOSORbIC LIME. THE CONSULTING
ENGINEERING URM IS UNITED ENGINEERS ANO CONSTRUCTORS. CURRENTLY, ERFC-
1ION OF THE SCRUBBING tOUIPMENT IS IN PROGRESS.
ALLEGHENY POKER SYSTEM
PLEASANTS 2
625 MH - NEM
CUAL; «.sz SULFUR
BABCOC* * HILCOX
LIMF.
STARTUP 3/8U
THE IHKEk PRINCIPAL OPERATING UTILITY COMPANIES OF THE ALLEGHENY POHER
SYSTEM ARE INSTALLING AN EMISSION CONTROL SYSTEM FOR THIS NEM COAL-FIRED
UNIT WHICH INCLUUES A HIGH EFFICIENCY ESP UPSTREAM OF FOUR TRAY TOMFRS
FOR THt CONTROL OF PARIICULATES ANO SULFUR DIOXIDE. DESIGN REMOVAL
EFFICIENCIES FOR THIS EMISSION CONTROL SYSTEM ARE 99.5 AND 9u PERCENT,
RESPECTIVELY. THE DRAVU CO. IS SUPPLYING THIOSORBIC LIME. THE CONSULTING
ENGINEERING FIRM IS UNITED ENGINEERS ANO CONSTRUCTORS. CURRFNUY, FOUNDA-
TION MURK ON THF SCRUBBER PLANT IS IN PROGRESS.
ARIZONA ELECTRIC POHER COOP
APACHE 2
200 MW - NEW
COAL; o.7z SULFUR, toz ASH
RESEARCH COTTRELL
LIMESTONE
STARTUP 0/78
REFER TO SECT KIN 3 OF THIS REPORT FOR ADDITIONAL INFORMATION. THE FGO
SYSTEM FUR THIS NFw 200 MH UNIT HAS SUPPLIED BY RESEARCH TOTTRELL. THE
DESIGN INCLUUES A 22 ACRE SLUDGE POND ANO A 64 ACRE ASH POND, BOTH OF
WHICH ARE UNLlNtD AND TEN FEET DEEP. A REHEAT SYSTEM IS NOT INCLUDED. THE
LINERS USED IN THE STACK AND THE OUCTS THAT LEAD TO THE STACK ARE A NEW
COIF RKAND cxL20oo WHICH HAS A VERY HIGH HEAT RESISTANCE. THIS UNIT BURNS
BITUMINOUS CUAL WITH SULFUR ANO ASH CONTENTS OF .71 AND 10Z RESPECTIVELY.
INITIAL OPERATION OF THIS UNIT BEGAN IN AUGUST, 1978.
ELECTRIC
COOP
APACHE 3
200 MH - NEW
COAL: 0.7X SULFUR, 10S ASH
RESEARCH COTTRELL
LIMFSTONE
STARTUP 4/79
CONSTRUCTION OF UNIT 3 IS NOW ESSENTIALLY COMPLETE. STRUCTURE
ERECTION OF IHt SCHUHBtR-ABSORHER TOMERS IS COMPLETE. EACH SCRUBHEH CAN
HANDLE 400,000 ACFM tf 270 F AND HECIKCULATE 20,000 f.PM OF SLURRY. BOILER
CONSTRUCTION HAS BEGUN. THERE ARE CURRENTLY 2 PONDS nITH A TOTAL OF 20-
YRS CAPACITY FOR THE DISPOSAL OF THE UNFIXATED SLUDGE. 2 ADDITIONAL PONDS
ARE PLANNED PROVIDING AN ADDITIONAL 20 YRS OF DISPOSAL CAPABILITY. THERE
HILL BE NO REHEAT. BECAUSE OF THE HIGH COST OF THE UNIT 2 STACK LINER,
UNIT 3 WILL USE A CEILCOTE LINING INSTEAD OF THE CXL2000 USED IN UNIT 2.
ARI70NA PUBLIC SERVICE
CHOLLA i
115 MH - RETROFIT
COAL; 0.55Z SULFUR. 10Z ASH
RESEARCH COTTRELL
LIMESTONE
STARTUP 10/73
RFFER 10 SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THIS LIMESTONE SCRUBBING SYSTEM HAS PLACED IN SERVICE IN OCTOBER 1973.
THE SCRUBBER PLANT CONSISTS l)F TwO PARALLEL SCRUBBING TRAINS. PARTICU-
LATE CONTROL IS PROVIDED BY THO FLOOOED-DISC SCRUBBERS. S02 CONTROL IS
PROVIDED BY ONE PACKED (MIINTERS PACKING) TOWER (A-SIDE). FLUE GAS CLEAN-
ING HASTES ARE DISCHARGED TO AN EXISTING FLY ASH POND. NO HATER IS RE-
CYCLED BACK FROM THE DISPOSAL POND. IN-LINE STEAM RFHEATERS RAISE THE
GAS TEMPERATURE 40 F.
ARIZONA PUBLIC SERVICE
CHOLLA 2
250 MH - NEM
COALf 0.55Z SULFUR. 10Z ASH
RESEARCH COTTRELL
LIMESTONE
STARTUP 6/70
REFER TO SECTION 3 OF THIS REPORT FOB ADDITIONAL INFORMATION.
THE CONTRACT FOR THIS HET LIMESTONE SCRUBBING SYSTEM HAS AHARDED BY THE
UTILITY 10 RtSEAHCH-COTTRELL. THE DESIGN INCLUDES MECHANICAL COLLECTORS
FOR PRIMARY PARTICULATE REMOVAL. THE F6D SYSTEM CONSISTS OF FOUR PARALLEL
FLOODEU-DISC AND PACKED TOMER ABSORBER TRAINS. THREE ARE REUUIRED FOR FULL
LOAD CAPACITY. INITIAL OPERATIONS BEGAN IN JUNE 1978. COMPLIANCE TESTING
MAS COMPLETED DURING THE SECOND HEEK OF AUGUST 1978. THE UNIT IS CURRENTLY
UNDERGOING SHAKEOOHN AND OEBUCGIN6 OPERATIONS.
-------
FPA uitLirr FGO SURVEY: AUGUST i<>78 - SEPTEMBER 1978
UNIT IDENTIFICATION
SECTION ?
STATUS OF FGI) SYSTtMS
CUMRfiNT STATUS
ARIZONA PURLIC SEKVICh
CHOLLA q
350 MW - Hit
CO*L; o.7x SULFUR
RESEARCH COTTRELL
LIMESTONE
STARTUP 6/80
UNIT NU. 0 Tb CUKRENTl Y UNUFR CnNSfRUCTION. APS HAS AWARDED THt FRO CON-
TRACT TO REStARCH COTTHELL. THE STATE REGULATORY AGENCY MAS NOT YET DE-
CIDED IHfc EMISSIONS REGULATIONS WHICH WILL APPLY TO THF PLANT. THE C-F
BOIlhR WILL FIKF THE SAM£ COAL »S CHULLA NO. 1, i»ITH SULFUR CONTENT OF
o.aa-i.o PERCENT. THE A-E FIRM is EBASCO. int FGU SYSTEM is A DOUBLE LOOP
LIMFSTtiNE ABSORPIION PHOCFSS ANO REVENUES OF THF CONTRACT TO R-f ARE
RFPOxTtn TO HF *b MM. K)R CONTROL OF PAHTICUL'TF »N F.SP »ILL HANDLE 100X
OF THF FLUE SAS.
ARIZONA PUBLIC SERVICE
FOUR CORNERS 1
175 MW - RETROFIT
COAL: o.7x SULFUR
THEMICO/APS
LIME/ALKALINF FLYASH
STARTUP 0/79
APS «ILL RE UPGRADING THE OPERATIONAL PARTICULATE SCRUBBERS AT THE FOUR
CORNERS 1, 2 AND 3 FUR ADDITIONAL S0<> KFMIIVAL. CURRENTLY, EACH UNIT H»S 2
CHEMICU VFNTURI SCRUBBER MODULES FOR PARTICULATE CONTROL. ROUGHLY 30Z OF
IHfc FLUF GAS SO? CONTENT IS REMOVFU AT THE PRESFNT TIME IN THF VENTURIS
rtlTH THE HIGH AIKALINF FLYASH. NEW MEXICO APC OFFTCALS INDICATED THAT
THE b FOUR CORNERS UNITS (KILL BE REOUIRFO 10 REMOVE AT LfcAST 67.5X OF THE
STATION S02 (ALl 5 UM1S CUNS10EHFO TOGETHER). ADDITIONAL ALKALINITY (KILL
BF IMPARTED TO THF SCRUBBING SOLUTION UY ADDING LIME.
ARIZONA PURLIC SERVICE
FOUR CORNERS 2
175 MW - RETROFIT
COAL: 0.7X SULFUR
CHFMICO/APS
LIMF./ALKALTNF. FLYASH
STARTUP 0/7<*
APS. HILL BE UPGRADING THfc OPERATIONAL PARTICULATE SCRUBBERS AT THE FOUR
CORNERS UNIT NUS. I, 2 AND 3 FOR ADDITIONAL SO? REMOVAL. EACH UNIT HAS 2
CHtMICU VENTURI SCRUBflER MODULES FOR PARTICULATE CONTROL. ROUGHLY iOI OF
THE FLUE GAS SO? CONTENT IS REMOVED AT THE PRESENT TIME IN THE VENTURIS
nlTH THF HIGH ALKALINE FLYASH. NE«< MfcXICU APC OFFICALS INDICATED THAT
THE b FOUR CORNERS UNITS WILL BE REQUIRED TO REMOVE AT LEAST 67.5X OF THE
STATION sm (ALL S UNITS, CONSIDERED TOGETHER). ADOITONAL ALKALINITY WILL
BF IMPARTED TO THE SCRUBBING SOLUTION BY ADDING LIME.
ARIZONA PUBLIC SERVICE
FOUR CORNERS i
229 MW - RETROFIT
CUAL; o.7x SULFUR
CHFMICO/APS
LIMF/ALKALINF FLYASH
STARTUP 0/79
APS WILL BE UPGRADING THE OPERATIONAL PARTICULATE SCRUBBERS AT THE FOUR
CORNERS UNIT NOS. 1, 2 AND 3 FOR ADDITIONAL S0
THE UTILITY IS CURRENTLY EVALUATING THE DATA AND INFORMATION ACCUMULATED
MURING THF HORIZONTAL PROTOTYPE SCRUBBING PROGRAM IN ORDER TO ASCERTAIN
VARIOUS POSSIBLE STRATEGIES TO CONTROL THE EMISSIONS FROM THIS COAL FIRED
755-MW UNIT. APS WILL BE REQUIRED TO REDUCE THE CURRENT LEVEL OF S02 FMIS-
STONS FROM THE ENTIRE PLANT BY INCREASING THE REMOVAL EFFICIENCY TO AT
LEAST 67.5X. A CONTRACT HAS BF.EN AWARDED TO UNITED ENGINEERS FQR THE
ENGINEERING AMD CONSTRUCTION OF AN FGD SYSTEM.
ASSOCIATED ELECTRIC COOP
THOMAS HILL 3
670 MM - NE«
COAL; 4.ax SULFUR/ 11.ax ASH
PULLMAN KELLOGG
LIMESTONE
STARTUP 1/82
BASIN ELECTRIC POWER COOP
ANTELOPE VALLEY 1
455 MM - NEW
LIGNITE; 0.68X SULFUR, 8X ASH
VENDOR NOT SELECTED
LIME
STARTUP 11/81
ASSOCIATED ELECTRIC COOP AWARDED A CONTRACT TO PULLMAN KELLOGG FOR THE
ENGINEERING, PROCUREMENT AND CONSTRUCTION OF AN FGO SYSTEM ON THE UTILI-
TY'S THOMAS HILL UNIT NO. 3 POWER PLANT, soa REMOVAL EQUIPMENT WILL OPER-
ATE IN CONJUNCTION WITH A HIGH EFFICIENCY ESP. THE SYSTEM, SCHEDULED FOR
START-UP IN 1982, WILL UTILIZE MAGNESIUM-PROMOTED LIMESTONE AS A REAGENT
IN THF FOUR MODULE WEIR FGD SYSTEM. REHEAT WILL PROBABLY NOT BE INCLUDED,
SINCE THE CHIMNEY WILL BE BRICK LINEO. THE DRV FIXATED SLUDGE MILL BE
HAULED TU AN ACTIVE STRIP MINE. THE GROUND BREAKING HAS TAKEN PLACE.
THE UTILITY HAS SELECTED A LIME SCRUBBING PROCESS FOR THEIR
PLANNED FGO SYSTEM. THE UNIT WILL FIRE LIGNITE COAL WITH A SULFUR CONTENT
OF 0.6R PERCENT AND AN ASH CONTENT OF 8.0 PERCENT (6600 BTU/LR). THE WATER
LOOP WILL BE OPEN WITH MAKE-UP COMING FROM COOLING TOMER SLOWDOWN. THE
SLUDGE WILL BE DISPOSED IN A MINE LANDFILL. A CONTRACT HAS BEEN AWARDED
TO WESTERN PRECIPITATION FUR A BAGHOUSE AND TO NIROLL ATOMIZER FOR A
DRY FGD SYSTEM.
-------
FPA UTILITY
SURVEY: AUGUST i«78 - SEPTEMBER
UNIT
SFMIIIN P
STATUS OF FBI) SYSTEMS
IDENTIFICATION CURRENT STATUS
BASIN FLECTRIC POWER COUP
ANTELP"E VALLEY ?
055 MM - HI ft
LIGNITE; O.hBl SULFUR, fit ASH
VENDOR NOT SELECTED
f-xnCESS NOT SELEC»El>
STARTUP 11/84
IHt UT1I1TY IS TENIAMVELY INVESTIGATING VARIOUS FGD PROCESSES FOR THIS
SFCONP I IGNITF-FIRF.D UNI T SCHEOULFO AT THE NfcH STATION LOCATED IN MERCER
COIIN1Y, NEAR BtULAH, NuRTM DAKOTA. THIS NEW FACILITY WILL BF KNOWN AS
THE ANTELOPF VALLEY STATION AND MLL BE REQUIRED TO COMPLY WITH STATE AIR
EMISSION STANDARDS VIA IMF BbST AVAILABLE TECHNOLOGY. START-UP IS NOW
SCHEDULED FOk NOVEMBER 1983.
BASIN FLECTRIC PO«EH COOP
LARAMIE RIVER 1
570 MO - Nt«
COAL: o.sx SULFUR, 71 ASM
PESEAHCH COTTRELL
LIMESTONE
STARTUP 0/8U
is CURRENTLY FABRICATING THE DUAL-LOOP LIMESTONE «ET
SCRUBBERS. ON-SIIE CONSTRUCTION COMMENCED IN JANUARY 1978. SLUDGE HILL BE
OEhATFt-ED TO 8 i* SOLIDS BEFORE LANDFILL. THE SCRUBBERS HILL BE MADE OF
STAINLESS STEFL AND hILL HANDLE 2.3 MM ACFM AT 286 F. L/C RATIO WILL BE
60. eft* HAS BEEN A»AHDEO A CONTRACT FOR TWO ESP'S. THE DESIGN DOES NOT
INCLUDE STACK GAS RFHEAT. COOLING TOWER HLOWDOnN »ILL BE USED FOR MAKE-UP
IN THIS CLOSED LOOP SYSTEM. CONSIRUCTTON IS NO* 20 PERCENT COMPLETE.
BASIN ELECTRIC POWFR COUP
LARAMIE RIVfcR 2
570 MM - NEW
COAL: o.sx SULFUR, 7i ASH
RESEARCH COTTMELL
IIMES10NE
STARTUP 10/80
WFSEARCH-CUTTREI 1 IS CURRENTLY FABRICATING THE DUAL-LOOP LIMESTONE NET
SCRUBBERS. Oh-SITF CONSTRUCTION COMMENCED IN JANUARY 1978. SLUDGE HILL BE
OFwATEkFO 10 83* SOLIDS BEFORE LANDFILL. THE SCRUBBERS HILL BE MADE OF
STAINLESS STEEL AND "ILL HANDLE 2.3 MM ACFM AT 2t»6 F. L/G RATIO HILL BE
60. BK* HAS bEEN AMAHDEO A CONTRACT FOR THD ESP'S. THE DESIGN DOES NOT
INCLUDE STACK GAS tfEHEAT. COOLING TOMER BLOHDOMN WILL BE USED FOR MAKE-UP
IN THIS CLOSED I OOP SYSTEM. CONSTRUCTION IS NOn 20 PERCENT COMPLETE.
BASIN ELFCTRIC POHER COOP
LAB*M1F RIVER 3
550 MM - NE«
COAL: 0.8Z SULFUR, J1 ASH
VENDOR NOT SFLFCTEO
PROCESS NOT SELECTED
STARTUP 0/8?
THE UTILITY IS NOH IN THE PROCESS UF EVALUATING BIDS. LARAMIE RIVER
STATION HILL FIRE SUB-BITUMINOUS COAL HITH THE FOLLOWING CHARACTERIS-
TICS: 8100 HTIJ/LB. 0.8 PERCENT SULFUR AND 7.0 PERCENT ASH.
BIG RIVERS ELECTRIC
GRFEN 1
250 MW - N£H
COAL; 3.751 SULFUR
AMERICAN AIM FILTER
LIME
STARTUP 12/79
THE EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED UNIT IS BEING SUP-
PLIED BY AMERICAN AIR FILTER. THE SYSTEM WILL CONSIST OF A COLD-SIDE ESP
AND THO SPRAY TOwERS CONTROLLING PARTTCULATE AND S02 TO 99.b PERCENT AND
90 PERCENT, HESPECUVLEV. THE BSH BOILER HILL FIRE HIGH SULFUR (3.5 TO
1.5 PERCENT) WESTERN KENTUCKY COAL. CONSTRUCTION IS NOH 66 PERCENT
COMPLETE ON THE BOILER AND 34 PERCENT COMPLETE ON THE FGD SYSTEM. THE
DESIGN INCLUDES AN INDIRECT HOT AIR REHEAT SYSTEM. IOCS HILL CONSTRUCT A
SLUDGE DISPOSAL SYSTEM TO SERVICE BOTH GREEN 1 AND 2.
BIG RIVERS ELECTRIC
GREEN 2
240 HH - NEW
COAL; 3.751 SULFUR
AMERICAN AIM FILTER
LIME
STARTUP 12/80
THE EMISSION CONTROL SYSTEM FOR THIS NEH COAL-FIHEO UNIT IS BEING SUP-
PLIED BY AMERICAN AIR FILTER. THE SYSTEM HILL CONSIST OF A COLD-SIDE ESP
AND TWO SPRAY TOwERS CONTROLLING PARTICULATE AND S02 TO 99.6 PERCENT AND
90 PERCENT, RESPECTIVELY. THE B*W BOILER HILL FIRE HIGH SULFUR (3.5 TO
0.5 PERCENT) WESTERN KENTUCKY COAL. THE FGO SYSTEM HILL INCLUDE AN
INDIRECT HOT AIR REHEAT SYSTEM. HJCS HILL CONSTRUCT A SLUOGE DISPOSAL
SYSTEM TO SERVICE BOTH GRFEN I AND 2. THE BOILER IS CURRENTLY 8X COMPLETE
AND NO WORK HAS YET STARTED ON THE FGD SYSTEM.
CENTRAL ILLINOIS LIGHT
DUCK CREEK 1
400 MW - NEW
COAL; 3.3i SULFUR* a.sx ASH
RILEY STOKER / ENVIRONEERING
LIMESTONE
STARTUP 7/78
CENTRAL ILLINOIS LIliHT
DUCK CREEK 2
400 MH - NEH
COALS 3.3Z SULFUR, 8.3X ASH
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 1/82
REFER 10 SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION. RILEY STOKER
HAS THf SUPPLIER OF THE FOUR VENTURI-SORBER MODULES AT THIS UNIT. SCRUBBER
TANKS AND PUMPS ARE NEOPRENE LINED. A HIGH EFFICIENCY ESP IS UPSTREAM OF
THE FOUR VENTURI-SORBER SCRUBBER MODULES FOR PARTICULATE CONTROL. THE
CONCRETE STACK IS LINED HITH CEILCOTE FLAKELINE 151. NO REHEAT SYSTEM 13
INCLUDED. THE FIRST LIMESTONE SLURRY SCRUBBER MODULE HAS PLACED IN SERVICE
ON SEPTEMBER 9, 1976, AND OPERATED INTERMITTENTLY UNTIL APRIL 1. 1977. ALL
FOUR MODULES BECAME OPERATIONAL ON JULY 24, 1973.
THE UTILITY MAS NOT YET SELECTED A SYSTEM SUPPLIER. A DECISION CONCERNING
THE STATUS OF THE BOILER AND CONTROL STRATEGY HILL BE ANNOUNCED IN LATE
1978. THE UTILITY WILL USE ESP'S FOR PARTICULATE CONTROL AND EITHER LIME-
STONE OR DOUBLE ALKALI FOR 802 ABSORPTION. THE UTILITY IS NON IN THE
PROCESS OF EVALUATING BIDS AND A STUDY IS UNDERWAY TO DETERMINE THE SLUDGE
DISPOSAL STRATEGY THAT HILL BE EMPLOYED.
-------
KfA UTILITY FGD SURVEY: AUGUST |97« - SEPTEMBER 1978
SECTION f
STATUS 01- FGD SYbTEMS
UNIT IDENTIFICATION
CURRENT STATUS
CENTRAL ILLINOIS PUBLIC SERV
NEKTON I
575 MM - Nb*
COAL: ax SULFUR
RUF.LL/ENV1ROTECH
DOUBLE ALKALI
STARTUP 11/7V
A CONTRACT HAS BEFN AWARDED HY CIPSCU TO BUELL/ENV1RQTECH FOR THE
INSTALLAIION Of- AN EMISSION CONTROL SYSTEM ON UNIT 1. THE KEY COM-
PONENTS UF THE EMISSION CONTROL SYSTEM INCLUDE: A HIGH-EFFICIENCY ESPJ
f-PlIP PKFCOUIERS, FiMIR POLYSPHERE AbSURdEwS, 1HREE TH1CKENFHS, TWO F.X-
PFRU.ENTAL REHEAT SYSUMS, AND THREF HORIZONTAL EXTRACTION FILTFrfS FOR
SI UOGE OEWATERING. MORt THAN 50 PERCENT UF THE CONSTRUCTION WORK
AT THF PLANT HAS HEFN COMPLFTFO. THF FGD SYSTFM WILL HAVE CEILCOTE-
LlNfU AHSORHE& MODULES.
CENTRAL MAINE POWER
SEARS ISLAND 1
600 MM - NEW
COAL; SOURCE UNDETERMINED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 11/Bb
BECAUSE OF THE DISCOVERY OE A GEOLOGICAL FAULT ON SEARS ISLAND, THE
UTILITY HAS CANCELLED PLANS FOR A 1150-Mw NUCLEAR POWER PLANT. A
tOO-Mh CUAL-FIKFI) UNIT IS NOW BEING PLANNED IN ITS PLACE. COMMERCIAL
OPERATION IS PHOJFCTED FOR NOVEMHEK l<»8b. COMPLIANCE wlTh SO* NSPS WILL
HF AC"IFVEU HY INSTALLING AN Fr.O SYSTFM. LIME AND LIMFSTUNF SCRUBBING
PROCESSES ARE BEING GIVEN PRIMARY CONSIDERATION. CURRENTLY, CMPCO HAS
FILED AN APPLICATION nlThi THE STATE PUBLIC UTILITIES COMMISSION. AN EN-
VTROfkMENlAl PFR.MIT APPLICATION MILL BE FRED WITHIN THE NEXT TWO YEARS.
CINCINNATI GAS * ELECTRIC
EAST BEND 2
600 MM - NEft
COAL
RABCOCK * WILCOX
LIME
STARTUP
A CONTRACT HAS BEEN CONDITIONALLY »"A»UED TO BABCOCK AND -ILCOX FOR A
COMMERCIAL LIME SCRUBBING SYSTEM. THE COAL SOURCE is F«PFCTEO TO BE A
nESTERN KENTUCKY COAL nITH A HIGH SULFUR CONTENT. THE THREE LIMfc SLURRY
FGD MODULES WILL PE PRECEDED BY AN ESP FOR PARTICULATE CONTROL. SLUDGE
• ILL BE OI5PUSEO OF ON-SITE USING A I)BY FIXATION SYSTEM. THE A-E DESIGN
FIRM Ib SARGENT AND LUNDY. UNIT FOUNDATION CONSTRUCTION HAS BEGUN ANL
FGO SYSTfcM CONSTRUCTION MILL BEGIN IN EARLY 197<».
COLORADO UTE ELECTRIC ASSN.
CRAIG 1
Q%0 MM - NEK
COAL; o.asz SULFUK
PEAHDDY ENGINEERING
LIMESTONE
STAHTUP 1/79
COLORADO UTE ELECTRIC ASSN.
CRAIG 2
050 MH - NEi
COAL; 0.45* SULFUR
PEABODY FNGINEEWING
LIMESTONE
STARTUP S/79
COLUMBUS ft SOUTHERN OHIO ELEC.
CUNESVILLE S
400 MM - NEM
COAL) a.71 SULFUR. 15.IX ASH
AIR CORRECTION DIVISION, HOP
LIME (MG-PROMOTEO)
STARTUP 1/77
PEAHUDY ENGINEERED SYSTEMS HAS BEEN AHARDED A CONTRACT TO DESIGN AND
SUPPLY A LIMESTONE SLURRY SPRAY TOMER ABSORBER SYSTEM FOR S0£ REMOVAL
FRUM IUM-SUI.EUR COAL-FIRED BOILER FLUE GAS FOR UNITS i AND 2. PARTIC-
UlATE CONTROL MILL BE. PROVIDED BY HOT-SIDE ESP'S UPSTREAM OF THE SCRUBBER
PLAM. SLUDGE «ILL BE STABILIZED AND HAULED TO A MIMFII.L. THERE «ILL BF
A STEAM CD1L TYPE STACK GAS RFHEATbU INCLUDED. REDUIRFU PtRTICULATE AND
301 REMOVAL EFFICIENCIES ARE 99.8 AND 85 PERCENT, RESPECTIVELY. FGD SYSTEM
CONSTRUCTION IS NOW 501 COMPLETE.
PEABODY ENGINEERED SYSTEMS HAS BEEN AhARDEU A CONTRACT TO UESIGN AND
SUPPLY A LIMESTONE SLURRY SPRAY TOMER ABSORBE.R SYSTEM FOR 302 REMOVtL
FROM LUW-SUI.FUR COAL-F1RE.O BOILER FLUE GAS FOR UNITS 1 AND 2. PARTICULATE
CONTROL nILL RE PROVIDED BY HOT-SIOF ESP'S UPSTREAM OF THE ABSORBER
SYSTEM. SLUDGF KILL »F STABILIZED AND HAULED TO A MINFFILL. THERE WILL BE
A STEAM COIL TYPE STACK GAS REHEATER INCLUDED. REQUIRED PARTICULATE AND
S02 REMOVAL EFFICIENCIES ABE 99.8 AND 85 PERCENT, RESPECTIVELY. FGO
CONSTRUCTION IS NOn 50X COMPLETE.
REFER TU SECTION 3 OF THIS REPORT EOR ADDITIONAL INFORMATION. THE
BOILER AND ESP *EHt COMPLETED AND PLACED IN SERVICE IN SFPT. 197b.
THE B-SIDE MODULE BECAME AVAILABLE FOR SERVICE IN JANUARY 1977.
COMMERCIAL OPERATIONS nERF ACHIEVED ON FEBRUARY 13. 1977. THE EMISSION
CONTROL SYSTEM FUR THIS UNIT CONSISTS OF A COLD-SIDE ESP FOLLOWED BY
TWO LI"E TCA MODULES SUPPLIED BY UOP. ORAVO IS SUPPLYING THE THIOSORBIC
LIME REAGENT. IUCS IS SUPPLYING A P02-0-TEC SLUDGE STABILIZATION
FACILITY.
COLUMBUS ft SOUTHERN OHIO ELEC.
CONESVILLE 6
400 MM - NEW
COAL; 4.67X SULFUR, is.ix ASH
AIR CORRECTION DIVISION, UOP
LIME CMC-PROMOTED)
STARTUP b/76
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFURMATON. CftSOE SIGNED
LONG-TERM CONTRACTS HITH ORAVO FOR THE PURCHASE OF THIOSORBIC LIME AND
WITH IUCS FOR A SLUDGE FIXATION SYSTEM. CONSTRUCTION COMMENCED IN 1977 AND
MAS COMPLETED IN JANUARY 1978. SIMILAR TO UNIT 5, THIS MINE MOUTH PLANT
BURNS COAL WITH 17X ASH AND 4.5 TO O.9X SULFUR CONTENTS. THE DESIGN IN-
CLUDES AN tSP UPSTREAM OF THE FGO SYSTEM FOR PARTICULATE CONTROL. THE FGD
SYSTEM INCLUDES Two TCA MODULES FOR THE REMOVAL OF S02.
COLUMBUS ft SOUTHERN OHIO ELEC.
POSTON 5
375 MH - NEM
COAL; 2.5X SULFUR
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 0/H3
THIS UNIT MILL BURN HIGH SULFUR OHIO COAL (APPROXIMATELY 2.5 PERCENT
SULFUR CONTENT). THE DESIGN OF THE EMISSION CONTROL STRATEGY HAS
NOT YET BEEN FINALIZED. THE PROCESS WILL EITHER BE LIME, LIMESTONE. OR
DOUBLE ALKALI.
-------
EPA UTILITY FGO SURVEY: AUGUST 1«»7» - SEPUMBER
UNIT IOFNTIFICAT ION
SECTION 2
bTATUS OF FGO SYSTEMS
CURRENT STATUS
POSTON 6
175 MW - Nt"
CO»L: 2.51 SULFUR
VENDOM NOT SELECTED
PROCESS NUT StLECTFO
ST*KTuP
1MIS UNIT MLL BURN HlbH SULFUR COAL (APPROXIMATELY 2.5 PERCENT
SULFUR CONTENT). THE otsir.N UF THE EMISSION CONTROL STRATEGY
FOB THIS MMT HAS HUT YF.T BEtN FINALIZED.
CUMHONHEALTH EDISON
POWERTON 51
«25 MM - RETROFIT
COAL: *.6X SULFUW
AIR CORRECTION DIVISION,
LIMESTONE
STARTUP 5/7")
HOP
THt AIK COfcKtCMUN DIVISION OF UUP "AS AWARDED THE CONTRACT FOR A WET
LIMESTCNE SYSTEM THAT WILL HE BACKFITTED ONTO BOILER NO. 51, ONE OF TWO
intNTILAL BORERS SUPPLYING STfcAM 10 AN B50-MW TURBINE-GtNFRATOR. THE
SiUOGF "Hi BE STABILISED AND HAULED TO A LANDFILL. REHFAT HILL BE
PKIIVIOtD HY A STEAM COIL WHICH WILL HEAT THE AMfllfNT AIR THAT IS PUMPED
IMTO TnF SCRUBBFW UllUtT HtFORE THE FLUF GAS ENTERS THE STACK. THE SO2
tMISSION STANDARD IS 1.8 LH. S02/MM BTU. CURRENTLY, EXCAVATION, BACKFILL,
AND STRUCTURAL STEEL FRECHON IS IN PROGRESS.
COOPERATIVE PUMER ASSOCIATION
COAL CREFK 1
5a5 MW - NE/i
LIGNITE; 0.b3X SULFUR
COMBUSTION ENGINEERING
LIME
STARTUP 2/79
THIS UNIT IS UNOtR THF COMBINED OHNFXSHIP OF CUOP POWER AND UNITED POKER.
A CONTRACT HAS H£EH AWARDED TO COMBUSTION ENGINEERING FOR THE INSTALLA-
TION OF LIME FI;O SYSTEMS ON UNITS i AND 2 AT THIS STATION. THE FGD SYSTEM
FOX EACH BUILFH AlLL CUNSIST OF FOUR SPRAY TQWFR ABSORBER MODULES FOR S02
RFKOVAl. ELFCTODSTATIC PRECTPITATORS KILL Bf INSTALLED UPSTREAK OF EACH
AHSOHBkH TWAIN. CONSTRUCTION REGAN FARLY IN AUGUST 1977 AND THE UNIT IS
85-901 CUMPLt-TE. BAD WINTER WEATHEH SL'JWtO CONSTRUCTION SLIGHTLY.
COOPERATIVE POWER ASSOCIATION THIS UNII is UNDER THE COMBINED OWNERSHIP OF COOP POWFR AND UNITED POWER
A CONTRACT HAS BEEN AWARDED TO COMBUSTION ENGINEERING FOR THE INSTALLA-
UF LIME FGO SYSTEMS UN UNITS 1 AND 2 AT THIS STATION. THE FGD SYSTEM FOR
EACH BOILER WILL CONSIST OF FOUR SPRAY TOWER ABSORBER MODULES FOR 302
REMOVAL. ELECTROSTATIC PRECIPIMTORS »ILL BE INSTALLED UPSTREAM OF E»CH
ABSORPtR TRAIN. CONSTRUCTION BEGAN IN AUGUST 1977 AND THE UNIT IS NOW 45Z
COMPLE1E. IHtRF HAVF BEEN MINOR DELAYS BUT STAHT-UP IS STILL SCHEDULED FOR
NOVEMBER 1979.
OFLMARVA'S DtLAKARt CITY PLANT HAS 0 BOILERS, J OF WHICH HAVE STEAM CAPA-
CITIES OF bOOK LHS/HR EACH. THE BOILERS GENERATE STEAM AS WELL AS ELECTRI-
CAL PGftER I-ON GETTY KFFINTNG ft MARKETING. 7-8X S COKE WILL BE BURNED IN
THE BOILERS (INSTEAD OF THE LOW-S CRUDE OIL NOW BURNED) WHEN THF CONTROL
SYSTEM GOFS INTO OPERATION IN APRIL 1980. DELMARVA WILL USE VENTURI SCRUB-
BERS FOR PAR1ICULATE RtMQVAL AND WELLPAN LORD FGD SYSTEMS AT EACH BOILER
GAS EXIT FUR S02 CONTROL. DESIGN PARTICULME AND S02 REMOVAL EFFICIEN-
CIES ARE 90 AND B5-90 PERCENT RESPECTIVELY. CONSTRUCTION IS lit COMPLETE.
REFFR TO SECTION A OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE FGU SYSTEM ON I«IS 4-RUILER UNIT CONSISTS OF FIVE COMMON-HtADERED
SINGLE S1AGF VtNTURI SCRUBBER-ABSORBERS DOWNSTREAM FROM A MECHANICAL
COLLtCTOR-ESP PARTICULAR REMOVAL SYSTEM. THE PLANT BURNS COAL HITH A
HEATING VALUE OF 11,000 HTU/LB AND SULFUR AND ASH CONTENTS OF 1.8 TO 2.2X
AND 21X RESPECTFVFLY. DEWATEKED SLUDGE FROM THt IUCS PLANT IS HAULED TO
AN OFF-SITE LANDFILL. THE SYSTEM INCLUDES A DIKECT OIL-FIRED STACK GAS
REHFAT SYSTEM. DESIGNED REMOVAL EFFICIENCIES ARE 99X (PART) AND 63X (302).
COAL CREEK ^
5a5 MW - NEW
LIGNITE; 0.63X SULFUR
COMBUSTION
LIME
STARTUP 11/79
DELMAHVA POWER & LIGHT
OELwARF CITY 1, ? K 3
180 MW - RETMUFIT
COKE: 7.5X SULFUR
DAVY POwFRGAS
NELLMAN LORD
STARTUP a/80
DUOUESNE LIGHI
FLRAMA POKER STATION
510 MW - RETROFIT
COAL; 2x SULFUR, ifa.sx ASH
CHEMICO
LIME
STARTUP 10/75
DUOUESNE LIGHT
PHILLIPS POWER STATION
410 MW - RETKUFIT
COAL; 2X SULFUR, 16.51 ASH
CHFMICO
LIME
STARTUP 7/73
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE FGO SYSTEM ON THIS b-BOILER UNIT CONSISTS OF ONE 2-STAGE AND THREE
SINGLE STAGE VENTURI SCRUBBER-ABSORBERS DOWNSTREAM FROM A MECHANICAL
COLIER10R-ESP PAHTICULATE REMOVAL SYSTEM. THE PLANT BURNS COAL WITH A
HEATING VALUE OF 11,000 BTU/LB AND SULFUR AND ASH CONTENTS OF 1.0 TO 2.2X
ANO 21X RESPECTIVELY. DEWATERED SLUDGE FROM THE IUCS PLANT IS HAULED TO
AN OFF-SITE LANDFILL. THE SYSTEM INCLUDES A DIRECT OIL-FIRED STACK GAS
REHEAT SYSTEM. DESIGNED REMOVAL EFFICIENCIES ARE 99X (PART) AND 83X (302).
FAST KENIUCKY POWER COOP
SPURLOCK 2
500 MW - NEK
COAL
ADL/COMt)USTION COUIP ASSOCIATE
LIME
STARTUP 3/80
A CONTRACT HAS BEEN AWARDED TO AOL/COMBUSTION EOUIP ASS. FOR A LIME SLURRY
FGD SYSTEM ON THE NEW 500-HH UNIT SPURLOCK 2. PARTICULATE WILL BE CONTROL-
LF.O BY A 99.5X EFFICIENT ESP. COOLING TOWER SLOWDOWN WILL BE THE MAKE-UP
SOURCE FOR THE FGD SYSTEM. THE DESIGNED 802 REMOVAL EFFICIENCY IS 90X.
-------
EPA UTILITY FGD SURVEY: AUGUST i9?B - SEPTFPBEW i<»7e
UNIT IDENTIFICATION
StCIION Z
STATUS "F FRO SYSTEMS
CURRENT STATUS
RENEWAL PUBLIC >ITILITJES
COHO 1
BOO MM - NH
CO»L; J.sx SULFUR
VENDOR NOT SELECTED
PROCF8S NOT SELECTED
STARTUP S/B7
STARTUP OATF »AS CHANGED TD b/87 FOR BOTH MUILf AND OE SMLF UR I Z A T TON
SYSTEM LIME AND LIMFSTUNE SCRUBBING ARE THE PRIMARY STRATEGIES HtINf,
CONSlOtPEP FOR COMPLIANCE « I TM NEW SOURCE PERFORMANCE STANDARDS. NO
DECISION HAS BEEN MADE YET, ALTHOUGH A SLURRY TYPE SYSTEM IS NUT
CONTEMPLATED.
GENERAL PUBLIC UTILITIES
SEWARO 7
800 MM - NE*
COAL
VENDOR NOT SELECTED
PROCESS NOT SELECIFO
STARTUP S/80
STARTUP OATF WAS CHANGtO TU 5/BO FOR BOTH HOILtR AND D£SULFUk12 AT ION
SYSTEM LIME AND LI*FSTuNt SCRUBBING ARE THE PRI"ARY STRATEGIES HtING
CONSIDERED FUR COMPLIANCE fttTH NE* SOURCE PERFORMANCE STANDARDS. NU
DFCISION HAS BEEN MADE Y£T. ALTHOUGH SLURRY fYPF WILL NOT HE USED.
GULF POMFR
SCHOLZ IB ft ae
23 MM - RETROFIT
COAL; ?x SULFUR
CHIYODA INTERNATIONAL
LIMESTONE
STARTUP 8/78
REFER TO SECTION 1 OF THIS REPORT FOM ADDITIONAL INFORMATION. CHIYODA IN-
TERNATIONAL SUPPLIED THIS ?? MM PROTOTYPE UNIT KMICH BEGAN OPERATION ON
AUGUST ^0, 1978. TMF CT-121 SYSTtM INCLUDES A NEwLY DEVF.LOPEO JET
BUBBLING REACTOR WHICH FEATURES A LARGE GAS-LlOUIO It,TtRF»ClAL ARFA AND
PROVIDES PARTICIPATE AS WELL AS Sn<> HFMOVAL. MIST ELIMINATION IS PROVIDED
BY A DOUBLE PASS VERTICAL CHEVRON. GYPSUM IS PRODUCED AND STACKED IN THF
EXISTING PONO. THF. STACKING CAPABILITIES OF THf (,YPSuM AWF BEING TESTED
ALONG MTH THE GROUND nAIfR NEAR THF STACK SITE TO CHECK FOR LEECHING.
HOOSIER ENERGY
MEROM 1
ISO MM - NEW
COAL; 3.5X SULFUR
MITSUBISHI INTERNATIONAL
LIMESTONE
STARTUP a/81
HOOSIER ENERGY
MEROM Z
ago MM - NEW
COAL; 3.5X SULFUR
MITSUBISHI INTERNATIONAL
LIMESTONE
STARTUP l/«2
INDIANAPOLIS POwER ft LIGHT
PETERSBURG 3
•530 MW - NEW
COAL; 3.25X SULFUR, 9.sx ASH
AIR CORRECTION DIVISION. UOP
LIMESTONE
STARTUP 10/77
INDIANAPOLIS POWER S LIGHT
PETERSBURG a
530 MM - NEH
COAL; 3.5x SULFUR, loz ASH
RESEARCH COTTRELL
LIMFSTONE
STARTUP 0/82
HOOSIEK ENERGY HAS AHARDEO A CONTRACT TO MITSUBISHI INTERNATIONAL CORP.
FOR TWO LIMESTONE FGO SYSTEMS FOR MFROM 1 AND Z. THE NE" 140 MB COAL-FIRED
UNITS ARE PLANNFD FOR LOCATION IN SULLIVAN, INDIANA. THE FLUE GAS STREAMS
HTLL BE CLEANED OF PARTICIPATES nITH ESP'S (99.«X) AND OF SULFUR DIOXIDE
nITH GRID-IOHF.R ABSORBERS (<>OZ). SLUDGE nILL Bt STABILIZED AND STOCK
PILED. THE GROUND HAS BROKEN FOR CONSTRUCTION IN NOVEMBER 1477, HUT DUE
TO THE BAD MlNTER WEATHER, CONSTRUCTION WAS DELAYED. CONSTRUCTION HAS
PROCEEDED ACCORDING TO SCHEDULE THROUGH THE SUMMER.
HOOSIER ENERGY HAS ANAROED A CONTRACT TO MITSUBISHI INTERNATIONAL CORP.
FOR TWO LIMESTONE FGO SYSTEMS FOR MEROM 1 AND ^. THE NE« U90 MM COAL-FIRED
UNITS ARE PLANNED FOR LOCATION IN SULLIVAN, INDIANA. THE FLUE GAS STREAMS
WILL BE CLEANED OF PARTICULATES WITH ESP'S (99.OX) AND OF SULFUR DIOXIDE
hITH GRID-TOnFR ABSORBERS (90S). SLUDGE "ILL BE STABILIZED AND STOCK
PILED. THF GROUND WAS BROKEN FOR CONSTRUCTION IN NOVEMBER 1977, BUT DUE
TO THE BAD KINIFR WEATHER, CONSTRUCTION WAS DELAYED. THE BOILER IS
ESSENTALLY COMPLETE. STARTUP IS EXPECTED SHORTLY.
REFER TO SECTION 1 OF THIS REPORT FOR ADDITIONAL INFORMATION. THE WET
LIMESTONE FGO SYSTEM INSTALLED ON THIS UNIT WAS SUPPLIED BY THE AIM
CORRECTION DIVISION OF HOP. UNIT 3 FIRbS BITUMINOUS COAL HAVINb A SULFUR
CONTENT OF 1.0-3.51, AN ASH CONTENT OF 9-10X AND A 11,000 BTU/LB HEATING
VALUE. TWO ESP5 PROVIDE PRIMARY PARTICULATE CONTROL UPSTREAM OF A FOUR-
MODULE TCA FGP SYSTEM. STABILIZED SIUDGE IS DISPOSED ON AN ON-SITE PONO.
THE DESIGN INCLUDES AN INDIRECT STEAM TUBE REHEAT SYSTEM. SHAKEDOHN-UEBUG-
GTNG OPERATIONS ARE STILL PROCEOING.
INDIANAPOLIS POWER & LIGHT AWARDED A CONTRACT TO RESEARCH COTTRFLL FUR A
LIMESTONE FGD SYSTEM. S08 REMOVAL EFFICIENCY WILL BE APPROXIMATELY
BO PERCENT. THIS NEW UNIT WILL FIRE HIGH-SULFUR SUBBITUMINOUS COAL WITH
A HEATING VALUE OF 11,000 BTU/LB AND ASH AND SULFUR CONTENTS OF 10 PERCENT
AND 3.b PERCENT, RESPECTIVELY. SLUDGE MILL BE DEwATERED AND MIXED WITH
FLYASH TO PRODUCE A DRY STABILIZED PRODUCT. PLANT CONSTRUCTION BEGAN IN
DECEMBER 1977.
KANSAS CITY POWER ft LIGHT
HAWTHORN 3
too MW - RETROFIT
COAL; ?x SULFUR, is.sx ASH
COMBUSTION ENGINEERING
LIME
STARTUP 11/72
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE SCRUBBER-ABSORBER SYSTEM ON THIS UNIT WAS CONVERTED FROM A LIMESTONE
FURNACE INJECTION AND TAIL-END SYSTEM TO A TAIL-END LIME SLURRY SYSTEM.
OPERATION IN THE LIME SCRUBBING MODE COMMENCED ON FEBRUARY 7, 1977. COM-
PLIANCE TEST RESULTS INDICATED THE UNIT MEETS THE KANSAS CITY 0.17 LB/
MM BTU PARTICULATE REG. FGD SYSTEM DESIGN INCLUDES A FINNED-TUBE STEAM
REHEATER, AN ON-SITE UNLINEO SLUDGE DISPOSAL POND, AND A CHEVRON MIST
ELIMINATOR SYSTEM. THE 2 FGD MODULES CAN BE BY-PASSED IN EMERGENCIES.
-------
EH* UTILITY FGO SURVEY: AUGUST »«78 - stPiFMHt* i"»7«
SECTION g
STATUS OF FGO SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
KANSAS CITY PulEH *• LIGHT
HAWTHORN 4
100 MM - RETKOFI!
COAL; 2x SULFUR. 12.« ASH
COMBUSTION ENGINEERING
LIME
STARTUP 8/7«;
WFFFK Td StCHON * OF THIS RfcPURI FOrt ADDITIONAL INFORMATION.
THfc SCkllBHhH-ABSURHFR SYSTEM ON THIS UNIT "AS CONVERTED FROM A LIMESTONE
HlKNACt INJECTION AND IAIL-END SYSTfM TO A TAIL-END LIMF SLURRT SYSTEM.
uPtRATiuN IN THF Lint SCMUHPING MODE COMMENCED ON JANUARY i, 1977. COM-
pii«NCt IFST RFSULIS INDICATED THF UNIT MEETS THE KANSAS CITY 0.17 LB/
MM RTII PAP1ICULATE RfcC.. FGO SYSTEM DESIGN INCLUDES A F1NNEO-TUHE STFAM
R^FATfcW, AN OM-SITE UNLINtn SLUOKF DISPOSAL PONO , AND A CHEVRON MIST
ELIMINATOR SYS^M. THE Z FGD MOOIILtS CAN HE BY-PASSED IN EMERGENCIES.
KANSAS CITY PUMEH * LIGHT
LA CYGNE 1
aao MW - NED
COAL; sx SULFUR, asx ASH
PARCOCK * WILCOX
LIMESTONF
STARTUP 3/73
KEFEH TO SECTION ? UF THIS RfcPOHT FOR ADDITIONAL INFORMATION.
IHE EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIHFO PPwFH-GFNERATING UNIT
CONSISTS OF ETliHT SCHUHHEt MlinilLES FUR FLY ASH AND SOS REMOVAL. EACH
MODULE INCLUDES * VENTURI SCRUHBF.R IN SERIES NITH A S-STAGE IMPINGEMENT
PLATt AflSOH«E». THE SCRUBBER »LANT IS AN INTEGRAL PART OF THE POwER-
GFNFWAUNK ruMPLEX. ALLOWING NO FI.UF GAS BYPASS. INITIAL OPERATIONS
COMMENCED IN FtH. 1>J73. COMMERCIAL SERVICE HAS ATTAINED BY JUNE 1973.
KANSAS POHER * LIGHI
JEFFREY I
660 MM - Nt«
COAL: o.sx SULFUR, 7.sx ASH
COMBUSTION ENGINEERING
LIMESTONE
STARTUP 8/78
TO SECTION 3 OF THIS REPORT FOrt ADDITIONAL INFORMATION. COMBUSTION
ENGINEERING SUPPLIED THE LIMI-SIONE EMISSION CONTROL SYSTFM FOR THIS NEW
COAL FIRED UNIT. THE SYSTEM CONSISTS OF A COLD-SIDE ESP AND SPRAY TOWERS
FOR THE CONTROL UF SO? ANO PARTICMLA IE EMISSIONS. 30X OF THE FLUE GAS IS
BYPASSED FUR REHEAT. NOX EMISSIONS AME CONTROLLED BY AN AIR OVERFIRE SYS-
TEM AT THE TANC.ENTIALLY FIRED PULVERIZED BURNERS. THE CLEANED GASES ARE
VF.NTED 10 A 600 FT STACK. SLUDGE IS MIXED MITH BOTTOM ASH AND DISPOSED
OF IN THE EXISTING ON-SITE BOTTOM ASH POND.
KANSAS POWER & LIGHT
JEFFREY ?
68" MW - NEW
COAL! 0.3X SULFUR, 7.SX ASH
COMBUSTION ENGINEERING
LIMESTONE
STARTUP b/XO
KANSAS POWER 1 LIGHT
LAWRENCE 4
125 MW - RETROFIT
COAL; o.sx SULFUR, loz ASH
COMBUSTION ENGINEERING
LIMESTONE
STARTUP
KANSAS POWER * LlfcHT
LAMRFNCE 5
•00 MW - NEW
COAL: o.st SULFUR, 101 ASH
COMBUSTION ENGINEERING
LIMESTONF
STARTUP 11/71
KENTUCKY UTILITIES
GREEN RIVER 1,2 * 3
b« MW - RETROFIT
COAL: s.7x SULFUR, n.ox ASH
AMERICAN AIR FILTER
LIME
STARTUP 9/7S
COMBUSTION ENGINEERING IS SUPPLYING THE EMISSION CONTROL SYSTEM FOR THIS
NEK COAL FIREO UNIT. THE SYSTEM HILL CONSIST OF A COLD SIDE ESP ALONG WITH
SPRAY towEKS FUR THE CONTROL OF 502 AND PARTICULATE EMISSIONS. 3ox OF THE
FLUE GAS WILL BF BYPASSED FOR HEHFAT. Ah OVEHFIRE AIR SYSTEM AT THE TAN-
GENTIAL FIRED PULVERIZED BURNERS WILL CONTROL NOX EMISSIONS. THE CLEANED
GASES WILL BE VENTED TO A bUO FT STACK. SLUDGE WILL BE MIXED WITH BOTTOM
ASH AND DISPOSED ON-SITE IN THE BOTTOM ASH POND. THE SYSTEM STEEL WORK IS
UP AND CONSTRUCTION IS APPROXIMATELY 10Z COMPLETE.
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE NEit LIMESTONE FGD SYSTEM COMMENCED OPERATIONS IN EARLY JANUARY 1977.
THE NEW SYSTEM REPLACED MARBLE-BED TOWERS WITH SPRAY TOWERS. THEME HAVE
BEEN NO FORCED SCRUBBER OUTAGES REPORTED SINCF START-UP. CONTINUOUS S02
MONITORS HAVE RECORDED 302 REMOVAL EFFIC1ANCIES OF BETTER THAN 65X.
THE UTILITY REPORTED PARTICULATE REMOVAL IS SUCH THAT NO VISIBLE PLUME
EXITS THE STACK THE PLANT IS FIRING COAL RATED AT 10,000 BTU/LB WITH A
SULFUR CONTFNT OF 0.5X.
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION. THE
ORIGINAL LIMESTONE INJECTION AND TAIL-END SCRUBBING SYSTEM WAS SHUT
DOWN ON MARCH 20 SO THAT THE NEW ROD-SCRUBBER AND SPRAY TOWER ABSORBER
SYSTEM COULD BE TIED INTO THE UNIT. THE NEW SYSTEM, WHICH INCLUDES TWO
MODULES, EACH CAPABLE OF HANDLING APPROXIMATELY 50 PERCENT OF THE TOTAL
BOILER FLUE GAS FLOW, CAME ON LINE ON APRIL 14, 1976. THE SYSTEM DESIGNER
AND SUPPLIER IS COMBUSTION ENGINEERING. THE UNIT FIRES LOW SULFUR WYOMING
COAL HITH A HEAT CONTENT OF 10,000 BTU/LB.
REFER TO SECTION 1 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE SCRUBBER PLANT INSTALLED AT THIS STATION CONSISTS OF ONE MODULE
DESIGNED TO REMOVE PARTICULATE (VARIABLE-THROAT VENTURI) AND 802 (MOBILE
-BED CONTACTOR) FROM COAL-FIRED BOILER FLUE GAS. THE SCRUBBER HAS DESIGNED
ANO SUPPLIED BY AAF. SLUDGE IS DISPOSED IN AN ON-SITE UNLINED PONO. THE
COAL BURNED HAS SULFUR AND ASH CONTENTS OF 3.7 AND 11 PERCENT RESPEC-
TIVELY AND A MOISTURE CONTENT OF 6-10 PERCENT. INITIAL STARTUP OCCURRED IN
SEPTEMBER 1975. COMMERCIAL OPERATION BEGAN IN JANUARY 1976.
LAKELAND UTILITIES
MCINTOSH 3
350 MH - NEW
COAL: a.fcx SULFUR, tox ASH
BARCOCK • MILCOX
LIMESTONE
STARTUP 10/61
THE CITY OF LAKELAND DEPARTMENT OF ELECTRIC AND WATER UTILITIES ANARDED A
CONTRACT TO 8ft* FOR AN EMISSION CONTROL SYSTEM ON THE UTILITY'S NEW
350-MW POWER GENERATING UNIT, MCINTOSH 3. THE UNIT WILL UTILIZE COLO
SIDE ESP'S FOR PARTICULATE REMOVAL ANO TwO LIMESTONE SCRUBBER-ABSORBER
MODULES. START-UP IS SCHEDULED FOR OCTOBER 1961. THE COAL WILL CONTAIN
ABOUT S.« SULFUR. THE UNIT DESIGN INCLUDES A REHEAT ANO AN IUCS SLUDGE
DISPOSAL SYSTEM. CONSTRUCTION SHOULD BEGIN IN THE FIRST PART OF 1979.
10
-------
EPA U11LITT FtiD SilkVFY: AUGUST 1978 - SEPTEMBER 1976
SECTION !•
bTATuS OF FKU SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
LOUISVILLE GAS ft ELECTRIC
CANE RUN 1
178 MM - RfcTROFll
CU»L: 3.75X SULFUR, i^>.5x AS>H
AMFRTCAN AIM FILTER
LIME (CARBIDE)
STARTUP 8/7b
RFFfR 10 SI-CIIUN 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
>Ht FGIi SYSTEM RETKOFITTED ON THIS BOILER flAS DESIGNED AND SUPPLIEU PY
AMERICAN AIR FILTER AM) flAS FIRST PLATED IN THE tAS P«TH ON AUGUST 7,
1«»7»>. THE SYSTtM TONSISTS UF TnO PARALLEL MODULE S WHICH INCLUDE MOBILE
hfO CONTACTORS A NO OPEK'lE nlTH A C'KBIHt LIME ADDITIVE. FOLLtnlNC. A
NIIHHER OF MAJOR SYSTEM MUOIF ICATIONS (CHE.VRON-TYPE MIST EL IM | r. ATuR . OIL
FIRED REHEAT, PIASI'E OUCT LINtR, HIGHER L/G), THE SYSTEM SUCCESSFULLY
PASSLO CMMPl 1ANCE TESTING 1 «5X SO? RfcMOVAl) UN AUGUST J AND «. 197 7.
LOUISVILLE GAS ft ELECTRIC
CANE RUN 5
18* MM - RETROFIT
COAL: 3.75X SULFUR, i^.bz
COMBUSTION ENGINEERING
HME (CARBIOF)
STARTUP l?/77
REFER 10 SECIIUN 3 OF IHIS REPURT FOR ADDITIONAL INFORMATION.
IMF. FGD SYSTtM FUR THIS UNIT HAS DESIGNED AND SUPPLIED B» COMBUSTION
FNblNFERING. IT CONSISTS OF TnO SPRAY TOnER ABSORBERS FUN FULL-LUAU soa
ASH RFMOVAi AND UTILIZES CARBIDE LICE AS THE ABSORBING REA&EM. IN-LINE STEAM
RFHEAT, A COHMON REACTION TANK, AND A THICKENER FOR SOLIDS OEMATERINC,
ARE INCLUDE!'. AN EXISTING IIPSTRFAM ESP PROVIDES PRIMARY PARTICULAR CON-
TROL. THE FGU SYSTEM BEGAN INITIAL f'PERATIO'J If UFC. '77 BUT A CUAI.
STRIKF FORCED A PLANT SHUTDOWN. THE SYSTEM HAS RE-STARTED MARCH .sz ASH
AOL/COMBUSTION EQUIP ASSOCIATE
DOUBLE ALKALI
STARTUP 12/7B
THE CONTRACT FU>-' THIS FULL-SCALF DEMONSTRATION F &D SrSTF" HAS HFfN
ArtARDFI) IO A.n.L ITILt/COMRUSTIUN EQUIPMENT ASSdC. FOR THf INSTtLLATION
OF A OiiUhLE AlKALT SYSTE". THF FE1ERAI FPA nJLL SUBSIDIZE A •••A>I«IIM
*O.S Mtn FOR OPERATION, RESKAKCH AND DEVELOPMENT, AND KEPURT WRITING FOR
A ONE-YEAR PERIOO FOLLO«1NG THE FIRSI THHEE MONTHS OF CPtRATlOU INUTEMHIS
SUBSIDY WILL NUT Bt APPLIED FOR ANY CAPITAL EXPENDITURES). CU"STWUCUON AT
THIS UNIT IS PRFSFNTLY 85t COMPLETE. UNII STAhl-llP IS tXPECTEO TO BE TN
DECEMBER
LOUISVILLE GAS * ELECTRIC
MILL CREFK I
330 MM - RETKOFI I
COAL; 3.7%x SULFUR, i^.sz
COMBUSTION ENGINEERING
LIME/LIMESTONE
STARTUP 1/81
ASH
A COMPLIANCE SCHEDULE MAS SUBMITTED TO THE JEFFFMSON COUNTY AIR POL-
LUTION CONIROL DISTRICT «ItH q/81 ESTABLISHED AS THE STAKTuP DATE f OR »N
FGO SYSTEM. OPERATING 1>AT» AND INFORMATION FKOM THE FULL-SCALE SCRUBBER
PI ANT NDn IN SERVICE ON THE NO. a UNII AT CANE RUrt flILL BE OBTAINED RFFORE
THt UTILITY PROCEEDS WITH ADDIUONAI SYSTEM DESIGN MORK. A CONTRACT HAS
ABARDEl) 10 COMBUSTION tNG INFER ^G FOR A LIME/LIMESTONE FGO SYSTEM.
LOUISVILLE GAS & ELECTRIC
MILL CREEK e
330 MW - RETROFII
COAi; 3.75« SULFUR, Ib.bX ASH
COMBUSTION ENGINEERING
LIME/LIMESTONE
STARTUP 1/82
A COMPLIANCE SCHEDULE MAS BEEN SUBMITTED To TMfc JEFFERSON COUNTY AJU POL-
LUTION CUNIRUL DISTRICT fllFH «/8PECTED,
UNIT START-UP HAS BEEN MOVED HACK TO JUNE 1480. CONSTRUCTION OF THIS NEM
4<>5-MM CUAL-FIRFD UNIT is ON SCHEDULE. CURRENTLY, FOUNDATION MORK is IN
PROGRESS. THIS AAF SYSTEM MILL INCLUOF MOBILE-BED ABSORBERS TREATING
HIGH SULFUR COAL FLUE GAS. THE SYSTEMS MATER LOOP MILL BE CLOSED. THE
SLUDGE "ILL BE STABILIZED MlTH LIME AND FLYASH. STEAM REHEAT MILL PRO-
VIDE GAS TEMPERATURE ELEVATION OF THE SCRUBBED GASES PRIOR TO DISCHARGE
TO THE MAIN STACK.
LOUISVILLE GAS ft ELECTRIC
PADDYS RUN b
b5 MW^- RETROFIT
COAL; 3.75X SULFUR, is.sx ASH
COMBUSTION ENGINEERING
LIME (CARBIDE)
STARTUP 0/73
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THIS SCRUBBING SYSTEM HAS DESIGNED BT COMBUSTION ENGINEERING AND PLACED
IN SERVICE IN APRIL 197?. IMfc FGO SYSTEM CONSISTS OF TMO 2-STA6E MARBLE
BED ABSORBERS MHlCH ARE DESIGNED TO USE CARBIDE LIME ADDITIVE AS THE
SCRUBBING REAGENT. PADDYS RUN NO. b IS A PEAK-LOAD UNIT THAT OPERATES
ONLY DURING DEMAND PERIODS. AN EXTENSIVE EPA SCRUBBER/SLUDGE EVALUATION
STUDY MAS COMPLETED IN AUGUST 1977. THIS UNIT HILL BE RETIRED MHEN MILL
CREEK 3 BECOMES FULLT OPERATIONAL.
II
-------
EPA UTILITY F&O SURVEY: tiiGUSr 1<»7S - SEPTEMBER
sn: i ION 2
STATUS OF FGD
UNIT IDENTIFICATION CURRENT STATUS
MINNESOTA POWER * LISHT MirNtsoTA P n L HAS AWARDED A CONTRACT TO PEABUDY ENGINEERING FOR A LIME/
CLAY BOSWELL « AIHALINE FLYASH SCRUBBING SYSTEM. THF. CONFIGURATION WILL BE VENTURI
500 MW - NEW SCKUHBE«S FOLI uwtD BY SPKAY TOnEKS. HOT SIDE ESP'S WILL HE USEU FOR
COAL: o.«x SULFUR, « ASH PAHTICULATE CONTROL. SIACK GAS REHEAT WILL BE ACCOMPLISHED BY BYPASSING
PEABODY ENGINEERING 5X OF ELUF GAS AROUND THE SCRUBBER. THE UNIT WILL FIRE SUB-BITUMINOUS
LIME/ALKALINF FLYASH C"LSIR|P COAL WITH A SoLEUrt CONTENT OF 0.8X, AND AN ASH CONTENT OF 9.OX
STARTUP 5/flO (HEAIING VAluE - «300 BTU/LB). HAKE-UP WATER SOURCE WILL BE THt RIVER AND
THE CLAY-LINED PONO. CUNSTRIIC T IPn OF THE FGO SYSTEM IS ABOUT 2UX COMPLETE.
MINNKOTA POWER COOPERATIVE RFEER 111 SlCTION 3 OF THIS REPOR1 FOR ADDITIONAL INFORMATION.
"ILTON R. YOUNG ? THIS L1Mb/ALKALINF FLYASH SCRUBBING SYSTEM WAS DESIGNED AND SUPPLIED BY
aSO MW - NEW ADL/CDKiMjSI I UN FuUIPMENT ASSOCIATES. IT CONSISTS OF A COLD-SIDE ESP
LIGNITE; O./X SULFUK, H.OX ASM FOLLOWED OY Trtil SPKAY IDwFRS. THE OFSIGN INCLUDES A WASH TRAY AND A
AOL/COMBUSTION ENUIH ASSOCIATE CHEVRON MIST ELIMINATOR, tsx FLi't GAS BYPASS PROVIDES STACK GAS REHEAT.
LIME/ALKALINE FLYASH IHE UNIT FIRES A LUw-SIM FUR NORTH DAKOTA LIGNITF WITH AN AVERAGE ASH
STARTUP 9/77 CONTENT OF 8 PERCENT. SUI FUR CONTENT OF 0.7 PERCENT, AND HEAT CONTENT
OF 6bOO HTU/Lrt. THE FLY ASH ALKALINITY IS IISF.O AS THE PRIMARY 502 REAGENT.
MONTANA POWER «FFFR TO SECTION 3 OF THIS REPORT FDR ADDITIONAL INFORMATION.
COLSTRIP I THIS FGO EullIPPFli UNIT WAS OECLAKFO COMMERCIAL IN NOVEMBER 1975. THE
360 MW - Ntrt SCRUBBING 5YSTE* PROVIDES PAKTICULATE AND S02 CONTROL WITH THREE SCRUB-
COAL; O.BX SULFUR, 12X ASH BFR MODULES. EACH MODULE CONSISTS OF A DUHNFLOW VENTUHI SCRUBBER CENTER-
ADL/COMBUSTION EQUIP ASSOCIATE F,n MITHTN AN UPFLO« SPRAY TOWER ABSORBER. EACH MODULE CAN TREAT aox OF
LIMF/ALKALINF FLYASH THE 101AL HOIltR FLUfc GAS AND THE MODULES CANNOT BE BYPASSED. THE UN-
STARTUP ll/7b STABILIZED SLUUf.E IS DISPOSED IN AN UN-SITE LINED DISPOSAL POND. IN-LINE
STEAM REHEAT AND CLOSFU WAIER LOOP CAPABILITY ARE INCLUDED IN THE SYSTEM.
MONTANA POWER REEER 10 SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
COLSTRIP 2 THIS FGD EQUIPPED UNIT nAS DECLARED COMMERCIAL IN AUGUST 1976. THE
360 MM - NEw SCRUBBING SYSTEM PROVIuES PARTICIPATE AND S02 CONTROL MTH THREE SCRUB-
COAL: 0.6X SULFUR, IPX ASH BEk MODULES. FACH MOUULF CONSISTS UF A DUMNFLOw VFNTURI SCRUBBER CENTER-
ADL/COMBUST10N EQUIP ASSOCIATE ED HlTHIN AN UPFLOw SPRAY TOwFR ABSORBER. EACH MODULE CAN TREAT OOX OF
LIME/ALKALINF FLYASH IHE TOTAL BOILER FLUE GAS AND THE MODULES CANNOT BE BYPASSED. THE UN-
STARTUP B/76 STABILIZED SLUDGt IS DISPOSED IN AN UN-SITE LINEU DISPOSAL POND. IN-LINE
STEAM REHEAT AND CLOSED WATER LOOP CAPABILITY ARE INCLUDED IN THE SYSTEM.
MONTANA PUWER A CONTRACT FUR THE INSTALLATION OF TWO ADDITIONAL LIMF/ALKALINE FLYASH
COLSTRIP 3 SCRUBBING SYSTE.MS HAS bEtv AWARDED TU A.D. iITTLE/COMBUSTION EQUIPMENT
700 MW - NEw ASSOCIATES. IHkSt SYSTEMS wILL BE INSTALLED ON UNITS 3 AND a OF THE
COAL: o.7x SULFUR COLSIRIP POMER STATION. COLSTRIP UNITS i AND 2 ARE BOTH EQUIPPED WITH
AOL/COMBUSTION EQUIP ASSOCIATE OPERATIONAL LIME/ALKALINE ELYASH SCRUBBING SYSTEMS FOR THE REMOVAL OF
LIME/ALKALINE FLYASH PARTICIPATES AND SULFUR DIOXIDE.
STARTUP 7/80
MONTANA POMER A CONTRACT FUR THE INSTALLATION UF TOO ADDITIONAL LIME/ALKALINE FLYASH
COLSTRIP 0 SCRUBBING SYSTEMS HAS BEEN AwAKDEO TO A.D. LITTLE/COMBUSTION EQUIPMENT
700 MM - NE.W ASSOCIATES. THESE SYSTEMS WILL BE INSTALLED ON UNITS 3 AND « OF THE
COAL; o.7x SULFUR COLSIRIP POWER STATION. COLSTRIP UNITS i AND 2 ARE BOTH EQUIPPED WITH
AOL/COMBUSTION EQUIP ASSOCIATE OPERATIONAL LIME/ALKALINE FLYASM SCRUBBING SYSTEMS FOR THE REMOVAL OF
LIME/ALKALINE FLYASH PARTICULARS AND SULFUR DIOXIDE.
STARTUP 7/81
NEVADA POMER CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM. 3PECIFICA-
MABRY ALLEN i TIONS HAVE NOT YET BEEN PREPARED.
soo MM - NEW
COAL
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 6/BS
NEVADA POMER CONSIDERING HOT SIDE ESP TN CONJUNCTION WITH AN FGD SYSTEM."""
HABRY ALLEN 2 TIONS HAVE NOT YET BEEN PREPARED.
500 MM - NEW
COAL
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 6/86
-------
EPA UTlLlTr FGD SURVEY: AUGUST 1978 - SEPTEMBER 1978
SfcCT ION /«7
CONSIDERING HOT SIOF ESP IN CONJUNCTION WITH AN FGU SYSTEM. SPECIFICA-
TIONS HAVE NOT YET BEF.N PREPARED.
NEVADA POHEK
HARRY ALLEN a
500 MM - NEW
COAL
VENDOR NOT SELECTtO
PROCESS NOT SELECTED
STARTUP »>/««
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM. SPECIFICA-
TIONS HAVE NOT YET BEEN PREPARED.
NEVADA POwER
REID GARDNER 1
125 MW - RETROFIT
COAL; O.SI SULFUR, OX ASH
ADL/tOMBUSTION EUUIP ASSOCIATE
SODIUM CARBONATE
STARTUP 0/70
10 SECTION 3 OF THIS REPQRI FOR ADDITIONAL INFORMATION.
THIS SODIUM CARBONATE-BASED (TRONA) SCRUBBING SYSTEM CONSISTS OF ONE
MODULE CONTAINING A THIN VARIABLE-THHOAT VENTURT SCRUBBER FOLLOWED BY A
SFPARAIOR IN SERIES WITH * SINGLE-STAGE PERFORATED-PLATE HASH TONER.
PRIMARY PARTICULATE CONTROL IS PROVIDED HY UPSTREAM MECHANICAL COLLECTORS.
AN INDIRECT STEAM HOT AIR REHEAT SYSTEM RAISES THE GAS TEMPERATURE 30 F
PR 10k TO DISCHARGE TO THE MAIN STACK. THE FLUE GAS CLEANING HASTES ARE
ULTIMATELY DISPOSED IN AN ON-SITE CLAY-LINED SOLAR EVAPORATION POND.
NEVADA POnER
REID GARDNER 2
125 HW - RETROFIT
COAL; o.5x SULFUR, HI ASH
AOL/CUM8USTION EQUIP ASSOCIATE
SODIUM CARBONATE
STARTUP 1/7«
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THIS SODIUM CARRONATE-UASED (1RONA) SCRUBBING SYSTEM CONSISTS OF ONE
MODULE CONTAINING A THIN VARIABLE-THROAT VENTURI SCRUBBER FOLLOWED BY A
SEPARATOR IN SERIES WITH A SINGLE-STAGE PERFORATED-PLATE HASH TONER.
PRIMARY PARTICULATE CONTROL IS PROVIDED HY UPSTREAM MECHANICAL COLLECTORS.
AN INDIRECT STEAM HOT AIR REHEAT SYSTEM RAISES THE GAS TEMPERATURE 30 F
PRIOR TO DISCHARGE TO THE MAIN STACK. THE FLUE GAS CLEANING HASTES ARE
ULTIMATELY DISPOSED IN AN ON-SITE CLAY-LINED SOLAR EVAPORATION POND.
NEVADA PONER
REID GARDNER i
125 MN - NEW
COAL; o.sx SULFUR, ax ASH
ADL/CUMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE
STARTUP 7/76
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THIS UNIT is A NEH CUAL-FIRED BOILLR THAT is EQUIPPED WITH SODIUM
CARBONATE-HASEU(TRUNA)SCRUBBING SYSTEM WHICH INCORPORATES A TWIN
VARIABLE-THROAT VENTURI SCRUBBER FOLLOWED BY A SEPARATOR IN SERIES WITH
A SINGLE-STAGE PERFORATED-PLATE NASH TONER. MECHANICAL COLLECTORS PROVIDE
PRIMARY PARTICULATE CONTROL. REHEAT IS PROVIDED BY AN INDIRECT STEAM HOT
AIR REHEAT SYSTEM. WASTE IS DISPOSED IN AN ON-SITE CLAY-LINED POND.
NEVADA PONER
REID GARDNER 1
250 MN - NFN
COAL? o.75x SULFUR
VENDOR NOT SELECTtD
PROCESS NOT SELECTED
STARTUP 0/83
NEVADA PONER COMPANY HAS SCRAPPED THIER ORIGINAL PLANS TO MAKE UNIT a A
COPY OF UNIT 3. THE NEW PLANS CALL FOR A 250-Mw UNIT TO BE IN OPERATION
BY 1983. THF UTILITY IS PREPARING SPECIFICATIONS AT THIS TIME. CONSTRUC-
TION IS SCHEDULED TO START IN 1980.
NEVADA POWER
WARNER VALLEY 1
250 MN - NEW
COAL
VENDOR NOT SELECTED
PROCESS NUT SELECTED
STARTUP 6/8U
SPECIFICATIONS ARE BEING PREPARED FOR A SCRUBBING SYSTEM. NEVADA PONER
HAS NOT YET ANNOUNCED PLANS FOR THIS UNIT'S EMISSION CONTROL STRATEGY.
NEVADA PONER
NARNER VALLEY 2
250 MN - NEW
COAL
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 6/85
SPECIFICATIONS ARE BEING PREPARED FOR A SCRUBBING SYSTEM. NEVADA PONER
HAS NOT YET ANNOUNCED PLANS FOR THIS UNIT'S EMISSION CONTROL STRATEGY.
13
-------
fP» UTILITY FtO SURVEY: AUGUST 1<»78 - SfcPTEMRER 1<»7B
StCTTON i
STATUS OF FGU SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
NE1 ENGLAND ELEC SYSTEM
BRAYTON POINT 1
650 MM - RETROFIT
FUEL OIL! l.OX SULFUR,
VENDOR NOT SELECTED
PROCESS NUT SELECTED
STARTUP U/ 0
NEh ENGLAND ELECTRIC SYSTEM HAS REQUESTED PERMISSION TO BURN t.St SULFUR
COAL »1 THIS UNIT. THIS IS ALLOWABLE UNDER STATE STANDARDS BUT 308 EMIS-
SIONS WOULD BE ABOVF ALLOWABLE FEDERAL LEVELS. A DECISION BY THE EPA IS
IX ASH STILL PENDING. MEAHKHlLE, THE UTILITY IS INVESTIGATING VARIOUS ADVANCED
REGENEBABLE FGO SYSTEMS WHICH OFFER A BREAKTHROUGH IN OPERATING COSTS AND
PRODUCE ELEMENTAL SULFUR AS AN END PRODUCT. THE UTILITY IS CURRENTLY IN-
VOLVED IN BFNCH AND LABORATORY SCALF INVESTIGATIONS OF SULFUR RECOVERY.
THIS UNIT IS CURKFNTLY OPERATIONAL FIRING LOn SULFUR FUEL OIL.
NIAGARA MOHAWK PO»ER COOP
CHARLES R. HUNTLEV 6
100 MM - RETROFIT
COAL; 3.sx SULFUR
ATOMICS INTERNATIONAL
AQUEOUS CARBONATE
STARTUP 0/80
A CONTRACT (.AS AWARDED TO ATOMICS INTERNATIONAL FOR THE DESIGN AND IN-
STALLATION OF AN A4UEOUS CARBONATE FGD SYSTEM. THIS DEMONSTRATION SYSTEM
HILL PkOOUCE END-PRODUCT SULFUR. FUNDS ARE BEING PROVIDED BY THE USFPA
AND I He EMPIRE STATE ELECTRIC ENERGY RESEARCH CORP. THE DESIGN S02 RE-
MOVAL EFFICIENCY HILL BE 90 PERCtNl. GROUND BREAKING FOR CONSTRUCTION MILL
BE TN LATE FALL 19f8.
NORTHERN INDIANA PUB SERVICE
HAILLY 7
190 MB - RETROFIT
COAL? 31 SULFUR
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP O/ 0
NORTHERN INDIANA PUBLIC SERVICE IS CURRENTLY CONSIDERING A LIME OR LIME-
STONE SCRUBBING UNIT FUR DAILLY 7 AND B. THEY ARE ALSO WAITING FOR
PERFORMANCE NFSULTS OF THE MELLMAN LORD/ALLIED CHEMICAL UNIT IN SERVICE
AT DEAN H. MITCHELL 11. LOM SULFUR COAL MAY BE EMPLOYED TO COMPLY WITH
so? EMISSION REGULATIONS. APPLICABLE INDIANA 302 REGULATIONS ARE STILL NOT
FIRMLY ESTABLISHED.
NORTHERN INDIANA PUB SERVICE
BAILLY 8
•00 MM - RETROFIT
COAL; sx SULFUR
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP O/ 0
NORTHERN INDIANA PUBLIC SIRVICE IS CURRENTLY CONSIDERING A LIME OR LIME-
STONE SCRUBBING UNIT FOR HAILLY 7 AND 8. THEY ARE ALSO WAITING FOR
PERFORMANCE RESULTS OF THE HELLMAN LORD/ALLIED CHEMICAL UNIT IN SERVICE
AT DkAN H. MITCHELL 11. LOW SULFUR COAL MAY BE EMPLOYED TO COMPLY WITH
so2 EMISSION REGULATIONS. APPLICABLE INDIANA so2 REGULATIONS ARE STILL NOT
FIRMLY ESTABLISHED.
NORTHERN INDIANA PUB SERVICE REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
DEAN H. MITCHELL n
us MW - RETROFIT
COAL; 3.5X SULFUR, lox ASH
DAVY POWERGAS
MELLMAN LORD
STARTUP 11/76
THIS FGD SYSIEM IS AN INTEGRATION OF THF MELLMAN-LORD 302 RECOVERY PROCESS
OFFERED BY DAVY POHER6AS AND THE S02 TO SULFUR REDUCTION PROCESS DE-
VELOPED BY ALLIED CHEMICAL. DAVY POWERGAS IS THE DESIGN AND CONSTRUCTION
FIRM AND ALLIED CHEMICAL IS SYSTEM OPERATOR AND PRODUCT MARKETER.
PERFORMANCE TESTS MERE SUCCESSFULLY COMPLETED ON SEPTEMBER 14, 1977. A
DEMONSTRATION YEAR COMMENCED ON SEPTEMBER 16, 1977.
NORTHERN STATES POWER REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
SHERBURNE 1 FULL COMMERCIAL OPERATION UF THE SYSTEM BEGAN ON MAY 1, 1976. THE SCRUB-
710 MM - NEW BING SYSTEM FOR THIS UNIT CONSISTS OF 12 MODULES. EACH SCRUBBING MODULE
COAL; 0.8X SULFUR, 9.5X SULFUR INCORPORATES A VENTUHI-ROD SECTION AND A MARBLE BED ABSORBER FOR PAR-
TICULATE AND SULFUR DIOXIDE REMOVAL. A FORCED OXIDATION SYSTEM CONVERTS
ALL THE CALCIUM SULFITE TO SULFATE PRIOR TO DISCHARGE TO A CLAY-LINED
SETTLING POND. STACK GAS REHEAT IS PROVIDED BY IN-LINE HOT HATER TUBES.
THE COAL BURNED AT THIS UNIT CONTAINS .8X SULFUR AND 9-10X ASH.
COMBUSTION ENGINEERING
LIMESTONE/ALKALINE FLVASH
STARTUP 3/76
NORTHERN STATES POWER
SHERBURNE 2
710 MM - NEW
COAL; o.ex SULFUR, 9.51 ASH
COMBUSTION ENGINEERING
LIMESTONE/ALKALINE FLVASH
STARTUP 4/77
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE SHERBURNE NO. 2 AIR QUALITY CONTROL SYSTEM IS IDENTICAL IN DESIGN TO
THE SYSTEM IN OPERATION ON THE NO. 1 UNIT AT THIS STATION. TWELVE 2-STAGE
PARTICULATE SCRUBBER (VENTURI-ROD SCRUBBER) AND SULFUR DIOXIDE ABSORBER
(MARBLE-BED ABSORBER) MODULES ARE PROVIDED FOR FLY ASH AND S02 CONTROL.
ELEVEN MODULES ARF REQUIRED FOR FULL GENERATING CAPACITY OPERATIONS.
THE CALCIUM SULFITE IS FORCIBLY OXIDIZED TO SULFATE PRIOR TO DISCHARGE TC
THE DISPOSAL POND. IN-LINE HOT HATER TUBES PROVIDE STACK GAS REHEAT.
NORTHERN STATES POWER
SHERBURNE 3
860 MM - NEN
COAL; O.BX SULFUR, 9.5* ASH
COMBUSTION ENGINEERING
LIMESTONE/ALKALINE FLYASH
STARTUP S/84
TMO ADDITIONAL COAL-FIRED POHER-GENERATING UNITS ARE SCHEDULED TO BE IN-
STALLED AT NSP'S SHERBURNE COUNTY GENERATING STATION IN BECKER MINNESOTA.
COMBUSTION ENGINEERING MAS AMAROED A CONTRACT FOR LIMESTONE SLURRY SPRAY
TOHER FGD SYSTEMS ON THE 860 MM UNITS 3 ft 4. THE 2-8TAGE SCRUBBING SYSTEM
MILL REMOVE PARTICULATE (99.5X) • 802 (80S). THE BOILER CONTRACT HAS BEEN
AHARDED TO BABCOCK AND MILCOX AND THE TURBINE HILL BE SUPPLIED BY GENERAL
ELECTRIC. START-UP HAS BEEN DELAYED TO MAY 1984 AND CONSTRUCTION START-
UP HAS BEEN SUSPENDED UNTIL APRIL 1980 DUE TO ENVIRONMENTAL PROBLEMS.
14
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EPA UTILITY PSD SURVEY: AUGUST 1978 - SEPTEMBER 1979
SECTION
STATUS OF FRQ
UNIT IDENTIFICATION
CURRENT STATUS
STATED P(JW£R
SHFRBURNE 1
DbO MM - NE*
COAL; 0.81 SULFUR. 9.5X
COMBUSTION ENGINEERING
LIMFSTONE/ALKALINE FLYASH
STARTUP 0/87
TWO ADDITIONAL CUAL-FIREO POWER-GENERATING UNITS ARE SCHEDULED TO BE IN-
STALLED AT NSP'S SHERBURNF COUNTY G^NFRATING STATION IN RECKFP MINNESOTA.
COMBUSTION ENGINEERING HAS AWARDED A CONTRACT FOR LIMESTONE SLURRY SPRAY
ASH IO«ER FGO SYSTEMS UN THE »bO MW UNITS i * «. THF 2-STAGE SCRUBBING SYSTEM
WILL REMuVF PARTICULATt (99.bZ) » S02 (8UX). THE BOILER CONTRACT HAS REEN
AWARDED TO HAHCOC* AND Hll.CUX AND THE TURBINE WILL BE SUPPLIED BY GENERAL
ELECTRIC. UNIT SIART-UP IS NOW TENTATIVELY SCHEDULED FQR 1987 ALTHOUGH
LOW DFHAnO AND ENVIRONMENTAL PROBLEMS MAY DELAY THIS INDEFINITELY.
OTTER TATl POwFR THIS NEW CUAL-F IREl) STATION IS JOINTLY OWNED RY FIVF UTILITIES. OTTER
COYUTE 1 TAII. POHER IS THE MAJOR UWNFR ANU CONSTRUCTOR. MONTANA-DAKOTA UTILITIES
ooo MN - NEW is THE FACILITY UPER»TOR. THIS PLANNEH UNIT WILL FIRE LOW SULFUR LIGNITE
LIGNITE; 0.9X SULFUR, 6.5X ASH FROM THE MERCER COUNTY AREA IN A B«W CYCLONE BOILFR. THE CONTRACT FOR THIS
MHEELAHMATOR-FRYE/A.I. AQUEOUS CARBONATE/FABR1C FILTER 503 SCRUBBER-ABSURBER HAS AWARDED TO
AQUEOUS CARBONATE KHfcEL»HRATOR-FMYfc ANU ATUM1CS INIERNATIUNAI. THE DRY REMOVAL SYSTEM COM-
STARTUP 5/81 MINES AI'S AUUEOUS CARUONATF PROCESS IN A N-F FABRIC FILTER. UNIT CON-
STRUCTION IS NOW 20X COMPLETE AND F(U> SYSTEM CONSTRUCTION HAS JUST BEGUN.
PACIFIC GAS AND FLECTRIC
FOSSIL 1
800 MW - NE*
COAL; O.BX SULFUR, tax ASH
VENDOR NOT SELECTED
LIMESTONE
STARTUP 0/Bb
PK&E ANNOUNCED PLANS TU BUILD Two UOU-HW COAL-FIRED pnwEw GENERATING
UNITS IN NORTHERN CALIFORNIA. THE FIRST UNIT WILL BURN COAL WITH A HEAT-
ING VALUE OF 12000 RTU/LB, 0.81 SULFUR AND IOX ASH CONTENTS. THE SECOND
UNIT HILL BURN COAL UF EUIIAL OR BETTER QUALITY. THE EMISSION CONTROL
SYSTEM «RL CONSISI OF AN ESP OR BAGHOUSE AND A LIMESTONE FGD SYSTEM.
SLUDGE WILL HE DISPOSED OF IN A LANDFILL. START-UP DATES ARE 1985 AND 1986
FOR NOS. 1 AND J RESPFCUVtLY.
PACIFIC GAS AND ELECTRIC
FOSSIL I
800 MX - NEW
COAL; o.sx SULFUR, lox ASH
VENDOR NOT SELECTED
LIMESTONE
STARTUP 0/8b
PGSE ANNOUNCED PLANS TU BUILD THO BOO-Mw COAL-FIRED POwER GENERATING
UNITS IN NORTHERN CALIFORNIA. THE FIRST UNIT HILL BURN COAL WITH A HEAT-
ING VALUE OF 12000 BTII/LU, 0.8Z SULFUR AND IOX ASH CONTENTS. THE SECOND
UNIT WILL BIIRK COAL OF EUIIAL OR BETTER DUALITY. THE EMISSION CONTROL
SYSTEM WILL CONSIST OF AN ESP OR BAGHOUSE AND A LIMESTONE FGD SYSTEM.
siUOGE WILL bF DISPOSED OF IN A LANDFILL. START-UP DATES ARE 1985 AND 1986
FOR NOS. 1 AND ? RESPECTIVELY.
PACIFIC POHER * LIGHT
JIM BRIDGER 0
509 MW * NE"
COAL; o.Sbx SULFUR, 9x ASH
AIR CORRECTION DIVISION, UOP
SODIUM CARBONATE
STARTUP 9/79
THE AIR CORRECTION DIVISION OF UOP WAS AWARDED A CONTRACT FOR AN FGD
SYSTEM AT THIS NEW-50<> Mw COAL-FIRED UNIT. THE FGO SYSTEM WILL CONSIST OF
PARALLEL TRAY TOnER ABSORBER MODULES, EACH TREATING ONE-THIRD UF THE
BOILER FLUE GAS AT FULL LOAD. AN ESP WILL PROVIDE PRIMARY PARTICULATE
CONTROL. AN ACID BRICK LINED w£T SIACK IS INCLUDED IN THE SYSTEM. PPL'S
PILOT STUDY INSPECIION REVEALED SCALE FORMATION PROBLEMS. TESTS ARE BEING
CONDUCTED TO RESOLVE THIS PROBLEM. TO DATE. b7X OF THE UNIT CONSTRUC-
TION IS COMPLFTF.
REFER TO SECTION 5 OF THIS REPORT FOR ADuITONAL INFORMATION.
THIS EMISSION CONTROL SYSTEM WAS DESIGNED TO REMOVE FLYASH AND S02 FROM
3.35 MM ACFM OF FLUE GAS USING THIOSURBIC LIME AS A SCRUBBING ABSORBENT.
THE INITIAL SHAKEDOWN AND DEBUGGING PHASE OF OPERATION BEGAN FOR PART OF
THE SYSTEM IN DECEMBER 1975. PARTIAL COMMERCIAL OPERATION COMMENCED IN
APRIL 19/b. THE UNIT HAS CERTIFIED FULL-LOAD COMMERCIAL IN JUNE 1976.
THE FGD SYSTEM HAS EXPERIENCED OPERATIONAL PROBLEMS SINCE IT HAS BEEN IN
SERVICE REQUIRING A NUMBER OF SYSTEM REPAIRS AND DESIGN MODIFICATINS.
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THIS EMISSION CONTROL SYSTEM WAS DESIGNED TO REMOVE FLYASH AND S02 FROM
3.35 MM ACFM OF FLUE GAS USING THIOSORBIC LIME AS A SCRUBBING ABSORBENT.
SIX SCRUBBING TRAINS, EACH INCLUDING THO VENTURI SCRUBBERS IN SERIES
ARRANGEMENT, ARF PROVIDED FOR FULL-LOAD OPERATION. THE INITIAL SHAKEDOWN
AND DEBUGGING PHASE OF OPERATION BEGAN FOR THREE TRAINS IN JULY, 1977.
FULL COMMERCIAL OPERATION FOR THE ENTIRE SYSTEM COMMENCED ON OCTOBER 1,
1977.
A CONTRACT HAS AWARDED TO PULLMAN KELLOGG FOR THE FGO SYSTEM AT THIS UNIT.
THE EMISSION CONTROL SYSTEM FOR THIS UNIT HILL CONSIST OF ESP'S UP-STREAM
OF FIVE HEIR HORIZONTAL CRUSSFLOH NET SCRUBBING MODULES. SLUDGE HILL RE
DISPOSED OF BY THE EXISTING SYSTEM AT THE BRUCE MANSFIELD PLANT. LINER IN
THE CHIMNEY HILL RE AN INCONEL 625 MATERIAL. THE UNIT IS CURRENTLY UNDER
CONSTRUCTION WITH ESP'S 70-80 PERCENT COMPLETE AND THE FGD SYSTEM 30
PERCENT COMPLETE. UNIT START-UP HILL BE IN APRIL 1980.
PENNSYLVANIA
HHUCF MANSFIELD 1
82S MH - NEW
COAL) 4.7X SULFUR, 12,5X ASH
CHEMICO
LIME
STARTUP fl/7b
PENNSYLVANIA POHER
BRUCE MANSFIELD 2
825 MH - NEW
COAL; a.7x SULFUR, 12.sx ASH
CHEMICO
LIME
STARTUP 7/77
PENNSYLVANIA POWER
BRUCE MANSFIELD 3
82S MW - NEW
COAL! «.7X SULFUR
PULLMAN KELLOGG
LIME
STARTUP 4/80
15
-------
FP» UTILITY FGD SURVEY: AUGUST 197« - SEP1F.MBEH 1978
SECTIUN 2
STATUS OF FGD bYSTEMS
UNIT IDENTIFICATION CURRENT STATUS
PHILADELPHIA ELECTRIC
CRDMBY
150 HH • RETROFIT
COAL: 2«4x SULFUR
UNITED ENGINEERS
MAGNESIUM nxioE
STARTUP h/80
THt UTILITY PLANS TO RtTROFIT ONE OF THE T«0 HOILERS AT CROMBY HITM AN
FGU S»5TEK. HOnFVFR. A FINAL DECISION HAS NOT HfEN MADE. THE SYSTEM
HFING GIVFN PRIMARY CONS IOERAT1 ON IS MAGNESIUM OXIDE. CURRENTLY, THF
UTILITY IS RE-NFbOTIATING CONSENT ORDERS AND THE STAKT-UH DATE OF JUNE
1980 IS lENTATIVt.
PHILADELPHIA ELECTRIC
FufUSTONF 1A
120 MH - RETROFIT
COAL; 2,sx SULFUR, lox ASH
UNITED ENGINFERS
MAGNESIUM OXIDE
STARTUP 9/75
RFFER 10 SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE EMISSION CONTROL SYSTFM I-OK THIS UNIT CONSISTS OF THRFE PARALLEL
SCRUBBING TRAINS FOR TnE CONTROL OF PARTICIPATE AND SULFUR DIOXIUE.
THE C-b!DF SCRUHDING TRAIN TNCLUDFS AN SU2 ABSORBER MODULE IN SERIES
ftlTH A PARTICULATE SCRURBFM. APPROXIMATELY ONE-THIRD OF THE BOILER FLUE
GAS IS SCRUBBED r»ITH MAGNFSIUM OXIOF SLURRY FOR S02 REMOVAL. THE SPENT
SLURRY IS RFGFNf-RATFD AT THE ESSEX SULFURIC ACIO PLANT IN NEWARK, n.J.
THE KEUENERAIFD MAbOX IS RETURNED TO THE PLANT FOR Su2 SCRUBBING SERVICE.
PHILADELPHIA ELECTRIC
EOOYSTOMF IB
200 MH - RtTROFIT
COAL: 2.5X SULFUR, toz ASH
UNITED ENGINEERS
MAGNESIUM OXIDE
STARTUP 6/BO
THE INSTALLATION OF AN F60 SYSTEM ON THE BALANCE OF IHE FLUE GAS FROM
THIS UM1 BILL FOLLOW PENDING THE OUTCOME OF THE PERFORMANCE OF THE EXPER-
IMENTAL SCRUBBING UNIT WHICH MAS BEFN INSTALLED AND CURRENTLY OPERATIONAL
UN Thlb UNIT. CURRENTLY, ) PARTICULATE SCRUHBFHS ARE TREATING THE FULL
GAS LOAD FROM THIS UNIT. CONSENT ORDERS ARE PRESENTLY BEING RE-NEGOTIATEO
AND THE START-UP DATt l)F JUNE 1480 IS TENTATIVE.
PHILADELPHIA ELECTRIC
EOOYSTONF 2
S3* MH - RETROFIT
COAL; 2.sx SULFUR, lox ASH
UNITED ENGINEERS
MAGNFSIUM OXIDE
STARTUP 6/80
THE UTILITY IS AhAIUNG PERFORMANCE RESULTS FROM THE EXPERIMENTAL FGD
SYSTEM INSTALLED ON UNIT 1 AT THIS STATION BEFORE PROCEEDING nlTH THE
DESIGN OF AN FGO SYSTEM FOR THIS COAL-FIRED BOILER. THE SYSTEM BEING
GIVEN PRIMARY CONSIOERATION IS "AGNESIUM OXIDE, DESIGNED JOINTLY BY
UNITED FNGINEERS AND PHILADELPHIA ELECTRIC. CURRENTLY. THE UTILITY is
RE-NEGOTIATING CONSENT ORDERS AND THE START UP DATE OF JUNE i"tto is
TENTATIVE.
POTOMAC ELECTRIC POHER
DICkFRSON 4
800 MH - NfcM
COAL? 2X SULFUR
VENDOR NOT SELECTED
PROCESS NUT SELECTED
STARTUP 5/85
THERE ARE NO FIRM PI ANS FOR INST ALLAI TtIN OF AN FGD SYSTEM. STARTUP DATE
OF THE HUILFR IS PLANNED FOR 1985. THIS UNIT MILL BURN 2 PERCENT SULFUR
COAL "ITH A HFATING VALUE UF 11,000 BTU/LB.
PUMER AUTHORITY OF NE« YORK
ARTHUR KILL PLANT
700 MH - NEH
COAL; 3x SULFUR - REFUSE
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 11/8Q
THE UTILITY IS CONSIDERING BOTH REGFNEHABLE AND LIMESTONE FGD PROCESSES.
FGD TECHNOLOGY IS BEING CONSIDERED FOR A FOSSIL FUEL BURNING UNIT WHICH
"ILL EMPLOY COAL AS THE PRIMARY FUEL AND OIL AS BACKUP. REFUSE HILL BE
PROVIDED AS A SUPPLEMENTAL FUEL SUPPLY. THE PREFERRED PLANT SITE IS THE
ARTHUR KILL FACILITY LOCATED ON STATEN ISLAND. THE PROJECT DESIGN ENGI-
NEERING FIRM IS SARGENT AND LUNOY. PUBLIC SERVICE COMMISSION HEARINGS
ARE IN PROGRESS.
PUBLIC SERVICE OF INDIANA
GIBSON 5
650 MH - NEK
COAL; 3.sx SULFUR
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 0/82
PUBLIC SERVICE CO OF INDIANA ANNOUNCED PLANS FOR THE CONSTRUCTION OF THIS
NEH 65G-MM COAL FIRED POnER GENERATING UNIT AT GIBSON STATION. BIDS
HAVE BEEN RECEIVED AND ARE BEING EVALUATED. INITIAL STARTUP IS SCHEDULED
FOR 198?.
PUBLIC SERVICE UF NEH MEXICO
SAN JUAN 1
314 MH - NEH
COAL; 0.8X SULFUR, 20X ASH
DAVY POHERGAS
HELLMAN LORD
STARTUP 4/7B
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION. THIS F60
SYSTEM IS AN INTEGRATION OF THE ftELLMAN LORD S02 RECOVERY PROCESS OF DAVY
POHERGAS AND ALLIED CHEMICAL'S 802 REDUCTION TO SULFUR PROCESS. A HOT
SIDE ELECTROSTATIC PRECIPITATOR PRECEEOS THE FGO SYSTEM. OF THE FOUR
ABSORBER TOHERS INSTALLED, THREE ARE NEEDED TO CARRY THE FULL LOAD. THE
COAL BURNED AT THIS UNIT HAS SULFUR AND ASH CONTENTS OF .8X AND 20X RE-
SPECTIVELY. THE SYSTEM OPERATES ON A CLOSED HATER LOOP HITH RIVER HATER
BEING USED AS MAKE-UP FOR LOSSES DUE TO EVAPORATION.
16
-------
EPA UTILITY FGn SURVEY: AUGUST 1978 - SEPTEMBER 1978
SECTION 2
STATUS OF FGO SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
PUBLIC sERvict OF NE* MEMCO
SAN JUAN 2
30h MW - RETROFIT
COAL; o.ex SULFUR, 2ux ASH
OAVY POWERGAS
WELLM4N LORD
STARTUP 7/7H
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN 3
46H MM - NEM
COAL: o.sz SULFUR, 201 ASH
OAVY POnERGAS
WELLMAN LORI)
STARTUP h/79
PUBLIC SERVICE OF NE* MEXICO
SAN JUAN
-------
EPA UTILITY FGO SURVEY: AUGUST 1«*78 - SEPTEMBER
SECTION f
STATUS OF FRO SYSTEMS
UNIT IDENTIFICATION
CURRENT STATUS
SIKESTON HOARD OF MUNIC. UT1L,
SIKESTON POWER STATION
235 Ml* - NEK
COAL; 2.«x SULFUR. 11.21 ASH
BARCOCK * MILCOX
LIMESTONE
STARTUP fc/Bl
Bft* HAS AWAROFU A CONTACT FOR THE RUILER AND AIM QUALITY CONTROL SYSTEM.
THE AOCS l»HL CONSIST UF g ESP'S FOLLOWED BY 3 FGO MODULES, EACH CAPABLE
OF HANULING bOX UF THE BOILER LOADS ONE WILL BE ON STAND-BY AT ALL TIMES.
THt UNIT WILL HURN A 2.flX SULFUR COAL. THE SIKESTON STATION HILL FEATURE
AN FRP-LINtO STACK, 2 KONOS (ONE FOR FLY ASH, ONE FOR SCRUBBER SLUDGE/
rtOTTOM-ASH DISPOSAL), AND a AXIAL FLOW FANS. NO STACK GAS REHEAT IS
PLANNED. MAXIMUM FLUE GAS CAPACITY IS 718.390 ACFM a 288 F. CONSTRUCTION
COMMENCED IN MAY 1470. THE UNIT IS NO* 10X COMPLETE.
SOUTH CAROLINA PUBLIC SERVICE
MINVAH 2
260 MM - NEK
COAL; i.oz SULFUR, 19X ASH
8ABCOCK It HlLCOX
LIMESTONE
STARTUP 7/77
HEFEH 10 SECTION 3 OF THIS REPORT FOK ADDITIONAL INFORMATION.
THE EMISSION CONTROL SYSTEM FOH THIS UNIT CONSISTS OF A 1001 CAPACITY ESP
FOLLOWED BY A SOX CAPACITY LIMESTONE F60 SYSTEM. ONE FGD MODULE. CONSIST-
ING OF A VENTUHI SCRUBBER AND TRAY TOWER AHSuRBEH, REMOVES 70X OF THE
INLET so2. REHEAT is SUPPLIED BY FLUE UAS BYPASS. THE SCRUBBING WASTES
ARE DISCHARGED TO AN ON-SITE, UNLINED DIKED POND. THE NO. 2 UNIT
COMMENCED INITIAL OPERATION IN JULY 1977. THE ACCEPTANCE TEST FOR COM-
MERCIAL CERTIFICATION riAS SUCCESSFULLY COMPLETED IN DECEMBER 1977.
SOUTH CAROLINA PUBLIC SERVICE
MINVAH 3
300 MW - NEW
COAL; I.7X SULFUR
RABCOCK ft HlLCOX
LIMESTONE
STARTUP 5/80
A CONTRACT HAS HEEN AWARDED TO HABCOCK AND nILCOX FOH THE INSTALLATION
OF THE FGO SYSTFM ON THIS UNIT. PAHT1CULATE REMOVAL MILL BE PROVIDED
BY RESEARCH COTTRELL ESP'S. THE 8011ER IS COAL-FIRED DRY-BOTTOM UNIT
HHICH HILL BURN COAL WITH A 1.7X SULFUR CONTENT AND HEAT VALUE OF 11,500
BTU/LB. THt GENERATING EQUIPMENT IS BEING SUPPLIED BY RILEY STOKER. 10t»X
OF THE FLUE GAS HILL BE SCRUBBED. FGD SYSTEM CONSTRUCTION HILL BEGIN
IN DECEMBER 1978. START-UP IS SCHEDULED FUR MAY 1980.
SOUTHERN ILLINOIS POKER COOP
MARION 4
184 MM - NEK
COAL; 3X SULFUR, IbX ASH
BABCOCK » H1LCOX
LIMESTONE
STARTUP 9/78
THE EMISSION CONTROL SYSTEM I-OK THIS NEK COAL-FIRED BOILER CONSISTS OF AN
ESP FOH PAHTICULATE CONTROL FOLLOWED BY 2 SPRAY TOWERS FOR S02 CONTROL.
LIMESTONE SLURRY KILL BE USED AS THE SCRUBBING REAGENT. SIPC TS NOT PLAN-
NING TO UTILIZE FLUE GAS REHEAT AND IS CURRENTLY PLANNING ON A BRICK
LINING FOR THE STACK. SIPC INTENDS TO USE A LANDFILL WITH ASH STABILIZA-
TION OF HASTE FOR SLUDGF DISPOSAL. CONSTRUCTION IS NEARLY 100X COMPLETE
AND THE SYSTEM HAS BEEN AIR TESTED. THE BOILER IS NOW. OPERATING. THE
FGO SYSTEM WILL START BY MID NOVEMBER.
SOUTHERN ILLINOIS POwfcB COOP
MARION 5
300 MW - NEK
COAL; 3X SULFUR, 16X ASH
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 0/84
SOUTHERN ILLINOIS POWER COOP IS PLANNING A N£H COAL-FIRED UNIT FOR ITS
MARION STATION, MARION 5. THE FGO PROCESS HAS NOT BEEN DECIDED. THE UNIT
WILL FIRE 3.OX SULFUR COAL AND MAY START UP AS EARLY AS 1983. THE UTILITY
IS WAITING FOR THE FINALIZATION OF THE S02 REGULATIONS THEY HILL HAVE TO
MEET.
SOUTHERN INDIANA GAS ft ELEC
A. B. RROHN 1
250 MW - NEW
COAL; 3.75X SULFUR
FMC CORPORATION
DOUBLE ALKALI
STARTUP 4/79
THE UTILITY HAS AWARDED A CONTRACT TO FMC FOR THE INSTALLATION OF A
DOUBLE ALKALI SCRUBBING SYSTEM UTILIZING SODA ASH AND LIME. THIS UNIT is
A PART OF A NEW POwFR STATION LOCATED IN WEST FRANKLIN, INDIANA. THE
SYSTEM KILL PRODUCE FILTER CAKE AS A WASTE PRODUCT HHICH HILL BE DIS-
POSED OF IN AN ON-SITE LANDFILL. THE PARTICIPATE EMISSIONS HILL BE CON-
TROLLED BY A BUELL-ENVIROTECH COLD-SIDE ESP. THE CONSTRUCTION WORK AND
ENGINEERING IS APPROXIMATELY 78X COMPLETE. THE FGO SYSTEM IS APPROX-
IMATELY 70X COMPLETE.
SOUTHERN MISSISSIPPI ELECTRIC
R. o. MORROW i
180 MH - NEW
COAL} IX SULFUR, 8X ASH
RILEY STOKER / ENVIRONEERING
LIMESTONE
STARTUP 8/78
A CONRTACT WAS AWARDED BY SM£ TO RILEY STOKER/ENVIHONEERING FOR THIS FGD
SYSTEM. PARTICULATES WILL BE CONTROLLED BY A HIGH-EFFICIENCY ESP UPSTREAM
OF THE FGD SYSTEM. DESIGNED S02 AND PARTICIPATE REMOVAL EFFICIENCIES ARE
85 AND 99.6 PERCENT, RESPECTIVELY. A HATER SPRAY HAS BEEN ADDED IN THE
BY-PASS DUCT TO PROTECT THE LINER FROM TEMPERATURE EXCURSION. SLUDGE HILL
BE STABILIZED WITH FLYASH AND DISPOSED OF ON-SITE. INITIAL STARTUP HAS
BEGUN. HOWEVER DUE TO BOILER PROBLEMS NO OPERATING TIME HAS BEEN ACCUMU-
LATED. ACCEPTANCE TESTING IS EXPECTED IN NOVEMBER.
SOUTHERN MISSISSIPPI ELECTRIC
R. D. MORROW 2
180 MH - NEW
COAL; ix SULFUR, ax ASH
RILEV STOKER / ENVIRONEERING
LIMESTONE
STARTUP 1/79
A CONTRACT WAS AWARDED BY SME TO RILIY STOKER/ENVIHONEERING FOR THIS F60
SYSTEM. PARTICULATES WILL BE CONTROLLED BY A HIGH-EFFICIENCY ESP UPSTREAM
OF THE FGD SYSTEM. DESIGN SULFUR DIOXIDE AND PARTICIPATE REMOVAL EFFI-
CIENCIES ARE 85 AND 99.6 PERCENT, RESPECTIVELY. A WATER SPRAY HAS
BEEN ADDED IN THE BY-PASS OUCT TO PROTECT THE LINER FROM TEMPERATURE
EXCURSION. SLUDGE WILL BE STABILIZED HITH FLYASH AND DISPOSED ON THE PLANT
SITE. CONSTRUCTION OF THE WET LIMESTONE SCRUBBING SYSTEM IS 85 PERCENT
COMPLETE.
18
-------
EH* UTILITY FGO SURVEY: AUGUST 1978 - SEPTEMBER 1478
StCT IUN f.
STATUS OF ^^,l) SYSTEMS
UNIT IDENTIFICATION
CUWREM STATUS
SU"TH«FSTE»N tLECTRIC POwER
HENRY H. PERKEY 1
720 MW - NEW
LIGNITES 0.8X SULFUR, 20X ASH
AIM CORRECTION DIVISION, UOP
LIMESTONE
STARTUP 2/84
A COMKACT Fun THE EMISSION CONTROL SYSTEM HAS BEEN AWARDED TO THE AIB
CORREC1ION DIVISION OF 'JOP. THE SYSTEM DESIGN INCLUDES TwO CULD-StOE ESP'S
FOH PAkTICULATE REMOVAL UP-STREAM FRO" 0 SPRAY TJWEWS WHICH UTILIZE LIME-
STONE SLURRY FOR SO? CONTROL. SLUDGF DISPOSAL nILL BE HANDLED BY AN IOCS
SYSTEM. START-UP is E»HECTEO HY FEBRUARY I98a.
SPRINGFIELD CITY UTILITIES
SOUTHWEST J
200 MM - NEW
COAL? *.5X SULFUR, 13X ASH
AIR CORRECTION DIVISION, uOP
LIMESTONE
STARTUP a/77
SPRINGFIELD HATER LIGHT ft PwR
OALLMAN )
190 MM - NE«
COALJ 3.7X SULFUR
RESEARCH COTTRELL
LIMESTONE
STARTUP 7/«U
REFER TO SECTION * OF THIS REPORT FOR ADDITIONAL INFORMATION.
THt EMISSION CONTROL SYSTEM FOR THIS NEM COAL-FIRED UNIT CONSISTS OF A
FOUR-FIELD HIGH EFFICIENCY ESP (99.hX DESIGN) AND 2 TURHULENT CONTACT AB-
SORBER MODULES (so* DESIGN) FOR IHE CONTROL OF PARTICULATES AND 502. BOTH
THE fcSP AND LIMESTONE FGO SYSTEM ARE SOPPLIEO BY HOP. THE SCRUBBING
ftASTtS AHE OEMATtREO BY A ROTARY DRUM VACUUM FILTER AND THE FILTER CAKE IS
HAULED A«AY TO A LANDFILL. INITIAL OPERATION OF TM£ FGO SYSTEM OCCURRED IN
APRIL 77. IN SEPT. 77, THE II*TI SUCCESSFULLY COMPLETED COMPLIANCE TESTING.
A CONTRACT HAS RbFN AWARDED TO RFSFAKCH COTTHFLL FOR THF INSTALLATION OF
A LIMESTONE FGO SYSTtM. REUUIHED SULFUR DIOXIDE REMOVAL EFFICIENCY
is <>o PERCENI. A SLUDGE DISPOSAL STRATEGY HAS NUT BEEN FINALIZED, BUT
THE UTILITY IS CONSIDERING EITHER PONDING OR LANDFILL. CONSTRUCTION OF
THE FGO SYSTEM SHOULD LOMMENCE IN LATE 1978. FGD START-UP IS SCHEDULED
FOR JULY I9RU. BOILER OPERATION IS SCHEDULED TO COMMENCE IN JUNE 1978.
ST. JOF ZINC
G. F. "EATON 1
hO MM - RETROF1I
COALJ sx SULFUR
BUREAU OF MINES
CITRATE
STARTUP I?/78
CONSTRUCTION CONTINUES ON THE CITRATE PROCESS SCRUBBING SYSTEM WHICH
MILL CONTROL SU2 EMISSIONS FROM A 60-Mw COAL-FIRED POWER GENERATING
UNIT Al ST. JOE MINERALS. THIS UNIT PROVIDES PQ»ER FOR THE LOCAL UTILITY
GRID. FGD SYSTEM STAKT-IIP IS SCHEDULED FOR DECEMBER 1978. THE REGENERABLE
FGD SYSTEM MILL PRODUCE ELEMENTAL SULFUR AS A BY-PRODUCT. ALL MAJOR
CONSTRUCTION IS COMPLETE. HIRING AND PIPING HORK IS NOn BEING COMPLETED.
TENNESSEE VALLEY AUTHORITY
SHAwNEE 10A
10 MM - RETROFIT
COAL? 8.91 SULFUR, 15.8X ASH
AIR CORRECTION DIVISION, UUP
LIME/LIMESTONE
STARTUP «/72
REFFR TO THE BACKGROUND INFORMATION IN SECTION 3 OF THIS REPORT. THIS
TURBULENT CONTACT ABSORBER (TCA) LIME/LIMESTONE SCRUBBING SYSTEM HAS BEEN
OPERATIONAL SINCt APRIL 197?. THIS TEST PROGRAM IS FUNOEO BY THE FPA WITH
TVA AS THE CONSTRUCTOR AND FACILITY OPERATOR. THE BECHTFL CORP. OF SAN
FRANCISCO is THF: MAJOR CONTRACIOR, TEST DIRECTOR, AND REPORT NRITEM.
TESTING MlTH AOIPIC ACID AS ADDITIVE FOR IMPROVING 302 REMOVAL EFFICIENCY
CONTINUED THROUGH AUGUST AND SEPTEMBER. HOTM VENTIIKI/SPRAY TOhER AND TCA
SYSTEMS wERWE UPhRATl-0 ON LIMESTONE SLURRY WITH HIGH FLYASH LOADING.
TENNESSEE VALLEY AUTHORITY
SHAnNfE 108
10 MM - RbTROFIl
COAL* 2.9X SULFUR, 15.8X ASH
CHEMICO
LIME/LIMESTONE
STARTUP 4/7«
REFER 10 THE BACKGROUND INFORMATION IN SECTION 3 OF THIS REPORT. THIS
VFNTIIRI/SPHAY TOMER LIMF/LI M£S TONE SCRUBBING SYSTEM HAS BEEN OPERATIONAL
SINCE APRIL 1972. THIS TtST PROGRAM IS FUNDED BY THE EPA WITH TVA AS THE
CONSTRUCTOR AND FACILITY OPERATOR. THF BECHTEL CORP. OF SAN FRANCISCO IS
THE MAJOR CONTRACTOR, TEST DIRECTOR, AND REPORT WRITER. TESTING MlTH
ADIPIC ACIO AS ADDITIVE FOR IMPROVING S02 REMOVAL EFFICIENCY CONTINUED
THROUGH AUGUST AND SEPTEMBER. BOTH VENTURI/SPRAY TuMER AND TCA SYSTEMS
MERE OPERATED ON LIMESTONE SLURRY MlTH HIGH FLYASH LOADING.
TENNESSEE VALLEY AUTHORITY
MIDOMS CREEK 7
575 MW - RETROFIT
COAL; 3.7X SULFUR
COMBUSTION ENGINEERING
LIMESTONE
STARTUP 10/80
TENNESSEE VALLEY AUTHORITY ANNOUNCED THAT A CONTRACT HAS BEEN AWARDED TO
COMBUSTIUN ENGINEERING FOR A LIMESTONE SLURRY SPRAY TOMER FGO SYSTEM. THE
FGU SYSTEM MILL TREAT HIGH SULFUR COAL FLUE GAS. THE SPRAY TOMER ABSORBERS
MILL BE CONSTRUCTED UF *17L STAINLESS STEEL. THF NO. 7 UNIT FIRES COAL
HlTH THE SAME CHARACTERISTICS AS THF COAL FIRED IN THE NO. 8 UNIT.
INITIAL OPERATIONS ARE SCHEDULED FOR OCTOBER 1980. THE FGD SYSTEM IS
CURRENTLY UNDER CONSTRUCTION.
TENNESSEE VALLEY AUTHORITY
MIOOWS CREEK B
sso MW - RETROFIT
COALI 3.7X SULFUR, 17X ASH
TENNESSEE VALLEY AUTHORITY
LIMESTONE
STARTUP 5/77
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
IHt EMISSION CONTROL SYSTEM FOR THIS 550-MM COAL-FIRED POWER-GENERATING
UNIT CONSISTS OF EXISTING ELECTROSTATIC PRECIPITATQRS FOLLOWED BY FOUR
PARALLEL SCRUBBING TRAINS, EACH CAPABLE OF HANDLING 25 PERCENT OF THE
BOILER FLUfc GAS FROM UNIT 8. EACH TRAIN INCLUDES A RECTANGULAR THROAT
VENTUR1 SCRUBBER AND A GRID-TOWER ABSORBER SUPPLIED BY POLYGON. THE GRID
TOWER CAN BE CONVERTED TO A MOBILE-BED TOWER IF GREATER 302 REMOVAL IS
REQUIRED.
19
-------
EPA UTILIT» FbO SURVEY: AUGUST 197« - SEPTEMBER 197«
StCTIUN 2
STATUS OF Ffif)
UNIT IDENTIFICATION
CURRENT STATUS
TtXAS MUNICIPAL PUHER AGENCY COMBUSlION ENGINEERING «.AS AWARDED A CONTRACT 10 DESIGN AND SUPPLY
GIBBONS CREEK I A aOO-X"* LIGNHF-F IHtl> rtulLEw. ESP, AND FGD SYSTE" AT GIBBONS CRtEK
000 MM - NEM STE«M ELECTRIC SIAIIUN UNIT NO. I. THE HUILEK HILL BUHN 1.U6X SULFUR
LIGNITE; 1.06X SULFUR, 25X ASM LIGNITt. FLUfc 6AS wILL Bt CLEANED OF PARTICIPATES BY A COLO-SIUE ESP
COMBUSTION fNGTNEERI*r, (99.73X EFFICIENCY). SU2 «ILL BF REMOVEO BY 3 SPRAY TOnFR MODULES UT1LIZ-
LIMESTONE INO A I IMFSTONE SLURRY (72.5 TO 87.5X EFFICIENCY). A CONTRACT HAS BFEN
STARTUP I/B2 AMARDEl' TO IUCS I- OH SI UDliE DISPOSAL. CUNSTrtUCTION IS TO BFGIN IN THE
SPMNG OF 1979. COMMERCIAL STAWT-UP IS SCHEDULED FOR JANUARY, 19B2.
TEXAS POWER I LIGHT
SANDOH 4
5«5 MM - NEW
LIGNITE
COMBUSTION
I I ME STONE
STARTUP 7/BU
COMBUSTION FNGINtERTNG HAS BEEN CHOSEN AS THE BOILER AND FGO VENDOR FOK
THIS UNIT. BOILER CONSTRUCTION BEGAN ON SEPTEMBER 9, 1977. PARTICULATE
REMOVAL EQUIPMENT «TLL HE LOCATED ON THE COLD-SIDE OF THt AIR HEATER.
SOME PORTION (IF FLUE GAS rtILL BYPASS THE SCRUBBER FOR REHEAT. THE SPENT
SLURRY «1LL bE PONDED AND HATER RECYCLED. FGD CONSTRUCTION IS SCHEDULED
TU BtGIN NOVEMBER 1978.
TE*AS POMf ft LIGHT
THIN OAKS 1
750 MM - NEM
LIGNITF.
VENDOR NOT SELECTED
LIMESTONE
STARTUP 8/fli
THIS UNIT «ILL BE JOINTLY OWNED BY THftL AND ALCOA. A FIRM DECISION HAS
NOT BFEN MADE WHETHER TO INSTALL FGD FACILITIES. THIS IS PRIMARILY
DUE TO THE FACT THAT SUCH A DECISION IS NOT YF1 kEUUIREO IN THE
UTILITIES PLANNING TIMETABLE.
TEXAS POWER * LIGHT
TnlN OAKS ?
7SO MM - NEH
LIGNITE
VENDOR NOT SELECTED
LIMESTONE
STARTUP 9/Ba
IHIS UNIT WILL BE JOINTLY UMNEU BY TPXL AND ALCOA. A FIRM DECISION HAS
Mil BEEN MADE NHE.THER TO INSTALL FGD FACILITIES. THIS IS PRIMARILY
out TO THF FACT THAT SUCH A DECISION is NOT YEI REQUIRED IN THE
IIULITIFb PLANNING UMMABLF.
TEXAS UTILITIES
FOREST GROVE 1
750 MM - NEM
LIGNITE
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP 0/61
TEXAS UTILITIES IS PLANNING A NFn 750-MM UNIT AT THE FOREST GROVE SITE.
TWO ESP'b nILL BE INSTALLED FOR PAHTICULATE CONTROL. THE UTILITY IS
CUKRtNILY REQUESTING BIDS FOR AN FGD SYSTEM. START-UP IS SCHEDULED FOR
LATF 19!«1. THE BOILER MILL BE SUPPLIED HY THE BABCOCK S ftTLCOX COMPANY.
THE DESIGN DOES NOT INCLUDE A STACK GAS REHEAT SYSTEM.
TEXAS UTILITIES
MARTIN LAKE 1
793 MM - NEM
COAL; o.ox SULFUR, ax ASH
RESEARCH COTTRELL
LIMESTONE
STARTUP B/77
TEXAS UTILITIES
MARTIN LAKE i
791 MM - NEM
COAL; o.9x SULFUR, ax ASH
RESEARCH COTTRELL
LIMESTONE
STARTUP 5/76
TEXAS UTILITIES
MARTIN LAKE 3
793 MM - NEM
COAL! 0.9X SULFUR, 8X ASH
RESEARCH COTTRELL
LIMESTONE
STARTUP 12/76
REEEk 10 SECTION * OF THIS REPUHT FOK ADDITIONAL INFORMATION. THIS NEM 793
M* UNIT FIRES TEXAS LIbNITE CONTAINING 0.9X SULFUR (AVG) AND BX ASH
(AVG). THE UNIT IS EUIIJPPEO WITH AN EMISSION CONTROL SYSTEM MHICH INCLUDES
COLD-SlOt tSP'S AND A LIMESTONE FGD SYSTEM BOTH SUPPLIED BY RESEARCH-COT-
THELL. THE FGD SYSTEM CONSISTS OF 6 PACKED/SPRAY TOMER ABSORBERS WHICH
TREAT 7SX OF THE TOTAL BOILER FLUE GAS. THE REMAINING FLUE GAS IS BYPASSED
FOR REHFAT. TOTAL 502 REMOVAL EFFICIENCY IS 70.5X. THE FLUE GAS CLEANING
HASTES ARE STABILIZED AND DISPOSED IN AN UN-SITE, LINED POND.
REFER TO StCTIUN 3 OF THIS REPORT FOR ADDITIONAL INFORMATION. THIS NEM. 793
MM UNIT FIRES TEXAS LIGNITE CONTAINING 0.9X SULFUR (AVG) AND 8X ASH (AVG).
THE UNIT IS EQUIPPED WITH AN EMISSION CONTROL SYSTEM CONSISTING OF COLD-
SIDE ESP'S AND A LIMESTONE FGO SYSTEM, BOTH SUPPLIED BY RESEARCH-COTTRELL.
THE FGD SYSTEM CONSISTS OF h PACKED/SPRAY TOwER ABSORBERS THAT TREAT 75*
OF THE BOILER FLUE GAS. THE REMAINING GAS IS BYPASSED FOR REHEAT. TOTAL
OFSIGN S02 REMOVAL EFFICIENCY IS 70.SX. THE FLUE GAS CLEANING WASTES ARE
STABILIZED AND DISPOSED IN AN ON-SITE, LINED POND.
THIS NEM 793-MM POnER GENERATING UNIT MILL FIRE TEXAS LIGNITE CONTAINING
0.9X SULFUR (AVG.) AND BX ASH (AVG.). TO MEET FEDERAL N3PS, THE UNIT HILL
BE EUUIPPEO WITH AN EMISSION CONTROL SYSTEM CONSISTING OF COLD-SIDE ESP'S
AND A LIMESTONE FGO SYSTEM, BOTH SUPPLIED BT RESEARCH-COTTRELL. THE FGD
SYSTEM CONSISTS UF 6 PACKED/SPRAY TONER ABSORBERS WHICH MILL TREAT 75X OF
THE TOTAL BOILER FLUE GAS. THE REMAINING GAS WILL BE BYPASSED FOR REHEAT.
TOTAL DESIGN 802 REMOVAL EFFICIENCY IS 70.5*. THE FLUE GAS CLEANING HASTES
MILL BE STABILIZED AND DISPOSED IN AN ON-SITE, LINED POND.
20
-------
FfA UTILITY FIJI) SURVEY: AUGUST 1978 - SEPTEMBER 1<>78
SECTION a
STATUS liF KT.U SYSTEMS
UNIT IDENTIFICATION
STATUS
TEXAS IIIlLllItS
MARTIN LAKE a
79? MM - NF.M
COAL: o.9x SULFUR* ax ASH
RFSEARCH COITKF.LL
LIMESTONE
STARTUP 11/8,?
THt CONTRACT FOH THIS KGI) STSTKC HAS fltEN AWARuEU TO HEStARCH-COTTkELL.
TMt BOILER Ib Mln HEINb EJECTED. START-UP HAS bEEN DELAYED TO EITHER 1985
DM 1986.
TEXAS UTILITIES
HUNTICELLU 3
750 MW - Nk*
LIGNITE; 1.5X SlJLFUK,
CHFMICO
LIMESTONE
STARTUP S/78
REFER TO SECTION 3 OF THIS RfcPDBT fOH ADDITIONAL INFORMATION. THE EMISSION
CONTkOL SYSTEM FUR THIS UNIT CONSISTS OF A HIGH EFFICIENCY ESP AND A LIME-
STONE FGO SYSTEM. THE tSP (PULLUTTUN CONTROL-WALTHER) PROVIDES PRIMARY
19X ASH PARTICIPATE CONTROL (99.561). THE FGI) SYSTEM CONSISTS OF 3 LIMESTONE
SCNUHRINi; SPRAY TOrtERS THAT PROVIDE PRICARI 502 CONTROL (70X). THE FQO
SYSTEM IS UFSIf.NEO Til TREAT 3MM ACFM OF FLUE GAS RESULTING FROM COAL NITH
i.bx SULFUR, i».9X ASH AND o.oax CL. THE FLUE GAS CLEANING HASTFS ARE
DTSPuSED IN AN UN-SITE, LINED POND.
UTAH POWER A LIGHT
EMERY 1
400 MH - NEW
COAL; o.sx SULFUR, 9-12X ASH
CHEMICO
LIME
STARTUP 12/78
UTAH POWER * LIGHT
EMERY 2
400 MW - NEW
COAL; o.sx SULFUR, 9-iax
CHEMICO
LIME
STARTUP fc/80
A CONTRACT HAS KEEN AHARDEO TO THE CHEMICO AIR POLLUTION DIVISION FOR
A PEBBLE LIME AFT SCRUBBING SYSTEM ON THIS NEH UNIT. THE SCRUBBING
SYSTEM Is (lEMGNEO Tu OPERATE IN AN OPF.N HATER LOOP MODE HlTM AM S02
REMOVAL EFFICIENCY OF 80 PERCENT FOR I.OH SULFHK UTAH COAL. PRIMARY
kARTICULATE CONTROL "ILL RE PROVIDED BY AN ESP UPSTREAM OF THE SCRUBBERS.
THE SLUOGE HILL BE STABILIZED HlTH FLYASH AND DISPOSED ON THE PLANT SITF.
THE A-t DESIGN FIRM FOR THIS PROJECT IS STEAKNS-ROGER. CONSTRUCTION IS NOW
APPROXIMATELY HS-90X COMPLETE AT THIS UNIT.
UTAH P*L AHAKOED CHEMICO A CONTRACT TO SUPPLY A LIME FGD SYSTEM FOR
EMERY 2 DESIGNED TO OPERATE IN AN OPEN WATER LOOP MODE HITH AN S03 REMOVAL
EFFICIENCY OF 80 PERCENT (FIRING LOH SULFUR UTAH COAL). PRIMARY PARTIC-
ASH UlATE CONTROl «ILL HE PRUVJHED BY AN ESP UP-STREAM OF THE SCRUBBERS. THE
SLUDGE MILL HE STABILUEO rtlTH FLYASH ANU DISPOSED ON THE PLANT SITE.
INITIAL BOILER AND FGD SYSTEM START-UP IS SCHEDULED FOR JUNE 1980. BOILER
CONSTRUCTION HAS BEGUN. THIS UNIT HILL BE IDENTICAL TO EMERY 1.
UTAH POwER & LIGHT
HUNIINGTON I
415 MW - NEW
COAL} O.SX SULFUR* IOX ASH
CHEMICO
LIME
STARTUP 5/78
KFFEK TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION. CHEMICO HAS
THE SUPPLIER OF A LIME SCRUBBING SYSTEM FOR THIS NEW UNIT. PRIMARY PARTIC-
ULATE REMOVAL IS PROVIDED BY AN ESP INSTALLED UPSTREAM OF THE WET SCRUB-
BING SYSTEM. A DAMPER is USED DURING OPERATION TO ALLOW BETWEEN 10 AND eo
PFRCENT OF THE FLUE GAS TO BY-PASS THE FGD SYSTEM. DESIGN REMOVAL EFFI-
CIENCIES FOR soa AND PARTICULATE »HE so AND 99.5 PERCFNT RESPECTIVELY.
SIUDGE IS DEWATEHEO (6UZ SOLIDS) AND TRUCKED TO AN ON-SITE LANDFILL.
INITIAL OPERATIONS AT THIS UNIT BFGAN ON MAY 10, 1978.
VIRGINIA ELECTRIC * POWER
MT. STORM
H47 MW - RETROFIT
COAL
VENDOR NOT SELECTED
PROCESS NOT SELECTED
STARTUP O/ 0
THE UTILITY IS CURRENTLY WAITING FOR AN EPA DECISION REGARDING » WEST
VIRGINIA STATE EMISSION CONTROL PROPOSAL. PLANS FOR SULFUR DIOXIDE
CONTROL ARE TEMPORARILY AT A STANDSTILL PENDING THIS DECISION. IF THE
PRESENT PROPOSAL IS ACCEPTED AN FGO SYSTEM MAY NOT BE REUUIRED.
WISCONSIN POWER S LIGHT
COLUMBIA i
527 MW - NfcW
COAL; o.sx SULFUR
CHEMICO
LIME/ALKALINE FLYASH
STARTUP I/SO
A CONTRACT HAS BEEN AWARDED TO CHEMICO FOR A LIME/FLYASH FGD SYS-
TEM. IT WILL CONSIST OF TWO SPRAY MODULES WITH A MOT-SIDE ESP FOR PAR-
TICULATE REMOVAL. A CLOSED LOOP HAIF.R SYSTEM IS ANTICIPATED WITH FLYASH
STABILIZATION OF THE SLUDGE. A SLUDGE DISPOSAL POND LOCATED OFF-SITE IS
BEING CONSIDERED. THE FGD SYSTEM IS BEING DESIGNED TO TREAT 60X OF THE
FLUE GAS RESULTING FROM THE COMBUSTION OF LOW SULFUR COLSTRIP COAL. THE
REMAINING 40X WILL BE BYPASSED FOR REHEAT.
-------
FPA IHILITY FGO SURVEY: »UGUSI 1978 - SEPTEMBER 1<»7B
SECTION 5
PERFORMANCE DESCRIPTION f-OR OPERATIONAL t-GO SYSTEMS
IHILITY NA"E ALAttAMA ELECTRIC COOP
IINTT NAME TOMHIGHtE ?
UNIT LOCATION JACKSON ALAhAMA
UNIT HAUNT, £25 MM
FuFl CHAHACIEKIbTICS COAL: 1.ISX SUII-UH
FGO VENOOM PEAHODY EMGlNEEHlNr,
PROCESS LIMtSIONF
NEW OH RETROFIT NE«
START UP DATE <>/7B
EFFICIENCY:
PAHTICULATES (ACTUAL)
(OESIGN) S9.S PERCENT
S0£ (ACTUAL)
(OESIliN) bO.O PERCENT
MATER MAKE UP OPEN LOOP 1.10 GPM/MM
SLUDGE DISPOSAL UNSTABILIZED/SLUDGE PONO
OPERATING OPERIENCE UPDATE:
AUGUST-SEPTEMBER 197fl - INITIAL OPERATION OF THIS UNIT REGAN DURING THE AUGUST-SEPTEMBER REPORT
PERIOD. THE FGO SYSTEH IS CURRENTLY IN THE SHAKEDOnN ANO DEBUGGING PHASE OF OPERATION. DUE TO THE
RECENT OPERATING STATUS, HOURS OF OPERATION ARF NOT Yfcl AVAILABLE.
-------
EPA IIIILITY F(,n SU»VEt: AUGUST 1<»78 - StPTFMHfcR 1978
SECTION 3
PFMFURMANCt DESCRIPTION FOR OPERATIONAL FGO S
UTILITY NAME ARIZONA FLFCTKTC M)i»tH COUP
UNIT NAME AHALMt 2
UNTI LOCATION COCHISF «kI?ON*
UNI1 HATING 30U Mn
FUEL CMAHACIEHISI ICS COAL: 0.7X SULFUH, 10X ASM
FGO VENKOW RESEARCH
PMOCESS LIMfcSTONE
NEW OR HFTROFIT Nt*
STAKT IIP DATE 8/78
FFFICIFNCY:
PAHTICULATES (ACUIAL)
4Q.O PtRCEM
SOa (ACTUAL)
(DESIGN) 85.0 PtWCENT
MATER MAKE UP OPEN LOUP 4.
SLUORt DISPOSAL IINSTABIL IZEIi/SLUDGF pijNU
IIPEHATING EKPECIENCk UPOATE:
AUGUST-SEPTEMBEK i<>7« - INITIAL OPERATION MF int FGO SVSTEM »t THIS UNIT BEGAN IN AUGUST AND IT is
CURHFNTL* BfcING TfcSTED. NO INIIIAL Pt*r)BLf"S HAVE HEFN HEPOMTED. DUE Tu THE WfcCtMT OPERATING STATUS
HUUHS OF OPERATION ARE NOT YET AVAILABLE.
-------
EP» uitLiiv pan SURVEY: AUGUST \ti6 - SEPIEKHER 1978
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL H!l> SYSTfcMS
M1ILITT NA«E
UNIT NAME
UNIT LOCATION
UNIT HATING
AHIZONA PUBLIC SFHVICE
CHOLLA i
JOSfcPH CITY AHTJONA
lib MI*
FUFL CHARACTERISTICS COAL: O.SbX SULFUN, 10J ASH
FGO VENDOR
PROCESS
NEH OH RETROFIT
START UP DATE
EFFICIENCY:
PAHTICULATES (ACTUAL)
(DESIGN)
SOi (ACTUAL)
(DESIGN)
HATER MAKt UP
SLUDGE DISPOSAL
RESEARCH COITWELl
I1MESTONF
RETROFI 1
10/73
99.7 PtRCENT
99.7 PERCENT
bO-60 PEhCfcM
58.5 PERCENT
OPEN LOOP I.00 GPM/Mn
IINSTAbRIZED/SLUDGE POND
EXPERIENCE UPOATM
RELIABILITY (I)
MONTH MODULE A MODULE H
JAN. 78 97 91
FtB. 78 99
MAR.
APR.
MAY
JUNE
JULY
AUG.
78
7H
78
78
78
78
74
100
67
100
99
100
70
too
98
100
100
95
COMMENTS
THE FLnontn DISC SCRUBBER TANK HEADER FOR SLURRY LIMESTONE HAS
RfPAIKFI) AFTER HE I NT, OAMAGEO DURING THE OVF.HHAUL. THE BOILER
WAS OPFRATFU ONLY 135 MRS. DURING JANUARY AS THE OVERHAUL HAD
EXTENDED INTO THIS MONTH. THE A-SIOE AND B-SIDE SERVICE HOURS
»tRE 1?1 AND \i3 HOURS RESPECTIVELY.
SOME MTNOH LEAK HbPAIHS AFTER THE OVERHAUL/CLEANING TOOK PLACE
OUHINb FEHRUArtY. SERVICE HOURS N£HE: BOILER = b«8» A-SIOfc =
bib, B-SIDE = SbQ.
ONE FURCFD SHUTUOnN OCCURRED UN THE A-SIDE. SERVICE HOURS MERE:
BOILEH = 10Q, A-SIOE = 74a, R-SIOE = 71S.
A MINOR LEAK REPAIR HAS NECESSARY AFTER AN OVERHAUL/CLEANING.
SERVICE HOOKS WERE: ROILER = 720, A-SIOE = 667, B-SIDE = 720.
THERE MERE NO SIGNIFICANT PROBLEMS REPORTED. ONLY GENERAL
MAINTtNANCE HAS PERFORMED ON THE SYSTEM.
NU PROBLEMS MERE REPORTED.
ONLY ROUTINE MAINTENANCE HAS HEuUIRED.
REPAIRS HtRE NECESSARY TO PLUGGED B-SIDE REHEAT COILS.
-------
FPA UTILITY FGO SURVEY: AUGUST 1978 - SEPTEMBER 1978
SFCTION J
PERFORMANCE DESCRIPTION FOB OPERATIONAL FGD SYSTEMS
UIILITY NAME ARIZONA PUBLIC SERVICE
UNIT NAME rHOI LA 2
UNIT LOCATIUN JOSEPH CITY ARI/ONA
UNIT MATING 250 MM
FUEL CHARACTERISTICS COAL; 0.55X SULFUH, )0t ASH
FGO VENDOR RESEARCH COTTRFLL
PHOCESS LIMESTONE
NEW OK RETROFIT NEM
START IIP DATE 6/78
EFFICIENCY:
PARTICULATES (ACTUAL)
(DESIGN) 99.7 PERCENT
802 (ACTUAL)
(DFSIGN) 75.0 PERCENT
WATER MAKE UP OPEN LOOP
SLUDGE DISPOSAL UNSTAHTLI7ED/SLUDGE PUNI)
OPERATING EXPERIENCE UPDATE:
APRIL-MAT 1978 - THE SCRUBBER ON UNIT 2 IS MOM nORKINb MOST OF THE TIME AND IS THEREFORE CONSIDERED
TO BE OPERATIONAL. SOME PROBLEMS HAVE OCCURRED WITH VIRRATTONS THROUGH THE SYSTEM. THE EPA HAS
GRANTED THF UTILITY AN EXTENSION FOR COMPLIANCE.
JUNE-JULY 1978 - UNIT 2 IS STILL UNDEKGOING SHAKEDOWN AND DEBUGGING OPERATIONS. THE SLURRY RECYCLE
P1PIN& HAS EXPERIENCED CONTINUAL VIBRATION. THE CONTRACTOR HAS BEEN INJECTING NITROGEN (GAS) INTO
THE LINES TO DAMPEN THE VIBRATIONS (AIR WAS NOT USED BECAUSE THE SULFITE fiOULD BE OXIDIZED TO
SULFATE AND RESULT IN SCALE FORMATION IN THE SYSTEM). A PROBLEM HAS ALSO OCCURRED HlTH PEELING OF
THE CORROSION RESISTANT COATING IN THE DOnNCOMEH AREA IN ONE OF THE ABSORBER MODULES.
AUGUST-SEPTEMBER 1978 - SHAKEDOHM/DEHUGGING OPERATIONS CONTINUE. THE SLURRY RECYCLE PIPING IS STILL
EXPERIENCING RESONANT VIBRATIONS.
-------
EPA UTILITY FGO SURVEY: MlPUST l97fl - SfcPIEMHtH 197H
itCTlON 3
PFRFORMANCb DESCWIPIION FOR OPERATIONAL FGl>
UTILITY NAME
UNIT NAMF
UNIT LOCATION
UNIT RATING
CENTRAL ILLINOIS
DUCK CHEEK 1
CANTON ILLINOIS
400 Mh
FUEL CHARACTFRISUCS CUAL: 3.3z SULFUR, «.3x ASH
FGn VENDOH RILEY SIOKEH / ENVIHONEtRlNb
PROCESS LIMESTONE
NfcH OH KEIHOFIT Him
START UP DATE 7/78
FFFICIENCY:
PAHTICULATES (ACTUAL)
(DESIGN)
802 (ACTUAL)
(DESIGN)
riATER HAKE UP
SLUDGE DISPOSAL
99.8 PERCENT
99.8 PERCENT
9i.h PERCENT
BS.O PF.RCFNT
CLOSED LOOP 1.5 GPM/MB
UNSTABILI2ED/SLUDGE PUND
OPERATING EXPERIENCE UPDATE:
JUNE-JULY 1976 - ALL 4 MODULES BECAME OPERATIONAL OH JULY 2a. THE SYSTEM HAS OPERATED INTERMIT-
TENTLY THROUGHOUT THE PERIOD. MODIFICATIONS HEKE MADt TO THE SLURRY TRANSFER TANK, SINCE IT HAS
FOUND TO BE UNDER DESIGNED. A PLUGGING PHOBLtM OCCURRED IN THE FGO SYSTEM DUE TO COAL FINES BEING
MIXED IN WITH THE SLURRY. THIS RESULTED FRUM THE USE OF COMMON UNLOADING AND TRANSFER SYSTEMS FOR
THE COAL AND LIMESTONE.
TOTAL
PERIOD PERIOD (HH)
AU6. 70 744
AVAILABILITY = 45*
OPERABILITY = 46S
RELIABILITY = 44Z
UTILIZATION = 42t
BOILER
OPFHATION (MR)
691
SYSTEM
AVAILABILITY (HR)
333
333
SYSTEM CALLED
TO OPEHATE (HR)
714
714
HR. SYSTEM
OPERATED
315
315
SEP. 78 720
AVAILABILITY : 46X
OPERABILITY s 4bZ
RELIABILITY = 44Z
UTILIZATION = 44Z
PROBLEMS CONTINUED TO EXIST THROUGH AUGUST AND SEPTEMBER HITH THE COMMON COAL AND LIMESTONE
UNLOADING FACILITY. SCREEN BASKETS HERE USED TO KEEP COAL PARTICLES OUT OF THE LIMESTONE IN
ORDER TO PREVENT NOZZLE PLUGGING. MORE PERMANENT SEPARATOR SYSTEMS ARE BEING STUDIED.
DESIGN DEFICIENCIES IN THE SLURRY TRANSFER SYSTEM PREVENTED PROPER FLOU OF THE SLURRY TO THE
SCRUBBER MODULE RECYCLE TANKS. THE OLD SYSTEM MAS REMOVED AND A NEH PIPING SYSTEM HAS IN-
STALLED. NO PROBLEMS HAVE BEEN ENCOUNTERED HITH THE NEH SYSTEM. PLUGGING OF THE RECYCLE
PUMP SHUT-OFF VALVES OCCURRED AND THEY ARE BEING REPLACED HITM PINCH VALVES. THE SCRUBBER
HASTE HATEH SUMP PUMPS HAVE ALSO BEEN PLUG-ING AND NEH PUMPS ARE BEING INVESTIGATED.
26
-------
£PA UlILIIT FGD SURVEY! AUGUST 1978 - SEPTEMBER 1978
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FRO
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT HATING
COLUMBUS & SOUTHFRM UMIu ILfcC.
CPNESVILIK <3
CONtSVILlE OHIO
ttOU Mm
FUEL CHARACTERISTICS COAL; a.7x SULFUR, 15.ix ASH
FGO VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
FFFICIFNCY:
PARTICUIATES (ACTUAL)
(DESIGN)
S02 (ACTUAL)
(OFSIGN)
WATER MAKE. UP
SLUDGE OISPO.SAL
AIR CORRECTION DIVISION, llOH
LIME IMG-PROMOTED)
NEH
1/77
99.6 PERCENT
»9.5 PERCFNT
OPEN LOOP l.?5 bPM/MW
STABILIZED/LANDFILL
OPERATING EXPERIENCE UPDATE:
PERIOD
OPERATION TIME (MR)
BOILER A-SIOE H-SIUE
JAN. 78 00
ALL INDEX VALUES = 0 PFRCKNT
FEB. 78
»LL INDEX VALUES = 0 PEWCtNT
MAR. 78 379 li hO
AVAILABILITY (X) = 20 £0
OPERABILITY (Z) = 19 1 f>
RELIABILITY (Z) = 64 Sd
UTILIZATION (X) =10 H
APR. 78 716 410 485
AVAILABILITY (X) = 67 65
OPERABILITY (X) = 58 59
RELIABILITY (X) = 61 63
UTILIZATION (X) s 5« V»
MAY 78 720 3?7 ^*>5
AVAILABILITY (X) = s^ sa
OPERABILITV (X) = 45 50
RELIABILITY (X) = 45 51
UTILIZATION (X) = 44 49
JUNE 78 720 269 217
AVAILABILITY (X) = 48 30
OPERABILITV (X) = 37 30
RELIABILITY (X) = 37 30
UTILIZATION (X) = 37 30
JULY 78 727 478 240
AVAILABILITY ex) = 66 43
OPERABILITV (X) s 66 33
RELIABILITY (X) = 66 33
UTILIZATION (X) s 64 32
COMMfcNTS
THE UNIT HAS SHUTDOWN FUR dVFHHAUL THROUGH FEBRUARY AND
STARTED UP ON MARCH 16.
IMPURITIES IN Li»«fc HAVF CAUSED PLUGGING PKOHLEMS. PH
CUNTKULS AND S02 ANALYSES H*\lfc GIVfeN SOME OPERATIONAL
PHOHLEMS.
'HE SYSTF.M MAS DOnN DUF TO AN EXCESS OF FLOCCULANT
IN THE THICKENER. THIS CAUSED A HIGH AMOUNT OF SOLIDS
IN THE OVERFLOW THAI RESULTED IN PLUGGING PROBLEMS IN
THE ABSORBER MODULES.
THF SYSTEM HAS TAKEN OUT OF SERVICE BECAUSE OF CONTINUED
PROBLEMS MITH THE FLOCCULANT FEED SYSTEM. THE THICKENFR
HAS EMPTIED TO RESTORE PROPER FLOCCULANT BALANCE.
FLOCCULANT HAS CLEANED OUT.
AN FRP PIPING FAILURE IN THE MIST ELIMINATOR DASH
SYSTEM UCCHRREO IN JUNE.
OUTAGE TIKE HAS DUE TO PLUGGING IN THE MIST ELIMINATOR
AND SCRUBBER BALL REGIONS.
27
-------
EPA UTILITY FGO SURVEY: AUGUST 1<»78 - SEPTEMBER IS7B
COLUMBUS ft SOUTHERN OMlU ELtC.
PERIOD
OPERATION 1 IMfc IHK)
BOILER A-SIDE H-SIOE
AUG. JK bbl M4 137
AVAILABILITY IX) = 10 IP
OPFHAaiLITV (X) r ?u 21
RELIABILITY (1) = 20 f\
IITTLIZAIIUN (1) = 18 1«
SEP. 78 707 Sin YOU
AVAILABILITY (X) = hi SO
OPERABILIT* (X) = flb a«
RELIABILITY (X) = Sb 5'
UTILIZATION (X) = «b a]
CUNtSVlLLE b
COMMENTS
FORCED OUTAGE TIME MAS RElJUIHEO TO REMOVE SCALE
FkOM THE HIST ELIMINATOR. IT MAS ALSO NECESSARY TO RE-
PLACE SOML OF THF PING PONG BALLS IN THfc MODULES.
HURINb THt AlIGUST-StPTEMHtH RfcPOHl PtRIOO PROBLEMS WERE
ENCOIINTbRf-.l) «1TH THE HYHASS OAMPFRS. OTHER PROBLEM
ARFAS INCLUDED bROKEN SLUDGE LINES AND PLUGGING OF THE
HMt SLURRY FEED LINFS.
-------
FPA UTILITY FGD SURVEY: AUGUST 1478 - SEPTEMBER 1478
SECTION j
rtRFURMANCt DESCRIPTION Mlk OPERATIONAL FGU SYSTEMS
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
CULIIMHUS * bOUTMFKN OHIO tLEC.
CUNtSVHLt 6
CONLSVILLE OHIO
aoo MM
FUEL CHARACTERISTICS COAL: a.671 SULFIIH, 15.lt ASH
FGD VENDOR
PROCESS
NEW OR RETROFIT
START UP DATE
EFFICIENCY:
PARTICULATES (ACTUAL)
(DESIGN)
S02 (ACTUAL)
(DESIGN)
MATER MAKE UP
SLUDGE DISPOSAL
AIR CORRFLT10N DIVISION, UOP
LIME (MG-PRUMUTEP)
NEW
6/78
99.h PERCFNT
«9.s PERCENT
OPEN LOOP 1.25 GPM/MR
STAHlLl/EU/LANDfILL
OPERATING EXPERIENCE UPDATE:
PERIOD
OPERATION TIME (HR)
BOILER A-SIDE B-SIDE
JUNE 78 524 173 175
AVAILABILITY (I) = 56 44
OPERABILITV (X) = 49 33
RELIABILITY (X) = 51 34
UTILIZATION (X) = 42 30
JULY 78 502 186 96
AVAILABILITY ix) = 83 70
OPERABILITY (X) = 37 19
RELIABILITY (X) = 63 33
UTILIZATION (X) = 25 13
AUG. 78 642 316 390
AVAILABILITY (X) = 47 62
OPERABILITY (X) s 50 60
RELIABILITY (X) = 66 81
UTILIZATION (X) = 43 52
SEP. 78 706 356 388
AVAILABLITV (X) s 55 69
OPERABILITY (X) = 50 55
RELIABILITY (X) s S3 57
UTILIZATION (X) s 49 54
COMMENTS
CONTROL OF THE LOUVERED DAMPER OF THE BYPASS SYSTEM
WAS LUST. THE RESULT HAS A BACK PRESSURE RUILO UP
THAT AUTOMATICALLY TRIPPFD THE BOILER OFF. SCRUBBER
CONTROLS HERE NOT OPERATING PROPERLY AND NEEDED ADJUST-
MENT.
THE LOUVEREO DAMPER PROBLEM CONTINUED. SCRUBBER
CONTROLS nE<
-------
EP» UTILITY FGO SURVEY! AUGUST 1978 - SEPIFMBER 1978
SECTION 3
PEKFUHMANCt DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
UTILITY NAME
UNIT NAHF
UNIT LOCATION
UNIT HATING
DUOUESNfc LIGHI
FLRAMA POnEH STATION
FLRAMA PENNSYLVANIA
510 Mh
FUEL CHARACTERISTICS COALS ai SUIFUR. i«>.si ASH
FGO VENDOR
PROCESS
NE« OR RFIROFIT
START UP D«TE
EFFICIENCY:
PARTICULATES (ACTUAL)
(DESIGN)
SOS (ACTUAL)
(DESIGN)
HATER MAKE UP
SLUDGE DISPOSAL
CHFMICO
LIMt
RETROFIT
10/75
99.0 PfcMCENT
99.0 PERCENT
75+ PFRCtNT
33.0 PERCENT
OPEN LOOP
STABILIZED/LANDFILL
OPERATING EXPERIENCE UPDATE:
OPERATING HOURS
PERIOD BOILEH SCRUBBER-ABSURbER VESSELS
101 201 301 401 501
JAN. 78 700 673 3B 181 2f>
DURING THE PERIOD A NE« MORMER RECYCLE PUMP IN-
STALLED IN NOVEMBER EXPERIENCED JACK SHAFT BEARING
PROBLEMS RESULTING IN THE REMOVAL OF TRAIN 501
FROM SERVICE. BOILER NO. 4 MAS CONNECTED ADDING
AN ADDITIONAL 176 MH LOAD TO THE SYSTEM. THE
IUCS SLUDGE DISPOSAL FACILITY IS NOH IN SERVICE.
A LOH LOAD DEMAND AND THE COAL STRIKE HAVE
HAMPERED SCRUBBER OPERATIONS. THERE IS SOME
OUTAGE TIME SCHEDULED FOR MARCH.
FEB. 78
MAR. 78
?04 277 0 107 121 THF SYSTEM HAS SHUTOOHN ON FEB. 11 DUE TO A COAL
00000 SHORTAGE. THE FOLLOWING REPAIRS HERE MADE DURING
THE OUTAGE HHICH CONTINUED THROUGH MARCH:
• BOILER EXIT 0»MPE»S HERE LINED HITH 316 S3 ON
AREAS OF HIGH EROSION CAUSED BY FLYASH IM-
PINGEMENT.
* EXPANSION JOINTS IN THE UPSTREAM DUCTMORK
HERE SHIELDED BY METAL PLATES HHICH HERE
HELDED AT ONE END.
• EXPANSION JOINTS IN THE OOHNSTREAM OUCTNORK
HERE COMPLETELY REPLACED.
* THE OOHNSTREAM OUCTHQRK HAS RELINED WITH
CEILCOTE.
• MODULE 401 INTERNALS HERE CLEANED AND SOME
HOLES IN THE UPPER CONICAL REGION MERE RE-
PAIRED.
BOILERS 1, 2 AND 4 ARE NOR COMPLETELY CONNECTED
TO THE FGD SYSTEM. BOILER 3 IS UNDERGOING
AN EXTENSIVE OVERHAUL AND HILL BE CONNECTED TO
THE SYSTEM IN LATE APRIL.
30
-------
EPA UTILITY FGO SURVEY: AUGUST 1978 - SEPTEMBER 1978
DIIOUESNE LIGHT ELRAMA PO*ER STATION
OPERATING HOURS
BOILER SCRUBBER-ABSORBER
MONTH 1 t 3 a »VG 101 201 101 401 Sol AVG
APR. 78 699 528 u 672 479
MAY 7« 7?J 72? U 740 547
DURING THE APRIL-MAY PERIOO BOILER NUMBER 1 WAS STILL HEING OVERHAULED. FGO SYSTEM CONSTRUC-
TION WAS CUMPLETEO AND PRELIMINARY TESTING VERIFIED SYSTEM S02 REMOVAL EFFICIENCY.
JUNE 78 691 616 U 662 498
JULY 7* 691 640 588 7^9 6h2
MODULE 101 HAS PULLED OFF FOR A MAJON CLEANING OVEH THE PEHIUO. MIST ELIMINATOR PLUGGING MAS
EXPERIENCED AS A HESUL1 OF LOW PH. THE CHHONIC INABILITY TO CONTROL CHEMISTRY (PH) IS
DIRECTLY RELATED TO GRIT BUILD-HP IN THE LiMt HANOLING AND SLURRY PREPARATION SYSTEM. THE
UTILITY IS CURRENTLY STUDYING nAYS TO TIGHTEN THE MATER BALANCE BY TAKING THICKENER SUPERNATE
FOR THE MlbT ELIMINATORS INTfcRMlITfcNTLY nITH CLEAR SERVICE HATER. A COMPLIANCE TEST SHOULD
TAKE PLACE DURING THE NEXT REPURT PERIOD.
AUG. '8 735 601 68f> 691 678
SEP. '8 676 5»5 674 720 664
DURING AUGUST MODULES 301 AND bOl nERE TAKEN DOWN FOR CLEANING. THE RUBBER LINING ON THREE
FAN HOUSINGS MAS REPAIRED. IT HAS ALSl) NECESSARY 10 SHUT OOMN THE LIME MIXING BASIN IN ORDER
TO CLEAN OUT EXCESSIVE GPU AND SOLIDS BUILD UP.
-------
EPA UTILITY FGO SuRvEYt AUGUST 1<»78 - StPTFMhtP I97fl
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO bYSTEMS
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
OUOUFSNfc IIGHT
PHILLIPS POKER STATION
SOUTH HtlGHI PENNSYLVANIA
alO MN
FUEL CHARACTERISTICS COAL: 21 SULFUR, 16.5X ASM
FGO VENDOM
PROCESS
NEM OH RETROFIT
START UP DATE
EFFICIENCY:
PARTICULATES (ACTUAL)
(DESIGN)
S02 (ACTUAL)
(DESIGN)
MATER MAKE UP
SLUDGE DISPOSAL
CHEMTCO
LIME
RtTROFT r
7/7?
99.0 PERCENT
99.0 PERCENT
75+ PERCtNT
83.0 PtRCFNT
OPEN LOOP
STAHILl/EO/tANOfILL
OPERATING EXPERIENCE UPDATE:
MONTH
JAN.
FEB.
1
BOILER
a
OPERATING HOUKS
AVG 101
SCRUBRfcR-ABSuRBEK
?.U\ 301 101
AVG
78 6«?7 570 o OBO 021
7R 209 267 18 152 167
AN OUTAGE OCCURRED BfcThEEN JAN. 6 AND JAN. 8 "HEN THE STACK DRAIN LEAKS MERE REPAIRED BY
SANDBLASTING THE OUTER HALL AND REPLACING THE CARBON STEEL BANDS WITH STAINLESS STEEL BANDS.
THE SYSTEM HAS SHIITOOHH ON FtH. 11 OUE TU THE COAL SHORTAGE. THE OUTAGE CONTINUED THROUGH
MARCH AND THE SYSTEM IS SCHEDULED TO HE UN LINt BY APRR 15. DURING THE OUTAGE THE FOLLOWING
REPAIRS AND MODIFICATIONS NFRE MADfc:
•THE HUILER MIT DAMPERS HERE LINED NlTH 316SS ON AREAS OF HIGH EROSION CAUSED BY
FLYASH IMPINGEHENI.
•EXPANSION JOINTS ON THE INLET OUCTHURK MERE SHIELDED HY METAL PLATES HHICH HERE
MELDED AT ONE END.
•NUMEROUS HOLFS IN THE MET GAS DUCT *ORK MERE REPAIRED AND THE DUCTS MERE RELINED
KITH CE1LCOTE.
•THE THROAT DAMPERS MERE CLEANED ON ALL THE SCRUBBERS.
•INTERNAL MIST ELIMINATORS MERE CLEANED. THE EXTERNAL HIST ELIMINATORS. MHICH
ARE BADLY DETERIORATED, t»AY BE REPLACED.
•THE STACK BRICKLINING HAS INSPECTED AND SOME BRICKS MERE REPLACED AT THE TOP OF THE
STACK.
CONSTRUCTION MORK ON AUDITIONAL EQUIPMENT SUCH AS THE THICKENER AND SILOS IS ALMOST COMPLETE.
IT HAS NOTED THAT THE CEILCOTE LINER COROLINE SOSAR HAS HELD UP HELL OVER THREE YEARS ON
THE CONICAL APEX OF MODULE aOl.
MAR. 76
APR. 78 358 0 562 623 524 0 315
MAY 7A 725 389 710 667 690 0 531
THE FGD SYSTEM CAME BACK ON LINE AFTER THE COAL STRIKE IN LATE MARCH. IT IS NOT OPERATING
AT FULL LOAD BECAUSE THE NO. 6 BOILER IS STILL OUT AND SHOULD BE BACK ON LINE IN MID-JULY.
COMPLIANCE TESTS HILL TAKE PLACE IN JULY, AFTER BOILER 6 IS BACK ON LINE, TO SEE IF THE
SYSTEM IS MEETING THE 03X S02 REMOVAL REUIIIREMfcNT FOR 21 SULFUR COAL. THERE MERE NO HOURS
REPORTED FOR THIS PERIOD BECAUSF OF PRELIMINARY TESTING BEING CONDUCTED IN PREPARATION FOR
THE COMPLIANCE TESTS. SO FAR, TESTS INDICATE THAT THE SYSTEM MILL COMPLY WITH THE REQUIRED
STANDARDS. THE AVAILABILITY FUR ALL FOUR TRAINS MAS BETMEEN 65 AND 75 PERCENT.
32
-------
EPA UTILITY FGD SURVEY: AUGUST 1978 - SEPTEMBER 1978
niJOUFSNE LIGHT PHILLIPS POWER STATION
OPERATING HUUKS
HOILER SCRUBBER-ABSORBER
MONTH 1 i 3 4 5 b AVG 101 301 TlM 401 AvG
JUNE 7B 632 5«1 61fl 720 518 0 518
JULY 7B 076 425 568 544 588 0 430
THE INTERNAL M|ST ELIMINATOR ON MODULE 201 MAS REMOVED AND CLFANEO OVER THE PERIOD. THE
FGD SYSTEM HAS ACCUMULATED APPKfU IMATFLY 21.000 HOURS OF OPERATION ON ALL FOUR MODULES SINCE
START-UP. THERE HAVE KEEN WATER HALANCE PROBLEMS AT THE UNIT WHICH CONTRIBUTED TO THE OCCUR-
RANCt- OF LOW PH AND EVENTUALLY "IS! ELIMINATOR PLUGGING. THE MIST ELIMINATOR PLUGGING IS
ALSO RELATED TO LOW PH RESULTING FKUM LIME HANDLING AND SLURRY PREPARATION SYSTEM FAILURE.
GRIT BUILD UP HAS tit EN THE MAJOR SOURCE OF THF. REAGENT HANDLING SYSTEM FAILURES. THE
UTILITY IS CURRENTLY STUDYING nAYS TO TIGHIFN THE HATER HALANCE BY TAKING THICKENER
SUPERNATfc FOR 1 HE MIST ELIMINA1DMS INTERMITTENTLY WITH CLEAR SERVICE nATEM. THE COMPLIANCE
TEST SHOULD TAKE PLACE DURING THE NFXT REPORT PERIOD.
AUG. 78 636 663 SOO 627 S91 623 607
SEP. 78 608 S99 5
-------
EP* UTILITY FGO SURVEY: MIGUST 1978 - SEPTEMBER
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGO SYSTEMS
\
UTILITY NAME GULF POhFK
UNIT NAMF SCHOLZ IB * 2b
UNIT LOCATION CHATTAHQOCHtE FLORIDA
UNIT RATING ?3 MM
FUEL CHARACTERISTICS COAL: ?x SULFUR
F60 VENDOR CHIYODA INTERNATIONAL
PROCESS LIMESTONE
NEH OR RETROFIT RETROFI1
START UP DATE 8/7«
EFFICIENCY:
PAKTICULATES (ACTUAL)
(DESIGN)
SOa (ACTUAL)
(DESIGN)
HATER MAKE UP OPEN LOOP
SLUDGE DISPOSAL GYPSUM/STACKED. EXISTING POND
OPERATING EXPERIENCE UPDATE:
AUG. 78 OPERATION OF THIS EXPERIMENTAL UNIT REGAN ON AUGUST 30 AND AVAILABILITY HAS BEEN REPORTED
SEP. 78 TO BE BETTER THAN 99Z. HOUMS OF OPERATION ARE NOT YET AVAILABLE BUT SHOULD BE FOR THE
OCTOBER-NOVEMBER PERIOD.
-------
EPA UTILITY FGI) SURVEY: AUGUST 1978 - SEPTEMBER 1978
bt-CTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
UTILITY NAME INDIANAPOLIS POWER II LIGHT
UNIT NAME PETERSHURb 3
UNIT LOCATION PETERSBURG INDIANA
UNIT RATING 530 MW
FUFL CHARACTERISTICS CIIAL; 3.251 SULFUR, 9.5* ASH
FGO VENDOR AIH CORRECTION DIVISION, UOP
PHOCFSS L1MESTONF
NEW OH RETROFIT NEW
START IIP DATE 10/77
EFFICIENCY:
PARTICULATES (ACTUAL)
(DESIGN) 99.3 PERCENT
S02 (ACTUAI )
(DESIGN) 80.0 PERCENT
MATER MAKE UP CLOSFD LOOP; 1.66 GPM/Mn
SLUDGE DISPOSAL SI ABTL I ZFO/SLUDfiF PUND
OPERATING EXPERIENCE UPDATE:
DECEMBER-JANUARY 1978 - OPERATIUN OF ALL HOUR MODULES WAS INITIATED IN DECEMBER 1977. A SUCCESSFUL
2U-HOUP RUN MAS COMPLETED ON DEC. 16 ANU 17 WITH MODULES "H", *C* AND "0" IN OPERATION. 'A- MODULE
HAD AN INOPERATIVE RECYCLE TANK AGITATOR. REPAIR Of- THE AGITATOR MAS COMPLETED ON DEC. 22
AND MODULE A "AS PLACED IN INITIAL OPERATION. A JO-DAY HUN SCHEDULED TO BEGIN JAN. 11 WAS POST-
PONED UNTIL MID-MARCH PENDING RESOLUTION OF PROBLEMS ASSOCIATED I»ITH THE FLY ASH REMOVAL SYSTEM.
THE COLO HEATHER NECESSITATED THE FRECTION OF TEMPORARY ENCLOSURES AROUND SEGMFNTS OF THE FGO SYSTEM
UNTIL THE INSTALLATION OF HEAT TRACING COULD BE COMPLETED.
FEBRUARY-MARCH 1978 - THF MODULES DID NOT OPERATE DURING FEBRUARY AS REPAIRS WERE MADE TO LINES AND
VALVES DAMAGED BY FREEZE-UPS DURING THE WINTER. DURING MARCH SOME SCHEDULED REPAIRS
MERE MADE WHICH INCLUDED INSTRUMENTATION WORK, INSULATION INSTALLATION AND REPAIR OF A BROKEN PINION
GEAR ON THE THICKENER. SYSTEM START-UP IS- STILL BEING DELAYED BY PROBLEMS WITH THE FLY ASH HANDLING
SYSTEM AND IS NOW EXPECTED TO BE IN MID-APRIL.
APRIL-MAY 1976 - THE UNIT CAME BACK ON LINE IN THE MIDDLE OF APRIL AFTER PROBLEMS WITH THE FLYASH
HANDLING SYSTEM MERE CORRECTED. THE SYSTEM OPERATED UNTIL THE MAIN POWER TRANSFORMER FAULTED.
CAUSING THF SYSTEM TO GU DONN. THE OUTAGE LASTED UNTIL JUNE 16. PROBLEMS HAVE ALSO BEEN EXPERI-
ENCED WITH ALL CONTROL VALVES AND PIPING. THE VALVES HAD TO BE SENT BACK TO THE FACTORY FOR MODI-
FICATIONS.
JUNE-JULY 1976 - THE UNIT IS STILL PROCEEDING WITH SHAKEDOWN AND DEBUGGING OPERATION AS FINAL DESIGN
MODIFICATIONS ARE BEING MADE. PREPARATIONS ARE BEING COMPLETED FOR THE COMPLIANCE TEST WHICH HAS
NOT YET TAKEN PLACE.
AUGUST-SEPTEMBER 1978 - SHAKEDOWN/DEBUGGING OPERATIONS CONTINUE. THE COMPLIANCE TEST IS NOW SET FOR
THE LAST MEEK IN OCTOBER. THE UNIT HAS EXPERIENCED PROBLEMS WITH CONTROLS. FIBERGLASS PIPING ANO
VALVES.
-------
EPA UTILITY FGO SURVFT: AUGUST n/e - stPiFMHEH ii7»
SECTION J
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGI) SYSTEMS
HIILIIY NAME KANSAS CITY POHtH « LIGHT
UNIT NAMF HAWTHORN 3
UNIT LOCATION KANSAS CITY HISSQIIKl
UNIT RATING 100 Mw
FUEL CHARACTERISTICS COAL: ?z SULFUR. i?.sx ASH
FGO VENDOR COMBUSTION tNGINEERING
PKDCFSS LiMt
ME* OH RMRUFIT Rt TROUT
START IIP UATF. 11/7?
PARTirilLATES (ACTUAL) •J'.O PERCENT
(DESIGN) 91.0 PERCENT
302 (ACTUAL)
(DESIGN) 70.0 PERCENT
WATER MAKE UP OPEN LOOP 7.0 GPM/Mn
SLUDGE DISPOSAL UNSTABIL IZEU/SLUDGE PUND
OPFMATING EXPERIENCE UPDATE:
FGD SYSTEM
MONTH PERIOD HHS. BOILbR HHS. FGO SYSTEM HRS. UTILIZATION (Z)
FEB. 78 t,1i 167 167 i*3
MAR. 7ft 7ao 40b 406 56
DURING FtBRUART THE UNIT HAS DOMN FOUR TIMES M1TH ECONOMIZER AND HATfcR HALL LEAKS (OUTAGE
TIMF APROX. SOa HRS). A THO HtEK OUTAGE HAS SCHEDULED DURING MARCH FOK SEASONAL MAINTENANCE.
HATER HALL LEAK REPAIR AS HELL AS ACID CLEANING OF THE BOILFH CAUSED ADDITIONAL OUTAGE TIME
DURING THE LAST HEEK IN MARCH.
APR. 16 ^^0 508 220 76
MAY 78 708 403 403 42
AN AIR PREHEATER FIRE DISCOVERED ON MAY 12 CAUSED DAMAGES THAT FORCED MODULE A Tu BE DOHN THE
REST OF THE MONTH.
JUNE 78
JULY 78
NO INFORMATION HAS AVAILABLF FOR THE JUNE-JULY REPORT PERIOD DUE TO A PLANT STRIKE.
AUG. 78
SEP. 78
THE SCRUBBING SYSTEM IS OPERATING ALTHOUGH THF UTILITY IS STILL IN THE MIDST OF A STRIKE.
FGD PERFORMANCE FIGURES ARE NOT AVAILABLE. THE UTILITY IS NOT RECORDING FGD SYSTEM OPERATING
HOURS DURING THE STRIKE.
-------
FP» UTILITY FbO SURVEY: AUGUST 1978 - SEPTFMRtR 1978
SECTION J
PEMFORMANCb DESCRIPTION FOR OPfcRATlONAL FGl) SYSTEMS
UTILITY NAME KANSAS CITY PUWFR * i Jf.HT
UNIT NAME HAWTHORN 4
UNIT LOCATION KANSAS CITY MISSOURI
UNIT HATING 100 MM
FUEL CHARACTERISTICS COAL: 2X SULFUR, 12.51 ASH
FGP VENDOR COMBUSTION ENGINEERING
PROCESS LIMfc
NEW OR RETROFIT RtTrtOFIT
START UP DATE 8/72
EFFICIENCY:
PARTICIPATES (ACTUAL) 99.0 PERCENT
(DESIGN) 99.0 PERCENT
SO? (ACTUAL)
(DESIGN) 70.0 PERCENT
MATER MAKt UP OPEN LOOP 7.0 GPM/Mrt
SLUDGE DISPOSAL UNSTABtLWED/SLUDGE POND
OPERATING EXPERIENCE UPDATE:
FGD SYSTEM
MONTH PERIOD HRS. BOILER MRS. FGD SYSTEM HKS. UTILIZATION (*)
FEB. 78 672 19B 198 30
MAR. 78 744 471 471 63
THE UNIT MAS DOWN THREE TIMES DURING FEBRUARY FOR NON-SCRUBBER RELATED PROBLEMS. THO OTHER
OUTAGES WERE THE RESULT OF A FUEL SAFETY TRIP PROBLEM AND GENERAL SCRUBBER MAINTENANCE. IN
MARCH THERE MERE THREE ECONOMIZER LEAK OUTAGES (APPOX. 231 HRS) AND THE SCRUBBER REQUIRED AN
ADDITIONAL 32 HRS OF OUTAGE TIME FUR MAINTENANCE.
APR. 78 720 288 288 40
MAY 78 744 421 327 44
FGO OUTAGE IN MAY HAS DUE TO CLARIFUR PLUGGING. APRIL OUTAGE TIME WAS SCHEDULED FOR
ROUTINE MAINTENANCE AND GENERAL CLEANING.
JUNE 78
JULY 78
NO INFORMATION HAS AVAILABLE FOR THE JUNE-JULY REPORT PERIOD DUE TO A PLANT STRIKE.
AUG. 78
SEP. 78
THE SCRUBBING SYSTEM IS OPERATING ALTHOUGH THE UTILITY IS STILL IN THE MIDST OF A STRIKE.
FGO PERFORMANCE FIGURES ARE NOT AVAILABLE. THE UTILITY IS NOT RECORDING FGO SYSTEM OPERATION
HOURS DURING THE STRIKE.
37
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FPA UTILITY Fen SURVEY: AUGUST 19/8 - SEPTEMBER 1978
SFCUON s
PEHFUHMAHCt DESCRIPTION f-OR UPfcRATlONAL FGO SYSTEMS
UTILITY NAME
UNIT NAMF
UNIT LOCATION
UNIT R«TING
KANSAS CITY PlIHUJ * LIGHT
LA CYGNt 1
LA CYGNt KANSAS
020 Hn
FUFL CHARACTERISTICS COAL: ">X SULFUR, 251 ASH
Fi>n VENDOR
PROCESS
NEK OR HFTRUFIT
START IIP UATF
EFFICIENCY:
PAHTiruLATES (ACTUAL)
(UESIGN)
808 (ACTUAL)
(DESIGN)
HATED MAKE UP
SLUDGE DISPOSAL
BAHCOCK & HlLCOX
LIMESTONE
NtN
2/73
SH.2 PERCEN1
9P.o PERCENT
90.1 PERCENT
76.0 PERCENT
OPEN LOOP l.«
UNSTABILIZEb/SLUDGF PONU
OPERATING EXPERIENCE UPDATE:
MONTH
BOILER HOURS
PERCENT AVAILABIL1TY-BY MODULE
8 C 0 E F
AVERAGE
FEB. 78 578 9? 93 95 94 91 97 96 93 9a
MAR. 78 701 95 9% 90 95 94 95 89 93 93
FGO OPERATIONS AT LA CVGNE HERE CONDUCTFO DURING THE REPORT PERIOD MITH NO MAJOR PROBLEMS
ENCOUNTERED.
APR. 78
620
91
92
91
90
92
91
91
91
MAY
THE BOILER MAS OOHU A TOTAL OF 100 HOURS IN APRIL. THIS TIME INCLUDED THREE OUTAGES DUE TO
BOILER LEAKS AND LACK OF LOAD REQUIREMENT. MODIFICATIONS TO THE FGO SYSTEM HERE PERFORMED
DURING THE OUTAGES HHTCH INCLUDED CHANGING THE REHEAT TUBE BUNDLES.
78 593 89 92 92 93 92 91 93 86 91
IN MAY THF BOILER HAS DOWN THICE FOR A TOTAL OF 151 HOURS. OUTAGES HERE AGAIN CAUSED BY
BOILER LEAKS. GENERAL MAINTENANCE AND REPAIRS ON THE FGD SYSTEM HERE CONTINUED.
JUNE 78
JULY 78
15
341
68
97
9?
94
86
93
93
95
93
THE UNIT WAS ONLY UP FOR 15 HOURS IN JUNE. IN THE FIRST PART OF JUNE THERE HERE BOILER TUBE
LEAKS. FROM JUNE 6 TO JUNE 17 A BOILER UUTAGE HAS NECESSARY FOR GENERATOR REPAIR. THE UNIT
OPERATED THROUGHOUT JULY.
AUG. 78 577 92 93 95 96 93 94 95 95 94
SEP. 7A 720 96 96 96 96 96 96 95 97 96
THERE KERF. THO BOILER OUTAGES INON-FGD-RELATED) IN AUGUST. THE FGD SYSTEM REQUIRED ONLY ROU-
TINE MAINTENANCE. THE UTILITY IS EXPERIMENTING HITH A 3-STAGE MIST ELIMINATOR AND SOME DOU-
BLE STAGE MIST ELIMINATORS. BETTER MIST ELIMINATION AT THE SCRUBBER EXIT MOULD REDUCE THE
FREQUENCY OF REHEATER CLEANING. OVER THE JULY-SEPTEMBER PERIOD THO I.D. FAN ROTORS HAVE BEEN
REPLACED.
36
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EPA UTILITY FGO SURVEY: AUGUST ma - SEPTEMBER i<»78
bF.CTION J
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGI) SYSTEMS
UTILITY NAME KANSAS HOnEk K LIbHl
UNIT NAMF JEFFREY I
UNIT LOCATION ST MARYS KANSAS
UNIT HAIING 68U HW
FUFL CHARACTEHIS1ICS COAL; O.U SULFUR, 7.SX >SH
FGO vfcNnnk CUMHUSMON
PROCESS LIHtSTOrlF
NEW OK RETROFIT NEM
START UP DATE 6/78
EFFICIENCY:
PARTICULARS (ACTUAL)
(DESIGN) 94.0 PbHLENT
S02 (ACTUAL)
(DESIGN) 60.o PERCENT
MATER MAKfc UP CLOSED LOOP .^9
SLUDGE DISPOSAL UNSTARILUED/SLUnbE PUNU
OPERATING EXPERIENCE UPOAIE:
AUGUST-SEPTEMBER I9;a - TMF SYSTEM is PRESENTLY IN THE SHAKEOOHN PHASE UF OPEKATION. EACH OF THE
SIX MODULES OPERAIFD DURING THIS PF.HIUO NO MAJOR PROBLEMS REPORTED. INTEGRATED OPERATION OF THE
SYSTEM IS FXPtCTED (0 BEGIN DURING THt FIRST HALF OF OCTOBER.
-------
EPA UIILITY F(,n SURVEY: AUGUST i<>78 - SEPIEMBER
SECTION S
PERFuRMANCfc DESCRIPTION FOR OPfcRATIOHAL ^ BO SYSTt«b
UTILITY NAME KANSAS POnEk * uir.H!
UNIT NAME LAftMFNCfc «
UNIT LOCAIIIIN LAHHFNCE KANSAS
UNIT MATING 125 "x
FUEL CHARACTERISTICS COAL: o.sx SULFUR. im ASH
FGf> VtHDOk COMBUSTION ENGINEERING
PHOCESS LIMESTONE
NE« OH RETROFIT PETWHHT
STAKT OH |)ATE
EFFICIENCY:
CACTIIAL) •»•»
(UESIGN) 98. <» PERCENT
502 (ACTUAL) 90+ PEKCENI
(OESI&N) 73.0 PEHCENT
MATER MAKE {JO OPEN LOOP
SLUDRE DISPOSAL UNSTABILIZEI//SLUDGF POND
OPERATING EXPERIFNCt UPDATE:
FEB. in THE FGO SYSTEM oPt«»TH) DURING THE RFHOKT Ptwiou MITH NO HAJOH PROBLEMS. THE THICKENER
MAR. 78 IJNOkKFLOM LINE IS SI ILL FHO/EN AND INU i INCH DIAMETER FIRE HOSES AWE BtlNR IISFO TO PUMP
THf UNOfcRFLU* SOLIDS 10 THE PONU.
APR. 78 THE IITILTTY REPuRTED THAT THE FGD SYS1FM ANu THE BOILER RAN MITHOUT ANY OUTAGtS DURING
MAY 78 THIS PEKIOO.
JUNE 7« THE BOILER ANU FGD SYSTEM ROTH OPERATED THROUGHOUT THE PERIOD. THE UTILITY
JULY 78 REPORTED THAT THE OPERATING HOURS EQUALED THE HUUHS IN THE PERIOD.
AUG. 78 HOURS OF OPERATION HERE NOT AVAILABLE RUT THF UTILITY REPORTED THAT THE SYSTEM RAN KITH NO
SEP. 7» FORCED OUTAGES DURING THE PtRlOD. THt UNIT HAS DOHN THE L»ST HEEK AND A HALF IN SEPTEMBER
FOR A SCHEDULED FALL TORB I HI /BOlLfR OUTAGE. ROUTINE MAINTENANCE INCLUDED BOILFR AND
TURBINE CLEANING AND REPAIR.
ao
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EHA UTILITY FGD SURVEY: AUGUST 1978 - SEPTEMBER 197B
SECTION 3
PFRFURMANCt DESCRIPTION FOM OPERATIONAL F f,[) SYSTEMS
UTILITY NAME KANSAS HHnF-k * LIGHT
UNI I NAMF LAWkfNCE b
UNIT LOCATION LAWMFNCF KANSAS
UNIT HATING 000 Mw
FUFL CHARACTEHlSUrS CUAl : I..5X SULFUR. |OX ASM
FGD VENDOM COMBUSTION ENGINEERING
PROCESS LIMESTONE
NEH OR HE I MOP IT NEW
STAHT (IP UATE 1 1/71
EFFICIENCY:
P»HTICUL»TES (ACTUAL)
(UFSIGN) 98.4 PFKCE^T
SOS (ACTUAL)
(DFSIGN) b?.0 PERCENT
MATER MAKE UP OPEN LOOP
SLUDGE DISPOSAL HNSTABUIZEU/SLIIPGF PUNO
OPEWATING EXPERIENCE UPDATE:
FEB. 78 THE ORIGINAL FGI) SYSTEM MAS PULLED OFF LINE ON MARCH £0 SO THAT THE NEH SCRUBBER-ABSORBER
MAR. 79 SYSTEM COULD HF TIED INTO THE GAS PATH. THIS NEW SYSTEM CONSISTS OF TKO MODULES EACH WITH
A ROD SECTION FOR PARTICULATE REMOVAL AND A SPRAY TOMER FOR SU£ HEMOVAL. THE CAPACITY IS
210 MM EACH. INITIAL OPERATION SHOULD BEGIN BY THE FIRST OF MAY.
APR. 76 THE NEM UNIT MENT IN SEKVICt ON APRIL 14 AND HAS OPERATED MITH NO OUTAGES SINCE START-UP.
MAY 78
JUNE 78 THE ROILEH OPERATED ALL BUT TMO DAYS OF THE JUNE-JULY PERIOD. THE TMO DAYS OF OUTAGE
JULY 78 TIME IN JUNE HEKE DUE TO A BOILfcW DRAIN LINE LEAK. THF FGD SYSTEM OPERATED THE ENTIRE
TIME THE BOILER MAS ON-LINE. NO PROBLEMS HfcRE REPORTED.
AUG. 7A THE SYSTEM HAN nITH NO FORCED OUTAGES DURING THE AUGUST-SEPTEMBER PERIOD. THE UNIT HAS
SEP. 7« TAKEN DUMN AT THF END OF SEPTEMBER FOR A SCHEDULED TMO MEEK TURBINE/BOILER OUTAGE. ROU-
TINE MAINTENANCE IS BEING PERFORMED ON THE BOILER AND TURHINE.
41
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EP» UTILITY FGD SURVEY: AUGUST 197*. - SEPIEM8ER l"»7fl
PERFORMANCE DESCRIPTION »• OR OPERATIONAL
SYSTEMS
IITILI'Y NAME
UNIT NAME
UNIT LOCATION
UNIT WAI I MR
Kt MUCKY UTILITIES
RREtN RIVER 1.2 * *
CENTRAL CITY KENTUCKY
60 **
FUEL CHARACiEKisTics COAL:
SULFUR, ii.ox »Sn
F6H VtNUON
PROCESS
NEM OR RE1RUFIT
START HP UATF
EFFICIENCY:
PARTICULATES (ACTUAL)
(OFSIGN)
802 (ACTUAL)
(DESIbN)
MATER MAKE UP
SLUDGE DISPOSAL
AHEKICAN ATK FtLTtR
LIME
RETROFIT
<»/75
S<».7 PERCENT
99.7 PEHCENT
80-90 PFRCtNT
80.0 PEHCFNT
OPEN LOOP l. OX
DURING THE FREEZE UP NUMEROUS GASKETS HFRE TORN THROUGHOUT THE SYSTEM.
DOMN COMPLETELY FOR REPAIR NORK.
THE SYSTEM HAS SHUT
669
744
MAR. 78 744
AVAILABILITY = toux
RELIABILITY s UNDEFINED
OPERABILITV B OX
UTILIZATION x OX
REPAIR NORK HILL CONTINUE UNTIL LATE APRIL 76 WHEN THE SCRUBBER-ABSORBER SYSTEM IS EXPECTED
BACK ON LINE.
APR. 78 720
AVAILABILITY = 41X
RELIABILITY s 99X
OPERABILITY s 99X
UTILIZATION • 41X
295
296
295
296
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Kf* UTILITY FGO SURVEY: AUGUST IIJB - SEPTEMBER i97t»
KENTUCKY UTILITIES WttN RIVEk \,i & J
TOTAL BOILER MOIHILF MUOUI E CALLED MB. MOOULF
PEH10U PERIOD (HH) OHF.KATION (HP) AVAILABILITY (MM) TO OHFRATF (HR) OPERATED
MAY 78 7«a 474 q?« 071 a7a
AVAILABILITY = b4X
RELIABILITY = IUOX
OPFRABILITY = ll)OX
UTILISATION = bqZ
THE SCKEENS UN THE SUCTIUN SIOl OF THF PUMPS THAT PUMP THE SLUkHY FROM THF PKEP ROUM TO THE
MO//LES tXPEMItNCFI) PLUCbING PhOBI tK-S. THE bCHFfcNS GET PlUC.bFl) HUH LARGF GMTT IN THE SLUWRY
AND ABfc SIICKEU OUT OF POSITION HY IHt PUMPS. THE UTILITY WEPOHTEO 'HAT THIS TENDS TO HE A
PHOHI tw.
JIINt 78 7c!0
AVAILABILITY = 7 5X
RELIABILITY = 1 001
OPEHAHILIIV = IOOX
II1ILIZATIUN = 7JZ
BOILtK ANO FUP SYSTEM IIIIIAbES DU>
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EPA UTILITY Fbl) SURVEY: »UGIlST !"»/» - SKPIFHPfcR 1978
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
UTILITY NAMf LOUISVILLt f.»S & tLECTRIC
UNIT NAMF CANE MIIN 1
UNIT LOCATION LOUISVILLE nFNTUCKY
UNIT RATING I7H Nh
FUEL CHARACTERISTICS COAL: 3.75X sun-uw, ib.sx ASH
FGO VENDOK AMERICAN Alh FILTER
PROCESS LIMfc (CARHIUE)
NEM Ok RETROFIT RETROFIT
START IIP DATE 6/76
EFFICIENCY:
PARTICULARS (ACTUAL) 99.0 PtRLF.NT
(DESIGN) 99.0 PERCENT
Sag (ACTIIAl) Bh-B9 PFRCbNI
(DESIGN) 85.0 PtRLFNT
MATER MAKt UP OPEN LOOP .bh GPM/Mn
SLUOGt DISPOSAL STABILIZED/bLUDbE PONU
OPERATING EXPERIENCE IIPDATF :
PFHFORKANCE FACTORS (ZJ
PERIOD HOURS HOILtR (HR) FGD SYSTEM (HR1 OPEHAHILITY UTILIZATION
FEB. ra t.72 o o o o
MAR. 78 744 ?49 34
THE UNIT HAS nOHN THE ENTIRE MONTH OF FFBRUARY DUE To THE COAL SHORTAGE AND A LACK OF AVAIL-
ABLE LIME RESULTING FROM THE SEVERE WINTER wfcATHfcR. THE UNIT CAME SACK ON LINE MARCH 21
AFTER MH1CH TIME THE FGD SYSTEM «AS UN LINE DURING 9bX OF THE bOILER HOURS THROUGH THE END OF
MARCH.
APR. 78 720 303 303 100 47
DURING APRIL THE HOILEM nAS UOftN FUR REPAIRS. THE UTILITY REPORTED THAT THE AVAILABILITY
AND RELIABILITY nERE BOTH 10UX.
MAY 78 744 35i 115 3S 12
THE BOILER MAS OOMN AGAIN IN MAY FOR REPAIRS. DURING THE BOILER OUTAGE A NUMBER OF MODIFICA-
TIONS MERE MAOt TO THE DAMPERS IN THE FGD SYSTEM. THE UTILITY REPORTED THAT THE FGD SYSTEM
HAS bEtN RUNNING MELL bINCE FHt MODIFICATIONS TOOK PLACE. THE AVAILABILITY AND RELIABILITY
FOR MAY MERE 31 AND 35 PERCENT RESPECTIVELY.
JUNE 78 720 ??0 715 99 99
JULY 7A 744 b«7 678 99 91
NO FGT> SYSTEM RELATED UUTAGES *ERE RLPURTFD BY THE UTILITY FOR THE JUNE-JULY PERIOD.
AUG. 78 744 744 701 94 94
SEP. 7H 720 138 I3H 100 19
THERE l»ERE NO FGD KORCtD OUTAGES DURING THE AUGUST-SEPTEMBER REPORT PERIOD. THE BOILER MAS
DOMN DURING SEPTEMBER FOR TUBE REPAIRS.
44
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UTILITY FGO SURVEY: AUGUST i9/a - SEPTEMBER 1978
SFtTION i
PERFURMANCe DESCRIPTION FOR OPERATIONAL FRI) SYSTLHS
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT RATING
LUUISVILLK (,AS K.
CANt RUN 5
LOUISVtLLK KENTUCKY
183 MW
FUEL CHARACTERISTICS COAL: 3.75* SULFUR, 15.5X ASH
FGD VENDOR
PROCESS
NEW OR RFTROFIT
START UP UATE
EFFICIENCY:
PARTICULATES (ACTUAL)
(OFS1GN)
S02 (ACTUAL)
(DESIGN)
MATER MAKE UP
SLUDGE DISPOSAL
COMBUSTION ENGINEERING
LIME (CARBIOE)
RETROFIT
12/77
S9.0 PERCENT
85.o PERCENT
OPEN LOOP
STABILIZED/SLUDGE POND
OPERATING EXPERIENCE UPDATE:
DECEMBER-JANUARY 14711 - OPERATION OF THE FGD SYSTEM AT CANE RUN 5 BEGAN ON DECEMBER 29. INITIAL
OPERATIONS HERE NUT CONTINUOUS. DURING OPERATION SOME OF THE CONTROLS HERE NOT HQRKING PROPERLY
AND MODIFICATIONS HERE NECESSARY.
FEBRUARY-MARCH 1976 - THE PLANT REMAINED OFF LINE THRuUGHUIlT FEBRUARY AND THEN RE-STAHTEO ON MARCH
24. THE BOILER OPERATED APPROXIMATELY 182 HOURS THROUGH THE END OF MARCH WITH THE FGD SYSTEM
OPERATING APPROXIMATELY 91 HOURS. VARIOUS INITIAL START-UP PROBLEMS HERE STILL BEING ENCOUNTERED
CAUSING FGD SYSTEM UUTAGF.S.
PERIOD HOURS BOILER (HR) FGO SYSTEM (HR)
PERFORMANCE FACTORS (X)
OPERABILITY UTILIZATION
APR. 78 720 669 648 97 90
MAY 78 744 432 364 80 49
FGD SYSTEM MODIFICATIONS HERE MADE DURING THIS PERIOD IN PREPARATION FOR PERFORMANCE TESTS.
TESTING TOOK PLACE HUT EPA TEST METHODS HERE NOT FOLLOWED ACCURATELY AND THE PROCESS OF DATA
ACQUISITION n»S HANDLED POORLY BY DATA CREHS. THE UTILITY HAS CONFIDENT THAT HAD THE CRENS
TAKEN THE DATA PROPERLY THE UNIT MOULD HAVE PASSED THE TESTS.
JUNE 78 720 685 590 86 82
JULY 78 744 632 506 80 68
THE UNIT EXPERIENCED REHEATER PROBLEMS OVER THE PERIOD. THE REHEAT COIL (STEAM) INSTALLATION
HAS BEEN A CHRONIC PROBLEM AREA. THE BANK OF TUBES AROUND THE DUCT HAS MELDS AT EACH END*
WHERE THE COIL FORMS A "U". THESE HELDS HAVE BEEN FAILING EVER SINCE INITIAL OPERATIONS.
AUG. 78 744 540 464 86 62
SEP. 78 720 609 485 80 67
PROBLEMS CONTINUED THROUGH AUGUST AND SEPTEMBER KITH THE REHEAT COIL HELDS.
AFFECTED ONLY SCRUBBER MODULE "A*.
THIS PROBLEM
45
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EPA UIILITY FGO SURVEY: AUGUST 1978 - SEPTEMBER i97«
SFCTION t
PERFORMANCE DESCRIPTION FOR (rPERATIONAL FGD SYSTEMS
UTILITY NAME LOUISVILLE GAS * ELECTRIC
IINII NAME MILL CREEK 3
UNIT LOCATION LOUISVILLE KENTUCKY
UNIT RATING «2b MM
FUEL CHARACTERISTICS COAL: 5.751 SlILFUH. Ib.bX *SH
FGD VENDOR AMERICAN Alk FILTER
PROCESS LIME (TARHIDE)
NEM OR RETROFIT NbM
START UP DATE 8/78
EFFICIENCY:
PARTICULATES (ACTUAL)
(DESIGN) 99 PERCENT
S02 (ACTUAL)
(DESIGN) 85 PtRLENT
MATER MAKE UP OPEN LOOP .35 GPM/MH
SLUDGE DISPOSAL STABILIZED/SLUDGE POND
OPERATING EXPERIENCE UPDATE:
AUGUST 1978 - INITIAL OPERATIONS BEGAN AT THIS UNIT ON AUGUST 12. DUE TO THE RECENT OPERATING
STATUS OF THE SYSTEM HOURS OF OPERATION MERE NOT AVAILABLE FOR AUGUST.
PERFORMANCE FACTORS (X)
PERIOD HOURS BOILER (HR) FGD SYSTEM (HH) OPERABILITY UTILIZATION
SEP. 78 720 714 57h 81 80
DURING THE MONTH OF SEPTEMBER PROBLEMS HERE ENCOUNTERED MTTH FRP PIPING AND CERTAIN PUMPS.
THE PUMP PROBLEMS MERE RELATED TO BEARING AND SHAFT FAILURES.
46
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EPA UTILITY FGO SURVEY: AUGUST 1978 - SEPTEMBER 1973
SECTION i
PERFORMANCE DESCRIPTION FOR OPERATIONAL FRO SYSTEMS
UTILITY NAME LOUISVILLE GAS * ELECTRIC
UNIT NAMF PADDYS HUN 0
UNIT LOCATION LOUISVHLE KENTUCKY
UNIT RATING 6b hw
FUEL CHARACTERISTICS COAL; i.7« SUI.HIH, i^.^t »SH
FGH VENDOR COMBUSTION ENGINEERING
PROCESS I IMK (CARBItiF)
NEH OR RETROFIT RETROi-Il
START UP DATE a/73
EFFICIENCY:
PAHTICULATES (ACTUAL) 99.u PERLENT
(OESIGN) 99.0 PtRLENT
503 (ACTUAL) 80-99 PERCENT
(DESIGN) 80.0 PERCENT
MATER MAKE UP OPEN LOOP 0.7 GPM/MM
SLUDGE DISPOSAL STA8UIZEU/LANOFILL
OPERATING EXPERIENCE UPDATE:
SEPTEMBER 1977-MARCH 1978 - PADDY'S RUN DID NOT OPERATE DURING THIS PERIOD DUE TO A LACK OF POWER
REDUTHEMFNT. THIS IS A PEAK LOAD UNIT THAT IS TO RF RETIRED SOON AFTER THE MILL CREEK * UNIT
BECOMES FULLY OPERATIONAL.
APRIL-MAY 1978 - PADDY'S HUN nAS ONLY ON LINE A Ftn HOURS DURING THIS PERIOD. NO OPERATIONAL
PROBLEMS HERE REPORTFO HY THE UTILITY.
JUNE-JULY 1978 - THIS UNIT RAN 1NIERM1TTFMLY FOR ABOUT EIGHT TO TFN DAYS OVER THE JUNE-JULY PERIOD.
AUGUST-SEPTEMbFR 197A - THIS UNIT WAS OPENATED FOW TnO «FfcKS IN SEPTEMBER SO THAT TESTING OF A NE"
FLOCCIILANT COULD HE CARRIED OUT. THE RESULTS OF THE TESTS «ILL DETERMINE THE TYPE OF FLOCCULANT
THAT HILL RE USED IN THE FUTURF AT THE OTHER LGSE UNITS.
07
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EP» UTILITY FGO SURVEY: AUGuSI 1978 - SfcPIFMBtP 1V78
SECTION J
PERFORMANCt DESCRIPTION FOR OPtPATJONAL FGD SYSTEMS
UTILITY NAME HJNNKUTA PO|»ER COOPERATIVE
UNIT N»HE MILTON H. YOUNG g
UNIT LOCATION CENTER NOKTh DAKOTA
UNIT HATING 050 MM
FUEL CHARACTERISTICS LIGNITE; o.?x SULFUR, n.ox ASH
F&n VENOOK AUL/COMoUSTI')N EUUlP ASSOCIATE
PHOCFSS LIMt/ALKALiNF FLYASH
NE* OK RETHUFIT NE«
START UP UAfE 9/J7
EFFICIENCY:
PARTICULATES (ACTUAL)
(DESIGN) 99.6 PtHCENT
802 (ACTUAL)
(DESIGN) 7S.O PERCENT
MATER MAKE UP OPEN LOOP 1.S6 GPK/HH
SLUDGE DISPOSAL UNSTAHILUED/LANOFILL
OPERATING EXPERIENCE UPDATE:
FEBRUARY-MARCH 197H - 8UTH IHt BOILERS AND FGD SYSTEM CAME HACK ON LINE FEB. 21 AFTER COMPLETION
OF THt TUMRINt RFPA1RS. ONE SCHIIBHtH-AHSUKHER FRHCfcl) DRAFT FAN MAD AN OIL LEAK AND A SHAFT ALIGN-
MENT PROBLEM. IT HAS TAKEN OFF THF LINE AND SHIPPED TO BUFFALO FORGE co.'s PLANT FUR REPAIRS. THE
AFFECTED MODULE MAS DOHN FROM FfcB. 23 THROUGH APRIL 10, WHFN THE REPAIRED UNIT HAS RE-INSTALLED.
THE VACUUM FILTER ON THE SECOND SCRUBbEH-ARSOKRER MAS MALFUNCTIONING. ALLUDING LARGER SIZE
PARTICLES TO ESCAPE THE FILTER. THIS CAUSED THE KUBBER LINING OOMNSTHEAM TQ PEEL HHICH, IN
TURN. CREATED A PLUGGING PROBLEM, tincu ENGINEERS ARE PRESENTLY STUDYING THE PROBLEM
AND HOPE TO INCORPORATE MODIFICATIONS TO IMPROVE THE PERFORMANCE OF THE FILTERS. THE COMPLIANCE
TEST HAS AGAIN BEEN RESCHEDULED WITH THE EPA FOR THE tND OF MAY.
APRIL-MAY 197tt - COMPLIANCE TESTING TOOK PLACE DURING THE WEEK OF JUNE b. THE RFPUMT SHOULD BE
AVAILABLE TO THE UTILITY BY THE END OF JUNE. THE UNIT MAS DOWN KITH DAMPER PROBLEMS (DOWN
ON THE 80TH OF JUNE). APPARENTLY THE CHAINS THAT PULL THE GUILLOTINE DAMPERS *>ERE UNDEMOESIGNED AND
HAVE BEEN REPLACED.
JUNE-JULY 1970 - NO INFORMATION MAS REPORTED BY THE UTILITY FOR THIS REPORT PERIOD.
AUGUST-SEPTEMBER 1978 - OFFICIAL RESULTS OF THE COMPLIANCE TEST PERFORMED ON JUNE 6 ARE STILL NOT
AVAILABLE. VARIOUS PROBLEMS hEHE ENCOUNTERED WITH THIS SYSTEM DURING THE PERIOD. THE THICKENER HAS
BEEN A MAJOR PROBLFM AREA. THE POLYFTHYLENE LINER HAS ACCIDFNTLY PIFRCED DURING REPAIRS AND HAD TO
BE PATCHED. BECAUSE OF INTERMITTENT OPERATION, HOURS AHF NOT VET AVAILABLE.
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FPA UTILITY FGD SUHVFY: AUGUST i<*;e - SEPTEMBER i<>7a
SECTION 3
PEHFORMANCE DEbCKIHTlON FOk OPERATIONAL FGI) SYSTEMS
UTILITY NAME
UNIT NAMF CULSTNIP 1
UNIT LOCATION COLSTkIP KUNTANA
UNIT HAT ING ihO MW
FUEL CHARACTERISTICS CUAL; 0.8X SULFUR, 121 ASH
FGO VENDOR AUL/COMBUST10N EUUIP ASSOCIATE
PROCESS LIME/ALKALINE FLYASH
NEW OH RETROFIT NEW
START UP DATE 11/75
EFFICIENCY:
PAHTICULATES (ACTUAL) 99.5 PERCENT
(DESIGN) S9.s PERCENT
SO* (ACTUAL) 75.0 PERCENT
(DESIGN) 60. o PERCENT
MATER MAKE UP CLOSED LOOP
SLUDGE DISPOSAL STABILIZED/SLUDGE PONU
OPERATING EXPERIENCE UPDATE:
JAN. 78 TOTAL SYSTEM AVAILABILITY = 96X
FEB. 78 TOTAL SYSTEM AVAILABILITY 1UOX
MAR. 78 TOTAL SYSTEM AVALIABILITY r 92X
APR. 7* TOTAL SYSTEM AVAILABILITY = 100X
MAY 78 TOTAL SYSTEM AVAILABILITY =
•THIS FIGURE IS BASED UPON 9.9Z HOURS OF OPERATION ON TnO SCHUBBERS WHILE UNIT 1 WAS BEING
BROUGHT BACK ON LINE AFTER COMPLETION OF ITS ANNUAL OVERHAUL. THE I.D. FAN MOTOR NAS NOT
AVAILABLE AT UNIT STARTUP ON THE IA MODULE.
JUNE 78 TOTAL SYSTEM AVAILABILITY = 7bX
JULY 78 TOTAL SYSTEM AVAILABILITY = 96X
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EPA UTILITY FGO SURVEY: AUGUSI 1<»78 - StPTEMBtR 197«
SECTION 3
PERFORMANCt DESCRIPTION FOH OPERATIONAL FGU SYSUMS
UTILITY NAHt MONTANA PONER
UNIT NAMF COLSTRTP i
UNIT LOCATION CULSTKIP MONTANA
UNIT RA1 INK 3*>0 MN
FUEL CHARACIEKISTICS COALJ O.BX SULFUR. IPX ASH
FED VENDOR AOL/COMBUSTION EQUIP ASSOCIATE
PROCESS LIME/AIKALINE FLYASM
NEN OR RETROFIT NEM
START UP DATF 8/7f>
EFFICIENCY:
PARTICULATES (ACTUAL) 99.S PEHLENT
(UESICN) 99.5 PERCENT
S02 (ACTUAL) 7S.O PERCENT
(DESIGN) 60.0 PERCENT
MATER MAKE UP CLOSED LOOP
SLUDGE DISPOSAL STABILIZED/SLUDGE POND
OPERATING EXPERIENCE UPDATE:
JAN. 78 TOTAL SYSTEM AVAILABILITY - 97X
FEB. 78 TOTAL SYSTEM AVAILABILITY s 9SX
MAR. 78 TOTAL SYSTEM AVAILABILITY a 89X*
•THIS FIGURE is BASED UPON THE 17 DAYS OF OPERATION BEFORE THE UNIT MAS SHUT DOHN FOR A
SCHEDULED ANNUAL OVERHAUL.
APR. 78 TOTAL SYSTEM AVAILABILITY = 87t*
•THIS FIGURE is BASED UPON 8 DAYS OF OPFHAITON IN APRIL AFTER A UNIT OVERHAUL.
MAY 78 TOTAL SYSTEM AVAILABILITY = 99X
JUNE 78 TOTAL SYSTEM AVAILABILITY s 97X
JULY 78 TOTAL SYSTEM AVAILABILITY - 9bX
SO
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EPA UTILITY F&O SURVEY: AUGUST i9?s - stPiFMBtn 1978
SECTION 5
PERFURMANCt OESCHIPTION I-OP OPERATIONAL Ff,u SYbHMS
UTILITY NAMt NEVADA POftFh
UNIT NAME HfclU GAkONEk 1
IJNIT LOCATION MOAPA NfcVAD*
UNIT HATING I25 Mw
FUEL CHARACfEHIbTlCS COAL: O.SZ bULFuH, 81 ASH
FGO VtNDOH AOL/COMbUST]ON fcQUlP ASSOClATfc
PHOCtSS SUDIUM CAHBUNATt
NEK OH HFTRUFIT RETKOFII
START UP OAlfc 4/74
EFFICIENCY:
PARTlCULAfES (AC I UA|_) <*<«•» PEhCt'll
(DESIGN) 41.0 PtHCFNT
SOi (ACTUAL) 85-9U PtKCENT
(DESIGN) tt-5.0 PERCENT
KATtR MAKE UP OPEN LOOP O.OO GPH/MM
SLUDGE DISPOSAL IINSIABILHEU/SOLAK EVAP PUNU
OPERATING EXPEHIENCE UPDATE:
HH.
ttOILER HOnULt CALLED
TOTAL OPERATION AVAILABLE UPON 10 OPERATION
PERIOD (HH.) (HH.) (HH.) OPERATE (Hit.)
FtR. 78 67£ 389 bS« 309 £92
AVAILABILITY s 97X
RELIABILITY = 901
OPERABILITY s 7bX
UTILIZATION s ajX
THE SCRUHBER-AHSOHUEH SYSTEM HAS OFF-LINE FOH APPROXIMATELY 18 HUURS DUHINb FEBRUARY DUE TO
PLUGGFU SENSING LTNES AND A DULT HI-LO PRESSURE TRIP. THE BUTLEH MENT OUT OF SERVICE ON
ON FEBkllAHY 17 FUH A THHbE MEEK UUTAbE.
MAR. 76 700 355 207 355 2»7
AVAILABILITY = 28X
RELIABILITY = 58X
OPERABILITY s S0X
UTILIZATION s Z8X
THE BOILER CAME HACK ON LINE MARCH 16 BUT PROBLEMS MITH THE GUILLOTINE SNITCHES DELAYED
START-UP OF THE FGO SYSTEM UNTIL MARCH 22. FGI) OOHNTIME HAS APPROXIMATELY 537 HOURS.
A PROBLEM MAS ALSO ENCOUNTERED MITH THE HEHEAT STF.AM HEGULATOR DURING MARCH.
APR. 78 720 SbO 7?0 5O1 5al
AVAILABILITY s 100X
RELIABILITY = 100X
OPERA8ILITY s 97X
UTILIZATION a 75X
THERE HERE NO F6D SYSTEM FORCED OUTA&ES. ALL DOWNTIME HAS BOILER RELATED (179 MRS.).
MAY 78 744 b30 721 605 582
AVAILABILITY s 97X
RELIABILITY s 9&x
OPEHABILITY s 42X
UTILIZATION s 78X
THE UNIT MAS DOHN 132 HOURS FOk A PRODUCTION CONTROL OUTAGE, 7 HUUUS FOR REPAIRS TO THE
CONDENSER. AND 23 HOURS DUE TO HIGH TEMPERATURE ON 1.0. FAN BEARING. (OUTAGES MERE BOILER
RELATED.)
51
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EPA UTILITY FGO SURVEY: AUGUST 1978 - SEPTEMBER 1978
NEVADA POHFk REM) GAKDNEH J
HM.
BOILER MODULI CALLED
TOTAL OPERATION AVATLAbLt UPON TO OPERATION
PERIOD (H«.) (Hk.) (Hk.) UPFRATt (MM.)
JUNE 7B 720 7c>0 644 644 644
AVAILABILITY = 041
RELIABILITY = 100Z
PPERABILITY = 89Z
UTILIZATION = «9X
THERE «AS UNE SCHEDULED EGO UUIAGE Til MFHA1H A LEAK ON THF VENTUHI KATER BOX.
JULY 70 744 744 744 7Jh 716
AVAILABILITY = 100*
RELIABILITY = 100X
OPERABILITY = 991
UTTLTZATION = <»9Z
A SCHEDULED FGO OHIAGE HAS REOlllKED TO RECTIFY A HIGH TRAY DIFI-EKENUAL PRESSOHF PKOHLEM.
THE TRAY HAS CLEANED OuT OuRING 1HE UUTA6F.
AUG. 78 744 706 698 707 661
AVAILABILITY = 942
RELIABILITY = 9JZ
OPF.KABILTTV r 901
UTTLIZATION = M9Z
THE SCMUBHbR HAS FURCEU OFF LINE ON AUGUST 5 BECAUSE OF A LOSS OF THE ASH PANEL CONTROL
POwFH. THIS LEFT THE UNIT WITHOUT EMERGENCY SPHAY TO THE SCHUBHtRS. A SECOND FORCED OUTAI.E
OCCUUREO UN AUGUST 20 NHEN THFkE HAS A SCHUHHEM VENTuRI HIGH TEMP ALARM. THE EXACT CAUSE *AS
NOT KNU«S BUT A ttOILER TuHE LEAK HAS SUSPfcCUO. THERE HAS ONE SCHEDULED OUTAGE DURING THE
MONTH TO CLEAN THE TRAY.
SEP. 7« 7?0 ou« /lb hi\ bib
AVAILABILITY = 9«i
RELIABILITY = 99t
OP?HAoILITY = <*7Z
UTILIZATION = B7Z
DURING IMF vt,.••!)< * "OlLFr, ihlH .JCCURi ohlCit KAS CAuStO hY SCKUMHtH HIGH DUCT PRESSURE. AS
A RESULT, ink OH I I MAS DUIN Flih b.5 MOoHb rtHILt THt bCflUHBEH PHESSOKk SENSING LINE!) nEHE
CLEANED. THERE »FWE THREE OTHtR HOILEH HF.LATEU UNIT OUTAGES DURING THE MONTH TOTALING 89
HOURS. A BOILER TUBE LEAK AND ThE NUMBFk b HOILtR BURNER flFrfE REPAIRED.
52
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FPA UTILITY FGf) SUkVFY: AUGUST 1<»7B - StPIFCHEW 1978
SFCTION i
PERFORMANCE INSCRIPTION »• OK OPeHATIUUAL FRO SYSTEMS
UTILITY NAME NEVADA pn«Eh
UNIT NAME HE II) GAKONEh 2
UNIT LOCATION MUAPA NEVADA
UNIT HATING l?b Mw
FUEL CHAHACTFHISMCS COAL: 0.5X SULFUR. BX «SH
FGO VENDOR AOL/COMHUSTinN EQUIP ASSOCIATE
PROCESS SODIUM CAKHUNATE
NE»» Ok RETROFIT HtTROFIT
START IIP 0»IE U/7a
FFFICIFNCY:
PARTICOLATES (ACTUAL) 99* PERCfcNI
(DESIGN) 91.0 PERCENT
SO? (ACTUAL) 85-90 PERCENT
(DESIGN) 8S.O PERCFNT
WATFR MAKE UP OPEN LOOP o.ao GPM/MH
SLUDGE DISPOSAL UNSTABILIZED/SOLAR EVAP PDNU
OPERATING EXPERIENCE UPDATE:
MR.
BOILER MODULE CALLED
TOTAL OPERATION AVAILABLE UPON TO OPERATION
PERIOD (HR.) IHR.) (MR.) OPERATE (HH.J
FEB. 7fl bJf bib bi-3 632 S8S
AVAILABILITY = 932
PELIABILITV = 9^1
OPFRABILITY = 92Z
UTILIZATION s 871
FGO UOMNIIMF DURING FEBRUARY MAS APPROXIMATELY as HOURS DUE TO A PLUGGED SENSING LINE AND
A DUCT HI-LO PRESSURE TRIP. THE BOILFR MAS OUT OF SERVICE ^4 HOURS.
MAR. 70 74a 6/2 7?b M4 595
AVAILABILITY = 98x
RELIABILITY s 97X
OPERABILITY = 89X
UTILIZATION = 80S
THERE WAS ONLY ONE FORCED FGD OUTAGE DURING MARCH WHICH LASTED APPROXIMATELY 18 HOURS. A
SCHEDULED BOILER OUTAGE AT THE BEGINNING OF THE MONTH TO REMOVE ASH BUILDUP HAS CANCELLED.
APR. 78 720 320 720 117 317
AVAILABILITY = 10UX
RELIABILITY = 100X
OPERABILITY = 98X
UTILIZATION = 44X
THERE WAS ONE SCHEDULED BOILER OUTAGE WHICH LASTED ABOUT 403 HOURS.
MAY 78 744 726 743 72b 724
AVAILABILITY = 100X
RELIABILITY = 100X
OPEHA8ILITY s 100X
UTILIZATION = 97Z
THE BOILER HAS OFF FOR APPROXIMATELY 18 HOURS FOR REPAIRS ON THE MILL SPOKES. THE 2A SEC,
BREAKER TRIPPED AND CAUSED AN OUTAGE OF ABOUT ONE HOUR.
53
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EPA III II MY Ff.D SURVI-r: AUGUST 1<»7*» - SEPTFMHtR 197B
POMFW REIU GARDNER
HOILER MtmuLt MR. CALLED
TfHAL llPtHATION AVAIlAHLF UPON TU OPERATION
(HH.) (Hk.) (MM.) UPEWATt (HM.)
.ln'Jl /« 720 7i;0 71« *««>* 6M
A\|A|LAM|L|TV = |UOX
RtHABUITY . luOl
"TILI/AI ION - «»«»»
iMEwt RFWE i«n SCHEDULED rr.u uuiAGts TU UNPLUG THE TWAYS AND TU CHANGE THE OIL ON THE i.o.
FAN. A FOwrtO FbO OuIAGt UCCUKRED HHEfe nTbll DUCT PRESSUHF CAUSED A BOILER THIP.
JUL» 78 /4u 676 S4(> 7U1 S55
»FLlAhlLl1Y - 7«
npf.RAHlLlTY = fl^t
IITTLI/AIION = 7at
IHt bOREB DAS OUT OF SFKV1CE UUfc in A BUILFK TUBE LEAK. THERE NAS ALSO A HUlLEK TRIP DUE TO
A HIGH ouri pRtssnwt. THIS AAS CAUSED HY A FAULTY POSITIONED UN THE I.o. FAN CONTROLLER.
IHK l.li. FA" FlPArvSlUN JOINT ON IHt SCHMBHtN WAS RfcPLACFU. ANOTHER FGU UUTAGE OCCURRED HHtN
A BIJlT, KHICH FFLL FHOM IHt FAn, CAUSED VloKAUONS. A StCUND BOILER TkIP DUKING JULY MAS
CAiiStn HY AN IIM)ETtWMlNFU SOuRCF . THF SUCIIUN L I Nt FROM THF VF.NIURI DISCHARGE LINE TO
IHt EFFLUENT PllHPS HAS CLEANED OUT, nH£N PLUGGING UCCURRtO.
AUG. 7« 744 751 h03 643 601
AVAILABILITY = BH
RELI»HILITY = <»JX
OPFHAhlLlTY - «ei
UTILIZATION = 811
TMil SCHEDIILFO OUTAGES (HIKING THE PERIOD nFME NECESSARY TO CLEAN THE SCRUBBER TRAY. A THIRD
SCHEDULED UUIAGE MAS NECESSARY TO CLEAN THE NOZZLES ON THE SCRUBBER SPRAY HACK. THE STAIN-
LESS SIEEL PIPE TO THE THAI SPRAY NOZZLES MAS ALSO REPLACED. THEME hERE THREE FORCED OUTAGES
DUXING THE MUN1H. ON AUGUST 1 THE SCRURBFH EXPERIENCED HIGH DUCT PRESSURE. ON AUGUST 3 IT
HAS NFCESSARV TO TAKE THE SCKUbBE» OFF LINE TO REPACK THE VENTlIRI PUMPS. THE THIRD OUTAGE
HAS CAUSED BY A LOSS OF THt ASH PANEL CONTROL POnER. THIS LEFT THE SCRUBBER WITHOUT EMERGEN-
CY SPRAY.
SEP. 78 7?0 693 720 675 675
AVAILABILITY = 100X
RELIABILITY = 100Z
nPEHAHlLlTY = 971
UTILIZATION = <)4X
A SCHEDULED SCRUBBER OUTAGE TOUK PLACE DURING THE MONTH IN ORDER TO CLfcAN THE THAT RECYCLE
TANK AS HELL AS THE TRAY AND SOME UF THE LINtS. THREE OTHER BOILER RFLATED OUTAGES HERE
CAUSED BY PROBLEMS MITH A 10-K* GFNEhATOH. CONTROL POnER SURGES MERE BEING CAUSED BY OVER-
VOLTAGE MOTOR TRIPS.
-------
EPA UTILITY FGO SUHVer: AUGUST 1978 - SEPTEMBER 197b
SECTION 3
Pf-RFORMANCt DESCRIPTION t OR OPERATIONAL K;I> bYSTFMS
tlTILIir NAME NtVAOA PDKFf,
UNIT NAME RfcH) GArfDNEK 4
UNIT LOCATION MdAPA NEVAOA
UNIT RATING J 2b Mft
FuFL CHARACTERISTICS CUAL: 0.5X iULFUW, 81 ASh
FGD VENDOR ADL/COMHUSTJO* EOUtH ASSOCIATE
PROCFSS SUOIUM CARBONATE
NE* OR HFIRQFIT Nt-M
StAHT UP DATE 7/7h
FFFICIFNCT:
PAHTICULATES (ACTUAL ) 9«» PERCt'Jl
(DESIGN) 9<>.0 PtHCFNT
S05 (ACTUAL) B'i-'JO PEkCfcNl
(DESIGN) 65.0 PtKCENT
HATER MAKE UP OPFN LOOP O.qo GP«/Mh
SLOUGt UISPUSAL IINSTAHIL I2E|i/SdLAM tVAP POM)
OPERATING EXPtHlFNCE UPDATE:
MM.
BOILER MUDULt CALLEO
TOTAL UPfcKATION AVAILABLE UPON Tu UPtUATION
PF.RIOD (Htt.) (HK.) (Hk.) uPtRATt (HK.)
FEB. 78 672 blf b02 hlfl S84
AVAILABILITY = 96X
RELIABILITY = 9bX
OPEHAHILITY = 9bJ
UTILIZATION = A8X
DURING FEBHUAHY FAULTY WJHINU CAustn A HIGH VENTUMI TEMPERATURE HFSULTING IN AN INITIAL 16
HOUR FbO SYSTEM OUTAGE. 1HFME MAS A SECUNO OUTAGE OF IS HOUKS TU CHECK THE VENTURI TFMPERA-
TURE INDICATOR. A THIRD OUTAGE AAS CAUStD BY PLUGGING OF InE MIX TAnK nHlCH HADE IT IMPOS-
SIBLE TO MIX CHEMICALS.
MAR. 78 740 7dt 734 738 718
AVAILABILITY = 97X
RELIABILITY = 97X
OPERABILITV = 97X
UTILIZATION = 96X
THE MIX TANK PROBLEM CUNHNUfcl) INTO MARCH CAUSING THE ONLY FGO DONNUHE FOB THE MONTH
(APROX. 20 HOURS). A FURNACE Hl-LO PRESSURE TRIP CAUSED A ftOILEk OUTAGF OF b HOURS.
APR. 78 720 704 b<»9 650 629
AVAILABILITY = 97x
RELIABILITY = 97X
OPEMABILITY = H9X
UTILIZATION = 87X
THE FGO SYSTEM MAS DOWN APPROXIMATELY 21 HOURS FOR REPAIRS ON THE VENTURI EMERGENCY SPRAY
SYSTEM. THE BOILER MS OOriN APPROXIMATFLV 70 HOURS DURING APRIL.
MAY 78 744 646 724 514 494
AVAILABILITY = 97X
RELIABILITY = 96X
OPERABILITV s 77»
UTILIZATION = 66X
THERE MAS A SCHEDULED OUTA6E OF 230 HOURS FOR BOILER MAINTENANCE, AND A FORCED OUTAGE OF
20 HOURS DUE TO A FAULTY TEMPERATURE PROBE AT THE VENTURI OUHlNG MAY.
55
-------
FPA UTILITY Flift SUtmr: »UGUS! 1978 - SEPTEMBER 1478
NEVADA PUHFR "Ell) GARDNER 3
BOILER MODULE HR. CALLED
TOTAL OPERATION AVAILABLE UPON Tu OPERATION
PERIOD (HH.) (HR.) (MK.) OPERATE (HR.)
JUNf 78 110 71S 7?0 715 6H6
AVAILABILITY = loot
RELIAbTLITY _ <»bX
OPFRABlLlTY - 96X
UTILIZATION = <»bX
A SCHFDULEU FGI) OUTAGE OCCURRED HHEN THE FIRE SPRAY SYSTEM MAS OUT OF SERVICE. THERE MAS
ALSO A BOlLFR IRIP (Hl-LU FURNACE PRESSUKE THlK).
JULY 78 71« 7^6 7aa 58J 5«J
AVAILABILITY = 1001
RELIABILITY = lUOt
OPEHArtlLlTY - Hot
UTILIZATION r 781
LOR VLNTUKI FLOH CAUSED UNe OF THHfcF SCHEnULEO FGI) OUTAGES. THIS MAS CORHECTFO HHEN THF
NOZZLES UN THF RACh TRACK "FkE CLEANED. ANOTHER OUTAGE OCCURKEO MHEN AN INSPECTION OF THE
VENTUW1 IANK AND RACE IKACK «AS REUUIREO. THE TANK ANO MACE TKACK NOZ/LES MERE CLEANED AND
THE MUHHER LINING ON THE VENTUCI SPOOL MAS REPLACED. A THIRD OUTAGE MAS REOUIKEU TO CLEAN
THE VFfcTllRI kACE TnACK. A SCHfcUIILtO OUTAGE. WHICH HAS N01 FGD SYSTEM RELATED. TO CLEAN THE
TIIMBINt LUHt OIL CuOLfRS ALSO UCLUrfDEO DURING JULY.
AUG. 78 70
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FPA UTILITY F(,t> SURVEY: AUf.uST 1978 - SEPTEMREH 1978
SECTION 3
PERFORMANCE DESCRIPTION FOR OPERATIONAL Fr,o SYSTEMS
UTILITY NAME
UNIT NAMF.
UNIT LOCATION
UNIT RATING
NORTHERN INDIANA PIIH SFUVICE
DEAN n. MIUHEIL It
GARY INDIANA
IIS >.«
FUEL CHARACTERISTICS COAL; 3.SZ bDLFuR, 101 ASH
FSO VENDOR
PROCF.SS
NEM OR RETROFIT
STAHT UP DATE
FFFICIFNCY:
PAHTICIILATES (ACTllAI )
(UFSIbfl)
S02 (ACTUAL)
(DESIGN)
WATER MAKE UP
SLUDGE DISPOSAL
OAVY POwEhliAS
"fcLLMAN LORtJ
RETROFIT
11/76
90.S PERCENT
99.5 PERCENT
91.0 PERCENT
9<1.0 PtKCFNT
CLOSFO LOOP
ELEMENTAL SULFUR PRODUCT
OPERATING EXPERIENCE UPUATE:
MONTH
HOURS
IN PERIOD
HOURS
AVAILABLE
HOURS
CALLED ON
TO OPERAIF
HOURS
OPERATED
AVAILABILITY RELIABILITY UTILIZATION
NOV. 77 720 531 596 Ola in 72 90
THE FGD UNIT OPERATED FOR IB CONSECUTIVE DAYS, AVERAGING 90S S02 REMOVAL HITH 285 LONG TONS OF
SULFUR RECOVERED. FGD OPERATION WAS INTFKRUPTEU UY A UNIT 11 BOILER TUBE LEAK AND HESUMPTION OF FGD
OPERATION WAS FURTHER DELAYED BY MAINTENANCE IN THE EVAPORATOR SECTION. MAINTENANCE MAS ALSO PER-
FORMED ON THE FLUE GAS ISOLATION DAMPER, FLUE GAS BOOSTER RLOWEh, AND SO? REDUCTION SECTION.
DEC. 77 768 379 272 0 19 0 0
THE F6D SYSTEM WAS NOT OPERATED DURING THIS PERIOD DUE TO ABNORMAL BOILER OPERATING CONDITONS
RELATED TO HIGH SILICA LEVELS IN THE FEED HATER. THE HIGH SILICA LEVELS RSULTED FROM HIGH MAKE-UP
WATER REQUIREMENTS DUE IN PART TO A HIGHER IHAN NURMAL FGD PLANT USAGE, AS HELL AS UNIT 11 COAL FEED
PROBLEMS AND A PRECIPITATOR MAI FUNCTION. MAINTENANCE WAS PERFORMED ON THt FG BOOSTER BLOhER AND
THE ABSORBER SOLUTION REGENERATION SECTION.
JAN. 78 720 576 0 0 80 0
THE FGD SYSTEM REMAINED DOWN THROUGHOUT JANUARY AS HIGH SILICA LEVELS IN THE UNIT 11 BOILER FEED
WATER PERSISTED. MAINTENANCE WAS PERFORMED ON THE UNIT 11 PRECIPITATOR. THE FG BOOSTER BLOWER AND
THE FGD SYSTEM S02 COMPRESSOR.
FEB. 78 720 336 0 0 17 0
THE FGD SYSTEM WAS NOT OPERATED DUE TO ABNORMAL BOILER OPERATING CONDITIONS RELATED TO HIGH SILICA
LEVELS IN THE BOILER FEED WATtR, COUPLED WITH UNIT 11 COAL FEED PROBLEMS. STOP VALVE PROBLEMS, PRE-
CIPITATOR MALFUNCTION AND A LEAKING BOILER TUBE AND WORK UN THE FLUE GAS ISOLATION DAMPER. MAIN-
TENANCE WAS ALSO PERFORMED ON THE FG BOOSTER BLOWER, THE EVAPORATOR CIRCULATING PUMP AND THE S02
SUPERHEATER PIPING.
MAR. 78 720 608 281 215 90 77 30
THE F60 SYSTEM OPERATED FOR TEN DAYS. OPERATION WAS INTERRUPTED BY SHUTDOWN OF THE UNIT 11 BOILER
FOR REPAIR OF COAL GRINDING MILLS AND PRECIPITATOKS. PROPER CONDITIONS COULD NOT BE RE-ESTABLISHED
FOR RE-START OF FGD OPERATION BECAUSE OF COAL FEED AND GRINDING PROBLEMS CAUSED BY EXTREMELY POUR
QUALITY COAL. MAINTENANCE WAS PERFORMED ON THE BOOSTER BLOWER AND OPERATING PROBLEMS WERE
ENCOUNTERED WITH THE FLUE GAS ISOLATION DAMPER.
57
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EPA UTILITY FUD SURVEY: AUGUST l<»78 - SEPTEMBER 1978
INUIANA PIIHLIC St*M bl 50 37
THF SO? RECOVERY PORTION UF THE FGD SYS1FM OPERATED FOR ?b DAYS. THE COMPLETE FGD SYSTEM OPERATED
FOR 11 DAYS. OPEHATION WAS INTERRUPTED BY FAILURb OF THK FLUE GAS ISOLATION UAMPER, PROBLEMS WITH
WET COAL WHICH rtEjUIRED THAT THF UNIT II UOILER OPERATE UN LOW SULFOR CUAL FOh A SHORT PERIOD AND
PLUGGING OF AN ENTSAINM^I SEPARATOR IN THF soa REDUCTION UNIT.
JUNE 76 7£Q 97 b?l 3 13 1 0
OPERATION OF I Ht FRO SYSTEM WAS I IM|TH> BY FARURb UF THE BOOSTER BLOnEH DRIVE TURBINE AND
INABILITY OF THE ISOLATION UAMPER TO uPtRATE. THE FGO PROCESS FACILITIES, CONSISTING OF THE
AHSORBEHt EVAPORATOR, SO? REDUCTION ANO PORGf TRFATMENT UNITS, nEHF AVAILABLE FOR OPERATION FOR
ESSENTIALLY THE ENURt PfRlOO.
JULY 71 7^0 0< 413 17 b « Z
OPERATION OF THt FGU SYSTbM KAS LIMITED BY IMBALANCE OF THE BOOSTER BLOHEH. OUE TO INABILITY
OF THE ISOLATION UAMPER To OPERATE, Tr-IS CONDITION COULD NO I HE CORRECTED UNTIL POWER DEMANDS
PERMITTED A Shill OOwN OF UNIT 11 tUULER. RtCURRlNG FLUCTUATIONS IN THE PRESSURE OF THE MAIN
STEAM SUPPLY TO THE FGD STSTFH ALSO LIMITED OPERATION. FLHE GAS BOOSTER bLnwER PROBLEMS INCLUDED
LOW OIL PRESSURE, LEAKING BMKTNG OIL SEALS AND DRIVE TURBINE GOVERNOR MALFUNCTION. THE FGO
PROCESS FACILITIES WERF AVAILABLE FOR O^EKATIUN FUR THE ENTIRE PERTOD.
AUG. 78 7i?0 7U7 7^0 707 98 96 98
THE UNIT 11 BOILER OPERATED CONTINOOUSLY ON HIGH SULFOR COAL THROUGHOUT THE PERIOD. THE FGD SYSTEM
ACHIEVED FULL OPERATION ON m FIRST DAY OF THE PERIOD. AFTER PROBLEMS WITH THE BOOSTER BLOWER
WERE CORRECTED, II REMAINED IN FULL OPERATION FUR THE BALANCE OF THE PERIOD WITH THE EXCEPTION OF
ONF TWO-HOUR 1NTERRUPIIUN DUE TO AN ELECTRICAL HO I OH MALFUNCTION.
SEP. 78 780 319 331 319 HI 99 44
THE UNIT II BOILER OPERATED ON HIGH SULFUR COAL UNTIL SEPTEMBER IZ WHEN IT WAS SHUT-DOWN FOR AN
ANNUAL OVERHAUL. THE BOILER REMAINED DOWN THROUGH THE END OF THE PERIOD. THE FGO SYSTEM CONTIN-
UED IN FULL OPERATION UNTIL SEPTEMBER 18, WITH THE EXCEPTION OF ONE TWO-HOUR INTERRUPTION DUE TO A
GOVERNOR MALFUNCTION UN THE so? COMPRESSOR DRIVE TURBINE, AND WAS THEN SHUT-DOWN CONCURRENTLY WITH
THE UNIT 11 BOILER.
-------
EPA UTILITY FGf) SURVEY: AUGUST |9fB - SEPTFHHtH 1978
SECTION J
PFHFORMANCt DESCRIPTION FOR OPERATIONAL FRO SYSTEM^
UIKITY NAMfc NURlHtKn STATfcS Pu«t»
UNIT NAMF SHK.RBURNF i
"NIT LOCATION RECKEh MINNESOTA
UNIT HATING 710 Kn
FUEL CHARACTERISTICS CUAL: 0.8X SULFUR, S.5Z SlJLHIM
FGO VENDOR CUMiJIISTION INGlNEkRINU
PKOCFSS LlMtSIONE/ALKAI.lNt HYASH
NtW OR ktlWUFIT NtA
START UP HAIE J/7b
FFFICIFNCY:
PARTICULATES (ACTUAL) 99* PERCENT
(DESIGN) 94.0 PERCENT
S02 (ACTUAL) 50-55 PEkCENT
(CiFStbNJ 50.0 PEkCENT
HATtR MAKt UP OPEN LOUP 1.13 bPM/Mh
SLUOGfc DISPOSAL FORCIBLY OX10I?en/SLUUGE PONH
OPFKATING EXPbRIF.NCb UPOAIE:
40ILFH UPtRATION TIME AND MUDULt UPEHAHIL1TY IX)
HOILfR
PERIOD HR. 101 102 103 100 105 106 107 108 109 111) 111 112
Ft*). 7* 63b 0 Qj 92 89 71 R5 19 88 7b Bb 88 67
TOTAL SYSTEM AVAILABILITY = 92 PERCENT
MEGA«ATT-HOU«b 6ENEHATEU = 3bh,?00
MODULE 101 HAS DOWN IN FEBRUARY FUR MUOIFICATIONS TO THfc SPHAY TO«Ek AHSORRF". A BULK
ENTRAINMENT SEPARATOR MAS INSTALLED ALONG nlTH A KOCH NASH TRAY. SPRAT NOZlLtS HERE
REPLACED. THE 2 IN. UTA. SS hOUS IN IHE PRIMARY CHNTACTOH isEKF REPLACED «ITH 6(5/8) IN. HIA.
CERAMIC COATEU C.b. RODS. TMt CFRAMlC blEtVEJ) ARE 9/16IN. THICK. MOOULFS BHICM ARE SMUHING
AVAILABILITY OF LESS THAN 80 PENCENT, AkE THOiE IN MHICH THt bTHAJNfcH MODIFICATIONS NERt
PERFORMED.
MAR. 7« 676 71 «i 64 89 90 83 62 89 97 71 79 90
TOTAL SYSTEM AVAILABILITY = 92 PERCENT
MEGAWATT-HOURS GENERATED = 023,220
STRAINER MOUIFICATIONS CONTINUED THROUGH MARCH AFFFCTING THt AVAILABILITIES OF MODULES 101,
103, 107 AND 110.
APR. 78 713 92 87 87 «« 81 8b •>! 86 92 <>1 87 52
TOTAL SYSTEM AVAILABILITY = 95 PERCENT
MEGAMATT-HOURS GENERATED = aba,520
IHE REASON FOR LOB AVAILABILITY ON MOOULF 100 AND 112 IN APRIL RESULTED FORM THE OUTAGE TIME
NECESSARY FOR THF INSTALLATION OF STEEL STRAINER SCREENS.
MAY 78 635 61 8b 85 86 89 6a 62 83 82 71 87 79
TOTAL SYSTEM AVAILABILITY = 9b PERCENT
MEGAWATT-HOURS GENERATED = sao.oio
THERE MERE NO MAJOR FGD RELATED OUTAGES DURING MAY.
JUNE 78 717 50 8a 85 85 62 78 55 83 88 82 78 95
TOTAL SYSTEM AVAILABILITY = 93 PERCENT
MEGAMATT-HOURS GENERATED = aia,670
59
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EP» UTILITY FGD SURVEY: AUGUST 1978 - StPfFMBEB 1978
NORTHERN STATtS POKER
SHEKHURNF
HUlLF.rt OPERATION TIME AND MODULE UPtRARRITY (X)
BOILER
PERIOD HM. 101 102 103 I»« 1 OS 1 Ob 107 108 109 111) 111
52 7b 64 b2 72 bb
73
JULY 78 b9u 82 7b 71 7 <. 7*j 52 7b 64 b2 7c
TOTAL SYSTEM AVAILABILITY = 9b PFNCENT
MEGAMATT-HOIIRS GENFWATEO = 390,blO
THF UTILITY IS IN THE PROCESS DF REMOVING THE ORIGINAL 2IIRN DUPLEX STRAINERS AND REPLACING
THEM nITH ?lb STAINLESS STFEL STRAINF.HS. THE OCCUHANCE OF PLUGGING PROBLEMS IN THE MIST
ELIMINATOR AND HI-HEATER HAS AEEN MORE FHEUIIEMT THAN NORMAL. THE UTILITY is EVALUATING NEn
RUHPF." LINED HUMPS (8uOu GPMl AND SIAINLFSS STEEL MIST ELIMINATOR "ASH LANCES (TO REPLACE
ORIGINAL i-lHFHGLAS LANCtS}. THE Fr.li SYSTEM HAS AkEN EXPERIENCING PRIMARY CONTACTOR MALL AND
MARHLE MED AEAH. THE UTILITY IS PREPARING FOR THE STATE COMPLIANCE DEADLINE ON NOV. 1.
CURRENTLY TtSllUG HAS BEFN PRUCEEUlNG ON iHKFtRfcNT MODULES IN AN EFFORT TO FINE TUNE THE
SYSTEM.
f>3
Bl
AUG. 7H /a^ bO bb 73
TOTAL SYSTFM AVAILABILITY = 91
MEGAWATT-HOURS GENERATED = «i6,93o
NO MAJOrf FGl) RELATED OUTAGES »FKE REPORTED HY THE UTRI1Y FUR THF MONTH OF AUGUST.
bfl
fert
8U
SEP. 78 3S7 89 b2 77 77 SB »,"
TOTAL SYSTEM AVAILABILITY = 97 PERCENT
MbCAAATT-HOURS bENFMATED = !8S,7aO
I HE HUlcEfi IAS TAKIN UOnN OH SEPTEMBER IS FUR A SCHEDULED ANNUAL BOILER AND TURBINE INSPEC-
TION. THIS IS EXPECTED TO LAST THROUGH OCTOBER Ib.
COMPLIANCE DEADLINE BE MOVED UP FROM NOVEMBER 1.
RUBBER LIMED HUMPS THAT THE UITLIIY HAS INVESTIGATING AS POSSIBLE SULUTIONS TO THE MIST
ELIMINATOR AND REHEATER PLUGGING PROBLEMS HAVE BEEN ORDERED. FOUR OF THE PUMPS HAVE BEEN
rfECETVED ANU ONE IS INSTALLED. THF OIHERS ft ILL Ht INSTALLED AS THEY COME IN. DIFFERENT
MIST ELIMINATOR SPRAY PATTERNS ARE ALSO BEING TESTED.
UTIIITY HAS ASKED THAT THE STATE
THF DECISION IS CURRENTLY PENDING. THE
60
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EPA UTILITY FGO SURVEY: »UGUST 1978 - SEPTEMBER 1978
SECTION *
PFRFOR^ANCt DESCRIPTION FOR OPERATIONAL FGU SrsUM;,
NAME NORIMbPN STATES PUnER
UNIT NAME ShEWbUMNE 2
UNIT LOCATION HECKFR MINNISOT*
UNIT HA] ING 710 Kft
FllFL LHARACIERISTICS COAL: 0.81 SULFUR, 9.bZ ASH
FGO VENOOK COMBUSTION I NGIhFtP INb
PROCFSS L IMESTONE/ALKALINt FLTAbH
Nbn OR RETROFIT Nfcn
START Ur> DATE 0/77
EFFICIENCY:
HAHTICULATtS (ACTUAL) 5«-Sb PERCENT
(DESIGN) 99.0 PtRCFNT
S02 (ACTUAL) 55.0 PERCENT
(DESIGN) bO.O PERCENT
HATER MAKE UP OPEN LOOP 1.15 bPM/Mtt
SLUDGE DISPOSAL FUHCIBLT OXIOIZED/SLUOGE POND
OPERATING EXPERIENCE UPDATE:
MU1LEK OPERATION TIME AND MUOULE UPERABILITY (X)
BOILER
PERIOD HR. 201 £08 £03 200 *OS 206 207 208 209 310 211 212
FEB. 7" 620 83 8b 55 91 A9 76 71 H9 85 81 97 60
TOTAL SYSTEM AVAILABILITY = 92 PERCENT
MEGAWATT-HOURS GENERATED = 367,080
MODULES 203 AND 212 HAVE LOW AVAILABILITY DUE TO STRAINER MODIFICATIONS.
MAR. 78 7411 82 92 9u 83 78 flb 91 62 B3 7» 80 89
TUTAL SYSTEM AVAILABILITY = 97 PERCENT
MEGANATT-HdURS GENERATED = ««3, 750
IN SPITE OF STRAINER MODIFICATIONS ON MODULES 208 AND 210, THE SYSTEM GENERATED MAXIMUM
MEGAMATT-HOURS AND TIED THE HIGHEST RECORDED AVAILABILITY OF 97 PERCENT.
APR. 78 719 70 82 90 80 91 83 80 86 78 90 67 85
TOTAL SYSTEM AVAILABILITY = 92 PEKCENI
MEGAMATT-HOURS GENERATED = 036,020
DURING APMIL MODULE aoi HAS CONVERTED FOR USE HITH THE NEN SPNAT TONER WHICH HAS INSTALLED.
MAY 78 120 97 90 80 90 90 89 90 92 28 91 78 10
TUTAL SYSTEM AVAILABILITY = 91 PERCENT
MEGAWATT-HOURS GENERATED = 70>070
THERE MLRE LINER FAILURES CCEILCOTE) IN MOST OF THE MODULES DURING MAY. THE LINERS HERE
REPAIRED BY THE CULCOTE COMPANY AT THEIR OHN EXPENSE. THE INLET SEAL STRIPS MERE ALSO
REPAIRED. THE UNIT HENT DO«N ON MAY 6 FOR THE FIRST YEAR HOILEM AND TURBINE INSPECTION AND
HAS DOWN FOH THE REMAINDER OF THE PERIOD.
JUNE 78 572 77 06 01 67 62 62 72 78 60 62 76 75
TOTAL SYSTEM AVAILABILITY = 95 PERCENT
MEGAHATT-HOURS GENERATED = 326, 730
61
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FPA UTILITY FGD SURVEY: AUGUST 19/fl - SEPTEMBER 1970
NORTHERN STATES POKtR
SHFxRllHNE 2
BOILER
PFRIOD HR. 201
OPE HA II ON TIMF AND MODULE UPERARIL1TY (X)
202 203 204 205 20b 207 206 209
86
b4
210
«l
211 212
73
7t
JULY 7« b97 «7 H9 b2 93 90 b«
TOTAL SYSTEM AVAILABILITY = 9s PERCENT
MEGAMATT-HOURS GENERATED = 393,MO
THE IIIILI'Y IS IN THE PROCESS OF REMOVING THE ORIGINAL ZURN DUPLEX STRAINERS ANU REPLACING
THEM WITH 31b STAINLESS STEEL STRAINFRS. THE OCCURANCE OF PLUGGING PROBLEMS IN THE MIST
ELIMINATOR AND RFHEATER HAS BtFfJ MORE FKFOUEM THAN NORMAL. THt UTILITY IS EVALUATING NEW
RURBEK LINFD PUMPS <«o<>u GPM) AND STAINLESS STEEL MIST ELIMINATOR HASH LANCES do REPLACE
ORIGINAL FIBERGLAS LANCES). I HE FGU SYSTEM HAS BEEN EXPERIENCING PRIMARY CONTACTOR HALL AND
MARdLE BED ftEAR. TriE UTIltTV 13 PREPARING FOR THE STATE CUMPLIANCF DEADLINE ON NOV. 1.
CURRENTLY, IESTING nAS BEEN PhOCEtOING ON DIFFERENT PuDULES IN AN EFFORT TO FINE TUNE THE
SYSTEM.
AUG. 78 b<*S 88 100 48 79 «1
TOTAL SYSTEM AVAILABILITY : 93 PERCENT
MEGAWATT-HOURS &ENFRATEU = js«,aoo
72
ba
flef
72
7b
78
80
82
71
bB
SEP. 78 720 72 82 70 bl 74 hfl
TOTAL SYSTEM AVAILABILITY = 9b PERCENT
MEGAWATT-HOURS GE.VFRAIEO = 39b,?>00
NO FGLs RELATED OUTAGES HERE RtPURTFO HY THF UTILITY FOR THF AUGUST-SEPTEMBER REPORT PERIOD.
THE UTILITY HAS ASKED THAT THE STATE COMPLIANCE TEST BE MOVED IIP FROM NOVEMBER 1. A DECI-
SION IS STILL PENDING. THE RuBBtk LINED PUMPS THAT THE UTILITY HAS INVESTIGATING AS POS-
SIBLE SOLUTIONS TO THE MIST ELIMINATOR ANU REHEATER PLUGGING PROBLEMS HAVE BEEN ORDERED.
FOUR OF THE PUMPS HAVE BEEN RECEIVED AND ONE IS INSTALLED. THE OTHERS "ILL BE INSTALLED AS
THEY ARE RECEIVtO. DIFt-FKENT MIST ELIMINATOR SPRAY PATTERNS ARE ALSO BEING TESTED.
62
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EPA uTturrr FGO SIIRVFY: AUGUST 19/8 • SEPTFHBER 1978
SECTION 5
pERFo»MANCt DESCRIPTION HIK IRRATIONAL FGU SYSTEMS
UTILITY NAME
UNIT NAME
UNIT LOCATION
UNIT HATING
FUEL CHAWACTFKISTics COAL: 4.71 SULFUR, 12,sx ASH
PENNSYLVANIA POftFk
BHUCF MANSFIELD i
SHTPPlNbPORI PENNSYLVANIA
F6D VENUIIK
PROCFSS
NEW OH RFTROFIT
START IIP DATF
EFF ICIFNCY:
PARTICULATES (ACTUAL)
(DESIGN)
802 (ACTUAL)
(DESIGN)
MATEH MAKE UP
SLUDGE DISPOSAL
CMEMICO
LIME
NtH
a/7b
so.-* PERCENT
99.« PtrtCENT
9S.O PfcRCENI
9?.J PtRLENT
OPtw LOOP
STAHILI/EU/LANDFILL
OPERATING EXPERIENCE UPDATE:
MONTH
aoiLER
OPERATING HOURS
FGD MOPULES
R C I)
NOV. 77 720 602 713 6S7 000
FGD AVAILABILITY FACTOR x <»5 <"> <»i o o o
FGO OPEHARILITY FACTOR X 95 99 91 0 0 0
FGO UTILIZATION FACTOR I 95 9V 91 0 0 0
TOTAL FGD LOSI GENERAIIUN FACTOR = 52.sx
REMOVAL OF THE OLD COATING AND PMlMING OF THt FLUE LINING IN FLUE IB IS PROCEEDING
SLOHER THAN ANUCJPATFU. IT is EXPFCTED THAT TOIAL NOMK ON THE FLUE HILL NOT ee
UNTIL FEdRUANY Ort MARCH J97H.
DEC. 77 fc,>6* 6/7 59^ 67S 0 0
FGD AVAILABILITY FACTOR x loo 93 99 o o
FGD OPERABILITY FACTOR X 100 9« 100 0 0
FGD UTILIZATION FACTOR X 91 79 91 0 0
TOTAL FGD LOSt GENERATION FACTOR = 61 X
SANDBLASTING OF UNIT 1-B FLUE IS HEARING COMPLETION.
CXL-20VO.
JAN. 78 331* 433 0 a32 0 0
FGD AVAILABILITY FACTOR X 100 0 100 0 0
FGD OPERABILITY FACIOU X 100 0 100 0 0
FGO UTILIZATION FACTOR 58 0 58 0 0
TOTAL FGD LOST GENERATION FACTOR = 60X
THE FLUE HILL BE RELINED HITH
THERE HERE PROBLEMS NtTH IB FAN nHICH NFCCESITATEO EXTENSIVF REPAIRS. LINING ABRASION AND
OISBONOMENT IN FAN CAUSED CORROSION OF UNDERLYING SUPPORT METAL. THE UNIT TRIPPED SEVERAL
TIMES DUE TO DIFFICULTIES IN BURNING MET STOCKPILE COAL.
FEB. 78 514* 534
FGD AVAILABILITY FACTOR X 79
F60 OPERABILITY FACTOR X 100
F6D UTILIZATION FACTOR X 79
TOTAL FGD LOST GENERATION FACTOR
410 SSI 0 00
61 B2 0 00
80 100 000
61 8? 0 00
= b4X
EXTENSIVE REPAIRS TO IB 1.0. FAN AND THE EMERGENCY NEED FOR LOAD FROM THE PLANT DURING THE
COAL STRIKE TEMPORARILY OVERLOADED 1A AND 1C TKAINS. THE MIST ELIMINATOR «ILL BE REPLACED ON
1C TRAIN AS A RESULT OF THIS. IB FLUE RELINING CONTINUES.
-------
EPA UTILITY FtiO SURVEY: AUGUST 19f8 - SEPTEMBER 197H
PENNSYLVANIA PDnEK
HHIICE MANSFULU i
MUNTH
BOILER
OPERATING HUURS
H C 0
01
98
f>70
90
97
48b
10
376
SO
SO
50
449
60
65
bO
HAH. 78 689 Va
FGO AVAILABILITY FACTUR * a*
FGO OPERABILITY FACTOR X 47
FGD UTILIZATION FACIOrf X O3 91
TUTAL FGO LOST GENERATION FACTOR = box
REPLACEMENT uF TnF LINING IN 1H CHIMNEY nllH CXL ?000 *A3 COMPLETED.
A. B, AND C FAN HOUSINGS.
APR. 78 780 biO 6*2 5b7 630 6*7 678
FGO AVAILABILITY FACTOR X 70 8« O9 H7 97 9O
FGO OPERAblLITY FACT OH X 70 88 <<9 87 97 94
FGft UTILIZATION FACTOR X 70 80 09 8/ 9/ 90
TOTAL FGD LOST GENERATIUN FACTOH = 181
MISCELLANEOUS LEAK REPAIRS HERE UONf ON FAN HOUSINGS AND DUCTS.
HF.PAIHS HERE DONb UN
MAY 78 457 04? 0 44)3
FGO AVAILABILITY FACTOR I 98 0 98
FGO OPFRA81LITV FACTOR X 97 0 97
FGO UTILIZATTUN FACTOR I 59 0 S9
TOTAL FGO LUST GENEHATIUN FACTO* = dix
EXTENSIVE RFPAIRS AEXE MADE ut< THE it>
JUNE 78 o o o »
FGO AVAILABILITY FACTUR 10 0 100
FGD OHERAHILITY FACTOH X 0 0 0
FGD IITILIJATJUN FACTOR x o o o
389
91
85
Si
394
9£
80
Si
92
86
ANNUAL 40TLER INSPECTION OUTAGE bFGAN UN MAY 2(1.
o
100
0
&
u
100
0
o
o
100
0
o
TOTAL FGD LOST GENERATION FACTOR = ox
UNIT OUTAGE TIME HAS FUR HUILEK INSPECTION AND GENERATOR STATDK COOLER REPAIRS.
•NOTE: AN ATTEMPT 15 AL«AYS MAOF TO RI-GIN OPFHAIIUN OF THE BOILER AND FGD SYSTEM SIMULTANEOUSLY AT
BRUCE MANSFIELD. OCCASIONALLY HHObl fcMb DELAY BOILER STAKT-UP MAKING IT POSSIBLE FOR MONTHLY
t-GD MODULE HUUKS TO EXCEED ACTUAL ttOJLtR HOURS.
60
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FCA UTILITY FGO SuRVFV: AUGUST 197* - StPTEMBER 1978
bFCTION 3
PFRFURMANCt OESCKIPTION FOM UPfcRATlflN*L FGO
UTILITY
UNIT fcAMt
UNIT LOCATTUN
UNIT HATING
PfNMSYI VAMA POfiFk
flKUCl MANSFJtLD ?
SMIPHINGPURT
B21) M»
FUFL CHARACTEWISUCS COAL; 1.7X iULFlIP, 12. SX ASM
FUD VtNOOR CHEMICO
PROCESS LIMt
NE» IK RETROFIT NEW
START UP DATF 7/77
FFFJCIENCY:
PARTICULARS (ACTUAL) 99.9 PERCENT
302
(DESIGN) 99.6 PERCENT
(ACTUAL) 95. U PERCENT
(DESIGN) 9a.i PERCENT
MAKE UP OPFN LOOP
SLUDGE DISPOSAL STABILIZED/LANDFILL
OPERATING EXPERIENCE UPDATE:
MONTH
BORER
OPERATING HOURS
FGU MDDULFb
BCD
NOV. 77 581* 598
FGD AVAILABILITY FACTOR Z 100
FGD OPERABILITY FACTOR X 100
FGO UTILIZATION FACTOR X t»3
TOTAL FGD LOST GENERATION FACTOR
584
96
100
81
= 271
533
an
9a
71
331
07
57
46
304
55
52
42
246
47
42
34
PROBLEMS ASSOCIATED nlTH THE STATION POHEB TRANSFORMERS CAUSED LIMITATION IN LOAD ON UNIT 2.
THREE OF THE SIX STATION TRANSFORMERS FOR UNIT 2 *ERE DESTROYED.
DEC. 77 607* 469 63B 618 644 513 565
FGD AVAILABILITY FACTOR x 74 99 98 100 89 99
FGD OPERABILITY FACTOR X 77 100 100 100 85 93
FGO UTILIZATION FACTOR X 63 86 83 86 69 76
TOTAL FGD LOST GENERATION FACTOR = 7.4X
COLO HEATHER CREATED SOME FREEZING PROBLEMS rtlTH PROCESS PIPING.
JAN. 78 391* 228 564 218 521 481 375
FGD AVAILABILITY FACTOR z 95 100 96 94 99 99
FGO OPEHAUILITY FACTOR Z 58 100 56 100 100 96
FGD UTILIZATION FACTOR Z 31 76 29 70 64 50
TOTAL FGD LOST GENERATION FACTOR = 4.3Z
UNIT TRIPPED SEVERAL TIMES DUE TO DIFFICULTIES IN BURNING MET STOCKPILE COAL. BOILER
CONTROL VALVE PROBLEMS ("K" VALVE) COMPOUNDED START-UP ATTEMPT DIFFICULTIES. "HEN THE UNIT
HAS ON LINE DURING THIS MONTH, THE MET COAL ALSO PREVENTED FULL LOAD OPERATION OF
COAL MILLS.
FEB. 78 672 321 460 594 480 664 525
FGD AVAILABILITY FACTOR z 84 87 89 97 99 78
FGD OPERAblLITY FACTOR Z 46 66 88 71 99 78
FGO UTILIZATION FACTOR Z 48 68 88 71 99 78
TOTAL FGD LOST GENERATION FACTOR = 18.6 Z
MANY PROBLEMS OCCURRED HITH I.D. FAN COOLERS DUE TO INCLEMENT HEATHER.
65
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EPA UTILITY FGO SURVE*: AUGUST J97B - SEPIEMRfcR 197(1
PENNSYLVANIA POnEK
MONTH
BOILfcR
OPERATING MOUHS
FGO MODULES
c D E
96
509
95
inu
474
95
9b
64
MAR. 7H 494* 502 449
FGD AVAILABILITY FACTOR X 100 9} IS
FGD OPFRAHIL1TY FACIOK X 100 91 10
FGO UTILIZATION FACTOR X 67 hi) 13
TOTAL FGO LOST GENERATION FACTOR = 28X
A BOILER TUBE LEAK CAUSED AN OuTAGF FOK SEVERAL DAYS.
nfxf. PERFORMED ON THE ^t FAN.
APR. 78 713 58) 583 484 108 101
FGD AVAILABILITY FACTuR X 100 100 59 15 14
FGD OPERABILITV FACTOR X 82 «2 59 15 14
FtiO UTILIZATION FACTOR X 81 HI 59 15 14
PRIICF
487
97
99
65
EXTENSIVE I.I). FAN HOUSING REPAIRS
96
13
IS
13
TOTAL FGD LOST GENERA11UN FACTOR = 3AX
^B CHIMNEY FLUt LINING REPAIRS HEGAN ON APRIL 5. EXTENSIVE REPAIRS MERE DONE ON THE it
FAN. i HE UN MAS DO*N FROM MARCH 6 THROUGH APRIL 1 3.
I.D.
MAY 78 270* ?76 i>7(< 276
FGD AVAILABILITY FACTOR X 100 100 100
FliD OPERAHILITY FACTOR X 100 100 100
FGO UTILIZATION FACTOR X 37 M 37
TOTAL FGO LOSI GENERAIIUN FACTOR = 81X
2H STACK FLUE LINING REPAIRS CONTINUED.
THE UNIT MAS OFF-LINE FOR 3 WEEKS FOR REPAIRS TO
THE 2C 1.0. FAN. THE FAN HOUSING MAS CLAD HITH INCOLOY
JUNE 70 417* 502 501 47A
FGD AVAILABILITY FACTOR X 70 69 66
FGD OPERAB1LITY FACTOR X 100 100 100
FGD UTILIZATION FACIOK X 70 69 66
TOTAL FGD LUST GENERATION FACTOR = 66X
2B FLUE LINING REPAIRS CONTINUED.
•NOTE: AN ATTEMPT is ALWAYS MADE TO Rt&iN OPERATION OF THE BOILER AND FGD SYSTEM SIMULTANEOUSLY AT
BRUCE MANSFIELD. OCCASIONALLY PROBLEMS DELAY BOILER START-UP MAKING IT POSSIBLE FOR MONTHLY
FGO MODULE HOUKS TO EXCEED ACTUAL hOILER HOURS.
66
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EH* uiiLity FGD SURVEY: »UGUSI i9?n - SEPTEMBER 1978
SECTION 4
PF.HFORMANO DESCRIPTION KOR OPERATIONAL FGU SVSU.MS
UTILITY NA-E
UNIT NAMF
UMT LOCATION
UNIT MATING
PHILADELPHIA fclECTHIC
fOOYSTONE 1A
FDDYSIONE PENNSYLVANIA
120 HN
FUEL CHARACTERISTICS COAL: 2.5X SULFUR. 101 ASH
FGO VFNOOW UMTFD ENGINEERS
PROCFSS MAGNESIUM OXUE
NEW OK HFTRUFI1 WtlHdFIl
START IIP DA IF 9/7S
FFFICIFNCY:
••ARTICULATES (ACTUAl ) 99.4 PERCENT
(DESIGN) «*9.9 PfcRCENT
503 (ACTUAL) 95-97 PEKCfcNT
(DESIGN) 90.0 PERCENT
MATER MAKE UP OPEN LOOP 1.1 GPM/Mw
SLUDGE DISPOSAL ACIU PLANT REGENERATION
OPERATING EXPERIENCE UPUATf:
FEH. 78
MAR. 7«
APR. 78
MAT 78
JUNE 7R
JULY 78
MONTH
AUG. 76
SEP. 78
TMF TuRBINF OVFRHAIIL CONTINUED DURING THE REPORT PERIOD. DURING THE SHUTDOWN PERIOD IT
NAS FOUND THAT SOME HIGH PRESbUHf STEAM TUBES MERE CRACKEU, SO UNIT MAINTENANCE HAS TAKEN
LONGER THAN EXPECTED. SO*E MlNuR FGO SYSTEM MODIFICATIONS HAVE BEEN INCORPORATED IN THE
COURSE OF THE SHUTDOWN PERlUO. START UP IS EXPECTED IN MID-APRIL 78.
THE UNIT JUST CAMt HACK ON LINF JUNt 1 AFTER AN EXTENSIVE SYSTEM MODIFICATION OUTAGE
WHICH BEGAN OECEMBFK 2?. THE UNIT HAS EXPECTED BACK ON LINE IN MID-APRIL. BUT THERE MAS
A PROBLEM WITH A SUPErf PRESSURE STEAM TURBINE.
DURINb JUNE THE SCRUBfcFR-AHSORHtR SYSTEM ACHIEVED A
-------
EPA UTILITY FGD SURVEY: AUGUST I»7fl - SEPTFMBfcB 197H
SECTION J
PERFORMANCE DESCRIPTION FOR OPERATIONAL FGD SYSTEMS
UTILITY NAME PUBLIC SERVICE OF NEft ME*ICO
UNIT NAME SAN JUAN 1
UNIT LOCATION KATERFIUH Nt" MEXICO
UNIT MATING ilt Mr.
FUEL CHARACTERISTICS CUAL; O.HI SULFUR, am ASH
FGO VENDOR OAVT PPnEKGAS
PROCESS HfcLLMAN LORD
NED OR KE1ROFIT NE«
START UP DAfF 0/7R
EFFICIENCY:
PARTICIPATES (ACTUAL)
(DESIGN) 99.fl PERCENT
502 (ACTUAL)
(UESII.N) 85.0 PbRLf-NT
MATER MAKE UP CLOitU LOOP 1 .Si bPM/MH
SLUDGE DISPOSAL ELEMENTAL SULFIIH PRODUCT
OPFRATING EXPERIENCE UPDATE:
FEBRUARY-MARCH 1970 - INITIAL SOS AHSUHPTION AT SAN JUAN NO. 1 BEGAN ON APRIL B, 1478. FULL COMMER-
CIAL OPERATION IS EXPECTED BY LATE JUNE. THE FGD SYSIFM IS CURRENTLY IN SERVICE WITH TuO OF THt
UNIT'S t-OUf AbSURBER CELLS OPEKATINb CONTINUOUSLY. A THIKI) CELL IS TO BF BROUGHT ON LINE LATER.
THREE CELLS MILL OE REUUIKFD KOR FULL LOAD HITH A FOURTH INCLUDED FUR SPARE FGD CAPACITY. THE CUR-
RENT MODE is TO KEEP 2 CELLS IN SERVICE AT ALL IIMES AND 2 OUT OF SERVICE, 2/5 OF THE FLUE GAS
IS BFING TREATED nHlLE 1/3 IS BEING BYPASSED. THE UNIT IS IN COMPLIANCE AT PRESENT HITH RESPECT TO
802 HITH ONLY 2 CELLS RUNNING BECAUSE THE BISULFITE CONCENTRATION HAS NOT YET BUILT UP IN THE ABSOR-
BENT LIUUOR. MHEN THE SYSTEM REACHES EQUILIBRIUM KITH RESPECT TO HISIJLFITE (18X BISULFITE) THE UNIT
NILL BE READY TO dEGIN REGENERATING OPERATIONS. REGENERATION IS EXPECTED TO BEGIN BY APRIL 27.
APRIL-*AY 1978 - OVER THE PERIOD THE UTILITY ACCUMULATED 22 DAYS UF DATA DURING WHICH THE BOILER
MAS DOWN FOR 7 HOURS AND THE ABSORBERS riEHF DOWN FOH 2A HOURS (UNSCHEDULED). THE UNIT IS STILL NUT
STABILIZED SO USEFUL FIGURES FOR nATER RETIREMENTS AKt UNAVAILABLE. THE CHEMICAL PLANT REMAINS IN
ITS START UP STAGE.
JUNE-JULY 1978 - THE UNIT EXPERIENCED A VERY HIGH PRESSURE DROP ACROSS THE VENTURIS DURING THIS
PERIOD. AS A RESULT. THE FANS MERE NOT ABLE 10 MOVE tooz OF THE FLUE GAS THROUGH THE FGO SYSTEM.
AUGUST-SEPTEMBER 1970 - DURING THIS PERIOD THE HIGH PRESSURE DROP PROBLEM MAS CORRECTED BY MODIFYING
ADJUSTABLE PLUMB BOBS HiThIN THE MODULES TO BE FARTHER A it AY FROM THE VENTURIS. THIS IMPROVED THE
GAS FLOW AND REDUCED THE PRESSURE ObOP. THE UTILITY ANTICIPATES THAT THEY NILL NOH BE ABLE TO SCRUB
loos OF THE FLUE GAS. IN ORDER TO PERFORM THESE MODIFICATIONS AT LEAST TWO MODULES HERE OONN AT ALL
TIMES THROUGHOUT THE PERIOD. MIST ELIMINATOR REPAIRS HERE ALSO MAOL WHILE THE MODULES HERE DOWN.
THEKE HAS A TOO MEEK DOILER OUTAGE IN SEPTEMBER CAUSED BY A FIRE IN THE START-UP TRANSFORMER DUCT
BANK. HOURS OF OPERATION FOR THIS NEWLY OPERATIONAL UNIT ARE NOT VET AVAILABLE.
-------
EPA UTILITY FGD SIJBVFY: AUGUST itm - SEPTEMBER 1970
SECTION 3
DESCRIPTION f-o» OPIRATIOUAL K;I> SYSTEMS
UTILITY NAME PUHLIC bERVJTh UF Nt w Mb XI CD
UNIT NAME SAN JUAN
NEW OP HFTROFIT ktTkOFIT
STAPT UP OAIE 7/78
FFFICIFNCt:
PAHTICULATES (ACTUAL)
(DESIGN) 9<».5 PfcHCENT
S02 (ACTUAL)
(DESIGN) 8S.O PtBCFNT
MATER MAKE UP CLOSEH LOOP
SLUDGE DI^PUSAL ELEMENTAL SULFUR PRODUCT
OPERATING EXPETFNCt UPDATE:
AUGUST-SEPTEMBF.R i9/e - INITIAL OPERATIONS BFGAN AT THIS UNIT LATE IN AUGUST. ALL THREE MODULES
RAN TOGE.THEK AT FULL CAPACITY FUR THE FIRST TIME IN stPTEMRt". A TWO »ttK BORES OUTAGE OCCUNRLO IN
SEPTEMBER AS A RESULT OF A FIRE IN THt START-UP TRANSFORMER DUCT BANK. PROBLEMS MERE ALSO ENCOUN-
TERED HITH THE aOOSIEK HOILER CONTROL DAMPER. DUE TO THE RECENT OPERATING STATUS OF THIS SYSTEM
HOURS OF OPERATION ARE NOT YET AVAILABLE.
69
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FP» UTILITY FG1 SURVEY: AMGUSI 197« - SEPTF.MRI-K 197ft
SECTION 1
PERFORMANCE DESCRIPTION F ON OPERATIONAL * f.U SYSTEMS
NAME SOUTH CAROl INA PUbLIT SERVlLF
UNIT N»Mf H1NYAM £
UNIT LOCATION GtOkG£TOi»N SOUTH CAHOLlNA
UNIT HAIIN^, ?au Hl»
FUEL CHARACTFHISTICS COAL; 1.0X SULFUR, 19» ASM
FGI) VENkl'N BABCOCK * WILCOX
PROCESS LIMESTONF
Nt» OH BFTWUFIT Ntli
SFAKT HP DATE 7/77
EFFICIENCY:
PAHTICULATES (1CIUAL) 94. u PERCENT
99.0 PERCENT
SOa (ACTUAL) 8S.O Pt«CENT
(DESIGN) 69.0 PERCENT
nATER MAKt UP OPEN LOUP
SLUDGE DISPOSAL ^STABILIZED/SLUDGE POND
OPERATING EXPERIENCE UPDATE:
FEB. 7« DURING THE FEB-MAR PERIOD THE FGD SYSTEM HAS DYPASSEO ONCE FUR SEVERAL DAYS TO ALLOW
MAR. 7A SYSTEM CLEANING. THIS HAS IN PREPARATION FuR TESTS THAT BABCOCK AND MILCOX HILL SOON
BE PEOFORMINbt AND FOR KHlCh THEY HAVE SET IIP TEMPORARY ON-SITE LABORATORY FACILITIES.
OTHEK«ISE, THE SYSTEM kAN «ELL DURING THE PEnlUD WITH UNLY A FEU MJNQH PLUGGING AND SPILL-
AGfc PROBLEMS IN VARIOUS SLURRY LINES.
APR. 71 THE SYSTEM MAS OPERATIONAL FOR MOST OF THIS PERIOD. THE ONLY PROBLEM ENCOUNTERED MAS
MAY 70 MINOK SCALING. BUT IT DID N01 CAUSE AN OUTAGE. THE UTILITY DID NOT HAVE ANT PERFORMANCE
FACTORS TO REPORT FOR THIS PERIOD.
JUNE 78 THERE HERE NO FGD RELATED OUTAGES DURING THE PERIOD. THE BOILER AND FGD SYSTEM RAN FOR
JULY 78 679 AND Tit HOURS FOR JUNE AND JULY, RESPECTIVELY. THERE HERE THREE BOILER OUTAGES DURING
THE PERIOD, ONE UF RHlCH HAS A SCHEDULED OUTAGE.
AUG. 70 NO FGD-RELATED OUTAGES HERE REPORTED.
SEP. 70 BOILE» AND FGD HUURS HERE NOT AVAILABLE FOR THIS PERIOD. DURING SEPTEMBER A CERTIFICATION
TEST HAS RUN ON THE S"2 ANALYZERS. THE ANALYZERS PERFORMED HELL.
70
-------
FP» UTILITY FGD SURVEY: AUGUST \
-------
FPA UTILITY FGO SURVEY: AUGUST 1<»78 - SEPIFMHtR l«*/tJ
SECTION 3
PFKFURMANCt DESCRIPTION K)K OPERATIONAL F Kl> SYSTEMS
UTILITY NAME SPRINGMtLD CITY UTlllTIES
UNIT NAMF SOUTHWEST 1
UNIT LOCATION SKRINGFIELO MISSOURI
UNIT RATING
-------
EPA UTILITY FGD SURVEY: AUGUSI 1978 - SEPTFMBER 1978
SPRINGFIELD CITY UTILITIFb
MONTH BOILFH
OPERATING HOURS
A-SIDE B-SIDE TOTAL
134 0 \i9
FOHCtO OUTAGE TIMF
A-SIOF R-Sir>£ FI1TAL
MEGAfcA T T-HOUR
PRODUCTION
JULY 78 7oa 134 0 \i9 b?0 7'it 1 ?h« 101,188
AVAILABILITY = 8X
OPERABILITY = Ht
RELIABILITY = «x
UTILIZATION = 8X
DURING IMF MUNIH PROBLEMS HERE ENCOUNTERED WITH THE MODULE A TRANSFER PUMPS.
RFOU1REO TO TRACE 1HE ELECTRICAL PROBLEM.
MNE DATS MERE
A 17 UAY OUTAGE HAS CAUSED BY PHUBLt*S MTH THE
WALL MILL AIM !>UHPLY WHICH RESULTEU IN THE UNAV«ILAHII I T t OF SLUKRV. H-MOuULE NtS STILL OOHN
MHILE THE UTILITY /(AlFfcD FU" ThE REPLACEMENT FxPANSIllN JOINT. MURK nAb DONE DURING THt MONTH
to IMPROVE THE INSTRUMENTATION. IT HAS DISCOVERED THAT MANY OF THt PKUBLEMS *«ERE DUE TO
SCALE ACCUMULATION ON 1HE PRUflES.
7aa
1049
AUG. 78 744 439 0 039 30b
AVAILABILITY = 30X
OPERABILITY - 30X
RELIABILITY - 3uX
UTILIZATION = 50X
THE B-MODULE REMAINED UflftN THROUGHOUT AUGUST BECAUSE THE REPLACEMENT EXPANSION JUlNT HAD NUT
YET ARRIVED. EXPANSION JOINT REPAIR WAS REQUIRED ON THE A-MODULE. PRUBLEMS WITH THE
THICKENER ANU KLUbbEU LTNF.S CAUSED A-MUOULE OUTAGES TOTALING 211 HOURS. THERE HERE NO SCHED-
ULED OUTAGES.
34B
780
1118
SEP. 78 557 159 0 159
AVAILABILITY = 11X
OPERABILITY = |qX
RELIABILITY = I4X
UTILIZATION = MX
CONTINUATION OF THE EXPANSION JOINT PROBLEM RESULTED IN IHE B-MODULE REMAINING DOWN THROUGH-
OUT THE MONTH. A-MOOULE DOWN TIME WAS HUE TO PLUGGING OF THE THICKENER SLuRhY MAKEUP LINES
AND FAILURE OF THE BALLS WITHIN THE MODULE. THE PING PONG BALLS HERE REPLACED WITH SOLID
RUBBER BALLS.
73
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FPA UTILITY Fi,n SURVFY: AUGUST i«»7R - SEPJFMBER i"»7B
SECTION i
DESCRIPTION FOH OPERATIONAL FGD SYSTEMS
UIILUY NAME TfNNFSSft VAILET AUTHURITY
UNI I NAMF SHAnNEF IOA
UNIT LOCATION PAOUCAH KEN1UCKY
UNIT RAT I'.r, 10 KK
FUEL CHAPACTFKJSTICS COAL: ?.
-------
EPA UlILIir FbT> SURVEY: »UGUSI 1978 - SEPTtl*BtR 1978
SECTION 3
PERFORMANCE DFJSCK IHT 1 Df4 FOK OPERATIONAL FGU
UTILITY NAME
UNIT NAMF
UNIT LOCA1ION
UMir MAI INK
TENNESSEE VALLEY AUTHORITY
SHAHNEF ion
PAOUCAH KfcNTIICKY
lu MM
FUEL CHARACTERISTICS COAL: ?."X bllLFuR, 1S.AI ASH
FliO VENLHIR
PKOCFSS
NEW OP. RETROFIT
START UP UATE
FFFICIEWCY:
PARTIfULATES (ACIIIAl )
(DESIGN)
302 (ACTUAL)
(UESIbN)
MATER MAKt UP
SLUDGE DISPOSAL
CHEMICO
I IMh/LlMES>TONE
HETRflFIT
a/72
EXPERIMENTALLY CUNTROLLED
EXPERIMENTALLY CONTROLLED
FXPERIMtNTALLY CONTROLLED
EXPtRIMtNTALLY
OPERATING EXPERIENCE UPDATE:
FEB. 71 MAJOR SYSTEM DOWNTIMES DUKING THE PERIOD INCLimto: JANUARY 26 THROUGH FEBRUARY a FOM THE
MAR. 70 VENIURI/SPRAV TUHER ANU JANUARY 26 THROUGH FEdRUAHV 2 FUR THE TC» SYSTEM DUt TO FREEZING
HEATHER, AND MARCH b THROUGH MARCH 17 FUR BOTH SYSTEMS DUE TO HOlLtR OUTAGE.
THE EFFECT OF T>1E SLURRY LfVFL IN THE AIR SPARGED OXIDATION TANK HAS INVESTIGATED IN THE
ToO SCRUBBER LOOP VENTURI/SPRAY TUHER SYSTEM AHICH IS OPFKATING ON LIMF SLURRY nITH HIGH
FLY ASH LOADING. NEAR COMPLETE SULFITE OXIDATION (98 PERCENT) MAS ACHIEVED WITH 10 FOOT
AND IB FOOT OXIDATION TANK LEVELS AT AN AIR STOICHIOMETRIC RATIO OF 1.0 ATOMS OXYGEN/MOLE
Su2 ABSORBED. AN AIR STDITHlUMETRIC RATIO UP TO AHOUT 3.6 HAS NEEDED TO YIELD NEAR COM-
PLETE OXIDATION WHEN THE TANK LEVEL HAS DRUPPEO TO 10 FEET.
A N£H TEST HLUCK HAS STARTED UN MARCri 1 ON THE VFNTURI/SPRAY TDftEM SYSTEM. MAGNESIUM
OXIDE HAS ADDED TO THE SPRAY TOnER SLURRY LOOP IN A TnO SCRUBBER LOOP OPERATION HlTH
FURCEO OXIDATION IN IMF VENTURI LOOP. THE SYSTEM KAS OPERATED IN A LIMESTONE SLURRY MODE
HlTH HIGH FLY ASH LOADING. THE PRIMARY OBJECTIVE OF MAGNESIUM ADDITION IS TD IMPROVE THE
S02 REMOVAL EFFICIENCY. BECAUSE UF THE SHORTAGE OF COAL CAUSED BY THE COAL MINERS'
STRIKE, CUALS FROM DIFFERENT SOURCES HERE BURNED IN THE BOILER. AS A RESULT, INLET S02
CONCENTRATION FLUCTUATED AS MUCH AS TENFOLD (350-3500 PPM), CAUSING PROBLEMS IN SYSTEM
CONTROL.
TCA HAS OPERATED HlfH BOTH LIME AND LIMESTONE, AND HlTH MAGNESIUM OXIDE ADDITION.
FLUE GAS rflTH HIGH FLY ASH LOADING HAS USED. THESE TESTS HERE CONDUCTED PRIMARILY TO
RESULVE SOME UF THE INCONSISTENT RESULTS OBTAINED DURING EARLIER LIME/MGO AND LIMESTONE/
MGO TESTS MADE IN APRIL-NOVEMdER 197ft. AIR LEAKAGE THROUGH THE SCRUBBER DOnNCOMEN HAS
SUSPECTED IN SOME OF THUSE EARLIFR RUNS, RESULTING IN HIGHER-THAN-NORMAL SULFITE
OXIDATION AND GYPSUM SATURAIION. TEST RESULTS SO FAR HERE INCONCLUSIVE BECAUSE OF THE
FLUCTUATION IN INLET 302 AND CONTROL PROBLEMS MENTIONED ABOVE.
APR. 70 THE VENTURI/SPRAY TOMER SYSTEM CONTINUED TO OPERATE THROUGH EARLY MAY HlTH MGO ADDITION
MAY 70 AND HlTH THO SCRUBBER LOOPS. THF SYSTEM HAS OPERATED HlTH LIMESTONE SLURRY AND rtlTH HIGH
FLY ASH LOADING. MGO HAS ADDED TO THE SPRAY TOHFR SLURRY LOOP TO MAINTAIN AN EFFECTIVE
MG»» ION CONCENTRATION OF 5000 PPM (ABOUT 8000 PPM IN THE VENTURI SLURRY LOOP) TO IMPROVE
THE 302 REMOVAL EFFICIENCY IN THE SPRAY TUHER. OXIDATION HAS FORCED IN THE VENTURI SLURRY
HOLD TANK. UNDER TYPICAL OPERATING CONDITIONS, THE OVERALL S02 REMOVAL HAS 96 PERCENT AT
2300 PPM INLET S02 CONCENTRATION. COMPARED TO 66 PERCENT REMOVAL AT 1600 PPM INLET 302
WITHOUT MGO AUDITION. S02 REMOVAL BY VENTURI ALONE HAS 30 PERCENT, ABOUT THE SAME AS THE
CASE HITHQUT MGO ADDITION. NEAR COMPLETE SULFITE OXIDATION COULD BE ACHIEVED AT AN AIR
ST01CHIOMETHIC RATIO AS LOH AS 1.3 ATUMS OXYGEN/MOLE S02 ABSORBED, IN THE SAME ORDER AS
THE CASE MlTHOUT MGO ADDITION.
FORCED OXIDATION HAS ALSO CONDUCTED ON THE LIMESTONE SLURRY BLEED STREAM FROM THE VENTURI/
SPRAY TOMER SYSTEM. A SINGLE EFFLUENT HOLD TANK HAS USED FOR BOTH VENTURI AND SPRAY
75
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EPA UTILITY FGO SIIRVFY: AUGUST 1978 - SEPTEMRER I97e
TFNNF.SSF.F VALLEY AUTHORITY
SHAHNEE 1UH
TUNED. "GO MAS Aontn Tn THE EFFLUENT HOLD TANK TO MAINTAIN AN EFFECTIVE MG»+ ION CONCEN-
TRATION OF bOul) PPM. * SLMKRY STREAM WAS TAKEN FROM THt SCRUBBER OONNCOMER AND SENT TO
AN OXIDATION lANK INTd MHIO ATM MAS SPARGEU. A RECYCLt STREAM OF ABOUT 30 GPM HAS SENT
HACK FROM THE OXTUAITON TANK IU THE FFFLUtNT HOLT) TANK TO CONTROL PH IN ThF OXIDATION TANK
AMU To PROVIDE bYPSUM SEEUS IN THE SCrtlldRER SLURRY. FINAL SYSTEM BLEED HAS WITHDRAWN FROM
THt OXIDATION TANK. AT AN AVFRAGt OXIDATION TANK PH OF 6, SULFITE OXIDATION AVERAGED 96
PERCENT. FILTE* CAKF SOI IDS CONTENT »AS 85 PERCENT, SIMILAR TO THAT OBTAINED WITH TWO
SCRllHoER LOOP OPERATIONS. MOnEvFR, THF SLURRY SOLIDS SETTLING HATE "AS ONLY ABOUT
U.O CM/MIN, COMPARED TO ABOUT 0.8 CM/MIN FOR THE TWO LOOP OPERATION. SETTLING HATF FOR
UNOxioilEO SLURRY CONTAINING MAGNESIUM ION FORMALLY mo NOT EXCEED 0.1 CM/MIN MITH 50 10
hO PERCENT FILTER CAKt SOI TI-S.
TCA CONTINUED TU OPERATE KlIH M&II ADDITION HllH ROTH LIME AND LIMESTONE SCRUBBING. FLUE
GAS MITH HIGH FLY ASH lOADINC, HAS UbEO. THE INTENT OF THESE TESTS MAS TO CLARIFY SOME OF
THF INCONSISTENT RESULTS OBTAINED DOMING EAKLIFR RUNS MADE IN APRIL-NOVEMBER 1976, DURING
MhlCH SCRUBHER OOnNCOHFR ATh LEAKAGE HAS SOSPECTFl) IN SOME OF THE TESTS. IN GENERAL*
TESTS RUMS MADE IN I97f> HAD HIGHFK INLET SO? CONCENTRATION, MOSTLY GREATER THAN 3UOO PPM,
WHILE THE RECENT RUNS HAD ONLY ABOUT cJSOO Pt>M. AT (HE HIGHER INLET SO? AND THE HIGHER
RESULTANT Si)? MARt-PEW-PASS, THt 1976 TESTS OPERATED EITHER MNSATuRAlED Oft SUPERSATURATED
WITH RFSPECI TO GYPSUM, DEPlNblNK On THE SULFITE OXIDATION LEVEL. SEVERE GYPSUM SCALING
OCCURRED MriEN THE OI-FhATION MAS UNDER GYPSUM-SATURATED MOOF. IN THE RECFNT HUNS, OPERA-
TION AAS MOSTLY UNDER GYPSUW-SATIIRATEU MODE. HOWEVER, BFCAUSE OF TriE LOiER INLET SO? AND
LOntR SO? MAKE-PEN-PASS, THt GYPSUM SATURATION LEVELS HERE NOT HIGH ENOUGH TO CAUSE ANY
SIGNIFICANT SCALING.
JUNE 78 FORCED OXIDATION ON THE HLFeD STREAM FROM THE VENTURI/SPKAY TOWER SYSTEM CONTINUED THROUGH
JOLY 78 MlO-JONt. I«0 TFbT RUNS nEKE MADE IN WHICH MGO HAS AODED TO MAINTAIN AN EFFECTIVE MR»+
CONCENTRATION OF 5000 PPM IN THE SCKUBRER SLURRY AND NO RECYCLE STREAM HAS SENT BACK FROM
THE DsIDAIION TANK (A FT OlAMETtR AND 16 FT TANK LEVFL) TO THE EFFLUENT HOLD TANK. AVER-
AGE SULFITE OXIDATION HAS 96 PERCENT OR HIGHER AT AN AIK STUICHIOMETRIC RATIO OF 1.6
ATOMS OxYGEN/MOLF SO? ABSORBED. THE OXIDATION TANK PH HAS 5.4 TO S.f>, ONLY 0.2 UNIT
HIGHER THAN THE EFFLUENT HOLD TANK PH. THE FILTER CAKE SOLIDS HAS 05 PERCENT AND THE
THE SOLIDS SETTLING RATE HAS u.a TO o.s CM/MIN.
BOTH SCRUBBER SYSTEMS HERE SHUT DOnN FUH TnO nFEKS FROM JUNE 19 DUE TO A BOILER OUTAGE
SCHEDULED FOR Rh-KOUTINb THE FLOF GAS DUCT FROM THE flOO-FI STACK TO THE NO. 11 SMALL
STACK.
FOLLDMINT; THE BOILER OUTAGE. MOTH SCKUHBER SYSTEMS STARTED ON NEH LIME AND LIMESTONE TEST
BLOCKS IN nnlCH AOIPIC ATIO, AN ORGANIC ACIU PH BUFFER, HAS ADDED TU THE SCRUBBER SLURRY
TO IMPROVE SO? REMOVAL EFFICIENCY.
INITIAL TEST RUNS HERE CONDUCTED nlTHOIIT ADIPIC ACID ADDITION TO ESTABLISH THE BASE CASE
so? REMOVAL IN BOTH LIME ANI. LINFSTUNE SCRUBBING FOR BOTH SCRUBBER SYSTEMS. THE VENTURI/
SPRAY TOMER SYSTEM HAS OPERATED HlTH TNU-bCKUBBER-LOOP CONFIGURATION HlTH FORCED OXIDATION
IN THE F1HST LOOP, ISHILF THE ICA HAS OPERATED IN A ONE-SCRUBBER-LOOP SCHEME HITHOUT FORCED
OXIDATION.
PRELIMINARY RESULTS SHOnEU THAT 96 TO 99 PERCENT SO? REMOVAL HAS CONSISTENTLY ACHIEVED IN
THF VENTUHI/SPRAY TONER SYSTEM OPERATING nITH ABOUT 1600 PPM AND 1400 PPM ADIPIC ACID IN
THE VENUIRI AND SPRAY TOWER, RESPECTIVELY. THESE SO? REMOVALS COMPARE VERY FAVORABLY WITH
THE 66 PERCENT REMOVAL FOR THE rtASE CASE LIKE RUN WITHOUT AOIPIC ACID. Ofc THE TCA SYSTEM,
A LIME RUN HlTH ABOOT 400 PPM AUIPIC ACID GAVE AHUUT 00 PERCENT SO? REMOVAL, COMPARED TO
67 PERCENT FOR THt BASF CASE RUN.
AUG. 78 TESTING HlTH ADIPIC ACID AS ADDITIVE FOR IMPROVING SO? REMOVAL EFFICIENCY CONTINUED
SEP. 78 THROUGH AUGUST AND SEPTEMBER. BOTH VENUIRI/SPRAV TONER AND TCA SYSTEMS MERE OPERATED ON
L.IMESTONF SLURRY HITH HIGH FLYASH LOADING DURING THIS PERIOD. THE TCA MAS OPERATED
WITHOUT FORCEO OXIDATION AND THE VENTURI/SPRAY TOWER WITH TMO-SCRUBBEH-UUOP FORCED OXIDA-
TION. AS IN THE LIME TESTS WITH ADIPIC ACIO ADDITION CONDUCTED IN JULY, SIGNIFICANT
IMPROVEMENT IN S02 REMOVAL EFFICIENCY HAS ALSO OBSERVED IN THE LIMESTONE TESTS.
UNDER TYPICAL OPERATION, SO? REMOVAL HIGHER THAN 90 PERCENT COULD BE ACHIEVED BY THt
VENTURI/SPRAY TOMER WITH ABOUT 2100 PPM AND 1500 PPM ADIPIC ACIO IN THE VENTURI AND SPRAY
TONER, RESPECTIVELY. UNDER THE -SAME OPERATING CONDITIONS HUT WITHOUT AOIPIC ACID, THE 802
REMOVAL WAS ONLY 57 PERCENT. THE SULFITE OXIDATION EFFICIENCY AND WASTE SLUDbE OEWATERIN6
PROPERTIES DID NOT APPEAR TO BE AFFECTED BY THE PRESENCE OF ADIPIC ACID.
IN THE TCA, HIGHER THAN 90 PERCENT S02 REMOVALS MERE OBTAINED MITH 790 TO 1500 PPM ADIPIC
ACIU, COMPARED TO 71 PERCENT REMOVAL FOR A BASE CASE RUN WITHOUT AOIPIC ACIO.
IN BOTH SCRUBBER SYSTEMS, THE PH IN THE SCRUBBER SLURRY NEEDS TO BE HIGHER THAN ABOUT 5.Or
THE UPPER PH BUFFER POINT OF ADIPIC ACID, FUR THIS PARTICULAR ADDITIVE TO BE FULLY
EFFECTIVE.
DETERIORATION OR DECOMPOSITION OF ADIPIC ACIO APPARENTLY TAKES PLACE IN THE SCRUBBER.
ACTUAL FEED RATES OF ADIPIC ACID WERE 2 TO 3 TIMES HIGHER THAN COULO BE ACCOUNTED FOR IN
THE SYSTEM DISCHARGE SLUDGE.
76
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EC* UTILITY Fun su«vtr: AUGUST i9/e - SFPTE»ntR i<»7a
SECTION 3
PERFORMANCE UFSCWIPTJON (• Ok OPERATIONAL ^ GO STSTfcMb
UTILITY NAMfc
UNI1 UA»t
UNIT LOCATION
UNIT RATING
TfcNNESSEE VAULFT AlllHURITY
NIDUMS CREEK ft
BKIUKEPURT ALABAMA
550 Mrt
FUEL CHARACTERISTICS COAL: *.7x SULFUR, i7x ASM
FGD VENDOR TENNFSSkE VALLFY AUTHORITY
PROCESS LIMESldNf
NEW OR RETROFIT RtTKOFIT
START UP DATE 5/77
EFFICIENCY:
••ARTICULATES (ACTUAL)
(OESIGN)
SOi (AC1UAL)
(OFSIGN)
MATER MAKE UP
SLUDGE DISPOSAL
90.5* PtKCfcNT
99.5 PtRtFNT
H5-94 PEKCENT
eo.o PERCENT
STABILIZED/SLUDGE PUNU
OPERATING EXPERIENCE UPDATE:
MONTH BUTLER A-SIUE
OPERATING HOURS
B-SIDE C-SIOE 0-Sint
COMMENTS
401
370
514
THE OUTAGE TIME FOR TWAINS A AND b HAS REUUIR-
ED TO REPLACE THE RUBBER LINEKS IN THE OOrtN-
COMER AREA HITH STAINLESS STEEL. THIS HILL BE
DONE TO THE REMAINING TnO TRAINS AS WELL.
FEB. 78 588 171
AVAILABILITY = 55X
OPEHABILITY s 54X
RELIABILITY 61X •
UTILIZATION = 47X
* THE UTILITY REPORTED THAT THEY COULD NOT ACCURATELY DETERMINE RELIABILITY BECAUSE OF THEIR
INABILITY TO CALCULATE UNIT LOAD DEMAND ON A DAILY BASIS. GENERALLY, IT IS ASSUMMED THAT SYSTEM
FORCED OUTAGE HOURS PLUS THE HOURS FGD SYSTEM OPERATED HILL GIVE ROUGHLY THE HOURS THE SYSTEM MAS
CALLED UPON TO OPERATE. IN THIS HAY, RELIABILITY CAN BE CALCULATED INDIRECTLY. HOMEVER, IN THIS
CASE. TnO TRAINS AT A TIMt HAVE BEEN DOHN ON A SCHEDULED OUTAGE FUR NECESSARY MODIFICATIONS. PART
OF THIS OUTAGE TIME LIMITED BOILER OPERATION so THAT THE UNIT COULD NOT RUN AT FULL LOAD HHEN THERE
HAS A DEMAND FOR FULL LOAD. FOR THIS CALCULATION IT HAS ASSUMMED THAT THERE HAS A DEMAND FOR FULL
LOAD DURING THE ENTIRE SCHEDULED OUTAGE SO THAT ALL OF THE TRAINS WOULD HAVE BEEN CALLED THE ENTIRE
SCHEDULED OUTAGE. THE RESULT HAS A VtRY CONSERVATIVE ESTIMATE OF RELIABILITY HHERE HOURS CALLED
= SYSTEM FORCED OUTAGE HOURS » SYSTEM SCHEDULED OUTAGE * HOURS THE FGD SYSTEM OPERATED.
NOTE: THIS is A PEDCO ESTIMATE.
MAR. 78 614
AVAILABILITY * 60X
OPERABILITY = 66X
RELIABILITY = 59X <
UTILIZATION = 58X
585 344 199 583 TRAIN B HAS OUT OF SERVICE MARCH 1 - MARCH 13
TO INSTALL STAINLESS STEEL IN THE ABSORBER AND
VENTUHI OOHNCOHER AREAS. STAINLESS STEEL
COVERS HERE INSTALLED AROUND TNO EXPANSION
JOINTS ON TRAIN C, IN ORDER TO PREVENT FLUE
GAS LEAKAGE FROM THE EXPANSION JOINTS. A
STAINLESS STEEL PLATE HAS MELDED OVER THE
ENTRY DOOR OPENINGS TO TRAIN C OUTLET AND
BYPASS GUILLOTINE DAMPERS FOR THE PURPOSE
OF ELIMINATING GAS LEAKAGE. TRAIN C HAS OUT
OF SERVICE MARCH 14 - MARCH 29 TO INSTALL
STAINLESS STEEL IN THE ABSORBER AND VENTURI
DOHNCOMER AREAS. SEVERAL LIFTER BARS ON THE
FEED AND DISCHARGE ENDS OF THE BALL MILL HERE
FOUND TO BE BADLY MORN. I HE UTILITY HAS HAD
MEAN PROBLEMS HITH THE SLURRY SUMP PUMP
LINERS AT THE BALL MILL.
77
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FPA iitiLiTr FGD SURVEY: AUGUST isrs - SEPTEMBER i<*7«
TENNFSSEE VAILEY AUTHORITY
MONTH BOILFX »-SIOE B-SIDE c-btot D-SIDE
APR. 7fl SaO 48U aba b7b
AVAILAHILITT = 64X
UPFHAblLITY = HJX
RtLlABHITY = t.71 •
IITILA2ATTON =
CHEEK 8
COHMENTS
DURING A BRIEF INSPECTION OF THE SCRUBBER IN
EARLY APRIL, SOLIDS DEPOSITION MAS NOTICED IN
THE MIST tLIHINATOR SfcCTION OF ALL TRAINS BE-
CAUSE OF PLUGGING THAT HAD OCCURRED IN SEVERAL
OF THE MIST ELIMINATOR SPrtAV NOZZLES. TRAIN 0
MAS NUT IN OPERATION FUM 17 DAYS. DURING THIS
PERIOD THE MIST ELIMINATOR HAS DISASSEMBLED
HY SECTIONS AND CLEANED. A STAINLESS STEEL
LINEN HAS INSTALLED ON THE SLOPING AREAS OF
THE ABSUMHFR AND VENTuRI . STAINLESS STEEL
PLATES MERF INSTALLED OVER THE ENTRY DOOR
OPENINGS TO TRAIN 0 INLET, OUTLET, AND BYPASS
GUILLOTINE DAMPERS TO REDUCE GAS LEAKAGE FROM
THE ENTRY DOOR OPENINGS. STAINLESS STEEL
COVERS MERE INSTALLED AROUND THE FIVE EXPAN-
SION JOINTS ON TRAIN D, TftO EXPANSION JOINTS
ON TRAIN A, AND ONE EXPANSION JOINT ON TRAIN
H, TO REDUCE GAS LEAKAGE 10 THE ATMOSPHERE.
THERE CONTINUES TO HE A HEAR PROBLEM MITH PUMP
LINERS AT THE BALL MILL. NO CAUSE UR SOLUTION
OF THE PROBLEM HAS BEEN ASCERTAINED AS YET.
70
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EP» UIILIIY FGD SURVFY: AUGUST i<»78 - SEPTEMBER 1978
SECTION 3
PERFORMANCE DESCRIPTION FOK OPERATIONAL FGO SYSTtMS
UTILITY NAME TEXAS II1ILI1TES
UNIT NAME MAR) IN (.AXE t
UNIT LOCA1ION TATuM TtXAS
UNIT HAT ING It* Mr.
FUEL CHARACTFRJSTICS COAL: o.9» SULFUR, HI ASM
FGD VENDOR RESEARCH C01TKFLL
PROCFSS lIMtbtONF
MEN OR KFIHUFIT NfcH
SFAHT up DATE tt/77
FFFICIFNCY:
PARTICULATES (ACIUAI.) 99* PERCENT
(DESIGN) >*9..« PERCENT
SO«J (ACIUAL) 7i.» PERCENT
(UESIGN) 70. i PfcWCENT
HATER MAKfc UP
SLUDGE DISPOSAL BLENDEH/SLUbGE PONO
OPERATING EXPERIENCE UPDAIE:
FEBRUAPY-MAKCM 197B - CERTIFICATION HAS RtCEIVFD FRUM THE EPA FUR THIS UNIT. THF BOILER AND
SCRUBBEK-AHSOK8ER SYSTEM OPERATED THROUGHOUT THE PEKtOO. THE UTILITY IS STILL HAVING SOME PROBLEMS
I HE SLURHV HANDLING bTSTEM, AND SOME FUHCEU UUTAUE TIME OCCURRED.
APRIL-MAY 1978 - THIS UNIT nAS tAKEN OFF LINE IN APHIL FOR AM ANNUAL 1«0 MEEK OUTAGE. GENERATOR
PROBLEMS nEHE ENCOUNTERED IN HAY CAUSING THE UNIT TO t)E TAKfcN OFF LINE THROUGH THE END OF THE MONTH.
JUNE-JULY 1978 - THE SYSTEM IS NOB RUNNING COMMERCIALLY. THE UTILITY HAS ENCOUNTERED SOME PROBLEMS
SINCE INITIAL OPERATION. THE DAMPERS FOR EACH ARSimstR MODULE HEME NOT FUNCTIONING PROPERLY. IT
HAS HtFN IMPOSSIBLE Tu ISOLATE INDIVIDUAL MODULES FOR REPAIRS (IHE ENTIRE SYSTEM nOULO HAVE TO BE
SHUTDOWN IF REPAIRS MERE REQUIRED ON ONLY ONE MODULE). THERE HAS ALSO HFEN A PROBLEM *ITH THE PH
METERS. THE METERS HAVE NOT OPERATED PRUPFKLY FOR &OME TIME NO*.
AUGUST-SEPTEMBER 1978 - ISOLATION DAMPFM PRbHLEHS ARF CONTINUING. THE UNIT STILL REQUIRES EXCESSIVE
MAINTENANCE. FLOM MEASUREMENT INSTRUMENTATION MAS BEEN FAILING. OPACITY HAS BEEN HIGHER THAN EX-
PECTED (20-Z5X) RESULTING FROM ESP PROBLEMS. FGD
SYSTEM ACCEPTANCE TESTS HERE PERFORMED DY THE IMILITY DURING AUGUST. RESULTS ANE NOT YET AVAILABLE.
79
-------
EPA iiTtLirr FGO SURVEY: AUGUST 1978 - SEPTEMBER 197B
SECTION 3
PERFORMANCE DFSCWIHUON FOR OPERATIONAL FRO SYSTEMS
UTILITY NAMt TEXAS UTILITIES
UNIT N«MF MARTIN LAKf ?
UNIT LOCATION TATUM TfcXAS
UNIT HATING 79j M»
FUEL CHARACTERISTICS COAL: o.9» SULFUR, AZ ASH
FGU VENUOH HEStAKCH CU1THi-LL
PROCESS LIMtSIONE
NE* OR RETROFIT Nt«
START UP OAIE 5/78
EFFICIENCY:
PARTICULATES (ACTUAL)
(UESIGN) 99.a PfcHCEM
SOe (ACTUAL)
(DESIGN) 70.5 PERCENT (TOIAL)
HATtR MAKE UP
SLUDGE DISPOSAL STABILISED/SLUDGE POND
OPERATING EXPERIENCE UPDAIE:
JIINt-JULY 1978 - THE FBI) SYSTEM MAS TESTED FOR COMPLIANCE IN THE FIRST PART Oh AUGUST. RESULTS
AME NOT RACK YET BUT iMfcY ARE ExPtCTEO TO RE 60UO, SINCE THt FGl) SYSTEM RAN WITH ALL 6 MODULES.
AUGUST-SEPTEMBER 197* - COMPLIANCE TEST RESULTS HAVE STILL NOT BEEN PUBLISHED. NO MAJOR FGO RELATED
PROBLEMS MERE REPORTED.
-------
FH» UTILITY Ftp SU&VFY: AUGUST i"»78 - SEPTFMHtR J978
SFCT10N i
PERFURMANCE DESCRIPTION FOK OPERATIONAL ^,1) SYSTtMS
UTILITY NAME TfcliAS UTlLlHtS
UNIT NAME HUNTICF.LLU 3
UNIT LOCATION MT. PLEASANT TEXAS
UNIT RATING 750 M*
FUEL CHARACTERISTICS IIGMTF; l.bl SULFUK. 191 ASH
FGO VENDOR CHEMICU
PROCESS LIMtSIONF
N£H OR RETROFIT Nbn
START UP DATE 5/78
EFFICIENCY:
HAHTICULATES (ACTUAL)
(DFSIGN) 99.5 PERCENT
S08 (ACillAL)
(DESIbN) 70.0 PERCENT
WATER MAKE UP CLOSED LOOP
SLUDGE DISPOSAL STABILIZED/SLUDGE PONU
OPERATING EXPERIENCE UPDATE:
APR. 78 THE TEXAS AIR CONTROL BUARl) REPORTED THAT THE 1EXAS UTILITIES 750 MM MONTICELLO UNIT 3
MAY 7H BEGAN FGD OPERATIONS DURING THE REPORT PERIOD. AS OF YtT THE UNIT HAS NOT RUN AT FULL LOAD
BUT IS EXPECTED TO BY THE END OF AUGUST.
JUNE 78 THE UNIT IS NOT AT FULL LOAD YET. ONE OF THk THREE FGO MODULES IS FULLY OPERATIONAL.
JULY 78 ANOTHER ONE IS PARTIALLY OPEHATIONALf WHILE THE THIRD IS NOT OPERATING AT ALL AS YET.
AUG. 78 THE COMPLIANCE TEST HAS NOT YET TAKEN PLACE. THE FGO SYSTEM IS OPERATIONAL. INSTRUMENTA-
SEP. 78 TION INDICATES THAT THE UNIT is IN COMPLIANCE.
81
-------
EPA UTILITY FGO SURVEY: AUGUST 147ft - SEPTEMBER 1978
SFCTION 3
PERF-URMANCt DESCRIPTION FOR OPERATIONAL FGO SYSTEMS
UTILITY NAME UTAH PdftEM « LIl>HT
UNIT NAME HUNTTNGTON i
UNIT LOCATION PRICE UTAH
UNIT RATING 41b MM
FUEL CHARACTERISTICS COAL: 0.51 SULFUR. 10* ASH
FGI> VENDOR CHeMICO
PHOCESS LIME
NEW OH KF.TROFIT NEW
START UP DATE b/78
EFFICIFNCY:
PAkTICULATES (ACTUAL)
(OESIGN) 99.5 PERCENT
S08 (ACTUAL)
(OESIGN) 80.0 PERCENT
WATER MAKE UP CLOSED LOOP .72 GPM/MH
SLUDGE DISPOSAL STABILIZED/LANDFILL
OPERATING EXPERIENCE UPDATE:
APRIL-MAY 1970 - INITIAL OPERATIONS BEGAN AT THIS UNIT ON MAY 10. 1978. DUE TO THE RECENT OPERATING
STATUS OF THE SYSTEM HOURS UF OPFRATlUN wfcRt NOT AVAILABLE FOR THE APMlt-MAY REPORT PERIOD.
PERIOD BOILER FRO SYSTEM PARAMETERS
MONTH HOURS HOURS HOURS OPERABILITV UTILIZATION
JUNE 71 720 720 470 6bl bSS
JULY 78 744 731 714 98X 96X
NO MAJOR PROBLEMS MERE REPORTED BY THE UTILITY FOR THIS PERIOD. 10-20X OF THE FLUE GAS MAS
BYPASSED THROUGH THE USE UF AN ADJUSTABLE DAMPER.
AUG. 78 744 S44 %44 1001 73Z
SEP. 78 720 496 496 1001 69S
THERE MERE NO FORCED FGD OUTAGES DURING THE AUGUST-SEPTEMBER PERIOD. MINOR PROBLEMS MERE EX-
PERIENCED MITH INSTRUMENTATION. A THREE WEEK BOILER OUTAGE OCCURRED AS A RESULT OF AN
EXPLOSION.
82
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FPA IJ1ILTTY FGn SURVEY: AUGUST 1978 - SEPTEMBER 1978
SECTION 4
SUMMARY OF FGD SYSTEMS HY COMPANY
UTILITY
ALABAMA ELEC1RIC COOP
ALLEGHENY POHFR SYSTEM
AR1ZUNA ELtCTRIC PUwER COOP
ARIZONA PUBLIC SERVICE
ASSOCIATED ELECTRIC COUP
bASIN ELECTRIC POWER COOP
Bib RIVF.RS FLECTRIC
CENTrfAL ILLINOIS LIGHT
CENTRAL ILLINOIS PUBLIC SERV
CFNTHAL MAINE POHER
CINCINNATI GAS * ELECTRIC
COLORADO DTE ELECTRIC ASSN.
COLUMHUS ft SOUTHERN OHIO ELEC.
COMMONHFALTH EDISON
COOPERATIVE POMER ASSOCIATION
OFLHARVA PUMER ft LIGHT
DUQHESNE LIRHT
EASTERN KENTUCKY PUHER CUOP
GENERAL PUBLIC UTILTIIES
GULF POMER
hOOSIER ENERGY
INDIANAPOLIS POMkR * LIGHT
KANSAS CITY POHEH ft LIGHT
KANSAS POHER * LIGHT
KENTUCKY UTILITIES
LAKELAND UTILITIES
LOUISVILLE GAS ft ELECTRIC
MINNESOTA POWER ft LIGHT
MINNKOTA PONE* COOPERATIVE
MONTANA POWER
NEVADA PUHER
NIAGARA MOHAWK POMER COOP
NORTHERN INDIANA PUB SERVICE
NORTHERN STATES POHER
OTTER TAIL PUȣR
PACIFIC GAS AND ELECTRIC
PACIFIC POWFK ft LIGHT
PFNNSVLVANIA POWER
PHILADELPHIA ELECTRIC
PUBLIC SERVICE OF INDIANA
PUBLIC SERVICE OF NEn MFxICO
SALT RIVER PROJECT
SAN MIGUEL ELECTRIC COOP
SEMINOLE ELFCTRIC
SIKESTON BOARD OF MUNIC. UTIL.
SOUTH CAROLINA PUBLIC SERVICE
SOUTHERN ILLINOIS POWER COOP
SOUTHERN INDIANA GAS ft ELEC
SOUTHERN MISSISSIPPI ELECTRIC
SOUTHWESTERN ELECTRIC POME«
SPRINGFIELD CITY UTILITIES
SPRINGFIELD MATER LIGHT ft PnR
ST. JOE ZINC
TENNESSEE VALLEY AUTHORITY
TEXAS MUNICIPAL POMER AGENCY
TEXAS POHER ft LIGHT
TEXAS UTILITIES
UTAH POHER « LIGHT
WISCONSIN POHER ft LIGHT
TOTAL
NO HW
z
t
i
ft
1
5
f.
2
1
1
I
2
a
1
i
I
2
i
a
i
e
i
3
4
1
1
«
I
1
4
10
1
J
a
1
Z
\
3
a
1
a
3
1
1
I
Z
Z
1
z
1
1
1
1
4
1
3
6
3
1
4bO.
1250.
000.
8804.
670.
2600.
440.
800.
575.
600.
600.
900.
1550.
-------
FPA UTILITY FliO SURVEY: AUGUST 1978 - SfcPTEMHER 1978
SECUON 5
SUMMARY (IF Fl,n SYSIEMS BY
IUTAL
MANUFACTURER/PROCESS
AOL/COMBUSTION tourp ASSOCIATE
DOUBLE ALKALI
LIME/ALKALINE FLYASH
SODIUM CAHbONAIE
TOTAL -
AIR CORRFCUON DIVISION, UUP
LIME (MC-PROMOIED)
LIHE/LIMtSIONE
LIMFSTUNE
SODIUM CARBONATE
TUTAL -
AMF.RTCAN AIM FILTER
LIME
LIME (CARBIDE)
TOTAL -
ATOMICS INTERNATIONAL
AUUEUUS CAHBUNATE
TUTAL -
BABCOCK * MILCOX
LIME
LIMESTONE
TOTAL -
BUFLL/ENVIROTtCM
DOUBLE ALKALI
TOTAL -
BUREAU OF MINES
CURATE
TOTAL -
CHEMICO
LIME
LIME/ALKALINE FLYASH
LIME/LIMESTONE
LIMESTONE
TOTAL -
CHIYODA INTERNATIONAL
LIMESTONE
TOTAL -
COMBUSTION ENGINEERING
LIME
LIME (CARBIDE)
LIME/LIMESTONE
LIMFSTONE
LIMESTONE/ALKALINE FLYASH
TOTAL -
DAVY POMERGAS
MELLMAN LORD
TOTAL -
FMC CORPORATION
DOUBLE ALKALI
TOTAL -
MO.
1
5
3
9
2
1
q
1
6
-------
FH» UTILITY FGf) SllRVF.Y: AUGUST 1<)7H - SEPTEMBER 1978
SUMMARY OF FUO SYSTFMS HY VENDOR
TUTAL
MANDFACTliRER/PHOCESS
TOTAL -
NUT SELECTED
LtME
TOTAL -
PEABODY ENGINEERING
LIME/ALKALINE FLYASH
LIMESTONE
TOTAL -
PULLMAN KELLOGG
LIMF
LIMESTONE
TOTAL -
RESEARCH COTTHELL
LIMESTONE
TOTAL -
R1LEY STOKER / ENV1HONEERING
LIMESTONE
TOTAL -
TENNESSEE VALLEY AUTHORITY
LIMESTONE
TOTAL -
ONITEO ENGINEERS
MAGNESIUM OXIDE
NOT SELECTfcO
TOTAL -
WHEELA8RATOH-FRYE/A.I.
AQUEOUS CARBONATE
TOTAL -
NO.
2
1
1
1
"4
5
1
i
4
13
13
3
3
1
1
1
2
3
1
1
Hn
9«0.
455.
455.
500.
1350.
1850.
«25.
137u.
2I<»5.
6147.
61«7.
760.
760.
5SO.
550.
1?0.
1510.
1630.
400.
400.
OPERATIONAL
NO.
0
n
0
0
1
1
0
0
0
5
<3
2
i
1
1
1
0
1
0
0
Mh
0.
0.
0.
0.
225.
225.
0.
0.
0.
2151.
2151.
5bO.
500.
550.
SbO.
120.
0.
120.
0.
0.
CONbTKUCT inu
NO.
2
u
o
1
3
4
1
2
3
6
6
1
1
0
0
0
0
0
1
1
MB
<»«0.
0.
0.
500.
1125.
1625.
R25.
700.
1525.
3013.
3013.
1AO.
180.
0.
0.
0.
0.
0.
400.
400.
CO«Ti,ACT
AflAHDtD
NU.
0
1
1
0
0
0
0
1
1
2
2
0
0
0
0
0
2
2
0
0
Ml»
0.
055.
155.
0.
0.
0.
0.
670.
670.
963.
9»3.
0.
0.
0.
0.
0.
1510.
1510.
0.
0.
107 04632.
ad 16051.
38
23 12450.
-------
EPA UTILITY FGO SURVFY: AUGUST |078 - SEPTEMBER 1<»78
SECTION 6
SUMMARY OF NE* AND RETROFIT FGI) SYSTEMS BY PROCESS
NE* OR OPERATIONAL CONSTRUCTION
PROCESS RETROFIT
NO. MH
L1"F
lIMt (CARuIDEJ
Ll"t (MG-PRUMOTED)
LIME/»LK»LINE FLY»SH
LIMt/LTMESTONE
L1MES10NF
LIMESTONE/ALKALINE FLVASH
SUBTOTAL - LIHE/I IM^STONE
AQUEOUS CARHONATF
CITRATE
DOUBLE ALKALI
MAGNFSIUM OXIOE
NOT SELECTED
SODIUM CARBONATE
NELLMAN LORD
TOTALS
LIME/LIMESTONE Z OF TOTAL MM
N
k
N
it
N
R
N
H
N
R
N
R
N
R
N
P
N
R
N
R
K
R
N
R
N
R
N
R
N
R
N
R
N
R
3
<3
I
i
i
0
3
0
0
2
la
a
a
0
?b.
14.
0
0
u
0
0
0
0
t
0
0
1
Z
1
Z
27.
19.
2065
1164
4i!5
4*6
800
0
1170
0
0
20
6501
»13
1420
0
12301.
*443.
0
0
0
0
0
0
0
120
0
0
125
250
31«
421
12020.
3234.
97
76
NO
q
0
0
(1
0
0
I
0
0
1
18
2
0
0
28.
*.
1
0
0
1
2
1
0
0
0
0
1
0
0
1
32.
6.
MH
«b50
u
u
u
0
u
500
u
u
330
7497
1000
0
U
12S47.
1330.
400
0
0
60
825
277
0
0
0
0
509
0
U
180
14201.
1847.
88
72
NO
4
0
0
U
0
0
3
0
0
1
a
0
2
0
ir.
i.
0
i
0
0
0
0
0
0
0
2
0
0
2
u
19.
4.
CONTRACT
AWARDED
MM
1955
0
0
0
0
0
1927
0
0
330
3960
0
1720
0
9570.
330.
0
100
0
0
0
0
0
0
0
1510
0
0
940
0
10510.
1940.
91
17
PLANNED
NO
0
0
0
0
0
0
0
3
0
0
6
0
0
0
6.
3.
0
0
0
0
0
0
0
3
10
2
0
0
0
0
24.
0.
MH
0
C
0
u
u
0
u
579
0
u
4050
0
0
0
4050.
b79.
0
0
0
0
0
0
0
726
0005
590
0
0
0
0
12055.
1095.
32
31
TOTAL NO.
OF
NO
16
5
1
3
2
U
7
3
0
4
46
6
4
0
76.
21.
1
I
0
1
2
1
0
4
IB
4
2
2
3
3
102.
37.
PLANTS
. MH
8570
1184
425
426
800
0
3597
579
0
680
22016
1013
3140
0
30540.
4602.
400
100
0
60
025
277
0
046
0005
2100
634
250
1254
601
50466.
0916.
76
S3
06
-------
EPA IITILMY F&n SURVEY: »ur,uSI 1<»7B -
1978
StCTIH'1 7
SUMMAHY OF iiPtRATiNi; Ffiu SYSTEMS MY
PROCESS AND GtNtHATINb UNITS
PROCtSS/GENtHAt ING UMTS
FGD/Mn SIAMTUP tXPF.H ItNCH»0. )
LIME
HMUCE MANSFIELD 1
HHUCE MANSFIELD I
FLiiAMA PUWEH STA1IUN
bRF-EN KIVEK 1,
<)-7S
11-7,;
R-7
<»-7 7
3u
IS
Jh
37
71
7 a
?b
lu
i.
h6
104
il
35
?b
14
7B
7|J
ISb
LIMESTONE
APACHE i
CHOLL* 1
CHOLL* 2
DUCK CREEK I
JEFFREY 1
L» CY6NF I
LAURENCE a
LAMRfcNCE 5
MARTIN LAKfc 1
MAHTIN LAKt 2
MONTICELLO 3
PETERSBURG 3
M. D. MOHHOH 1
SCHOLZ IB « 2B
SOUTHWEST 1
TOMRIGBFfc 2
MIOOHS CREEK 6
NINYAH 2
LIMESTONE/ALKALINE FLVASH
SHERBURNE 1
400
«>»0
ao°
'50
530
<8°
23
200
?«5
5*0
«-7B
>°-74
fc-78
7-7«
8-7fl
2-73
B'77
S"78
5-76
10-77
*'7B
a-78
4-77
«»-76
5-77
7'77
7314.
«
S
2
•><»
na
BS
Ia
1«
»
I/
5I
-------
EP» UTILITY FGO SIIHVEY: AUGUST 197A - SEPTEMBER 147H
StCTION 7
SlIMMAKY OF OPERATING F Kl bYSTfcMb Of
PROCESS ANO GtNERAUNG UNITS
PROCtSS/GtMtHATIMG UNITS
STAHTUP t
«-7
-------
EPA UIILITY FGn SllRVFY: AUGUST 1978 - SePTFfRtR l<»78
bt-CUON H
SUMMARY OF SLUDGt DISPOSAL PHACTICtS FUU OPEHAMONAL FGI> SYSTEMS
PRUCESS/GENEHAT ING UNIT --SLUDGF — --SLUDGF — --- PONU--- --- PliNl) ---
bTAHUlZtn llNSTArUL17tn LlNFO II
LIME
UHUCF MANSFltLU I Bi>5
H*UCt MANSKItLO 2 H^S
tLRAMA PUMEH S1AIIUN 510 510
GREEN HIVEH \,l ft 3 ba fa a
HAWTHORN ) 100 100
HAwTHUKN a 1UO 100
MUNTINGTON 1 415 415
PHILLIPS POWER STATION 1 1 U 010
TOTAL £<»B5. 8bfl. 0.
LIME (C»KBIDE1
CANE RUN a 17R 178
CANE RUN *> 185 IBi
MILL CKEEK 3 a^5
PADDYS RUN 6 65 t>5
T01AL "51. 0. 0. a26.
LIME (MG-PHOMOIED)
CONESVILLE 5 flOO «00
CONESVILLE 6 «00 «00
TOTAL «00. 0. 0. 800.
LIME/ALKALINE FLYASH
COLSTHIP 1 ' 3«>0 Sb°
COLSTRIP 8 5t>° 36°
MILTON R. YOUNG i fl^°
TOTAL 0- 1170. 3bO. 360.
LIMESTONE
APACHE 2 ?0° ??•
CHOLLA 1 »" »«
CMOLLA ? 2^0 f"
OUCK CREtK I «<"> ^an q°°
JEFFREY 1 6BO 68°
L* CY6NE 1 •« MO
LAV.RENCE a •« '"
LAURENCE S a°° _„_ a°°
MARTIN LAKE 1 793 '«
MONTJCELLO 3 750 750
PETERS60RG 3 530 «o
R. D. MORROW 1 >«0 - 1B
SCHOLZ IB t 2B " "
TOMBI6BEE i. ll* e" ssfl
NIOOMS CREEK 6 ll°. Ill
WINYAH 2 2«° "°
TOTAL 2«3' q068'
LIMESTONE/ALKALINE FLYASH
SHERBURNE 1 !}° J|"
SHERB1IRNE 2 7l° ?1°
TOTAL °- la20' la20'
SODIUM CARBONATE
REID GARDNER 1 I2S
-------
EPA UTILITY FGI1 SuHtfF.Y: AUGUST 1978 - StHIFMHE* 1S7B
SECTION 8
SIIMMAHY |,F SLUUGE DISPOSAL PRACTICES FUR OPERATIONAL Flip SYSTEMS
I INC. MNl I --SLUDbF-- —aLUObE— ---PUND--- ---PuNO---
STAHILIZtO UMSTAHILIZEH LlNFO UNLINED
WE 10
0. 3/«i. 0.
-------
EPA UTILITY FGD SURVEY: AUGUST \
-------
EPA UTILITY FtO SurtVEY: AUGUST 1978 - StPIEMREW I47B
StCTTUN 9
SUMMARY OF FGO SYSTEMS «Y PROCESS AND KEGULATOKY CLASS
KkGULATURY OPERATIONAL
PHOCFSS CLASS
DOUBLE ALKALI
MAGNESIUM OXTDE
NUT SELECTED
SOPIUM CAkHONATE
*
HEILMAN LORD
TUTALS
LIME/STONE 1 OF TOTAL MM
A
H
C
I)
t
A
H
C
U
t
A
h
C
0
t
A
b
C
U
E
A
t)
C
1)
E
A
h
C
1)
E
A
B
C
0
E
NO.
0
0
0
0
0
0
1
0
0
0
b
0
0
0
0
3
b
b
b
0
0
2
1
0
0
It.
23.
8.
0.
0.
MM
b
0
b
0
b
u
120
U
0
0
b
0
0
0
0
375
0
b
b
b
b
h?0
115
b
0
5(>bl.
8Mb.
165/.
0.
b.
93
92
93
b
0
CONSTRUCTION
NO.
2
1
0
0
b
b
b
0
0
0
0
0
0
0
b
0
i
b
b
0
o
0
1
0
b
20.
15.
i.
0.
b.
MM
825
ill
0
0
b
0
u
o
0
0
b
b
0
0
0
0
509
b
b
0
0
0
iao
o
u
84H2.
babe.
1 I8b.
0.
0.
8b
87
85
b
0
CONTRACT
AWARDED
NP.
0
0
0
0
0
0
0
0
0
0
0
2
0
0
0
0
b
0
b
n
0
2
0
b
I)
12.
10.
t.
0.
0.
Mn
0
0
0
0
0
0
0
0
0
0
0
1510
0
0
0
0
0
0
0
0
0
940
b
0
0
V»95.
6355.
100.
0.
0.
100
bl
b
0
0
PLANNED
NO.
0
o
0
b
0
0
3
0
b
0
14
4
2
0
0
0
0
b
b
b
0
b
b
b
0
17.
13.
2.
0.
b.
Mh
b
b
b
b
b
b
72b
b
b
0
7050
1 755
590
b
b
0
0
b
b
b
b
0
0
b
b
915b.
5010.
590.
0.
b.
23
50
0
0
0
TOTAL NO.
PLANTS
NO
2
1
0
0
b
b
4
0
b
0
14
b
2
b
0
3
1
b
b
0
b
4
2
b
0
b4.
bl.
14.
0.
0.
MN
825
277
0
0
u
b
d4b
0
b
0
705b
32b5
590
0
0
375
509
0
b
b
0
15t>0
295
0
0
29288.
2b5b7.
3527.
0.
b.
70
75
72
b
b
A. BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
B. BOILER SUBJECT TO STATE STANDARD THAT 13 MORE STRINGENT THAN THE FEDERAL NSPS
C. BOILER SUBJECT ID STATE STANDARD THAT IS EQUAL TO OR LESS STRINGENT THAN NSPS
D. OTHER
E. REGULATORY CLASS UNKNOMN
92
-------
EPA uriLUT FGD SURVEY: AUGUST 1978 - SEPTEMBER i97e
SECTION to
SUMMAWY Of FGD SYSTEMS UNDER CONSTRUCTION
UTILITY COMPANY
STATION
NtW OH
RETROFIT
SI If OF hGII
UN II (Mn)
PHOCESS/VENOOH
ALABAMA ELECTRIC COOP
TOMBIGBEE 3
ALLEGHENY POWER SYSTEM
PLEASANTS i
ALLEGHENY POnER SYSTt*
PLFASANTS 2
ARIZONA ELECTRIC POME" COOP
APACHE 3
ARIZONA PUBLIC SERVICE
CHOLLA a
BASIN ELECTRIC PUMER COOP
LARAHIE RIVER 1
BASIN ELECTRIC POWER COOP
LARAMIE RIVER 2
BIG RIVERS ELECTRIC
GREEN 1
BIG RIVERS ELECTRIC
GREEN 2
CENTRAL ILLINOIS PUBLIC SERV
NEnTON I
COLORADO IITE ELECTRIC ASSN.
CRAIG 1
COLORADO UTE ELECTRIC ASSN.
CRAIG Z
COMMONWEALTH EDISON
PONERTON SI
COOPERATIVE POBER ASSOCIATION
COAL CREEK 1
COOPERATIVE POWER ASSOCIATION
COAL CREEK Z
DELMARVA POWER 4 LIGHT
DELWARE CITY 1, Z ft 3
HOOSIER ENERGY
MEROH 1
HOOSIER ENERGY
MEROM 2
INDIANAPOLIS POWER ft LIGHT
PETERSBURG 4
KANSAS POWER ft LIGHT
JEFFREY 2
LOUISVILLE GAS ft ELECTRIC
CANE RUN 6
LOUISVILLE GAS t ELECTRIC
MILL CREEK 1
LOUISVILLE GAS ft ELECTRIC
MILL CREEK 4
aon
550
S70
S70
57S
aso
flbO
54S
54S
180
490
490
530
680
277
330
495
PF.AHODY ENGINEERING
LIMESTONE
HAHfOCK K ftlLCOX
LIME
HArtCOCK K nILCOX
LIMF
RESEARCH COTTRELL
LIMESTONE
RESEARCH COTTRtLL
LIMESTONE
RESEARCH COTTRELL
LIMFSTONE
HESEARCH COTTRELL
LIMFSTONE
AMtRiCAN AIR FILTER
LIME
AMERICAN AIR FILTER
LIME
BUELL/ENVIROTECH
DOUBLE ALKALI
PEABOOr ENGINEERING
LIMESTONE
PFA800T ENGINEERING
LIMFSTONE
AIR CORRECTION DIVISION, UOP
LIMESTONE
COMBUSTION ENGINEERING
LIME
COMBUSTION ENGINEERING
LIME
DAVY POhERGAS
WELLMAN LORD
MITSUBISHI INTERNATIONAL
LIMESTONE
MITSUBISHI INTERNATIONAL
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
COMBUSTION ENGINEERING
LIMESTONE
AOL/COMBUSTION EQUIP ASSOCIATE
DOUBLE ALKALI
COMBUSTION ENGINEERING
LIME/LIMESTONE
AMERICAN AIR FILTER
LIME
START-UP
DATE
6/79
3/79
3/80
4/79
6/80
4/8U
10/8U
J2/79
12/80
11/79
3/79
3/79
3/79
2/79
11/79
4/80
4/81
1/82
4/82
6/80
12/78
1/81
6/80
93
-------
EPA UTILITY FbO SURVEY: AUGUST 1978 - SEPTEMBER 1978
SECTION 10
SUMMARY UF FGD SYSTEMS UNDER CONSTRUCTION
UTILITY COMPANY
POHEM STATION
MINNESOTA POKER ft LIGHT
CLAY ROSNELL «
OTTER TAIL POWER
COYOTE 1
PACIFIC POrtFH ft LIGHT
JIM dlilDGER 4
PENNSYLVANIA POKE"
BRUCE MANSFIELD 3
SALT RIVER PROJECT
CORONADO t
SALT RIVER PROJECT
CORONADO t
SAN MIGUEL ELECTRIC COOP
SAN MIGUEL 1
SIKESTON HOARD OF MUNIC. UTIL.
SIKESTON POWER STATION
SOUTHERN ILLINOIS POHER COOP
MARION 4
SOUTHERN INDIANA GAS > ELEC
A. B. BROHN 1
SOUTHERN MISSISSIPPI ELECTRIC
R. D. MORROh 2
ST. JOE ZINC
6. F. BEATON 1
TENNESSEE VALLEY AUTHORITY
NlDOitS CREEK 7
TEXAS UTILITIES
MARTIN LAKE 3
UTAH POHER ft LIGHT
EMERY I
NEM OH
RETROFIT
SIZE OF FGD
UNIT (MN)
500
PROCESS/VENDOR
START-UP
DATE
PEA800Y ENGINEERING 5/80
LIME/ALKALINE FLYASH
400 MHEELADRATOR-FrfVE/A.I. 5/61
AQUEOUS CARBONATE
AIR CORRECTION DIVISION, UOP 9/79
SODIUM CARBONATf
PULLMAN KELLOGG a/au
LIME
350 PULLMAN KELLOGG 1/79
LIMESTONE
350 PULLMAN KELLOGG 1/60
LIMESTONE
400 BABCOCK ft NILCOX 6/80
LIMESTONE
235 BABCOCK ft MILCOX 6/61
LIMESTONE
1B4 BABCOCK ft HILCOX 9/76
LIMESTONE
250 FMC CORPORATION 4/79
OOUBLE| ALKALI
180 KILEV STOKER / FNVIRONEEHING 1/79
LIMESTONE
60 BUREAU OF MINES 12/76
CITRATE
575 COMBUSTION ENGINEERING 10/60
LIMESTONE
793 RESEARCH COTTRELL 12/76
LIMESTONE
400 CHEMICO 12/76
LIME
94
-------
EPA utiLTTT FGO SURVEY: AUGUST 1970 - SEPTEMBER 1978
SECTION 11
SUMhARY OF PLANNED FRO SYSTEMS
UTILITY COMPANY
POnEK STATION
CONTRACTS ArtAHOED
ARI70NA PUBLIC SERVICE
FOUR CUNNFxS 0
ARIZONA PUHL1C SERVICF
FOUR CORNERS 5
AssociATto ELECTRIC COOP
THOMAS HILL 5
BASIN FLtCIRIC POKtH COOP
ANTFLOPF VALLEY 1
CINCINNATI GAS ft ELECTRIC
EAST BEND i
EASTERN KENTUCKY PUHER COOP
SPURLOCK i
LAKELAND UTILITIES
MCINTOSH 3
LOUISVHLF GAS ft ELECTRIC
MILL CHFFK 2
MONTANA PCIHEH
COLSIRIP J
MONTANA POftFR
COLSTRIP 4
NIAGARA MOHAWK PO"ER COOP
CHARLES R. HUNTLEY b
NORTHERN STATES POOER
SHERHIIRNE 3
NORTHERN STATES POMER
SHERdURNfe 4
PUBLIC SERVICE OF NE" MFXICO
SAN JUAN 3
PUBLIC StRVICE OF NEW MEXICO
SAN JUAN a
SOUTH CAROLINA PUBLIC SERVICE
MlfcYAH 3
SOUTHHESTERN ELECTRIC POMER
HFNRY N. PERKEY t
SPRINGFIELD HATER LIGHT S PUR
DALLMAN 3
TEXAS MUNICIPAL POMER AGENCY
GIBBONS CREEK I
TEXAS POMER ft LIGHT
SANDON a
TEXAS UTILITIES
MARTIN LAKE 4
UTAH POMER » LIGHT
EMERY 2
WISCONSIN POMER * LIGHT
COLUMBIA 2
Hi* OR
RETROFIT
K
h
N
N
r.
N
N
R
N
N
R
N
N
N
N
N
N
h
N
N
N
N
St/E OF FGli Vt-NDOR/PRUCESS
UNIT (Mn)
7SS
7->5
670
ab5
600
SOO
5bO
330
7UO
700
100
860
8hO
flbfl
072
300
720
190
aoo
5«5
793
aoo
527
UNITtD FNG1NEFRS
NOT SELECTtn
UNITED ENGINEFRS
NOT SELECTED
HULLMAN KELLOGG
LIMESTONt
NOT SELECTEO
LIMF
HAHCOCK « AILCUX
LIME
COMBUSTION FNGINEERING
LIMF.
UABCOCK « NILCUX
LIMESTONE
COMHUS110N ENGINtERlNG
LlME/LlMtSTONF
AOL/COMBUSTION EUUIP ASSOCIATE
LIME/ALKALINE FLYASH
AOL/COMBUSTION EUUIP ASSOCIATE
LIME/ALKALINE FLYASH
ATOMICS INTERNATIONAL
AI1UEOUS CARBONATE
COMBUSTION ENGINEERING
LIMFSTONE/ALKALINE FLYASH
COMBUSTION ENGINEERING
LIMESTONE/ALKALINE FLYASH
OAVY POKERGAS
MELLMAN LOhD
OAVY PUHERGAS
MELLMAN LORD
HAHCOCK ft MILCOX
LIMESTONE
AIR CORRECTION DIVISION* UOP
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
COMBUST IUN ENGINEERING
LIMESTONE
COMBUSTION ENGINEERING
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
CHEMICO
LIME
CHEMICO
START-UP
DATE
0/62
0/S2
1/62
11/81
1/81
3/80
10/81
1/82
7/80
7/81
0/80
5/8a
0/87
6/79
1/82
5/80
2/84
7/80
1/82
7/80
11/82
6/80
1/80
LIME/ALKALINE FLYASH
95
-------
FPA UTILITY FGD SURVEY: AUGUST 1978 - SfcPTFMBEH 1978
UTILITY COMPANY
POKFK STATION
SECTION II
SUMMARY OF PLANNED F6D S»STK"S
NE« OK SIZE OF FRO VENDOK/PROrESS
RETROFIT UNIT (Mn)
START-UP
OATF
LETTER OF INTENT SIGNtU
PHILADELPHIA ELECTRIC
EODrSTONE IB
UNITED ENGINEERS
MAGNESIUM OXIDE
6/8U
HEUUEStING/EVALUATlNfc HIUS
t.
BASIN ELECTRIC POnER COOP
LAMAMIE RIVER 3
CENTRAL ILLINOIS LIGHT
U'ICK CRFfcK 2
PUBLIC SERVICE OF INDIANA
GIBSON 5
TFXAS UTILITIES
FORFST GROVE I
400
*>50
NOT SELECTED
NOT SELECTED
NOI SELECTED
NOT SELECTED
NUT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
4/62
1/82
0/82
0/81
CONSIDERING FGD SYSTEM
AR1/ONA PUBLIC SERVICE
FOUR CORNFRS 1
ARIZONA PllbLIC SERVICE
FOUR CURNERS ?
ARIZONA PUBLIC SERVICE
FOUR CORNERS 3
BASIN ELECTRIC POHER COOP
ANTELOPF VALLEY 2
CENTRAL MAINE POWER
SEARS ISLAND 1
COLUMBUS » SOUTHERN OHIO ELEC.
POSTON 5
COLUMBUS ft SOUTHERN OHIO ELEC.
POSTON 6
GFNErtAL PUBLIC UTILITIES
COHO 1
GENERAL PUBLIC UULITIES
SEHARD 7
NEVADA PONER
HARRY ALLEN 1
NEVADA POWER
HAMRY ALLEN 2
NEVADA PONER
HARRY ALLEN 3
NEVADA POKER
HARRY ALLEN 4
NEVADA POWER
REID GARDNER 4
NEVADA POKER
WARNER VALLEY 1
NEVADA PUNER
WARNER VALLEY Z
175
175
229
455
800
375
375
800
800
500
500
500
500
250
250
250
CHEMICO/APS
LIMF/ALKALINE FLYASH
CHEMICO/APS
LIME/ALKALINE FLYASH
CHEMICO/APS
LIME/ALKALINE FLYASH
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
NOT SELECTED
0/79
0/79
0/79
11/83
11/86
0/83
0/85
5/67
5/84
6/85
6/86
6/67
6/68
0/83
6/84
6/65
-------
EPA UTILITY FGO SURVEY: AUGUST I<»7H - SEPTEMBER 1978
SECTION 11
OF PLANNED FGO SYSTEMS
UTILITY COMPANY
POMEH STATION
NORTHERN INDIANA PUB SERVICE
BAILLY 7
NORTHERN INDIANA PUR SERVICF
BAILLY 8
PACIFIC GAS AND ELtCIRIC
FOSSIL 1
PACIFIC GAS AND ELECTRIC
FOSSIL a
PHILADELPHIA ELECTKIC
CROMbY
PHILADELPHIA ELECTRIC
tOOYSTONt t
SALT BIVEB PROJECT
CORONADO 3
SFHINOLE ELECTRIC
SEHINOLE I
SOUTHERN ILLINOIS POWER COOP
HAHION 5
TEXAS POrtER « LIGHT
TWIN OAKS 1
TEXAS POftEH ft LIGHT
TWIN OAKS 3
NtM OR
RETROFIT
SIZF OF FT,I)
UMf
VtNDOR/PHOCESS
I-JO NOT SELECTED
MOT SELECTED
100 NOT SELECTED
NOT SELECTED
flOO M)T SELECTtD
LIMESTONE
BOO NOT SELECTED
LIMESTONE
IbO UNITED ENGINEERS
MAGNESIUM OXIOfc
lih UNITED ENGINEERS
MAGNESIUM OXIDE
ISO NOT SELECTED
LIMFSTONE
*00 NOT SELECTED
LIMESTONE
300 NOT SELECTED
NOT SELECTED
750 NOT SELECTED
LIMESTONE
7bO NOT SELECTED
LIMESTONE
START-UP
OATE
O/ (j
O/ U
0/85
0/Bb
b/80
6/80
0/87
6/83
0/80
8/83
97
-------
EPA UTILITY FGO SURVEt: AUGUST 1"78 - SEPlFMHtR 1978
SECTION
TOTAL FGO MEGAnATT CAPACITY BY YEAH
YFAR NO. UNITS
1<*6«
1971
197?
1973
1974
1975
1976
1977
1978
1979
I960
1981
19(12
1903
1984
I98S
1986
1987
1988
UNDEFINED
1
1
4
4
2
4
6
10
19
18
24
9
12
5
6
4
3
4
1
2
12*
400
£20
141U
250
1054
2313
4921
7075
6626
10348
4310
6795
243U
3680
1925
1900
2510
500
590
• TOTALS DISPLAYED DO NOT INCLUDE TERMINATED OR INACTIVE SYSTEMS.
98
-------
APPENDIX A
FGD SYSTEMS ECONOMICS
A-l
-------
INTRODUCTION
The cost of flue gas desulfurization (FGD) systems for the
control of sulfur dioxide emissions is an area of intense inter-
est and substantial controversy. As a result, many computer
models have recently been developed to estimate capital and
annual costs. As part of an effort by the U.S. Environmental
Protection Agency to provide meaningful economic data concerning
FGD systems, reported economic data have been incorporated into
the EPA Utility FGD Survey report. This information has appeared
as a separate appendix of the report since October 1976. Until
January 1978, this cost appendix consisted entirely of data
reported by the utilities with little or no interpretation pro-
vided by PEDCo Environmental, Inc. Beginning with the May 1978
report, the format and content of the cost appendix were revised
to include reported and adjusted costs for the operational FGD
systems.
The rationale for including adjusted as well as reported
costs stems primarily from the lack of comparability of the
reported costs. Many of the reported cost figures, both capital
and operating, are largely site-sensitive values that cannot be
accurately compared because they refer to different FGD battery
limits and different years in which the expenditures were made.
As a result, an analysis of the cost data was made for the opera-
tional units since these systems offer the potential of having
complete and accurate economic data. The adjustments were made
to provide comparable, accurate cost data for the sulfur dioxide
portion of the emission control system. This, in effect, will
eliminate much of the confusion that exists concerning the re-
ported data, and it will provide a common basis for the reported
costs.
A-2
-------
APPROACH
In March 1978, each utility having at least one operational
FGD system was given a cost form containing all available cost
information then in the PEDCo files. The utility was asked to
verify the data and fill in any missing information called for
on the form. A follow-up visit by the PEDCo Environmental staff
was arranged to assist in data acquisition and to insure com-
pleteness and reliability of information. Results of the cost
analysis were forwarded to each participating utility for final
review and comment.
The cost data were treated solely to establish the accurate
costs for FGD systems, on a common basis, not to critique the
design or reasonableness of the costs reported by any utility.
Adjustments focused primarily on the following items:
0 All capital costs were adjusted to July 1, 1977, dol-
lars using the Chemical Engineering Index. All capital
costs, represented in dollars/kilowatt ($/kW), were
expressed in terms of gross megawatts (MW). Actual
costs were reported by utilities in dollar values for
years 1970 to 1980. These values are represented in
terms of the year of greatest capital expenditures.
0 Gross unit capacity was used to express all FGD capital
expenditures because the capital requirement of an FGD
system is dependent on actual boiler size before de-
rating for auxiliary and air quality control power
requirements.
0 Particulate control costs were deducted. Since the
purpose of the study was to estimate the incremental
cost for sulfur dioxide control, particulate control
costs were deducted using either data contained in the
cost breakdowns or as a percentage of the total direct
cost (capital and annual). The percentage reduction
varied depending upon system design and operation.
A-3
-------
The capital costs associated with the modification or
installation of equipment not part of the FGD system
but needed for its proper functioning, were included
(e.g. - stack lining, modification to existing ductwork
or fans, etc.).
Indirect charges were adjusted to provide adequate
funds for engineering, field expenses, legal expenses,
insurance, interest during construction, allowance for
startup, taxes, and contingency.
All annual costs, represented in mills/kilowatt-hour
(mills/kWh), were expressed in terms of net megawatts
(MW) .
Net unit capacity was used to express all FGD annual
expenditures because the annual cost requirement of an
FGD system is dependent on the actual amount of kilo-
watt-hours (kWh) produced by the unit after derating
for auxiliary and air quality control power require-
ments .
All annual costs were adjusted to a common capacity
factor (65 percent).
Replacement power costs were not included since only a
few utilities reported such costs and these were pre-
sented using a variety of methods.
Sludge disposal costs were adjusted to reflect the
costs of sulfur dioxide waste disposal only (i.e.,
excluding fly ash disposal) and to provide for disposal
over the anticipated lifetime of the FGD system. This
latter correction was necessary since several utilities
reported costs for sludge disposal capacity that would
last only a fraction of the FGD system life. The
adjustments were based on a land cost of $2000/acre
with a sludge depth of 50 ft in a clay-lined pond (clay
is assumed to be available at the site).
A 30-year life was assumed for all process and economic
considerations for all new systems that were installed
for the life of the unit. A 20-year life was assumed
for all process and economic considerations for retro-
A-4
-------
fit systems that were installed for the remaining por-
tion of the life of the unit.*
0 Regeneration and by-product recovery facility costs
were added for those regenerable systems not reporting
such costs.
To the extent possible, all cost adjustments were made using
the previous assumptions developed by PEDCo Environmental. When
cost data were inadequate, adjustments were made using process
design data in conjunction with the previous cost assumptions.
In some cases, no adjustments were possible because of in-
sufficient data.
* The use of a 30-year service life for new units coincides with
the conclusion of the National Power Survey of the Federal
Power Commission which recognized this value as reasonable for
steam-electric plants. A 20-year service life was assumed for
all retrofit units even if the remaining life of the units is
less than this value. Thus, two different rates are used and
should be noted when making comparisons between new and retro-
fit systems.
A-5
-------
DESCRIPTION OF COST ELEMENTS
Capital costs consist of direct costs, indirect costs, con-
tingency costs, and other capital costs. Direct costs include
the "bought-out" cost of the equipment, the cost of installation,
and site development. Indirect costs include interest during
construction, contractor's fees and expenses, engineering, legal
expenses, taxes, insurance, allowance for start-up and shake-
down, and spares. Contingency costs include those costs result-
ing from malfunctions, equipment alterations, and similar un-
foreseen sources. Other capital costs include the nondepreciable
items of land and working capital.
Annual costs consist of direct costs, fixed costs, and over-
head costs. Direct costs include the cost of raw materials,
utilities, operating labor and supervision, and maintenance and
repairs. Fixed costs include those of depreciation, interim
replacement, insurance, taxes, and interest on borrowed capital.
Overhead costs include those of plant and payroll expenses. The
various capital and annual cost components are discussed and
defined in greater detail in the following paragraphs.
The direct capital costs include the following elements:
c Equipment required for the FGD system. Table A-l
provides a summary of the major process equipment used
in regenerable and nonregenerable systems.
0 Installation of equipment, including foundations; steel
work for support, buildings, piping and ducting for
effluents, slurries, sludge, and make-up water, control
panels, instrumentation, insulation of ducting, buildings,
piping, and other equipment, painting and piling.
0 Site development may include clearing and grading,
construction of access roads and walkways, establish-
ment of rail, barge, and/or truck facilities, and
parking facilities.
A-6
-------
TABLE A-l. MAJOR PGD SYSTEM EQUIPMENT SUMMARY
Category
Description
Material handling-
raw materials
Feed preparation-
raw materials
Sulfur dioxide
absorption
Flue gas reheat
Gas handling
Sludge disposal
Utilities
By-product
handling
Equipment for the handling and transfer of
raw materials includes unloading facilities,
conveyors, storage areas and silos, vibrators,
atmospheric emission control associated with
these facilities, and related accessories.
Equipment for the preparation of raw material
to produce a feed slurry consists of feed
weighers, crushers, grinders, classifiers,
ball mills, mixing tanks, pumps, agitators,
and related accessories.
Equipment for treating the flue gas includes
absorbers, mist eliminators, hold tanks,
agitators, circulating pumps, pond water re-
turn pumps, and related accessories.
Equipment required includes air, steam, or
hot water heaters, condensate tanks, pumps,
soot blowers, fans, fuel storage facilities,
gas bypass equipment, and related accessories.
Equipment to handle the boiler flue gas in-
cludes booster fans, ductwork, flue gas by-
pass system, turning vanes, supports, plat-
forms, and related accessories.
Nonregenerable FGD systems require solids/
water separation equipment such as clarifiers,
vacuum filters, centrifuges, sludge fixation
equipment, and related accessories.
Equipment to supply power and water to the
FGD equipment consists of switch-gear, break-
ers, transformers, piping, and related
accessories.
Equipment for processing the by-product of
regenerable FGD systems may include a rotary
kiln, fluid bed dryer, conveyor, storage silo,
vibrator, combustion equipment and oil stor-
age tanks, waste heat boilers, hammer mills,
evaporators, crystallizers, strippers, tanks,
agitators, pumps, compressors, sulfuric acid
absorber and cooling, mist eliminator, pumps,
acid coolers, tanks, etc.
(continued)
A-7
-------
TABLE A-l. (continued)
Category
Description
Regeneration
Purge treatment
Auxiliary
Equipment for regeneration of the absorbing
medium of an FGD system may consist of re-
actor vessels, material handling system,
storage, weigh feeder, conveyor, rotary kiln,
fluid bed calciner, dust collector, storage
silo, vibrator, combustion equipment and oil
storage tanks, waste heat boiler, hammer
mill, evaporators, crystallizers, strippers,
tanks, agitators, pumps, compressors, sul-
fur ic acid absorber and cooling, mist elimi-
nator, pumps, acid coolers, tanks, etc.
Equipment for the removal of purge material
(e.g. sodium sulfate) includes refrigeration,
pumps, tanks, crystallizer, centrifuge,
dryer, dust collector, conveyors, storage,
and related equipment.
Equipment not directly related to the
FGD system, but which may require design or
modification to accommodate an FGD system
may include such items as existing fans,
ducts, or stack. If new fans, ducts, or
stacks are added to improve boiler perfor-
mance and accommodate the FGD systen, the
costs are prorated to the boiler and FGD
system.
A-8
-------
Indirect capital costs include the following elements:
0 Interest accrued on borrowed capital during construction,
0 Contractor's fee and expenses, including costs for
field labor payroll; field office supervision; person-
nel; construction offices; temporary roadways; railroad
trackage; maintenance and welding shops; parking lot;
communications; temporary piping and electrical and
sanitary facilities; safety security (fire, material,
medical, etc.); construction tools and rental equip-
ment; unloading and storage of materials; travel ex-
penses; permits; licenses; taxes; insurance; overhead;
legal liabilities; field testing of equipment; start-
up; and labor relations.
0 Engineering costs, including administrative, process,
project, and general; design and related functions for
specifications; bid analysis; special studies; cost
analysis; accounting; reports; consultant fees; pur-
chasing; procurement; travel expenses; living expenses;
expediting; inspection; safety; communications; model-
ing; pilot plant studies (if required because of pro-
cess design or application novelty); royalty payments
during construction; training of plant personnel; field
engineering; safety engineering; and consultant ser-
vices .
0 Legal expenses, including those for securing permits,
rights-of-wayf etc.
• Taxes, including sales, and excise taxes.
0 Insurance covering liability for equipment in transit
and at site; fire, casualty, injury, and death; damage
to property; delay; and noncompliance.
« Allowance for start-up and shakedown includes the cost
associated with system start-up.
0 Spare parts including pumps, valves, controls, special
piping and fittings, instruments, spray nozzles, and
similar items.
Other capital costs include the following elements:
• Land required for the FGD process, waste disposal, re-
generation facility, and storage.
e Working capital, including the total amount of money
invested in raw materials and supplies in stock,
finished products in stock, and unfinished products
A-9
-------
in the process of being manufactured; accounts re-
ceivable; cash kept on hand for payment of operating
expenses such as salaries, wages, and raw materials
purchases; accounts payable; and taxes payable.
Annual cost of an FGD system includes the following direct,
fixed and overhead charges:
e Direct Charges
• Raw materials, including those required by the FGD
process for sulfur dioxide control, absorbent regenera-
tion, sludge treatment, sludge fixation, flocculants,
etc.
Utilities, including water for slurries, cooling and
cleaning; electricity for pumps, fans, valves, lighting
controls, conveyors, and mixers; fuel for reheating of
flue gases; and stream for processing.
Operating labor, including supervisory, skilled, and
unskilled labor required to operate, monitor, and
control the FGD process.
* Maintenance and repairs, consisting of both manpower
and materials to keep the unit operating efficiently.
The function of maintenance is both preventive and
corrective to keep outages to a minimum.
Byproduct Sales; credit from the sale of byproducts
regenerable FGD processes (e.g. sulfur, sulfuric acid)
is a negative charge deducted from the annual direct
cost to obtain the net annual direct cost of the FGD
system.
e Fixed Charges
Depreciation - the annual charge to recover direct and
indirect costs of physical assets over the life of the
asset.
• Interim, replacement - costs expended for temporary or
provisional replacement of equipment that has failed or
malfunctioned prematurely.
• Insurance, including the costs of protection from loss
by a specified contingency, peril, or unforeseen event.
Required coverage could include losses due to fire,
personal injury or death, property damage, explosion,
lightning, or other natural phenomena.
A-10
-------
Taxes, including franchise, excise, and property taxes
levied by a city, county, state, or Federal government.
Interest on borrowed funds.
0 Overhead
Plant and administrative overhead is a business expense
that is not charged directly to a particular part of a
project, but is allocated to it. Overhead costs in-
clude administrative, safety, engineering, legal and
medical services; payroll; employee benefits; recrea-
tion; and public relations.
Table A-2 provides a summary of the means used to determine
the missing cost elements if the costs were not reported or
insufficient information prevented their actual determination.
The assumptions and cost bases for determining the capital and
annual costs of FGD systems were developed by the PEDCo staff
based upon previous economic studies conducted for the U.S. EPA
(Flue Gas Desulfurization Process Cost Assessment, May 1975;
Simplified Procedures for Estimating Flue Gas Desulfurization
System Costs, June 1976, EPA-600/2-76-150; Particulate and Sulfur
Dioxide Emission Control Costs for Large Coal-Fired Boilers,
March 1978, EPA-600/7-78-032).
A-ll
-------
TABLE A-2. COST ELEMENT FACTORS
Category
Value
Indirect capital costs:
Interest during
construction
Field overhead
Contractor's fee and
expenses
Engineering
Taxes
Spares
Shakedown allowance
Other capital costs:
Contingency8
Direct annual costs:
Raw materials:
Fixation chemicals
Lime
Limestone
Magnesium oxide
Sodium carbonate
Salt cake (credit)
Sulfur (credit)
Sulfuric acid (credit)
Utilities:
Electricity
Water
Steam
Operating labor:
Direct labor
Supervision
10% of total direct capital costs
10% of total direct capital costs
5% of total direct capital costs
10% of total direct capital costs
2% of total direct capital costs
1% of total direct capital costs
5% of total direct capital costs
20% of total direct and indirect
capital costs
$2/ton
$40/ton
$10/ton
$150/ton
$80/ton
$50/ton
$65/ton
$25/ton
25 mills/kWh
$0.20/103 gal
$0.SO/106 Btu
$8.50/man-hour
15% of direct labor costs
Contingency costs are used only when the cost data supplied are
incomplete (such as equipment costs or direct costs only) and a
contingency cost must be factored in to give an accurate estimate
of the total capital cost.
(continued) A-12
-------
TABLE A-2. (continued)
Category
Value
Maintenance:
Labor and materials
Supplies
Overhead:
Plant
Payroll
Fixed annual costs:
Depreciation
Interim replacement
Taxes
Insurance
Capital costs
4% of total direct capital costs
15% of labor and materials costs
50% of operation and maintenance costs
20% of operating labor costs
3.33% or 5% (new or retrofit)
0.7% or 0.35%
4%
0.3%
9%
Some system components have life spans less than the expected
service life of the system. Interim replacement is an allow-
ance factor used in estimating annual revenue requirements to
provide for the replacement of these short-lived items. An
average allowance of 0.35% of the total investment is normally
provided and used for systems with an expected service life of
20 years or less. A higher allowance of 0.70% of the total
investment is provided and used for systems with an expected
service life of 30 years or more.
A-13
-------
DEFINITION OF COST ELEMENTS
The costs displayed in Appendix A are accompanied by a
series of alphabetic characters summarizing data presented for
each FGD system. These relate to the cost elements described
earlier in this section and identify what has been included and
excluded for reported and adjusted capital and annual costs. The
alphabetic characters, along with their titles, are briefly de-
scribed in Table A-3.
A-14
-------
TABLE A-3. DESCRIPTION OF COST
Code
Title
Description
Particulate control (required for FGD pro-
cess) included in capital cost.
Particulate control (included in FGD
process) included in capital cost.
Total direct capital costs included.
Partial direct capital costs included.
Total indirect capital costs included.
L
N
N
0
Partial indirect costs included.
Chemical fixation of sludge included in
capital cost.
Dry sludge disposal included in capital
cost.
Off-site lendfill area included in
capital cost.
Sludge pond included in capital cost.
Additional sludge disposal capacity
added for life of system.
Stack included in capital cost.
Modifications to stack, ducts, and/or
fans included in capital cost.
Total regeneration facility cost included
in capital cost.
Partial regeneration facility cost in-
cluded in capital cost.
R 6 D costs included in capital cost.
Particulate precollection device (ESP,
fabric filter, venturi) prior to FGD
system required for proper operation of
S02 control system.
Particulate collection equipment (venturi
scrubber) is included in the FGD system.
Complete cost of all PT.D equipment, the
labor and materials required for equip-
ment installation, and interconnecting
the system is included in the total
capital cost.
One or a number of direct cost items, or
the cost associated with one or a number
of direct cost items, are excluded from
the total capital cost.
Complete cost of all the indirect cost
elements, including interest during con-
struction, contractor's fees, engineer-
ing, legal expenses, taxes, insurance,
allowance for start-up, and spares, is
included in total capital cost.
One or a number of indirect cost items,
or the cost associated with one or a
number of indirect cost items, are ex-
cluded from the total capital cost.
The cost of a chemical fixation process
which stabilizes the flue gas cleaning
wastes prior to disposal is included in
the total capital cost.
The cost of a secondary dewatering or
treatment method, such as filtration, cen-
trifugation, or forced oxidation, which
ultimately produces a dry sludge cake
for final disposal, is included in the
total capital cost.
The cost of an off-site area used as a
landfill for flue gas cleaning wastes is
included in the total capital cost.
The cost of an on-site disposal area for
ponding of treated or untreated flue gas
cleaning wastes is included in the total
capital cost.
The cost of additional SO, waste disposal
capacity required for FGD system operation
over the anticipated service life of the
unit is included in the total capital cost.
The cost of the stack is included in the
total capital cost.
Modifications to existing equipment (stack,
fans, ducts, etc.) which are required be-
cause of inclusion of an FGD system.
Complete cost of entire regeneration
facility included in total capital cost.
Part of the cost associated with the re-»
generation facility included in the total
capital cost.
Bench scale or pilot plant studies to de-
termine process and design characteristics.
(continued)
A-15
-------
TABLE A-3. (continued)
Code
Title
Description
H
X
Costs underwritten by system supplier in-
cluded in capital cost.
Excess reagent supply costs included in
capital cost.
Total direct annual costs included.
Partial direct annual costs included.
Total fixed annual costs included.
Partial fixed annual costs included.
Overhead cost included in total annual
cost.
Particulate control costs included in
direct annual cost.
Sludge disposal service costs (contract)
included in direct annual cost.
Replacement energy costs included in
total annual costs.
Capital expenditures underwritten by the
system supplier for system repairs or
modifications for optimisation of perfor-
mance or R t D programs.
Capital expenditures for reagent supply
exceeds the amount required for the period
of initial operation.
Complete cost of all raw materials,
utilities, operating labor and maintenance
and repairs is included in the total
annual cost.
One or a number of direct annual cost items,
or the cost associated with one or a number
of direct annual cost items, are excluded
from the total annual cost.
Complete cost of all fixed cost elements,.
including depreciation, interim replace-
ment, insurance, taxes, and interest, is
included in the total annual cost.
One or a number of fixed annual cost items,
or the cost associated with one or a
number of fixed annual cost items, are ex-
cluded from the total annual cost.
Plant and payroll overhead costs are in-
cluded in the total annual cost.
The cost of operating particulate collection
equipment included in the PGD system is in-
cluded in the total annual cost.
The treatment and disposal of flue gas
cleaning wastes that are handled by an
outside firm.
The cost of additional power-generating
capacity required to compensate for power
used by the FGD syst—
A-16
-------
RESULTS OF COST ANALYSIS
The results of the operational FGD system survey are
summarized in Tables A-4 and A-5. Table A-4 summarizes the re-
ported and adjusted capital and annual costs for all the
operational FGD systems addressed in the survey. Table A-5 pro-
duces a summary of a categorical analysis of the reported and ad-
justed capital and annual costs for the operational FGD systems
addressed in the survey. Included in this categorical analysis
are the ranges, means, and standard deviation for all the various
types and categories of FGD systems examined.
A-17
-------
TABLE A-4. REPORTED AND ADJUSTED CAPITAL AND ANNUAL
COSTS FOR OPERATIONAL FGD SYSTEMS*
Cholla 1
Cones vi lie 5
Elrama 1-4
Phillips 1-6
Petersburg 3a
Hawthorn 3-4
La Cygne 1
Green River 1-3
Cane Run 4
Cane Run 5a
Paddys Run 6
M.R. Young 2a
Colstrip 1-2
Reid Gardner 1-2
Reid Gardner 3
D.H. Mitchell 11
Sherburne 1-2
B. Mansfield 1-2
Eddystone 1A
Winyah 2
Southwest la
Widows Creek 8
Reported
Capital
$AW
52.0
55.6
113.5
107.0
99.5
29.3
53.7
70.3
66.6
62.4
52.9
86.0
77.1
42.9
113.6
•»
49.3
120.7
156.8
47.5
77.3
98.2
Annual
mills/kWh
2.19
4.71
8.62
7.83
8.40
1.70
14.35
2.75
0.27
2.10
2.10
1.99
13.18
1.61
2.99
Adjusted
Capital
$/kW
56.0
70.8
127.2
140.6
100.6
87.3
68.0
77.6
80.6
67.5
76.5
93.1
77.3
60.9
107.9
71.5
102.2
233.3
66.5
117.7
113.2
Annual
mills/kWh
2.58
7.42
7.81
8.57
6.56
4.35
3.78
5.24
5.78
5.56
6.51
5.16
4.06
3.20
4.38
2.77
7.67
2.92
6.17
5.28
a Annual costs were not reported by
because of the lack of meaningful
status.
the utility for this system
data due to recent operating
b Annual costs were not reported by the utility for this system
because of the lack of meaningful data due to peak load status
of unit.
c Reported and adjusted cost data are being assembled by project
participants.
d Annual cost data are being assembled by the utility.
* Newly operational units do not appear as cost data are currently
being assembled.
A-18
-------
TABLE A-5. CATEGORICAL RESULTS OF THE REPORTED AND ADJUSTED
CAPITAL AND ANNUAL COSTS FOR OPERATIONAL FGD SYSTEMS
All
New
Retrofit
•onregeo-
erable
Regenerable
LlBMtoni
Ue*
Alkaline/fly
Mh/ltBMtOM
Alkaline fly
••h/llM
SodlM
carbonate
Hagneeliai
oxide
Reported
Capital
Rar«e, $/kW
27.0-1S6.B
47. 5- 120. 7
27.0-156.8
27.0-120.7
156.8
57.5-99.5
27.0-120.7
•9.1
77.1-86.0
42.9-113.6
156.8
Avg.,
S/kH
77.6
78.0
77.2
73.7
156.8
71.4
75.1
49.3
81.6
78.3
156.8
o
32.2
26.8
37.8
27.3
23.7
31.7
6.3
50.0
Annual
Range.
•llla/kWh
0.27-14.35
0.27-13.18
2.10-14.35
0.27-14.35
1.61-3.00
2.75-14.35
1.99
0.27
2.10
A»g. .
•llla/kVh
*.77
3.65
5.74
4.77
2.13
8.08
1.99
0.27
2.10
a
4.32
4.41
4.28
4.32
0.64
4.34
Adluated
Capital
Range. $/kU
56.0-233.3
66.5-117.7
56.0-233.3
56.0-149.7
233.3
56.0-117.7
67.5-149.7
71.5
77.3-93.1
60.9-107.9
2.33.)
*v». ,
S/kW
95.8
87.6
103.4
89.0
213.)
87.0
94.1
71.5
85.2
84.4
233.3
0
40.1
18.9
52.5
25.4
26.7
29.3
11.2
33.2
Annual
Range,
•llla/kUh
2.58-9.54
2.77-7 67
2.58-9.54
2.58-9.54
2.58-6.56
4.09-9.54
2.77
4.06-5.55
3.20-4.38
Avg.,
•llla/kUh
5.53
5.13
5.92
5.53
4.55
7.03
2.77
4.81
3.79
0
2.09
1.79
2.38
2.09
1.69
1.81
1.05
0.83
-------
FP« UTILITY FliO SURVEY: AUGUST |97« - SEPTEMBER 197B
SECTION A-l PCD SYSTEM ECONOMICS: OPERATIONAL SYSTEMS
REPORTtO ANT) ADJUSTED COSTS
UTILITY
STATION
IINTT(S)
FRO MB
ELEMENTS
INCLUDFU IN
CAPITAL AND
ANNUAL COSTS
TOTAL ANNUAL - M1LLS/KNH
CAPACITY CAPITAL ———————
FACIOR »/KH TOTAL DIRECT FIXED
X (YFAR) (YEAR)
ALABAMA ELECTRIC COOP
TUMHI6HEE
2
25S
C.E.J
*•••*••*•**»••• REPORTED •••••»•••••••••
69.5
(1978)
••••••••••••••• ADJUSTED •••*••*•••«••••
ARIZONA ELFCTHIC POwEH COUP
APACHE
2
200 B.C
••*•*•••*••*••• REPORTED «••»••••••••••«
5.3
(197H)
•••••*•••**•*•• ADJUSTED •••••**•»••*•••
ARIZONA PUBLIC SERVICE
CHOLLA
1
B,C.E,S.H,X ••••••••••••••• REPORTED ••••••**»••••*•
8b 52.0 2.19
(1973) (1976)
C,E»K,S,U,H •••••••••••••*• ADJUSTED •«••••••••»••••
bb 56.0 2.58 .08 2.10
(1977) (1977)
CENTRAL ILLINOIS LIGHT
DUCK CREEK
1
aoo C.F.J.M
••*••*•••***••• REPORTED •»••••*•••*••••
93.3 3.31
(1978) (1976)
••••••••••••••• ADJUSTED •••••••*•*••••*
COLUMBUS ft SOUTHERN OHIO ELEC.
CONESVILLE
s
an B,C,J,M,T,M ••••*••.»*••••• REPORTED *•*•••****•**•*
,1 SI 5b.6 a.71 a.71
(1975) (1977)
CrE»J.M,S,u •••«•••••••»••• ADJUSTED •••••*•••**••••
,w,Y 6b 70.8 7.a2 S.06 2.36
(1977) (1977)
COS1 ELEMENTS
CAPITAL:
A - PARTICULATE CONTKOL (REQUIRED FOR FGO PROCESS) INCLUDED IN CAPITAL COST
B - PARTICULATE CONTROL (INCLUDED IN FGD PROCESS) INCLUDED IN CAPITAL COST
C - TOTAL DIRECT CAPITAL COSTS INCLUDED
0 - PARTIAL DIRECT CAPITAL COSTS INCLUDED
E - TOTAL INDIRECT CAPITAL COSTS INCLUDED
F - HAHTJAL INDIRECT CAPITAL COSTS INCLUDED
G - CHtMICAL FIXATION Of SLUDGE INCLUDED IN CAPITAL COST
H - DRY SLUDGE DISPOSAL INCLUDED IN CAPITAL COST
I - OFF-SITE LANDFILL AREA INCLUDED IN CAPITAL COST
J - SLUDGE POND INCLUDED IN CAPITAL COST
K - ADOITONAL SLUDGE DISPOSAL CAPACITY ADDED FOR LIFE OF SYSTEM
L - STACK INCLUDED IN CAPITAL COST
M - MODIFICATIONS TO STACK, DUCTS. AND/OH FANS INCLUDED IN CAPITAL COST
N - TOTAL REGENERATION FACILITY COST INCLUDED IN CAPITAL COST
0 - PARTIAL REGENERATION FACILITY COST INCLUDED IN CAPITAL COST
P - R t D COSTS INCLUDED IN CAPITAL COST
0 - COSTS UNDERWRITTEN BY SYSTEM SUPPLIER INCLUDED IN CAPITAL COST
R - EXCESS REAGENT SUPPLY COSTS INCLUDED IN CAPITAL COST
ANNUAL:
S - TOTAL DIRECT ANNUAL COSTS INCLUDED
T • PARTIAL DIRECT ANNUAL COSTS INCLUDED
U - TOTAL FIXED ANNUAL COSTS INCLUDED
V - PARTIAL FIXED ANNUAL COSTS INCLUDED
H - OVERHEAD COSTS INCLUDED IN TOTAL ANNUAL COSTS
X • PARTICULATE CONTROL COSTS INCLUDED IN DIRECT ANNUAL COSTS
Y - SLUDGE DISPOSAL SERVICE COSTS (CONTRACT) INCLUDED IN DIRECT ANNUAL COSTS
Z - REPLACEMENT ENERGY COSTS INCLUDED IN DIRECT ANNUAL COSTS
A -20
-------
UTILITY
STATION
EPA uTfLUY FGD SURVEY: AUGUST 197* - SEPTEMBER 1978
SECTION A-l FGO SYSTfM ECONOMICS: DfrEMATIONAL SYSTEMS
REPOkTfcO ANO ADJUSTED COSTS
TOTAL ANNUAL - MlLLS/KnH
CAPACITY CAPITAL
FACTOK S/KM TOTAL oiwtCT FIXED
* (YFAH) (YEAR)
INCLUOFD IN
CAPITAL AND
FC,D MH ANNUAL COS1S
COLIJMbllS & SOUTHERN (IHIU kLEC.
CONESVtLLE
6
411
C.F.J.M.S.U
•51
65
55.6
(1975)
REPORTtU
70.8
(1977)
AOJUSTFO
DUQUESNE LIGHT
ELRAMA POWER STATION
510 H.n.F.I.J.M
fT.V.X.Y
C.F,I,J,M,S
,U,T
»«»<•««...« REPORTED •«»•»•••«••••••
04 113.5 5.31 2.82 2.49
(1976) (1977)
............ ADJUSTED •••«».•••«•••••
65 127.2 7.81 3.36 4.45
(1977) (1977)
DIJQUESNE LIGHT
PHILLIPS POfcER STATION
4to H,n.F,t,j,h
iT.V.X.Y
C,E(I,J,H,S
............... REPORTED ...............
70 107.0 7.83 3.69 4.14
(1972) (1977)
............. ADJUSTED «..«....«...«..
65 140.6 8.57 3.58 4.99
(1977) (1977)
INDIANAPOLIS POKER & LIGHT
PETERSBURG
3
532 C,F,G,J,M
C»E f (»f J f Hf S
>U,M,Y
65
i..... REPORTED »»*«««««»«*•»•*
99.5
(1976)
>...•• ADJUSTED ...............
100.6 6.56 3.57 2.99
(1977) (1977)
KANSAS CITY PUHER ft LIGHT
HAWTHORN
3
110 8,0,F,T,X
B,C.E,J,K,3
............... REPORTED «*«•»«»*««««•»•
14 29.3 8.40
(1972) (1977)
............... ADJUSTED «•»»«**»«««««••
65 87.3 4.35 2.93 1.42
(1977) (1977)
COST ELEMEN1S
CAPITAL:
A - PARTICIPATE CONTROL (REQUIRED FOR F6D PROCESS) INCLUDED IN CAPITAL COST
B - PANICULATE CONTHOL (INCLUDED IN FGD PMOCESS) INCLUDED IN CAPITAL COST
C - TOTAL DIRECT CAPITAL COSTS INCLUDED
0 - PARTIAL DIRECT CAPITAL COSTS INCLUDED
E - TOTAL INDIRECT CAPITAL COSTS INCLUDED
F - PARTIAL INDIRECT CAPITAL COSTS INCLUDED
6 • CHEMICAL FIXATION OF SLUDGE INCLUDED IN CAPITAL COST
H - DRY SLUDGE DISPOSAL INCLUDED IN CAPITAL COST
I - OFF-SITE LANDFILL AREA INCLUDED IN CAPITAL COST
j - SLUDGE POND INCLUDED IN CAPITAL COST
K - AODITONAL SLUDGE DISPOSAL CAPACITY ADDED FOR LIFE OF SYSTFM
L - STACK INCLUDED IN CAPITAL COST
M - MODIFICATIONS TO STACK, DUCTS. AND/OR FANS INCLUDED IN CAPITAL COST
N - TOTAL REGENERATION FACILITY COST INCLUDED IN CAPITAL COST
0 - PARTIAL REGENERATION FACILITY COST INCLUDED IN CAPITAL COST
P - H « 0 COSTS INCLUDED IN CAPITAL COST
0 - COSTS UNDERWRITTEN BY SYSTEM SUPPLIER INCLUDED IN CAPITAL COST
R - EXCESS REAGENT SUPPLY COSTS INCLUDED IN CAPITAL COST
ANNUAL!
S - TOTAL DIRECT ANNUAL COSTS INCLUDED
T - PARTIAL DIRECT ANNUAL COSTS INCLUDED
U - TOTAL FIXED ANNUAL COSTS INCLUDED
V - PARTIAL FIXED ANNUAL COSTS INCLUDED
W - OVERHEAD COSTS INCLUDED IN TOTAL ANNUAL COSTS
X • PARTICULATE CONTROL COSTS INCLUDED IN DIRECT ANNUAL COSTS
Y - SLUDGE DISPOSAL SERVICE COSTS (CONTRACT) INCLUDED IN DIRECT ANNUAL COSTS
Z - REPLACEMENT ENERGY COSTS INCLUDED IN DIRECT ANNUAL COSTS
A -21
-------
EPA UTILITY FGO SURVFY: AUGUST 19/s - SEPTEMBER i97a
SFCT10N A-l F6n SYSTEM ECONOMICS: OPERATIONAL SYSTF.MS
REPORTED AND ADJUSTED COSTS
UTILITY
STATION
UNIT(S)
ELEMENTS
INCLUDED IN
CAPITAL AND
FGD Mt« ANNUAL COSTS
TOTAL ANNUAL - MILLS/KMH
CAPACITY CAPITAL —— —————
FACTOR >/KM TOTAL DIRECT FIXED
X (TEAR) (YEAH)
KANSAS CITY POWER » LIGHT
HAWTHORN
4
110 B.O.F.T.X
fU.H.X
••••*»»**•••*•* REPORTED •••••••*••»••••
la 29.3 e.au
(1972) (1977)
••*•**•***•••»• ADJUSTED •••••••••••••••
6b 87.3 4.35 2.93 1.42
(1977) (1977)
KANSAS CITY POWER ft LIGHT
LA CVGNE
1
874 R,C,E,J,S
C,f ,
•••*••**•****** REPORTED ••••••«•*••«*«•
30 53.7 1.70 1.70
(1972) (1977)
*••*•*•••«•••** ADJUSTED ••*••*»••••••••
65 68.0 3.76 1.70 2.OB
(1977) (1977)
KENTUCKY UTILITIES
GREEN RIVER
1,2 ft 3
64 B,C.E.J,S,li
C,E,J,S,U,W
•••••••••**•••• REPORTED *•••••*•*••••»*
16 70.3 14.35 5.06 9.29
(1975) (1977)
•«•»*»*•«»••*•• ADJUSTED «***«•**•»«•***
65 77.6 5.24 2.71 2.53
(1977) (1977)
LOUISVILLE GAS » ELECTRIC
CANE HUN
4
190 C,E,H,J,Q,T
C,E,H,J,K,0
,S.U,W
*•*••**••****•• REPORTED ••••*•*••»••»**
55 66.6 2.75
(1975) (1977)
•*•*•*•*•**•*** ADJUSTED •«»••••*••*•**»
65 60.6 5.78 3.62 2.16
(1977) (1977)
LOUISVILLE GAS * ELECTRIC
CANE RUN
5
200 C,E,H,J
C,E,h,J,K,S
,u,w
••»*»•••**•»•*• REPORTED •••••••••*••«»•
62.4
(1977)
••**••••*•***** ADJUSTED *•«•»*•»•»*»••»
65 67.5 5.56 3.47 2.09
(1977) (1977)
COST ELEMENTS
CAPITAL:
A - PAHTICULATE CONTROL (RfcOUIRED FOR FGD PROCESS) INCLUDED IN CAPITAL COST
B - PARTICULATE CONTROL (INCLUDED IN FGO PROCESS) INCLUDED IN CAPITAL COST
C - TOTAL DIRECT CAPITAL COS1S INCLUDED
0 - PARTIAL DIRECT CAPITAL COSTS INCLUDED
E - TOIAL INDIRECT CAPITAL COSTS INCLUDED
F - PARTIAL INDIRECT CAPITAL COSTS INCLUDED
G - CHEMICAL FIXATION OF SLUDGE INCLUDED IN CAPITAL COST
H - DRY SLUDGE DISPOSAL INCLUDED IN CAPITAL COST
I - OFF-SITE LANDFILL AREA INCLUDED IN CAPITAL COST
J - SLUDGE PUNO INCLUDED IN CAPITAL COST
K - AODITONAL SLUDGE DISPOSAL CAPACITY ADDED FOR LIFE OF SYSTEM
L - STACK INCLUDED IN CAPITAL COST
M - MODIFICATIONS TO STACK, DUCTS, AND/OR FANS INCLUDED IN CAPITAL COST
N - TOTAL REGENERATION FACILITY COST INCLUDED IN CAPITAL COST
0 - PARTIAL REGENERATION FACILITY COST INCLUDED IN CAPITAL COST
P - R > D COSTS INCLUDED IN CAPITAL COST
0 - COSTS UNDERWRITTEN BY SYSTEM SUPPLIER INCLUDED IN CAPITAL COST
H - EXCESS REAGENT SUPPLY COSTS INCLUDED IN CAPITAL COST
ANNUALS
S - TOTAL DIRECT ANNUAL COSTS INCLUDED
T - PARTIAL DIRECT ANNUAL COSTS INCLUDED
U - TOTAL FIXED ANNUAL COSTS INCLUDED
V - PARTIAL FIXED ANNUAL COSTS INCLUDED
N - OVERHEAD COSTS INCLUDED IN TOTAL ANNUAL COSTS
X • PARTICULATE CONTROL COSTS INCLUDED IN DIRECT ANNUAL COSTS
Y - SLUDGE DISPOSAL SERVICE COSTS (CONTRACT) INCLUDED IN DIRECT ANNUAL COSTS
Z - REPLACEMENT ENERGY COSTS INCLUDED IN DIRECT ANNUAL COSTS
A -22
-------
UTILITY
STATION
UNIT(S)
FP» iiTiLiir FGD SUWVFY: AUGUSI 1970 - SEPTFMHEH 1978
SECTION A-I F,,n SYSHM t-r.nNiiMirs: OPEWAUONAL SYSTEMS
AUD AuJuSIFI) COSTS
ANNU»L - MILLS/KMH
tlt'-ENTS
INCLUDFU IN
CAPITAL AnO
FGU MW ANNUAL COSTS
LOUISVILLE GAb & ELECIWIC
PADDYS HUN
6
70
f F » S.U,*
T01AL
CAPACITY CAPITAL
FACTMk s/Kn IUIAL DIKEC1 FUEO
* (YFAR) (»E»R)
65)
HF.PURIED
(1973)
...... ADJUSTED .......t
76.5 b.M 3.9£
(1977) (1977)
2.S9
HINNKOTA POHEH COOPERATIVE
MILTON M. YUUNG
177
C(I-,M,K
C.E.",H,H,S
*•.*»•••*«*•*••
(JB.O
(1976)
..•.. ADJUSTED «««».««•
93.1 S.55 i.d) (1977)
••»•••«*•**•••• ADJUSTED »*•••••<
6S 77.3 a.06 1.51
(1977) (1977)
MONTANA POKER
COL3TRIP
2
330 8,C,E.J,P,T
C,F,J,K,P,S
76
..*.. REPORTED ••«••«•«
77.1 .27 .27
(197S) (J977)
•*•** ADJUSTED ••«•»••«
77.3 a. 06 I. SI
(1977) (1977)
2.5S
NEVADA PO«ER
REID GARDNER
I
125 B,D.E,P,S,U
B,C,E,J,P.S
•u.i.x
•*»•••**•»•*••* REPORTED •••••••*••*•*««
67 42.9 2.10 1.30 .80
(1973) (1977)
•**•**«•*••**•• ADJUSTED •••«•••••••••••
6S 60.9 3.20 1.30 1.90
(1977)
(1977)
COST ELEMENTS
CAPITAL:
A - PARTICULATE CONTROL (REQUIRED FOR FGD PROCESS) INCLUDED IN CAPITAL COST
8 - PARTICULATE CONTROL (INCLUDED IN FGD PROCESS) INCLUDED IN CAPITAL COST
C - TOTAL DIRECT CAPITAL COSTS INCLUDED
0 - PARTIAL DIRECT CAPITAL COSTS INCLUDED
E - TOTAL INDIRECT CAPITAL COSTS INCLUDED
F - PARTIAL INDIRECT CAPITAL COSTS INCLUDED
G - CHEMICAL FIXATION OF SLUDGE INCLUDED IN CAPITAL COST
H - DRY SLUDGE DISPOSAL INCLUDED IN CAPITAL COST
I - OFF-SITE LANDFILL AREA INCLUDED IN CAPITAL COST
J - SLUDGE POND INCLUDED IN CAPITAL COST
K - AODITONAL SLUDGE DISPOSAL CAPACITY ADDED FOR LIFE OF SYSTEM
L - STACK INCLUDED IN CAPITAL COST
M - MODIFICATIONS TO STACK, DUCTS. AND/OR FANS INCLUDED IN CAPITAL COST
N - TOTAL REGENERATION FACILITY COST INCLUDED IN CAPITAL COST
0 - PARTIAL REGENERATION FACILITY COST INCLUDED IN CAPITAL COST
P - H » D COSTS INCLUDED IN CAPITAL COST
Q • COSTS UNDERWRITTEN BY SYSTEM SUPPLIER INCLUDED IN CAPITAL COST
R - EXCESS REAGENT SUPPLY COSTS INCLUDED IN CAPITAL COST
ANNUAL:
S - TOTAL DIRECT ANNUAL COSTS INCLUDED
T - PARTIAL DIRECT ANNUAL COSTS INCLUDED
U - TOTAL FIXED ANNUAL COSTS INCLUDED
V - PARTIAL FIXED ANNUAL COSTS INCLUDED
H • OVERHEAD COSTS INCLUDED IN TOTAL ANNUAL COSTS
X - PARTICULATE CONTROL COSTS INCLUDED IN DIRECT ANNUAL COSTS
Y - SLUDGE DISPOSAL SERVICE COSTS (CONTRACT) INCLUDED IN DIRECT ANNUAL COSTS
Z - REPLACEMENT ENERGY COSTS INCLUDED IN DIRECT ANNUAL COSTS
A -23
-------
FP» UTILITY FbO SURVEY: AUGUST 1978 - SEPTEMHKR 1976
SECTION A-l FGO SYSTEM ECONOMICS: OPERATIONAL SYSTEMS
kEPOKTEO ANT) AOJUSIEO COSTS
UTILITY
STATION
IINIT(S)
FGO MM
INCLUDED IN
CAPITAL AND
ANNUAL COSTS
TOTAL ANNUAL - MRLS/KWH
CAPACITY CAPITAL — — ——— ———
FACTOK S/KH TOTAL DIRECT FIXED
X (YEAH) (YEAR)
NtVAOA POWEK
HEID uAHDNFk
2
125 H.n.E.P,S,u
tt>, x
R,C.E,J,P,S
,U,W,X
REPORTED ••••••»•••••••*
2.10
67 4i».9
(1973)
...*.••«•**• ADJUSTED
65 60.9 5.20
(1977)
l.3u .80
(1977)
••••«*••••*•»••
1.30 1.90
(1977)
NEVADA
REID GArfDNErt
3
B,C.E,L,S,U
.M.X
B,C,F,S,li.W
.X
•••••••»••••••• REPUR IED •*»•••*••***•••
2.10
1.3U
(1977)
115.6
(1975)
>•**•• ADJUSTED ••••«*••
IU7.9 4.38 1.30
(1977) (1977)
.80
NORTHERN INDIANA PUB SERVICE
DEAN H. MITCHELL
11
•**** REPURTED
•«••••••*••*••* ADJUSTED ***••**•*••***•
NORTHERN STATES POWER
SnFRHURfcE
1
720 n,C,J,S,U,x
C,E, J,K,S.II
. *
**••*•»•••*•••• REPORTED ••••••*•*•«*•»•
73 49.3 1.98 1.05 .93
(1972) (1977)
•*•*••******•** ADJUSTED •*«•••**•«•«••»
65 71.5 2.77 .75 2.02
(1977) (1977)
NORTHERN STATES PU»ER
SHFHRURNF
2
720 B,C,J,S,U,X •*•••••••••«••• REPORTED ••*••*•••••••«•
,i 73 49.3 1.98 1.05 .93
(1972) (1977)
C,F,J,n,S,U ••••••••••••••• ADJUSTED •••«••*••••*•*•
,n 65 71.5 2.77 .75 2.02
(1977) (1977)
COST
CAPITAL:
A - PAHTICULATE CONTROL (RfcOUIHED FOR FGO PRUCESS) INCLUDED IN CAPITAL COST
B - ^ARTICULATE CONTROL (INCLUDED IN FGO PMOCESS) INCLUDED IN CAPITAL COST
C - TOTAL UIHECT CAPITA! COS1S INCLUDED
D - PARTIAL DIRFCT CAPITAL COSTS INCLUDED
E - TOTAL INDIRECT CAPITAL CUSTS INCLUDED
F - PARTIAL INDIRECT CAPITAL COSTS INCLUDED
G - CHEMICAL FIXATION OF SLUDGE INCLUDED IN CAPITAL COST
H - DRV SLUDGE DISPOSAL INCLUDED IN CAPITAL COST
1 - OFF-SHE LANDFILL AREA INCLUDED IN CAPITAL COST
J - SLUDGE POND INCLUDED IN CAPITAL COST
K - AOUITONAL SLUDGE DISPOSAL CAPACITY ADDED FOR LIFE OF SYSTEM
L - STACK INCLUDED IN CAPITAL COST
M - MODIFICATIONS TO STACK, DUCTS, AND/OH FANS INCLUDED IN CAPITAL COST
N - TOTAL REGENERATION FACILITY COST INCLUDED IN CAPITAL COST
0 - PARTIAL REGENERATION FACILITY COST INCLUDED IN CAPITAL COST
P - R t I) COSTS INCLUDED IN CAPITAL COST
0 - COSTS UNDERWRITTEN BY SYSTEM SUPPLIER INCLUDED IN CAPITAL COST
R - EXCESS REAGENT SUPPLY COSTS INCLUDED IN CAPITAL COST
ANNUAL!
S - TOTAL DIRECT ANNUAL COSTS INCLUDED
T - PARTIAL DIRECT ANNUAL COSTS INCLUDED
U - TOTAL FIXED ANNUAL CUSTS INCLUDED
V - PARTIAL FIXED ANNUAL COSTS INCLUDED
M - OVERHEAD CUSTS INCLUDED IN TOTAL ANNUAL COSTS
X - PARTICULATE CONTROL COSTS INCLUDED IN DIHECT ANNUAL COSTS
Y - SLUDGE DISPOSAL SERVICE COSTS (CONTRACT) INCLUDED IN DIRECT ANNUAL COSTS
Z - REPLACEMENT ENERGY COSTS INCLUDED IN DIRECT ANNUAL COSTS
A -24
-------
UTILITY
STATION
UNIT/KW TOTAL DIRFCT FIXED
X (rFAM) (YFAR)
PENNSYLVANIA
HRUCE MANSFIELD
i
"M7 8,C,E.G.I,I
.S.U.n.x
t>"3
...... RLPURTEO ...............
120.7 13.18 u.08 9.1U
(197S) (1977)
...... ADJUSTED ...............
10.J.2 7.67 S.U.H,X
C,E,G,I,M,S
>U,n
10
...... HtPURTEO .•.«..«........
I2U.7 M.18 a.UH 9.IQ
(1975) (1977)
...... ADJUSTED ••«•»««•.....••
10*.? 7.67 «.5o 3.17
(19/7) (1977)
PHILADELPHIA ELECTRIC
EDDYSTO.NE
1A
10S D.F.N.P
C.F.N.P
REPORTED
(1972)
ADJUSTED
(1977)
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN
1
357 A.C.E.N
1?7.9
(1977)
REPORTED
ADJUSTED
PUBLIC SERVICt OF NtM MEXICO
SAN JUAN
357
A.C.E.N
REPORTED
(1977)
ADJUSTED
CUSI ELEMENTS
CAPITAL:
A - PARTICULATE CONTROL (REQUIRED FOR FGO PROCESS) INCLUDED IN CAPITAL COST
B - PARTICULATE CONTROL (INCLUDED IN FGD PROCESS) INCLUDED IN CAPITAL COST
C - TOTAL DIRECT CAPITAL COSTS INCLUDED
0 - PARTIAL DIRECT CAPITAL COSTS INCLUDED
E - TOTAL INDIRECT CAPITAL CUSTS INCLUDED
F - PARTIAL INDIRECT CAPITAL COSTS INCLUDED
G - CHEMICAL FIXATION OF SLUDGE INCLUDED IN CAPITAL COST
H - DRY SLUDGE DISPOSAL INCLUDED IN CAPITAL COST
I - OFF-SHE LANDFILL ARE* INCLUDED IN CAPITAL COST
J - SLUDGE POND INCLUDED IN CAPITAL COST
K - AODITONAL SLUDGE DISPOSAL CAPACITY ADDED FOR LIFE OF SYSTEM
L • STACK INCLUDED IN CAPITAL COST
M - MODIFICATIONS TO STACK, DUCTS. AND/OH FANS INCLUDED IN CAPITAL C03T
N - TOTAL REGENERATION FACILITY COST INCLUDED IN CAPITAL COST
0 - PARTIAL REGENERATION FACILITY COST INCLUDED IN CAPITAL COST
P - R ft D COSTS INCLUDED IN CAPITAL COST
0 - COSTS UNDERWRITTEN BY SYSTEM SUPPLIER INCLUDED IN CAPITAL COST
R - EXCESS REAGENT SUPPLY COSTS INCLUDED IN CAPITAL COST
ANNUAL:
s
T
u
v
N
TOTAL DIRECT ANNUAL COSTS INCLUDED
- PARTIAL DIRECT ANNUAL COSTS INCLUDED
- TOTAL FIXED ANNUAL COSTS INCLUDED
- PARTIAL FIXED ANNUAL COSTS INCLUDED
- OVERHEAD COSTS INCLUDED IN TOTAL ANNUAL COSTS
X - PARTICULATE CONTROL COSTS INCLUDED IN DIRECT ANNUAL COSTS
Y • SLUDGE DISPOSAL SERVICE COSTS (CONTRACT) INCLUDED IN DIRECT ANNUAL COSTS
Z - REPLACEMENT ENERGY COSTS INCLUDED IN DIRECT ANNUAL COSTS
A -35
-------
FPA UTILITY F(,n SUWVEr: AUGUST 197* - SEPTFhBLH 1478
SECTION A-l KiO 5YSTFM ECONOMICS: OPERATIONAL SYSTEMS
KEPIIKTtO AND ADJUSTED COSTS
UTILITY
STATIUN
UNIT(S)
ELEMENTS
IrtCLUUFU IN
CAPITAL ANH
Ff.O MM ANNUAL COSTS
TOTAL ANNUAL - MH.LS/KHH
CAPACTTY CAPITAL
FACT Dt- S/KM TOTAL DIRECT FIXED
I (YFAH) (YEAR)
SUIMH CAROLINA PIIHL 1C SERVICE
AlNYAH
lao
C.t-,
r ,F
(1975)
•••••••••*••••• REPORTED ••••»••«
4U 17. b l.hl .88
(1976) (1977)
•*•••*••»••*•*• ADJUSTED «••«•••«
.73
SOUTHERN MISSISSIPPI ELECTRIC
R. 0.
1
HtPORII-0
C.F.,J,R,M,S
t Uf K
•••••••***•• ADJUSTED ••••«*••«••••••
6-5 66.5 2.92 l.Oa 1.8B
(19//) (19/7)
SPRINbFlELO CITY UTILITIES
SOUTHnFST
1
•••••••••**••••
•••••••••«•••••
C.F.H,J,«,P
,S,U,n
77.3
(1970)
>•*•** ADJUSTED •••••••<
117.7 6.17 «!.B7
(1977) (1977)
>•*••
3.30
TkNNFSSEE VALLEY AUTHORITY
MinuMS CREEK
ft
5*0 R,C.F,P,H,T
fU
••••••••••••••• REPORTED ••«•••«••••••••
60 98.2 2.99
(1976) (1977)
••••••••••••••• ADJUSTED »••*•*•••*•••••
6b 113.2 b.2R l.«a 3.U4
(1977) (1977)
TEXAS UTILITIES
MONIICELLO
3
7SO
REPORTED ••••»•»»•«••••»
(I97fl)
•••a*********** ADJUSTED ••*•••••••••**•
COST ElfcMtNIS
CAPITAL:
A - PAHTICULATE CONTROL (HEQUIREU I- OH FGO PRUCtSS) INCLUOFD IN CAPITAL COST
H - PARTICULATE CONTROL (INCLUDED IN FGO PROCESS) INCLUDED IN CAPITAL COST
C - TOTAL DIRECT CAPITAL COSTS INCLUDED
D - PARTIAL DIRECT CAPITAL CUS1S INCLUDE!)
fc - TOTAL INDIRECT CAPITAL COSTS INCLUDED
F - PARTIAL INIITHFCT CAPITAL COSTS INCLUDED
6 - CHEMICAL FIXATION OF SLUDGE INCLUDED IN CAPITAL COST
H - DRY SLUDGE DISPOSAL INCLUDED IN CAPITAL COST
1 - OFF-SHE LANDFILL AREA InCLUDEO IN CAPITAL CUST
J - SLUDGE POND INCLUDED IN CAPITAL COST
K - AODITUNAL SLUDGE DISPOSAL CAPACITY ADDED FOR LIFE OF SYSTEM
L - STACK INCLUDEO IN CAPITAL COST
M - MODIFICATIONS TO S1ACK. DUCTS, AND/OR FANS INCLUDEO IN CAPITAL COST
N - TOTAL REGENERATION FACILITY COST INCLUDED IN CAPITAL COST
0 - PARTIAL REGENERATION FACILITY COST INCLUDED IN CAPITAL CUST
P - R » D COSTS INCLUDED IN CAPITAL COST
0 - COSTS UNDERWRITTEN BY SYSTEM SUPPLIER INCLUDED IN CAPITAL COST
R - EXCESS REAGENT SUPPLY COSTS INCLUDED IN CAPITAL COST
ANNUAL:
S
T
U
V
H
• TOTAL DIRECT ANNUAL COSTS INCLUDED
- PARTIAL DIRECT ANNUAL COSTS INCLUDEO
- TOTAL FIXED ANNUAL COSTS INCLUDED
- PARTIAL FIXED ANNUAL COSTS INCLUDED
- OVERHEAD COSTS INCLUDED IN TOTAL ANNUAL COSTS
X - PARTICULATE CONTROL COSTS INCLUDED IN DIRECT ANNUAL COSTS
V - SLUDGE DISPOSAL SERVICE COSTS (CONTRACT) INCLUDED IN DIRECT ANNUAL COSTS
Z - REPLACEMENT ENERGY COSTS INCLUDEO IN DIRECT ANNUAL COSTS
A -26
-------
*PA uriLitr FGD SUHVEY: AUGUST 1978 - SEPTEMBER 1978
SECTION A-i Fun SYS1FM KCUNUMirs: NUNDPEkATlllNAL SYSTEMS
kEPOHTtn AND ADJuStFI) COSTS
UTILITY
STATION
UN|T(S)
FKU MW
tt
iNCLIIOFu IN
CAPITAL AND
ANNUAL U'bTS
ALABAMA ELECTRIC CHOP
TUMiilGBEE
3
ARIZONA ELECTRIC PO*EK COUP
APACHE
3
BASIN ELECTRIC POHFtt COOP
LARAMIE RIVER
1
BASIN ELECTHIC POKER COOP
LARAMIE R1VEH
BIG RIVERS ELECTRIC
GRFtN
1
BOSTON EDISON
MYSTIC
6
CENTRAL ILLINOIS PUBLIC StRV
NEWTON
i
COLORADO UTE ELECTRIC ASSN.
CRAIG
1
?55
aon
550 C,F
550 C,F
155 B.C.E.N.O
575 C.E.G
450 B,0,E
TOTAL ANNUAL - MILLS/KWH
CAPACITY CAPITAL
FACTOR S/KM TOTAL DIRECT
* (YEAH) (YEAR)
............... RtPORTEO ..........
(1978)
............... REPORTED • •'
5.3
(1976)
............... REPORTED ..........
he. 2
)
....*.......... REPORTED ..........
6B.2
(I<*HO)
...*........... REPORTED .........
(1976)
............... REPORTED •«»•••.••
63.4 3.00
(1972) (1970)
............... REPORTED «»•••••••
1H9.0
(19/9)
....*.......... REPORTED «•«««««»«'
117.0
(1979)
COST ELtMENTS
CAPITAL:
A - PARTICIPATE CONTROL (REQUIRED FOR FGD PROCESS) INCLUDED IN CAPITAL COST
6 • PARTICULAR CONTROL (INCLUDED IN F60 PROCESS) INCLUDED IN CAPITAL COST
C - TOTAL DIRECT CAPITAL COSTS INCLUDED
0 - PARTIAL DIRECT CAPITAL COSTS INCLUDED
E - TOTAL INDIRECT CAPITAL COSTS INCLUDED
F - PARITAL INDIRECT CAPITAL COSTS INCLUDED
G - CHEMICAL FIXATION OF SLUDGE INCLUDED IN CAPITAL COST
H - DRY SLUDGE DISPOSAL INCLUDED IN CAPITAL COST
I • OFF-SITE LANDFILL AREA INCLUDED IN CAPITAL COST
J - SLUDGE POND INCLUDED IN CAPITAL COST
K • AOOITONAL SLUDGE DISPOSAL CAPACITY ADDED FOR LIFE OF SYSTEM
L - STACK INCLUDED IN CAPITAL COST
M - MODIFICATIONS TO STACK, DUCTS. AND/OR FANS INCLUDED IN CAPITAL COST
N - TOTAL REGENERATION FACILITY COST INCLUDED IN CAPITAL COST
0 - PARTIAL REGENERATION FACILITY COST INCLUDED IN CAPITAL COST
P - R & 0 COSTS INCLUDED IN CAPITAL COST
0 - COSTS UNDERWRITTEN 8V SYSTEM SUPPLIER INCLUDED IN CAPITAL COST
R - EXCESS REAGENT SUPPLY COSTS INCLUDED IN CAPITAL COST
ANNUAL:
S - TOTAL DIRECT ANNUAL COSTS INCLUDED
* - . ARTiAL DIRECT ANNUAL COSTS INCLUDED
U ' TOTAL FIXED ANNUAL COSTS INCLUDED
V - PARTIAL FIXED ANNUAL COSTS INCLUDED
M - OVERHEAD COSTS INCLUDED IN TOTAL ANNUAL COSTS
X - PARTICULATE CONTROL COSTS INCLUDED IN DIRECT ANNUAL COSTS
t - SLUDGE DISPOSAL SERVICE COSTS (CONTRACT) INCLUDED IN DIRECT ANNUAL COSTS
I - REPLACEMENT ENERGY COSTS INCLUDED IN DIRECT ANNUAL COSTS
A -27
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EPA UTILITY FGD SURVEr: AUGUST 1978 - SEPTFMHER 1VTH
SECTION A-<> FbO SYSTEM ECONOMICS: NONOPERATIONAL SYSTEMS
RFPORTfcD AND ADJUSTED COSTS
UTILITY
STATION
UNIT(S)
ELEMENTS
INCLUDED IN
CAPITAL AND
FGD M* ANNUAL CUSIS
TOTAL ANNUAL - HILLS/KHH
CAPACITY CAPITAL —-——————
FACTOR S/KN IOIAL DIRECT FIXED
I (YEAR) (YEAR)
COLORADO UTE ELECTRIC ASSN.
CRAIG
4bO
>••••» REPORTED •••*••*•••••<
117.0
(1979)
COMMONWEALTH EDISUN
POMERTON
SI
C,E,n,J
•***••••••*••*• REPORTED •••••••••••••••
117.7
COMMONHEALTH EDISON
HILL COUNTY
I
167 B,C,E,G,J,X
••••••**•*•**** REPORTED •••*•••<
49 113.0 13.06
(1972) (1975)
DETROIT EDISON
ST. CLAIR
6
1t>3 H,C,E,J,M,X
•*••••»•»»**••• REPORTED *•••»•*••••••••
80.3 9.60
(1976) (1976)
ILLINOIS POnER
MOOD RIVER
4
110 »,C,E,M,M
*••••••***•*•*• REPORTED »•••••••••»•*••
82.5
(1972)
LOUISVILLE GAS » ELECTRIC
CANE RUN
6
277 C,E,H,M,S,V
••»•••••••••«»* REPORTED *••••«•*•»»••»*
57.9 3.24 1.92 1.32
(1977) (1979)
PACIFIC POMER » LIGHT
JIM RRIDGER
509 C.E.J
••*•****<
REPORTED •••••*••****••*
120.0
(1979)
POTOMAC ELFCTRIC POWER
OICKERSON
3
190
*,C,E,M
»«••••••»•••••• REPORTED *••••*»•*•••*»•
68.0
(1973)
COST ELEMENTS
CAPITAL:
A • PAHTICULATE CONTROL (REQUIRED FOR FGD PROCESS) INCLUDED IN CAPITAL COST
B - PARTICULATE CONTROL (INCLUDED IN FGD PROCESS) INCLUDED IN CAPITAL COST
C - TOTAL DIRECT CAPITAL COSIS INCLUDED
0 - PARTIAL DIRECT CAPITAL COSTS INCLUDED
E - TOTAL INDIRECT CAPITAL COSTS INCLUDED
F • PARITAL INDIRECT CAPITAL COSTS INCLUDED
G • CHEMICAL FIXATION OF SLUDGE INCLUDED IN CAPITAL COST
H - DRY SLUDGE DISPOSAL INCLUDED IN CAPITAL COST
I - OFF-SITE LANDFILL AREA INCLUDED IN CAPITAL COST
J - SLUDGE POND INCLUDED IN CAPITAL COST
K - AOOITONAL SLUDGE DISPOSAL CAPACITY ADDED FOR LIFE OF SYSTEM
L - STACK INCLUDED IN CAPITAL COST
M - MODIFICATIONS TO STACK, DUCTS, AND/OR FANS INCLUDED IN CAPITAL COST
N - TOTAL REGENERATION FACILITY LUST INCLUDED IN CAPITAL COST
0 - PARTIAL REGENERATION FACILITY COST INCLUDED IN CAPITAL COST
P - H ft D COSTS INCLUDED IN CAPITAL COST
0 - COSTS UNDERWRITTEN BY SYSTEM SUPPLIER INCLUDED IN CAPITAL COST
R - EXCESS REAGENT SUPPLY COSTS INCLUDED IN CAPITAL COST
ANNUAL:
S - TOTAL DIRECT ANNUAL COSTS INCLUDED
T - PARTIAL DIRECT ANNUAL COSTS INCLUDED
U - TOTAL FIXED ANNUAL COSTS INCLUDED
V - PARTIAL FIXED ANNUAL COSTS INCLUDED
H - OVERHEAD COSTS INCLUDED IN TOTAL ANNUAL COSTS
X - PARTICULATE CONTROL COSTS INCLUDED IN DIRECT ANNUAL COSTS
V - SLUDGE DISPOSAL SERVICE COSTS (CONTRACT) INCLUDED IN DIRECT ANNUAL COSTS
Z - REPLACEMENT ENERGY COSTS INCLUDED IN DIRECT ANNUAL COSTS
A -28
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EHA UIILI1Y FGf> SIIWVEY: «ur,uST 1978 - SEPTEMBER 1978
SECTION A-* FGI) SYSHM ECONOMICS: NUNOPERAT ION»L SYSTEMS
RFPOHTtD AND AI1JUSTF.U COSTb
UTILITY
STATION
UNIT(S)
tLE*ENTS
INCLUDED IN
CAPITAL ANP
(-60 HW ANNUAL COblS
ANNUAL - MILLS/KKH
TOTAL
CAPACITY CAPITAL
FACTOR I/KK MJIAL OINECI
PUBLIC SFRVICE OF COLORADO
VALMONT
5
B.C.E.J
H7.0
(1970)
REPUKTFO
SALT RIVER PROJECT
CORONADO
1
3SO C.F
REPORTED
9H.O
U97H)
SALT RIVER PROJECT
CORONAOO
3*0 C,F
9B.O
(1978)
REPORTED
SOUTHERN INDIANA GAS * ELEC
A. B. HROHN
1
C.E.G
KtPUHIEf)
(197^)
SOUTHERN MISSISSIPPI ELECTRIC
M. D. MQRROft
180 C.F
37.a
(1975)
REPORTED
WISCONSIN POWER & LIGHT
COLUMBIA
2
REPORTED
5/.0
(190U)
COST ELEHtNTS
CAPITAL:
A - PARTICULATt CONTROL (REQUIRED FOR FGD PROCESS) INCLUDFD IN CAPITAL COST
B - ^ARTICULATE CONTROL (INCLUDED IN FGO PROCESS) INCLUDED IN CAPITAL COST
C - TOTAL DIRECT CAPITAL COSTS INCLUDED
D - PARTIAL DIRECT CAPITAL COSTS INCLUDED
E - TOTAL INDIRECT CAPITAL COSTS INCLUDED
F - PARITAL INDIRECT CAPITAL COSTS INCLUDED
G - CHEMICAL FIXATION OF SLHDG1 INCLUDED IN CAPITAL COST
H - DRY SLUDGE DISPOSAL INCLUDED IN CAPITAL COST
I - OFF-SHE LANDFILL AREA INCLUDED IN CAPITAL CUST
J - SLUDGE POND INCLUDED IN CAPITAL COST
K - AOOITONAL SLUDGE DISPOSAL CAPACITY ADDED FOR LIFE OF SYSTEM
L - STACK INCLUDED IN CAPITAL COST
M - MODIFICATIONS TO STACK, DUCTS. AND/OR FANS INCLUDED IN CAPITAL COST
N - TOTAL REGENERATION FACILITY COST INCLUDED IN CAPITAL CUST
0 - PARTIAL REGENERATION FACILITY COST INCLUDED IN CAPITAL COST
P - R « 0 COSTS INCLUDED IN CAPITAL COST
0 - COSTS UNDERWRITTEN BY SYSTEM SUPPLIER INCLUDED IN CAPITAL COST
R - EXCESS REAGENT SUPPLY COSTS INCLUDED IN CAPITAL COST
ANNUAL!
S - TOTAL DIRECT ANNUAL COSTS INCLUDED
T - PARTIAL DIRECT ANNUAL COSTS INCLUDED
U - TOTAL FIXED ANNUAL COSTS INCLUDED
V - PARTIAL FIXED ANNUAL COSTS INCLUDED
W - OVERHEAD COSTS INCLUDED IN TOTAL ANNUAL COSTS
X - PARTICULATE CONTROL COSTS INCLUDED IN DIRECT ANNUAL COSTS
Y • SLUDGE DISPOSAL SERVICE COSTS (CONTRACT) INCLUDED IN DIRECT ANNUAL COSTS
Z - REPLACEMENT ENERGY COSTS INCLUDED IN DIRECT ANNUAL COSTS
A -29
-------
APPENDIX B
FGD PROCESS FLOW DIAGRAMS
THIS APPENDIX COMPRISES BOTH ACTIVE AND INACTIVE UNITS
ARRANGED ALPHABETICALLY ACCORDING TO UTILITY
"SUPPLEMENTAL EDITION"
CHANGES/ADDITIONS
B-l
-------
STACK
I.D. FAN
COAL SUPPLY-
FEEDER
PULVERIZER
STACK GAS
IR HEATER
DEMISTER
TACK GAS REMITTER
RECYCLE
WATER
STACK'
GAS
SCRUBBER
Kansas Power and Light
Original Operational FGD System at Lawrence No. 4.
-------
CMSMD
INWOM
HCU1
Ht»MOI
7
I
Kansas Power and Light,
Lawrence No. 4 Operational FGD System
Simplified Process Flow Diagram
-------
COAL SUPPLY—\ / ~
FEEDER—£fc.
STAC 1C
I.D. FAN
PULVERIZER
•STACK GAS REHEATER
RECYCLE
WATER
STACK'
GAS
SCRUBBER
Kansas Power and Light
Original FGD System Installed at Lawrence No. 5:
Simplified Process Flow Diagram.
-------
wni ran
LIKSTOK si*""*
td
cn
DIIUIION MUI
(fMH KCIKUUTION T«M)
«OITI« STOMUt
TMK M WllOi
STAC POND RETURN
(MAKE-UP)
1 WATER
SPRAY
PUMPS
COLLECTION
0 TANK
JSTRAINER
EfFLUENT
BLEED PUMP
REACTION
TANK
'TO STRAINER! t*-
WASHERS "^
MAKE-UP WATER
PUMP
L
HASH
PUMP
I,
TANK
RECIRC
PUHPS
EFFLUENT
BLEED
THICKENER
WEIR
OVERFLOW
TO
SETTLING
UNDERFLOW PUMPS
Kansas Power and Light,
Lawrence No. 5 Operational FGD System
Simplified Process Flow Diagram
-------
AIR
HEATER
•+•*
PREC1PITATOR
INLET TEST
PORT LOCATION
W
a\
SCRUBBER INLET
TEST PORT LOCATION-
ESP
"B" ABSORBER
NODULE
rfc
—I "'" /I
p°-1" <;»
BYPASS DUCT \!
SCRUBBER INLET
TEST PORT LOCATION
TOP OF STACK
ELEVATION IMS'
TEST PORT
ELEVATION 1516'
—TOP OF OUTLET BREECHING
ELEVATION !372'-2 3/8"
-TOP OF BYPASS BREECHING
ELEVATION 1307'• 8 Ml"
—GRADE ELEVATION )»!'
Springfield City Utilities, Southwest No. 1:
Simplified Process Diagram
-------
APPENDIX C
DEFINITIONS
C-l
-------
DEFINITIONS
Boiler Capacity Factor:
Boiler Utilization Parameter;
Efficiency:
Particulates
SO.
FGD Viability Indexes
(kWh generation in year)/
maximum continuous generating
capacity in kW x 8760 hr/yr).
Hours boiler operated/hours in
period, expressed as a percen-
tage.
The actual percentage of
particulates removed by the
emission control system (mech-
anical collectors, ESP, or
fabric filter and FGD) from
the untreated flue gas.
The actual percentage of SO.
removed from the flue gas by
the FGD system. Design removal
efficiency values are presented
for nonoperational systems for
which actual removal data are
not available.
Several parameters have been
developed to quantify the
viability of FGD system tech-
nology. Various terms such as
"availability," "reliability,"
"operability," and "utilization"
are used to accurately repre-
sent the operation of any FGD
system during a given period.
The above-mentioned parameters
are defined below and dis-
cussed briefly. The objectives
of this discussion are to make
the reader aware that several
different definitions are
being used and to select
appropriate parameters that
can be used for reporting
purposes so that reasonably
consistent comparisons can be
made.
C-2
-------
DEFINITIONS
Availability Index
Reliability Index
FGD Operability Index
Hours the FGD system is avail-
able for operation (whether
operated or not) divided by
hours in period, expressed as
a percentage. This parameter
tends to overestimate the
viability of the FGD system
because it does not penalize
for election not to operate
the system when it could have
been operated. Boiler down-
time may tend to increase the
magnitude of the parameter
because FGD failures generally
cannot occur during such
periods.
Hours the FGD system was
operated divided by the hours
the FGD system was called upon
to operate, expressed as a
percentage. This parameter
has been developed in order
not to penalize the FGD
system for elected outages,
e.g., periods when the FGD
system could have been run but
was not run because of chemi-
cal shortages, lack of manpower,
short duration boiler operations,
etc. The main problem in
using this formula is the
concise determination whether
or not the system was "called
upon to operate" during a
given time period. In addition,
an undefined value can result
when the FGD system is not
called upon to operate for a
given period (e.g., turbine or
boiler outage when FGD system
is available).
Hours the FGD system was opera-
ted divided by boiler operating
hours in period, expressed as
a percentage. This parameter
indicates the degree to which
the FGD system is actually
used, relative to boiler
C-3
-------
FGD Utilization Index
FGD Status:
Category 1
Category 2
Category 3
operating time. The parameter
does not reflect the extent of
exertion on the FGD system,
that is, the magnitude of the
parameter has little or no
correlation with FGD system
operating time. Also, the
parameter is penalized when
options are exercised not to
use the FGD system in periods
when the system is operable.
In addition, an undefined
value can result when the FGD
system is not called upon to
operate for a given period
(e.g., turbine or boiler
outage when FGD system is
available).
Hours that the FGD system
operated divided by total hours
in period. This parameter is
a relative stress factor for
the FGD system. It is not a
complete measure of FGD system
viability because the para-
meter can be strongly influ-
enced by conditions that are
external to the FGD system
(e.g., infrequent boiler
operation will lower the value
of the parameter although the
FGD system may be highly
dependable in its particular
application).
Operational - FGD system is in
service removing SO-.
Under Construction - ground
has been broken for installa-
tion of FGD system, but FGD
system has not become opera-
tional .
Planned, Contract Awarded -
contract has been signed for
purchase of FGD system but
ground has not been broken for
installation.
C-4
-------
Category 4
Category 5
Category 6
Category 7
Category 8
FGD Vendor
Fuel Characteristics
New
Nonregenerable
Planned, Letter of Intent
Signed - letter of intent has
been signed, but legal con-
tract for purchase has not
been awarded.
Planned, Requesting/Evaluating
Bids - bid requests have been
released but no letter of
intent or contract has been
issued.
Considering only FGD Systems -
an FGD system is proposed as a
means to meet an SO- regula-
tion.
Considering an FGD system as
well as alternative methods.
Nonoperational - FGD system
has been in service in the
past but has been shut down
permanently or for an extended
indefinite period of time.
A firm which fabricates and
supplies FGD systems, most
notably the flue gas treating
and ancillary equipment.
Type of fuel, average gross
heating value in Btu/lb.
average percent ash and average
percent sulfur content for
fuel as fired.
FGD unit and boiler were
designed at the same time or
space for addition of an FGD
unit was reserved when boiler
was constructed.
The SO, removed from the flue
gas is not recovered in a
usable or marketable form and
resulting sulfur-bearing waste
products must be disposed in
an environmentally acceptable
fashion.
C-5
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Operational Experience
Process
Regulatory Class
Regenerable
Retrofit
Sludge Disposal
C-6
Summary of FGD status and
description of current month's
progress.
Company name if process is
patented. Generic name if
several companies have similar
processes.
A. New boiler constructed
subject to Federal New
Source Performance Stan-
dards .
B. Existing boiler subject
to State Standard that is
more stringent than the
Federal New Source Per-
formance Standard (NSPS).
C. Existing boiler subject
to State Standard that is
equal to or less strin-
gent than NSPS.
D. Other (unknown, undeter-
mined) .
The SO2 removed from the flue
gas is recovered in a usable
or marketable form (e.g.,
sulfur, sulfuric acid, gypsum,
ammonium sulfate, sodium
sulfate).
FGD unit must be added to an
existing boiler not specifi-
cally designed to accommodate
FGD unit.
Disposal method for nonregen-
erable systems producing
sludge including: lined
or unlined ponds, stabilized
or unstabilized sludge, and
on- or off-site disposal,
disposal type (minefill,
landfill, structural fill).
For the regenerable systems,
the form or method of sulfur
recovery is provided (e.g. -
molten elemental sulfur,
sulfuric acid plant).
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Start-up Date
Total FGD System Lost
Generation Factor
Unit Cost
Unit Location
Unit Name
Unit Rating
Date when initial SC>2 removal
began or is scheduled to
begin.
The total monthly lost genera-
tion hours due to FGD train
outages divided by the total
monthly expected generation if
the FGD trains would have been
available for operation,
expressed as a percentage.
Capital Cost in $/kW includ-
ing: SC>2 absorption and
regeneration system, S02
recovery system, solids dis-
posal, site improvements,
land, roads, tracks, substa-
tion, engineering costs,
contractors fee and interest
on capital during construc-
tion.
Annualized Cost in mills/kWh
including fixed and variable
costs. Fixed costs include:
interest on capital, deprecia-
tion, insurance, taxes, and
labor costs including over-
head. Variable costs include:
raw materials, utilities, and
maintenance.
City and State listed in
mailing address.
Unit identification as it
appears in Electrical World -
Directory of Electrical Util-
ities, McGraw-Hill - Current
Edition - or as indicated by
utility representative for
installations in planning
stages.
Operational - Maximum con-
tinuous gross generation
capacity in MW; Preopera-
tional - maximum continuous
design generation capacity in
MW.
C-7
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Utility Name Name of corporation as it
appears in Electrical World -
Directory of Electrical Util-
ities, McGraw-Hill - Current
Edition - as space permits.
Water Make-Up Gallons per minute of make-up
water required per MW of
capacity.
C-8
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-600/7-79-022a
2.
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
EPA Utility FGD Survey: August-September 1978
6. REPORT DATE
January 1979
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
M. Melia, M.Smith, T.Koger, and B. Laseke
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
PEDCo Environmental, Lie.
11499 Chester Road
Cincinnati, Ohio 45246
10. PROGRAM ELEMENT NO.
EHE624
11. CONTRACT/GRANT NO.
68-02-2603, Task 24
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Periodic; 8-9/78
14. SPONSORING AGENCY CODE
EPA/600/13
is. SUPPLEMENTARY NOTEsEpAoject Officers are N.Kaplan (IERL-RTP, MD-61, 919/541-
2556) and J.C.Herlihy (DSSE,202/755-8137). EPA-600/7-78-051a thru -051d are
previous reoorts in this series.
16. ABSTRACT i
The report is an updated supplement to EPA-600/7-78-051a and should be
used in conjunction with it. It presents a survey of utility flue gas desulfurization
(FGD) systems in the U.S. , summarizing information contributed by the utility indus
try, process suppliers, regulatory agencies, and consulting engineering firms. Sys-
tems are tabulated alphabetically, by development status (operational, under constru
ction, in planning stages, or terminated operations), by utility company, by process
supplier, by process, by waste disposal practice, and by regulatory class. It pre-
sents data on system design, fuel sulfur content, operating history, and actual per-
formance. It discusses problems and solutions associated with the boilers and FGD
systems. Process flow diagrams and FGD system economic data are appended to
the report.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c. COSATi Field/Group
Pollution
Flue Gases
Desulfurization
Electric Utilities
Waste Disposal
Boilers
Maintenance
Pollution Control
Stationary Sources
Utility Boilers
13B
2 IB
07A,07D
15E
13A
18. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (ThisReport)
Unclassified
20. SECURITY CLASS (TMlpagt)
Unclassified
154
22. PRICE
EPA Form 2X20-1 (t-73)
C-9
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